Cast Iron Casting

1. Lost foam casting (also known as full-mold casting) for cast iron involves creating a mold using a foam plastic (such as EPS) that matches the exact shape of the intended casting. This mold is then embedded in dry sand, and molten metal is poured directly into it. The molten metal displaces and vaporizes the foam mold, ultimately forming the casting. During the manufacturing process of cast iron parts in our factory, the cast iron materials used are mainly ductile iron and gray iron.
2. Gray cast iron and ductile iron are common materials used in lost foam casting. This process reduces defects such as shrinkage and porosity in cast iron parts and is suitable for the production of complex-shaped castings (such as cylinder heads, mechanical housings, transmission housings, fire hydrant valve bodies, and brake housings). It has a proven track record in the iron casting industry.
Gray cast iron, the commonly used material in the foundry industry, contains flake graphite in its microstructure, which imparts good castability and shock and vibration resistance.
Ductile iron is a type of cast iron produced by adding magnesium to form graphite into spherical shapes. Compared to gray cast iron, ductile iron offers higher strength, toughness, and ductility, and performs exceptionally well under high loads and impact conditions.

Core Advantages of Lost Foam Casting

1. High Casting Quality: Dimensionally precise and with a smooth surface, reducing subsequent processing.

2. Complex Part Capability: Castings with complex cavities and special shapes can be directly formed without the need for additional sand cores.

3. Simple and Efficient Process: Eliminating steps like core making and box assembly, foam molds can be prefabricated in advance, allowing for flexible production switching.

4. More Controllable Costs: Less metal waste (high material utilization), eliminating the need for expensive molds for small and medium-sized batch production.

5. Wide Compatibility: A wide range of materials, including cast iron, cast steel, and aluminum alloys, can be used, offering a wide range of applications and high flexibility.