ISSN (1897-3310)

ARCHIVES Volume 13
Special Issue
of 2/2013

22– 28
FOUNDRY ENGINEERING
Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences
4/2

Research on the Influence of Basic

Parameters of the Pre-Expansion of
Granules Density
K. Buczkowska, R. Kaczorowski, T. Pacyniak *
Department of Materials Engineering and Production Systems, Lodz University of Technology,
1/15 Stefanowskiego Street 90-924 Lodz, Poland
*Corresponding author. E-mail address: tadeusz.pacyniak@p.lodz.pl

Received 11.07.2013; accepted in revised form 09.09.2013

Abstract
The paper presents the process of pre-expanded polystyrene used to produce models in the Lost Technology. There were research on pre-
expansion process in order to determine the effect of pressure and time for the initial expansion of the materials density. Analysis of the
results confirmed that the higher the pre-expansion pressure is the materials density decreases. There was also a change in the intensity of
the process in function of time and pressure, which may indicate the phenomena of material physical and chemical properties during the
process.

Keywords: Foundry, Lost, Polystyrene models, Casts

There are two stages of the models manufacturing process: pre-

1. Introduction expansion and final shaping. During the first stage granules of
expanded polymer such as polystyrene is subjected to heat pre-
The main role in manufacturing process of casting Lost
treatment, drying and activation. In the second stage, the pre-
technology is the density of pre-expanded polystyrene [1,2]. The
expanded granulate filled matrix by subjecting them to a heat
higher the models density and irons temperature is during the
treatment, cooling, and then matrix is removed from the finished
pouring, the larger amount of gases there is when metal contacts
model.
the model. In case of ferroalloy the amount of gases that were
The bulk density of granules is defined as the ratio of the mass to
made is over three times higher than for aluminum alloy (it is
its volume. It should be taken into account that the density of pre-
strictly related to higher pouring temperature). In the gas gap,
expanded polystyrene may be slightly different from the density
which was made between the surface of a liquid iron and the front
of the model made. The models density made of expanded
of gasified model, there is high pressure slowing down the metal
polystyrene is approximately 20% higher than the bulk density
movement, what can cause it stops. Too low models density
polystyrene. This is connected with a better density granules in
decreases its mechanical properties what can, in the end, lead to
matrix cavity. The recommended density models expanded
destruction of the model during the molding process.
polystyrene - EPS shown in Table 1 [3,4].
Through the shaping best fit model parameters (pressure and
sintering time) can improve the mechanical properties, while
maintaining the lowest possible density.

22 ARCHIVES of FOUNDRY ENGINEERING Volume 1 3, Special Issue 2/2013, 22-28

Table 1. 0,45

Recommended density polystyrene models for typical casting

materials [3,4].
EPS models 0,4

Porowatość
Pouringtemperature,
Type of alloy density,
°C
kg/m3

Porosity
Aluminium alloys 705-790 24-27 0,35

Copperalloys 1040-1260 20-21,6

Gray cast iron 1370-1455 ≤20 0,3
0 1 2 3 4 5 6

Caststeel 1595-1650 ≤17,6 Średnica granulki

Pelletsdiameter [mm][mm]

Fig. 1. The dependence of porosity on the diameter of the pre-

2. Basic technological pre-expansion
process
Pre-expansion is used to obtain a specific bulk density of the
expandable polymer. As a result of the heating medium located in
the blowing agent in the interior of the granules evaporates
increasing the volume of the granules. The granulated pre-
expansion can be accomplished by heating it in boiling water,
steam, and a high frequency infrared radiation. Most often used for
this purpose steam that heats the blowing agent to a temperature of
evaporation, but also wets the wall of granules, so that they are
more flexible. The main parameters of the process are time and
temperature of the pre-expansion [5]. The temperature value is
determined based on the graph enthalpy - entropy of saturated
steam. The objective is to obtain a granulate with a minimum
density possible.
Granules activity during expanding is a key indicator of the
quality polystyrene, which allows to obtain models with minimum
density and good surface quality. It is expressed as the ratio of the
bulk density of the pellets before and after pre-expanding. The
minimum bulk density ρ min is the limit value and achieving it in
pre-expansion process prevents a further increase in the volume of
the granules. Exceeding this value during the final shaping
process, prevents the granules in a monolithic combination of a
smooth surface model. The bulk density of the pre-expanded
granules determines the models density, what can be expressed as
(1) [3]:
expanded granules [3]
The diagram shows that with increasing diameter of the granules
its porosity reduces, which in turn may lead to the fact that the
final form of the model will not fulfill the requirements of
hardness and strength.
In practice, the models should be done with a little more density
than specified in the above formula, because it does not take
adequate strength and hardness of the model. In the process of
shaping model at the pre-expansion, to ensure these properties
should be left supply of foaming activity. The minimum
technological models density is given by below (2)
 min
 mod
tech
 K zap (2)
1 m
The value of the granules activity stocks is
K zap = 1,15÷1,20 [4].
In the process of the pre-expansion granules may increase its
volume up to 60 times. The figure 2 shows the granulate before
and after the pre-expansion.

