FATA Aluminum: Lost Foam Casting System

[@Mercmad]

Fascinating! especially as the sand is loose and not packed as you would expect when casting .

[@mpetersen6]

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

[@chipcity3016]

@@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.

[@rsz90182]

Where did they find the lost foam ?

[@lawl114]

Somewhere in the atmosphere

[@jan-eriklundberg3259]

It was hidden!

[@RRaucina]

In the lost and foamed dept.

[@boogerking7411]

What prevents the sand from occupying the space when the foam melts after pouring the molten aluminum? The sand doesn't seem hardened so why it didn't collapse onto the liquid aluminum?

[@donaldasayers]

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

[@noahdawn3964]

@@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?

[@donaldasayers]

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

[@billburkhalter411]

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

[@الإقتصادالمصرىالرؤيةوالحلول]

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

[@robertgoidel]

Fascinating video. What I am trying to get my head around is I understand the foam building process as shown. What I do not understand is when the foam model is placed into the cylinder and filled with casting sand, and immediately it appears the pour of aluminium is done, then how is the foam eliminated from the cavity of the cylinder of casting sand? Does the casting pour eliminate the foam model as it pours into the sand filled cylinder?

[@lylestephens8828]

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.

[@bryanst.martin7134]

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.

[@jmcguckin]

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

[@BrandonsGarage]

What is that coating they put on the foam?

[@chipcity3016]

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.

[@pattygq]

How would they have cast carburetors and engine blocks back before injection molding of Styrofoam was a thing?

I want to make a mold using an existing object but I dont know how to scale up the existing object to compensate for shrinkage? How do we scale up and existing object? Can someone help

[@debojackson23]

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?

[@debojackson23]

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.

[@debojackson23]

parçala behçet no problem good luck to you

[@georgekuzma8075]

Please help! I wonder when you are doing operation "cluster coating", does anybody know what kind of material you use to coat the foam? Is it polyurethane or something else? Thank you! Its right on 03:10

[@wikusdp]

It's a zirconium refractory coating water based.

[@nexus7tablet610]

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

[@Lkmeswoo]

HOW to prevent the gas void defects which the foam burning on casting process?

[@الإقتصادالمصرىالرؤيةوالحلول]

must be applying suction to take sll gases form burn foam

[@gadaadhoon]

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.

[@mustafagbar2304]

Which type of foam use for casting aluminum

[@paulbains9152]

Is that a ceramic shell slurry that the styrofoams are dipped in and dried , before being supported by the dry sand ? If so , how do they stop the ceramic shell slurry from beading , and not sticking evenly to the styrofoam ? Ive cast aluminum intake manifolds this way , but an engine block , WOW !

[@DodgyBrothersEngineering]

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

[@mpetersen6]

As I recall one advantage to this process is the reduction in matching operations needed

[@cwhuffman01]

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.

[@الإقتصادالمصرىالرؤيةوالحلول]

yes of course it is very reduction in machine

[@jerrywhidby5259]

I enjoyed this immensely. Thank you for sharing. Can you tell me what you use to coat the foam?

[@Joe11Blue]

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

[@lylestephens8828]

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

[@paulbains9152]

@@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 " ,

[@mode1charlie170]

Amazing process….

[@Pistolero]

No vacuum when pouring??

[@rsz90182]

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

[@jononame8915]

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

[@adrianjackman9422]

Currently reverse engineering engine block from a 60's mini. Fair to say the detail and finishing wasn't so good back then but still amazing for the equipment they had back then.

[@alfeovaldez8066]

Thank you for sharing.

[@ulfcarlfinnes2820]

Do you use furan oil in the sand?

[@biofall38]

I wish I could have a few of those foam moulds

[@notyou1877]

This is some ancient shit! Them robots been obsolete since the 90's

[@nathanielgarrido5734]

Love the gran turismo music 😂

[@ChicknNudleSoup]

Can I get a whole engine made of foam? Manifolds and everything? Sounds like it would be a great prank prop.p

[@akeemsimon3597]

Music sounds great.

[@vincedibona4687]

I wonder what percentage of their castings are failures, needing to be remelted altogether…?

[@metalmogul4691]

Wow nice job, will last forever.

[@WickedTRX]

Fiat 16V 1.2 or 1.4 liter

[@iplayloud2]

Cool video, eerie music with the seagulls squealing.. I bet they they sound like that after a pass over the chimney where the burned styrofoam fumes come out lol

[@РенатРоссия-ь3е]

Такие продвинутые и крутые технологии, а движки на современных машинах "ходят" всё меньше и меньше!! Если агрегаты 80х годов ходили от 500т. до 1млн.км.,то сегодня, а это сорок лет развития материалов и технологий, движки и 200т.км. не "выхаживают"! И речь идёт о таких производителях как Мерседес, Порше, БМВ да и японцы стали этим баловаться! Давно известно, как и из чего нужно сделать агрегат, чтобы он при правильном обслуживании служил десятки лет и сотни тысяч километров без проблем!

[@scottpecora371]

BIG MONEY, WHAT A HUGE INVESTMENT

[@Budivedder]

Cara molding yg efisien

[@relaxareaobligatorie9695]

Thanks 😚😚😚

[@UncleKennysPlace]

Shot in lovely 4:3 aspect ratio using only the finest russet potatoes.

[@gotany1]

same music down at our social centre and the jumping to.

[@anagemingjihanml_ff9535]

Ok thanks of this vedeos made block engine ...I want to tray at home

[@jackpistone8015]

its lit!

[@rsz90182]

If I apply to work here and get the job please let me handle the Styrofoam side of the factory. :-)

[@mamunakonmusic2874]

Thank you fore your vedio.

[@Rizo-Intelligent]

A Die casting machine peripheral automation equipment manufacturer in Shenzhen

[@tequse-foundrymachine]

Good machine

[@jasons699]

Would have been better without the music. Sorry I couldn't watch the whole video

[@vincedibona4687]

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

[@joe-ut7ee]

The bad thing about this process is the pollution with the burning of that foam.

[@vincedibona4687]

Pobre cita.

[@RRaucina]

Imagine that all this will be gone and scrapped if electric autos take over.

[@MarceloPereira-ll4go]

Legal

[@AirCrash1]

Great background music, if you need narration to understand what is going on then you need to follow the Kardashians and not engineering.

[@gadaadhoon]

Do tell. How are they preventing gas defects?

[@jaboi9900]

Ooo… burn! 😂

[@daveticehurst4191]

Would have been more interesting if you got rid of the constant crap music and told us what was happening in the different processes. After watching this video, I am still none the wiser as to how the process works.

[@vincedibona4687]

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

[@bryanst.martin7134]

Music was a waste of bandwidth.

[@vincedibona4687]

Mute the video then.

[@bryanst.martin7134]

It's sad that most of the workers have no clue of what it is that they are making. While I ponder as to this being a diesel engine due to the single intake port. If anyone knows different, please enlighten.

[@iplayloud2]

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

[@philpullan8595]

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

[@IONredline06]

They look like GEN 1 L61 Ecotec 2.2l engines.

[@alexandradossantos3629]

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

[@laurencejoaquin3675]

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

[@get-the-lead-out.4593]

*Get Rid Of Your STUPID Music* It doesn't make our viewing experience any better than if having got to hear the actual sounds of the machines and processes!

[@firemanjim324]

lose the music. rather have a narrator explain the steps or even some sub titles to explain, briefly.....

[@vincedibona4687]

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

[@MrEst1953]

Thar music is awful and boring. Please loose the noise .

[@vincedibona4687]

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