Economic data for an aluminium Lost Foam foundry

To reduce wastes from sand casting and to reduce energy consumption. Example plants 

Several example plants are reported in Germany and France. 

Ceramic shell moulding is a patented process (Replicast ) in which a polystyrene model is covered with a ceramic shell (2-3 mm thickness), based on ethyl silicate and refractory sand. The shell is hardened using ammonia and sintered at 1000 °C. The sintering cures the shell and bums away the polystyrene model. The metal is then poured into the shell. 

The sintering furnace is equipped with post combustion to reduce emissions. 

The technique allows a casting design with no parting lines, cores and draft angles and reduced feed metal. This reduces the need for finishing and machining operations. 

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Table 4.27 Economic data for an aluminium Lost Foam foundry [96, Spillner, 1997]...

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