 min
 mod
min
 (1)
1 m

Figure 1 shows the dependence porosity of on the diameter of the

granules m pre-expanded beads.

Fig. 2. The granulate before and after the pre-expansion

In the mass production the pre-expansion process is carried

out in devices known as expander. In the industry, there are now
two types of expanders. Due to the nature of work stand out:

ARCHIVES of FOUNDRY ENGINEERING Volume 13, Special Issue 2/2013, 22-28 23

expander for batch and continuous. The process differs from each
mode of administration the material into the expander chamber
and the way of pouring out.
In batch expander (Fig. 3.) the appropriate amount of material is
placed into the from the storage tank located above. The chamber
is closed, what allows to maintain a constant pressure throughout
the interior. This ensures a uniform expanding of the granules. In
the insulated chamber there are stirrers, which task is to prevent
the granulate from caking and provide uniform expanding [6]. To
the expansion chamber a heating medium is provided (steam, hot
air, a current of high frequency or infrared). Heating the chamber
and pre-expansion (using steam) is carried out at a temperature of
90 - 110 ° C [3]. By opening the cover located in the lower part of
the pre-expanded chamber the granules goes to a fluid bed drier.
Pouring out the granule from the chamber is supported by
launching the blow.
Fig. 4. Schematic of the expanding chamber in continuous
expander [7]
1 –pour out system, 2 – stirrer engine, 3 – feeder engine, 4 –
cochlear feeder, 5 perforated bottom, 6 – stirrer, 7 – receiver
windows, 8 – hogging rods, 10 – expanding chamber, 11 –
chamber under the perforated bottom

Reducing loss of thermal energy required in the pre-expansion

process can be achieved by using a closed circuit for a heating
medium.

After the pre-expansion process the granules are poured out to a

fluid bed dryer (fig 5.). Drying the granules is to reduce the
temperature of the pre-expanded granules, prevents the weight of
the granules caked during transport to the tray.

Fig. 3. Schematic of the expanding chamber in batch expander [7]

1 - pour out system ,2 – stirrer engine, 3 – perforated bottom, 4 –
izolated chamber, 5 – stirrer o, 6 – hogging rods, 7 – actuator
cover, 8 – cover, 9 –dryer chamber, 10 – expanding chamber, 11 –
chamber under the perforated bottom

In continuous expander (Fig. 4.) the material is served through a

feeding screw into the perforated bottom. During the pre-
expansion as a result of steam and the expansion of the blowing
agent granules rises to the top. On the side wall of the chamber at
different heights there are windows for receive the granules.
Pouring outexpanded granules takes place automatically through
receiver windows (sections). The pre-expansion density is adjusted
by the height ofreceive window. Lower density is achieved by Fig. 5. Fluid bed dryer
opening the window located above, and similarly, a higher density
can be achieved by opening a window on a lower level. The figure 6 illustrates the steps of the pre-expansion process,
and drying at the example of batch expander linked to fluid bed
dryer and storage container. After setting the parameters of the pre-
expansion process, measured amount of pellets is placed in the
charging chamber (a). Granules goes to the heated expansion
chamber (b) when the process starts. Since the process of pouring
out the pellets has launched the stirrers starts to move, preventing
the granulate from caking . When the pouring out process finishes
the chamber closes and the steam is released (c). At temperature
appropriate for pre-expanded polystyrene (100 ÷ 105 ° C), the

