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Shell Core Casting
A process that can be fully automated, shell molding is the most rapidly used technique for molding, and as well, as core making.
Also known as The Croning Process, this casting technique was invented and patented by J.Croning during World War II.
Also know as the “C” process, shell molding technique is used for making thin sections and for acquiring surface finish and dimensional accuracy.
How Process Works: In the first stage of shell molding, a metal pattern is made which is resistant to high temperature and can withstand abrasion due to contact with sand. The sand and resin mixture for the shell mold is brought in contact with the pattern. The mold is placed in an oven where the resin is cured. This process causes the formation of a thin shell around the pattern. The thickness of the mold can be 10-20mm as compared to the heavy mold made for sand castings. When fully cured the skin is removed from the pattern, which is the shell mold.
For each shell molds there are two halves know as the cope and drag section. The two sections are joined by resin to form a complete shell mold. If an interior void is required, specially sized cores are placed inside the mold before sealing the two parts.
For heavy castings, shell mold are held together by metals or other materials. Now, the molten metal is poured into the mold, and once it solidifies, the shell is broken to remove the casting. This process is highly useful for near net shape castings. Another advantage is that shell molding can be automated.
Advantages: A sizable amount of the casting in the steel industry are made by shell molding process, that ensures better profitability. Carbon steel, alloy steel, stainless steel, low alloys, aluminum alloys, copper, are all cast using shell molding process. Casting that require thin section and excellent dimensional accuracy are cast using this process. Body panes, truck hoods, small size boats, bath tubs, shells of drums, connecting rods, gear housings, lever arms, etc. are cast using Croning Process.
Thin sections, complex parts and intricate designs can be cast
Excellent surface finish and goal size tolerances
Less machining required for the castings
Near net shape castings, almost 'as cast' quality
Simplified process that can be handled by semi skilled operators
Full mechanized and automated casting process
Less foundry space required.
How it works Illustration
Examples of Shell Core produced Parts
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