Metal Casting Zone Info Blog

Archive for July, 2010

Learn how to cast your silver designs. From carving your wax, investing, burn-out process, casting, and polishing it up, you will walk away with your very own finished piece.

Hello,

Now that you have learned the basics of Metal Casting, you can begin to
get a broader perspective of the entire Casting Process as a whole.

Metal casting has endured through the ages since the time of
Ancient Egypt, possibly longer. Since then small foundries have
developed to meet the needs of the individual caster. There are
several reasons that people choose to create their own home grown
foundries. A top reason is the need to create parts and pieces
that are no longer available on the market or that are just too
expensive to purchase. Those who get into metal casting for this
reason are usually interested in restoration projects, home
improvement projects, or hobby building like model planes and trains.
Artists are the other group that see metal casting as a cheap and
easy way to create sculptures from small to large. Jewelers even
use metal casting to create complex pieces that would just
otherwise be impossible to create.

Given the wide scope of metal casting there are several methods
and techniques that have developed. For those new to metal casting
or for those wanting to try some of these other methods may find
it difficult to find information on your own. Luckily, there are
several metal casting associations and groups that are more then
willing to share information and exchange ideas, projects, and
pictures of the goings on in the their home foundries.

On the internet, metal casting associations and groups are either
message boards full of casters where they can ask questions, post
ideas, and pictures or are websites that are maintained by a set
group of people offering general information and educational resources.

Both of these types of websites are incredibly helpful to metal
casters who can benefit from the educational purposes of some of
the sites tempered with the real life applications and experiences
of the message boards.

There will be more industrial foundry and metal casting information
than sites directed at the small home foundries. Industrial metal
casting sites can be wonderful sources of information so do not
skip by these. Use both small metal casting sites and industrial
sites to your advantage.

One of the most popular message board type sites for information
is the Casting Hobby Group found through Yahoo Groups. This casting
group was developed and maintained by experienced metal casters and
enjoys a high amount of activity. This is a great place to go to
for quick information and ideas not to mention photos and even
furnace building plans.

The Casting Hobby Group can be found at
http://groups.yahoo.com/group/castinghobby/

The Association of Backyard Metal Casters is located at
http://www.abymc.com/.  This online metal casting association
has an extensive membership complete with informative articles,
forums, and even live chat. Of course, pictures are posted on the
site to give visitors ideas about what other furnaces and foundries
look like. Don’t worry if you’re foundry isn’t pretty, there
actually doesn’t seem to be very many of them that are.

Now, The American Foundry Society is mainly for the industrial
metal casters and companies but they also promote information and
education to consumers. The information provided on the site is
great for anyone wishing to follow advancements in metal casting
technology. There is even an online store.

http://www.afsinc.org/ is the online home for the American Foundry Society.

For the most part metal casting associations and groups exist on
the local level more than a unifying force on the web. What does
exist on the web is a great source of information, ideas,
and insight. It is a great idea to join any of the groups you can
in order to share and find knowledge.

Here is a link to a Web Page that provides more information about this
Metal Casting topic:
http://www.metalcastingzone.com/casting-associations/

P.S.
There is more…If you sign up as a member of Metal Casting Zone, you
will get special access to 2 Free eBooks on the site. Both of the eBooks
are about Metal Casting Basics.  Here is the best part, becoming a member is Free!
Wait…Both of the Metal Casting Basics eBooks are free!

Sign Up Now to get all these Free Benefits!
http://www.metalcastingzone.com/index.php?option=com_comprofiler&task=registers

Hello,

Today we learn about the different types of casting furnaces.

In Metal Casting, the type of furnace you have at your foundry, or
workshop determines a lot of the work you can or can not do.
Many metal casters enjoy making their own furnaces and have done
so quite successfully. The plans for home made furnaces are eagerly
shared among the enthusiasts so finding blueprints and instructions
should not be difficult. But before you rush off to find the
blueprints you may want to take time to learn about the types of
casting furnaces available to help determine which one will suit
your needs. This is not saying that you should only have one
furnace at any given time, but this way you will know what project
will work best for which furnace.

