Shell Casting

Dawang Steel Castings Co., Ltd. has more than 5 years of experience in the shell moulding industry and provides high quality shell casting for customers. Seeking affordable mould casting manufacturers? Do not hesitate to contact us.

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Shell Molding Manufacture

Shell casting, is a process that forms a shell by coating fire-resistant materials on a model, heating it to melt and discharge the model, and finally injecting molten metal into the shell. In recent years, shell mold casting process has emerged as a novel casting technique, distinct from both precision casting and sand casting. This innovative approach offers a unique set of advantages in the realm of metal casting.

Shell molds can be crafted from a variety of materials, allowing for versatility in applications. We will assist customers in designing suitable production plans based on their specific needs, reducing production costs and improving production efficiency while ensuring product quality. This flexibility, combined with the process’s precision, makes shell molding an excellent choice for various industries.

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Advantages of Shell Mold Casting

Precision in Shell Molding

For precision manufacturing, we specialize in crafting small castings (up to 40kg) using the shell casting process. The distinctive advantage lies in achieving superior surface precision, reaching an impressive ct11 rating. 

Smooth Casting Surfaces

For large castings ranging from 40kg to 2t, shell mold products outshine their sand casting counterparts. The casting surfaces are smoother and more refined, enhancing customer satisfaction and aesthetic appeal.

Elevated Production Efficiency

Compared to traditional methods, the shell mold casting process significantly reduces production cycles, enhancing overall production efficiency. This streamlined approach ensures swift and efficient manufacturing.

Complex Components Made Possible

Ideal for crafting intricate structures and parts with rich details, our expertise in ceramic shell casting ensures the manufacturing of complex components. This method meets diverse design requirements, providing a versatile solution for intricate and detailed parts.

Consistent and Stable Quality

Achieving uniformity and repeatability in castings is realized through rigorous process control and mold design, ensuring the stability of product quality. This commitment to precision guarantees consistent and reliable results.

Reduced Material Waste

Compared to investment and sand casting processes, shell mold casting minimizes material waste. With a one-time forming capability and no need for tree assembly cutting, it stands out for its superior environmental performance.

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Shell Casting Process

Shell Mold Casting

1. Mold Development

Iron molds have stronger heat resistance and are more suitable for forming shell molds.

Shell-Mold-Casting

2. Shell Mold Manufacture

Fully automatic shell casting production equipment with higher efficiency.

3. Shell Mold Assembly

The precise assembly of shell molds and cores strictly controls the production of complex structural castings.

Melting_Furnace

4. Melting and pouring

Six smelting furnaces work simultaneously, ensuring efficient production and customer delivery time.

Machining_Samples

5. Cleaning

Fine polishing and processing to ensure the surface accuracy of castings.

CNC_3D_inspections

 6. Inspection

Multiple professional testing equipment ensures that each casting meets customer requirements.

Why Choose Us

Dawang Castings started planning for shell casting production in 2018,and now mass production has been achieved. Our team in charge of this research underwent many tests and mass productions that upgraded to a mature shell moulding casting technology. Specifically, Dawang casting can produce high-quality shell castings in a cost-effective solution with finer details. We have planned a complete shell molding process and prepared an automated production line. 

Equipment Capacity

Dawang Factory’s advanced Shell Casting equipment excels in precision and surface quality. We proudly produce highly accurate small parts (10kg-40kg) meeting CT11 standards with fine surface finishes. Our equipment’s worktable dimensions (1.5m x 800mm) enable easy production of large parts (up to 200kg) with a smooth surface. At Dawang Factory, we blend equipment performance and craftsmanship to deliver top-quality shell mold casting products.

Latest Tooling Facility

Dawang Factory employs iron molds, offering exceptional advantages. Iron molds are known for their extended lifespan, superior dimensional precision, and smooth casting surfaces, making them perfect for precision casting. And iron molds provide strength and stability, making them ideal for producing large and heavy components while maintaining reliability.

Quality Assurance

Our Shell Casting products undergo ISIR (Initial Sample Inspection Report) testing to ensure compliance with stringent quality standards. We employ various testing methods, including Radiographic Testing (RT), Non-Destructive Testing (NT), X-ray inspection, as well as tensile strength, pressure, and low-temperature operation testing. These diverse tests guarantee product quality and performance in various aspects.

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Applications of Shell Mould Casting

 

Shell casting is famous for a wide range of industrial applications. Some best examples of shell mould castings are gearbox housing, cylinder head, hydraulic or pneumatic valve bodies, truck hoods, camshafts, engine blocks, automotive transmission parts, manifolds connecting rods, lever arms, drum shells, etc. Besides the products mentioned above, the agricultural, automotive, petrochemical, and construction industries require shell mould casting to create the machinery for their respective fields.

tractor_castings

Agricultural Machinery Casting

Railroad Casting

Railroad Casting

Petrochemical Engineering Casting

Material Handling Equipment

Construction Machinery Casting

Valve Body Casting

Valve Casting

Automobile Casting Parts

Automobile Casting

FAQ

Which is the higher production efficiency between shell casting and investment casting ?

Investment casting is a very ancient casting process, also known as wax loss method. The reason why it is called wax loss method is because during the production process, the shell that needs to be cast is first made with a mold, and then molten steel is melted for casting.
The difference between shell casting process and investment casting process is that the shell casting process uses a mold to directly produce the shell that needs to be cast, and then directly melts molten steel for casting.
The sharp contrast in production steps clearly demonstrates the advantages of shell casting process, which omits tedious steps in shell making and saves a lot of time. So, compared to others, the production efficiency of shell casting process is higher.

Shell moulding vs sand casting

Shell moulding is an upgraded version of the sand casting technique. Sand casting typically uses expandable mould, whereas shell moulding uses a ready-made thin-walled shell. The following points are the direct comparisons of shell moulding vs sand casting.

Shell MouldingSand Casting
Creates a thick shell around the casting patternIt doesn’t need such a technique, and it’s simply expandable
Creates a more refined surface finishProduces a rough surface that needs further machining
Produces tighter tolerancesHave fewer tolerances
Suitable for small and medium-sized castingsSuitable for medium and large-size castings
Has high geometrical accuracyHas low geometrical accuracy
Works both for ferrous and non-ferrous metalsWorks both for ferrous and non-ferrous metals
Easy and cost-effective solutionEasy and cost-effective solution
What materials of castings are suitable for shell casting process ?

A typical shell casting process works with ferrous and non-ferrous metals, such as cast iron, alloy steel, carbon steel, stainless steel, etc. Usually, shell moulding is ideal for small and medium-sized metal castings in most cases. In some cases, this process also creates larger metal shell castings.

If you have any more questions about sand casting, please contact us now.