A review of physical and kinetic models of thermal degradation of expanded polystyrene foam and their application to the lost foam casting process

Kannan, Pravin; Biernacki, Joseph J.; Visco, Donald P.

doi:10.1016/j.jaap.2006.06.005

Cited by 73 publications

(45 citation statements)

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“…Kannan et al [43], Liu et al [34], Barone and Caulk [44] and Mirbagheri et al [9] had studied the thermal degradation of Expanded Polystyrene Foam (EPS) used for EPC Process. The authors had advanced physical and kinetic models for the degradation of the polystyrene foam applied in EPC Process.…”

Section: Structure and Thermal Degradation Of Foam Patternmentioning

confidence: 99%

“…The physical models advanced that the composition of the mixture of degradation products is a function of the time that the products reside in the interface before escaping out through the coating and sand [43]. Worthy of note is Figure 2.…”

Section: Structure and Thermal Degradation Of Foam Patternmentioning

confidence: 99%

“…Evaporative Pattern Casting (EPC) Process http://dx.doi.org/10.5772/intechopen.73526 99 [6,43,45,49,50]. Attempts have been made to study comprehensively the behaviour of the liquid metal poured into EPC molds.…”

Section: Characteristic Behaviour Of Molten Metal In Prepared Moldsmentioning

confidence: 99%

“…The molten metal displaces the foam because of its high temperature; resulting in pyrolysis products like monomers and emissions toxic to human [13]. All the products formed in the mold have been established as potential causes of defects in castings obtained by EPC process Evaporative Pattern Casting (EPC) Process http://dx.doi.org/10.5772/intechopen.73526 99 [6,43,45,49,50]. Attempts have been made to study comprehensively the behaviour of the liquid metal poured into EPC molds.…”

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Evaporative Pattern Casting (EPC) Process

Omidiji¹

2018

Advanced Casting Technologies

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The chapter provides details of operations and activities in evaporative pattern casting (EPC) Process. The process was developed in the year 1956 to tackle some of the inadequacies of the traditional sand casting processes but has in itself some challenges that should be taken care of if sound castings would be obtained. The challenges come mainly from the evaporative pattern employed as pattern material in the process. The material makes the process to be sensitive to process variables such that proper and adequate control should be ensured to have castings of sound integrity. Some of the known process variables are pouring temperature, refractory coating, vibration and pattern and molding materials. In the whole the EPC is known to have edge over the traditional sand casting methods.Keywords: pattern, molding, casting, variables and coating History of evaporative pattern casting (EPC) processEvaporative pattern casting (EPC) Process is a sand molding process that makes use of evaporative patterns produced industrially by steam molding or machined out from a block of expandable polystyrene foam (EPS) [1,2]. The pattern is buried in the sand mold and the melted casting material is poured into the mold without removing pattern, unlike the traditional sand casting method that makes use of wooden, plastic and metallic pattern which is removed from the mold before molten metal is advanced.It was in 1956 that Shroyer made a documentation of his work on EPC where green sand was used as the molding material [3]. The author machined a shape from expanded polystyrene (EPS) and supported it inside a flask with bounded sand. Another researcher called Flemmings © 2018 The Author(s). Licensee IntechOpen. This chapter is distributed under the terms of the Creative Commons Attribution License (http://creativecommons.org/licenses/by/3.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.came up in 1964 to use unbounded silica grains for the process [1]. Foundry men later came to differentiate between the two; calling the first the full mold and the second the lost foam processes. The subtle difference only lied in the use of bounded (green) sand and loose sand.The process became known to foundry men in 1958 and many trade names have been formed to describe it [3]. They include styrecast, replicast, full mold, lost foam and evaporative process. A distinguishing feature of this type of sand process is that an evaporative pattern made of polystyrene foam is used [4]. It is coated with a coating developed from a refractory material usually silica or zircon sand before being buried in the mold. It is not removed from the mold once it is buried.After 1964, some works have been done by researchers to understand the variables that affect the process. Some works in the automotive industry have also been done. General motors have produced a number of automotive components with the method. This started in the year 1980 and they are still in the use of the p...

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Section: Structure and Thermal Degradation Of Foam Patternmentioning

confidence: 99%

Section: Structure and Thermal Degradation Of Foam Patternmentioning

confidence: 99%

Section: Characteristic Behaviour Of Molten Metal In Prepared Moldsmentioning

confidence: 99%

mentioning

confidence: 99%

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Evaporative Pattern Casting (EPC) Process

Omidiji¹

2018

Advanced Casting Technologies

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“…In the LFC, an expendable foam pattern has been introduced to manufacture castings, which greatly reduces the cost of production [18][19][20] .…”

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Effect of thermophysical property and coating thickness on microstructure and characteristics of a casting

Cheng

Jia²,

Guo

et al. 2017

China Foundry

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Fast pyrolysis kinetics of expanded polystyrene foam

2009

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Fast pyrolysis of polymers, biomass and other substances is of great interest in various applications. For example, in the lost foam casting process, kinetic information about expandable polystyrene (EPS) decomposition under extremely high-heating rate conditions is essential for further process development. A simple laboratory-scale fast pyrolysis technique has been developed and demonstrated for elucidation of EPS decomposition kinetics. Pyrolysis experiments were performed at different reaction temperatures. The cumulative gaseous yields were determined using a flame ionization detector (FID) connected in series with the fast pyrolysis reactor. The governing equations for a semibatch reactor type were modified and applied to obtain kinetic parameters (activation energies and the pre-exponential rate constants) for the EPS decomposition process. V

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A review of physical and kinetic models of thermal degradation of expanded polystyrene foam and their application to the lost foam casting process

Cited by 73 publications

References 20 publications

Evaporative Pattern Casting (EPC) Process

Evaporative Pattern Casting (EPC) Process

Effect of thermophysical property and coating thickness on microstructure and characteristics of a casting

Fast pyrolysis kinetics of expanded polystyrene foam

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