Metal Casting Zone Info Blog

Archive for January, 2010

The first of 12 videos showing how I make alloy castings in my home made foundry. Part one shows how the mould is made and in part two the metal is melted and poured.

• ISBN13: 9781901543131
• Condition: NEW
• Notes: Brand New from Publisher. No Remainder Mark.

Product Description
This is a fully comprehensive guide to painting and constructing miniature models. This book should help to get you started if you’re coming to painting with no experience, and encourage you to try out a few new or different methods if you have painted before. Each technique is described in detail along with pictures to illustrate every step as clearly as possible. There’s also a vast array of ‘beauty shots’ to inspire you to pick up those paint brushes!

REVIEWS

“Every so often a book comes along that answers every question you may have about painting miniature figures. This book fits that description … Would I recommend this book? You bet!!! At a list price of $39.95, it’s a book that should be on every miniatures’ painter’s shelf. “IPMS 12511 2007

FOUNDRY MINIATURES PAINTING AND MODELING GUIDE

Can anyone point me to a foundry where can I have my sculpture cast in bronze? Foundry that specialized in sculpture lost wax casting to be exact.

Die casting is a custom manufacturing process that produces engineered metal parts by injecting molten metal under very high pressure into reusable molds, called “dies,” made from premium tool steel. The dies can be designed to cast very complex shapes and sharply defined product features with a high degree of accuracy and repeatability, often with no post-casting machining required to meet part specifications. Unusually smooth surfaces can be produced as-cast, as well as a variety of textured surfaces. Die castings are suitable for a range of cosmetic finishes to match other mated parts or add extra durability in use.

Advanced high-pressure die casting, with some machines operating at die clamping forces exceeding 4500 pounds per square inch, is capable of producing net- or near-net-shape castings of high integrity and dimensional precision— at very high cycle speeds. A complete die casting cycle can vary from less than one second for small components weighing less than an ounce, to no more than two-to-three minutes for a casting of several pounds.

The process’ advantages make die casting the most efficient technology available for producing a wide range of commercial, industrial and consumer products in durable, rigid metal. A range of metals can be die cast, but the majority of die castings are non-ferrous parts, in aluminum, magnesium and zinc. High pressure die casting is an efficient, economical process that offers a broader range of shapes within closer tolerances than many other metal manufacturing techniques. Die cast parts are used in many industries including automotive, locomotive, agricultural, marine,  and plumbing.

Sandblast is a process wherein a stream of sand is driven by a jet of compressed air or by water against a surface. This creates a powerful abrasive action that can clean and abrade any surface put under the jet of these abrasive particles.

Abundant materials such as powdered quartz, emery, and iron globules are usually used as the abrasive materials in sandblast.

Sandblast is widely used for cleaning casting iron at foundries. Sandblast is also used for preparing different surfaces for painting, enameling and during galvanizing. Sandblast can also be used in cleaning stubborn grime that has accumulated in the stonework of most buildings.

Sandblast can also be used to create frosted designs on glass by placing a suitable stencil or pattern over a plate of glass and applied with a little sandblast. The jet of abrasive particles of the sandblast will strike the uncovered portions of the plate glass and create that frosted effect.

A sandblast operation can sometimes be a toxic undertaking. Sandblast operators can be exposed to several harmful particles such as lead or zinc that are important components of most commercial surface coatings.

Sandblast operators can also be exposed to the hazards of the abrasive particles being used. Without the proper safety equipment like goggles to cover the eyes and suitable protective clothing to shield against the flying particles, the sandblast operator and crew will be dangerously exposed to possible injury.

That is why there are several safety regulations to be followed before any sandblast operations.

Sandblast operators should use a standard issue air breathing apparatus while operating the machine. This will insure that the sandblast operator will have a steady supply of clean air supply amidst the workplace that will be filled with air contaminants during operation.

It is also important to consider that the hoses as well as the other equipment used to give the air supply to the sandblast operator should be able to deliver clean and contaminant-free air.

