why lost foam

WHY LOST FOAM ?

Presented by Karel Cermak

1.CASTING TOLERANCES ARE SMALLER

• DIMENSION [mm]• < 25 • 25 to 80• 80 to 125• 125 to 175• 175 to 250• > 250• Rough guide <175

>175

• TOLERANCE [+/-mm]• 0.17

• 0.25

• 0.30

• 0.43

• 0.003 per mm

• 0.002 per mm

• 0.50

• 0.80

2.NO CORES ARE REQUIRED

• LARGE DESIGN FREEDOM

• “CONTROLLABLE” WALL THICKNESS

• NO CHAPLETS

• NO FINS

• NO MISMATCH

• NO CORE DEFECTS

• NO SAND MIX PROBLEMS

3.NO PARTING LINES

• NO DEMOLD DRAFT

• SEVERAL LAYERS POSSIBLE

• DOWNSPRUE AND RISERS CAN BE POSITIONED OPTIMALLY

• NO MISMATCH OR FINS

4.COMBINATION/CONSOLIDATION OF PARTS

IS POSSIBLE

• “GLUE INSTEAD OF FASTENERS”

• DECISIONS IN THE EARLY DESIGN PHASES ENABLE A HIGH ADDED VALUE TO BE ACHIEVED

• Al-alloy ( 319 T5 )

• 11.8 kg.

• 490 x 330 x 135

• Semi-Permanent mold and cores

• Lighter

• Reduced machining

• No fettling

• Higher productivity

• Smoother

• Product performance

• Combination.

– Fewer parts

• Less leaks


• Fewer fasteners

• Reduced assembly

• Fewer seals

CYLINDER HEAD 16 V

SATURN / GM1200 PER DAY

IN-HOUSE FOUNDRY

so far 1.7 million castings produced

• Al-alloy (319 T5)

• 18.2 kg.

• 435 x 445 x 280


• Lighter


• Reduced fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

ENGINE BLOCK

SATURN / GM / 1.9 l / 124 PS1,200 PER DAY

IN-HOUSE FOUNDRY


• Al-alloy

• 22 kg.

• 600 x 300 x 400.

• Die-cast with salt cores

• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

ENGINE BLOCK V6

MERCURY MARINE300 PER DAY

IN-HOUSE FOUNDRY

• Al-alloy

• 12.4 kg.

• 400 x 300 x 350

• No comparison possible

• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

ENGINE BLOCK V2

KOHLER OHC / 16 PS350 PER DAY

INTERMET

OIL COOLER

IVECO300 PER DAY

ALUMINIUM DONGO

• Al 319.

• 2.5 kg.

• 250 x 150 x 30


• Lighter


• Less fettling



• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

INTAKE MANIFOLD

FIAT3,500 PER DAY

ALUMINIO DONGO

• Al 319.

• ca. 5 kg.

• 280 x 220 x 50


• Lighter


• Less fettling



• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals


CYLINDER HEAD

FIAT - FIRE ENGINE - PUNTO 1600 PER DAY

ALUMINIO DONGO

• Al 319.

• 12 kg.

• 370 x 140 x 120


• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

INTAKE MANIFOLD

GM-OPEL CORSA1,200 PER DAY

ALUMINIUM DONGO

• Al- alloy.

• 2.45 kg.

• 260 x 220 x 190.

• Comparison difficultSand casting?

• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

INTAKE MANIFOLD

FORD 2.3 l / 4 Cyl.1,200 PER DAY

INTERMET

• Al - alloy

• 5.2 kg.

• 450 x 220 x 85.

• Semi- Permanent mold and cores

• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

• Al-alloy

• 12 kg.

• 450 x 420 x 180.

• Sand casting and cores

• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

GEAR HOUSING

SAUER SUNDSTRAND220 PER DAY

WILLARD INDUSTRIES

FMC250 PER DAY

WILLARD INDUSTRIES

• Al-alloy

• 1.04 kg.

• 139 x 125

• Comparison difficult

• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

CLUSTER HUB

• Al-alloy

• 0.7 kg.

• 90 x 90 x 32.

• Die-cast

• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

HEATED COVER

XXXX1,000 PER DAY

INTERMET

HYDRAULIC HOUSING

SAUER SUNDSTRAND210 PER DAY

WILLARD INDUSTRIES

• Al- alloy

• 13 kg.

• 350 x 200 x 200.


• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

• Al-alloy

• 2.8 kg.

• 350 150 x 150.


• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

SUCTION PIPE

MERCEDES BENZ200 PER DAYHANDTMANN

ALUMINIUM FAILURES

• Wrong product choice

• Reluctance to adapt design

• Underestimation of development costs

• Inexperience

• Al-alloy

• 0.78 kg.

• 190 x 170 x 130.


• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

SUPPORT/CARRIER

FLOP 1

• Al-alloy

• 5.1 kg.

• 300 x 300 x 310


• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

CYLINDER HEAD

FLOP 2

• Al-alloy

• 1,1 kg.

