Processes

 

Lost Foam

Pre-forms are molded in expandable polystyrene, glued together to form complex shapes, assembled into a cluster around a sprue and coated with refractory paint.

The cluster is then put in a flask and covered with dry sand which is compacted around the cluster by means of vibration.

When the aluminum alloy is poured, the polystyrene pattern vaporizes and is replaced by the metal to form the casting.

 

Advantages
No binder nor cores are needed.
Very complex shapes can be cast.
Machining and assembling operations can be reduced.