The Ceramic Shell Mold Process

This process has largely replaced the original block or solid mold
process except for some smaller high volume parts and for some
aluminum casting where the mold is plaster bonded.

The ceramic shell mold technique involves dipping the entire cluster
into a ceramic slurry, draining it, then coating it with fine ceramic
sand. After drying, this process is repeated again and again, using
progressively coarser grades of ceramic material, until a selfsupporting shell has been formed. The shell may be from 3/16 to 5/8
in. thick.
The coated cluster is then placed in a high temperature furnace or
steam autoclave where the pattern melts and runs out through the
gates, runners and pouring cup. This leaves a ceramic shell
containing cavities of the casting shape desired together with a
suitable running and feeding system.

Ceramic mold casting

From Wikipedia, the free encyclopedia

Ceramic mold casting, also known ambiguously as ceramic molding,[1] is a group of metal
casting processes that use ceramics as the mold material. It is a combination ofplaster mold
casting and investment casting.[2][3] There are two types of ceramic mold casting: the Shaw
process and the Unicast process.[4]
These casting processes are commonly used to make tooling, especially drop forging dies, but
also injection molding dies, die casting dies, glass molds, stamping dies, andextrusion dies.[3]
Contents
[hide]

1 Shaw process
2 Unicast process

3 Characteristics

4 References

Shaw process[edit]
The Shaw process, also known as the Osborn-Shaw process, uses a mixture
of refractory aggregate, hydrolyzed ethyl silicate, alcohol, and a gelling agent to create a mold. This
slurry mixture is poured into a slightly tapered flask and a reusable pattern (i.e. the item used to
create the shape of the mold) is used. The slurry hardens almost immediately to a rubbery state (the
consistency of vulcanized rubber). The flask and pattern is then removed. Then a torch is used to
ignite the mold, which causes most of the volatiles to burn-off and the formation of
ceramic microcrazes (microscopic cracks). These cracks are important, because they allow gases to
escape while preventing the metal from flowing through; they also ease thermal expansion and
contraction during solidification and shrinkage. After the burn-off, the mold is baked at 1,800 F
(980 C) to remove any remaining volatiles. Prior to pouring metal, the mold is pre-warmed to control
shrinkage.[2][3]

Unicast process[edit]
The Unicast process is very similar to the Shaw process, except it does not require the mold to be
ignited and then be cured in a furnace. Instead, the mold is partially cured so the pattern can be
removed and it is then completely cured by firing it at approximately 1,900 F (1,040 C). If a metal
with a low melting point is cast then the firing can be skipped, because the mold has enough
strength in the "green state" (un-fired). [5]

Characteristics[edit]
The main advantages of ceramic molds are: a reusable pattern (the item used to create the shape of
the mold), excellent surface finish, close dimensional tolerances, thin cross-sections, and intricate
shapes can be cast. For undercuts and other difficult to cast features, part of the pattern can be
made from wax in conjunction with a standard pattern; essentially using investment and ceramic
mold casting techniques together. The main disadvantages are: it is only cost effective for small- to
medium-sized production runs and the ceramic is not reusable. Ferrous and high-temperature nonferrous are most commonly cast with these processes; other materials cast include: aluminum,
copper, magnesium, titanium, and zinc alloys. [1][2][4]
Weight limits are 100 grams to several thousand kilograms (3.5 oz to several tons). Cross-sections
as thin as 1.3 mm (0.051 in) are possible, with no upper limit. Typical tolerances are 0.1 mm for the
first 25 mm (0.005 in for the first inch) and 0.003 mm per additional mm (0.003 in per each additional
in). A draft of 1 is typically required. The typical surface finish is 24 um (75150 uin) RMS.[2]

Ceramic Mold Casting

The manufacturing process of ceramic mold casting is like the process of plaster mold
casting but can cast materials at much higher temperatures. Instead of using plaster to create
the mold for the metal casting, ceramic casting uses refractory ceramics for a mold material.
In industry, parts such as machining cutters, dies for metalworking, metal molds, and
impellers may be manufactured by this process.

