Shell Molding Process Guide - The Eagle Group

SHELL MOLDING PROCESS
EAGLE GROUP
Prepared by Jeff Cook
Vice President, Sales and Marketing
Eagle Alloy, Inc.
with support from Kyle Wenning
www.eaglegroupmanufacturers.com
TABLE OF CONTENTS
1 | Introduction to the Shell Mold Process
2 | Shell Process Chemistry
3 | Shell Core Production
4 | Molding Process
5 | Pouring
6 | Surface Finish
7 | Comparison to Other Casting Methods
8 | Shell Mold Buyers Guide
9 | Glossary of Terms
CHAPTER 1
Introduction
to the Shell
Mold Process
EAGLE GROUP | 03
The Shell Mold Process J. C.
Chapter 1
Introduction to
the Shell Mold
Process
Introduced in the U.S. after The shell molding process is
World War II, shell molding is known for being able to hold
one of the least understood relatively tight tolerances and,
forms of metal casting. In this with the use of cores (see
article, we will break down p.8), more complex parts can
the facts and rule out some be cast. Shell molding uses
common misconceptions preheated cast iron or steel
about this metal casting tooling to “bake” molds and
process. cores with a hardened shell.
This allows for a much
We will also illustrate how smoother surface finish
shell molding stacks up compared to other sand
against other casting casting finishes.
processes, such as
investment and greensand, Common industries that use
and we will offer a basic, step- shell molding to cast
by-step overview of how the parts: valve manufacturers,
shell molding process works oil and natural gas,
—and how it can help you construction equipment and
agriculture manufacturers.
procure quality castings.
CHAPTER 2
Shell Process
Chemistry
EAGLE GROUP | 05
Chapter 2
Shell Process Chemistry
Sand + Phenolic + Hexamethylenetetramine (hexal)

Resin→ ∆Heat → Cooling → Resin Coated Sand → ∆Heat → Cured Core or Mold
As shown above, the shell molding process begins with resin-

coated sand. The resin melts when heat is applied, bonding sand
grains. When the sand cools, the grains are permanently bonded.
This resin-coated, heat-bonded sand becomes the "shell" of

the mold.
CHAPTER 3
Shell Core
Production
EAGLE GROUP | 07
Chapter 3
Shell Core
Production “You have to keep in mind the
mechanical and physical
limitations of the core itself.”
-Larry Stahl of General Motors
Cores are one of the most

important and versatile Engineers must design core
components used in the boxes to ensure they are
metal casting industry, and giving their customers the
the reason castings often most economical design that
appeal to customers still holds up to the intense
compared to a fabricated factors to which they are
design. subjected during the process.
Without cores, the casting A core must remain strong

industry would not be able to enough to hold the
provide customers with dimensional tolerances that
intricate shapes and the application requires. Hot
designs. A lot goes into their and cold tensile strengths are
production, and there are important for cores and are
many factors involved in monitored by most foundry
making sure that they will quality departments to
stand up to forces that will be ensure that cores will not
applied when the metal is break from the extreme
poured. conditions.
Here, we will discuss long run production cores, and the shell

process it takes to make them.
A common sand used to make cores is a mixture that includes

silica and a resin that, when heated, binds the sand together to
create a solid core (see p.6). The resin used to make cores
generally reacts around 550 F˚ (287 C). This is why coreboxes are
preheated, like the one shown below.
After the coreboxes have been heated, the core sand will be
blown into the corebox cavity and set to cure for a specific
amount of time. When the desired thickness of the core’s wall is
reached, the rest of the sand will be poured back out, leaving the
core hollow. Since coreboxes have to be able to withstand high
temperatures, they are generally made of cast iron or steel;
however, ceramic is sometimes used as well.
(A typical U180 shell core machine heating up)
CHAPTER 4
Molding
Process
EAGLE GROUP | 10
Chapter 4
Molding Process
The shell molding process is very unique in the metal casting
industry. Like coring, this step requires tooling that must be able
to withstand a lot of heat. What enables this to be a cost effective
solution is the end product that this process provides. The shell
patterns usually last for the lifetime of the project, but the shell
molds used in the process are not reusable, and after the metal
is poured the molds are destroyed.
A unique benefit of shell molds is their ability to be stored, which