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granules increases rapidly up to 60 (d). After the expanded pellets
are dried and cooled (e) they have to be seasoned – activated (f)
[3].
Fig. 6. Pre-expanding process [7]
Pre-expanded and dried granulate passes through the active control
system, in which the density measurement is made. Monitoring the
granules density is carried out on a regular basis, in case of
fluctuations of the measured granules density from required
parameters so that the pre-expanded process and drying can be
automatically corrected. Using active control system in the
production line reduces maintenance time by the worker and helps
to automatize the process. The figure 7 is an example of an active
control mechanism [8].
Fig. 7. Active control system
ARCHIVES of FOUNDRY ENGINEERING Volume 13, Special Issue 2/2013, 22-28
3. The workstation for pre-expansion
process
3.1. Description of the workstation for pre-
expansion
Pre-expansion workstation shown in Figure 8 consists of:
water purification plant Epurosoft ES 37, steam generator LW
40.1 of Prometr, batch pre-expander SC-500 with fluidized-solids
drying plant of GROM, linked with steam generator by pressure
regulator of direct action and silo used for seasoning expanded
polystyrene.
Water purification plant is a ion exchange water softener consists
of: a column of fluid known as ion exchange resin, brine tank
with a capacity of 25 dm3 and multi-function control head.
Carbohydrates, calcium and magnesium dissolved in water,
responsible for water hardness are captured in the ion-exchange
column of plasticizer during the water flow through the bed. After
treatment a certain amount of water, the bed loses its properties.
Regeneration of a saturated solution of salt (NaCl) restores the
original properties of resin.
All processes of the device run on automatically. The device
allows for treatment to 0.8 m3 of water per hour.
Steam generator with electric heating is a source of steam. It is
equipped with 50 liter water tank,impeller pump and two modules
of electric heaters each for heating power 14 kW. It allows to
obtain a steam pressure of 6 bar and has a capacity to 40 kg of
steam per hour.
The batch pre-expander SC-500 shown in Figure 9 is connected
through a pressure regulator to the steam generator. A pre-
expander was equipped with insulated chamber (2) of pre-
expansion process with capacity of 90 cm3. On the wall of the
chamber is installed sight-glass (22), which allows observation of
the expansion process. A pre-expander allows to (depending on
the parameters of expansion and the kind of raw material) obtain
the bulk density of expanded polystyrene from 15 to 40 kg/m3.
Pre-expander control is based on the Mitsubishi programmable
controller placed in the control box (18). This makes the process
of expansion fully automatically and repeatedly. Automatic cycle
proceed as follows. After pressing the start button on the control
box begins to rotate the stirrer (3) moven by an electric motor
(26). The flap value of charge of raw material opens (24) and
expandable polystyrene EPS located in a pouring out container
(25) is taken away to the expansion chamber by a pneumatic
nozzle. Then the flap valve of charge of raw material is closed
(24), the valve of the chimney (1) valve of condensate (9) and
opened the main steam valve (6). Steam is delivered to a inflow of
the branched into three channels to the chamber at the bottom of
the slot (5). Then moves to the right chamber. This solution is
designed to obtain steady stream of steam. Expansion chamber
filled with steam to set value pressure. Then blow steam lasts for
a limited time and at a given pressure. Alternately opens and
closes the valve chimney and steam. After end phase of the steam
valve closes the main steam valve and opens the valve chamber.
This causes pressure reduction to atmospheric pressure in
expansion chamber. Ventilation phase begins - accompanied by a
blow fan and blow-condensate valve open. Ventilation of the
25
chamber finishing cycle of expansion. Pneumatic cylinder (20) bed drying of polystyrene beads. After the drying cycle is opened
opens the cap dump (21) and polystyrene beads are transported to lock (16) and runs the crusher (15), whose task is to break glued
the drying chamber. Then cap dump is closed and turn on the pieces of expanded polystyrene. Beads are transported to the silo
dryer fan. The air passes through the water heater (12) and is by air.
served at the perforated bottom of the dryer (17). Then fluidized

Container
of raw Manometer
material Reducing
Valve of raw Chimney of
valve
material expansion
charge chamber

Blow Valve of
Drying chimney
valve Condensate
chimney
vessel
Expansion
chamber Air cycle
Lock Valve to
control Steam cycle
mamometer
Pneumatic Pressure Pressure
regulator limiter
Obieg wody
actuator of cap