The Process
The first step in manufacture by ceramic mold casting is to combine
the material for the mold. A mixture of fine grain zircon (ZrSiO 4),
aluminum oxide, fused silica, bonding agents, and water, creates a
ceramic slurry . This slurry is poured over the casting pattern and let
set. The pattern is then removed and the mold is left to dry. The
mold is then fired.
The firing will burn off any unwanted material and make the mold hardened and rigid.
The mold may also need to be baked in a furnace as well. The firing of the mold
produces a network of microscopic cracks in the mold material. These cracks give the
ceramic mold both good permeability and collapsibility for the metal casting process.

Figure:29

Once prepared, the two halves of the mold are assembled for the pouring of the metal
casting. The two halves,(cope and drag section), may be backed up with fireclay
material for additional mold strength. Often in manufacturing industry, the ceramic
mold will be preheated prior to pouring the molten metal. The metal casting is poured,
and let solidify. In ceramic mold casting, like in other expendable mold processes, the
ceramic mold is destroyed in the removal of the metal casting.

Properties And Considerations Of Manufacturing By

Ceramic Mold Casting

Manufacturing by ceramic mold casting is similar to plaster

mold casting in that it can produce parts with thin sections,
excellent surface finish, and high dimensional accuracy.
Manufacturing tolerances between .002 and .010 inches are
possible with this process.

To be able to cast parts with high dimensional accuracy

eliminates the need for machining, and the scrap that would be
produced by machining. Therefore precision metal casting
processes like this are efficient to cast precious metals, or
materials that would be difficult to machine.

Unlike the mold material in the plaster metal casting process,

the refractory mold material in ceramic casting can withstand
extremely elevated temperatures. Due to this heat tolerance,
the ceramic casting process can be used to manufacture
ferrous and other high melting point metal casting materials.
Stainless steels and tool steels can be cast with this process.

Ceramic mold casting is relatively expensive.

The long preparation time of the mold makes manufacturing

production rates for this process slow.

Unlike in plaster mold casting, the ceramic mold has excellent

permeability due to the microcrazing, (production of
microscopic cracks), that occurs in the firing of the ceramic
mold.

Shell Mold Casting

Shell mold casting or shell molding is a metal casting process in manufacturing industry in
which the mold is a thin hardened shell of sand and thermosetting resin binder, backed up by
some other material. Shell molding was developed as a manufacturing process during the
mid-20th century in Germany. Shell mold casting is particularly suitable for steel castings
under 20 lbs; however almost any metal that can be cast in sand can be cast with the shell
molding process. Also much larger parts have been manufactured with shell molding. Typical
parts manufactured in industry using the shell mold casting process include cylinder heads,
gears, bushings, connecting rods, camshafts and valve bodies.

The Process
The first step in the shell mold casting process is to manufacture the
shell mold. The sand we use for the shell molding process is of a
much smaller grain size than the typical green sand mold. This fine
grained sand is mixed with a thermosetting resin binder. A special
metal pattern is coated with a parting agent, (typically silicone),
which will latter facilitate in the removal of the shell. The metal
pattern is then heated to a temperature of 350F-700F degrees,

(175C-370C).

Figure:30

The sand mixture is then poured or blown over the hot casting pattern. Due to the
reaction of the thermosetting resin with the hot metal pattern, a thin shell forms on the
surface of the pattern. The desired thickness of the shell is dependent upon the
strength requirements of the mold for the particular metal casting application. A
typical industrial manufacturing mold for a shell molding casting process could be .
3in (7.5mm) thick. The thickness of the mold can be controlled by the length of time
the sand mixture is in contact with the metal casting pattern.

Figure:31

The excess "loose" sand is then removed, leaving the shell and pattern.

Figure:32

The shell and pattern are then placed in an oven for a short period of time, (minutes),
which causes the shell to harden onto the casting pattern.