Cupola
Cupola furnaces are among the most popular with backyard foundries.
Many casters construct their own cupola which proves to be cost
effective and highly efficient if done properly. Since cupola
furnaces can achieve high melting temperatures they are primarily
used for the melting of iron and bronze, though aluminum can also
be melted when attention is paid to keeping the temperature low.
The primary fuel source for cupola furnaces are coke using limestone
for flux.

By not using a crucible, the Cupola furnace is able to melt the
metal at a faster rate. While individual designs of these furnaces
differ due to varying resources and design ideas, the basic
component of a cupola furnace is the same. The cupola furnace must
be elevated above the ground and installed with a drop bottom
usually hinged, which will allow the excess metal, fuel source, and
other waste to drop from the furnace. The tap hole and shaft which
will allow the molten metal to flow from the furnace and into the
ladle and air shafts are also required.  A slag tap hole can be
placed on the furnace usually in the back, higher then the tap hole,
which will allow the slag to flow out easily.

With most small home foundries, the cupola furnaces are preferred
over that of other furnaces for its high melting rates and for how
easily the construction of such a furnace can be.

Reverberatory
The Reverberatory Furnaces are commonly found in industrial plants
but there have been quite a number of home grown foundries that
have used this furnace type with much success. The basic idea of a
Reverbeatory Furnace is to use the heat reflecting off a surface,
usually brick, to heat the metal, which is aluminum in most cases.
This way, the metal does not come into contact with the fuel or the
flame. This process is also used in Puddling Furnaces. The name
Reverberatory and Puddling are often used interchangeably. By placing
the metal in a shallow depression and then directing an intense flame
over that depression and to the wall, the heat rebounds to melt
the metal. Many casters will adjust the length of the flame since
a longer path will mean that the heat will be more intense.

There are many designs for the reverberatory furnace, all of which
will include exhaust ports and the rear of the furnace must be
able to withstand the intense heat and be able to bounce it back
into the chamber.

Bronze, aluminum, tin, and many other ores can be melted in a
reverberatory furnace all depending on the construction of the
actual furnace and the heat of the flame. This type of furnace has
been around since at least the Middle Ages and was used primarily
for bronze work.

Electric Arc
Electric Arc furnaces are normally used in Industrial foundries.
Most hobby casters do not use these furnaces due to cost, space issues,
and a general inconvenience. There are two forms of the electric
arc furnace, the direct and indirect.

The direct arc has three electrodes which are used to heat metal by
way of the arc. This creates an incredible amount of heat and so
water jackets and other cooling devices will be needed for operation.

The indirect arc just uses one electrode and works in much the same
way as the direct arc furnace.

Electric Induction
Electric Induction furnaces are becoming all the more popular with
large industrial size foundries that enjoy the clean burning and
efficiency of an electrical furnace. Copper coils surround the
crucible with the metal inside which can reach extremely high
temperature suitable for melting most metals.

Rotary
The Rotary style furnaces are hailed for their ease of use being
fully or at the very least partially automatic. These furnaces tend
to be harder to construct though there are resources and companies
online that sell rotary furnace.

The different furnace types do affect the quality of the work being
produced, so it is important to keep that in mind as you cast.
With a little trial and error, you should find the perfect furnace
to fit your needs so you can start building one of your very own.

Here is a link to a Web Page that provides more information about this
Metal Casting topic:

http://www.metalcastingzone.com/casting-furnaces/

P.S.
There is more…If you sign up as a member of Metal Casting Zone, you
will get special access to 2 Free eBooks on the site. Both of the eBooks
are about Metal Casting Basics.  Here is the best part, becoming a member is Free!
Wait…Both of the Metal Casting Basics eBooks are free!

Sign Up Now to get all these Free Benefits!
http://www.metalcastingzone.com/index.php?option=com_comprofiler&task=registers

Hello,

Today’s topic is about Crucibles.  A very important part of metal
casting.

From the earliest attempts to make lead into gold and to the
more modern use of making those empty soda cans into a replacement
part for that model plane, crucibles have been an absolute
necessity in metal casting.

