Lost Foam Metal Casting, Casting, and Metal Casting Information
Learn about Lost Foam Metal Casting, and Metal Casting Information
Lost
Foam Casting is a relatively new casting process compared to other metal
casting procedures that date far back into antiquity. The first patent for Lost
Foam Casting was made in 1958 but it was not until 1964 that what we know
commonly as Lost Foam Casting was introduced.
Lost Foam Casting is a form of Investment Casting much like Lost Wax Casting.
The key material of Lost Foam Casting is of course foam which is not used in
other metal casting methods. The use of foam has many benefits to the artisan
like ease of use and shaping and the relative inexpensive cost of the material.
Each casting is going to be one of a kind since the original casting of foam is
lost during the process.
The foam original will be replaced by the molten metal unlike the Lost Wax
Casting where a wax mold is made of the original and then coated with a ceramic
shell in preparation for the molten metal. Luckily, most foam is pretty
inexpensive so the loss of the original shouldn't pose a significant financial
loss, just an annoying creative loss.
Foam is easily shaped by hand held tools but even still some practice may be
needed to prefect the sculpting of the material. You will need to place a sprue
into the foam which will allow the molten alloy to spread into the foam and
adopt the shape of the item. Packing the foam and sprue in sand is a good way
to insure that the mold will retain its shape through the pouring process. The
metal will replace the foam by vaporizing it, and it is really quite a sight to
behold.
Though there are many who prefer to adopt the procedures used in Lost Wax
Casting for the Foam casting. After spruing the foam original you are going to
dip it into a solution to create a shell and then pour the metal. The goal of
this is to create a cleaner surface.
Whichever method you choose is really up to you. Many use Lost Foam Casting a
quick and easy way to create something when visual appearance isn't all that
important. Many refer to Lost Foam as the "quick and dirty method".
As for the type of foam to use you are going to want to steer clear of anything
that will give off toxic fumes when heated. Urethane foam is toxic. The
popular foams to use are the polystyrene kind which is used to pack electronics
and the polystyrene foam used for insulation. These foams can be found at many
home improvement stores and even a few all purpose retail stores.
Lost Foam Casting is kind of like alchemy, transforming something inexpensive
into something invaluable. Whenever you cast, make sure to take all proper
safety precautions and wear safety gear. Always wear a long sleeve shirt,
jeans, and the proper shoes. Don't forget eye and face wear and of course
gloves. Never forget that you are dealing with material that can very easily
harm and disfigure or worse if not handled properly.
Many first time casters begin with Lost Foam Casting since it doesn't involve
mold making but if you are experienced and never attempted this method you will
still want to be careful.
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