Metal Casting Zone Info Blog

Kent Kelin asked:


 
Metal casting is known and loved for the high temperatures, glowing molten metal, and the possibility to make nearly anything. Metal and their alloys are not the only things that can be used in casting. Casting in plastic, most notably resin casting, is becoming popular with artists and jewelers looking for something odd and unique. Resin casting does not involve the use of furnaces, crucibles, or casting sand. In fact all one really needs for resin casting is a mold, some resin (of course), and time. There are actually two forms of resin casting. The first kind is the one that more closely resembles metal casting, uses a mold and even gates and runners if it’s complex enough. The second type of resin casting is simply incasing an object in the resin. An example of this is using an ice cube tray and placing an object like a small pendant in one of the tray’s cavities and then filling it with the resin solution. After the resin dries you can pop it out of the tray. The pendant is now encased in hard plastic. This form is usually employed by jewelers and crafty moms but tends to be fun for everyone no matter age or experience. At the very least it’s a great way to get rid of some of the clutter around your house and disguise it as art. You can cast leaves, coins, and other objects in the resin to make anything from charms to magnets. Resin casting using mold is generally used by those who work with models and miniatures. Resin casting is a great way to make several pieces at once so you can avoid shelling out money you may not have and waiting several weeks for delivery of your items. Who has that kind of time anymore? Like metal casting, resin casting will require you to build a mold. If you are fortunate enough then you can easily find pre-made molds, especially if you are working with miniatures. If you don’t feel like buying these pre-made molds or just like doing things the hard way, then you will have to make the mold yourself. Don’t worry, it’s still fun. You will need to find a molding box this will hold the rubber that will be used to make the actual mold until it dries. Many who work with smaller objects find that working with toy building blocks to create this molding block work extremely well and will provide added convenience. A wooden box will work as well, of course. The box, or flask, will not have a top or bottom, just the four walls. Place molding clay at the bottom of the flask and insert your original. Make sure to add a way for the resin plastic to enter the mold. This cup or funnel should be placed at the top of the mold. You are going to prepare the silicone rubber and catalyst which will be used to create the mold. Follow the instructions on the labels since each type will vary. A process called degassing can be used which will remove all the air bubbles from the rubber. This is a fun process involving a vacuum pump. Slowly pour the rubber into the flask, covering the original. This can take up to a day to dry, so be patient. Remove the molding clay and repeat the process using the bottom part of the flask, or drag. You should have two parts now, with the original in the middle. When dry, remove the mold from the box and very carefully split the mold to remove the original. Place the mold back together and prepare the resin solution, follow the instructions to the letter. Pour the resin into the top of the mold, where you placed the cup. The set time for the resin should be stated on the bottle, but for most it will take up to 30 minutes. When ready crack the mold open and remove the cast. Resin casting can be a great family craft project but just make sure to follow all of the safety guidelines. This type of casting can still be dangerous even though you are not dealing with molten metals. Often times, the solutions and chemicals used in resin casting are poisonous if consumed. Not to mention that resin casting can be a bit smelly so working outside or in a well ventilated room is advisable.

Home Metal Casting

Kent Kelin asked:


 
Metal casting is known and loved for the high temperatures, glowing molten metal, and the possibility to make nearly anything. Metal and their alloys are not the only things that can be used in casting. Casting in plastic, most notably resin casting, is becoming popular with artists and jewelers looking for something odd and unique. Resin casting does not involve the use of furnaces, crucibles, or casting sand. In fact all one really needs for resin casting is a mold, some resin (of course), and time. There are actually two forms of resin casting. The first kind is the one that more closely resembles metal casting, uses a mold and even gates and runners if it’s complex enough. The second type of resin casting is simply incasing an object in the resin. An example of this is using an ice cube tray and placing an object like a small pendant in one of the tray’s cavities and then filling it with the resin solution. After the resin dries you can pop it out of the tray. The pendant is now encased in hard plastic. This form is usually employed by jewelers and crafty moms but tends to be fun for everyone no matter age or experience. At the very least it’s a great way to get rid of some of the clutter around your house and disguise it as art. You can cast leaves, coins, and other objects in the resin to make anything from charms to magnets. Resin casting using mold is generally used by those who work with models and miniatures. Resin casting is a great way to make several pieces at once so you can avoid shelling out money you may not have and waiting several weeks for delivery of your items. Who has that kind of time anymore? Like metal casting, resin casting will require you to build a mold. If you are fortunate enough then you can easily find pre-made molds, especially if you are working with miniatures. If you don’t feel like buying these pre-made molds or just like doing things the hard way, then you will have to make the mold yourself. Don’t worry, it’s still fun. You will need to find a molding box this will hold the rubber that will be used to make the actual mold until it dries. Many who work with smaller objects find that working with toy building blocks to create this molding block work extremely well and will provide added convenience. A wooden box will work as well, of course. The box, or flask, will not have a top or bottom, just the four walls. Place molding clay at the bottom of the flask and insert your original. Make sure to add a way for the resin plastic to enter the mold. This cup or funnel should be placed at the top of the mold. You are going to prepare the silicone rubber and catalyst which will be used to create the mold. Follow the instructions on the labels since each type will vary. A process called degassing can be used which will remove all the air bubbles from the rubber. This is a fun process involving a vacuum pump. Slowly pour the rubber into the flask, covering the original. This can take up to a day to dry, so be patient. Remove the molding clay and repeat the process using the bottom part of the flask, or drag. You should have two parts now, with the original in the middle. When dry, remove the mold from the box and very carefully split the mold to remove the original. Place the mold back together and prepare the resin solution, follow the instructions to the letter. Pour the resin into the top of the mold, where you placed the cup. The set time for the resin should be stated on the bottle, but for most it will take up to 30 minutes. When ready crack the mold open and remove the cast. Resin casting can be a great family craft project but just make sure to follow all of the safety guidelines. This type of casting can still be dangerous even though you are not dealing with molten metals. Often times, the solutions and chemicals used in resin casting are poisonous if consumed. Not to mention that resin casting can be a bit smelly so working outside or in a well ventilated room is advisable.

