FACULTY OF ENGINEERING TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING TECHNOLOGY

PROJECT REPORT LOST FOAM CASTING

Course Name CASTING TECHNOLOGY

Course Code BNM 30303
Session/Semester 2018/2019 - 2
Section 2
Programme Code BNM
Group 1
Name Matrix No.
1. MUHAMMAD TAUFIQ BIN ZULKIFILI DN160199
2. ANAS SYAHMI B ABD RAZAK DN150041
Group Members
3. AYYUB FAKHRUDDIN B RAMLEE DN160036
4. LAI WAI SHUN DN160281
5.
En. Muharam Rafidi Jaafar, En. Ts Haffidzudin Hehsan,
Lecturer Name
Dr Aslinda Saleh
Introduction /10%
Objectives /5%
Scope /5%
Safety Precaution/Toolbox Talk /5%
Experimental Procedures /20%
Assessment Result and Analysis /25%
Discussion /10%
Conclusion /10%
Recommendation /5%
References /5%
TOTAL /100%
INTRODUCTION

Casting Technology (BNM30303) is one of the compulsory and core subject for
Bachelor of Mechanical Engineering Technology (Manufacturing), Faculty of Engineering
Technology students in Universiti Tun Hussein Onn Malaysia. The subject qualification
required student to perform lost foam casting by applying knowledge within the class syllabus.

Lost foam casting is a manufacturing process that pour molten metal directly onto a
refractory-coated foamed polymer pattern which is buried in loose sand. The molten metal will
gradually replace the polymer pattern which undergoes thermal degradation and solidifies to
obtain the casting (Shivkumar, Wang, & Apelian, 1990). According to Shivkumar et al.,(1990),
in order to obtain the metallic part, initially, a polymer pattern of the required shape is
produced. When the molten metal replacing the polymer pattern, it will duplicate all features
implement in the pattern (Emami, Divandari, Hajjari, & Arabi, 2013). Expandable polystyrene
(EPS) is the most common polymer that used in lost foam casting pattern making. Complex
shapes can be produced by joining several sections of the polymer with a hot-melt adhesive
and coated with a water based slurry and dried out.

Lost foam casting are familiar with numerous of advantages. The main features of lost
foam casting are no mold parting line, no cores and no environmental pollutants. Besides,
casting part can get more accuracy in dimension and able to have complex design and also cost
reduction. Advanced pattern also possible to mount desired ready solid part inside the
polystyrene pattern (coring) before the casting process take place (Emami et al., 2013). With
this particular possibility, it is also convincing that it is possible to join different material within
this process.
OBJECTIVES

1. To design a pattern from a selected product to be cast using polystyrene.

2. To decide the gating system for the pattern.
3. To produce the aluminum casting using lost foam casting process.

In order to achieve these objectives, axe emblem is chosen as the product. The
design is first design in CAD software to generate a simple preview before proceed to the
second objective which is determining a suitable gating system for the pattern. After that,
polystyrene is cut and adhere using white glue. It is then cast using aluminum material
using lost foam casting process.

SCOPES

1. Group of 3 to 5 persons.
2. The size of the pattern (product) must not exceed L60mm*W60mm*H80mm.
3. Polystyrene as the material for pattern making.
4. Cut polystyrene using knife or suitable method.

A group of 4 persons are form for this project. In this project, the axe emblem is scaled
to L60mm*W30mm*H80mm. The pattern of the axe emblem is make using polystyrene.
In order to form the polystyrene into the shape of axe emblem, portable hot wire foam
cutter is used. The outline of the axe emblem is print and paste onto the polystyrene
beforehand.
METHOD AND PROCEDURE

PROCEDURE PICTURE
1. Pattern Making

 Preferred pattern design is selected

and printed.
 The printed design is then pasted on
the polystyrene board.
 Blade is used for straight cuts.
Bladed implements like knives, box
cutters, through polystyrene,
especially don’t need to make any
curved cuts. For a smoother cut, run
the blade along an old candle before
cutting the polystyrene.

 Polystyrene cutter also used for

smooth cuts and rounded edges is
made.

