Reinforcement of castings in lost foam casting process
DOI:
https://doi.org/10.15407/mom2026.02.048Keywords:
lost foam casting, casting reinforcement, mounting base, polymer pattern, additive technologies, 3D printing of patterns, spring elements, internal chillers, TRIP effect, differentiated propertiesAbstract
Based on the analysis of patent solutions for reinforcement methods, the article investigates the technological features of manufacturing reinforced and bimetallic castings using the lost foam casting (LFC) method. The authors analyze the drawbacks of traditional reinforcement methods in hollow sand molds, the most critical of which are the difficulty of spatial fixation of the reinforcement, the risks of displacement of its elements during mold tilting or transportation, and the high probability of destruction of the sand mold surface when mounting the reinforcement to its walls. The concept of using a polymer pattern not only as a shaping element but also as a reliable mounting base is substantiated. This approach allows for the integration of reinforcing components directly into the pattern body, ensuring high positioning accuracy in the future casting. The dual functional role of the reinforcing elements is noted: in addition to mechanical strengthening, they act as internal micro-chillers, which allows for effective control of crystallization processes, refinement of the metal structure, and minimization of shrinkage defects in massive sections. Attention is also paid to the synergy of the LFC process with additive technologies. The use of 3D printing of polymer patterns makes it possible to create internal niches in the pattern and place reinforcement in them with high geometric precision. The paper presents the practical implementation of this technique on the example of the development of a cast armored barrier with integrated spring elements. The mechanism of the TRIP effect (transformation-induced plasticity) realization for hardened iron-carbon alloys is described, where spring structures act as accumulators of phase transformation energy, which increases the survivability of the structure under dynamic and impact loads. The proposed technology opens up new opportunities for the production of lightweight metal products with differentiated properties, intelligent means of passive protection, and highly loaded mechanical engineering parts.
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