An Investigation into the Effects of Processing Conditions on Airborne Emissions from the Lost Foam Casting Process

Steven U. Behm | MS | 2001

Abstract:

In this work, lost foam casting experiments are performed in an effort to better understand the characteristics of airborne emissions from the process. The lost foam casting process is widely considered to be more “environmental friendly” than other traditional casting methods. However, the process is known to produce hazardous chemicals and aerosols in its emissions. Understanding the relationship between selected process variables and process emission, will allow planners to make environmentally responsible decisions when selecting processes and process variables.

A designed experiment is conducted to investigate the impact of three process variables on the characteristics of process emissions. The process variables investigated are 1) the temperature of the metal poured into the foam pattern, 2) presence or absence of a refractory coating on the foam pattern, and 3) the surface area to volume ratio of the foam pattern. The characteristics of the process emissions that are monitored include temperature, aerosol concentration, aerosol size distribution, and the concentration of various organic species.

Statistical analysis is performed on the results obtained to determine the effects of the chosen process condition on the emissions. The presence of a refractory coating and the pattern surface area to volume ratio are shown to have significant impacts on the temperature and chemical makeup of process emissions. The aerosol characteristics of the emissions are shown to be largely independent of process variables. In addition, significant differences are noted in process emissions produced during pouring and those given off during shakeout.

Finally, conclusions are summarized and subsequent recommendations are given for future work to be done in this area.

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