Aluminum Superman logo sand cast in petrobond from a 3d print. My BEST aluminum casting to date!
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- Опубликовано: 12 апр 2022
- This video demonstrates the process to create a sand cast item from a 3d printed pattern. This is the first time I used petrobond and I am surprised by the results. This so far is my best aluminum sand casting.
Disclaimer--Metal casting is dangerous and can cause injury or death. This video is only for entertainment purposes.
Damon's Metal Casting
damonsmetalcasting@gmail.com
#castingprocess
#sandcasting
#aluminumcasting #metalcasting 
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That was really cool!
Some of the best casting I have seen!
Well done! 🎉
Thank you! I appreciate it.
That came out REALLY good!
Thank you!
Great! Keep them coming!
Thank you!
Hi !
Thanks for uploading such creative topics around metal casting. I am new in this industry and your channel is helping me in insight that how casting works.
I am glad it helped. I started casting this year so just make sure you start out with a good selection of casting metal and a good selection of casting sand. I bet you will do all right.
You did an awesome job of explaining everything in a simple but detailed way. I’m totally subscribing now 👍
Thank you for subscribing and I appreciate the feedback!
Great shirt!
Looks awesome, need some pouring tongs😁
Thank you and you are absolutely right, I do need some pouring tongs. I will be working on some in the near future.
Looking smart with the glasses.
Nope my IQ is the same, my eyes are just getting old. lol
Great work 👍
Thank you
This just popped up in my recommended, great to find another fellow metal caster, subscribed and rang the bell for more. 👍👊
Thank you so much I appreciate it!
I just returned the favor and subscribed back.
Great casting Damon, I love using petrobond, the detail is just so good, but I hate the waste of the burned part
I agree, its unfortunate. Thanks so much for watching and leaving a comment!
Nice job! That really is a great result. Personally, I don't mind a bit of pitting or other minor imperfections. To me, that's part of the charm of a cast part. Then again, there aren't a lot of things I cast that require a mirror finish. :)
Thank you so much!
Nice.
Thanks
There's a guy I learned a LOT from on a channel called old foundry man. He's in Australia. Well worth checking out.
Yeah I watched his videos among other people's videos before I started casting. When I started casting and posting he found my early video and took his time to give me advice that helped out and I really appreciated that. (His post is still there on my channel) I think the casting community is pretty cool, alot of people out there that want to help each other out. You are right he is a good guy to watch.
Olfoundryman is awesome!
I love new sand day! I have that same furnace, what brick did you use for that? The one that came with mine broke pretty quickly and I haven't found anything I like.
The little orange brick I set the crucible on was the same one that came with the furnace. Also, if you got the same furnace as me don't forget to put a refractory material over the ceramic wool in the furnace. I had a few people tell me how bad that is for your lungs. Thanks for watching.
I am new to casting and I am curious, what the tool is called that you used to create the well and channel to your mold?
The part I used is a 3D printed pattern I made in tinkercad then I primed and painted it to make it smooth like my other patterns. The metal travels down the tapered part called the sprue. The taper is to help reduce the amount of air being pulled in like a venturi effect. The metal then flows through the channel past the part into the spintrap. The spintrap will aid in collecting loose sand in the channel with also taking up a surge of aluminum entering the mold. The aluminum when finally entering the mold needs to flow smooth and evenly. I can follow up later when I find videos that explain this bettter but that was a breif version.
Nice!
Cost has been the main reason I've been using green sand. I've seen some videos where there has been a tremendous amount of smoke and sometimes flame with petrobond. Does it smell like burning oil?
I purchased my green sand and my petrobond from amazon, both I remembered were just over $2 a pound. It does have a noticable smell to it(not over welming) and smokes a little bit. I also was told in a facebook group that the sand will eventually need to have a little bit of oil put back in it. So far I am removing the burnt parts and discarding them. The chard sand I scrape off and discarded in the trash. Its too early for me to see how many times I can use petrobond before I need to mull it and add a bit of oil back to it. I still like my green sand, I only have enough to do one casting and then it has to be rehydrated and let it sit in a closed bucket. My green sand is 180 mesh and my petro bond is 190 mesh so the results should be nearly the same for quality.