Figure:33

Once the baking phase of the manufacturing process is complete, the hardened shell is
separated from the casting pattern by way of ejector pins built into the pattern. It is of
note that this manufacturing technique used to create the mold in the shell molding
process can also be employed to produced highly accurate fine grained mold cores for
other metal casting processes.

Figure:34

Two of these hardened shells, each representing half the mold for the casting, are
assembled together either by gluing or clamping.

Figure:35

The manufacture of the shell mold is now complete and ready for the pouring of the
metal casting. In many shell molding processes, the shell mold is supported by sand or
metal shot during the casting process.

Figure:36

Properties and Considerations of Manufacturing by

Shell Mold Casting

The internal surface of the shell mold is very smooth and rigid.
This allows for an easy flow of the liquid metal through the
mold cavity during the pouring of the casting, giving castings a
very good surface finish. Shell mold casting enables the
manufacture of complex parts with thin sections and smaller
projections than green sand mold casting.

Manufacturing with the shell mold process also imparts high

dimensional accuracy. Tolerances of .010 inches (.25mm) are
possible. Further machining is usually unnecessary when
casting by this process.

Shell sand molds are less permeable than green sand molds
and binder may produce a large volume of gas as it contacts
the molten metal being poured for the casting. For these
reasons, shell molds should be well ventilated.

The expense of shell mold casting is increased by the cost of

the thermosetting resin binder, but decreased by the fact that
only a small percentage of sand is used compared to other
sand casting processes.

Shell mold casting processes are easily automated.

The special metal patterns needed for shell mold casting are
expensive, making it a less desirable process for short runs.
However, manufacturing by shell casting may be economical
for large batch production.

Ceramic Shell Molds

Introduction: A process that can be fully automated, ceramic shell molding
is the most rapidly used technique for mold and core making. Also known a
croning process, this casting technique was invented and patented by
J.Croning durign World War II. Also know as the C process, shell molding
technique is used for making thin sections and for acquiring surface finish and
dimensional accuracy.
Process: In the first stage of ceramic shell molding, a metal pattern is made
which is resistant to high temperature and can withstand abrasion due to
contact with sand. The sand and resin mixture for the shell mold is brought in contact with the pattern.
The mold is placed in an oven where the resin is cured. This process causes the formation of a thin shell
around the pattern. The thickness of the mold can be 10-20mm as compared to the heavy mold made
for sand castings. When fully cured the skin is removed from the pattern, which is the shell mold.
For each ceramic shell molds there are two halves know as the cope and drag section. The two
sections are joined by resin to form a complete shell mold. If an interior design is required, the cores are
placed inside the mold before sealing the two parts.
For heavy castings, ceramic shell molds are held together by metals or other materials. Now, the molten
metal is poured into the mold, and once it solidifies, the shell is broken to
remove the casting. This process is highly useful for near net shape castings.
Another advantage is that shell molding can be automated.
Automated Ceramic Shell Molding Machines and Robots: Shell molding
machines like the cold shell molding machines helps in making castings with
little molding material. In a cold shell molding machine the molds are made
using cold binding materials. In it patterns made of wood, metal or plaster

can be used. And the greatest benefit is that the mold can be kept horizontally or vertically.
Robotizing: Using robots for ceramic shell molding is a milestone for the old molding technology.
Robots which are multi functional and re programmable are used in some foundries. Robots are used for
a number of activities like robotic gate and sprue removal, robotic cutting of wedges for gate valves,
robotic core setting, etc. The robots are reliable, consistent, more productive, provides better surface
finish, and less machining etc.
Applications: A sizable amount of the casting in the steel industry are made by shell molding process,
that ensures better profitability. Carbon steel, alloy steel, stainless steel, low alloys, aluminum alloys,
copper, are all cast using shell molding process. Casting that require thin section and excellent
dimensional accuracy are cast using this process. Body panes, truck hoods, small size boats, bath tubs,
shells of drums, connecting rods, gear housings, lever arms, etc. are cast using croning process.
Advantages:

Thin sections, complex parts and intricate designs can be cast

Less machining required for the castings

Near net shape castings, almost 'as cast' quality

Simplified process that can be handled by semi skilled operators

Full mechanized and automated casting process

Less foundry space required.