Foundry

Kent Klein asked:


Metal Casting provides the hobbyist with a great way to create personalized parts and pieces that may otherwise be unattainable or far too expensive. Casting is an ancient art that is still is use to this day by major industries to artists to those with backyard foundries. This skill is a valuable one that promises to provide the hobbyist with a rewarding past time. Most hobbyists begin their casting careers with a modest sized furnace to fit their most basic needs. Within a few months, the hobbyist might find that the furnace has grown and that they are casting at every chance that comes along. Don’t worry, this is completely natural.

To say that metal casting is addictive is an understatement. Metal casting provides a way for an idea to materialize through molten metal. This is perhaps one of the greatest parts of the entire metal casting process like seeing what was once just sketches solidify from liquid iron, or whatever metal is used. All the metal caster needs is an idea and red hot liquid metal.

The furnace is the pride and joy for the metal caster. Most will construct their own furnace tweaking the design here and there to better suit their needs. Many home foundries are based on home made furnaces and if constructed correctly can prove to be highly effective. The crucial part of the furnace is the furnace torch. The torch brings the heat, incredibly high heat, and without it that chunk of metal would just sit in the crucible and never see life as something new and exciting. Except as a paper weight; a very ugly paper weight.

When searching for an appropriate casting torch the hobbyist will need to take several things into consideration. The size of the furnace, and what metals you plan to use are chief among the considerations. Many casters will use a torch that uses propane gas as it provides enough pressure and heat to melt most metals. If the hobbyist plans to use natural gas like the kind that is provide in households they may find that the pressure is just not enough and the desired temperatures will not be reached. The same is true for Butane. While natural gas and Butane can be used, propane seems to yield the best results. Oxyacetylene torches are a favorite with many casters especially for casting iron.

Price is yet another consideration. While it may be possible to rig a casting furnace it is not always advisable. Torches can range in price from $40 to several hundreds of dollars depending upon the size, the use, and accessories.

Many jewelers are able to use small independent casting torches but when dealing with metal casting in furnaces you will need to use a torch that can be mounted and used in such a fashion. Many think that just because you need a furnace torch you are going to need a large furnace. This is simply not true. A small furnace and furnace torch can produce enough heat to melt aluminum, iron, and a number of other metals. One of the furnaces functions is to help the flame reach optimum temperature and in the case of Reverberatory Furnaces, a furnace torch is an absolute requirement.

Casting torches can be found in some hobby shops and in hardware stores. Several online shops also sell torches for the hobby metal caster. When buying a torch hobbyist should shop around in order to find the best deal. Always use caution when dealing with a furnace torch.

Aluminum Metal Casting

Kent Kelin asked:


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.

