PRODUCTION METHOD
PRODUCTION METHOD
MAIN FEATURES
Accuracy class
7
Cast blanks (products) of high quality and performance
Virtually any configuration, starting with dimensional and weight accuracy class 7, depending on the blank (product) weight and configuration.
No internal defects
High precision and roughness of cast products
Vacuum is needed to give strength to molds, which helps produce castings with high precision and roughness, as well as venting out the gases produced during pouring, which makes the castings sound without internal defects.
PATTERNS AND CAST PRODUCTS
PATTERNS AND CAST PRODUCTS
Part name: “Frame”
Part name: “Engine crankcase cover”
Part name: “Lever arm”
Part name: “Connecting rod”
Part name: “Flange”
Part name: “Insert”
Part name: “Compressor motor body”
Part name: “Case”
Part name: “Transfer-case housing”
Part name: “Motor housing”
Part name: “Crankcase cover plate”
ADVANTAGES OF THE LFC METHOD
ADVANTAGES OF THE LFC METHOD
Sand-and-Clay Molds (SCM) and Cold-Curing Mixtures (CCM)
1. Higher surface roughness (Rz-40 on average, as with LWC).
2. Higher density of the cast product metal, as there is a forced venting of gases during pouring (vacuum).
3. Smaller machining allowances and, therefore, lower cast product weight.
4. The manufactured aluminum production tooling (mold) serves almost the entire required period, without costly repair or replacement, because the mold is not exposed to dynamic, high-temperature, and other mechanical stresses during its use, unlike wood, plastic, or even aluminum tooling used in the SCM or CCM methods that require regular repair or replacement.
5. Higher quality with approximately the same productivity of facilities that are similar in terms of their capacity.
6. Consistent quality in terms of dimensional and weight accuracy, as the mold during its use does not change its geometric dimensions, unlike production tooling used in the SCM and CCM methods.
7. Possibility of manufacturing some types of cast products without making expensive aluminum molds.
8. More environmentally responsible production.
Lost-Wax Casting (LWC)
With comparatively similar parameters of dimensional and weight accuracy, roughness and metal density in the castings, the LFC method features a significantly lower cost of production due to less labor-intensive manufacturing, which significantly affects the pricing.

High productivity, as compared to LWC, at the same cost for process tooling (mold), comparable to SCM and CCM methods.
Gravity Die Casting
Higher productivity.
Higher density of the cast product metal, as there is a forced venting of gases during pouring (vacuum).
No need for repair of the process tooling or manufacture of a new one, contrary to gravity die casting that requires regular manufacturing of new expensive metal mold pattern.
Consistent quality in terms of dimensional and weight accuracy, because the mold during its use does not change its geometric dimensions, unlike process tooling used in gravity die casting, which are burnt up during the use.
High-Pressure Casting (HPC)
If you do not need high dimensional and weight accuracy, which can only be achieved using the HPC method (dimensional and weight accuracy classes 3-5), it is advisable to consider the possibility of manufacturing using the LFC method (the 7th dimensional and weight accuracy class).
The cost of manufacturing molds for LFC (comparable to LWC) is 5–10 times lower than for HPC.
The manufacturing time for HPC molds is at least 6 months, for LFC it is equal to 2–3 months.
The service life of HPC molds is 2,000 to 5,000 cycles (pouring metal into the mold); after this a new mold shall be made. The service life of mods for LFC is unlimited.