| The Lost Foam Casting Process (LFCP), which employs expanded foam patterns placed in unbonded sand, is increasingly gaining popularity in the foundry industry. The time and cost associated with introducing new Lost Foam (LF) castings into production could be significantly reduced by using simulation codes capable of modeling metal fill and solidification and predicting defect formation. The development of accurate models of Lost Foam casting (LFC) has been hindered by a lack of understanding and data on the mechanism of metal/pattern exchange.; This research work focused on developing a mathematical model of metal/pattern exchange and generating pattern and glue degradation data necessary for the model. The experimental work was conducted using the foam pyrolysis apparatus developed earlier in this research and included experiments to (a) evaluate the effects of the heater size and shape on foam pyrolysis, (b) observe the morphology of the heater/pattern interface, (c) extend the temperature capabilities of the foam pyrolysis apparatus to iron and steel pouring temperatures of 1600°C (2910°F), (d) measure the temperature of the gaseous degradation products of expanded polystyrene (EPS) exiting the kinetic zone (KZ), (e) measure the EPS degradation resistance pressure and the molecular weight of EPS liquid degradation products, and (f) develop quantitative glue joint degradation data.; A simplified mathematical model of heat and mass transfer in the KZ was developed to calculate data necessary to predict the pattern resistance to metal flow. KZ parameters, including KZ thickness and temperature, density and viscosity of degradation products, and heat flux, were calculated for aluminum casting conditions using experimental pattern degradation data. The predicted heat flux values showed good agreement with measured.; Modeling of different aspects of LFC, such as fluid flow, heat transfer, and defect formation, is discussed. |
