Lost Foam Casting in India: Top Manufacturers and Its Process
Introduction
Lost foam casting is a modern casting method. In this method a foam pattern is used to make the cast. This mold is then used to add melted metals. This type of casting method is used in industries like automotive industry, agricultural machinery, in valves and pumps and other industrial components. This form of casting method was invented by Armand Vaillancourt who was a Canadian sculptor in the 1950s. This type of concept was new during its early years but it gained popularity in the 80s. It was during these times when the automotive industry started using it for manufacturing their intricate parts.
How Lost Foam Casting Works
The process of Lost Foam Casting in India includes making of a foam pattern, then coating the foam with a refractory material and adding it in sand and then finally adding melted metal. This vaporizes the foam and the final cast is made.
Step by step process:
- Creation of foam pattern
With the help of a mold a polystyrene foam pattern is made in the shape of one’s choice. After the pattern parts are made they are combined together.
- Pattern assembly and clustering
These pattern parts which are created are then assembled together to form a cluster which is more like a ‘tree’ structure.
- Coating
The pattern is then coated with a material by making a shell which can hold high amount of heat of melted metals.
- Drying
The coated pattern is then dried to make sure that the coating is strong and can hold the shape during the pouring process of melted metals.
- Flask preparation
This pattern is then put into the flask which is later filled with dry sand.
- Pouring
Pouring of melted metals is done in this step. The melted metal is poured into the flask which vaporizes the foam pattern and fills the empty space.
- Solidification
The melted metal is then solidified which then shapes itself in the form of the flask.
- Removal
The cast is removed from the flask.
- Finishing
At last the finishing process is done like machining or surface treatment.
Key Materials Used
Key materials used during the process of Lost Foam Casting Products are,
- Foam pattern material:
Polystyrene (EPS)
This a foam used to make shape and also provide dimensional stability and to cleanly vaporize the metals.
Other materials like polymethyl methacrylate (PMMA) can also be used.
- Refractory coating:
The refractory material used for the coating material are usually silica, alumina, and other compounds which are ceramic based.
- Sand:
Silica sand is most commonly used to embed into the foam pattern as it is readily available and is cheaper to buy.
- Casting alloys:
Metals: a variety of metals can be used like aluminum alloys which are lightweight and has strong parts., steel which is strong and is resistant to corrosion and cast iron is also used.
- Gating and riser materials:
The same materials are used which are used in refractory coating.
Application of Lost Foam Casting
There are Various industries which use this method. These include,
- Automotive industry:
- a. Engine blocks and cylinder heads: This casting process has the ability to make complex internal passages and thin walls which are very important for the engine parts.
- b.Other complex parts: This casting method is also used for other automotive parts which are very intricate. This process makes the design flexible for the parts and also reduces the weight.
- Aerospace industry:
- a. Lightweight components: This casting method is used for making lightweight components of the spacecraft and aircraft which require high strength-to-weight ratio.
- b. Intricate designs: The casting method can make complex shapes which are necessary for the aircraft and spacecraft.
- General engineering:
- a. Customized parts: This method is also used in Lost Wax Casting Manufacturers in India to customized metal parts for different applications of engineering.
- b. Complex geometries: This method is best used for parts which have intricate designs which would be next to impossible to make if we use traditional methods of casting.
- Industrial machinery:
- a. Pump casings and valve bodies: This method can be use to make components for industrial machinery like pumps and valves.
- b. Motor housings: This method is used to make motor housings which have complex designs.
- Other applications:
- a. Railway and infrastructure: This method is also used to make heavy parts of railway and large projects.
- b. Marine applications: The method can make outboard engine components like engine blocks and cylinder heads used in marine industry.
- c. Iron castings: This method is very popular in iron castings.
How India Has Become A Hub For This Casting Process
There are many factors which can be considered as to why India is becoming a hub for lost foam casting. These include,
- Cost effectiveness: The casting process is highly cost saving in comparison to traditional casting method and also reduces the manufacturing costs and machine requirements.
- Precision and quality: This process makes the intricate design and high accuracy parts easily and also makes the automotive and aerospace parts with high precision and accuracy.
- Material versatility: The materials used in the casting process are reusable and low amount of waste is produced making this process eco friendly in nature.
Top Lost Foam Casting Manufacturers In India
There are many companies which specializes in the lost foam casting method. These include,
- Gujarat Metal Cast: This company is the leading lost foam casting manufacturer and specializes in production of ductile iron, aluminum alloy castings etc.
- Castofoam India Private Limited: This company specializes in manufacturing lost foam casting plants, V process casting plants and related equipment.
- TOCSI Steel: This company makes automotive and engineering parts.
- JK Foundry: This provides lost foam casting solutions
- GDM technics: This company has an expertise in vacuum assisted lost foam casting.
Conclusion
Today India’s lost foam casting industry is a combination of tradition and innovation. As the number of manufacturers are increasing while also growing industries like automotive and agriculture India is becoming a hub for the lost foam casting process.
If you are a business looking for reliable and efficient casting process, lost foam casting is the best option.