Shell Mold Casting Process | PDF

In this document, we have covered the Shell Mold Casting Process steps and features. The shell-mold casting process is also known as the shell molding process, is an expendable mold casting process that uses resin-covered sand to form the mold.

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Shell mould casting is a metal casting process similar to sand casting, in that molten metal is poured into an expendable sand-based mould. However, in shell mould casting, the mould is a thin-walled shell created by 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 moulds. A reusable pattern allows for higher production rates, while the disposable moulds enable complex geometries to be cast.

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Compared to sand casting, this process has better dimensional accuracy, a higher productivity rate, and lower labour requirements. It is often used for small to medium parts that require high precision.

Shell mould casting is used for both ferrous and non-ferrous metals. The most commonly used are cast iron, carbon steel, alloy steel, stainless steel, aluminium alloys, and copper alloys. Typical parts cast using this process are small-to-medium in size and require high accuracy, such as gear housings, cylinder heads, connecting rods, and lever arms.

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