often reduces lead times to the customer.
(An example of a 30x40 shell plate with the cope side of the

tool on the right and the drag side on the left. Draft applied to
all “vertical” surfaces allows the mold to lift off of the pattern.)
These molds are made in a similar fashion to the cores. Again,

patterns are usually made out of cast iron or steel. Each pattern
is heated, and the resin-coated sand is applied in a gentle, non-
erosive manner. The sand-covered pattern is left to stand for
varying amounts of time, depending on the requirements of the
casting. After the mold is hardened in this process, ejector pins
lift the mold off of the pattern. Each half is then either manually
or automatically glued together with special thermal glue that
reacts to the heat and begins setting up immediately. The mold is
then pressed together, thus sealing it in preparation for pouring.
Typically 1˚ to 2˚ of draft will be applied to the pattern from the

parting line. Proper venting is also important. Venting
methodology is determined by the foundry’s engineering team.
A typical shell mold will be approximately 7 mm thick.
( An operator opening vents in the mold

so gas can exit when poured)
CHAPTER 5
Pouring
EAGLE GROUP | 13
Chapter 5
Pouring
By this point in the process we solidification rate and the
have produced both the cores casting’s section thicknesses.
and the molds, and are ready
to pour our castings. If a mold The picture below shows
or core was made incorrectly relatively large shell-molded
or is too thin, the resulting castings being poured. If you
pour will result in a runout or look closely you can see that
ruin. If the mold was made the blind (closed) risers
correctly, it will be poured and include vents to let gas
left to escape. Shell molds are not
solidify. This step will vary permeable, so venting is
from part to part, and will important.
depend on the material's
Due to the extreme conditions

involved, molds may break if
made incorrectly.
,
(Pouring temperatures vary based on the material, but most
steel alloys will be poured around 3000 F˚.)
Once solidified, the parts will be moved to shakeout. Here, the

sand will be removed to reveal a raw casting that must then be
processed.
(A group of shell molds that have just

been poured and left to solidify.)
CHAPTER 6
Surface Finish
EAGLE GROUP | 16
Chapter 6
Surface Finish
Many buyers believe that This means that the
shell molding results in nomenclature or lettering on a
similar surface finish to shell casting comes out crisp
other types of sand castings. and legible.
This is a common
misconception. Different material types have
different surface-finish
Shell molding provides a capabilities. In general, a steel
smoother surface finish casting will have a rougher
compared to other types of finish than an iron casting
“sand” processes, such as because of elevated pouring
greensand. temperature.
According the American
Foundry Society, shell
molding produces a surface
finish between 150-300RMS.
“If you look at resin-coated sands,

typically those are always associated
with good surface finish applications."
-Doug Trinowski, Vice President of HA
International
(American Foundry Society Microfinish Comparator)
CHAPTER 7
Comparison to
Other Casting
Methods
EAGLE GROUP | 18
Chapter 7
Comparison to Other
Casting Methods
The shell mold process is unique and exhibits many advantages
over other forms of metal casting, but many people don’t fully
understand its benefits. It is important to keep in mind that all
processes have their own appropriate applications.
Here, we will compare and contrast the shell mold process with
investment and greensand casting methods. We make our
comparison based on surface finish, dimensional tolerances,
production costs and typical production quantities.
(Investment casting process)

