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

• Reduced machining

• 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

• Semi-Permanent mold and cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

ENGINE BLOCK

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

IN-HOUSE FOUNDRY

so far 1.7 million castings produced

• Al-alloy

• 22 kg.

• 600 x 300 x 400.

• Die-cast with salt cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Semi-Permanent mold and cores

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

INTAKE MANIFOLD

FIAT3,500 PER DAY

ALUMINIO DONGO

• Al 319.

• ca. 5 kg.

• 280 x 220 x 50

• Semi-Permanent mold and cores

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

so far 3.5 million castings produced

CYLINDER HEAD

FIAT - FIRE ENGINE - PUNTO 1600 PER DAY

ALUMINIO DONGO

• Al 319.

• 12 kg.

• 370 x 140 x 120

• Semi-Permanent mold and cores

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

• Al-alloy

• 12 kg.

• 450 x 420 x 180.

• Sand casting and cores

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

CLUSTER HUB

• Al-alloy

• 0.7 kg.

• 90 x 90 x 32.

• Die-cast

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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.

• Sand casting and cores

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

• Al-alloy

• 2.8 kg.

• 350 150 x 150.

• No comparison possible

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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.

• Semi-Permanent mold and cores

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

SUPPORT/CARRIER

FLOP 1

• Al-alloy

• 5.1 kg.

• 300 x 300 x 310

• Semi-Permanent mold and cores

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

CYLINDER HEAD

FLOP 2

• Al-alloy

• 1,1 kg.

• 110 x 220

• Welded part

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

DIFFERENTIAL CASE

SATURN / GM1,200 PER DAY

IN-HOUSE FOUNDRY

• GGG 40

• 11.1 kg.

• 250 x 200 x 160

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

CITATION FOAM CASTING COMPANY

• GGG 40

• 13.4 kg.

• 280 x 200 x 160

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

• GGG

• 12.3 kg.

• 400 x 250 x 160.

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

CLAMP GUIDE

XXXXX200 PER DAY

CITATION FOAM CASTING COMPANY

• GGG 40

• 5.9 kg.

• 260 x 230 x 220.

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

SUPPORT / CARRIER

MERCEDES BENZ, COMPR. MOTOR120 PER DAY

CITATION FOAM CASTING COMPANY

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

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

STATOR FRAME

EXPERIMENT

• GGx-highly magnetic

• 0.8 kg

• from 80 to 140 mm x 70

• No comparison possible

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Sand casting and cores

• Lighter

• Reduced machining

• Less fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

• GG 25.

• 4.5 kg.

• 360 x 200 x 130.

• Sand casting

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

WATER INLET / COMPONENT BRACKET

CUMMINS ENGINE CO180 PER DAY

CITATION FOAM CASTING COMPANY

• GG 40

• 22 kg

• 600 x 300 x 100.

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

EXHAUST MANIFOLDMERCURY INBOARD

120 PER DAYCITATION FOAMS

• GG

• 10 kg.

• 280 x 350 x 220

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

COOLING WATER PUMP

DETROIT DIESEL120 PER DAY

CITATION FOAM

• GG

• 22 kg.

• 300 x 400 x 400

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

WATER VALVE BODYM & H NW 15080 PER DAY

CITATION FOAMS

• GG

• 53 kg.

• 550 x 225 x 100.

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Sand casting with cores

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

ANCHOR CLUSTER

EXPERIMENT

“DRILL HOOK”

PAALS2,000 PER YEAR

GUSSTAHL LIENEN

• GS 25CrMo4

• 1.6 kg.

• 150 x 100

• No comparison possible

• Lighter

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• 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

• Reduced machining

• Reduced fettling

• Higher productivity

• Smoother

• Product performance

• Combination

– Fewer parts

• Less leaks

• Reduced machining

• Fewer fasteners

• Reduced assembly

• Fewer seals

• Tooling costs

CERMAK ENGINEERING PFAHLER STR.21,

65 193 WIESBADEN, TEL.+49 611-1509 9495 E-Mail : kcermak@aol.com

PLEASE ENQUIRE ABOUT OUR PRESENTATION PART 2

“HOW IS LOST FOAM CONTROLLABLE?”