Other casting Processes

Shell Molding Process

Shell molding first was developed in the 1940s and has grown singnificantly.
It can produce many types of castings with close dimensional tolerance and a good
surface finish at low cost.
Shell-molding applications include small mechanical parts requiring high precision,
such as gear housings, cylinder heads, connecting rods, and high-precision molding
cores. In this process (see Figure)
a) A mounted pattern made of a ferrous metal or aluminum is heated to 175o C 370o C.
b) Coated with a parting agent such as silicone.
c) Clamped to a box or chamber that contains fine sand, mixed with 2.5% to 4%
thermosetting resin binder (such as phenol-formaldehyde) that coats the sand particles.
d) The box is either rotated upside down or the sand mixture is blown over the pattern, to
coat the pattern.
e) The assembly is then placed in an oven for a short period of time to complete the
curing of the resin.
f) The shell hardens around the pattern and is removed form the pattern using built-in
ejector pins.
g) Two half-shells are made in this manner and are bonded or clamped together to form a
mold. Figure 11.9
 The thickness of the shell can be determined accurately by
controlling the time that the pattern is in contact with the mold.
The shells are light and thin (usually 5-10 mm), and
consequently their thermal characteristics are different from
those for thicker mold.
Shell sand has a much lower permeability than sand used for
green-sand molding, because finer sand is used for shell casting.
The decomposition of the shell-sand binder produces a high
volume of gas; unless the molds are properly vented, trapped
airand gas can cause serious problems in shell molding of
ferrous castings.
The high quality of the finished casting can reduce cleaning,
machining, and othe finishing costs significantly.
Complex shapes can be produced with less labor, and the
process can be automated fairly easily.
Advantages of shell moulding process
The surface of the shell mould is smoother than conventional green
sand mould. This permits easier flow of molten metal during
pouring and better surface finish on the final casting.
Surface finish of the order of 2.5 m can be obtained. Good
dimensional tolerances of the order of 0.25 mm can be reached
in a small to medium sized parts.
Machining operations are reduced because of good surface finish.
can be mechanized for mass production and will be economical too.
Disadvantages
expensive metal pattern is required, and hence not suitable for
small quantities.
Examples of parts made using shell molding include gears, valve
bodies, bushings, and camshafts.
Figure - Steps in shell-moulding: (1) a match-plate or cope-and-drag metal
pattern is heated and placed over a box containing sand mixed with
thermosetting resin
Figure Steps in shell-molding: (2) box is inverted so that sand and resin fall
onto the hot pattern, causing a layer of the mixture to partially cure on the
surface to form a hard shell
Figure - Steps in shell-moulding: (3) box is repositioned so that loose
uncured particles drop away
Figure - Steps in shell-muolding:
(4) sand shell is heated in oven for several minutes to complete curing
(5) shell mould is stripped from the pattern
Figure 11.5 - Steps in shell-moulding:
(6) two halves of the shell mould are assembled, supported by sand
or metal shot in a box, and pouring is accomplished
(7) the finished casting with sprue removed
The process of creating a shell mold consists of six steps:[2][3]
Fine silica sand that is covered in a thin (36%)
thermosetting phenolic resin and liquid catalyst is dumped,
blown, or shot onto a hot pattern. The pattern is usually
made from cast iron and is heated to 230 to 315 C (450 to
600 F). The sand is allowed to sit on the pattern for a few
minutes to allow the sand to partially cure.
The pattern and sand are then inverted so the excess sand
drops free of the pattern, leaving just the "shell".
Depending on the time and temperature of the pattern the
thickness of the shell is 10 to 20 mm (0.4 to 0.8 in).
The pattern and shell together are placed in an oven to
finish curing the sand. The shell now has a tensile strength
of 350 to 450 psi (2.4 to 3.1 MPa).
 Setup and production of shell mould patterns takes weeks, after
which an output of 550 pieces/hr-mould is attainable. [Common
materials include cast iron, aluminium and copper alloys.[1]
Aluminium and magnesium products average about 13.5 kg (30 lb)
as a normal limit, but it is possible to cast items in the 4590 kg
(100200 lb) range. The small end of the limit is 30 g (1 oz).
Depending on the material, the thinnest cross-section castable is 1.5
to 6 mm (0.06 to 0.24 in). The minimum draft is 0.25 to 0.5 degrees.[1]
Typical tolerances are 0.005 mm/mm or in/in because the sand
compound is designed to barely shrink and a metal pattern is used.
The cast surface finish is 0.34.0 micrometers (50150 in) because a
finer sand is used. The resin also assists in forming a very smooth
surface. The process, in general, produces very consistent castings
from one casting to the next.[3]
The sand-resin mix can be recycled by burning off the resin at high
temperatures.[4]
Plaster-Mold Casting
 Plaster-Mold Casting

It is known as precision catsing because of the high dimensional accuracy and

good surface finish obtained (as well as ceramic-mold and investment
casting).
Typical parts made are lock components, gears, valves, fittings, tooling, and
ornaments.
In this process:
a) The mold is made of plaster of paris (gypsum or calcium sulfate) with the
addition of talc and silica flour to improve strength and to control the time
required for the plaster to set.
b) These components are mixed with water, and the resulting slurry is poured
over the pattern.
c) After the plaster sets (usually within 15 minutes) it is removed, and the mold
is dried at a temperature range of 120o C to 260o C to remove the moisture.
d) The mold halves are assembled to form the mold cavity and are preheated to
about 120o C. The molten is then poured into the mold.
e) Because plasters molds have very low permeability, gases evolved during
solidification of the metal cannot escape. Consequently, the molten metal is
poured either in vacuum or under pressure.
f) Mold permeability can be increased by the Antioch process, in
which molds dehydrated in an autoclave (pressurized oven) for
6-12 hours and then dehydrated in air for 14 hours.
g) Foamed plaster containing trapped air bubbles is another
method used to increase permeability of the mold.
Patterns here are generally made of materials such as
aluminum alloys, thermosetting plastics, brass, or zinc
alloys.
Since there is a limit to th maximum temperature that the
plaster mold can withstand (about 1200o C), plaster-mold
casting is used only for aluminum, magnesium, zinc, and
xome copper-based alloys.
The castings have a good surface finish with fine details.
Molds have lower thermal conductivity than others, the
castings cool slowly, and thus, a more uniform grain structure
is obtained with less warpage.
 ADVANTAGES AND DISAVANTAGES

Advantages:
Good dimensional accuracy and surface finish
Capability to make thin cross-sections in casting
Disadvantages:
Moisture in plaster mould causes problems:
Mould must be baked to remove moisture
Mould strength is lost when is over-baked, yet moisture
content can cause defects in product
Plaster moulds cannot stand high temperatures, so
limited to lower melting point alloys
 Plaster molds cannot withstand the same high
temperatures as sand molds.
They are therefore limited to the casting of lower-melting-
point alloys, such as aluminum, magnesium, and some
copper-base alloys.
Applications include metal molds for plastic and rubber
molding, pump and turbine impellers, and other parts of
relatively intricate geometry.
Casting sizes range from about 20 g (less than 1 oz) to
more than 100 kg (more than 220 lb).
Parts weighing less than about 10 kg (22 lb) are most
common
 Casting Ceramic Mold
Ceramic-mold casting is similar to plaster-mold
casting, except that the mold is made of refractory
ceramic materials that can withstand higher
temperatures than plaster. Thus, ceramic molding
can be used to cast steels, cast irons, and other
high temperature alloys.
Its applications (relatively intricate parts) are
similar to those of plaster-mold casting except for
the metals cast. Its advantages (good accuracy and
finish) are also similar.
Investment Casting