Metal Casting Zone Info Blog

Archive for October, 2011

DON’T TRY THIS AT HOME!!!!!  An overview of my aluminum foundry. Only cost me about $30 bucks at Ace Hardware. Got some scrap aluminum at a welding yard for free and tried to mold them into ingots using a wal-mart muffin pan.

Aluminum Pour in a Home Built Foundry

Me and my friend made a video showing you how to make brass, which is copper + zinc, not copper + tin. Anyway, after we make brass, we show you how to cast it, and of course casting it into any symbol you want!

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can’t remember if it was brass or bronze we were casting into a 1 off mold (loss wax), took about an hour for the metal to melt and about 4 hours for the mold to cool

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Ohio State 2nd-year Materials Science and Engineering students participate in metal casting lab (MSE 281), and create aluminum OSU stadia pieces.

Continuous casting for Brass and copper rod, pipes,profiles ,sections.

foam aluminium skull halloween
from a light foam skull to a 5 kilo aluminium skull
lost foam casting
For God’s Sake not a Damien Hirst diamond skull

first time i melted and made a mold and first cast i ever made
neighbour whas sitting on the roof
waiting for things to go wrong
laughed when my leather motorgloves shrinked 5 sizes and cought fire
by the immense heat off the molten alluminium
laughed when a black smoke arised when i poored in the molten alluminium (foam burnout)
but he whas impressed by the result off this first skull

foam skull i used
5x foam skull + shipping to holland = 100 Euro
http://www.brandsonsale.com/hg-004627.html
another cheaper
http://www.centerstagestar.com/lisirefoskha.html
hee im dutch so cheaper
http://halloweentownfl.com/product/36523975-8ae5-db11-9100-001676ca3a71.aspx
or search for “realistic foam skull” from F.I.T.C.O.
http://images.google.com/images?hl=en&client=mozilla&rls=org.mozilla:…
FITCO (First Imperial Trading Company)
Straight From The Grave
http://www.firstimperial.com/
the foam is burned away when aluminium is poored into the mold
think i used brusselse aarde
no i used bindolzand (rode kneedbare zand / red sticky sand)
from http://www.hazelaar.nl 25kilo = 44 euro

a petrobond sand mold. ?

wasted my motor gloves because off extreme heat
and wasted the chickens water pan

next 2 videos inspired me
http://www.youtube.com/watch?v=3rb8BdMn7B0
http://www.youtube.com/watch?v=yR3ekOrQ1sw

i do not understand the price i payed for the scrap aluminium
on the londen metal exchange LME
the price is 2700 usdollar per 1000 kilo
2.7 dollar per kilo
2.7 U.S. dollars = 1.82679296 Euros
1.82 euro * 22 kilo = 40.18euro and i paid 25 euro
could get sleeping rich if i where a scrap metal dealer

An average aluminium can (without its contents)
weighed 16.55 grams in 1992.
By 2005 the aluminium can weighed about 14.7 grams.
thats 68 / 69 cans in a kilo
aluminium can price is 1.5 usd a kilo or 1500usd per ton

so this skull is aprox 345 cans

Aluminium has a melting point of 660°C
compared with 1540°C for iron

If all the aluminium cans sold in the UK were recycled for cash it would raise more than £30 million for collectors.
Setting up an aluminium can recycling scheme is a great way to raise funds for a charity or good cause without having to ask for donations.

Bangladesh Village Metal Casting

Preparing the scrap metal, the furnace and crucibles for casting and explaining a bit about the mould making process. The firing process and casting takes several hours and unfortunately we couldn’t stay. Rice husk is mixed with the clay to make it more refactory. Old crucibles are used to cap the new ones. A combination of brass, copper and zinc is used to make a ‘bell metal’. Both mould and crucible are placed in the furnace, when the metal is molten, both are removed from the furnace, a hole is pierced in the side of the crucible and the metal is poured.
Thanks to Riaz and Britto.

Dhamrai Metal Casting

Breaking the layers of clay away from a lost wax casting in brass at Dhamrai metal casting.