Department of Foundry Technology, NIAMT Ranchi

Process Variables Affecting Product

Quality & Characteristics
Pouring temperature
Calculated Pouring time
Type of Alloy
Department of Foundry Technology, NIAMT Ranchi

These are the deciding factors for

Additives used
Shell thickness and other variables.
 Advantages
The Shell Moulding process has several unique
properties
1. Excellent Surface Finish even with fine details.
2. Longer Shelf Life: shell sand has Indefinite Shelf
Department of Foundry Technology, NIAMT Ranchi

Life if stored properly.

3. Hollow Cores: Hollow Cores & Even Thin Profile
Mould is possible, hollow cores improves
permeability so even fine sand can be used.
4. Ease of Handling: have exceptional resistance to
damage and humidity.
 5. Resistance to Moisture: higher resistance and
can be stored even in humid conditions. Resin
used is very stable & Moisture resistant.
6. Excellent Flowability: Dry coating on sand
gives better flowability & blowing ability,
which helps in producing intricate cores and
Department of Foundry Technology, NIAMT Ranchi

mould which can be blown to a greater

density.
7. Less Inclusion & High Thermal Stability: less
prone to erosion by molten metal due to
higher thermal stability of phenolic resin,
reducing casting defects.
8. Lesser Pattern wear: Metallic pattern used
 9. Draft allowance zero, as mould broken to
obtain the product, reducing cost.
10. Relatively smooth mould wall, which offer
low resistance and can produce casting with
sharp corners & thinner sections.
Department of Foundry Technology, NIAMT Ranchi

11. Versatile as can be used for Ferrous & Non

Ferros.
12. Flexible for Automation.
 Limitations
1. High Cost of Process: phenolic resin (used in
higher percent ) used is costly.
2. Separation of resin from sand in the end of
process.
Department of Foundry Technology, NIAMT Ranchi

3. Thicker shell thickness needed for bulky casting,

but chances of breaking of shell increases with
increase in weight of casting.
4. Slow curing rate, heterogeneous mixture of sand
& resin (phenolic resin dissolved in alcohol used
for improvement)
 6. High Tooling Cost: Thermoset in nature, require
higher curing temperature.
7. Higher Cycle Time
8. Limited Casting Weight: best suited for small,
intricate & light weight casting upto 80 kg.
Department of Foundry Technology, NIAMT Ranchi
 Application
Widely accepted for products where accuracy &
surface finish are of prime importance.
Automobile sectors
Hydraulic application
Department of Foundry Technology, NIAMT Ranchi

Gear housing
Connecting rods
The main application is in mass production of:
Near to net shape castings particularly in small
to medium scale range.