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Energy savings of 25 to 30 percent are typically achieved by the lost foam process compared to conventional sand casting. |
Cast Metal Products Made with the Lost Foam Process
CLEARPOR® is a unique expanded bead foam used to mould product shapes, which in turn are used as patterns to make cast metal parts for use in the lost foam (LFC), or evaporative casting process. Products made with this process include automotive engine parts, and cast metal parts for many other markets as well.
Benefits of CLEARPOR® include less carbon, a smooth surface appearance and dimensional accuracy. Finished metal parts cast using CLEARPOR® may require less machining to achieve the finished surface and shape, based on the finer tolerances CLEARPOR® allows.
Mould patterns made from CLEARPOR® are comprised of extremely small beads, 0.4 mm and 0.5 mm in diameter, depending on grade.
Advantages include the best of both worlds
CLEARPOR® provides benefits on the "white" side (pattern production), and also on the "black side" (casting)
- Less carbon, fewer carbon cavities
- Moulded as easily as EPS
- Greater dimensional accuracy than EPS
- Faster thermal reaction than PMMA
- Easier to handle than PMMA
- Allows thin walls, tight tolerances, complex shapes
- Enhanced pyrolysis
| CLEARPOR® provides superior pyrolysis properties, and contains far less carbon. |
The Evaporative Casting Process
CLEARPOR® pattern shapes are moulded on standard EPS moulding equipment. The lost foam casting process, also known as evaporative casting, is a low cost technique for manufacturing intricate, complex thin-walled casting iron and aluminium castings. Lost foam casting typically generates only 20% of the spent sand that green sand moulding does.
Automotive castings that benefit from the use of CLEARPOR® include engine blocks, exhaust manifolds, bearing caps, differential gear cases, cylinder sleeves and other engine parts. Other products made with the CLEARPOR® lost foam process include water and drainage hardware castings, valves, and metal castings of all types made from ferrous metals.
Click here for more information on the Lost Foam Casting Process. |
