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I Forge Iron

Andrew Golabek

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Everything posted by Andrew Golabek

  1. It looks to me like the burner is running way too rich, (even outside the forge) and the mounting tube is too long, preventing adequate airflow to the burner, increasing the problem when mounted in the forge Also be sure to rigidize the ceramic blanket if not done already
  2. I suppose for this casting it served as double duty, as both sprue and gate at the end of it i don’t have any methods currently to turn it into other parts so it will probably just be used in the next melt
  3. Did some grinding today; break down of the casting -sprue weighed 523g -tip thing I made weighed 36g -sword weighed approx 1250g once cleaned off as of this picture it weighs 1151g (2.53lbs) balance point is about 5.75 inches forward of the guard going to lighten it up at the front some more, handle is planned to be made of bubinga wood
  4. It will be work hardened, and I’m still not sure if it will be annealed or not before, it is quite stiff already, and some pieces I cast beforehand were slightly brittle, although perhaps brittle is an exaggeration as they were beat on with a sledgehammer haha the bronze knives I’ve made so far we’re cast, and then the edges were work hardened, no annealing was done at all.
  5. The mold is made from greensand, in an oak flask I made, with the particle board faces so the sand doesn’t crack outwards. Greensand mix was 75grit silica, 10% western bentonite, I’m guessing it was about 70-80lbs to fill the flask!! The foundry is propane fired, I used a graphite crucible, and the only flux was charcoal, both powdered and in chunk form (charcoal was made in the foundry prior in a heavily reducing atmosphere) i used a wooden pattern that I ground out on a bench belt grinder. this is my sixth bronze blade, although it’s about 4 times larger than anything I’ve cast bef
  6. Today I successfully cast a bronze sword, this was my second attempt. 1.86kg of 12%tin bronze was used in the casting Not a perfect finish, but I’m pretty happy! will update as it is finished
  7. Awesome, pretty happy with my first propane burner :), tested today melting 2kg of copper alloyed to be classic bronze, worked perfectly well, although my mould making wasnt up to par haha Yeah mikey I think thats probably what happened with the previous gasoline burner, when the fuel wasnt flowing through, the inside oxidized, leading to problems with sufficient fuel flow, So I decided to make this propane burner.
  8. its got a choke, so adjusting it from here should be easy :), the actual internal diameter of the tube is approx 0.04 inches, maybe a little smaller, was hard to tell using the calipers. 8 inch 3/4 pipe for mixing, and i think 2 or 2.5 inch reducer coupling
  9. Running at a lower propane pressure in this picture but I think I got it running just slightly lean now, opened up the choke and filled the intake a bit. Should have a full range from oxidizing to reducing atmosphere now for casting what do you think of the nozzles which have A swell and then close narrower at the exit? I’ve seen them advertised for industry burners, not sure how it would work on one of these though sidenote, instead of a mug tip I used a 1/8th steel capillary tubing, cutting it short left a nearly perfect sized outlet for the propane (just slightly o
  10. It’s my own design, I think the burner tube is a little on the long side, but I’ll try to open the entrance first, thanks
  11. No this is a propane one, had some trouble setting up one of my gasoline ones, so decided to try it, had the propane tank anyways. Running with a 0-30psi regulator
  12. This nozzle was homemade, and fired in the foundry pictured, made of calcined alumina, with bentonite, and carbon fibre for the green state binder. Total weight when fired was 23.7grams, Internal length of 34mm, and width of 33mm. The firing schedule was approximately as follows -air dry until no longer cool to the touch -dry in oven at 200f for 30mins, and then increase temp to 300f, hold at least 20mins -transfer to forge while hot, slowly increase forge temp until red hot, and then full blast -final temp approx 1300c, total firing time from start of 30-40mins.
  13. First properly successful ceramic nozzle tested today in my foundry, attached are some pictures. -Yes I know the burner is too far into the forge, this was just a test run, and the mount isn't permanent so I had to run it like this for now. Worked pretty well, any ideas for future nozzle shapes?
  14. I formed some ceramic nozzles for the burner v2.0, and have added a better lid to the foundry, and proper castable refractory (3200f)
  15. Im thinking, that if you only had one ridge at the front and back of the forge, and a kiln shelf which rested on top, and was slightly narrower than the whole forge-thus allowing the circulation of the flames around the kiln shelf, you would get the effect you are desiring without having the problem of stock falling between ridges, and it would be easy to remove and clean the kiln shelf or switch it out
  16. The original nozzle was steel, not brass, I'm happy with the burner as is, just wanted the nozzle to last longer.
  17. Note; this is being going to be used for a gasoline burner of my own hybrid design, reminiscent of the riel linear burner, and a coleman stove. (I've posted in the alternative gas-oil/gasoline forum on here about the details of that build.) The reason I'm attempting to build a ceramic burner nozzle is that the original burner nozzle from my gasoline burner oxidized away quite quickly in my foundry/forge, probably this was accelerated by the slightly oxidizing conditions it was originally being run at, and the burner design caused flame in the nozzle, this excessive heat destroyed the chea
  18. Just recently finished my second bronze knife, (bday gift for my gf). -increased tin content to 12.4%, is certainly harder and is slightly easier to sharpen - katalox wood handle -currently re-lining my forge/foundry , got some 3200f refractory (unicast 70c)- should be more durable
  19. I dont think the steel wool is helping
  20. Very interesting, beryllium is however very toxic, I wouldn't want to make one.
  21. Here it is, complete with the handle finished, peened 3/16 brass pins, I'm quite happy with it as my first knife of any sort, couple of things to improve for next time though. The edge should probably be further work hardened, I'm going to try 12% tin bronze to see how much harder it is, and maybe aluminium bronze eventually. The handle finishing and flattening the tang to fit the scales was the longest part of this project for sure without any grinder except an angle grinder which isn't ideal ( was flattened by hand). The edge is actually quite sharp, although sharpening by hand seems
  22. I got the copper from a nearby company which had pure copper scrap, and the tin from 97%tin solder 3% copper. The edge is work hardened, i made a little jug which you can hammer and slide the edge back and forth to get perfect hits. Im now finishing the handle (zapote) and planning the next one, with a very different blade shape. This one is a bit thick, weighs 318g for a 9.75inch knife. I wasnt sure how strong it would be and left some margin of error for casting.
  23. Starting from a wooden carving , to sand casting in bronze. 90% copper 10% tin
  24. Added the mounting, and made a lid for now, as well as a choke, turns out it was running very lean, i was able to close the choke alot as shown in the pictures. The forge easily reaches temperature for casting bronze/copper
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