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Engineered Shell Program
As your investment casting quality control partner, Nalco Water offers expertise and experience in process reliability, defect prevention and material integrity. Our engineered shell experts are dedicated to supporting consistent shell performance and casting quality. We offer a range of products within our effective shell system program.
Engineered Shell Program Product Portfolio
- Size (nm): 4-13, (engineered available)
- Area m2/gm: 230-750
- % Solids 15-30
- pH: 10-10.5
- Polymer-Enhanced Available
- Size (nm): 8-60, (engineered available)
- Area m2/gm: 50-375
- % Solids 22-50
- pH: 8.5-10
- Polymer-Enhanced Available
We offer multiple investment casting polymers designed with a range of characteristics:
- Flexible and sticky: ideally suited for wax adherence in prime slurry applications
- Designed to complement the rheology benefits of one of our backup slurry binders
- Rigid and strong: ideally suited for backup applications
We offer additives with a range of applications including wetting agents, biocide and anti-foam chemistries specified for slurry.
Wax cleaners help improve slurry adhesion, assist in preparation of sensitive waxes, improve casting surface quality and reduce casting defects. Our wax pattern cleaners are emulsifiable blends that optimize cleaning capabilities and product life while helping to reduce VOC's and personnel safety issues.
We offer a range of flour options to best suit the needs of the shell room, including zircon, fused silica and alumino-silicate based flours and stuccos. We have developed multiple engineered shell systems that can be utilized to achieve specific goals of the foundry.
Specialized Testing and Characterization Capability for Engineered Shells
Our customer analytical team provides specialized testing and characterization:
Shell System Testing
- Shell Permeability: Measurement of gas flow through shell layers
- Shell Strength:
- Green Strength: Evaluation before firing.
- Fired Strength: Assessment after firing for structural integrity
Slurry and Supernatant Analysis
- Viscosity, density, and chemical composition checks to maintain slurry consistency and prevent defects
Microbiological Testing
- Culture-Based Methods: Detect and quantify microbial contamination
- Molecular Techniques: Rapid identification of microorganisms
- Microscopy: Visual confirmation of contamination sources.
Casting Defect Characterization
- XRF (X-ray Fluorescence): Elemental composition analysis
- SEM/EDS (Scanning Electron)
- Microscopy/Energy Dispersive Spectroscopy): Microstructural and chemical mapping
- Light Microscopy: Surface and defect morphology evaluation
Process Characterization
- Thermal Cycling (XRD): Phase changes during heating/cooling
- Metal Mold Reaction (XRD/XRF): Interaction between metal and mold materials
- Cristobalite Formation/Content (Semi-Quantitative XRD): Monitoring silica phase transformation
Metallurgical Analysis
- Microscopy: Grain structure and defect analysis
- XRF & OES (Optical Emission Spectroscopy): Alloy composition verification
- XRD: Phase identification in metal components
Nalco Water is a Colloidal Silica Leader
- First patented colloidal silica manufacturing process in 1941
- One of the largest colloidal silica manufacturers globally
- Innovative RD&E teams for customized product development
- Products designed for manufacturing efficiency, quality, and control
- Delivering high value through innovative particle design and quality support