Abstract
The purpose of this paper was to analyze the process factors affecting the occurrence of lustrous carbon defects in ductile cast iron castings when using the lost-foam casting (LFC) method. This phenomenon results in creating raw surface defects, which sometimes may even lead to cast iron scrapping. A series of trial melting batches were carried out for variable process assumptions. The analysis was performed to reflect, to the greatest extent possible, real foundry production conditions. Industrial tests were performed in Odlewnia Rafamet Sp. z o.o., Kuźnia Raciborska, Poland. The polystyrene patterns created by gluing components together, used in the tests, met the requirements of the high-tech lost-foam casting (LFC) process. The performed analysis allowed the obtaining of lustrous carbon defects in test castings as well as the determination of the process parameters with the highest impact on lustrous carbon inclusions in ductile iron castings. The test results were used to eliminate the possibility of creating a defect and thus directly improve the efficiency of the lost-foam casting (LFC) process used in the foundry.
Highlights
The lost foam casting (LFC) process has been known globally since 1958 when Shroyer published his patent [1], where he described the use of a Styrofoam pattern reflecting the shape of the casting.The method is referred to as “Full Mold”, which emphasizes pouring a mold without removing the casting, which is subject to gasification with the heat of a hot alloy filling the mold [2]
A significant increase in the interest in the lost-foam casting (LFC) method was observed in the late 1980s
The production of ductile cast iron increases dynamically, which is stimulated by higher demand for cast iron with nodular graphite [4]
Summary
The lost foam casting (LFC) process has been known globally since 1958 when Shroyer published his patent [1], where he described the use of a Styrofoam pattern reflecting the shape of the casting.The method is referred to as “Full Mold”, which emphasizes pouring a mold without removing the casting, which is subject to gasification with the heat of a hot alloy filling the mold [2]. The lost foam casting (LFC) process has been known globally since 1958 when Shroyer published his patent [1], where he described the use of a Styrofoam pattern reflecting the shape of the casting. The Styrofoam patterns featured a low dimensional-shape accuracy and a considerable roughness of the casting surfaces. A significant increase in the interest in the lost-foam casting (LFC) method was observed in the late 1980s. Thanks to the use of modern production technologies, e.g., CNC machine tools and laser cutting, Styrofoam patterns featured higher accuracy than in the earlier years [3]. The production of ductile cast iron increases dynamically, which is stimulated by higher demand for cast iron with nodular graphite [4]. Casting defects associated with lustrous carbon are treated as inclusions
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