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?

Suggest you research green sand casting. Probably your best option on a budget. Just be careful, lots of ways to get hurt with molten metal.

use what ever you have handy for pouring the ingots, Where are you getting the bauxite?

42 minutes ago, Steve Sells said:

use what ever you have handy for pouring the ingots, Where are you getting the bauxite?

It is just regular clay from the ground. I also have comercial clay additive in bags laying around. Would any of the items i have be used to make the mold and not harm myself or others?

I would be more worried about where you are getting the power for the Bayer process and how to dispose of the waste fluoride

I think Steve is gently indicating that the "smelting" process is more correctly used for making your aluminum from ore (bauxite for aluminum).  You most likely are just re-melting aluminum from already manufactured aluminum scrap?  Did you do your own research on the green sand casting process as I suggested?

4 hours ago, Latticino said:

 

Yes i did do research and am still doing so. But i think everyone here isnt understanding. I have a budget of $0 and can only use what i have which is what i mentioned. Is there a way for me to use the resources i have available to do what i love doing but dont have a way to do it.

I'm afraid it is you that aren't understanding.  The questions you are asking are imprecise and the potential options are varied (and potentially dangerous).  You still haven't answered Steve's basic question: aluminum scrap for a source, or ore?  If you don't know the difference, you shouldn't even consider doing any casting until you do.

You say you want to continue doing something you love.  If you have done it before, why not follow the same process?  I find it hard to believe that you can't find sand at little or no cost (but then I grew up on an island and sand was easily available).  You can get sand at a big box store at 50 lbs for $4.  Hopefully that isn't out of your reach, or you are going to have trouble coming up with fuel to melt your aluminum scrap.

As far as green sand casting of aluminum, a 2 second Google search gave me tons of good reference material.  Here is one that appears to suit your limited budget:  http://foundry101.com/new_page_7.htm.  If you are having trouble with reading comprehension, here is a video: https://www.youtube.com/watch?v=PQ4mLdyp-Zw

Note that these are other's sites and I haven't personally vetted any materials, processes or procedures.

Note that this forum is primarily centered on forging processes for ferrous metals (I Forge Iron).  If you want something better targeted for casting aluminum  there are other forums that will be more helpful.

Good luck.

28 minutes ago, Latticino said:

 

It is most definitely scrap. Thank you all for the info. Have a great day.

The cheapest method is to find folks near you that are already doing backyard metal casting and get them to help you out or even piggyback pours.  If you live over there I could suggest an old friend; however not knowing where you are at I can't make any suggestions on finding supplies or people.

I might have a few people near me that can help. Thank you so much thomas.