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Book: Casting
Series: ASM Handbook
Volume: 15
Publisher: ASM International
Published: 01 December 2008
DOI: 10.31399/asm.hb.v15.a0005252
EISBN: 978-1-62708-187-0
... Abstract Shell molding is used for making production quantities of castings that range in weight from a few ounces to approximately 180 kg (400 lb), in both ferrous and nonferrous metals. This article lists the limitations or disadvantages of shell mold casting. It describes the two methods...
Abstract
Shell molding is used for making production quantities of castings that range in weight from a few ounces to approximately 180 kg (400 lb), in both ferrous and nonferrous metals. This article lists the limitations or disadvantages of shell mold casting. It describes the two methods for preparation of resin-sand mixture for shell molding, namely, mixing resin and sand according to conventional dry mixing techniques, and coating the sand with resin. Shaping of shell molds and cores from resin sand mixtures is accomplished in machines. The article discusses the major steps in producing a mold or core and describes the problems most frequently encountered in shell-mold casting. The problems include mold cracking, soft molds, low hot tensile strength of molds, peelback, and mold shift. The article concludes with information on examples that provide some relative cost comparisons between shell molding and green sand molding.
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Published: 01 December 2008
Fig. 28 Cost of shell molding versus green sand molding for production of a chair seat bracket in ascending quantities. Pattern costs not included
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Published: 01 December 2008
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Published: 30 November 2018
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Published: 01 December 2008
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Published: 01 December 2008
Fig. 2 Shell-mold castings. (a) Shell-mold casting. (b) Wheel cylinder with O-ring grooves. (c) crankshaft
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Published: 01 December 2008
Fig. 3 An intricately cored value body cast in a shell mold. This shape was economically producible only by the casting process. Cored passages between individual chambers are not visible in the above views.
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Published: 01 December 2008
Fig. 17 A thin-wall casting that was successfully produced in a shell mold from magnesium alloy AZ63A. Rejection rate was less than 5%.
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Published: 01 December 2008
Fig. 6 Unusual padding of the center cavity of this stainless steel shell mold casting simplified production. Without the padding, complicated risering would have been necessary and would have caused high residual stresses.
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Published: 01 December 2008
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Published: 01 December 2008
Fig. 5 Motorcycle cylinder that was cast in a shell mold made using the cope-and-drag pattern shown
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Published: 01 December 2008
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Published: 01 December 2008
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Published: 01 December 2008
Fig. 8 Steps in making a shell mold by the dump-box technique. (a) The pattern is rotated and clamped to the dump box. (b and c) The box is then rotated 180° to make the investment. (d) Pattern and shell are removed from the box. Voids (c) and resulting peelback (d) are disadvantages
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Published: 01 December 2008
Fig. 9 Production of a shell mold by the dump-box method in which pattern and dump box are rotated at high speed on a circular track. (a) Rotation. (b) Rollover. (c) Reverse rotation
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Published: 01 December 2008
Fig. 10 Steps in the production of a shell mold by the use of a louver-type dump box. (a) Pattern raised into dump box. (b) Pattern clamped to dump box, and louver retracts to dump sand onto the pattern. (c) Pattern and dump box inverted, and excess sand falls. Louver returns. (d) Original
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Published: 01 December 2008
Fig. 11 Cross sections of blown shell molds of three different structural shapes. (a) Outer surface contoured to pattern. (b) Open-back box. (c) Closed (hollow) box
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Published: 01 December 2008
Fig. 12 Two types of machines for blowing shell molds. Machine in (a) is shown as used for blowing an open-back box mold ( Fig. 11 ) but is also used for molds whose outside surface is contoured to pattern ( Fig. 11 ). Machine in (b) is used for blowing closed (hollow) box molds ( Fig. 11 ).
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Published: 01 December 2008
Fig. 14 Electric ovens for curing shell molds. Heating elements normally located under ceiling of oven, as shown in (a), may be augmented by elements along inner side walls (b) to prevent overcuring of high portions of a mold.
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Published: 01 December 2008
Fig. 15 Blast-tip gas-fired manifold oven (a) for curing shell molds. Oven can be fitted with extension burners (b) for directing heat into mold cavities.
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