Manometer
Safety-valve
Cap

Drying Non-return
chamber valve of Main Steam Steam
condensate inlet valve
steam max
valve
Vent Resin
Drain
vessel
Non-return
min valve Filter Filter
Feed
Blow Valve of water
fan condensate Feed Feed
Solenoid Pump
valve check check
Condensate valve valve
Drain
Condensate Drain valve Heaters
Fan of vessel valve Brine
Crusher dryer Steam heater
Condensate

Silo Bath pre-expander SC-500 Steam generator LW 40.1 Consists of water purification plant

Fig. 8. Scheme station of pre-expansion the polystyrene, equipped with a batch pre-expander

25 26 1

19 24

23
Wyświetlacz 3
Panel temp.
sterowniczy Start/stop
4
18
22
Mieszadło Suszarnia Rozdrabniacz
20
Silos Pokrywa Śluza

5
Włącznik
awaryjny 21

16 Komora 8 6
suszenia 17
Steam from
9 generator
15

Condensate

14 13 12 11 10

Fig. 9. Scheme a batch pre-expander SC-500

1 – cut-off valve of the chimney, 2 – chamber of pre-expansion process with thermal insulation, 3 – stirrer, 4 –hogging rods, 5 –
perforated bottom, 6 – main valve of the steam , 7 –vessel on the drip, 8 – non-return valve of condensate, 9 – valve of condensate, 10 –
hot-well, 11 –valve of heater, 12 –steam heater 13 – fan dryer, 14 – blow fan, 15 – crusher, 16 – lock, 17 – perforated bottom of the dryer,
18 – control box, 19 – main switch, 20 – pneumatic actuator cap, 21 – cap dump, 22 – sight-glass, 23 – valve of blow, 24 - valve of
charge of raw material, 25 – container on raw material, 26 – stirrer engine

4. Studies the process of pre- expansion

of ed polystyrene
4.1. Scope, purpose and research materials
For studies was selected two expandable polystyrene: D833B
and D933B of IneosNova. Physico-chemical properties of those
materials are presented in Tables 2 and 3

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Table 2. and drying expanding were cleaned thoroughly. After a
Physical and chemical properties of expandable polystyrene predetermined time, seasoning material was transferred to a
D833B [9] density test stand. Granules were poured into the vessel to the
Material: D833B control line at a height of 2 liters. The material metered this way
Form: Solid, small sphericalbeads was weighed on a laboratory scale with an accuracy of ± 0.02 g.
Fraction: [mm] 0,25-0,5 On the basis of weight and volume, the pre-expanded material
bulk density was calculated in the sample.
Color: White For each settings the process was repeated four times, and then
Aroma: Perceptibleodor from the results of the density the median and standard deviation
Flashpoint: [°C] < -50°C (pentane) was calculated.
Autoignition point:[°C] 285°C (pentane) (ASTM E-659)
Density: [g/ml] 1020–1050kg/m³, 20°C (balls) 4.3. Analysis of test results
Bulkdensity: [g/ml] aprox. 600kg/m³, 20°C
The softening point:[°C] 70-75°C (beads expand with 1. Influence of pre-expansion time on the materials density
pentanes change) a) Studies of the material: D933B
Explosiveproperties: In use, there may form flammable
or explosive vapor-air mixture

Table 3.
Physical and chemical properties of expandable polystyrene
D933B [10]
Material: D933B
Form: Solid, small sphericalbeads
Fraction: [mm] 0,2-0,4
Color: White
Aroma: Perceptibleodor
Flashpoint: [°C] < -50°C (pentane)
Autoignition 285°C (pentane) (ASTM E-659)
point:[°C] Fig. 10. Dependency material density (ρ) as a function of the pre-
expansion time (t)
Density: [g/ml] 1020–1050kg/m³, 20°C (balls)
Bulkdensity: [g/ml] aprox. 600kg/m³, 20°C
b) Studies of the material: D833B
The softening 70-75°C (beads expand with pentanes
point:[°C] change)
Explosiveproperties: In use, there may form flammable or
explosive vapor-air mixture

The purpose of the study was to investigate on the workstation

GROM SC-500 the influence of the basic parameters of the pre-
expansion process on materials density. For the stability of the
process, each time before the pre-expanding the chamber is
heated to a temperature of 95 ˚ C. There has been studied for a
range of pressures from 1.15 ÷ 1.4 bar, and the time of 20 to 180
seconds.

