The full form pouring is a prototype procedure for the production of complex workpieces from metallic materials, e.g. Aluminum. It belongs to the casting procedures with lost form. The name full form pouring deduces itself from the procedure characteristic. The form is "full" when pouring off, it has thus no cavity, which corresponds to the workpiece which can be manufactured.
The characteristic of the full form pouring lies in it that the melt (1) is poured into a Sandform, in which a model from PS-E (2) is contained, which corresponds to the desired workpiece. In the respective proximity of the melt guest the PS-E completely; the freed gas (3) is sucked off by the moulding sand (4) from the form (5). After solidifying the workpiece can be taken from the melt out of the form, similarly as with the usual sand casting.
Provided as preparation of actual pouring a 1:1 model of the workpiece from expandable polystyrene (PS-E), better admits under the trade name polystyrene. The EPS model can be built up from several parts. Thus complex workpieces leave themselves (e.g. Intake manifolds) from form-technically simple, behind-cut-free elements develop. The PS-E model becomes with a protective layer, for which so-called simple one covered, so that when pouring off a direct contact of the melt is avoided to the sand. In such a way prepared PS-E model is brought into a container with moulding sand, with which those are final pre-working
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