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    Shell Process

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    Vrinda Nilotpal
    The document discusses the shell process/moulding or croning process for casting. It was discovered by Johannes Croning in Germany in 1929. In this process, silica sand is mixed with phenolic resin and a curing agent. The process involves preparing a sand mixture by mixing dry sand with thermosetting resins and heating it. Phenol formaldehyde resin is commonly used and acts as a binder when cured with sand. The cured resin-sand mixture is called an aggregate and is prepared using different coating processes like warm, hot, or cold coating. Properties of resins like softening point, flow rate, and particle size are checked to ensure quality.

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    Download as PDF, TXT or read online from Scribd

    Shell Process

    Uploaded by

    Vrinda Nilotpal
    51 views7 pages
    The document discusses the shell process/moulding or croning process for casting. It was discovered by Johannes Croning in Germany in 1929. In this process, silica sand is mixed with phenolic resin and a curing agent. The process involves preparing a sand mixture by mixing dry sand with thermosetting resins and heating it. Phenol formaldehyde resin is commonly used and acts as a binder when cured with sand. The cured resin-sand mixture is called an aggregate and is prepared using different coating processes like warm, hot, or cold coating. Properties of resins like softening point, flow rate, and particle size are checked to ensure quality.

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    The document discusses the shell process/moulding or croning process for casting. It was discovered by Johannes Croning in Germany in 1929. In this process, silica sand is mixed with phenolic resin and a curing agent. The process involves preparing a sand mixture by mixing dry sand with thermosetting resins and heating it. Phenol formaldehyde resin is commonly used and acts as a binder when cured with sand. The cured resin-sand mixture is called an aggregate and is prepared using different coating processes like warm, hot, or cold coating. Properties of resins like softening point, flow rate, and particle size are checked to ensure quality.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    51 views7 pages

    Shell Process

    Uploaded by

    Vrinda Nilotpal
    The document discusses the shell process/moulding or croning process for casting. It was discovered by Johannes Croning in Germany in 1929. In this process, silica sand is mixed with phenolic resin and a curing agent. The process involves preparing a sand mixture by mixing dry sand with thermosetting resins and heating it. Phenol formaldehyde resin is commonly used and acts as a binder when cured with sand. The cured resin-sand mixture is called an aggregate and is prepared using different coating processes like warm, hot, or cold coating. Properties of resins like softening point, flow rate, and particle size are checked to ensure quality.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 7

    Shell Process/Moulding

    or Croning Process
    • Discovered by Johannes Croning in Germany
    In this process Silica, Zircon sand is mixed
    with Phenolic Resin with a Curing Agent.
    Department of Foundry Technology, NIAMT Ranchi

    Johannes Croning, in 1929 performed


    extensive tests on the application of high
    frequency melting equipments to produce all
    three parts of the casting process melting,
    pouring and solidification, in a permanent
    mould.
    Process
    Sand Mixture Preparation
    In this process the mould & core are prepared by
    mixing the dry free flowing sand with
    thermosetting resins & heating.
    The mixture of fine sand (100-150 mesh) &
    Department of Foundry Technology, NIAMT Ranchi

    thermosetting resin is called aggregate.


    The Sand need to be:
    Free of Clay
    100-150 mesh size & can be varied
    according to need.
    Resin & Catalyst
    Phenol Formaldehyde; most commonly used
    resin, are thermosetting in nature and provide high
    strength & resistance to heat when cured with
    sand, as coating to sand. Catalyst used is hexa
    Department of Foundry Technology, NIAMT Ranchi

    methylene tetramine i.e. Hexa.


    Resin 4-6% of sand by weight and Catalyst like
    coal dust, manganese dioxide, calcium carbonate,
    lignin, iron oxide is 14-16% of sand by weight.
    Curing temperature of resin with catalyst is
    around 150o C and curing time 50-65 seconds
    Resins available
     Water borne
     Flake type
     Granular type
    The specifications of Liquid, Flake Or Powder type
    Department of Foundry Technology, NIAMT Ranchi

    resin can be obtained from IS8246-1976 IS11266-


    1985 & IS10979-1981 respectively.
    The Resin Sand mixture agregate can be prepared
    by:
    1. Warm Coating Process
    In this process different sand formulation which is
    liquid solvent solution is used and Curing takes
    place at around 80o C. The process is simple but
    Department of Foundry Technology, NIAMT Ranchi

    quantity of Resin consumed is more.


    2. Hot Coating Process: here the Curing of Resin
    takes place due to combined effect of Heat &
    Chemical action of the resin with catalyst.
    After Curing completes sand mixture is cooled to
    40-50oC to prevent lumps & improve Flowability.
    3. Cold Coating Process:
    In this process the Sand is first mixed with Catalyst
    then the Resin mixed with Alcohol is mixed to form
    the aggregate. Here the amount of Resin required is
    highest in all processes.
    Phenol Formaldehyde Resins:
    Department of Foundry Technology, NIAMT Ranchi

    Used as a binder in Shell Moulding Process. It can


    be used in form of Flakes or Liquid form. Liquid
    resin is resin dissolved in alcohol.
    Liquid Resin is used for Warm Coating process
    whereas Soild/Flake Resin is used for Hot Coating
    Process.
    The following properties of Resin are checked for
    acceptance criteria:
    Solid Resins Liquid Resins
    1.Softening point 1.Clarity
    2. Flow rate 2. Viscosity
    3. Specific Gravity
    Department of Foundry Technology, NIAMT Ranchi

    3. Particle size
    4. Solid content
    5. PH Value

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