Crucibles are placed inside of the furnace where the metal is
placed and then melted. The crucible then collects the melted
alloy which will then be poured into the model. Since the crucible
will be holding metals melted at extremely high temperatures the
crucible will need to be created from very strong material.
The durability of the crucible will add a certain aspect of safety
to the metal casting process. Using a crucible that is low in
quality can result in shattering, which, let’s face it, is never
ever a good thing.

Any crucible at any given moment can shatter or fail which is
why using appropriate safety gear at all times is so important.
In order to handle the crucible which will be red hot you will
need to wear boots, jeans, and gloves.  The tools for lifting
the crucible from the furnace and then the tool for tilting the
crucible so that the molten metal will pour easily into the mold
will vary crucible from crucible. Those that make their own
crucible will be able to create them in an identical manner so
the same tools can be used. The idea of these tools is to make
sure that the crucible can be safely and securely lifted and
poured. You will never want to directly touch a hot crucible,
even with gloves.

For those that either can not or will not make a home made
crucible can buy a crucible and tools from any of the online
stores. A common material for crucibles is graphite as it can
withstand the molten metal. Many who cast metal will prefer
using graphite crucibles as it can prevent impurities from being
introduced into the gold or other precious metal being used.
Another option is the Silicon Carbide crucible.

Silicon Carbide is a great though expensive alternative to the
graphite crucible.  A crucible made from Silicon Carbide can
handle rougher treatment then graphite so if you are not
particularly gentle with your toys then this is a terrific option.

Yet another option available to the home foundry is creating your
very own crucible. Many don’t really recommend this since
commercially created crucible tend to be more durable and will
instill a bit more confidence in the casters. It is, however,
possible to create a crucible as many of us will at one time or
another.

If you plan on creating your own crucible then keep this in mind.
There are a few areas of home metal casting where you should not
cut corners, these definitely include crucibles. The crucibles
job is the transportation of incredibly hot molten metal which
can easily exceed 1,000 degrees Fahrenheit and is really the only
thing between you and this metal. When you plan on melting metals
with extremely high melting points you will need crucibles made
from material that will cost a little extra. Spend that money
and do so gladly since it is just a small price to pay for your safety.

Crucibles should only be used to melt one kind of metal. If you
have always melted aluminum but decide to try melting brass then
you will need a new crucible. This is done for safety reasons.
Remember, a crucible is not meant to last forever. Always check
your crucible before use to make sure there are not cracks or
imperfections if there are then do not use that crucible.

Crucibles come in a variety of sizes and can be made from a
variety of materials. It all depends on the type of metal to be
used and the size of the job. Never skimp on the price of this
tool and always follow safety guidelines and use common sense
when dealing with a hot crucible.

Here is a link to a Web Page that provides more information about this
Metal Casting topic:

http://www.metalcastingzone.com/crucibles/

P.S.
There is more…If you sign up as a member of Metal Casting Zone, you
will get special access to 2 Free eBooks on the site. Both of the eBooks
are about Metal Casting Basics.  Here is the best part, becoming a member is Free!
Wait…Both of the Metal Casting Basics eBooks are free!

Sign Up Now to get all these Free Benefits!

http://www.metalcastingzone.com/index.php?option=com_comprofiler&task=registers

Hello,

We have an exciting topic today!  It is called Casting Sand.

Sand casting is the most ancient form of metal casting and has been
around since at least Ancient Egypt. Many metal casters prefer
using sand casting over many of the other forms of processes
because it’s cheap and the sand used is readily available.

Many experienced metal casters will continue to use sand casting
even though their abilities and resources allow them to use the
other metal casting methods like Lost Wax Casting or Investment
Casting. Sand casting involves less material and less effort than
the other casting methods. Sand casting is a great way for new
casters to get into the trade.

In sand casting, the metal caster will create a mold by placing an
original in the flask which is filled with sand. The original will
be a pattern of what you want to cast. By ramming or vibrating
the sand, the caster creates a mold of the original. The casting sand
used needs to be able to retain the shape of the mold. Finding the
right mixture of sand to water is crucial. Too much water can ruin
the mold and possibly destroy it while too little water will create
a poor casting. Green sand is a type of casting sand that many
prefer since its ability to retain the shape of the mold is far
better then normal sand. Green sand usually contains bentonite clay,
sand, and water.

