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5/9/2014 11:52 AM

THE FUTURE IS IN YOUR HANDS

Lost Foam: The Vulcan Advantage

Experience: Vulcan has more complete Lost Foam projects than
all other competitors. In addition, Vulcan has been involved, as a
partner, with these customers to design complete systems which
work for the process, not just as mechanical and electrical devices.
People: People are the key, and Vulcan has the people with the
expertise and the experience. Our staff includes some of the top
Lost Foam process experts in the world, from jobbing foundry
experience to automotive. These are experts in tooling, foam
making, casting, and metallurgy who have worked for many years
in Lost Foam operations.
Proprietary Designs: Vulcans mechanical designs for handling
systems, sand fill, compaction, coating tanks, glue machines,
screener/classifiers, coolers, etc., are unique for the Lost Foam
process. Most of these designs are available only from Vulcan due
to the collected data and experience.
Controls and Software: Control systems and software are all
designed by Vulcans in-house Electrical/Computer/Controls
Group, who also work with empirical data only available at Vulcan.
These same people travel to our project sites during installation,
start-up, and operation, bringing field experience to each new
design.

Manufacturing: Vulcan equipment and controls are built in our

own plant. This gives Vulcan control over construction techniques
and workmanship, as well as providing competitive pricing.
Testing: Experience has taught us that Lost Foam equipment
must be tested for correct performance before shipment. This is
imperative if reliable production parameters are to be met. Again,
Vulcan is the only company with the background data, experience,
and facilities to properly test Lost Foam systems in-house.
Complete Package: Vulcan provides a true one source for a Lost
Foam project. We have the expertise and the experience in all
phrases, from tooling, to foam making, to casting, to finishing. We
design and build our own facilities coating systems, robots, drying
oven, casting systems, sand processing, degating and finishing
machinery, and much more.
Vulcan operates a separate facility for training in tooling, foam
making, casting, and all phases of the Lost Foam process. This,
combined with our exclusive technology packages, can include
actual work in a production foundry while developing process
parameters for your participating casting. As a result, Vulcan can
get you into production faster, and therefore save excessive startup costs.

LOST FOAM CASTING SYSTEMS

Vulcan Engineering Co. is known worldwide for complete start to finish Lost Foam systems. We offer
equipment and solutions for all phases of the Lost Foam process.

One Vulcan Drive, Helena, AL 35080 | +1 (205) 663-0732

sales@vulcangroup.com | www.vulcangroup.com

Lost Foam

Design, Cost, and Environmental Advantages

No cores, core defects, core fins

No core shift/float
No parting line or fins
No shift
Dry unbonded sand
No moisture or binder related defects
Easily recycled sand
Extremely low and clean solid waste
disposal
Non-hazardous materials used
Reduced grinding, blasting, finishing
Extremely low external emissions

Improved working environment (noise,

dust, fumes, heavy lifting)
Lower insurance rates
Close dimensional tolerances
Excellent surface finish
Decreased/eliminated machining
More complex shapes
Casting weight reduction
Low draft / no draft / reverse draft
Improved pressure-tight castings
Reduced assembly
Cast-In inserts
Improved part performance

Design freedom
Extremely long tool life
Long-term repeatable dimensions
Just-in-time capabilities
Simpler process control
Lower labor costs
Lower capital costs
Reduced floor space requirements
High productivity
Reduced machining scrap
Lower machining tool damage
Lower energy consumption

A Process for All Metallurgies

Lost Foam has been successfully applied to alloys of aluminum, gray iron, ductile iron, brass, bronze, and steel. With or without slight
variations virtually any alloy can be produced using Lost Foam. Vulcan Engineering has licensing or associations for variations of the basic
Lost Foam process such as Replicast CS, Castyral, Polyform, and others. Below are just a few examples casting advantages.

Cylinder Heads
Cylinder heads, overhead cam, or push rod design
utilize Lost Foams greater design flexibility to enable
a high degree of component integration to reduce
parts and assembly operations including the SHC
journal pedestal and EGR passages.

Other as-cast features can include:

Combustion chambers
High pressure oil lines
Lifter lubrication slots
Cam journal lube lines
Water outlet
Oil return lines

Complete

Lost Foam

Foundry

General Steps in the Lost Foam Process

Engine Blocks
Engine blocks can be an outstanding example of
simultaneous product/process engineering, where
the as-cast capabilities of the Lost Foam process are
fully utilized. As-cast fluid distribution lines on blocks
and heads can eliminate gun drilling, and associated
equipment and tooling.

Valves
Several manufacturers have designed and are in
production of water main valves cast using the Lost
Foam process. Consistent with the process, here are
some of the illustrative features:

Some of these as-cast features can include:

High pressure oil lines to the main bearings and
the cylinder head
Oil filter plumbing
Water pump, thermostat, and water distribution
passages
Oil return lines
Accessory brackets

Flanged end faces cast with no draft

As-cast bolt holes
As-cast reverse draft in the gasket seat
As-cast gate seat sealing surface
As-cast O ring groove
Eliminated machining

Bead Pre-Expansion: Purchased raw polymer

beads are expanded using steam to achieve a
controlled low density.
Foam Molding: Beads are injected into an
aluminum tool and steamed to fuse them
together into a precision replica of the finished
part.
Gluing: For some complex parts which cannot
be made in one piece, multiple foam sections
may be glued together.
Cluster Assembly: Individual foam replicas
may be glued or bonded to a gating system to
form a tree or cluster.
Coating: Foam replicas or clusters are coated
with a water-based refractory coating which

adds rigidity, acts as a barrier between molten

metal and sand, and control gas pressure.
Drying: Water in the coating is driven out to
provide a dry, rigid, permeable coating.
Cluster Insertion: The coated, dried cluster
is inserted into a special flask designed for
its response to vibration. Manual insertion is
shown, automatic or mechanized insertion can
be used.

Compaction: The same vibration, when properly

controlled, will compact the sand around the
cluster to near its maximum density, much
harder than any other sand molding process.
Metal Pouring: Molten metal displaces the
foam inside the coating forming a casting which
has the details, holes, passages, dimensions, and
surface finish characteristics of the foam replica.

Extraction: After cooling the castings may

be simply dumped out with the sand or
Sand Fill: Dry, unbonded sand is rained in
automatically extracted, as the internal passages
at controlled rates while varying vibration is
simply drain of the dry sand. The sand is easily
applied in a special sequence. The sand fluidizers recycled.
and fills the external and internal areas of the
cluster.
As-Cast Cluster: Showing high metal yield,
flask utilization, and productivity gain