The gas gap in lost foam casting has not yet reached its potential because of the complexity of the process. In
this paper, the melt/foam interface (gas gap) resulting from degradation during mould filling in the lost foam was
presented. In aluminium lost foam casting, the foam pattern mainly decompose into liquid polystyrene and gas.
The melt-foam interface reaction and gas evolution has been detected by thermocouples during mold filling. The
result indicate that metal pouring temperature, foam density, cross-sectioned of gating system and the thickness
of coating layer affect mold filling time.

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