After the sand is packed, the pattern or original is removed carefully.
Molten metal is poured into the mold and allowed to cool. The metal
caster will then break the mold and dig out the casting.

While sand casting has its benefits the use of green sand can
greatly increase the likelihood of a successful casting. Green sand
is not really green the color refers to the damp nature of the sand.
Green sand is created by adding water and bentonite to the sand.
One of the benefits of using bentonite in green sand is that it
makes the sand more permeable which allows more gas to escape.

Metal casters can get the bentonite from a variety of sources like
home improvement stores and even from household resources. Many
have milled the type of cat litter that clumps since one of the
ingredients is bentonite. Remember to work in a well ventilated
room or to wear proper face gear when working with bentonite since
it will irritate the lungs.

There are several recipes online for green sand but the most common
method is experimentation. What you are looking for when mixing the
sand, water, and bentonite is a texture that is not wet but damp
and will retain its shape when molded.

The type of sand you use to make green sand depends on you and the
availability of the sand. Many will use sand that they found out
in the wilds of nature and some will buy bags of sand like
playground sand. As you cast with green sand you will find out
which works best with what metals.

Green sand is growing in popularity as more casters are recognizing
the properties of this method. If you have traditionally used
regular sand casting, green sand casting will prove to be easier
to work with and will produce better casts.

The best part about green sand casting is that is does not cost
a lot of green.

Here is a link to a Web Page that covers this E-Course Email:
http://www.metalcastingzone.com/casting-sand/

P.S.
There is more…If you sign up as a member of Metal Casting Zone, you
will get special access to 2 Free eBooks on the site. Both of the eBooks
are about Metal Casting Basics.  Here is the best part, becoming a member is Free!
Wait…Both of the Metal Casting Basics eBooks are free!

Sign Up Now to get all these Free Benefits!
http://www.metalcastingzone.com/index.php?option=com_comprofiler&task=registers

Hello,

Here we are on day three, ready to learn about Lost Wax Casting.

Lost Wax Casting is an ancient technique that has been used to
create very complicated metal castings and involved pieces that
would other wise be impossible either because of economic reasons
or manufacturing reasons. Everyone from small jewelers to large
industrial foundries can use Lost Wax Casting. This process is also
called Investment Casting when it is used in commercial industries.
While jewelry makers are the primary ones to use the Lost Wax Casting,
many others use it to achieve a number aims and goals.

Lost Wax Casting is the ideal and preferred method for artists who
are interested in making items like sculptures or rings from a
variety of alloys like bronze, steel, or copper. This process is q
uite involved but not all that complex as long as you have some kind
of metal casting know-how. For anyone wanting to experiment with
different casting methods Lost Wax Casting is a great option because
it involves a few materials and methods that are not normally
found in other methods like Sand Casting.

The most noticeable difference of Lost Wax Casting from other
castings is exactly what’s in the name; the wax. To use Lost Wax
Casting you do not necessarily have to be an artists but some skill
in sculpting might be nice. You are going to start off by creating
a sculpture from wax that will be the original.

You will then create a mold of the original. The mold is usually
created from plaster with latex lining to help preserve the details
of the original. If this is your first attempt at Lost Wax Casting
you may want to make an original without a lot of detail just to
get the feel for the entire process and so you do not become
discouraged if something does not work out. Remember metal casting
is a skill that must be learned by research, trial, and error.
Chances are that you will not be completely successful, the first
time around. The original piece is usually lost after the construction
of the mold. This is normal and if you do want to prevent this from
happening you can create the original from material other then wax
like a metal alloy.

When the mold is ready you are then going to pour molten wax,
you’re not ready for metal just yet, into the mold. The amount
of wax needed for this step depends on the desired thickness.
Once the copy is ready, you are going to remove it very carefully
from the mold. You will remove any of the impurities from the copy.
This is called chasing.

