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The permeability of Lost Foam pattern coatings for Al alloy castings

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Abstract

The Lost Foam casting of Al alloys has not yet reached its full potential because of the complexity of the process, and the fact that it is still poorly understood. In this paper, the permeability of typical pattern coatings for the Lost Foam casting of Al was measured, and found to vary from about 0.1 Darcy, (10−13 m2), for a low permeability coating, to about 1 Darcy (10−12 m2), for a high permeability coating. Permeability was reduced by increasing coating thickness, but examination of the coatings on a hot-stage SEM suggested it would be unaffected by increased temperature. The results were used to infer how the filling of a Lost Foam polystyrene pattern could be influenced by the permeability of the pattern coating.

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Acknowledgements

The authors would like to gratefully acknowledge the assistance of Mr. Adrian Caden of the University of Birmingham with the execution of the experiments, Mr. Dennis Nolan of Foseco Morval, Ontario, Canada, for provision of materials, and EPSRC for the provision of a studentship for one of the authors (PJD).

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Authors and Affiliations

  1. Department of Metallurgy and Materials Science, School of Engineering, University of Birmingham, Edgbaston, Birmingham, B15 2TT, UK

    W. D. Griffiths

  2. Honda of the UK Manufacturing Ltd., Highworth Road, South Marston, Swindon, Wiltshire, SN3 4TZ, UK

    P. J. Davies

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  1. W. D. Griffiths
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  2. P. J. Davies
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Correspondence to W. D. Griffiths.

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Griffiths, W.D., Davies, P.J. The permeability of Lost Foam pattern coatings for Al alloy castings. J Mater Sci 43, 5441–5447 (2008). https://doi.org/10.1007/s10853-008-2844-2

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  • DOI: https://doi.org/10.1007/s10853-008-2844-2

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