Shell molding:

 Also called shell-mold casting

 An expendable mold casting process
 Mold is a thin shell made up of patterns( 2 symmetric halves) created from sand held
together by thermosetting resin binder.

Steps:

1. Pattern creation: A two-piece metal pattern is created in the shape of the desired part.
Since the sand resin mixture is to be cured at about 150°C temperature, only metal patterns
with the associated gating are used. The metal used for preparing patterns is gray cast iron,
mainly because of its easy availability and excellent stability at the working temperatures .
2. Mold creation:
 The metallic pattern plate is heated to temperature of 200 to 350°C depending on
the type of the pattern. It is essential that the pattern plate is uniformly heated so
that the temperature variation across the whole pattern is within 25 to 40°C
depending on the size of the pattern. A silicone release agent is sprayed on the
pattern and the metal plate which acts as lubricant to facilitate easy removal .
 Next, the heated pattern is clamped to a dump box, which contains a mixture of
sand and a resin binder. (Fig.-1)
Sand : Generally, dry and fine sand that is completely free of clay is used and the
sand should not be too fine which will require more resin which is expensive.
Resin: Normally thermosetting synthetic resins (e.g., phenol formaldehyde (mostly
used), urea formaldehyde, polyester resin) are used which get irreversibly hardened
upon heating.

Additives may be sometimes added into the sand mixture to improve the surface
finish and avoid thermal cracking during pouring. Some of the additives used are
coal dust, pulverised slag, manganese dioxide, calcium carbonate, ammonium
boroflouride and magnesium silicofluoride.

Some lubricants such as calcium stearate and zinc stearate may also be added to the
resin sand mixture to improve the flowability of the sand and permit easy release of
the shell from the pattern.
 The dump box is inverted, allowing this sand-resin mixture to coat the pattern. The
heated pattern partially cures the mixture, which now forms a shell around the
pattern. (fig.-2)
 When a desired thickness of shell is achieved, the dump box is rotated backwards by
180 degrees so that the excess sand falls back into the box, leaving the formed shell
intact with the pattern.(fig.-3)
 Each pattern half and surrounding shell is cured to completion in an oven ( electric
or gas fired) and then the shell is ejected from the pattern. (Fig.-4)

Mold assembly: Shell halves are stripped from the pattern (fig.-5) and joined together
by either mechanical clamping or by adhesive bonding. The resin used as an adhesive
may be applied at the parting plane before mechanical clamping and then allowed for
 20 to 40 s for achieving the necessary bonding. Finished shell mold ready for pouring is
then kept inside a flask where it is supported by sand or metal shots . (fig.-6)

Pouring and cooling: Then molten metal is poured from aladle into the gating system
and fills the mold cavity and when the mold cavity is completely filled , the molten metal
is allowed to cool and solidify into the shape of the final casting.

Casting removal : After the molten metal has cooled, the mold can be broken and the
casting removed. Trimming and cleaning processes are required to remove any excess
metal from the feed system and any sand from the mold.

The machine that is used for this process is called a shell molding machine. It heats the
pattern, applies the sand mixture, and bakes the shell.

Advantages:

- Very large parts possible

- Accurate shapes with good dimensional accuracy and better surface finish
- Reduced machining costs
- Low tooling and equipment costs
- Can be completely automated for mass production
- High production rate and low labor costs if automated
- Smoother cavity surface permits easier flow of molten metal
- Mold collapsibility usually avoids cracks in casting
- Very less problem due to gases as they can escape easily through the thin
shell and also moisture is absent.

Disadvantages:

- More expensive metal pattern and only economical in mass production

- High porosity possible
- Sophisticated equipments are required for handling heated metal patterns

Applications:

Cylinders and cylinder heads for air cooled IC engines, gear blanks, automobile
transmission parts and refrigerator valve plate etc.

- -

Fig.-3

Fig.-1 Fig.-2
Fig.-4 Fig.-5

Fig.-6