Shell Mould Casting

Shell mold casting or shell molding, is a technique used to manufacture high quality, dimensionally accurate parts. We use this technique to create best quality Air & water cooled blocks to provide strength to the engine. In this process, the mold is made of sand covered with resin, which is thin and the shell is hard. It is similar to sand casting but provides better quality custom-made casting parts with a low labour requirement.

Why is shell mold casting important?

As a responsible manufacturer of cylinder & Water blocks in India we use this method to make different parts to make them safe and strong. Common applications include gear housings, cylinder heads, and various engine components where these qualities are crucial.

Shell mold casting offers various advantages over traditional sand casting. It uses a pre-made shell, formed by setting a resin-bonded sand mixture around a heated pattern. This shell creates a smoother mold surface, leading to castings with a superior finish. Additionally, the shell sets rapidly, enabling faster production cycles compared to sand casting. Thanks to its rigidity, the shell maintains its shape during the casting process, resulting in parts with greater dimensional accuracy.

Advantages

Shell molding is a technique that has significance for manufacturers of engine parts, particularly cylinder liners and air & water-cooled blocks. This process provides high class wear resistance to the engine parts.

This quality is crucial for cylinder liners, as they constantly rub against pistons. Shell molding creates a close-grained structure that enhances heat transfer, benefiting both air and water-cooled blocks by enabling efficient engine temperature control.

Material Grade

Gray Cast Iron Grades

Country	Standard	Equivalent Grades of Grey Cast Iron
ISO	ISO 185	100	150	200	250	300	350	-
China	GB 9439	HT100	HT150	HT200	HT250	HT300	HT350	-
USA	ASTM A48	-	NO.20 NO.25	NO.30	NO.35	NO.40 NO.45	NO.50	NO.55 NO.60
Germany Austria	DIN 1691	GG10	GG15	GG20	GG25	GG30	GG35	GG40
European	EN 1561	EN-GJL-100	EN-GJL-150	EN-GJL-200	EN-GJL-250	EN-GJL-300	EN-GJL-350	-
Japan	JIS G5501	FC100	FC150	FC200	FC250	FC300	FC350	-
Italy	UNI 5007	G10	G15	G20	G25	G30	G35	-
France	NF A32-101	-	FGL150	FGL200	FGL250	FGL300	FGL350	FGL400
UK	BS 1452	100	150	200	250	300	350	-
India	IS 210	-	FG150	FG200	FG250	FG300	FG350	FG400
Spain	UNF	-	FG15	FG20	FG25	FG30	FG35	-
Belgium	NBN 830-01	FGG10	FGG15	FGG20	FGG25	FGG30	FGG35	FGG40
Australia	AS 1830	-	T150	T220	T260	T300	T350	T400
Sweden	SS 14 01	O110	O115	O120	O125	O130	O135	O140
Norway	NS11 100	SJG100	SJG150	SJG200	SJG250	SJG300	SJG350	-

SG Iron Grades

Country	Standard	Equivalent Grades of Ductile Iron (SG Iron/Nodular Graphite Iron Casting)
ISO	ISO 1083	400-15 400-18	450-10	500-7	600-3	700-2	800-2	900-2
China	GB 1348	QT400-18	QT450-10	QT500-7	QT600-3	QT700-2	QT800-2	QT900-2
USA	ASTM A536	60-40-18	60-42-10 60-45-12	70-50-05	80-55-06 80-60-03	100-70-03	120-90-02	-
Germany Austria	DIN 1693	GGG40	-	GGG50	GGG60	GGG70	GGG80	-
European	EN 1563	EN-GJS-400-15 EN-GJS-400-18	EN-GJS-450-10	EN-GJS-500-7	EN-GJS-600-3	EN-GJS-700-2	EN-GJS-800-2	EN-GJS-900-2
Japan	JIS G5502	FCD400	FCD450	FCD500	FCD600	FCD700	FCD800	-
Italy	UNI 4544	GS370-17	GS400-12	GS500-7	GS600-2	GS700-2	GS800-2	-
France	NF A32-201	FGS370-17	FGS400-12	FGS500-7	FGS600-2	FGS700-2	FGS800-2	-
UK	BS 2789	400/17	420/12	500/7	600/7	700/2	800/2	900/2
India	IS 1865	SG370/17	SG400/12	SG500/7	SG600/3	SG700/2	SG800/2	-
Spain	UNF	FGE38-17	FGE42-12	FGE50-7	FGE60-2	FGE70-2	FGE80-2	-
Belgium	NBN 830-02	FNG38-17	FNG42-12	FNG50-7	FNG60-2	FNG70-2	FNG80-2	-
Australia	AS 1831	300-17 400-12	-	500-7	600-3	700-2	800-2	-
Sweden	SS 14 07	0717-02	-	0727-02	0732-03	0737-01	0864-03	-
Norway	NS11 301	SJK-400.3 SJK-400	-	SJK-500	SJK-600	SJK-700	SJK-800	-

