Open Mold Casting with Aluminum at home using my Propane Foundry
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- Опубликовано: 21 сен 2017
- Today I try sand casting aluminum using an open mold. Unlike normal sand casting, this involves only one flask. It also results in lumpy aluminum castings, but hey, I'm a lumpy guy so it works.
In this video I use an Oliver upwind propane burner I built in a previous video: • Easy to Make Propane B...
The furnace is a mini metal foundry based on the KOR's design, but with commercial refractory cement for a lining.
If you want to check out Conedodger's channels they are here: / @conedogames .
And / conedodger240
Here's the luckygen1001 video about degassing • Can you degass aluminu...
Also mentioned chirpy, the casting master. Here's his channel / @chirpystinkerings
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Music: "Quirky Dog" by Kevin MacLeod. incompetech.com/
#metalcasting #foundry Хобби
Want to use your 3D printer to learn Sand Casting in your home shop? paulsmakeracademy.mykajabi.com/joinus
Love metal casting 😉 great video!!!
I've seen other RUclipsrs cast using this method, and they always press the sand into the object they're casting early on. Then dump all the sand they can to fill it.
So I think you should be doing that. Makes sense.
Another great video. You're my favorite!
+Supra Kooper thanks! Glad you enjoyed :D
Cheers for the informative and engaging video!
You're welcome on the baby power tip!
Corn starch works well too.
another entertaining video, thanks
Finally built my own furnace, excited to try it out. I have some of that HIPS filament I mentioned once before so will give it a go and let you know how it turns out.
+Cody Bond awesome! Yeah let me know, I've never tried that stuff
Paul's Garage I also just saw a Facebook post in a 3d printing group about someone printing with wax filament and casting with pewter! Interesting
Hey Paul, another cool video! Open face casting is another technique I need to try.
+eviltwinx thanks! I don't think I'll do open face casting anymore, the normal sand casting with the 2 flasks and risers just gives better quality results thanks to the head pressure. Open face is more fun to watch, though, molten metal looks awesome!
Not sure how you have no views... RUclips must be against sand casting
+Evan Stapleton it's a conspiracy!
Still says that weird
Could i place a thick piece of steel ontop af the sand to make them les lumpy and get a flat side?
If you find the time please try this.
This is the kind of casting I'm doing when I finally try out my foundry
Do you think hot glueing the positives to a surface before putting the sand in could work? I figure when you lift the mould off, the positives would stay stuck to the surface and so you'd avoid all the damage around the edges caused by knifeing them out
Double-side glue pads(the cheap foam ones that's umpteen in a pack for next to nothing), work great at the end of something to remove patterns and other things from tricky places....
so, the large head, ill fitting hats situation is my life.
in completely unrelated news, i purchased a bunch of crap this weekend at junk sales, literally called the "junk jaunt" and i'm now beginning to restore/refinish/make shiny some old saws and a few hatchets, maybe these will help me not suck at some of the skills needed to then begin forging with aluminum. it looks like fun, even though you continue to point out how it probably isn't "fun" in the strictest definition.
thanks for the video!
+Drew Fausett those junk sales look like fun, too bad I've never been to one. Swap meets are similarly fun but it sucks when everybody thinks their scrap is worth gold price...
I have seen people pre-drill shallow holes in the back of the design so they can put a screw in the and lift it straight up out of the mold leaving a cleaner cavity to pour into
+Braden Lumley that's a good idea, it certainly would have helped
You are a funny guy, very entertaining. Thanks man you did a good job, didn’t die and still made me laugh.
+Randy Farmer thanks! Haven’t died yet
Interesting to watch your trial of open face casting. I am hoping to get my electric furnace (patterned after TAOW's) up and running thus weekend so I am glad you talked about degassing with washing soda. I wonder chemistry is going on to remove the hydrogen from the aluminium.
Greatly enjoyed your video!
+Mark Shymanski I think removing the hydrogen works through the same process as osmosis, the hydrogen wants to balance out, so it moves from the area of most hydrogen (in the aluminum) to the area of least hydrogen (the hydrogen-free gas). Lots of gas bubbles through carrying the hydrogen out of the aluminum until only a tiny, unproblematic amount remains.I could be wrong though.
I recently saw a casting video that recommended using aquarium sand for things that you want a lot of detail from. IDK if that was good advise or an attempted prank, but aquarium sand from pet stores costs more than play sand. Go to the salt water section. The fresh water section is usually more like gravel. I guess it just depends on how badly you want more detail. I think you might still like open faced casting for making ingots, if you enjoy a specific shape that you don't have a better mold for.
You can add a little hook to remove your items straight up.
Are you saying I need a respiratory when smelting aluminium ? I’m new to this and haven’t melted yet ! How about copper and tin and brass ?
