A newly developed low-pressure expendable pattern casting (LP-EPC) process was introduced and its basic principles or effect factors were further analyzed. According to theoretical calculation and experimental results, the major casting parameters that are of great and critical importance on the process include pressure and flux of filling gas, decomposition characteristic and density of foam pattern, thickness and permeability of coating, pouring temperature, vacuum degree and their combination. Most of casting defects can be effectively avoided by choosing the suitable parameters. The success achieved in pouring motor housing and exhaust manifold castings demonstrates the advantages of LP-EPC process in the production of high-complicated castings with high dimension accuracy.
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