processingdetails

Shell Mold Casting

Shell molding, also known as shell-mold casting, is an expendable mold casting process in that molten metal is poured into an expendable mold. Shell mold casting is very similar to sand casting, as compared to sand casting, this process has better dimensional accuracy, a higher productivity rate, and lower labor requirements. In shell mold casting, the mold is a thin-walled shell created from applying a sand-resin mixture around a pattern. The pattern, a metal piece in the shape of the desired part, is reused to form multiple shell molds. A reusable pattern allows for higher production rates, while the disposable molds enable complex geometries to be cast. Shell mold casting requires the use of a metal pattern, oven, sand-resin mixture, dump box, and molten metal. It is used for small to medium parts that require high precision.

Shell mold casting allows the use of both ferrous and non-ferrous metals, most commonly using cast iron, carbon steel, alloy steel, stainless steel, aluminum alloys, and copper alloys. Typical parts are small-to-medium in size and require high accuracy, such as gear housings, cylinder heads, connecting rods, and lever arms.