Implementation of Metal Casting Best Practices - EERE - U.S. ...

tools. Like many of the other facilities that participated in this project, Lost Foam Facility-2 was
unaware of available IAC services. Since the facility was new, it had installed cutting-edge lost
foam equipment and incorporated the results of Metal Casting R&D into its operation.
1. Implemented Best Practices
Starting with the Best
Lost Foam Facility-2 is a greenfield facility that only produces lost foam castings. During the
development of the facility, its managers implemented many of the technologies and practices
developed by ITP-funded research. The facility already had the newest technologies on its
manufacturing line, making it difficult for the facility and the assessment team to evaluate the
extent of implemented R&D’s impact on the overall operation.
For example, Lost Foam-1 facility has only used mullite sand in its operation because of its low
coefficient of thermal expansion, a quality that helps produce a better dimensional cast product
with less thermal degradation than does silica sand. The University of Alabama – Birmingham
and the Lost Foam Consortium has demonstrated the relative benefits of mullite. Learning about
these developments prior to opening its door, this facility incorporated mullite into its operations
from the outset. Likewise, the foundry incorporated the UAB coating tests into its operations.
These practices and technologies control the facility’s scrap rate at a mere 1-2% a year, whereas
the industry average is 5%.
Furthermore, when constructing the facility its management considered which essential
technologies would be needed to have a successful lost foam operation. The facility’s single
largest investment involved installing automated casting lines. Facility management viewed this
technology as being critical to the success because it increased the facility’s throughput. The
facility also installed a state-of-the-art multiple pattern-making machine that enabled them to
produce their own patterns. The company viewed this as a way to reduce its lead-time and
implement a just-in-time manufacturing approach to its production. It also gave the company the
ability to work more closely with its customers on the design of the casting. 58
The facility managers have also used the Lost Foam Consortium as a source of knowledge on the
advancements in lost foam process, and have even invited the University of Alabama scientists
to perform research on site. According to the foundry managers, this has been a good way for
them to offset the fact that they do not have an in-house R&D staff. Furthermore, the foundry
finds it useful to learn from large lost foam producers such as GM.
With the benefit of starting with a greenfield operation, Lost Foam Facility-2 was able to develop
a state-of-the-art lost foam facility. The scrap rate at this facility is well below the industry
average, which allowed Lost Foam Facility-2 to develop a niche market by being a jobbing
facility that can compete effectively for business to produce parts that otherwise would be
produced via machining or die casting processes.
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