- The process offers excellent dimensional accuracy. (Even greater accuracy can be achieved by using zircon sand.)
- Products have good surface finishes
- It can be used to produce complex shapes with fine details
- The process can be automated for large-scale production to reduce labour cost and increase productivity
- Parts can be cast from a range of ferrous or non-ferrous metals, including aluminium alloys, copper alloys, alloy steel and stainless steel, as well as the more traditional carbon steel and cast iron
- The process has relatively shorter project lead times
- Minimal waste because any scrap can be re-used
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Shell Casting
Shell casting for production of precision parts
Omnidex Mining has been providing shell casting solutions to the mining sector for many years. As with all other casting options we provide, we closely monitor and manage all material specifications, dimensional accuracy and tolerances throughout the process. We also use powerful simulation software to ensure every casting operation runs as smoothly as possible.
Shell Casting is a process characterized by the use of temporary shell molds made with a resin covered fine sand. The process offers superior dimensional accuracy across a wide range of ferrous and non-ferrous alloys.
The process of Shell Molding:
Step 1
The metal pattern is heated to between 175°C (350°F) and 370°C (700°F). (The pattern can be used many times to form multiple shell molds.)
Step 2
Fine sand mixed with a thermosetting resin is poured over the hot pattern to form the mold.
Step 3
The pattern and sand are inverted to remove excess sand, leaving a shell mold.
Step 4
The shell is further heated in an oven to harden and then removed from the pattern.
Step 5
Two or more shells are combined to form a mold.
Step 6
The shell mold is placed inside a flask, and surrounded with shot, sand, or gravel for metal pouring.
This process has a number of advantages:
These advantages make Shell Molding the ideal solution for large-scale production of small to medium-sized high-precision parts. It is often used in the manufacture of oil and gas components, camshafts, crankshafts, gear housings and many more.
It should be reminded that Shell Casting also has its own disadvantages and limitations:
- Equipment cost is high
- The sand resin used to make the shell mold is expensive and cannot be reclaimed
- Product size is limited by the shell molding machines
- Products often need additional machining
Contact us to learn more about shell casting and other metal casting process we offer. You can also learn more about Omnidex Mining and our manufacturing processes on this website.
Get in touch with Omnidex Mining if you need more information or a quote.
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Omnidex Mining Brochure
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