Particle shape analysis improves lost foam casting

Automated particle size and shape analyzer is providing essential information in the manufacture of complex metal components using lost foam casting in the automotive industry.

Malvern Instruments' FPIA-2100 automated particle size and shape analyzer is providing essential information in the manufacture of complex metal components in the automotive industry.

By enabling variations in the ceramic mould used in the lost foam casting process to be measured and minimized, the FPIA-2100 is playing an important role in improving efficiency by enhancing casting quality and reducing waste.

Waste reduction is a key factor in determining the more widespread use of lost foam casting.

This method of casting has the advantage of using almost a quarter less energy and a third less molten metal than conventional casting methods.

It also enables the joining of several components within a single casting, saving downstream machining and assembly.

But to date its use has been hindered by excessive scrap rates, caused by problems with the permeability of the ceramic moulds formed during the casting process.

One of the factors contributing to the permeability problems has been an inability to control the particle size and shape of unbonded sand in the matrix surrounding the mould.

Digital imaging of particle size and shape using the FPIA-2100 has helped overcome these problems by enabling variations in the mould matrix to be measured and minimized.

A versatile, easy-to-use instrument, the FPIA-2100 produces scattergram plots of size against shape.

These provide an effective method of 'fingerprinting' materials, enabling visual comparisons to be made between samples.

It is proving to be a valuable tool in numerous industries - toners, abrasives, column-packing materials, pharmaceuticals, food, and now lost foam casting - where particle size and shape are important parameters with a profound influence on the quality of the final product.

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