Lost Foam Casting
EXPENDABLE PATTERN CASTING
ABOUT EPC
Shaped in foam.
Formed in metal.
Lost foam casting, also known as full mold casting, starts with foam patterns shaped like the finished casting. The patterns are assembled, coated with refractory material and dried before being embedded in compacted dry sand.
Molten metal is poured under negative pressure, replacing the foam pattern. After cooling and solidification, the sand is removed and the casting is cleaned.
YX CAST applies this process to heat resistant and wear resistant alloys, carbon and low alloy steels, and ductile iron components.
The EPC Process
Foam Pattern Making
Produce foam patterns to match the casting geometry and assemble the gating system.
Coating & Drying
Apply a refractory coating to the pattern cluster and dry it thoroughly.
Dry Sand Molding
Place the pattern in a flask, fill with dry sand and compact by vibration.
Vacuum-Assisted Pouring
Pour molten metal under vacuum to replace the vaporizing foam pattern.
Cooling & Cleaning
Allow the casting to solidify and cool, then remove the sand and clean the casting.
Pattern Assembly
Foam sections can be assembled into complex shapes, creating a practical route for a range of casting geometries.
Dry Sand & Vacuum
Vibration compacts the dry sand around the coated pattern, while negative pressure supports the pouring process.
Application-led Engineering
Material, wall thickness, surface finish and machining allowances are considered together with the product geometry.