Shell Process

Well suited to higher volume production where uniformity and consistency are required, the Flowserve Dayton Foundry’s Shell Process can routinely produce castings to ASTM Shrinkage Severity Level II.

These castings are made in shell molds and have a superior surface finish and outstanding dimensional integrity. For larger production runs, this process can offer significant cost savings. The ultimate goal is to deliver high- quality castings while keeping expensive machining at a minimum or better yet eliminating it entirely.

Shell Capabilities


Shell ProcessFlowserve pours stainless steel and nickel-based alloys in accordance with several specifications. Custom alloys can also be produced.

Standards and Specifications

  • Stainless Steels: ASTM A217; A351; A743; A744; A747; A890; A995
  • Nickel Base: ASTM A494
  • Heat Resistant Grades: ASTM A297


  • 1000 lb (454 kg) and 4000 lb (1814 kg) coreless induction furnaces

Maximum Weights

  • 340 lb (154 kg) gross; 150 lb (68 kg) net

Minimum Casting Wall Thickness

  • 1/4 in (6 mm) depending on part configuration

Maximum Casting Size

  • Patterns: 15 in x 20 in x 12 in (380 mm x 510 mm x 305 mm)
  • Patterns: 20 in x 30 in x 12 in (510 mm x 760 mm x 305 mm)


  • ±0.015 in/in (±0.015 mm/mm)

Surface Finish

  • 150-200 RMS (as cast)

Quality, Inspection, Testing

A full range of laboratory, mechanical and non-destructive testing services is available as required.

Routine procedures include:

  • X-ray fluorescence spectroscopy
  • Leco carbon and gas (H, N, O) analysis
  • Mechanical testing (tensile and impact)

Miscellaneous Capabilities

  • Welding qualified to ASME Section IX Boiler and Pressure Vessel Code and ASTM A488
  • Blasting with steel or stainless steel shot; aluminum oxide
  • Heat treating and quenching
  • Pattern, mold and core making
  • Rapid prototype process