After operation, sandblast crew should only remove their air breathing apparatus when they are well away from the workplace. The sandblast particles can remain suspended in the air for long periods even after the operation.

It is also necessary for sandblast operators to wear coveralls that will provide suitable protection against rebounding abrasives during the operation of the sandblast.

Work gloves must also be used to protect the full forearm. Sand blast operators must also be able to wear the appropriate safety footwear.

It is also important to carry out the sandblasting operations in an area where the abrasive materials and other possible contaminants are safely contained and will poser no threat to other workers or to the public.

There are also some precautions that are to be observed when it comes to the sandblast machine. The sandblast pot where the abrasive particles are placed should be well grounded at all times.

It also must be provided with a safety shut down feature to further protect the sandblast operator. It is also important to remember to turn off the sandblast pot first while filling it with the abrasive particles to prevent accidents from happening.

The entire sandblast unit should be thoroughly inspected for possible defects before it is to be used. Sandblast nozzles should also be equipped with a safety control switch that will enable the operator to control the sandblast at the nozzle.

Following these simple tips will ensure the crew with a trouble-free sandblast operation.

Brighton is recognized for designing goods with a message. Many of its products’ collection have a defining feature that gives them special meaning. Whether it is love notes engraved in jewelries like pendants, rings and bracelets or a photo incorporated to a handbag. Brighton helps to create lasting memories.

The company was established in 1991 and has started out with just a single belt collection. Through the years, Brighton became an accessory company. In 1993, accessories like handbags were added to their product lines and then came the jewelries, the watches, fragrance line, small leather goods, home accessories, eyewear and the latest for now is luggage.

Brighton features products that coordinate from head-to-toe. Matching accessories of jewelry, lipstick, sunglasses, wallet, handbags and even footwear are just some of Brighton’s merchandise. Virtually creating a complete coordinating collection composed of multiple accessories.

Its philosophy, the “Brighton Difference” says that the difference is in the details. Their house designers draw each creation by hand and then supervise the product’s concept to fruition. Brighton still keeps the traditional process of making things from the Renaissance era. Brighton’s design team goes to travel and seek inspiration for their products and their ornamentation. It is also working with a host of artisans whose main jobs are to capture and bring to life all the detail of the designer’s original sketch.

Brighton leather accessories are mostly made of fine Italian leather. Manufacturing leather accessories can take up to 140 individual manufacturing steps using 40 different parts at the most. “Brightonians” are terms used to denote people collecting Brighton’s leather accessories.

The company’s products are distributed and sold through a network of more than 6,000 specialty stores nationwide most of them are family-owned, and has 100 Brighton Collectible stores across the globe. Brighton hosts seminars for their specialty retailers aimed to inspire, motivate and educate them. Events such as Brighton Week, Brighton Across America and Brighton on the Road are all focused at helping storeowners and their employs to improve marketing and their success.

Brighton has been known for it heart logo. The company’s numerous products like handbags always have a dangling silver heart and jewelries and accessories are adorned with them, too.

Brightoncs marketing strategy, which they call ‘Girlfriend Marketing’, is one of the ingredients of the company’s success. Girlfriend Marketing involves selling in small stores managed by nice people. These are stores wherein they know their customers by name and thus, able to make their customers feel that they are really valued. So, in return, their customer’s later on spread the news about the Brighton product they bought and so on.

Brighton jewelries such as rings are made up of sterling silver. Other jewelry products and silver items are cast in zinc or solid brass and then generously dipped in pure silver. A protective layer of lacquer is added because silver is naturally predisposed to tarnish (due to oxidation) and scratch. Lacquer helps in retarding this natural occurrence. All French wires, posts and lever backs used for Brighton earrings are also sterling silver.

A gate house is located at entrance of a home. The unit is used to house the guard during adverse weather conditions. It can also be used as a small outdoor storage space. The unit can be constructed from different materials. This include sheet metal, aluminium, timber, bricks and stones. The sheet metal gate house should be comfortable to stay in during adverse weather. The internal wall surfaces should be cushioned from heat and cold.

