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The Shaw Process

Until the 1940s when Noel Shaw invented the process which now bears his name, castings have been made for centuries using the traditional "Lost Wax" or sand mould process. Shaw's new ceramic process offered several advantages over the old system, notably high quality, remarkably accurate castings, as well as significant cost savings.

The Shaw Process uses a very pure, strong gel to bond ceramic refractory powders to form a mould suitable for molten steel. he exceptional permeability of the fired mould not only minimizes shock, but also allows free passage of air, eliminating the need for venting. High temperature thermal stability also minimizes mould distortion after pouring, resulting in extremely accurate castings.

Because a "split-mould" technique is used, pattern equipment is less expensive than for the expendable pattern process.

The unique feature of the Shaw Process is the "micro-crazing" that is created when the casting solution is burned off to dry the mould. This enables the Shaw Process mould to retain its original volume and dimensional accuracy.

The major advantages of Shaw Process Castings include:

Dimensional accuracy to 0.25mm tolerance.

Reduced machining costs by eliminating preliminary machining.

Increased output by reducing machining time.

Extremely fine surface detail.

Increased design possibilities, even for high alloy steels.

High integrity castings.

Relatively low pattern costs.


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