2. Pattern Assembly
 Gating system is made and glued
together with the pattern.
3. Sand Fill and Compaction
 The pattern is then is now invested
in a foundry pail with loose,
unbounded sand which is vibrated in
order to provide a tight compaction,
leaving behind the pattern in the
sand.

4. Pouring molten metal

 The molten metal is poured on to the

top of the gating system, which is
responsible for directing the molten
metal through the cluster. The
molten metal being poured causes
the pattern made in the first step to
immediately vaporize.
 Pouring is continued until the mould
is filled.

 Once the mould has been filled, it is

left in order for the molten material
to solidify. Once solidification has
taken place, the sand and shell
mould is broken, and risers and
gates are removed, leaving behind
the final casting/product.

5. Shakeout, Clean-up, and

Finishing
 The final product can then also be
heat treated or undergo other
finishing operations much like what
is seen in other casting processes.
Procedure of molten metal (furnace)

PROCEDURE PICTURE
1. General Process Description
 Depending upon the metal being
cast temperatures can range from
600°C to 1600°C.The piece of
equipment can interfere with pace
makers, so any person with a
pacemaker is not allowed to use
it.
 The equipment MUST be used
with at least two people present,
and both people properly trained
on this piece of equipment
2. Hazards of Furnace/ Class of
Hazard
 In order to melt metal
temperatures greater than 600°C
is usually required.
Temperaturesat this level will
cause severe tissue damage.
Extreme care must be taken when
castingthe molten metal.No metal
which is deemed toxic is allowed
to be melted in thisfurnace.
 Ensure that your metals will not
oxidize before they melt
 Ensure that thematerial of the
crucible will not react with the
molten metal (i.e. graphite
crucible plusmolten iron are
incompatible). There is a shock
hazard if person comes in contact
withcopper coil.
3. Personal Protective Equipment
(PPE)
 Before using the RF Furnace,
ensure that you will at least meet
the following protective
requirements:
1. Safety Glasses
2. Thermal gloves
3. Aluminized Heat Resistant
Jacket
4. Closed-toe shoes with socks
5. Long pants (no shorts!)
6. Lab coat
7. Face shield
SAFETY PRECAUTION

General Foundry Hot Work Safety Rules (Bezalel, 2011)

1. Personal Protective Equipment (PPE)

o Clothing covering all skin, purpose built or made of natural materials like
leather, heavy wool or heavy cotton. No polyester or nylons. Boots to be Class
1 safety. Full face shield and leather gauntlets.
2. Tidy foundry area
o Pouring area to be free from all items not involved in pouring process. Floor to
be clear of trip hazards and concrete slabs and pavers covered with minimum
1” layer of sand.
3. Clamp or weight flasks
o Hydrostatic pressure of liquid metal can lift a lot of weight, once the cope and
drag have separated due to this pressure the uncontrolled flow of metal is
extremely hazardous.
4. Use dry clean metal
o Impurities on the surface of the melt metal nay become airborne breathing
hazard and often increase the dross to be removed from the melt.
5. Preheat all metal and furnace tools
o This reduces the risk of condensation a tools and furnace recharge metal from
steam explosions occurring in the melt.
6. Move the melt slowly and a short distance furnace to flask
o It is said that liquid metal is runnier than water and splashes further, thus
minimize the possibility of spills and splashes.
7. Know what you are melting
o The characteristics like melting temperature, adverse health effects of hazardous
alloy are good to know before starting.
8. Inspections before use
o Knowing the condition of the crucible the furnace walls the fuel lines burners
and pouring tools is critical. Failure of any items during melt or pour can be
extremely undesirable.
9. Watch for bubbling sprue
o Low permeability sand or excess moisture in the mold can result in a steam
build up or blow back out the sprue.
10. Plan emergency exit route
o Identity escape routes before start to pour if the unexpected eventuates.
11. Be alert
o Do not working in the foundry if exhausted, sick, drugged stoned or drunk.
12. Zn and Mg fluxing
o These metals and others (like phosphorous) evaporate and ignite easily at
relatively low temperatures.
13. No water
o Water or moisture that manages to get below the surface of liquid metal in the
furnace or mold can cause explosion.
14. Watch for leaks
o If strange aroma in the melt that has leaked out of the back of the flask trickled
around under the drag along the floor.
15. First aid
o Despite best planning, maintenance, preparation and care, sometimes accident
do happen. Thus, prepared for the worst and use first aid before proceed further
action.
RESULT

No Figure Description

Figure of pattern and sprue for casting.

