wear resistant castings by lost foam process · 3.3 dip-coating & drying the whole foam need be...

Wear Resistant Castings by Lost Foam Process

Zhang Jianman, Liang Qingmin, Lei Bo, Ding HuanjunWeb:www.jianhengid.com Email: [email protected]

Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China

武汉建恒工业技术有限公司Wuhan Jianheng Industrial Technology Co.,Ltd.

http://www.jianhengid.com/

Wuhan Jianheng industrial technology Co.,Ltd is an integrated service company

committed to the development of foundry industry. The company owns a team with

professional knowledge and rich practical experience in casting technology and

management, engaging a number of senior foundry experts as consultant; the company

will strive to become a modern service industry enterprises focusing on foundry

consulting, research, technology, production, supplyment, trade, human resources and

other service.

Lost foam process have been widely used in many foundries and getting good

performance for many kinds of castings. This process is also been widely used for

production of wear parts especially for those which have smaller size but with many

different kind of types. If use this process for right castings, the production cost will be

greatly reduced and the casting quality will be enough for all kinds of working

conditions.


Web:www.jianhengid.com Email: [email protected] Address: B2001, Guanggu Times Square,, Hongshan District, Wuhan, Hubei, China

Brief introduction:


Hammer：13% Mn or 18% Mn, usually weight is less than 50kg;



ⅠIntroduction & typical products


Lining plate:

Including many kinds of lining plate made by manganese steel and high chrome

iron material.13% Mn, 18% Mn 20% Cr, 26% Cr; Alloy steel; Alloy cast iron;





Blow bar: smaller size blow bar, with 20% and 26% Cr content;




Pump parts: high Cr castings for pump parts;


Others: heat resistant castings; some special shape castings which is

difficult to produce by sand casting process, etc;





ⅡWhat is Lost foam casting?

White foam

makingMolding

Pouring CleaningShake out

Coating &

drying

Heat treatment

Foam

assembling




3.1 White foam making

Ⅲ How it works:

Manual cutting: for small quantity and simple shape castings;

Automatic cutting: for more complex shape castings;

Foam machine: use special pattern for big batch of castings or for high surface

requirement castings;

Manual cutting Automatic cutting machine



Foam machine

Note:1. The dia. of resistance wire is less than or equal to 0.3mm;2. During mass batch production, we should using eps beads of lost foam, and control density of foam less than 18kg/m3.


3.2 Foam checking & assembling



For complex castings usually use different foam sheets,meanwhile assembling

gating system togather,assisted by wood strips and asbestos sheets under glue;

Note:1. Choose the right reduced scale of white foam to make sure right size of casting.


3.3 Dip-Coating & drying

The whole foam need be coated 2~3 times ,and dryed in special heating room to

get good coating layer, for every coating layer, the heating will be important.



Note:1. Ensure the quality first while paying attention to power savings.2. India and other Southeast Asian countries has high humidity and needs to

make the necessary dehumidification measures.


3.4 Molding & Pouring

we use dry sand for molding, and the sand will be reused after shakeout, no any binderand chemical agents; when molding, sand will be filled by several times and assisted byvibrating; we also use ceramic sand instead of silica sand or olivine sand;

Pouring will be under suitable parameters: Vacuum pressure, pouring time andtemperature



.


3.5 Shaking out



Due to the use of dry sand, it is only necessary to tilt the flask to pour the casting

out of the flask. The recovery rate of sand is greatly improved.


Ⅳ Advantage of lost foam casting

1) Low investment;

For easiest equipment and trial, we just need a flask, vibration table and vacuum

system; if we want to produce 200-300T wear parts per month, equipment investment as

follows.



Purpose Workshop Key equipment Price/usd

200-300T/month

White area Foam cutting device 700-800

CNC foam cutting machine 4400-4500

Yellow area Mix station 3700-3800

Black area

Vibration table 17500-18500

Sand filling system 2300-2500

Sand preparation system 17000-18000

Vacuum system 14000-15000



1) Low investment cost;

Lost foam equipment including some flask (make by oneself), sand hopper (make by

oneself), screw conveyor, vibration table and sand preparation system (because use dry

sand, it is very simple), vacuum system.

Equipment of small wear resistant parts is more simple, make production is more

flexible suit for multi-variety castings.





2) Low production cost

①White foam: No need to develop wood patterns, especially for small batch products;

② use dry sand: no any binder, sand recovery rate >95%, less molding labor;

③ high efficiency: for small parts, we can pour a string at a time, high molding efficiency;

④ Surface quality: better surface quality and no parting line, reduced clean work;

⑤ labor cost more less, because better work environment.




3) More environment friendly.

① Production environment is better;

② use dry sand, no binder, low energy and simple flow for sand circulation; sand

recovery rate >95%;




Ⅴ. Typical simple equipment

1）Production efficiency: 2-5 mold/h;

2）Lower investment cost;

3）More flexible production;




For small wear resistant castings, our service including:

1. Basic casting technique consulting and data analysis;

2. Plant and shop layout designing and implement;

3. Equipment designing and selection;

4. Foundry materials selection and using guidence ;

5. Casting defects analyze and solution;

6. Workers training and operation guidance;

7. Guidance and advice on production control and management

8. Supply for any necessary equipment and material.

We will offer whole support for the project till the production stable

For more information please visit: www.jianhengid.com





Contact information

Zhang JianmanTel: +86-135-45239290 Email: [email protected]

Liang QingminTel: +86-187-71036713 Email: [email protected]

Lei BoTel: +86-156-23247330Email: [email protected]

www.jianhengid.com www.jhcasting.cn


mailto:[email protected]




http://www.jhcasting.cn/

wear resistant castings by lost foam process · 3.3 dip-coating & drying the whole foam need be...

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