The sheet metal gate house is a unit of eight to ten feet by ten feet. The shape can be circular, rectangular or square. The height internally is eight feet. The floor can bee made of concrete slabs jointed with cement mortar. The structure is made of sheets that are angled at the edges. The angle is bent one and a half inch long. This is the part that is bolted together. The unit has a window, door, internal partitions and vents for air circulation.

The gate house construction starts by locating the area to erect it near the entrance. The setting out of the unit is marked. The ground is excavated the size of the room about eight inches deep. Hardcore is laid and compacted. The edge where the sheets will be fixed is cast with a concrete kerb. This kerb is of two inches wide and four inches deep. Steel bolts are cast into the kerb. This steel bolts are for holding the sheet metal sides of the house.

The sheet metal sides are fastened with the bolts on to the ground. Once the sides are all erect, they are bolted to one another. The floor slabs are laid on to the ground. The roof is then fixed onto the sides sheets with bolts. When the house is complete, soft boards are fixed onto the ceiling and the sides. This is done to keep off the cold and heat. When boards are fixed on the surfaces, decoration is done to the walls and the ceiling for aesthetics.

The concept of furniture has evolved over the years. From the middle-ages to the present furniture that is influenced by modernism. The dark or gilded carved wood and richly patterned fabrics have given way to the simplicity and geometry of polished metal. The use of new materials such synthetic fibers, vinyl, steel and tubular metal gain its popularity. The forms of furniture evolved visually heavy to light.

Metal furniture can give your house an attractive, tasteful and contemporary look. You can get everything from kitchen and dining room tables and chairs, cabinets, hostess carts, beds, folding cots, folding card tables, and children’s furniture such as play yards and high chairs. With so much choice on the market today it will be easy to coordinate the look and theme that you wish to achieve in your living spaces.

The most common metal furniture is made from iron, aluminum and steel.

Much of the iron furniture available today is wrought iron, rather than cast iron. They reflect fine blend of traditional designs and contemporary style and give the appealing look to your living space. Wrought iron is good for garden furniture, providing a classic look. However, it’s heavy, which is a challenge, but appreciated on windy days. It needs much care, though, and can easily rust and corrode if not waterproofed.

Wrought iron is any kind of metal, which is hammered, twisted or bent into shape. Its can be finished with brush paint, spray paint, or powder coating to achieve the look you desire. When you are buying wrought iron, look for pieces made with solid metal rather than hollow tubing, and that are welded, rather than bolted, together. The elegantly styled wrought iron furniture has reached to the modern homes by presenting fresh and sophisticated looks in new varieties and styles.

Steel, a hard tough metal, is an alloy of iron and various small percentages of metallic elements. The alloys produce hardness and resistance to rusting. Galvanized steel has been plated with zinc and stainless steel has been alloyed with chromium.

The presence of chromium in stainless steel furniture makes it stainless and virtually immune to rust and corrosion because of its thin film of oxide on the surface. This type of furniture is good for low maintenance. A stainless steel can be easily melted and recycled, it is also environmental friendly.

Steel furniture is typically pricier when it’s used as furniture, with the price varying according to the type of metal and thickness. However steel furniture is available in varied styles ranging from traditional, antique to modern ones, designs, color and patterns.

Aluminum furniture is more common than steel furniture, mostly because it doesn’t rust, although it oxidized, turning into a chalky white. It is also lightweight but not exceedingly wind stable. Caste and heavy tube aluminum give better quality.  Aluminum has to be thicker than steel if it is to have as much strength. Tubular aluminum is flexible and hollowing, besides less sturdy.

Best quality aluminum pieces have a powder-coated finish, which determines the final color of the piece and the durability of metal. Being extremely malleable, aluminum is easily fabricated, formed, welded, riveted or bolted into various shapes which appropriate to be used in a variety of applications.

Often people consider metal furniture with being uncomfortable, as images of “metal” conjure up cold, hard-backed chairs as well as cold, shiny surfaces. However, it’s easy to add cushions and upholstery to make the furniture comfy, as well as attractive. Also, adding some simple curves also adds to comfort as many types of metal furniture manufacturers have done.