4.2. Research methodology

In the pre-expansion process the main parameters which
affect the bulk density of material are: time and temperature.
However, in practice it is easier to control the temperature of the
vapor pressure than water. According to the enthalpy-entropy
diagram of water vapor the relationship of these two parameters
can be determined.
After determining the pre-expansion parameters, timing and
filling up the tank with the right amount of material (200 g) the
process was launched. After it’s completed the granulate was
dried in a fluid bed dryer (300 s) and then transported to the
container and seasoned for 30 min. After each process chamber
Fig. 11. Dependency material density (ρ) as a functionofthepre-
expansion time (t)
Both materials are characterized by an individual for
themselves intensity of the pre-expansion process, but a certain
regularity is noticeable. In time range from 20 to 80 s a
characteristic inflection takes place, what indicates a change of
speed transformation. At this time, the largest decrease density
occurs. Over that time, the intensity of density decrease
asymptotically decreases. When a polystyrene is expanded longer
than 100 s , it is followed by a slight decrease in density. It is not
a process with the same dynamics.

ARCHIVES of FOUNDRY ENGINEERING Volume 13, Special Issue 2/2013, 22-28 27

For optimum material density the D933B must be pre-expanded
80 to 120 s, and for D833B the process should take 40 to 80 s.
Due to the efficiency of the process (pre-expansion time) using
material D833B is preferred.
2. Influence of pre-expansion pressure on the materials
density
a) Studies of the material: D933B
Fig. 12. Dependency material density (ρ) as a function of the pre-
expansion pressure (P)
b) Studies of the material: D833B
Fig. 13. Dependency material density (ρ) as a function of the pre-
expansion pressure (P)
For the tested materials a certain regularity can be seen.
Initially, the material density decreases significantly, at a pressure
about 1.2 ÷ 1.3 bar the inflection of the curve occurs, indicating
the presence of chemical reactions, which result in slowing
density decrease. The use of higher pressure causes increased
intensity in decrease of density.
For D933B optimal material density can be obtained for pressure
1.4 bar. For D833B desired density can be obtained for pressure
1.2 ÷ 1.4 bar. The use of higher pressure significantly reduces the
time of process.
From an economic point of view, it is preferable to use a
material D833B.
28 ARCHIVES of FOUNDRY ENGINEERING Volume 1 3, Special Issue 2/2013, 22-28
5. Sumary
The data presented in the paper show the following conclusions:
 due to the efficiency of the process, the most preferred time
of pre-expansion is in the range of 20 to 80 s,
 expanding longer than 100 s is followed by a slight decrease
in density,
 largest decrease of density is achieved at pressures 1,15÷1,2
bar and 1,35÷1,4 bar,
 for D933B desired material density can be obtained with a
pressure of 1.4 bar, whereas for D833B,4 with a pressure
from 1.2 bar.
References
 Pacyniak, T. (2007). Effect of foamed pattern density on the
Lost Foam process. Archives of Foundry Engineering. 7(3),
231-236.
 Sands, M. & Shivkumar, S. (2003). EPS molecular weight
and foam density effects in the lost foam process. Journal of
materials science. 38, 2233-2239.
 Pacyniak, T. (2006). The theoretical and technological base
of the manufacturing process by Lost Foam casting.
985(350). Łódź: Wydawnictwo Politechniki Łódzkiej.
 Anon. Foundy Trade Journal Internationale, (1990). 13, 2,
34.
 Niemann, E. H. (1988). Trans A.F.S. 96, 793.
 Foks, H., Gruszka, S., Guga, J. (1988). A board preparing
process of expanded polystyrene. Polska. Patent No. 142753.
Opubl. 15.11.88.
 Majchrzak, B. (2010). The study of pre-expansionpolystyrene
on the workstation. Praca dyplomowa KTMiZP PŁ.
 The equipment documentation TS – of LAB-TRADE.
 Material specification D833B. Retrieved April 28, 2012,
from http://www.ineos.com/Show-document/?Grade=EPS%
20D833B&DocumentType=Technical%20Data%20Sheet&B
U=INEOS%20Styrenics&Language=EN
 Material specification D933B Retrieved April 28, 2012, from
http://www.ineos.com/Show-document/?Grade=EPS%20D9
33B&DocumentType=Technical%20Data%20Sheet&BU=I
NEOS%20Styrenics&Language=EN