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[January 2005]
Ceramic Mould Measurement in Lost Foam Processing
Malvern Instruments Ltd (Malvern, Worcs, England) says that its FPIA-2100 automated particle size and shape analyser is providing essential information in the manufacture of complex metal components in the automotive industry. By enabling variations in the ceramic mould used in the lost foam casting process to be measured and minimised, the instrument is playing an important role in improving efficiency by enhancing casting quality and reducing waste.
Waste is a key factor in determining the more widespread use of lost foam casting. This method of casting has the advantage of using almost a quarter less energy and a third less molten metal than conventional casting methods.
It also enables the joining of several components with a single casting, saving downstream machining and assembly. However, to date its use has been hindered by excessive scrap rates, caused by problems with the permeability of the ceramic moulds formed during the casting process.
One of the factors contributing to the permeability problems has been an inability to control the particle size and shape of unbonded sand in the matrix surrounding the mould. Digital imaging of particle size and shape using the FPIA-2100 has helped overcome these problems by enabling variations in the mould matrix to be measured and minimised.
www.malvern.co.uk
ENDS