Shell Molding

The shell molding process was originally developed by the German inventor Johannes Croning and has been reliably used in foundries around the world for more than 75 years. Even today, shell molding is indispensable in the production of certain cast components, especially as it is so easy and delivers such high-precision castings.

About the shell molding process

With the invention of the shell molding process, Johannes Croning developed a new, stand-alone mold casting process based on an entirely new production principle, as well as an innovative resin-bonded molding material for the production of castings. The biggest difference between this process, for which a patent application was filed in 1944, and the compact, box-bound mold casting processes was the shell- or mask-like reproduction of the outer contour of the casting mold, which is what gave the process its name.

Today, shell molding is a technically mature, extensively tested production process for shell and core manufacturing. With regard to the dimensional accuracy of the resulting castings, the shell molding process is still the most accurate sand-casting process in the foundry industry.

HA offers foundries that use the shell molding process, a wide range of coating resins, finished sands, and finished molding materials.

EcoFlo 3.0

EcoFlo 3.0 is the next generation of environmental series resin coated sand that is part of the HA International EcoMission product line. It is designed to maintain low ammonia and formaldehyde emissions while having increased strength compared to other environmental grades. This allows for the potential to reduce the total resin content required for environmental resin coated sands or the ability to maintain resin levels of conventional grades if converting to environmental.

Advantages

• Reduced Emissions – 70% reduction in ammonia and formaldehyde emissions when compared to conventional formulas.
• High Humidity Resistance – Increased humidity resistance is substantial, especially when compared to other environmental grades of resin coated sand.
• Low Lumping – Reduced lumping means better flowability in hot and humid climates, which also reduces the need for additional processing.
• Increased Strength – Increase in tensile strength when compared to other environmental grades.

Benefits

• Drop-in replacement for the incumbent grade at a lower resin content
• Higher sand tonnage allowance within the same VOC permit tier
• Lower core-making emissions for an improved operator environment
• Potential to improve cycle times during core-making
• 6-14% Reductions observed on specific jobs
  

Custom Coat

Our Custom Coat product line is designed for today's demanding foundry applications. This sand has been designed to provide high levels of productivity by using the latest technology available to the foundry industry.

Our Custom Coat products are produced and manufactured to your product's exact specifications:

• Resin content: 1-5%
• Hexa content: 10%+ (BOR)

Custom Coat EcoFlo

CC EcoFlo is an environmental resin coated sand that is part of the HA EcoMIssion product line. CC EcoFlo is designed to reduce both ammonia and formaldehyde emissions while improving humidity resistance compared to other environmental grades. CC EcoFlo maintains strength in shell cores, emits minimal ammonia, and, most importantly, reduces lumping propensity, even in hot and humid conditions.

Advantages:

• Reduced Emissions
  70% reduction in ammonia and formaldehyde emissions when compared to conventional formulas
• Increased Humidity Resistance
  Increased humidity resistance is substantial, especially when compared to other environmental grades of resin coated sand
• Reduced Lumping
  Reduced lumping means better flowability in hot and humid climates, which also reduces the need for additional processing