Excellent surface finish and good size tolerances

CERAMIC SHELL MOLDS FOR SCULPTURAL CASTINGS 11 Ceramic Shell Molds for
Sculptural Castings Garrett Krueger Faculty Sponsor: Cambid-J Choy, Department of
Art ABSTRACT The research for the process of ceramic shell mold making was done
by first studying the ceramic shell method and then comparing and contrasting it
with other methods I have used: resin-bonded-sand and traditional investment. The
results showed both the advantages and disadvantages of the shell method as
compared with the other mold making techniques. Differences in size and weight,
time of creation, and the outcome of the final casting were all factors that were
considered when figuring the results for this research project. INTRODUCTION Metal
casting has been used for centuries to produce many items that can be useful and
aesthetically pleasing and interesting. There are many different ways to create a
casting, but they all involve the same basic principles. First, an original pattern is
created. This is the form that will later be cast in metal. It is usually created in wax
or some other moldable material. Next, a mold is made around this pattern. This
mold is made of materials that will not only be able to capture the detail of the
original pattern, but will also be able to withstand the heat and pressure of the
molten metal. Once the mold is completed, the original pattern is removed and a
negative impression is left. Molten metal is then poured in, filling the impression left
by the original pattern. Once the metal has cooled, the mold can be opened, and
the final casting can be removed. Different techniques are used to create metal
castings. I researched the ceramic shell mold making method in order to compare it

with the other methods I have used (resin-bonded-sand and traditional investment).
Each method has the ability to capture a different amount of detail in the final
casting. Also the time and work in making the mold and cleaning the casting after it
has been poured vary between the different mold types. I researched the method of
ceramic shell mold making to determine if it was a superior method than the others
I have used. METHODS The first method I learned was resin-bonded-sand. In this
method, a pattern is taken and a mold is created out of silica sand and sodium
silicate, a resin that hardens the sand and allows it to retain a shape. Sand molds
are often done in two or more parts so that the mold can be opened in order to
remove the pattern. Once the pattern is removed, channels for pouring metal and
venting gasses, called sprues, are carved into the hardened sand. The sand mold is
then bound back together, and the metal is poured in. The sand mold took about
two days to make and weighed approximately 55 lbs. The next mold method I
learned was traditional investment. This method involves a wax pattern with the
sprues for pouring and venting created in wax and attached to the pattern. A12
KRUEGER one piece, cylindrical mold is made around the pattern out of plaster and
silica sand. Since it is a one pieced mold and cannot be taken apart, the wax pattern
must be burnt out of the mold. This is done by placing the mold in a special kiln
upside down. This gets rid of both the wax and any moisture that may be left in the
mold. Once the mold is cleaned out, it must then be removed from the kiln and
immediately poured into. If the mold is not hot when the molten metal is poured
into it, thermal shock will occur, causing miscasting and a potential for danger
towards the people pouring, due to metal being spit back. Because of thermal
shock, metals that have a high melting point, such as iron, cannot be poured into
investment molds. The investment mold, used on the same pattern as was used for
the sand mold took about a half hour to make. However, the burnout took three
days. The final mold weighed approximately 120 lbs. The ceramic shell method is
similar to the traditional investment method. A wax pattern is created with a sprue
system attached to it. A one-piece mold is created around the pattern, which must
then be melted out of the mold. However, there are several differences. One is the
makeup of the mold. Ceramic shell molds are made from slurry and stucco. The
slurry is a liquid binder, which is silicon dioxide (SiO2) particles suspended in water.
These materials allow the mold to withstand great amounts of heat and pressure, so
thermal shock is not as big of a concern as in traditional investment. Also, this type
of mold allows gasses to vent through its sides, so the sprue system is less intricate
than the one used in investment molds. The shell also takes longer to make. The
pattern is dipped in the slurry, and then the stucco sand is applied. Now the piece
has to dry, which takes 12 to 24 hours. Once it has completely dried, another layer
is applied. This is done until approximately eight layers have been built up. This
takes about eight days to complete. Once the mold is completely built up. The wax
pattern is burnt out. This takes less than an hour, a significantly less amount of time
than the three days to burn out the investment mold. Another difference is the size
and weight of the mold. The shell mold of the same pattern used for both the sand
and investment molds only weighed 2.5 lbs., considerably less than either of the
others. RESULTS I made eleven castings during my research. Since I had worked
with resin-bonded-sand and traditional investment in the past, I only made one of
each for this project. I had varied results with the nine shell molds I had made. One

