Investment Casting Foundry | Sand Casting

Stainless Steel Castings, Grey Iron Castings, Ductile Iron Castings

Gray Cast Iron Lost Foam Casting Gearbox Housing for Heavy Duty Truck

Short Description:

Material: Gray Cast Iron, HT200, HT250, GG20, GG25

Manufacturing Process: Lost Foam Casting + CNC Machining

Application: Gear Box Housing for Heavy Duty Trucks

Heat Treatment: Annealing + Nomorlization 

Weight: 32.20 kg


China OEM custom lost foam casting products of gray cast iron from China iron casting foundry with services of CNC machining, heat treatment and surface treatment. 

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China OEM custom lost foam casting products of gray cast iron according to your drawings and requirements, used for heavy duty truck gear box housing. 

Lost Foam Casting, also called Lost Foam Casting (LFC) or Full Mold Casting, is a kind of Evaporative Pattern Casting (EPC) with dry sand casting process. The EPC is sometimes could be short for Expendable Pattern Casting because the lost foam patterns could be used only once. After the foam patterns are finished by special machined, then the foamed plastic patterns are coated with refractory coating to form a strong shell to withstand the molten metal. The foam patterns with shells are put into the sand box, and fill it with dry sand sand around them. During pouring, the high-temperature molten metal makes the foam pattern pyrolyzed and “disappears” and occupies the exit cavity of the patterns, and finally the finished desired castings are obtained.

lost foam casting process at RMC Foundry in China

The Steps of Lost Foam Casting:
1- Use foam molds to produce foam patterns and casting gating systems
2- Bond the patterns and runners to form a mold bundle module
3- Dip paint on the module
4- Dry the paint
5- Put the module into the sand box and fill it with dry sand
6- Vibrate molding in order to fill the cavity with dry sand and then compact the molding sand
7- Pouring molten metal to vaporize the foam and then forming the desired castings
8- After the castings have cooled, clean the castings. The dry sand can be recycled

Advantages of Lost Foam Casting:
✔ Greater design freedom for complex structural castings
✔ No draft angle is needed to save lots of cost.
✔ Function integrated foam patterns could be assembled from several pieces of foam patterns.
✔ Lost foam castings are near-net-shape process
✔ High flexibility through short set-up times
✔ Longer EPS mould service lives, hence lower proportionate tool costs
✔ Assembly and treatment costs are reduced by the omission of the treatment process, installation parts, screw connections, etc.
✔ Expansion of the scope of applications

Metals and Alloys Could Cast by Lost Foam Casting Process
• Gray Cast Iron, Ductile Cast Iron
• Carbon Steel: Low carbon, medium carbon and high carbon steel
• Cast Steel Alloys: Low alloy steel, high alloy steel, special alloy steel
• Aluminium and their alloys
• Brass & Copper.

Industries The Lost Foam Castings Used For:
Just as mentioned above, the lost foam casting is specially suitable to produce the large and thick-wall castings. They are serving mostly the heavy machineries with the requirements of complex structure of the desired castings.

Casting Tolerances Reached by Lost Foam Casting Process:
Generally speaking, the casting tolerances of lost foam castings are better than sand casting, but worse than shell mold casting and no-bake casting processes. For our foundry, we basically could achieve the following casting grades. But we would like to talk with you the specific castings and then decide what numbers we can provide for you.
✔ DCT Grade by Lost Foam Casting: CTG9 ~ CTG13
✔ GCT Grade by Lost Foam Casting: CTG5 ~ CTG8


Production Process Annual Capacity / Tons Main Materials Casting Weights
Sand Casting 6000 Gray Iron, Ductile Iron, Aluminium, Brass 0.3 kg to 200 kg 
0.66 lbs to 440 lbs
Lost Foam Casting 4000 Gray Iron, Ductile Iron, Steel Alloys 10 kg to 300 kg
 22 lbs to 660 lbs
Investment Casting (Lost Wax Casting) Water Glass Casting 3000 Carbon Steel, Steel Alloys, Stainless Steel, Brass 0.1 kg to 50 kg 
0.22 lbs to 110 lbs
Silica Sol Casting 1000 Carbon Steel, Steel Alloys, Stainless Steel, Brass 0.05 kg to 50 kg
0.11 lbs to 110 lbs


grey cast iron lost foam casting gearbox housing


lost foam patterns for casting

Foam Patterns for Casting

lost foam casting patterns-gear box housing

Lost Foam Casting Pattern

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