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.

We offer a comprehensive portfolio of colloidal silica slurry binders. See product information below for the range of particle size, structure, concentration, pH, surface charge and surface modification available:

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

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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

Engineered Shell Program Product Portfolio

Prime and Intermediate Slurry Binders

Size (nm): 4-13, (engineered available)
Area m2/gm: 230-750
% Solids 15-30
pH: 10-10.5
Polymer-Enhanced Available

Backup Slurry Binders

Size (nm): 8-60, (engineered available)
Area m2/gm: 50-375
% Solids 22-50
pH: 8.5-10
Polymer-Enhanced Available

Polymers

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

Slurry Additives

We offer additives with a range of applications including wetting agents, biocide and anti-foam chemistries specified for slurry.

Wax Pattern Cleaners

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.

Engineered Flour and Flour Options

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.

Get In Touch with Us

Give Us a Call

With unparalleled expertise and cutting-edge technology, we partner with customers to deliver world-class results and optimized operations. Contact us to learn how we can help you.

Nalco Water
Colloidal Technologies Group
1601 W. Diehl Road
Naperville, Il 60563

For additional information or assistance, please contact our Colloidal Technologies Group.

Nalco Water Customer Service: +1-800-288-0879

Contact Our Colloidal Technologies Experts

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