Investment Casting
Investment casting is an When comparing surface
ancient casting technique that finishes and tolerance
has been used for centuries. capabilities, investment
Some may know it as “lost casting comes out at the top
wax” casting, but the process of all methods.
has not changed significantly.
With tolerances of +/- .005
Investment casting uses wax and a surface finish of around
to create replicas (patterns) 125 RMS, parts can have crisp
that are assembled onto lettering and fine detail. This
“trees” and then dipped into casting technique is more
a ceramic slurry. The ceramic suitable for smaller parts, but
layers are allowed to air dry. certain castings weighing
Then, the wax is melted out, more than 100 lbs can also be
and the molds are preheated cast using this method.
and then poured. This
process has lower tooling The main drawback of
costs but higher production investment casting is that it
costs in most cases. is a relatively expensive
process. Much of the cost is
Shell molding is usually less due to the skilled labor that is
expensive than investment involved in production.
casting, due mainly to lower
labor costs. The casting The investment process is best
buyer gets lower start-up used for castings with intricate
costs in the investment geometries or high amounts of
process, in exchange for machining; and for lower-volume
production projects.
higher pound prices.
Greensand Casting
(Greensand Casting Process)
Greensand is the most common molding process used for

making castings. It is a sand casting process that uses a no-bake
system for molding. The name “Greensand” has nothing to do
with the color of the sand, but denotes that there is moisture
present in the sand. The tooling is constructed of metal, wood or
plastic and usually at a lower cost than shell tooling. Cores can
be inserted into the mold to produce a hollowed-out section.
As previously stated, The principle drawback of

greensand is one of the most greensand casting is that the
popular casting methods in finish surface of parts is
practice today, largely due to relatively rough.
its prevalence in the
automotive industry where A basic comparison
high production volume is between greensand and shell
necessary. Most automatic molding shows
molding / pouring systems that greensand requires less
are designed to utilize the capital investment, but
green sand process because certain technical
of its ease of use and sand specifications might not be
recyclability. met. In comparison, shell
molding often calls for a
An article by the American larger up-front investment,
Foundry Society states that but these costs can be
“With a production rate up to offset by amortization.
500 molds per hour, these Shell molding also allows for
lines produce molds without more intricate
flasks, thus eliminating the designs, smoother surface
cost to produce and maintain finishes and tighter
the framing around each tolerances.
mold.” (MCP Staff). The low
cost of manufacturing and the
small investment needed to
start has made greensand
casting a top process in high-
volume scenarios.
.
CHAPTER 8
Shell Mold
Buyers Guide
EAGLE GROUP | 23
Chapter 8
Shell Mold Buyers Guide

If you think that the shell molding process could fit your
casting needs and would like to request a quote, please keep
these points in mind:
1. Always provide a net weight. If one is not available, do

your best to estimate it.
2. Make your corners, radii and fillets as generous as

possible.
3. Work with your foundry to maximize the number of

castings that can be fit on a single mold. The more castings
can be fit in a mold, the lower the piece price will be.
4. Existing tooling can often be transferred to a different

foundry, but you should expect some modification costs.
5. Get to know your foundry and their management team,

and make sure they have good processes in place to insure
you’ll receive a quality casting.
6. Get your foundry involved in the design process as early

as possible to avoid unnecessary delays and added costs.
Chapter 9
Glossary of Terms
Cope: the top half of a two-part casting mold.
Core: a preformed sand shape inserted into a mold to form

the interior of a casting, or a hollow part.
Corebox: a tooling used to produce a core.
Draft: taper on the vertical sides of a pattern or corebox

allowing the core or sand mold to be removed without
distorting or tearing the sand.
Drag: the bottom half of a two-part casting mold.
Ejector Pins: protruding attachments that push the mold away

from the pattern after the sand has hardened.
Green Sand Molding: a common casting process, using moist,

clay-bonded molding sand.
Investment Casting: a casting process involving wax and

ceramic, allowing for smooth finishes and tight tolerances.
Mold: a rigid frame into which liquid metal is poured to form a

casting.
Pattern: a replica of the part to be cast, used to shape the

mold.
Riser: a reservoir built into the mold, placed to prevent parts

from shrinking during cooling.
Runout: when liquid metal leaks from a defective or poorly