Your setup is really clean.
You use a nice poring basin with a tapered sprue and a spin trap on the end. This is really textbook.
The only thing which you can improve which I see is, your gate might be too small and you are missing a riser to feed the cast to improve shrinkage but I don´t think you really need those in those simple casts.
Thanks! It didn't seem like I had too much shrink. I normally just mill the back flat, but you are right the part is not too complex and I didn't notice shrink. The one thing I have changed though, is all the air holes I punched through the sand. I think that is possibly jeopardizing my castings if sand falls back down from all those air vents. Thanks for taking the time to give feed back. In the future I will be more generous with my gates and if its a bigger part I will keep the riser in mind.
@@DamonsMetalCasting You are most welcome, I like your videos. You might be right with the air holes, that´s a tricky one because on the other hand you also need them for the gases to escape. When punching them you could try pressing orthogonal to the hole once you have punched through, I hope you get what I mean.
The "milling off the back site tactic" is good because it is simple and produces a really nice result but I would really like to see a more complex cast.
My little more "innovative" idea for complex casts with undercuts is to combine investment casting with sand casting.
Basically using poly cast filament for the master --> covering the master with investment thinly, also using steel wool as a reinforcement within the investment to prevent cracks-->placing the thing in a sand cast mold (basically a bucket of green sand for more stability) and then burning the thing out with a weed burner and casting.
cheers from Germany.
@@sierraecho884 I want to grow my channel so I agree, I need to do more complex castings. I have been planning on making more functional castings. Since I live in the in desert climate its 90F/32C at night and upwards of 118F/47C during the day right now, so all I can do is design things and will cast again when it gets cooler or as soon as its tolerable. I also will try to make some lost wax castings too. I have made the wax castings I just need to move forward with the coatings and metal pouring.
@@DamonsMetalCasting What kind of function would those castings have, do you already have some ideas ?
You situation is basically opposite to mine, I have to work during the summer in Germany otherwise it is rainy.
@@sierraecho884 Yeah I was thinking of stirling engines, atleast a few different types. Also, should show casting some small pneumatic turbines and pnuematic engines. If I want my channel to grow I probably should have different content then the other casting channels.
Were can you buy green sand?
I have purchased both my green sand and petrobond from Amazon.com My greens and is 180 mesh teton black. I am not sure where to get it if you don't have the ability to order from amazon
Good day nice video please tell me where did you get the casting sand to buy thank you
Teton-Bond Petrobond Ultra-FINE (190 Mesh) from Amazon.com Thank you for watching my video.
if the sand is crumbling when you cut a channel then it’s not been rammed hard enough (it’s too loose).
Thanks. I will try and pack it harder in my next videos.
that's what she said
Pitting is not from gas. Try Nordic gold the next time. An easier cast/better color .
I agree about the pitting. This was early on when I started casting. I was just done casting low melting point metals in silicon molds for furniture handles. Those do trap air and if a powder like talc is not used it does cause imperfections in the metal that look like pitting. I did realize after sand casting several times that I must of had loose sand. I will try to do a different metal down the road. Thank you for your comment and watching my video.
How many pounds of petrabond did you need for this?
I dont know exactly but this might help. My flask I used is 8.5"(L)X5.5"(W)X5"(D) internal volume. The depth equals both halves stacked on top of each other, so the volume in total is 233in^3. Amazon claims that the 10lbs of the type of petrobond I used can fill 200in^3 or 6x6x6 which is actually 215in^3. I dont think you need to have the depth of the 2 flasks that deep to acheive this casting. My pattern was maybe 1/2inch thick. You also might be able to do this in a slightly smaller flask to save on sand too. I purchased my sand at the 50lbs size to get the cheaper price. Also, I found out to get a good finish always use brand new sand just for the facing sand and reuse old sand to pack the rest of the mold. As the sand gets reused it won't give a good quality finish. I found this out by using the same sand over and over. Good Luck!
@@DamonsMetalCasting excellent thanks for the reply! Petrobond isn’t sold where I live so I have to import it and shipping is more expensive than the product itself lol that’s why I need to order the minimum viable amount. I’m trying to cast a handle that has a bit more depth than what you made here. So might need a bit more.