A foam engulfment model for lost foam casting of aluminum

In lost foam casting of aluminum, pressure equilibrium between the liquid metal and the decomposing foam can produce a variety of different shapes for the metal flow front, ranging from convex to concave. In extreme cases, the flow front can become so strongly concave that small pieces of the foam pattern begin to break off inside the concave hollow of the flow front and become enveloped by the advancing liquid metal. When this happens, the entire mechanism of foam decomposition changes from steady ablation to a more chaotic motion in which the metal seems to “chew” its way through the pattern, creating large bubbles of vaporizing polymer liquid in its wake. These bubbles usually lead to undesirable anomalies in the final casting. In most cases, the nonlinear equations that govern the shape of the flow front depend on a single nondimensional number, which relates the onset of the engulfing motion to specific material, geometric, and process parameters. Numerical solutions to these equations are obtained for several special cases. These solutions help to explain a number of experimental observations that until now have been poorly understood.