Metal Casting Zone Info Blog

Kent Klein asked:


Metal Casters have the luxury of choosing between several casting methods to accomplish their goals. Often times the metal caster chooses one method and sticks with it for several years until need directs him to another. Of course, there are those adventurous few who like to sample each casting method to find the best fit. Sure, sand casting might be the most popular but what about Lost Foam or Investment?

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.

Everyone should try die casting at least once if they can afford the initial cost. Besides, who knows when you’ll need a small battalion of metal soldiers which can be made quickly and easily with die casting.

Iron Metal Casting

Kent Klein asked:


Bronze Casting has been practiced for centuries. Many civilizations have used this alloy for weapons, sculptures, and general pieces of hardware. The popular way to cast bronze is the Lost Wax Casting process which was first used sometime in the 3000 BC near ancient Sumeria. The Lost Wax process is still used to this day and its modern equivalent Investment Casting is very popular with jewelry makers.

Bronze is the preferred alloy for metal working artists as it’s relatively easy to work with and resistant to corrosion. The properties of bronze tend to be stronger than most other alloys, except of course for steel, and lends itself easily to the molding and casting process. Many small foundries like the kind that can be found in a backyard or workshop find that bronze is a great material to work with and with a melting point of 1,700 Fahrenheit or about 925 Celsius many homemade furnaces are able to melt down the bronze quickly and efficiently.

Many modern day artists create their own furnaces with the metal casting in mind. These metal casters employ the Lost Wax Casting method which proves to be the best when dealing with the alloy. The Lost Wax Casting is making an original of the sculpture from wax and then creating a mold using this original. Often times the original is lost during the mold making process so keep that in mind if you want to hang on to the original for whatever reason. Molten wax is poured into the mold which is chased or smoothed of imperfections. During this point, any other pieces are attached and small wax tubes are placed into the piece. These tubes will be how the molten bronze is going to travel into the piece replacing wax with the alloy. When this is complete the artist will create a ceramic shell around the wax model. This shell will help form the molten bronze which will melt the wax. When the molten bronze is poured the bronze takes place of the wax. Afterwards, the artist will crack the shell and reveal the bronze piece. This method allows the transfer of very exact detail from the wax to the bronze.

Patina is added to the figure at the artist’s discretion. The Patina is a chemical that when applied to bronze creates colors and makes the bronze take an aged look. The Patrina compounds used depends on the type of color desired. Ferric Nitrate will make the bronze take on a red or brown color while Sulphurated Potash will make black and Cupric Nitrate will create blue and green. Modern day artists choose to go with a very high polished bronze instead of using these compounds. This step depends solely on the artist’s taste and the look they are going for.

Bronze casting will remain a popular medium until another alloy is developed that exhibits properties that are easier to manage and are more resistant to corrosion. Casting the alloy is easily done so metal casters that want to experiment are encouraged to do so. Making anything from small figurines, large sculptures, and even cabinet handles can be accomplished with the use of bronze. The only limitations in bronze casting are with the caster himself.

Back Yard Metal Casting

Kent Klein asked:


Bronze Casting has been practiced for centuries. Many civilizations have used this alloy for weapons, sculptures, and general pieces of hardware. The popular way to cast bronze is the Lost Wax Casting process which was first used sometime in the 3000 BC near ancient Sumeria. The Lost Wax process is still used to this day and its modern equivalent Investment Casting is very popular with jewelry makers.

Bronze is the preferred alloy for metal working artists as it’s relatively easy to work with and resistant to corrosion. The properties of bronze tend to be stronger than most other alloys, except of course for steel, and lends itself easily to the molding and casting process. Many small foundries like the kind that can be found in a backyard or workshop find that bronze is a great material to work with and with a melting point of 1,700 Fahrenheit or about 925 Celsius many homemade furnaces are able to melt down the bronze quickly and efficiently.

Many modern day artists create their own furnaces with the metal casting in mind. These metal casters employ the Lost Wax Casting method which proves to be the best when dealing with the alloy. The Lost Wax Casting is making an original of the sculpture from wax and then creating a mold using this original. Often times the original is lost during the mold making process so keep that in mind if you want to hang on to the original for whatever reason. Molten wax is poured into the mold which is chased or smoothed of imperfections. During this point, any other pieces are attached and small wax tubes are placed into the piece. These tubes will be how the molten bronze is going to travel into the piece replacing wax with the alloy. When this is complete the artist will create a ceramic shell around the wax model. This shell will help form the molten bronze which will melt the wax. When the molten bronze is poured the bronze takes place of the wax. Afterwards, the artist will crack the shell and reveal the bronze piece. This method allows the transfer of very exact detail from the wax to the bronze.

Patina is added to the figure at the artist’s discretion. The Patina is a chemical that when applied to bronze creates colors and makes the bronze take an aged look. The Patrina compounds used depends on the type of color desired. Ferric Nitrate will make the bronze take on a red or brown color while Sulphurated Potash will make black and Cupric Nitrate will create blue and green. Modern day artists choose to go with a very high polished bronze instead of using these compounds. This step depends solely on the artist’s taste and the look they are going for.

Bronze casting will remain a popular medium until another alloy is developed that exhibits properties that are easier to manage and are more resistant to corrosion. Casting the alloy is easily done so metal casters that want to experiment are encouraged to do so. Making anything from small figurines, large sculptures, and even cabinet handles can be accomplished with the use of bronze. The only limitations in bronze casting are with the caster himself.

