avk-esg-2024-25 - Flipbook - Page 31
LOST FOAM
TECHNOLOGY
Boosting efficiency in production while contributing to a
lower environmental impact
Our Advanced Castings foundry in Anhui, China,
supplies the AVK Group with valve, hydrant and
other metal castings. At the foundry, we use the
innovative lost foam method.
The lost foam method refers to the process of
creating a foam model of the desired casting,
embedding it in binder-less moulding sand, and
finally replacing the foam with molten metal.
In traditional casting of components with
multiple sand cores, each core must be
individually manufactured, handled, and
assembled for each casting. In contrast, the
lost foam method enables the production
of complex parts with near-net shape and
eliminates the need for separate cores, making
it possible to reduce material waste, as the
core is integrated into a single foam pattern.
The production method allows for low wall
thickness and minimal draft angles, contributing
to reduced component weight. Another benefit
is that the use of a single foam pattern with
integrated core and mould eliminates the
complex, physically demanding, and timeconsuming process of assembling sand cores.
The sand used to embed the foam model
is ceramic and requires no binders, which
simplifies demoulding and allows for
exceptionally high reclamation rates – typically
above 99%. As a result, the process generates
only about 1% sand waste and produces
minimal dust. In comparison, traditional casting
typically results in 5-7% of the sand mixture
being discarded as hazardous solid waste
due to the use of chemical binders, creating a
continuous waste stream. Additionally, since the
ceramic sand contains no resins or chemical
binders, there are no unpleasant chemical
odours, and emissions of Volatile Organic
Compounds (VOCs) are significantly reduced.
Compared to traditional sand casting, the
process offers improved performance by
reducing energy consumption and lowering
particle emissions into the atmosphere.
In addition, the process supports a safer
working environment in our production, as the
lightweight foam patterns reduce physical strain
on operators.
We use recycled steel scrap as the main
material in our castings, constituting 85-90%
of the total melt. Melting is done in electric
induction furnaces.
AVK Advanced Castings maintains a strong
safety-oriented culture and is widely renowned
for its clean working environment. The
foundry is frequently visited by other industry
professionals and government officials seeking
updated knowledge and valuable experience.
AVK Group Sustainability report 2024/2025 | 31
