Custom Steel & Iron Castings via the Lost Foam Process

Yile Machinery is a leading foundry specializing in the Lost Foam Casting (LFC) process, also known as evaporative pattern casting. This advanced manufacturing technique enables us to produce large, intricate, and highly accurate steel and iron castings for Original Equipment Manufacturers (OEMs) across heavy industry.

We deliver near-net-shape components that reduce machining time, improve part integrity, and offer unparalleled design freedom compared to traditional sand casting.

The Advantages of Lost Foam Casting (LFC)

The LFC process is ideal for parts that are difficult or impossible to produce with conventional methods. By using a foam pattern that is vaporized by molten metal, we can achieve superior results.

• Unmatched Design Freedom: Create complex internal and external geometries without the need for traditional cores or draft angles. This allows engineers to design for function, not for manufacturability.

• Part Consolidation: Combine multiple components into a single, integrated casting. This reduces assembly time, eliminates joints and fasteners, and increases overall structural strength.

• Superior Dimensional Accuracy: Achieve tighter tolerances and a smoother surface finish directly from the mold, significantly reducing the need for secondary machining operations.

• No Parting Lines or Core Shift: As the mold is a single piece, it eliminates the parting lines, fins, and potential core-related defects common in traditional casting.

• Cost-Effective for Complex Parts: Reduces or eliminates the high cost of creating and maintaining complex multi-part patterns and core boxes.

Our Lost Foam Casting Process

Our process is meticulously controlled to ensure the highest quality results for every part.

1. Foam Pattern Creation: We produce a precise, one-piece pattern of your part using expanded polystyrene (EPS) foam.

2. Refractory Coating: The foam pattern is coated with a permeable refractory slurry and dried, forming a thin, hard shell.

3. Sand Compaction: The coated pattern is placed in a flask and surrounded by unbonded sand, which is compacted by vibration to support the pattern.

4. Pouring: Molten metal (steel or iron) is poured into the flask. The hot metal instantly vaporizes the foam pattern, perfectly replicating its shape within the refractory shell.

5. Cooling & Finishing: After cooling, the casting is removed from the sand, and the refractory coating is cleaned off, revealing the finished metal part.

Materials & Capabilities

We provide a full-service solution for your large casting needs.

• Materials Poured:

• Carbon Steels (e.g., ZG230-450, ZG270-500)

• Alloy Steels (e.g., ZG20SiMn, ZG34CrMo)

• Gray Iron & Ductile Iron

• Casting Size & Weight: We specialize in large-scale castings, with capabilities to produce parts weighing from hundreds of kilograms to several tons.

• Value-Added Services: We offer post-casting services including heat treatment (annealing, normalizing, quenching & tempering), precision machining, and Non-Destructive Testing (NDT) .

Partner with Our Foundry for Your Next Project

Unlock new design possibilities with Lost Foam Casting. Send us your 3D models and technical specifications, and our engineering team will provide a detailed analysis and competitive quote for your custom casting needs.