View source for Evaporative-pattern casting

'''Evaporative-pattern casting''' is a type of [[casting]] process that uses a [[pattern (casting)|pattern]] made from a material that will [[evaporate]] when the molten [[metal]] is poured into the molding cavity. The most common evaporative-pattern material used is [[polystyrene foam]].<ref name="degarmo">{{harvnb|Degarmo|Black|Kohser|2003|p=321}}.</ref>

The two major evaporative-pattern casting processes are:<ref name="degarmo"/>
*[[Lost-foam casting]]
*[[Full-mold casting]]

The main difference is that lost-foam casting uses an [[molding sand|unbonded sand]] and full-mold casting uses a bonded sand (or green sand). Because this difference is quite small there is much overlap in the terminology. Non-proprietary terms that have been used to describe these processes include: cavityless casting,<ref>{{US Patent|4068704}}.</ref> evaporative foam casting, foam vaporization casting, lost pattern casting, the castral process, and expanded polystyrene molding.<ref>{{harvnb|American Society for Metals|Stefanescu|ASM International Handbook Committee|ASM International Alloy Phase Diagram Committee|1991|p=229}}.</ref><ref name="totten">{{harvnb|Totten|Funatani|Xie|2004|p=357}}.</ref> Proprietary terms included Styro-cast,<ref>{{Citation | title = Styro-cast | url = http://www.efpcorp.com/markets/styrocast.php | access-date = 2009-03-29 }}{{Dead link|date=August 2019 |bot=InternetArchiveBot |fix-attempted=yes }}.</ref> Foam Cast,<ref>{{Citation | title = American Foam Cast | url = http://www.americanfoamcast.com/home.asp | access-date = 2009-03-29}}.</ref> Replicast,<ref>{{Citation | title = Replicast Process (CS) | url = http://www.engnetglobal.com/tips/glossary.aspx?word=Replicast+Process+(CS) | access-date = 2009-03-29}}.</ref> Policast.<ref name="totten"/> and Lost Foam Sintered Shell (LFSS)<ref name=":0">{{Cite web|url=http://www.metaforecastings.com/|title=Metafore Castings Private Limited - Pioneers in Stainless Steel, Alloy Steel and SGI Castings through Lost Foam Sintered Shell Process in India|website=www.metaforecastings.com|access-date=2018-12-05}}</ref>

==History==
The first patent for an evaporative-pattern casting process was filed in April 1956, by Harold F. Shroyer. He patented the use of foam patterns embedded in traditional [[molding sand|green sand]] for [[metal casting]]. In his patent, a pattern was machined from a block of [[expanded polystyrene]] (EPS), and supported by bonded sand during pouring. This process is now known as the full mold process.<ref>{{Citation | last = Donahue | first = Raymond | first2 = Kevin | last2 = Anderson | title = Lost Foam Casting | publisher = [[ASM International (society)|ASM International]] | url = http://www.asminternational.org/portal/site/www/AsmStore/ProductDetails/?vgnextoid=ac4266ecb9f1f110VgnVCM100000621e010aRCRD | access-date = 2010-04-06 | postscript =.}}</ref><ref>{{US Patent|2830343}}</ref>

In 1964, M.C. Flemmings used unbonded sand for the process. The first [[North American]] [[foundry]] to use evaporative-pattern casting was the Robinson Foundry at [[Alexander City]], [[Alabama]]. [[General Motors]]' first product using these processes was the 4.3 L, V-6 diesel [[cylinder head]], which were made in 1981 at [[Massena (town), New York|Massena]], [[New York (state)|New York]].<ref>{{Citation | last = Biswanath | first = Mondal | title = Proceedings of the National Conference on Investment Casting: NCIC 2003 | publisher = Allied Publishers | year = 2004 | url = https://books.google.com/books?id=PRYPsBr7cqgC&pg=PA169 | isbn = 978-81-7764-659-7 }}</ref>

A study found in 1997 that evaporative-pattern casting processes accounted for approximately 140,000 tons of aluminium casting in the United States. The same survey forecast that evaporative-pattern casting processes would account for 29% of the aluminium, and 14% of the ferrous casting markets by 2010.<ref>{{Citation | last = Bodine | first = Jack R. | title = From a monument to the Vega: the journey of the aluminum casting industry | journal = Modern Casting | page = 13 | date = 1999-05-01 | url = http://www.allbusiness.com/manufacturing/fabricated-metal-product-manufacturing/266328-1.html}}.</ref><ref>{{Citation | title = Success through partnership: lost foam | date = September 1998 | url = http://www1.eere.energy.gov/industry/metalcasting/pdfs/mciof.pdf | access-date = 2009-03-30}}.</ref>

==References==
{{Reflist}}

===Bibliography===
*{{Citation | last = American Society for Metals | last2 = Stefanescu | first2 = D M | last3 = ASM International Handbook Committee | last4 = ASM International Alloy Phase Diagram Committee | title = ASM Handbook | publisher = ASM International | year = 1991 | volume = 15 | edition = 10th | url = https://books.google.com/books?id=KCUjfz-ILSEC | isbn = 978-0-87170-021-6}}.
*{{Citation | last = Degarmo | first = E. Paul | last2 = Black | first2 = J T. | last3 = Kohser | first3 = Ronald A. | title = Materials and Processes in Manufacturing | publisher = Wiley | year = 2003 | edition = 9th | isbn = 0-471-65653-4}}.
*{{Citation | last = Totten | first = George E. | last2 = Funatani | first2 = Kiyoshi | last3 = Xie | first3 = Lin | title = Handbook of metallurgical process design | publisher = CRC Press | year = 2004 | edition = illustrated | url = https://books.google.com/books?id=3zjfgq8pUvcC | isbn = 978-0-8247-4106-8}}.

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[[Category:Casting (manufacturing)]]

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