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  1. Hi All, I am new here but I wanted to share my 3 year long project to create a functioning arc furnace capable of melting pretty much any metal using simply the electricity from a common outlet. That was the goal anyway... After 3 years, I determined that, while a common 120V household outlet would likely melt steel in small quantities (less than 5 oz.) it wouldn't be efficient for anything larger. The project was inspired by a similar project produced by Gregory Hildstrom, you can simply google Hildstrom carbon arc furnace if you are interested in seeing his project. Anyway, his ra
  2. Hello all, First post here to show some results of experimenting with the slip casting of aluminiumoxide (alumina). https://en.wikipedia.org/wiki/Slipcasting Got interested to make shapes with refractory oxides by the posts of MonkeyForge and Mellin although they were using zirconia and veegum/bentone and were forming the mass by hand. Zirconia is a little too expensive to mess around with so i went with alumina. Using a combination of digitalfire.com, wikipedia, google patents, google scholar I found a lot of info which I all read. But a lot of it was above what was achievable at ho
  3. I am looking a way to create a good cast/mold for my aluminum smelting projects. I have been curious about using wood ash or clay for the cast. Just because those are the only materials i have besides regular dirt. Please help what would be the best to use in your exerience or knowledge? And how do i acheive the best outcome with the items i have available?
  4. So i'm trying to make a mould of an old axe head i have (which i believe is viking inspired) to bronze cast as a gift. I use green sand to make my mould so my problem is that i can't get a mould to keep the gap in the axe-head. The only idea i have come up with is putting a steel rod made into the shape of the gap and putting it into the mould but i would prefer an alternative as this would take a lot of time and i don't think i have the proper tools. If anyone can come up with an alternative way i would appreciate it.
  5. This is my first post, which I hate to make a series of questions but the deed is done. I'll try to find a place to be helpful, but I am pretty knew to this so I don't know where that would be. I also do not know if this is the correct place to pose a question, if it is not I apologize and ask I be told the correct place. I would absolutely love to make cast iron cook wear, but that seems to be very outside the realm of possibility for my self at the moment. I really want a nice solid skillet that wasn't purchased from lodge. So I was thinking about casting bronze cook wear. I have
  6. Pyrolized Bread Metal Casting Foundry Well earlier today I found this video posted yesterday by one of the guys I subscribe to on YouTube. He isn't the most safety conscious person, but he is an experienced machinist. The entire set up should of been outside, but its his house right? Its an interesting concept and he understands it and enjoys nerding out on the scientific to those of us who are not as, well you know...
  7. Hey guys I made a video about casting aluminum and when I poured the molten metal into a mold I made, it started to bubble. Why does it do that?
  8. I have a question concerning the longevity of a greensand mold, specifically what is the maximum time period I can make them in advance of casting before they begin to crumble? I am taking a metal working class at my local university and, due to time constraints, I only have 1 class left and I am worried that I am not going to be able to cast my bronze projects. It occurred to me that I could make my molds at home and then cast them at my last class, but I am concerned about the molds drying out beforehand; could I coat the outside in parting dust and plug the risers to prevent dry out? Thanks
  9. Hello, I am an acupuncturist who goes through a good quantity of surgical stainless steel needles, likely 316 or 304? Currently I have to send these needles as biohazard material to a certified waste disposal company. I am looking for ideas on how I could possibly repurpose this material for potential art projects. I understand that SS is difficult to melt, so casting may not be an option. I also understand that any use of this material would have to include sterilization because of the biohazard nature of the waste. My initial thought was that melting the needle would take care of that aspec
  10. Hello all, I am a new member and this is my first post. I just wanted to share my first few backyard metal casting projects, all of the pics posted are with rough sanding/grinding only, I hope to take some new pictures of the finished products soon. I have found a lot of very helpful information on this site and would like to pass on my thanks to all the experienced members who have taken time to post tutorials for us newbies. So far I have learned that I can do this and that I am more handy than I thought, but that each project comes out a bit different than what is in my head, an
  11. Hello fellow metal workers, I have some questions regarding making aluminum tank tracks for a robotics project. The tank tracks are 4.25" wide x 5/8" tall (length TBD) they are made up similar to the way an Abrams tank track is put together. I found a metal works company who specializes in turning small 6061 aluminum - rubber coated wheels and though expensive they can produce what I'm looking for. So now I'm back to the tank tread portion which I'll probably make myself. My experience: 10+years experience with TIG welding/fabrication and can weld most things. Many years ago I read a book
  12. I am taking a metalworking class at my local university and am planning, amongst other things, casting two jewelry boxes, one for each of my daughters. I'm planning on making them out of mild bronze, and they will be approximately 7 inches long by 3 inches wide by 3 inches deep. Should I cast the individual plates and later weld them together, or can something this size simply be casted in two pieces, namely the box and the lid? Would it make more sense to simply cast ingots and beat them into plates? Thanks for any help! (Attached is an image of the basic design I am going to attempt to
  13. Is it safe to cut into a brand new empty propane tank to make a foundry? It was bought without ever being filled, so am I guaranteed I won't blow up or should I still remove the valve?
  14. I'm not sure if this is the right place to post this but I've got some questions on casting brass. I was given all this brass for free and was wondering if I could cut it into smaller chunks and melt it down and pour it into brass hammer molds. Or if there are other things I can do with them. Now for those of you who know about bushings how they have those ones that have graphite in them theses ones are not all of these are solid graphite free inch thick brass bushings. Each one ways 50lb so if any one knows if this can be done please let me know also they are out of a turbine of some sort. t
  15. It was suggested by someone I trust that my next furnace (to cast a minimum of 50#) a pour should be a tilting one - I agree - I have a 21" diameter compressor tank to make that and my muller - but looking for plans. Chastain has a book but cant find a copy - they want $700+ on Amazon for it. and as much as $2k! anyone have any designs they can share? Thanks.
  16. This is a 5" x 7" clay plaque pattern I made for a bronze casting class I'm taking. I like working with hot metal lots better to get shapes I want.
  17. Hi! I started my smithing/smelting adventure not long ago. I've built a furnace, melt some alluminium, poured it into my clay cast, let it cool down (and used water to make the process faster). Then I wanted to make a sword out of it (as it was just a base stick cast). I heated it up, hit it with a hammer and... it just cracked. Later I discovered that I can even tear my casted metal pieces apart with my bare hands... Please tell me guys, what am I doing wrong?
  18. Nobody Special

    furnace2

    Heh heh.....my new casting furnace works GREAT. Steel crucible on the other hand..............
  19. Nobody Special

    furnace1

    Heh heh.....my new casting furnace works GREAT. Steel crucible on the other hand..............
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