The lost foam process is accepted as the process of choice for high-volume complex components such as blocks and heads the automotive and marine; compressors for heating and air conditioning industry; Electric motor housings; counterweights for heavy equipment; Hydraulic valves, hydrants, pipe and fittings for water distribution industry; heat exchangers for various industries. The cast features an added value in such holes, threaded fasteners and internal fluid passages have made the LFCP attractive solutions for many buyers. Before the start of the current research program was to survey the most significant questions technical sponsors identify industries. The industrial sponsors of research identified six areas to be addressed in the current program. The tasks to solve the issues were:
1. An increased understanding of the replacement process metal / pattern reduce casting defects and improving computational models. Approach – Identify the mechanism of gas and liquid pyrolysis removed from the casting cavity using the pyrolysis Pattern apparatus and equipment Real-Time X-Ray. This mechanism is necessary to improve the computational models current and direct further research would result in better quality solutions. The data will be added to the existing data base.
2. Improve quality and consistency pattern reduce casting defects. Approach – Long-Lost Foam Casting suppliers time believed that 80% of defects quality solutions direct result of poor pattern. The approach to this task to the specific properties of control patterns filled metal and casting defects later identify and develop equipment to measure these properties.
3. innovative techniques to expedite removal pattern pyrolysis product solutions to reduce defects and improve quality development solutions. Approach – Since the addition of bromide is the subject of study successful pattern from the level of bromide. In addition, studies to determine the effects of bromide addition to the planned shield. Further studies on other additives intended.
4. techniques and procedures developed to improve the mechanical properties of solutions using solidification under pressure and vacuum assisted filling metal. Approach – Data from the literature are diverse in their opinion on the effects of solidification under pressure for aluminum castings. A study is planned to determine the mechanical properties of 319, A356 and 206 aluminum alloy solidified under pressure. Ding solutions will be used for the cooling effects from the solidification rate given pressure.
5. design package including mechanical properties develop solutions for designers and marketing plan to increase the Lost Foam Casting applications implementation. Approach – design package that reflects the current state of the art for the mechanical properties of aluminum alloy development. The data will be compared properties open cavity, sand band and Lost Foam processes using solidification pressure and atmospheric pressure. Most of the data will be removed from Task 5; However, additional data will be from another process (vacuum assisted pouring). Further details will be developed for Compacted Graphite Iron (CGI).
6. Translate the technologies developed production management and production floor. Approach – Technical exchange meetings will be held every four months, alternating between UAB, AFS and sponsorship Lost Foam facility. Approved technical papers will be presented at conferences worldwide solutions. Personnel – Dr. Charles Bates was the principal investigator (PI) until his retirement in 2006. John A. Griffin took the responsibility PI from 2006 to the present. Dr Bates ordered the Lost Foam Consortium since its foundation and was instrumental in the solicitation of funding for equipment such as the equipment Real-Time X-Ray, solidification chamber pressure and other foundry equipment. Harry E. Littleton directed technical approaches and development equipment associated with the program as it is from the foundation of the program. John A. Griffin supervised the laboratory procedures and experiments throughout the entire program.