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Shell Moulding and Croning Process

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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Vrinda Nilotpal
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38 views7 pages

Shell Moulding and Croning Process

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.

Uploaded by

Vrinda Nilotpal
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

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
[Link] point [Link]
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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