Cast Aluminium Parts

B

buster

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I am working on a prototype 'thing' and I need some cast aluminum shapes. I can make the pattern easy enough but I am a bit shaky on what would be a good economic melter and how large it should be. I assume size will be by weight of alloy to melt. My early efforts have been ok - I made a mold using Plaster of Paris (thoroughly baked dry) and had decent result with nice finish, but it was only a small bracket about 4" x 2" (cross slide thrust block for lathe) I used my O/A torch as melter.
I think my new parts will be from old auto pistons and I may be able make steel dies for the mold - depends on how simple I can design the parts.

Any advice on how to proceed is greatly appreciated.
 
First thing to do is go over and register at Alloy Avenue. It's the home of most of the casters. Then get Gingery's book and bill Ammens book. Most important is don't get too caught up in doing it perfect. A workable furnace can be thrown together from an old can, sand, and clay dug from the backyard. It will work fine. It may not be the most efficient or longest lasting but the goal (at least for me) is the parts, not the most efficient furnace. Many, many ways to skin the cat. Do something, learn a little then do more. Lots of luck and Godspeed. Lots of people willing to help at the site, as am I.

dave
beone
 
Mr. Pete has some great videos on you tube, on making the molds the mold boxes the sand and casting.
 
I made a foundry out of fire brick. Dimensions are up to you. That's an old BBQ cart.
PA130043a.jpgPA130044a.jpg

Plenty of info on the net on making up your own burner. I found a couple of old fire extinguishers at the scrap yard that made good crucibles. The paint burns off, so stay up wind.
PA130045a.jpg

Gets pretty hot. A burner with forced air will get hotter, but I haven't needed to go there yet.
PA240056a.jpg

PA130043a.jpg PA130044a.jpg PA130045a.jpg PA240056a.jpg
 
Google "MYFORDBOY" tons of great videos on pattern making, casting and machining the castings.
 
Hawkeye....... Hey nice furnace!!!! I really like the design. Of course I have to steel that idea now. Thanks for posting .....pics speak a thousand words, dontthey?

Best Regards
 
Mike, I just gotta ask, I have never been around this, ok I got the fire brick and the fire ex. part. Now the burner, do you use a regulator on
the propane tank or just go direct like a weed burner thing.?. I have a share of good alum junk/swarf odds & ends I would simply like to
pour in like gold what ya call them block thingys billion bullion? something like a brick for stock. I have a burner used for asphalt repares that
is direct of the propane tank, will that work????????? Hawkeye
sam I see your burner but whats the orfice like>?
 
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Hawkeye,
How a bout a build thread on your furnace with a parts list and expose' on the burner assembly and plumbing. I think many of our members would love to have a brief and thorough explanation of the entire build along with any caveats and cautions. I for one would love to add casting to my repertoire. A parts list for your burner outlining what parts and the modifications to the carburetor pipe would be a very nice part of the entire build to know, because that is where most builds fall short of reaching the required temps. How bout it???

Bob
 
Sam & Bob,

I'm in the middle of a QCTP project for the new lathe, but I'll put it on the list for this winter. It's been a few years since I built the foundry. I'll have to take the burner apart to make up a sketch. IIRC, the oriface was drilled with a #60 bit. No regulator, just straight off the BBQ tank.

I think a tiger torch would work, but you'd need a bigger inlet pipe than I used. I have a feeling that my burner puts out more than the tiger. Don't forget a hole in the floor of the foundry, in case the crucible fails. You want the aluminum to run out rather than pooling in the cavity.
 
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