Figure of pattern and sprue for casting

(front view)

2
 Figure of product casting (bottom view)

Figure of product casting (side view)

Figure of product casting (front view)

5
Based on the table above shows the various view of the pattern and product produced in this
casting project. Referring to figure 1-2 shows the final pattern made of polystyrene. The pattern
was cut by using electric wire cutter, paper knife and sand paper for the finishing. The
dimension of the pattern is 60mm length, 30mm width and 80mm height. However, based on
figure 3-5 shows the actual product produced by using lost foam method. The product was
completely the same with the pattern and had a same dimension.

DISCUSSION

The discussion had been made between our group members in order to find out any
problem and come out with the best solution. Based on casting axe emblem that has been casted
in this project, we had found that the final product had many pores cover all over the axe
emblem. This defect is required a machining process for finishing section. However it will lead
to material lost due to the process. In order to prevent this problem from occurring during
casting process, the pattern should be well crafted and has a smooth surface texture by sanding
the pattern properly. This is because in lost foam casting, the pattern will be evaporated due to
high temperature and the molten metal will be fill in the space cause from this evaporate pattern
with having a same surface texture as the pattern. In order to prevent the material from wasted,
a pouring basin should be made suitable with the dimension of the patter and has a good drain
to let a molten metal flow from pouring basin to the sprue of the pattern. The sprue of the
pattern also must be well designed in order to prevent any silica sand from blocking the molten
metal to fill trough the pattern. This is because of lost foam casting process only required to
use a silica sand to create a mould. Silica sand is suitable to use in lost foam due to its
characteristic that originally in small particle and does not damage the pattern while making a
mould.
CONCLUSION

As a conclusion, lost foam casting is a simplified production technique and reduce a

evironmental waste due to binder system emissions and sand disposal. The process is well-
suited for casting with complex geometries, tight tolerance, and smooth as- cast surface finish
requirements. Besides that, a student understand the importance of lost foam casting quality
and how it affects the lost foam casting process. A student also can recognize casting defects
that occur with the lost foam casting process. Finally, a student allow to display the common
pouring control methods used in the lost foam casting process. and review the mold preparation
process, including general design rules.

RECOMMENDATION

1 POLYSTYRENE’S DENSITY

 If the density is less than standard, the casting is carried out with less iron, with the
risk that the mould is not filled, losing both the pattern and the casting.
 If the density is greater, the casting will be carried out with an excessive amount of
iron, and there may be several tonnes of excess in the ladle, with nowhere to pour it.

2. POLYSTYRENE’S QUALITY

 To obtain a good surface finish for the castings, it is fundamental that the polystyrene’s
quality is good and for the surface finish to be thin. In this regard, it is recommended:

 The polystyrene plates must be manufactured with pearls (balls) with small diameters
(Ø1.5 to Ø2.5 mm).

 Polystyrene machining conditions must be adequate, such that the polystyrene is not
ripped or burned from friction.
REFERENCES

Bezalel. (2011). 15 Hot Work Safety Rules (Foundry) | Home Model Engine Machinist.
Retrieved April 30, 2019, from https://www.homemodelenginemachinist.com/threads/15-
hot-work-safety-rules-foundry.14397/

Emami, S. M., Divandari, M., Hajjari, E., & Arabi, H. (2013). Comparison between
conventional and lost foam compound casting of Al/Mg light metals. International
Journal of Cast Metals Research, 26(1), 43–50.
https://doi.org/10.1179/1743133612y.0000000037

Shivkumar, S., Wang, L., & Apelian, D. (1990). The lost-foam casting of aluminum alloy
components. Jom, 42(11), 38–44. https://doi.org/10.1007/BF03220435