You will then sprue the copy. Spruing is the act of carefully
placing paths that will let the molten metal in and air out.
Afterwards, a ceramic shell is created around the copy. The shell
isn’t really ceramic but a combination of liquid silica and sand.
Traditionally, and in some areas still, animal dung and dirt is
used to create the shell. The choice of which shell material you
want to use is up to you. The shell is hardened in the kiln and
the wax melts out. If you want to reuse the wax then collect it
during this step. Wax can be reused a number of times and if you
are on a budget or are just trying out different designs and methods,
collecting the wax is encouraged. Once the wax is gone and all that
remains is the hollow shell you will want to run water through it
to make sure there are no leaks. If there are then you will need to
patch them before pouring the molten metal.

You are going to want to reheat the shell before pouring the metal
to avoid shattering the shell. The shell is still on the sprue tree
so pouring the metal is an easy process. When the metal has hardened,
then break the shell carefully and remove the cast. Afterwards, it
is up to you to finish the piece to your liking and preference.

The Lost Wax Casting process is an enjoyable experience but it does
use a few tools that you might need to purchase before hand, like
the wax and spruing tree. At the very least, you might want to try
Lost Wax Casting once or twice to get a feel for it. This way you
have another casting process at your disposal.

Here is a link to a Web Page that covers this E-Course Email:
http://www.metalcastingzone.com/lost-wax-casting/

P.S.
There is more…If you sign up as a member of Metal Casting Zone, you
will get special access to 2 Free eBooks on the site. Both of the eBooks
are about Metal Casting Basics.  Here is the best part, becoming a member is Free!
Wait…Both of the Metal Casting Basics eBooks are free!

Sign Up Now to get all these Free Benefits!
http://www.metalcastingzone.com/index.php?option=com_comprofiler&task=registers

Hello,

Today we are going to talk about Die Casting.

What about Die casting?
Die casting is used by industrial foundries and manufacturers to create
practically anything and everything, such as die cast cars. Many small
foundries, like the one in your garage, backyard, of workshop may
find that die casting is really just not economical. But who said that
having fun and trying new things was ever economical? The process
of Die Casting involves a simple concept. The molten metal is
injected with high pressure into the mold or mold cavities.
The mold used in die casting can have several small civilities of
either the same pattern or different pattern.

The name Die Casting comes from the molds which are called dies. These
molds are reusable and are often made from steel but other alloys can be
used as long as they can withstand high pressure. The reason dies must be
created from metal and not from sand or other material is due to the high amount
of pressure used to get the molten metal into the mold. If sand molds were
used in a Die casting procedure then the mold would crumble. There are plenty
of advantages of using dies in a casting procedure which makes this method
desirable for anyone wishing to create a high volume of similar castings.

Die casting is perfect for anyone that needs to make a lot of the same thing
without any quality or pattern deviation. This is especially helpful in
certain industries where quantity and quality count. Many hobbyists may have
no use for die casting on a practical basis but will often try at least one
Die casting for the sake of trying.

There are two types of machines used in the Die Cast procedure. These machines
are essentially the same and are called the Hot-chamber and the Cold-chamber.

The Hot-chamber machine melts the alloy and feeds it into a section of the
machine referred to as the gooseneck. A piston then forces the alloy into
the mold. A separate furnace is not needed but the draw back of this is that
metals with higher melting points can not be used.

The Cold-chamber is used for metals that can not be used by the Hot-chamber
such as aluminum and copper. A separate furnace is needed to melt the alloy
which is then poured into the injection cylinder and then shot into the mold.

The advantages of using Die casting vary but the most noticeable advantages
are the repeated quality, smooth casting surface, and the quick production of
casts. While the initial cost of Die Casting exceeds several of the other
casting procedures, those that need a high number of casts in the shortest
amount of time possibly will benefit greatly from the investment.

Die casting is commonly used to create commercial goods as it yields a
high volume. The molds, or dies, used vary in life cycle depending upon the
material used to create the die. The die can have one cavity or several
cavities depending upon the need.