Help! I have a highly detailed Bas Releif plaque about 3.5" X 5" that I would like to use in an 'open casting' project using .999 silver. Is it possible? Any tips?
I wish I was your brother. Keep up the good videos and keep learning so I can learn.
+Joe Tuinstra I'll keep doing it! I have a brother, he doesn't melt anything
Great Video ;)
Reeeeally old video but quick question...Im looking to get some oil casting sand but I have no clue how dense it is. Could you tell me roughly how many pounds of sand that is in the flask? Also maybe you said in another video but I forget, where did you buy it from? Thanks paul!
I'm glad you did this open mold casting, I kept wondering if it would be a way to easily make flat-backed pieces. Now I know, ram up the second flask... is that what you call the sand in a box...? and pour it using risers to get that pressure .
Thanks
+swdweeb yeah definitely do normal sand casting with 2 flasks. The risers are a huge help when it comes to details.
Damn son your casting sand is awesome in Australia to buy petrobond sand it's about the price of a new kidney ☹️😒. And I recon your failed castings look better than some of my successes 😁. Either way keep it up my friend 😉🤘🏻
+bigstackD really? Of the sand I found for sale petrobond was the cheapest! Unless I bought in crazy quantities like a professional foundry. It still isn't cheap but I got 60 lbs of the stuff and I'm a cheapskate! It couldn't be that expensive :D
Oh! Oh! Additional suggestion for shielding gas during casting: argon is king, of course, a most noble of gases, but nitrogen is must cheaper, if you have a means by which to entrap it upon the casting. Argon's additional advantage over nitrogen is that it is slightly heavier than the surrounding atmosphere and tends to lie quietly in low places until blown away. Be aware that argon can fill large spaces and suffocate humans if contained too effectively in too large of a space. I knew four guys who are all now deceased (two different episodes of industrial fatality). Actually, a helium/argon mix is not a bad choice if you need to surround the items above and below.
Now that I've seen that 2 flasks 1 fun video I can never un-see it...
+Max Emmer and now I will forever think of that when I see open mold casting. Thanks for that :D
hehe anytime man... Much love, I thoroughly enjoy your humor ;)
Quick question about aluminum. if I'm melting aluminum car parts and say a steel dowel pin is inside the aluminum. once the aluminum is melted will the steel come up to the top?
nope, sink to the bottom. Steel is much denser than aluminum. it will be there in the bottom of the crucible after you pour the aluminum.
Paul's Garage that's what I figured. thanks for the reply. love the channel man its great!
Cool video Enjoyed !.
+andy wilson thanks!
That baby powder has asbestos when he blew it and caughed I about died lol
You are fun to watch and informative. People need to subscribe! Beat the King of Random in numbers.
Thanks!
Great video, Paul, very entertaining! Quick suggestion: beeswax is very helpful when grinding aluminum. Apply the beeswax to the grinding wheel. Greatly improves the efficiency and smoothness.
Thanks for the info! I have some beeswax somewhere I'll have to give it a shot
Hey um I'm remaking my furnace and I got a paint can in the plaster of Paris and I was wondering how to get it out
Otago Harbour Fishermen who cares? seriously, just let it burn out on it's own lol
drill some small holes and u can use screws to remove parts from sand and maybe sand edges first
I want to do that. But I wonder if you could use a tuna, or sardines can to make a top just over the cast?
You still wouldn't have any head pressure and the can might act as a "chill' which can screw up the casting if not used properly
Learn a lot from watching your vids. Question for you what should I use for flux? Borax or light salt? Keep up the great work.
+The Nocturnal Alchemist lite salt for fluxing aluminum, borax (also boric acid) is generally for copper alloys. Not sure about other metals
Paul's Garage ok cool thanks man
@@PaulsGarage should i wear any masks when melting any metals? Not sure what metals have toxic gas when melted or what happens when they melt(gases/air/moisture in the air getting in the metal making it non pure)
sand and prime the 3d prints, also drill small holes in back and use screws to screw into the back to pull it. Also the holes in the logo that came out put screws in there when pounding the sand and try that.
+Little Frog Innovations thanks for the tips! I'll try that
This guy shows how to build a foundary that I am currently building. If you watch the video, see how he removed stuff from the petrobond. ruclips.net/video/gBK0P4ASZ0o/видео.html
He is where I got my inspiration and somehow I ended up following your channel as well in some weird way.
Hey do you know if you can use a cast iron as a cubicle?
+Emilio Greenwood cast iron is not a great crucible material, it is dissolved by aluminum and oxidizes in the furnace heat. If you want a one time use crucible for meting aluminum or zinc though it might work
I love your channle soooooooo much keep it up
+TJSZ Sounds thanks! I will!
Where do you buy your aluminum? You mention you can buy it all over the internet but I can’t find any to buy?
