Utron research

[Cherryman]

Now I decided on the design, its time to make some solid ones.


I decided on casting them in aluminium. As I have never done that before, i chewed up some youtubes and mocked up a proof of concept in the garden today.
I'm actually quit happy with the results.


Not a finished product, but a decent enough proof of concept for me! : )


Anyway, here is my first attempt in melting and casting molten aluminium:


https://youtu.be/qMut-4mFCxU

[Grumage]

Dear Cherryman.

Your last video took me way back in time!

I ran a successful foundry and precision engineering business for nigh on 30 years.

http://www.alynfoundry.co.uk/

I would suggest using Propane gas and a large torch for heating and try to find larger pieces of Aluminium scrap to melt. Using thin sections of scrap makes more " Dross " as the metal prefers to oxidise rather than melt.

Regarding your moulds you could use a metal die for such a simple shape ( if you have a Lathe ) of course. If your sand is too wet you will get steam forming that will ruin the surface finish.

Drop me a PM if you'd like to learn more.

Kind regards, Graham.

[Cherryman]

Dear Cherryman.

Your last video took me way back in time!

I ran a successful foundry and precision engineering business for nigh on 30 years.

http://www.alynfoundry.co.uk/

I would suggest using Propane gas and a large torch for heating and try to find larger pieces of Aluminium scrap to melt. Using thin sections of scrap makes more " Dross " as the metal prefers to oxidise rather than melt.

Regarding your moulds you could use a metal die for such a simple shape ( if you have a Lathe ) of course. If your sand is too wet you will get steam forming that will ruin the surface finish.

Drop me a PM if you'd like to learn more.

Kind regards, Graham.

Graham, many thanks for your suggestions and offer.


I already did this morning a second try, with some more heat and things learnt from yesterday.


My sand kinda works ok.  I siffed some birdcage sand and with just a little moist it works very well for the simpel set up, rather nice smooth surface, and more stable as expected.
I had more problems with indeed oxidation and... Unfortunately my crucible melted also and i lost half of my alu in the fire.  My next crucible will be of stainless steel instead of a coffee can ; )
I do not have acces to a lathe or other expensive tools, but i'm also happy to try it the "bush" way and learn along.


I do have a question, I added some salt as "flux"  i heard somewhere it helps the liquid being more fluent. is that a good idear ?


Anyway thank you for you offer and expertise.


Here is a little overview of this mornings experimentation.


With respect RK


PS. Nice website and craftsmanship, you must be horrified to see an amateur plowing along, but i have to say it's fun.  Fire, molten metals.. creating stuff.

https://www.youtube.com/watch?v=sGi8Y95wsto


Here is a picture of the first and second.. It ain't much.. But I see improvement : )

[Grumage]

I do have a question, I added some salt as "flux"  i heard somewhere it helps the liquid being more fluent. is that a good idear ?

PS. Nice website and craftsmanship, you must be horrified to see an amateur plowing along, but i have to say it's fun.  Fire, molten metals.. creating stuff.

https://www.youtube.com/watch?v=sGi8Y95wsto


Here is a picture of the first and second.. It ain't much.. But I see improvement : )

Dear Cherryman.

Hmmm...  Salt not sure about that. A proprietary covering flux would be better but if this is just for a few castings the cost wouldn't be worth it. We used to use a " de gasser " tablet " rabbled " into the melt prior to pouring, this generated Chlorine gas which combined with the absorbed gasses reducing the risk of porosity. Might be the Salt actually de gasses ?

As to your endeavours, on the contrary. It's exactly the same as I over 40 years ago. I made so many mistakes to start with but with each subsequent cast the failures became fewer and fewer.

Cheers Graham.   

[Grumage]

The title says it all !!


https://www.youtube.com/watch?v=l6s4Bh0ggVM