Metal Casting Information

Kent Klein asked:


Lost Wax Casting is known as Cire Perdue in French. It is a process in which an artist’s sculpture is used to cast bronze. The Lost Wax Casting method is also known as Investment Casting in the modern industrial world. This is a very ancient method used for casting small bronze sculptures, but today it is used to make many different artifacts and the process varies from foundry to foundry. Today this developed method of Lost Wax Casting is used to make articles like fine jewelery, show pieces, dental restoration, a few specific industrial parts and also some machine tools.

Process of Lost Wax Casting:

Rough Sculptor making: A creative artist makes an original sculptor or mold or an artwork by using raw material like wax, plaster of Paris or clay. A mixture of oil based clay and wax is preferred as these materials retain their softness.

Final Mold Making: A mold is then made as per the original sculptor. The mold is made up of two pieces and a key with shim is placed between the two pieces during construction so the mold can be put accurately back together. Molds are generally made using plaster or fiberglass or any other material that may be suitable. An inner mold of latex or vinyl or silicone is put pup preserve the details of the original art work. Generally, the original art work made of plaster mold cracks and breaks during the initial phase of deconstruction. Many a times, numerable molds are required to get the exact replica of the original art work.

Filling up the mold: Once the latex and plaster mold is complete and finished, molten wax is poured into the mold till it gets an even coating all around the mold. The thickness of the wax coating is around 1/8 inch. This process is then repeated until the desired thickness is achieved.

Removal of wax replica: The hollow wax replica of the original art work is then removed from the mold. The original mold can be used for making more wax replicas, but due to the wear and tear of the original mold the reuse of the mold is limited.

Softening: Each wax mold is then chased or softened using heated metal tools. The metal tools are rubbed around portions that show cracks or the joining line of the mold, where the pieces have come together. Separately molded wax pieces are then heated and attached. The finished mold is then dressed in order to hide any imperfections. The final piece then looks like a bronze sculpture.

Making paths for molten bronze: It is also known as “spuring”, in short the wax copy is then branched with treelike wax, so that the molten bronze reaches the right parts and also it helps the air to escape. The critical and careful spuring begins from the top of the wax copy. The top of the copy is attached to by wax cylinders to different points on the wax copy.

Slurry, burnout, testing, pouring, release, metal-chasing, and painting are the final steps in the process of Lost Wax Casting.

Bronze Metal Casting

Kent Klein asked:


Many believe that iron casting is just simply out of reach for small furnaces but this is not the case. While alloys like aluminum are more prevalent in home foundries. Artists and hobbyists have also used brass, bronze, and even iron to fulfill their casting needs.

Industrial foundries commonly use iron for a variety of items like cookware, like cast iron pans, and even bridges. Casting iron provides an easy and effective method of making such large structural pieces and even smaller pieces for around the home.

The most common furnace type used by home foundries is the cupola furnace. The cupola is a basic furnace type that does not need a crucible as it allows the caster to pour the molten metal directly from the furnace into a ladle which is then poured into the mold. Cupola furnaces resemble smoke stacks and can be home made for those with enough confidence and some mechanical know-how to attempt it. The fuels used to heat the metal in a cupola furnace depend on the caster’s resources and preference. Many will use propane and some will use coal. There are a select few that will use waste material such as old scraps of metal and the powder at the bottom of bags of barbecue coal to fuel the cupola. For iron many would recommend the use of propane, but there have been some casters that have succeeded with waste material. Don’t be afraid to experiment with different fuel types to find the perfect fit for your furnace and need.

Finding a source of iron can be difficult and a trip to the scrap yard might be in order. This is just one of the exciting ventures that metal casting can provide you. After you locate your iron you will need to prepare your mold. This is assuming you have a pattern in mind that you want to cast. If not, then go ahead and figure something out even if it’s a small piece in order to test your iron casting ability. Since sand casting is the most popular casting method you might want to use it for the iron casting especially if you are familiar with the method and not with iron.

After making the sand mold and placing the runner for the molten iron you will melt the metal. The melting point of iron is 2,800 degrees Fahrenheit or about 1538 degree Celsius. Since all metals melt at different temperatures don’t be impatient if iron takes longer to melt and don’t be surprised if it’s quicker.

When the molten iron is ready you are going to pour some into a ladle and the pour that into the sand mold. The sand mold is held in place by the cope and drag, which is the top and bottom part of the mold. The runners are in place in the mold to allow the molten iron a place to enter. When the iron is cool, remove the cast from the sand carefully and there you have a cast of iron.

As with all metal casts, you will need to follow the appropriate safety steps to avoid any accidents. Accidents with molten metal will always be very painful so make sure you wear gloves, jeans, boots, and a long sleeve shirt. You may also want a heavy duty leather apron and a pair of goggles.

Iron casting is a great way to create restoration items or pieces for around the home and even for artistic purposes.

Metal Casting Basics

Kent Klein asked:


Metal Casters have the luxury of choosing between several casting methods to accomplish their goals. Often times the metal caster chooses one method and sticks with it for several years until need directs him to another. Of course, there are those adventurous few who like to sample each casting method to find the best fit. Sure, sand casting might be the most popular but what about Lost Foam or Investment?

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.

Everyone should try die casting at least once if they can afford the initial cost. Besides, who knows when you’ll need a small battalion of metal soldiers which can be made quickly and easily with die casting.

Metal Casting Information