I get my aluminum for free as scrap, but there are a number of websites around that sell ingots. I would search for a specific alloy, like A356 if you are going to do any casting. You can usually buy it in large single ingots, like 22 or 50lbs each. A quick search found one place at sculpt.com, though I have never ordered from them so i can't vouch for them. that or look for cast aluminum alloy wheels on craigslist, those are usually A356 aluminum alloy.
Hey Paul I found out actually how yo get a piercing blue flame!! You just need one of those big red propane regulators
+Flipping Nation I got a big regulator, I just don't crank it up super high. The furnace I have doesn't have a big enough hole in top to vent the gases so I can't really crank it up.
You have said several times that you have musical background. Did you compose the theme song for your channel?
No i didn't, the music is from incomptech.com and it's written by a guy named kevin macloed. It's royalty free when referenced in the comments. He's got some great music on there. I never wrote music like that when i was a composition major, but i suppose i could try to write a new theme song at some point if i get the time. Might be fun.
3:25 if they ever recast Deadpool, I think you'd be a good fit. Hahaha
Together the cope and drag make a flask.
hey paul im actually debating what i want to cast for the first time i actually found some softball sizish skulls at the dollar tree and iv been trying to decide how to possibly cast them their cheap thin plastic and well im not worried about money loss a few decent sized aluminum or copper skulls or whatever you would like to use would be a nice go for Halloween and well yea.....btw dunno if anyone else noticed the pepper in the back ground was that for extra heat? yea corny i know but hey figured id shoot it out their
+Johnathan Welch lol the pepper was just there, no reason. Skulls would be cool but if they are complex 3D shapes then lost plastic casting or something else would have to be used. Don't know without seeing them though. Good luck!
I have a Datsun...it's a forklift...it's kinda ruff and lumpy...I NEVER use pool chlorine on it..
Hey Paul, I got a 1 at solo and ensemble this year, lol.
Good job! I did that a few times. What do you play?
Paul's Garage Tenor Sax, solo and a sax quartet. It was fun, pretty cool you were also involved in music during high school!
Love the DUCK!
The duck is awesome, I might try to make some of them. I got that one as a kid when we visited mall of America
1:00 it's called "elephants foot" when the first layer sticks out from the rest of the print.
What If you print the hodor door stopper on its side so the "teeth" or the ridges aren't on the side where it would get stuck in, also when I did stuff with aluminum I was told dust can give you Alzheimer's not really sure how true that is but it always made me be safe with it
+Mr Butter yeah ground aluminum is dangerous, always wear a respirator. I could print the hodor stop at another angle, but really for best results adding draft to the model and then sanding and finishing would be the best bet. Lots of programs have a feature for draft so it's easy
If it is melting anything; It's the SD card.... lol 😆
lol never heard of that ;D
I heard you say "Jeep Stuff". I think I know what RUclipsr you watch.
Hey Paul, not really having to do with this vid except, well it IS about Aluminum melting. You were right-yellow flame not enough air. Finally added a hair dryer and now I can melt the legs off the neighbors dog...uh, off the neighbors Aluminum siding. Yeah, that's it. Do you still use Morton Lite to lessen your dross? Reason I ask is I've just been spooning it off but last night I melted a big aluminum pan the wife gets frozen lasagna in. Still had remnants of whatever grand-it does NOT smell like lasagna when you subject it to 1500 degree heat-it also left a puddle of floating ashy, volcanic rock-like stuff that took me 20 minutes of burning my hands to get scraped off. Oh and last but not least, if you go to remelt something fairly thick and large and you realize you should have a pool of Al to melt it into? Don't forget 30 minutes later it was in the furnace and grab it bare-handed. Causes a severe 'Ouchie-oh S**T! Motherhumper! Da...dang!" Just sayin'.
Love your vids Paul. Have you checked out olfoundryman?
+Andrew McWhirter yes! I've watched a bunch of his videos. Good stuff
I've actually read that some people use Morton's light salt in place of the washing soda
+C Stone lite salt is more of a flux than a degasser, but lite salt works well. Washing soda not so much
I know Myfordboy uses a uk brand washing soda as a degasser.
+C Stone yeah the luckygen video (link in description) is actually a response to a disagreement he was having with myfordboy on a forum. Very interesting points on both sides.
Anyone else loving that duck toy?
+darktideryezing me. I love that duck toy! :D. I got it as a kid from the mall of America in the twin cities. That duck has quite a few miles on it
for easy smoothing of surface just dipp the parts in molten wax
+steffankaizer that's a good idea thanks!
