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Metal Casting Technologies : September 2008
put into this technology. This has provided enough confidence for investors to increase their investment in this process. Castings made by lost foam are only about 1.2% of the total castings produced in China in 2006. As more large state-owned foundries are investing in lost foam operations or are planning to adopt or expand lost foam operations, there would be an steady increase primarily in iron and steel castings by lost foam technology in the coming years. Although aluminum castings made by the lost foam process are very limited in quantity in China due to technical difficulties in aluminum lost foam process in mass production, there have been significant advancements in aluminum lost foam casting technology in China in the past three years. One primary driving force is the increasing application of aluminum castings in cars and trucks. Figure 5 shows an aluminum exhaust pipe made by lost foam process. The scrap rate for this part is less than 10% in pilot production. It appears that China’s lost foam community is making solid progress in aluminum lost foam technology. It would not be surprising that there is a tremendous increase in aluminum castings produced by lost foam process in the next several years in China. There will be an increasing demand for equipment and consumable materials for the lost foam process. Upgrading of outdated equipment in current lost foam operations is occurring to increase the productivity and capacity. More lost foam foundries will be built in the coming years as this promising technology becomes mature. In addition, as Chinese government regulations on health, safety and environmental protection become increasingly strict, lost foam foundries, will adopt more and more state-of-art equipment and safer consumable materials so they meet or fall well within safety guidelines for foundry operations in China. Summary China’s foundry community is a pioneer in lost foam casting technology development and has established advantages in the iron and steel lost foam casting process. The market for the lost foam process will continue its rapid growth in iron, steel and aluminum in China. Acknowledgments The author would like to acknowledge the help and support from Professors YE Sheng-Ping and Wu Zhi-Chao at Huazhong University of Science and Technology, Mr. Hongchao Sun at Heli Group, Zhenjia Xia at FAW, Mr. Guangzhe Liang at China Full Mold Casting Committee of China Foundry Association, for providing data, pictures, and insight for this paper. The author also thanks Carlito Bangcuyo, James Cecere, Lee Horvath and Ralph Showman in Ashland Casting Solutions for reviewing this paper. ¦ Copyright 2008 American Foundry Society (www.afsinc.org) REFERENCES 1. Process, Proceedings of the 7th China Lost Foam Casting Technology Conference, pp 91-96 (2006). Liang G., Forty Years of Full Mold (Lost Foam) Casting Technology in China, Proceedings of the 9th China Full Mold Casting Technology Conference, pp 1-11(2006). 2. Ye S., Wu Z., Lost Foam Casting Technology Development in China – Market, Design and Tooling, Lost Foam Casting Workshop, March 13-15, Birmingham, Alabama. 3. Swartzlander M.W., An Overview of the Chinese Metal Casting Market, AFS Transactions, vol 114, pp 1009-1015 (2006). 4. Ye S., Wu Z., Lost Foam Casting in China, China Foundry, vol 3, pp134-136 (2006). 5. Duca A. Flemings M.C., Taylor H.F., Art Casting, AFS Transactions, vol 70, pp801-810 (1962). 6. Zhang G., Development of Full Mode Castings for Forging Die, Proceedings of the 9th China Full Mold Casting Technology Conference, pp 240-246 (2006). 7. Huang W., Liu T., Huang S., Development of A Compaction Table, Proceedings of the 9th China Full Mold Casting Technology Conference, pp 426 – 433 (2006). 8. Xu Y., Research and Development of Special Glues for EPS Foam for Lost Foam G & C Instrument Services P/L Ph (02) 4981 72 55 Email: firstname.lastname@example.org METAL Casting Technologies September 2008 73 Spectrometer The quick and easy solution for your Alloy Analysis Belec Lab 3000s