That's why they put the mold in a vibration station.

@@mpetersen6 Thats why the ceramic slurry is first applied to the lost foam pattern, the slurry is the actual mold surface. The dry sand is extra support. The vibration ensures the dry sound sounds the ceramic shell mold properly. The sand is not packed tight light with green sand moldings.

Somewhere in the atmosphere

It was hidden!

In the lost and foamed dept.

Polyurethane resin. At least, that is what is most commonly used.

They are dipped into a ceramic slurry, like a thin plaster.

@@lylestephens8828 Ceramic shell slurry gets baked hard like concrete . When its hard , you can blow through it with your mouth , its cool stuff . The whole idea is not to trap any air . The air gose into the support sand , and up . The type of low density styrofoam you use is very important . When the styrofoam burns up , it makes a small amount of residue , the less the better , because those become inclusions , I build balloon protrusions into fine detailed projections off the main body , and saw them off the main body later . The residue hopefully gose into those pockets . Avoid glueing anything as much as possible , glue makes residue . . An inclusion isnt the end of the world ,if its not internal , you can fix it by Tig . Want to make people jealous ? have aluminum intake manifolds with you name on them , in raised writing . Oh ya , and stamp , " close-to factory part numbers on it " ,

You saw the orange flames come up as the metal was being poured into the flasks. That was the styrene foam burning up from the heat of the metal. After shakeout you could see some black carbon residue left from burning the styrene.

Yes. The foam evaporates as the 1200 degree Fahrenheit or so aluminum is poured into the mold, but the sand must allow for the evaporating fumes to escape permitting the light weight aluminum to occupy the space. It's a delicate balance. There is also investment casting where a slip of clay is formed over it and baked. The foam is gone and a thin shell is left to provide the borders for the aluminum or even steel. Fascinating either way.

They may preheat the mold in an oven, that would melt and evaporate the styrene

@Paul Bains you have cast intake manifolds but you have no KZfaq content what gives?

The foam is coated in a refractory coating which hardens when the hot metal touches it. see 3:09

@@donaldasayers i got that part but never saw the step where they did a burnout of the foam. Or was the foam just burned out with the aluminum?

@@noahdawn3964 Plastic foam, vs molten aluminium at 800C, the foam just disappears. Search for lost foam casting.

Looks like the foam casting is dipped in a ceramic slurry several times then allowed to cure before the sand is poured.

the casting coating as you see this coatong is very strength so no. sand during pouring metal

There are actually a number of options to lost foam using glued foam sections. Fewer machining operations is one, but the main advantage is being able to make passages, channels, etc. in a component that is optimized for better performance or efficiency. This is commonly done on a lot of engine components or complex valve components.

yes of course it is very reduction in machine

Its a ceramic slurry, similar to plaster of paris. this is what actually becomes the mold surface. The surrounding course sand is just extra support.

It's a zirconium refractory coating water based.

It allows the aluminium to burn out the foam and fill the void without the sand collapsing?

parçala behçet, the sand is the mold and the foam is the object, sand is fit tight around the object which in this case shaking to fill into the foam and around it , thus making it mold air tight, when molten is poured it burns the intire foam piece and forms the object which was made of foam,there is no loss of size.

When the molten metal solidifies wont it shrink?

parçala behçet not that I have seen when I do my projects same size as the foam object every time.

I see. I read or watched somewhere that you need to compansate for the shrinking metal so you need to scale up the existing object like 2-3 percent. maybe i am mistaken. Thank you for taking your time to answer.

parçala behçet no problem good luck to you

must be applying suction to take sll gases form burn foam

I had the same question. It's a problem with smaller scale projects. I wonder if this just stays liquid so long that it isn't a problem because of the huge amount of molten metal.

You would probably pull too much aluminum through the sand and ruin the mold. My thoughts.

Degassing is done before the pore also vacume would ruin lost foam

You know you can just turn the volume down/mute the video, right???

Do tell. How are they preventing gas defects?

Ooo… burn! 😂

Pobre cita.

Bryan St.Martin They look bored but they fully understand what's happening.

They all look like parts from the gm/vauxhall ecotec engine... We have a version here in the uk 2.2 normally aspirated engine code z22se.. I believe in the us there's a 2.0 turbo charged version

They look like GEN 1 L61 Ecotec 2.2l engines.

First head casting is Fiat FIRE 16v 1.2 up to 1.4.

@@alexandradossantos3629 is correct. FATA is a OEM supplier to FIAT.

Mute the video then.

No narration needed unless you’re dense. And if the music bothers you, mute the video. People…

If the music bothers you, mute the video. If you can’t understand what is going on by watching, find another interest.

Mute the damn video then. JFC the whining in these comments about the music…