Non - Ferrous Shell Mold Casting

Non - Ferrous Shell Mold Casting: Manufacturer, Supplier.

Indo German Shell Cast has established itself as a premier manufacturer and supplier of non-ferrous shell mold castings in the industry. Manufacture of all grade of brass Gun metal aluminium. Further,we also handle sand moulding, shell moulding. We are a professionally managed company with the required expertise in different fields and we complete our deliverable within the scheduled time to create satisfied customers.

Process:

Shell mold casting for non-ferrous metals is a refined casting process that uses a thin walled shell made from a sand resin mixture to form molds, enabling the production of high precision components. Non-ferrous metals commonly cast using this method include aluminum, copper, brass and bronze alloys which are favored for their low weight, corrosion resistance and excellent thermal and electrical conductivity. The process begins with the creation of a reusable metal pattern, often made of steel or aluminum. This pattern is heated to a specific temperature and coated with a lubricant to prevent sticking. A dump box containing resin coated sand is inverted over the heated pattern, allowing the sand to adhere and partially cure into a shell. The shell is then fully cured in an oven to achieve sufficient strength before being removed from the pattern.

The shell halves are assembled using adhesives or clamps and cores are inserted if required to create hollow sections or variety of shapes. The assembled mold is placed in a flask and supported with backing material for stability during the pouring process. Molten non-ferrous metal is poured into the mold cavity through a flow control system, filling the precise contours of the shell. Once the metal solidifies and cools, the shell mold is broken away to reveal the casting. Post casting processes such as trimming and surface finishing are performed to remove excess material and achieve the desired specifications.

This method is widely used in diverse industries for components like engine parts, pump housings, electrical connectors and decorative items. Shell mold casting excels in producing small to medium sized parts with elaborate designs and high dimensional accuracy while maintaining compatibility with the unique properties of non-ferrous metals.

Benefits

• High Dimensional Precision: Shell mold casting ensures accurate dimensions, making it suitable for varied non-ferrous metal parts.
• Superior Surface Finish: The resin coated sand provides a smooth surface finish, reducing the need for extensive post processing.
• Complex Shapes: This process allows the creation of detailed and complex shapes, ideal for non-ferrous metal components.
• Wide Material Compatibility: It supports various non-ferrous metals like aluminum,copper and brass, offering flexibility in material selection.
• Efficient Production Rates: Reusable patterns and quick mold preparation enable faster fabrication cycles for large scale manufacturing.
• Reduced Defects: The absence of moisture in the mold minimizes issues like gas porosity or bubbling during casting.
• Economical for High Volumes: While setup costs are higher, the process becomes economical for mass production of non-ferrous parts.

Applications :

• Engine Components: Shell mold casting is used to produce non-ferrous engine parts like cylinder heads and intake manifolds with high precision.
• Pump Housings: Non-ferrous pump housings such as those made from aluminum or bronze, are cast for corrosion resistance and durability.
• Electrical Connectors: This process is ideal for creating copper based electrical connectors due to its ability to handle intricate designs.
• Aerospace Parts: Low weight aluminum components for aerospace applications such as brackets and housings, are manufactured using shell mold casting.
• Valve Bodies: Shell mold casting produces precise valve bodies for fluid control systems in industries like oil and gas.
• Heat Exchanger Components: Aluminum and copper parts for heat exchangers are cast to ensure efficient thermal conductivity..
• Automotive Components: Critical automotive parts such as transmission cases and steering components are made using this method for accuracy and performance.