SHELL MOLDING SERVICES

SUPER VAC’S SHELL CASTING PROCESS

For high production rates and superior dimensional accuracy, customers look to Super Vac’s shell molding services. This process delivers an expendable mold used to cast aluminum parts. The mold is made from a thin “shell” of resin sand that is broken apart to reveal the cast part. Super Vac offers the largest shell core machine in Colorado, which can accommodate core boxes that weigh up to 2,500 lbs.

Casting Metal Types

The Shell Casting Process

Part Examples

Casting Metals

We use the following casting metals in our shell casting process:

Aluminum Foundry

• 319 Aluminum (319SR)
• 356 Aluminum (356.2)
• 535 Aluminum (535.2)
• 713 Aluminum (713.1)

The Shell Casting Process

STEP 1 THE SHELL MOLDING PROCESS

Before shell casting can begin, the shell mold must be created first. First, a two-piece metal pattern, typically made from iron, is created in the shape of the desired part. Each half is inserted into the shell core machine and heated to 400° F. Meanwhile, resin-coated sand is poured into the machine. Once the patterns have been heated, the press closes the two halves together and inverts the cradling, allowing for the sand to coat the pattern; at 200° F, the sand cures to form the shell mold, which is then ejected from the pattern. These molds can then be used for shell casting.

STEP 2 THE SHELL CASTING PROCESS

Once the two shell halves have been created, they are clamped together and placed into a pouring flask to form the complete shell mold. (During this step, shell or CO2 cores can be inserted to create hollow parts.) Molten metal is then poured into the shell mold cavity and left to cool, solidifying into the final casting. After the metal has cooled, the casting is removed by breaking the shell mold.

Shell Casting Products

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