Low Pressure Lost Foam Casting Process for Aluminum- and Magnesium alloys

M. Aitsuradze, J. Bast, (Freiberg University of Mining and Technology, Freiberg, Germany),
T. Hahn (Pittsburg State University, Kansas, USA)

ABSTRACT

The Lost Foam casting process can be utilized to create complex castings at a high production rate and low cost. Some aspects of this technology, however, are still not very well understood. One critical process step is filling the mold with molten metal. Precise control of the flow rate of the metal has the potential of reducing casting defects.

A new casting machine utilizing the new low-pressure Lost Foam casting process was developed. It combines the advantages of Lost Foam casting with the low-pressure Permanent Mold casting. A series of experiments was conducted to test the casting machine’s suitability for manufacturing Lost Foam castings. It could be concluded that low-pressure Lost Foam casting will result in higher casting yields and lower energy consumption.