Number of Castings Required. - Dimensional Accuracy Required. - Economics
Number of Castings Required. - Dimensional Accuracy Required. - Economics
Disadvantages:
– Normally used for smaller parts.
– Relatively expensive.
The shell casting process, also called the Dump
box process, is the process in which dry and fine
sand mixed with resin is allowed to come into
contact with heated metallic pattern, so that a thin
and strong shell of mould is formed around the
pattern.
The shell is removed from pattern. After that the
shell is placed into the flask with necessary back
up materials and the molten metal is poured into
the mould.
All metals can be casted in investment process.
Applications: Cylinders and cylinders heads for
IC engines, small crank shafts, and automobile
transmission parts, and brake arm.
Steps 1: A metal pattern is heated and
placed over a box containing sand
mixed with thermosetting resin
Disadvantages:
– Curing takes too long to render it unsuitable for
volume production.
• Similar to sand casting in terms of process
except the mold is made from plaster of Paris
(Gypsum).
• In mold-making, plaster and water mixture is
poured over plastic or metal pattern and allowed to
set
– Wood patterns not generally used due to
extended contact with water
• Plaster mixture readily flows around pattern,
capturing its fine details and good surface finish
• Plaster mold is for lower temperature alloys
Advantages:
– Good surface finish and dimensional control.
– Capability to make thin cross sections.
Disadvantages:
– Curing takes too long to render it unsuitable for
volume production.
– Mold must be baked to remove moisture
• Moisture can cause problems in casting
– Mold strength is lost if over-baked
– Plaster molds cannot stand high temperatures
• Limited to lower melting point alloys
• Similar to plaster except that mold is made of
refractory ceramic material that can withstand
higher temperatures than plaster.
• Can be used to cast steels, cast irons, and other
high temperature alloys
• Advantages (good accuracy and finish) also
similar
Step 1: Thin pre-heated plastic sheet
sucks onto the vacuum vented pattern
surface.