Aluminum Grades

UK	ISO	France	Germany	Italy UNI	USA (AA/ASTM)	USA	Japan
LM0	AL 99.5	A5	-	3950	150	-	-
LM2	AL-Si10Cu2Fe	A-S9U3-Y4	-	5076	384	383	ADC12
LM4	Al-Si5Cu3	A-S5Ue	G-AlSi6Cu4 (225)	3052	319	326	AC2A
LM5	AL-Mg5Si1	AG6		3058	514	320	AC7A
LM6	AL-Mg6 AL-Si12Fe Al-Si12	AS13	G-AlSi12 (230)	4514	A413	-	AC3A
LM9	Al-Si10Mg	A-S10G	G-AlSi10Mg (233)	3049	A360	309	AC4A
LM12	Al-Cu10Si2Mg	A-U10G	-	3041	222	34	-
LM13	Al-Si12Cu Al-Si12CuFe	A-S12UN	-	3050	336	321	AC8A
LM16	Al-Si5Cu1Mg	A-S4UG	-	3600	355	322	AC4D
LM20	Al-Si12Cu Al-Si12CuFe	A-S12-Y4	G-AlSi12 (Cu)(231)	5079	A413	305	-
LM21	Al-Si6Cu4	A-S5U2	G-AlSi6Cu4(225)	7369/4	308	326	AC2A
LM22	Al-Si5Cu3	A-S5U	G-AlSi6Cu4(225)	3052	319	326	AC2A
LM24	Al-Si8Cu3Fe	A-S9U3A-Y4	G-AlSi8Cu3(226)	5075/3601	A380	306	AC4B/ADC10
LM25	Al-Si7Mg	A-S7G	G-AlSi7Mg	3599	A356	323	AC4C
LM26	Al-Si9Cu3Mg	A-S7U3G	-	3050	332	332	-
LM27	Al-Si7Cu3Mn0.5	-	-	7369	-	-	AC2B
LM28	Al-Si19CuMgNi	-	-	6251	-	-	-
LM29	Al-Si23CuMgNi	-	-	6251	-	-	-
LM30	Al-Si17Cu4Mg	-	-	-	390	-	-
LM31	Al-Zn5Mg	A-Z5G	-	3602	712	310	-

Steel Grades

Austenitic Stainless Steel Casting Grades
	Carbon	Manganese	Silicon	Chromium	Nickel	Molybdenum	Phosphorus	Sulfur	Copper
	Min-Max	Min-Max	Min-Max	Min-Max	Min-Max	Min-Max	Max	Min-Max	Min-Max
CF-16Fa-303	0.16 Max	1.5 Max	2.0 Max	18.0 -21.0	9.0-12.0	0.40-0.80	0.04	0.20-0.40
CF-8-304	0.08 Max	1.5 Max	2.0 Max	18.0-21.0	8.0-11.0		0.04	0.04 Max
CF-3-(304ML)	0.03 Max	1.5 Max	2.0 Max	17.0-21.0	8.0-12.0		0.04	0.04 Max
CF-8M-316	0.08 Max	1.5 Max	2.0 Max	18.0-21.0	9.0-12.0	2.0-3.0	0.04	0.04 Max
CF-3M-(316L)	0.03 Max	1.5 Max	1.5 Max	17.0-21.0	9.0-13.0	2.0-3.0	0.04	0.04 Max
CF-8C-347	0.08 Max	1.5 Max	2 Max	18.0-21.0	9.0-12.0		0.04	0.04 Max
CG-8M-317	0.08 Max	1.5 Max	1.5 Max	18.0-21.0	9.0-13.0	3.0-4.0	0.04	0.04 Max

Ferritic Stainless Steel Casting Grades
	Carbon	Manganese	Silicon	Chromium	Nickel	Molybdenum	Phosphorous	Sulfur	Copper
	Max	Max	Max	Min-Max	Max	Max	Max	Max	Max
409/Nb	0.16	1.5	2	10.5-11.75	0.5		0.045	0.045
442(CB-30)	0.3	1	1.5	18.0-22.0	2		0.04	0.04
446(CC-50)	0.5	1	1.5	26.0-30.0	4		0.04	0.04

