Machining cast aluminum? possible?

[RainsFire]

I want to make an idler wheel, and a drive wheel out of aluminum for the belt sander I am assembling, and I was wondering if this is would work..

I have access to 30 or so 6x2x2 billets of cast aluminum, and I was wondering if, after making a casting of.. lets say a 2x6 wheel with a plug like extension to mount in the metal lathe, can I turn it down like I would purchased aluminum stock of that size and shape? are they the same, even though the aluminum has been cast?

I realize that this aluminum, may be contaminated.. but if this would work, with cast 6061 aluminum, then I think it is worth a shot, as apposed to spending $100 on a chunk that size

anyway, any help would be appreciated as always, thanks.

Edited November 18, 2008 by RainsFire

[mike-hr]

Why recast? Just chuck up the 6x6 billet and turn a wheel out of the 2 inches on the end. Drill the hole and use a part-off tool to cut it off the billet. Remember to set the compound at one or two degrees from parallel and cut towards the center of the wheel from both edges to give it a slight crown, so your belts track good.

[RainsFire]

sorry, I mistyped.. I meant 6x2x2.. or so for the billets.. my guess is 2-5 billets in a crucible.. and I could make a few wheels.. but it is neccessary for me to recast.

but anyway, my question is, can it be machined post casting? is cast aluminum workable?

[DragonEagle]

should work fine. people do that all the time.

[Frosty]

Sure, no sweat.

Frosty

[ThomasPowers]

Look at pistons, they get machined after casting---make good stock for casting too as the general rule is that styff that was cast is generally a better alloy for casting than stuff that was extruded. How are you planning to degass your melt?

[RainsFire]

I have no idea.. I was just going to work on constructing a small propane melting furnace durring the week, and trying out a sand casting, over sized so I can turn it down.. definately a new field for me

[Rob G]

ever entertain the idea of forge welding the aluminum?

[RainsFire]

I think it would just become goop.. as soon as it reached an even temp, its really conductive.. or inconductive.. whichever means it disperses heat well

[Rob G]

i don't know, i've forged 2" square aluminum solid, and i've heard of people forge welding aluminum

[Frosty]

I know a couple guys who forge Al regularly. Never heard of anyone forge welding it but that doesn't mean it isn't done. I'd sure love a how to.

Frosty

[LarryM]

You can melt aluminum with charcoal briquets if you have to. With crucible made from pipe capped on one end. You can make a wheel very easily melt the aluminum. Then skim the dross off top of the melt. You then just pour it in empty coffee can. Pour it a little deeper than you what finish wheel. Once you have a blank wheel center and drill it. Then do all your machining on a mandrel.

Hope this helps
Larry

[KNeilson]

Casting aluminum and 6061 are two different animals. If you want to cast, use old scrap castings as your material source. You will find the 6061 (a wrought alloy)will melt but not "run" very well into a mold unless it is very well preheated. A casting alloy will more than likely machine better too......imho......Kerry

[saintjohnbarleycorn]

I was thinking of doing this also but I was going to tig them and then turn them down.

[Jocko 58]

U can and it does work