• 110 x 220

• Welded part

• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

EXHAUST PIPE

FLOP 3

DUCTILE IRON• PROs

– No fixed mold process available - very good accuracy

– All parts, like for Al, pourable

– Cleaning room cost savings greater than for Al

– Environmentally cleaner than sand casting processes

• CONs– The process is

sensitive to uncontrolled carbon pickup

• GGG 60 ( US 0.7060)

• 11.34 kg.

• 450 x 200

• Mask tool & 9 cores

• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

CRANK SHAFT

SATURN / GM1,200 PER DAY

IN-HOUSE FOUNDRY

• GGG 50 / 60

• 4.2 kg.

• 150 x 140

• Sand casting with cores

• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

DIFFERENTIAL CASE

SATURN / GM1,200 PER DAY

IN-HOUSE FOUNDRY

• GGG 40

• 11.1 kg.

• 250 x 200 x 160


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

SPRING HANGER A

VOLVO - GM HEAVY TRUCK240 PER DAY

CITATION FOAM CASTING COMPANY

SPRING HANGER B

VOLVO - GM HEAVY TRUCK240 PER DAY


• GGG 40

• 13.4 kg.

• 280 x 200 x 160


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

• GGG

• 12.3 kg.

• 400 x 250 x 160.


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

CLAMP GUIDE

XXXXX200 PER DAY


• GGG 40

• 5.9 kg.

• 260 x 230 x 220.


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

SUPPORT / CARRIER

MERCEDES BENZ, COMPR. MOTOR120 PER DAY


DUCTILE IRON FAILURES• Wrong product

choice

• Reluctance to adapt design

• Underestimation of development costs

• Inexperience

• GGG !!!

• 2.0 kg.

• 280 x 300

• Sand casting & 4 cores

• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

STATOR FRAME

EXPERIMENT

• GGx-highly magnetic

• 0.8 kg

• from 80 to 140 mm x 70


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

EL.-MAGN. CLUTCH FOR CAR A/C - ROTOR

EXPERIMENT

GRAY IRON

• Thinner hard iron surface

• More even solidification– Reduced stress

• Quicker machining

• Increased machine tool life

• GG

• 10 - 80 kg

• up to 800 x 1000


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

STATOR FRAMESIEMENS, ABB, BALDOR, DIEZ

CA.1000 PER DAYCITATION FOAM, VSETIN

ELECTRIC MOTOR END SHIELD

BALDOR40 PER DAY

CITATION FOAMS

• GG

• 12 kg.

• 400 x 100


• Lighter


• Less fettling


• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

• GG 25.

• 4.5 kg.

• 360 x 200 x 130.

• Sand casting

• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

WATER INLET / COMPONENT BRACKET

CUMMINS ENGINE CO180 PER DAY


• GG 40

• 22 kg

• 600 x 300 x 100.


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

EXHAUST MANIFOLDMERCURY INBOARD

120 PER DAYCITATION FOAMS

• GG

• 10 kg.

• 280 x 350 x 220


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

COOLING WATER PUMP

DETROIT DIESEL120 PER DAY

CITATION FOAM

• GG

• 22 kg.

• 300 x 400 x 400


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

WATER VALVE BODYM & H NW 15080 PER DAY

CITATION FOAMS

• GG

• 53 kg.

• 550 x 225 x 100.


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

CYLINDER HEAD - DIESEL

JIN HONG400 PER DAY

IN-HOUSE FOUNDRY

ELECTRICAL MOTOR END SHIELD

80 PER DAYCITATION FOAM

• GG

• 26 kg.

• 711 x 120


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

STEEL CASTINGS

• High accuracy• Good surface quality• Also 3 + mm wall

thickness possible• Reduced machining• Increased machine tool

life• Reduced cleaning room

costs• Complicated castings

possible

ADVANTAGES LIMITATIONS

• Alloys with C < 0.15 %

• GS - Heat resistant

• 1.2 kg.

• 180 x 200 x 30.

• Furan Sand

• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

ANCHOR CLUSTER

EXPERIMENT

“DRILL HOOK”

PAALS2,000 PER YEAR

GUSSTAHL LIENEN

• GS 25CrMo4

• 1.6 kg.

• 150 x 100


• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

WATER COOLED GRATING BODY

NOELL5,000 PER YEAR

GUSSTAHL LIENEN

• GX 40CrNiSi27-4

• 32 kg

• 650 x 260 x 100.

• Furan Sand

• Lighter




• Smoother


• Combination

– Fewer parts

• Less leaks


• Fewer fasteners


• Fewer seals

• Tooling costs

CERMAK ENGINEERING PFAHLER STR.21,

65 193 WIESBADEN, TEL.+49 611-1509 9495 E-Mail : [email protected]

PLEASE ENQUIRE ABOUT OUR PRESENTATION PART 2

“HOW IS LOST FOAM CONTROLLABLE?”

why lost foam

Technology

machining fewer fasteners

day intermet al alloy

semi permanent mold

day aluminium dongo

day aluminio dongo al

fasteners decisions

day inhouse foundry

intake manifold fiat