Backyard Metal Casting

K-Tina asked:


It’s supposed 2 be funny

bloodninja: Baby, I been havin a tough night so treat me nice aight?
BritneySpears14: Aight.
bloodninja: Slip out of those pants baby, yeah.
BritneySpears14: I slip out of my pants, just for you, bloodninja.
bloodninja: Oh yeah, aight. Aight, I put on my robe and wizard hat.
BritneySpears14: Oh, I like to play dress up.
bloodninja: Me too baby.
BritneySpears14: I kiss you softly on your chest.
bloodninja: I cast Lvl. 3 Eroticism. You turn into a real beautiful woman.
BritneySpears14: Hey…
bloodninja: I meditate to regain my mana, before casting Lvl. 8 Cock of the Infinite.
BritneySpears14: Funny I still don’t see it.
bloodninja: I spend my mana reserves to cast Mighty F*ck of the Beyondness.
BritneySpears14: You are the worst cyber partner ever. This is ridiculous.
bloodninja: Don’t f*ck with me bitch, I’m the mightiest sorcerer of the lands.
bloodninja: I steal yo soul and cast Lightning Lvl. 1,000,000 Your body explodes into a fine bloody mist, because you are only a Lvl. 2 Druid.
BritneySpears14: Don’t ever message me again you piece of shit.
bloodninja: Robots are trying to drill my brain but my lightning shield inflicts DOA attack, leaving the robots as flaming piles of metal.
bloodninja: King Arthur congratulates me for destroying Dr. Robotnik’s evil army of Robot Socialist Republics . The cold war ends. Reagan steals my accomplishments and makes like it was cause of him.
bloodninja: You still there baby? I think it’s getting hard now.
bloodninja: Baby?
Yeah it was pretty sweet.

This one was good.

bloodninja: Ok baby, we got to hurry, I don’t know how long I can keep it ready for you.
j_gurli3: thats ok. ok i’m a japanese schoolgirl, what r u.
bloodninja: A Rhinocerus. Well, hung like one, thats for sure.
j_gurli3: haha, ok lets go.
j_gurli3: i put my hand through ur hair, and kiss u on the neck.
bloodninja: I stomp the ground, and snort, to alert you that you are in my breeding territory.
j_gurli3: haha, ok, u know that turns me on.
j_gurli3: i start unbuttoning ur shirt.
bloodninja: Rhinoceruses don’t wear shirts.
j_gurli3: No, ur not really a Rhinocerus silly, it’s just part of the game.
bloodninja: Rhinoceruses don’t play games. They f*cking charge your ass.
j_gurli3: stop, cmon be serious.
bloodninja: It doesn’t get any more serious than a Rhinocerus about to charge your ass.
bloodninja: I stomp my feet, the dust stirs around my tough skinned feet.
j_gurli3: thats it.
bloodninja: Nostrils flaring, I lower my head. My horn, like some phallic symbol of my potent virility, is the last thing you see as skulls collide and mine remains the victor. You are now a bloody red ragdoll suspended in the air on my mighty horn.
bloodninja: Goddam am I hard now.

This kinda sucked.

BritneySpears14: Ok, are you ready?
eminemBNJA: Aight, yeah I’m ready.
BritneySpears14: I like your music Em… Tee hee.
eminemBNJA: huh huh, yeah, I make it for the ladies.
BritneySpears14: Mmm, we like it a lot. Let me show you.
BritneySpears14: I take off your pants, slowly, and massage your muscular physique.
eminemBNJA: Oh I like that Baby. I put on my robe and wizard hat.
BritneySpears14: What the f*ck, I told you not to message me again.
eminemBNJA: Oh shit
BritneySpears14: I swear if you do it one more time I’m gonna report your ISP and say you were sending me kiddie porn you f*ck up.
eminemBNJA: Oh shit
eminemBNJA: damn I gotta write down your names or something

Ew this chick was nasty. Yeeeeaah.

bloodninja: Wanna cyber?
Katie_007: Sure, you into vegetables?
bloodninja: What like gardening an shit?
Katie_007: Yeah, something like that.
bloodninja: Nothing turns me on more, check this out:
bloodninja: You bend over to harvest your radishes.

(pause)

Katie_007: is that it?
bloodninja: You water your tomato patch.
bloodninja: Are you ready for my fresh produce?
Katie_007: I was thinking of like, sexual acts INVOLVING vegetables… Can you make it a little more sexy for me?

(pause)

bloodninja: I touch you on your lettuce, you massage my spinach… sexily.
bloodninja: I ride your buttocks like they were amber waves of grains.
Katie_007: Grain doesn’t really turn me on… I was thinking more along the lines of carrots and zucchinis.
bloodninja: my zucchinis carresses your carrots.
bloodninja: Damn baby you’re right, this shit is HOTT.
Katie_007: …
bloodninja: My turnips listen for the soft cry of your love. My insides turn to celery as I unleash my warm and sticky cauliflower of love.
Katie_007: What the f*ck is this madlibs? I’m outta here.
bloodninja: Yeah, well I already unleashed my cauliflower, all over your olives, and up in your eyes. Now you can’t see. Bitch.
Katie_007: whatever.

Casting Furnace

Kent Kelin asked:


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.

Foundry