sealed mold.
Shakeout: the process of vibrating molds-casting

combinations in order to separate the mold from the casting.
Shell molding: a casting process that uses a thin layer of resin-

bonded sand to form a mold.
Tree: a cluster of wax or plastic patterns mounted together

during the investment casting process.
Venting: allowing gas to escape from a mold, either through

microscopic gaps in the sand, or through pre-planned
channels.
(Clockwise from top left: a shell core; a

shell mold; grinding; pouring )
White paper prepared by:
Prepared by Jeff Cook

Vice President, Sales and Marketing
Eagle Alloy, Inc.
with support from Kyle Wenning
Contact: 231-788-7002 | jcook@eaglealloy.com
About the Eagle Group
From concept to completion, The Eagle Group’s

diverse capabilities offer solutions for multiple
casting needs. Our lean manufacturing process
ensures timely production and delivery. The
synergies that all Eagle Group companies share
assure that your casting and/or machining
requirements are met with the best process for the
application. Magma 3D Model Simulation assures
that we are producing the very best casting for your
needs. We are also involved in the growing 3D
printed molds market.
All text, images and other media contained in

this white paper are the sole property of the
Eagle Group, unless otherwise noted. Do not
reproduce or distribute this material without
prior written consent of the Eagle Group.
© 2017 The Eagle Group

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SHELL MOLDING PROCESS

1 | Introduction to the Shell Mold Process

2 | Shell Process Chemistry

3 | Shell Core Production

7 | Comparison to Other Casting Methods

8 | Shell Mold Buyers Guide

Shell Process Chemistry

Sand + Phenolic + Hexamethylenetetramine (hexal)

As shown above, the shell molding process begins with resin-

This resin-coated, heat-bonded sand becomes the "shell" of

Cores are one of the most

Without cores, the casting A core must remain strong

Here, we will discuss long run production cores, and the shell

A common sand used to make cores is a mixture that includes

(A typical U180 shell core machine heating up)

A unique benefit of shell molds is their ability to be stored, which

(An example of a 30x40 shell plate with the cope side of the

These molds are made in a similar fashion to the cores. Again,

Typically 1˚ to 2˚ of draft will be applied to the pattern from the

A typical shell mold will be approximately 7 mm thick.

( An operator opening vents in the mold

Due to the extreme conditions

Once solidified, the parts will be moved to shakeout. Here, the

(A group of shell molds that have just

“If you look at resin-coated sands,

(American Foundry Society Microfinish Comparator)

(Investment casting process)

(Greensand Casting Process)

Greensand is the most common molding process used for

As previously stated, The principle drawback of

Shell Mold Buyers Guide

1. Always provide a net weight. If one is not available, do

2. Make your corners, radii and fillets as generous as

3. Work with your foundry to maximize the number of

4. Existing tooling can often be transferred to a different

5. Get to know your foundry and their management team,

6. Get your foundry involved in the design process as early

Core: a preformed sand shape inserted into a mold to form

Corebox: a tooling used to produce a core.

Draft: taper on the vertical sides of a pattern or corebox

Drag: the bottom half of a two-part casting mold.

Ejector Pins: protruding attachments that push the mold away

Green Sand Molding: a common casting process, using moist,

Investment Casting: a casting process involving wax and

Mold: a rigid frame into which liquid metal is poured to form a

Pattern: a replica of the part to be cast, used to shape the

Riser: a reservoir built into the mold, placed to prevent parts

Runout: when liquid metal leaks from a defective or poorly

Shakeout: the process of vibrating molds-casting

Shell molding: a casting process that uses a thin layer of resin-

Tree: a cluster of wax or plastic patterns mounted together

Venting: allowing gas to escape from a mold, either through

(Clockwise from top left: a shell core; a

White paper prepared by:

Prepared by Jeff Cook

About the Eagle Group

From concept to completion, The Eagle Group’s

All text, images and other media contained in

© 2017 The Eagle Group

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