The lost foam casting process has used expanded polystyrene (EPS) as the pattern material since the inception of the process. EPS is derived from petroleum distillation which carries a heavy carbon footprint and health concerns from the decomposition products during casting. A novel molding bead technology has emerged that derives an expandable polylactic acid (EPLA) foam molding bead from sustainable domestic biological sources. Bio-based foam patterns were evaluated for its potential to replace EPS as a lost foam pattern material using laboratory testing and casting trials. The lab results showed the EPLA materials didn’t produce hazardous air pollutants (HAPs) nor carcinogens. The casting trials successfully produced lost foam castings in both aluminum and gray cast iron without any modifications to the lost foam casting process.
Speakers:
Jacob Balke, Mercury Marine
This AFS Members Only Webinar will begin at 1 p.m. CT.