Since the dawn of time, various civilizations have used various adornments to symbolize beauty, fashion, status, possession, culture, belonging, magical powers, mood, and faith – especially in warding off evil. Amazing isn’t it? It’s likely that you may have not given that much thought to the trinket other than as its role as an accessory to your new wardrobe.

Traditional ornaments for the body were made of seeds, twigs, berries, leather, ivory, shells, horn, bone, feathers, and various other findings amongst the landscape. Found objects in the day of primitive man were considered very precious and were worn and showcased on the body as prized possessions, although the jewelry so created was very organic in its construction. Stories were told and memories were cast between all the little findings woven together in full circle – quite a mesmerizing concept.

Over time, as religion started to play a greater role in historical civilizations, jewelry espoused one’s convictions and belief system and began to take on a deeper symbolic role – that still exists today. Think about how many times you’ve seen someone with a religious symbol strewn on a simple chain dangling as a pendant. Precious stones were thought to contain certain protective powers and curative properties (both of which are still believed by many today) and precious metals were connected with worship. Thus, composition of jewelry became a little more sophisticated and pursuant to that its scope of placement on the body broadened. Hence we saw earrings, hair jewelry, rings, etc. Eventually jewelry in the role of functionality blossomed – like the watch or the belt or barrettes for example, and so was born the category of accessories! Stay tuned for more on that one!

Today, jewelry still holds most if not all of its original values. The artists that create it have such a wonderful and monumental task of ensuring it is represented in the most expressive way – a real tribute to it evolution and meaning to man.

Self-made fire pits can complement accessories gathered from home improvement stores. However there is nothing like constructing it in the original way. You can use plain landscaping blocks or stones. A few decide to use concrete blocks. Although this tends to get deteriorated with heat, however worth using as changing them is not costly. Drainage is an important part of domestic fire pits. You can dig a 3-4 inch hole 24 inches. Then fill it with gravel. This hole requires to be dug right in the bottom center of the pit. It is supposed to work like a sump and let the water drain. You have to dry-stack the stone first. The dry-stacking is as well useful for replacing cracked or broken stones. A few opt to cement the courses by laying cement on exterior half. This is considered useful for shielding the cement from high temperature.

Here are a few other things required here, retaining wall blocks, steel pit ring with tabs, metal grate, sand and gravel. Ring and grate are necessary things when constructing a fire pit at home. This can be found at home improvement stores or near garden stores. At times it is easy to buy these online. The width of the wall blocks used here can be 12 inches wide, 4 inches high and 8 inches deep. Put a substantial amount of sand and gravel in the pit.

Dig a hole at this moment. This hole is supposed to be 2 feet wider than the fire pit. Dig the hole around 7 feet diagonal to the fire pit. The hole is supposed to be round. To make it so, mark the circle. Dig out 1 foot of soil. Then dig for four inches of gravel plus four inches of sand. That layer is required to be compressed flat, next work with the base course of blocks. It has to be laid down and you have to level it carefully. The space out of the blocks has to be filled; you can fill it with gravel. The first course will be more or less buried this way; this in turn will strengthen the stone base.

Now you have to focus on laying more helpings of stone. At this point you will draw on the steel ring. The ring should keep the grill intact. This is done to confirm that each of the helpings is round with precise diameter. The ring has to be made vertical to each other and to the ground surface. If you notice that the center of your pit is roughly 36 inches in diameter- you will recognize you did well. At this point you can overlap the stone layers. In each of the helpings, you are supposed to leave 3-4 openings between stones. The openings are planned to let air to flow in and help the fire burn.

Given that by now the entire job is finished, it is now time to lay the last helping of stone. Ahead of the final helping is laid; the steel ring has to be placed in the spot. As a standard guides, a fire pit constructed this way can have 7 layers. Your pit constructed this way is supposed to be 24 inches high. For better results from your fire, you can take out a layer or two.