I have some small projects that I think would be better off made from cast aluminum instead of me trying to hog them out of solid billet...anyone BTDT on the small scale of things??

sand, lost foam or what kind of process?

charcol, propane or ???

As I recall, the sand is a special type, and probably has to be wetted to bind together. Foam or wax are good materials to make forms out of. I'm not sure what the shrinkage factor is, but I know that the wooden masters we had made were oversize. We were very fortunate that the shop making the master was next door to the foundry and they were always working together on such jobs. Castings can be pretty rough and porous, so they may need to be oversized even more to allow for finishing. Vacuum casting or pressure casting reduces the porousity and increases the strength. Cast alloy wheels use these processes. Choosing the correct alloy for casting is also important.

Better to do the design and subcontract the casting to a foundry.

There are a handful of books out on home-built forges and casting. The British seem esp. keen on this. Search on Barnes&Noble and I'm sure you'll find them. The one on my shelf is "How to Cast Small Metal and Rubber Parts", 2nd Ed. William A Cannon, TAB 1986.

My father (who lives in the sticks) built a forge using a big truck drum brake to hold charcoal, and fed in air using a vacuum cleaner. Cannon's book describes making a smelting furnance out of a 5-gallon paint can, some cement, and a hair-dryer. Propane fired.

Back in my school days we did sand casting in shop class. It was not a very complex proceedure. You might check a few schools, may do it as a class project.

David

My God Mike,

Is there anything you won't try?

Good thing you're in to 914's and not space travel.

Paul

Mike,


My interests in making castings at home where for Silicon Bronze parts for my sailboat. Aluminum is somewhat "easier" as melt temps are lower as you know. Some of these guys built the forge for nothing, using junk found around the barnyard. The refractory brick is the only "specialty" item you need to build the forge. Of course, you'll need a crucible.


Here you go:

http://www.backyardmetalcasting.com/oilburners.html

http://budgetcastingsupply.com/

http://pacificcoast.net/~kerslake/BronzeSi...ingFurnace.html


I've seen crucibles on Ebay for under $40 Buy it Now



Let me know when you set it up. I want to watch the first pour!!

Brian