Shell mold casting is a popular casting process that is used to produce complex shaped parts in high quantities.It is also called pre-coated resin sand casting, core casting,hot shell molding casting
This process involves molding a thin-walled shell around a pattern that is made of metal or wax. The shell is made of a mixture of sand and a thermosetting resin binder that hardens when heated.
Shell mold casting parts have many benefits, such as superior surface quality, tighter dimensional tolerance, intricate geometric structure, and fewer casting defects.
Shell Mold Casting Capabilities
At HXN, our fully equipped facility and knowledgeable engineering team allow us to design and manufacture the shell mold casting parts (precoated sand casting parts) as per your drawings, specific requirements, and samples to meet or exceed your expectations.At the same time, we can provide feasible and the best cost-effective to match your custom requirement for different material industry requirements.
Our superior shell mold casting parts are used across heavy-duty trucks, energy, farm machinery, rail trains, pumps and valves as well as construction machinery, etc.
You will find a brief introduction shown below to what we could achieve in the shell mold casting process:
• Maximum Size: 1,000 mm × 800 mm × 500 mm
• Weight Range: 0.5 kg - 100 kg
• Annual Capacity: 2,000 tons
• Tolerances: On demand
Shell Mold Casting Steps
1. Pattern Making: The first step in shell mold casting is the creation of a pattern of the desired part. This pattern can be made of metal, wood, or wax.
2. Shell Mold Creation: A shell mold box is made by placing the pattern in a box filled with sand mixed with a thermosetting resin binder. The sand mixture is then vibrated to fill all the voids.
3. Curing the Shell Mold: The shell mold is cured by heating it in an oven to a temperature that causes the resin to harden. Once the shell is hardened, it is removed from the pattern.
4. Pouring the Molten Metal: The shell mold is then placed in a pouring cup and molten metal is poured in the shell. The metal fills the voids in the shell and takes on the shape of the pattern.
5. Cooling the Mold: The metal cools and solidifies quickly due to the thin walls of the shell mold. The shell is then broken away to reveal the finished part.
6. Cleaning and Finishing: The finished part is then cleaned and finished to remove any excess material or imperfections.
Overall, shell mold casting is a highly effective and efficient process that produces accurate, complex parts in high quantities. By following these steps with care and attention, high-quality parts can be produced in an efficient and timely manner.
Advantages of Shell Mold Casting
Shell mold casting is a popular manufacturing process that is used to produce high-quality metal parts. It is a flexible process that is suitable for producing a wide range of parts with varying sizes and complexities. The process involves creating an expendable mold using a mixture of sand and resin, which is then heated to cure the mold and create a hard shell.
One of the advantages of shell mold casting is that it is a cost-effective process. The initial setup costs are relatively low, and the production process is efficient, which makes it a cost-effective option for producing large quantities of parts. Additionally, the process is highly repeatable and can produce parts that are consistent in terms of size and shape.
Another benefit of shell mold casting is that it produces parts with a high level of precision and accuracy. The molds are created using a pattern that is precisely machined to the desired shape and size, ensuring that the final product is also precise. This makes it an ideal process for producing parts that require a high degree of accuracy, such as engine components or aerospace parts.
Shell mold casting is also a versatile process that can be used to produce parts from a wide range of materials. The process is suitable for casting parts from various metals, including aluminum, copper, brass, and steel. This makes it a popular option for manufacturers working in industries such as automotive, aerospace, and construction.
Finally, shell mold casting is a speedier process than other manufacturing methods. The molds are heated quickly, and the molten metal is poured into the mold, allowing the product to be produced quickly. This means that shell mold casting is an ideal process for manufacturers that need to produce parts quickly to meet demand.
In conclusion, shell mold casting is a cost-effective, highly precise, versatile, and efficient process for manufacturing metal parts. It is a popular option for manufacturers in various industries who need to produce large quantities of parts quickly and accurately.
More Services We Could Provide
Apart from the above shell mold casting services, we can also provide the value-added services of post- processes. Some of them are finished at our long term partners, but some are produced at our in-house workshops. our integrated source capability can allow us to offer you a one-stop service.
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