Direct pouring process

Casting process in which the liquid metal is poured directly through the feeder. In this way, the exothermic-insulating feeder with integrated pouring filter standing directly on the pattern can eliminate the gating system (Fig. 1, Foseco Foundry Division Vesuvius GmbH)

This technology can be used when a conservative gate system is not possible, for example the component construction or limited space on the pattern plate. This process is often used in automatic high-pressure molding lines that do not have access to the cope site of the molding box.

Functional principle (Foseco Foundry Division Vesuvius GmbH):

The feeder is placed on the centering mandrel attached to the pattern, which also serves as a sprue column (Fig. 2, Foseco Foundry Division Vesuvius GmbH). The integrated filter moves into a vertical position by means of a folding hinge. Then the molding and pressing process is initiated (Fig. 3, Foseco Foundry Division Vesuvius GmbH). Here, the breaker core is compressed and optimally compacts the molding sand in the area of the feeder. When the pattern is removed from the mold, the foam ceramic filter returns to its original position. After the cope site of the molding box has been placed in place and the pouring pool has been milled, the casting process can begin (Fig. 4, Foseco Foundry Division Vesuvius GmbH). At the end of the pouring process, the filter floats in order to enable process-reliable feeding. The  video  shows the complete functionality.

This casting and feeding technology consist of the following components (Foseco Foundry Division Vesuvius GmbH):

The main advantages (Foseco Foundry Division Vesuvius GmbH):

  • Fig. 1: Feeder with integrated pouring filter for the direct pouring process (Foseco Foundry Division Vesuvius GmbH)
  • Fig. 2: Principle of direct casting process (Foseco Foundry Division Vesuvius GmbH)
  • Fig. 3: Feeder after compression of the molding material (Foseco Foundry Division Vesuvius GmbH)
  • Fig. 4: Casting process with direct casting process (Foseco Foundry Division Vesuvius GmbH)
  • Fig. 5: Feeder that can be molded on a high pressure molding machine (Foseco Foundry Division Vesuvius GmbH)
  • Fig. 6: Metallic cover of the feeder (Foseco Foundry Division Vesuvius GmbH)
  • Fig. 7: Integrated foam ceramic filter (Foseco Foundry Division Vesuvius GmbH)
  • Fig. 8: Compressor sheet according to breaker core technology (Foseco Foundry Division Vesuvius GmbH)
  • Fig. 9: Directional solidification, uniform mold filling and best filtration effect (Foseco Foundry Division Vesuvius GmbH)
  • Fig. 10: Low cleaning costs through the use of the compressor plate from Fig. 8 (Foseco Foundry Division Vesuvius GmbH)