I thought aluminium steals oxygen not hydrogen coz for thermit you use iron oxide 3 so when the aluminium gets contact it'll take the oxides creating pure iron and aluminium oxide 3
🖒😎
You've got the affinity of aluminum wrong. Aluminum (and other reactive metals like titanium) has a very strong affinity for oxygen and to a lesser extent carbon, not hydrogen. Because of this, it will pull oxygen out of most things and leave whatever's left to fend for itself. This is usually hydrogen. Hydrogen has a low but significant solubility in molten aluminum, so it stays dissolved and bubbles out as the metal solidifies. The typical way of extracting hydrogen from aluminum is to use an inert carrier like nitrogen or argon: this extracts the hydrogen out since hydrogen is also obviously soluble in nitrogen gas and so it slowly diffuses out into the carrier.
Degassing with most other things won't work well. The problem is molten aluminum is EXTREMELY reactive: it really wants to go back to aluminum oxide, so as you mentioned it will pull water vapor apart to release hydrogen. Thus, almost any other carrier gas imaginable (carbon dioxide, oxygen, nitrous oxide, etc) will immediately be broken down before they can properly draw the hydrogen out. (Plus, the aluminum oxide byproduct will cause other flaws in the metal). By the way, in industry chlorine gas is added to the nitrogen or argon stream to remove sodium and lithium-- it is not necessary to remove hydrogen.
Degassing with solids is not a fantastic idea either. Sodium carbonate has a deceptively high affinity for water in storage, and so by adding it to your melt you may actually worsen the hydrogen pitting. It also reacts with molten aluminum to some degree. Adding pool chlorinators is also not a great idea: the common ones either contain hydrogen in their active ingredient or in their filler (calcium hydroxide in calcium hypochlorite shock, for example). Plus, aluminum itself reacts with with oxidizers vigorously (hence why it breaks water apart), and in the solid state and with powdered degassing agents such a reaction could be explosive. (The principle itself is that aluminum reacts with an active chlorine source to release aluminum chloride. This is volatile at aluminum melting temperatures, and so it acts as a carrier gas to remove dissolved hydrogen. However, these substances contain no hydrogen to avoid worsening the problem, and further the aluminum chloride produced is extremely corrosive-- imagine muriatic acid fumes but worse.)
Something you might try is to add sodium chloride salt to try and act as a degasser. No idea if it'll work, but it might be worth a shot.
heeeeeeeey paul, how are you going
+Taite Lennox heeeeeeeeey taite doing good
haha the duck do xD
+LocalFireworks it's a good duck. Lots of miles on that duck.
Try clay carve mold casting
I work in an aluminum foundry. We degass it with nitrogen.
I would love to get a nitrogen bubbler thing set up
I was think you could have used hot glue and something thing to pull those out
And every time I melt metal the charcoal gets in my mouth and nose and when ever I eat I taste charcoal:'( the food flavour is lost
+Otago Harbour Fishermen that's a bummer. Hamburgers grilled over charcoal taste great, charcoal itself not so much
Wow no views and ten comments, nice.
+Logan Feakes all the comments must be from ghosts or something
I need information about that duck... for reasons... yeah. totally not looking for one for me to play with. absolutely not.
it's called a duck push toy or something, i think you can find them on etsy? I got that one at the mall of america when i was little
Sodium carbonate....soda ash
I would like to subscribe to your discord channel. Just created an account. Where do I find your email address to request....
+Dan Harold there's a link on my channel page I think, but it's vloggarage@gmail.com
BAM! 1st lol Say NO to open face casting.
+worldtraveler can confirm 1st. Also it appears we reached the same conclusion...
Paul's Garage get going on ceramic shell. you'll be glad you did. check my channel... I'm doing a quasi tutorial.
+worldtraveler I'll check that out. It seems to me the most attractive kinds of casting are normal sand casting (with 2 flasks) and ceramic shell. Haven't tried ceramic shell but I really want to give it a shot.
+worldtraveler Just watched your jewelry case video, I really like the look of the finished product, so much cleaner. Music was cool too. Kinda had that "Come comrades we must drink wadka and survive the cold Siberian winter" feel to it. ;-)
swdweeb that's a perfect description of that music. lol... Thanks. I'm finishing up some pieces now and will have part 4 up soon. I promise it won't be so long and boring.
2nd😥😓😓😓
+TheBushMaster silver medal is still good!
Don't breathe too much baby powder, it's nasty stuff for your lungs :(
OMFG this duck toy is so awesome hahaha :D
+ChaosPotato it's a very good duck toy ;)
stop talking
Borax works for a lot of metals wear a face mask if you’re worried about dust stop telling people that the cast they enjoy casting do you enjoy their foundries do you showBe more interesting be helpful first time I watched you you’re funny as hell don’t know you must’ve had an off day anyhow good luck with casting take more time in it and yeah you can get your metals pure enough at least I do
I appreciate you but i wish you would stop rambling all the time dude. thank you.