Lost foam casting is a precision casting method in which the pattern is formed from a foam (EPS) replica left inside the mould, and molten metal takes its place by vaporising the foam. The method largely eliminates the need for cores and parting surfaces required in conventional moulding, allowing complex geometries to be produced as a single piece with tight tolerances.
Why Lost Foam?
Minimised parting lines and flash formation, dimensional repeatability and smooth surface quality are the standout advantages of the lost foam method. Especially in complex parts with internal channels — such as heavy-vehicle brake discs, manifolds and pump housings — it reduces the machining allowance and post-assembly processing load.
R&D Approach at Morçelik
Our engineering team evaluates the adaptability of the lost foam method to serial production through trials on foam pattern quality, refractory coating permeability and sand compaction parameters. Our aim is to expand our grey and ductile iron product range with high-added-value parts that can be produced using this technique.