Here is a link to a Web Page that covers this first email:
http://www.metalcastingzone.com/die-casting/

P.S.
There is more…If you sign up as a member of Metal Casting Zone, you
will get special access to 2 Free eBooks on the site. Both of the eBooks
are about Metal Casting Basics.  Here is the best part, becoming a member is Free!
Wait…Both of the Metal Casting Basics eBooks are free!

Sign Up Now to get all these Free Benefits!
http://www.metalcastingzone.com/index.php?option=com_comprofiler&task=registers

Hello,

Welcome to the Metal Casting seven-day E-mail course.  Today you are
going on a journey.  You are going to learn about the basics of
Metal Casting.  I hope you are as excited as I am about this topic.

Here are the things we will be covering in the course:
What is Casting?
Die Casting
Lost Wax Casting
Casting Sand
Crucibles
Casting Furnaces
Next Steps – Casting Organizations

Lets get on with Day 1 of the Course:
What Is Casting?

Metal casting is an ancient technique that has a variety of applications and
purposes. Civilizations from the dawn of time to present day have used metal
working as a way of creating artistic, religious, and practical items.
The process of metal casting involves melting metals at high temperatures
and using molds to then shape the metal into new items. The furnaces used in
metal casting helped pave the way for the Industrial Revolution, without which
the course of history would be dramatically different. Metal casting is
just one form of metal working that has seen a recent surge in popularity as
resources are becoming more affordable and communities are springing up to
share information, ideas, and projects.

Metal casting requires specialized equipment, knowledge, and some creativity.
While metal casting is used on an Industrial level as the process cuts cost
and proves to be highly efficient, many individuals participate in metal casting
as a hobby and in artistic endeavors. Many people are drawn to metal casting
for one reason or another, although there seems to be two main motivations
that stand out. The first motivation that brings hobbyists to practice metal
casting is need; people may need to create items or parts for other ventures.
Metal casting is a great way to build hard to find pieces for models,
restoration projects, and even just small replacement parts needed for
common household items. The second motivation for using metal casting is
using it as a way to create sculptures or other artistic endeavors.

Whatever the reason, small scale metal casting is attractive because that
it can be done right at home, either in the backyard or workshop.
Individuals working in metal casting are able to create home made tools
and equipment like furnaces and molds. Metal casting is only limited by
the individual’s desire, so for those with the time and the need, virtually
anything is possible.

The actual casting process in metal casting has several forms, the most
popular being sand casting. Sand casting involves creating a mold from sand
which can be created at home, and then pouring the liquid metal into the mold.
Afterwards, the metal is allowed to air dry and the mold is removed.
This type of casting proves to be the most economical, but other types of
casting can provide fuller detail and higher quality results.

Here is a link to a Web Page that covers this first email:
http://www.metalcastingzone.com/casting-general/

Have a good one,
Ivan Irons

P.S.
There is more…If you sign up as a member of Metal Casting Zone, you
will get special access to 2 Free eBooks on the site. Both of the eBooks
are about Metal Casting Basics.  Here is the best part, becoming a member is Free!
Wait…Both of the Metal Casting Basics eBooks are free!

Sign Up Now to get all these Free Benefits!
http://www.metalcastingzone.com/index.php?option=com_comprofiler&task=registers

Product Description
When casting, this machine creates a vacuum at one end of the flask, which pulls the air and gases from the mold so that the molten metal flows quickly to every opening. Larger flasks can be cast with vacuum casting than with the centrifugal machine (although it is not possible to specify exact sizes, as the amount of metal to be cast, the shape of the cavity, etc., will all affect the size). This machine is capable of creating a negative mercury pressure equal to 27″-29″ at sea level. The vacuum table measures 10-1/2″ x 10-1/2″ and rests on joggle springs. Unit comes complete as shown

VACUUM TABLE COMPLETE WITH PUMP

Product Description

Arcair Model 94-378-267 1/2″ Upper And Lower Head Assembly For TRI-ARC Foundry Torch

Arcair Model 94-378-267 1/2″ Upper And Lower Head Assembly For TRI-ARC Foundry Torch