“Expandable Pattern Casting,

&Plaster Mold

Casting”

Expandable Pattern Casting

Also known as Expanded Polystyrene Molding or Full Mold Process, the EPC or Lost Foam process is an economical method for producing complex, close-tolerance castings using an expandable polystyrene pattern and unbounded sand.

The EPC process involves attaching expandable polystyrene patterns to an expandable polystyrene gating system and applying a refractory coating to the entire assembly. After the coating has dried, the foam pattern assembly is positioned on several inches of loose dry sand in a vented flask. Additional sand is then added while the flask is vibrated until the pattern assembly is completely embedded in sand.

A suitable downsprue is located above the gating system and sand is again added until it is level to the top of the sprue. Molten metal is poured into the sprue, vaporizing the foam polystyrene, perfectly reproducing the pattern. Gases formed from the vaporized pattern permeate through the coating on the pattern, the sand and finally through the flask vents.

In this process, a pattern refers to the expandable polystyrene or foamed polystyrene part that is vaporized by the molten metal. A pattern is required for each casting.

Expendable mold casting is a generic classification that includes sand, plastic, shell, plaster, and investment (lost-wax technique) moldings. This method of mold casting involves the use of temporary, non-reusable molds.

AdvantagesNo cores are required.Reduction in capital investment and operating

costs. Closer tolerances and walls as thin as 0.120 in. No binders or other additives are required for the

sand, which is reusable. Flasks for containing the mold assembly are

inexpensive, and shakeout of the castings in unbounded sand is simplified and do not require the heavy shakeout machinery required for other sand casting methods.

Need for skilled labor is greatly reduced.Casting cleaning is minimized since there are no

parting lines or core fins.

Disadvantages

The pattern coating process is time-consuming, and pattern handling requires great care.

Good process control is required as a scrapped casting means replacement not only of the mold but the pattern as well.

Expandable Pattern Casting

Example products of Expandable Pattern Casting 

Plaster mold castingPlaster mold casting is a metalworking casting

 process similar to sand casting except the molding material is plaster of Paris instead of sand. Like sand casting, plaster mold casting is an expendable mold process; however it can only be used with non-ferrous materials. It is used for castings as small as 30 g (1 oz) to as large as 45 kg (99 lb). Generally, the form takes less than a week to prepare. Production rates of 1–10 units/hr can be achieved with plaster molds.

Plaster mold casting is a manufacturing process having a similar technique to sand casting. Plaster of Paris is used to form the mold for the casting, instead of sand. In industry parts such as valves, tooling, gears, and lock components may be manufactured by plaster mold casting.

DetailsThe plaster is not pure plaster of Paris, but rather has

additives to improve green strength, dry strength, permeability, and castability. For instance, talc or magnesium oxide are added to prevent cracking and reduce setting time; lime and cement limit expansion during baking; glass fibers increase strength; sand can be used as a filler. The ratio of ingredients is 70–80% gypsum and 20–30% additives.

Typical tolerances are 0.1 mm (0.0039 in) for the first 50 mm (2.0 in) and 0.02 mm per additional centimeter (0.002 in per additional inch). A draft of 0.5 to 1 degree is required. Standard surface finishes that are attainable are 1.3 to 4 micrometres (50–125 μin).

The pattern is usually made from metal, however rubber molds may be used for complex geometry; these molds are called Rubber plaster molds. For example, if the casting includes reentrant angles or complex angular surfaces then the rubber is flexible enough to be removed, unlike metal. These molds are also inexpensive, reusable, more accurate than steel molds, fast to produce, and easy to change.

Process

Initially plaster of Paris is mixed with water just like in the first step of the formation of any plaster part. In the next step of the manufacture of a plaster casting mold, the plaster of Paris and water are then mixed with various additives such as talc and silica flour. The additives serve to control the setting time of the plaster and improve its strength.

The plaster of Paris mixture is then poured over the casting pattern. The slurry must sit for about 20 minutes before it sets enough to remove the pattern. The pattern used for this type of metal casting manufacture should be made from plastic or metal. Since it will experience prolonged exposure to water from the plaster mix, wood casting patterns have a tendency to warp. After striping the pattern, the mold must be baked for several hours, to remove the moisture and become hard enough to pour the metal casting. The two halves of the mold are then assembled for the casting process.

Advantages & disadvantagesPlaster mold casting is used when an excellent surface

finish and good dimensional accuracy is required. Because the plaster has a low thermal conductivity and heat capacity the metal cools more slowly than in sand mold, which allows the metal to fill thin cross-sections; the minimum possible cross-section is 0.6 mm (0.024 in). This results in a near net shape casting, which can be a cost advantage on complex parts. It also produces minimal scrap material.

The major disadvantage of the process is that it can only be used with lower melting temperature non-ferrous materials, such as aluminium, copper, magnesium, and zinc. The most commonly used materials are aluminum and copper. The maximum working temperature of plaster is 1,200 °C (2,200 °F), so higher melting temperature materials would melt the plaster mold. Also, the sulfur in the gypsum reacts with iron, making it unsuitable for casting ferrous materials.

Another disadvantage is that its long cooling times restrict production volume.

Plaster is not as stable as sand, so it is dependent on several factors, including the consistency of the plaster composition, pouring procedures, and curing techniques. If these factors are not closely monitored the mold can be distorted, shrink upon drying, have a poor surface finish, or fail completely.

Plaster Mold Casting

Example products of Plaster mold Casting 

Video of Expandable Pattern Casting

Video of Plaster Mold Casting