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Lost-foam casting (LFC) is a type of evaporative-pattern casting process that is similar to investment casting except foam is used for the pattern instead of wax. This process takes advantage of the low boiling point of polymer foams to simplify the investment casting process by removing the need to melt the wax out of the mold.
Cooling - After the mold has been filled, the molten metal is allowed to cool and solidify into the shape of the final casting. Casting removal - After the molten metal has cooled, the mold can be broken and the casting removed. Trimming and cleaning processes are required to remove any excess metal from the feed system and any sand from the mold.
Mold cavity: The combined open area of the molding material and core, where the metal is poured to produce the casting. Riser: An extra void in the mold that fills with molten material to compensate for shrinkage during solidification. Gating system: The network of connected channels that deliver the molten material to the mold cavities.
Another method involves filling the entire mould with molten wax and letting it cool as a solid object. [citation needed] If a core is required, there are two options: soluble wax or ceramic. Soluble wax cores are designed to melt out of the investment coating with the rest of the wax pattern; ceramic cores are removed after the product has ...
Wax patterns are used in an alternative casting process called investment casting. A combination of paraffin wax, bees wax and carnauba wax is used for this purpose. In this case the wax "pattern" is melted out from the mould cavity which is normally a rigid plaster like material rather than sand, so the wax "pattern" can only be used once. [5]
The lost wax process originated in ancient Mesopotamia. The earliest known record of lost-wax casting is a clay tablet written in cuneiform in the ancient city of Sparta, Babylon, which specifically records how much wax is needed to cast a key. [6] The earliest-known castings in the global archaeological record were made in open stone molds. [7]
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