Martensitic Stainless Steel Casting Grades
	Carbon	Manganese	Silicon	Chromium	Nickel	Molybdenum	Phosphorous	Sulfur	Copper
	Min-Max	Max	Min-Max	Min-Max	Min-Max	Min-Max	Max	Min-Max	Min-Max
410	0.05-0.15	1	1.5 Max	11.5-14.0	1.0 Max	0.5 Max	0.04	0.04 Max	0.50 Max
416	0.15 Max	1.25	1.50 Max	11.5-14.0	0.50 Max	0.50 Max	0.05	0.15-0.35	0.50 Max
420	0.15 Max	1	1.0 Max	12.0-14.0			0.04	0.03 Max
15-5 PH	0.05 Max	0.6	0.50-1.00	14.00-15.50	4.20-5.00		0.025	0.025 Max	2.5-3.2
17-4 PH	0.06 Max	0.7	0.50-1.00	15.5-16.7	3.60-4.60		0.04	0.03 Max	2.8-3.5

Duplex Stainless Steel Casting Grades
	Carbon	Manganese	Silicon	Chromium	Nickel	Molybdenum	Phosphorous	Sulfur	Copper
	Max	Max	Max	Min-Max	Min-Max	Min-Max	Max	Max	Min-Max
ASTM A890 Grade 1A (CD4MCu)	0.04	1	1	24.5-26.5	4.75-6.00	1.75-2.25	0.04	0.04	2.75-3.25
ASTM A890 Grade 4A (CD3MN)	0.03	1.5	1	21.0-23.0	4.5- 6.5	2.5-3.5	0.04	0.02	1.00 Max

Common Alloy Steel Grades for Casting
	C	Si	Mn	Cr	Mo	P≤	S≤	Ni
	Min-Max	Max	Min-Max	Min-Max	Min-Max	Min-Max	Max	Min-Max
35CrMo	0.32-0.40	0.17-0.37	0.40-0.70	0.80-1.10	0.15-0.25
40CrNiMo	0.37-0.44	0.17-0.37	0.50-0.80	0.60-0.90	0.15-0.25			1.25-1.65
4130	0.28-0.33	0.15-0.35	0.40-0.60	0.80-1.10	0.15-0.25	0.035	0.04
4140	0.38-0.43	0.15-0.35	0.75-0.10	0.80-1.10	0.15-0.25	0.035	0.04
8630	0.28-0.33	0.15-0.35	0.70-0.90	0.40-0.60	0.15-0.25	0.035	0.04	0.40-0.70

Brass Grades

Nominal Composition%	Application
Cu-10Sn-1p	Wear-resistant parts that work under high loads and high sliding speeds
Cu-10Sn-2Zn	Complex shaped castings, valves, pump bodies, gears, turbines, etc.
Cu-10Sn-5Pb	Structural materials, corrosion-resistant and acid-resistant accessories
Cu-6Sn-6Zn-3Pb	Parts that work under friction conditions, such as bushes, bearings, etc.
Cu-5Sn-5Zn-5Pb	Wear-resistant and corrosion-resistant parts that work under high load and medium sliding speed
Cu-10Sn-10Pb	Automobiles and other heavy-duty parts
Cu-15Pb-8Sn	Acid-resistant parts, parts for high-pressure work
Cu-17Pb-4Sn-4Zn	Bearings with high sliding speed and general wear parts
Cu-13Mn-8Al-3Fe	Shaft sleeves and high-strength wear-resistant and pressure-resistant parts for heavy machinery
Cu-13Mn-8Al-3Fe-2Ni	High-strength corrosion-resistant castings and wear-resistant and pressure-resistant parts
Cu-9.4Al-4.5Fe-4.5Ni-1.5Mn	Corrosion-resistant, high-strength castings, wear-resistant parts that work at 400°C

Industries
We serve

Automobile Industry

The automobile industry relies heavily on custom-made casting parts for its functionality and innovation. These parts, created using molds for intricate shapes, are essential for engines, transmissions, and other core components.

Aerospace Industry

Custom-made casting parts are the backbone of the high-tech aerospace industry. Their ability to take complex shapes makes them ideal for crafting lightweight yet strong airframes, jet engine components, and other critical structures within aircraft.

Oil And Gas Industry

This industry is growing rapidly. We have used alloys to manufacture our custom made casting parts. It provides strength and corrosion resistance to valves, pumps and wallheads.