of the first things I learned was that the slurry had to be maintained. It had to
constantly be mixed and the amount of moisture had to be constant. I hadnt
properly maintained the slurry and evaporation took place. This caused the interiors
of one of the shell molds to weaken and the final castings surface had a chipped or
broken texture. Another problem I faced was proper venting. Even though the shell
mold allows gasses to vent out through its sides, it still needs an adequate amount
of venting with the sprues. About three of my molds had gasses trapped in them,
and the metal didnt fill the patterns completely. These are problems that cannot
usually be detected prior to pouring, so they are discovered after the piece has
been cast. The successes I had with the shell method were great. The sprue
systems were less intricate, and therefore they required less time and effort to
remove and clean up than the investment mold. Also there was less flashing in the
shell than in the sand and investment molds. Flashing is when molten metal fills
into tiny cracks along the surface of the molds interior pattern. The flashing has to
be chiseled off of the casting and is slightly detectable inCERAMIC SHELL MOLDS
FOR SCULPTURAL CASTINGS 13 the final piece. On the shell casting, there was
almost no flashing at all. There was also a greater amount of detail in the final
castings. The surface texture of the metal is as smooth or textured as it was in the
original wax pattern. Because of the placement of the complex sprue system in the
investment mold, some details and surface textures were lost. The sand mold
captured less detail due to the sand grains that make up the mold. The final casting
has a slightly sand like texture to it. But the shell molds liquid slurry allows it to fill
in and capture the tiny details that other methods cant. CONCLUSIONS I feel that
this research has allowed me to broaden my knowledge base in the technical field of
sculpture. I am now able to easily choose the method of mold making that better
fits my purposes. The ceramic shell method of mold making, once understood, is a
highly effective way to create metal castings. Still, like resin-bonded-sand and
traditional investment, problems can and will occur. But in terms of weight of the
mold, resistance to heat and pressure, and detail in the final casting, I see the
ceramic shell as a slightly superior method than the other two I have used. But
matters of time and available materials make the other methods necessary and
useful as well. My research has also introduced the ceramic shell method to the
advanced sculpture class here on the UW-La Crosse campus. It has returned mostly
successful results and will most likely be used by both the advanced class and me in
the future. ACKNOWLEDGEMENTS I would first like to thank the UW-L Undergraduate
Research Committee for funding this project. My deepest thanks go out to my
faculty sponsor, Cam Choy, for all the time and effort he put into helping me in my
research. I would also like to thank Dan McGuire, sculpture professor at UWWhitewater, for the information he provided me with, and the technical department
at Ransom & Randolph Dents ply for all the assistance they gave me. Finally, I would
like to thank classmate Tracy Inlow for taking slides for me, allowing me to
document and understand my successes and failures. REFERENCES Fennell, Robert
A., Young, Ronald D., Methods for Modern Sculptors United States of America:
Ronald D. Young and Robert A. Fennel, 1980. Ceramic Shell Manual, Ransom &
Randolph Dents ply.