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Grede Lost Foam Casting
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- čas přidán 27. 01. 2015
- An advanced science that translates into fine art, lost foam casting opens a world of design opportunity.
By achieving as cast design complexity and multiple component integration into a single near net finished part, the lost foam process presents substantial value added and total cost advantages unimaginable with stampings, forgings or other conventional methods.
Advantages such as:
• Longer tooling life, as foam tooling can last hundreds of thousands of cycles, capable of producing potentially millions of parts
• Component weight reduction by as much as 30% due to reduced draft, the ability to achieve thinner, more uniform walls and the elimination of sub assembly as a result of design architecture, that allows for component integration
• The reduction or elimination of casting finishing, machining, welding and balancing operations
• Improved component integrity strength and appearance, and improved component functionality and performance
In summary, lost foam casting is the type of metal casting process that uses a foam replica as the pattern or core, coated with a refractory material and packed in un-bonded sand, the foam remains in the mold during the metal pour, under the heat, the foam breaks down and volatizes into the coating and surrounding sand.
As one of the world’s largest independent producers of ferrous metal lost foam castings, Grede has nearly 20 years of experience mastering the art and value of lost foam, beginning with the foam pattern itself.
Grede’s internal capabilities include this dedicated facility supplying foam patterns to its nearby casting plant in Alabama.
From bead pre-expansion and aging to mold press PLC programming, the foam pattern process is designed to insure the foam maintains strict dimensional accuracy, proper surface finish and holds a consistent bead fusion level for optimum breakdown when the metal is poured. For many lost foam castings, complexity requires molding and gluing together multiple foam patterns.
Here again, the process involves PLC programming and dedicated fixturing, in this case to insure precise mold to mold orientation. Before casting each production run mold set undergoes a designated frequency inspection to confirm dimensional accuracy.
Next Grede combines individual foam patterns of the same part into cluster assemblies to meet high volume demands. These clusters are then robotically dipped in a refractory coating, carefully formulated to make the casting process work.
The coating is a key factor in the entire process. It is very carefully controlled through testing for viscosity and permeability because one must control the velocity of the foam’s gas dissipation. Too fast and you end up with Carbon impurities in the castings. Too slow, and the mold collapses in on itself, due to the outside pressure of the un-bonded sand.
Coated clusters are then dried in a climate-controlled room to insure stability. When ready for casting, they are inserted into flasks that are conveyed through the casting process. Cluster configurations vary to accommodate a wide range of parts from as small as 2 pounds to as large as this 800 pound electric motor housing.
In the dry media compaction phase while the flasks are filled with un-bonded sand, they are simultaneously vibrated to fluidize the sand and insure it fills any and all internal passages or geometries in the mold.
Next the molds are ready for the metal. To insure the highest metallurgical quality, process controls begin with the purchasing of raw materials and continue through the melting and alloying phases where Grede manipulates the base chemistry to create various grades of ductile and gray iron.
Multiple chemistry checks and a double nodularity confirmation both from the pouring deck and minutes later in the lab insure the microstructure is of the highest quality ductile iron.
Just like with other casting methods, we test everything to ASTM standards, from a mechanical stress standpoint, lost foam ductile iron is no different from green sand ductile iron and from a microstructure standpoint, it is actually better, because there is no chilling effect on the metal due to the fact we use dry un-bonded sand.
Once poured and cooled, the castings are discharged from the flask in a shakeout process as the lost foam process yields no parting lines or flash, very limited gating and usually no risers. The castings generally can be moved to a simple automated finishing process, even the surface finish is near net and the part is ready to be shipped.
At the end of the day, the lost foam process provides design freedom for obtaining significant weight reduction, better performance, integrity and aesthetics and best of all, a lower total cost to the customer.
I work for Grede's in Reedsburg, but I was an electrician... however I was a furnace tender for Richland foundry
I'm glad they are still around.
Grede used to have a foundry in Wichita, KS.
I can't find anything on the Pryor Oklahoma plane. Why!!
They didn't ask me to put that in the video
Lindo trabalhador parabéns tem mas video 👏🏼👏🏼👏🏼👏🏼quero trabalhar nesta area
Those are Dana 60 axle housings used in Ford Super Duty trucks.
Keep America working!
Indeed they are.
Thanks that was a good video.
I'm glad you enjoyed it. I'm surprised to see that it is my most watched video.
Thank you. I am surprised it has become so popular.
Very nice news
Good information
I'm glad you liked it.
how does the iron stay in the cavity if there is loose sand around the polly pattern is there a special coatings on the polly pattern?
When the foam model is coated, the mixture used is resistant to heat. The sand sticks to the coating when the hot metal is poured and holds its shape. The foam evaporates from the heat of the metal, and when the metal cools, the coating and sand have to be shaken free from the cast part in a huge vibrating container, because the sand and coating hold together so well. It is an amazing process, and if you have the chance to visit a casting facility, I think you will be fascinated.
Good question. First of all, the sand is packed in fairly tightly, through vibration and weight. Secondly, when the metal is poured in, it creates outward pressure which pushes against the sand, helping to hold it in place against the walls of the container. And third, the foam evaporates fairly quickly as it makes contact with the hot metal, but the coating on the mold is more heat resistant and holds its shape long enough for the metal to fill the form, so the sand has nowhere to go.
I refuse to believe this is not an instructional video from 1997.
You're not far off. It was shot in 2005
I only produced the video, I don't work for Grede, so I can only tell you what I saw while I was on site at the plant. The parts come out of the mold with somewhat of a matte-satin finish, with a mild texture to it. For any surface that does not need to mate seamlessly, the surface is usually completely usable once initial manufacturing is complete. However, the metal can be milled to a completely smooth finish if needed for parts that need to line up to high tolerance or contact to other metal parts. In almost every case, significantly less processing and finishing is necessary when compared to standard castings.
You can find out more, by contacting the company. Information is available at the web address below:
www.company-histories.com/Grede-Foundries-Inc-Company-History.html
I’m curious to know if this was the brewton Alabama plant. Got an interview coming up and trying to do research?
@@Re_DEEMD No, it was not Brewton. But it was in Alabama, outside of Huntsville ... if I remember correctly.
Thanks for that amazing video
And please can you tell me any kind of glue they use and the matter for painting?
I do not know the answers to those questions, as I only made the video and not the actual parts. The company is located in Alabama. You may look them up and ask them directly.'
do you have any question about the lost foam
@@zhangjian6133 hello, which one is better between lost foam and lost wax in term of cost production and volume productivity?
thank you
You are welcome!
You are welcome. I am glad you enjoyed it.
👏🏼👏🏼👏🏼👏🏼 linda
♥.♥
Slightly similar to the Lost Wax method.
Yes, it is quite similar. It allows for more detail and reduced finishing.
Yes it is
that womans voice is every lady over 40 in florida
What a coincidence! She is over 40 and I understand she went to Florida once!
Local 8511 Grede foundry hates there employees
I don't have anything to do with that. I don't work for Grede. I just make videos.
what is the Standard surface Finish and what we can archive in this method castings
pro tip : watch series at instaflixxer. Been using it for watching a lot of movies recently.
@Santino Zechariah Yup, I have been watching on InstaFlixxer for months myself =)
The unbonded sayunnnd
Dayunnnd sun
its called as the COCO foamalio process..
Video is interesting, music is of zero value, sucks actually...
I would be happy to consider using some of your music, if you have created something that will work better.