Aesir Claims Lost-Foam Breakthrough with Stainless Steel

Aesir Metals LLC reports it has begun lost-foam casting of parts in 316 stainless steel, noting that it believes it is the first foundry to cast stainless grades on a commercial scale using the lost foam process. The casting will be used in a chemical industry operation that requires a submersible component, and in situ testing revealed that the corrosion-resistance for the part has been in compliance with the customer’s expectations, according to Aesir.

Further design and performance details are confidential, the foundry noted.

Aesir Metals was established late last year in Struthers, OH. It has been producing gray and thin-walled ductile iron castings by the lost-foam process, and with an emphasis on high-tolerance products on short lead times — both of which are made possible by the lost-foam process. According to operations manager Mark DeBruin: “We planned to focus on gray and ductile iron. However, the customer demand has been strong for the use of the lost foam process with stainless steel and other corrosion resistant alloys such as Ni-hard D5-S ductile iron.”

The finished products provide the corrosion resistance of stainless steel with the benefits of lost-foam castings, including no need for machining and part consolidation. Aesir Metals co-founder Jeff Rocco, who has extensive experience casting steel components, indicates there is little difficulty reapplying his insights to the higher-value stainless grades. “It’s like I’ve seen before,” Rocco stated. “There doesn’t appear to be any difference.”

Producing castings in stainless may broaden the potential ferrous metal applications for the lost-foam process, according to Aesir. Besides components for chemical industry processes, the marine and energy sectors may offer opportunities for success with stainless lost-foam castings.