Above 1200 Sq/FT Cleaning Up My Shop

[jimreed2160]

Overheard in the barnyard:

Cow1--I hear Farmer has a forge now and is casting metal.
Cow2--Is there grass over there?
Cow1--I don't think so.
Cow2--Meh...

 

[Justind97]

Interesting comment. I was involved with a few discussions years ago about Stanley plane castings. Folklore was that the cast iron was kept outside in a shed to "season" for a year's worth of thermal cycles. It was rumored to relieve stresses. I dunno.

Maybe the foundry just made large batches and it took awhile for the assembly line to keep up. I think metal is metal and wood is wood. Once the casting cools down, I would be surprised if it changes properties over time.

Funny you mention something like this. There is a tale of the Williams F1 team back in the 70s who were using the BMW M10 motors. The motors were pulled from cars (BMW 2002s) that had around 50 000 miles. The blocks were then left outside of the factory and peed on for a year or so (seasoned) before they were used in the F1 cars.

 

[Terrick down Under]

From my toolmaking trade they taught us that most castings would last a longer time if they were seasoned before machining. We used to buy old running chevy motors for rebuilds, but would run them with no coolant so that they would stress relieve before machining. It worked very well for me as I never did a head gasket or such like ever!

 

[oldironfarmer]

Andy: speaking of waste are you collecting all those aluminum chips to re melt them or is there a limit on how many times aluminum cans material can be melted and re used?

It's an element. You might lose some additives but the aluminum is good as ever. Me, use scrap to remelt? Huh? You think I can't afford new? Who you calling cheap? Oh, yeah, it's me. Guilty.

i love the part you made BTW.

Thank you!

you haven't mentioned the cows much lately so i'm assuming they are still getting fed while all this foundry building and learning is going on especially those little guys that were just in their mom's womb a few months ago. yes??

I'm out before breakfast every morning feeding the cows. I figure you guys can only stand so much cow stuff. In fact, we had a new baby this morning. He came up stumbling behind his momma, knows nothing about this world except to stay close to the warm milk machine. He will be playing with his siblings tomorrow but today it was all new.

cheers and best of luck with the foundry work

Thank you! And thanks for stopping in!

"Lot's of advice on the internet is conflicting and lot's is flawed as we all know. In our own area of expertise we see erroneous truths posted all the time. And, it being our field, we know why the posters are in error, or at least misleading. So in this area where I am a novice, sorting out the truth, old wives tales, and reasonable advice is difficult. It may very well be after casting cans for some time when I move to structural and scrap castings I'll not want to go back to cans for the bother. That would make the advice true but misleading "you'll find melting cans to be less efficient than heavier sections" for instance. We will see."

Well, brother, if you never tell the truth again in your life, you told it there!!

You caught me telling the truth, one time! And you had to broadcast it, go figure.

Pour on.

My new motto: Pour every day until you get sick of it!!

Overheard in the barnyard:

Cow1--I hear Farmer has a forge now and is casting metal.
Cow2--Is there grass over there?
Cow1--I don't think so.
Cow2--Meh...

You got them figured out. It's all about food. I've got some friends who are that way...

Funny you mention something like this. There is a tale of the Williams F1 team back in the 70s who were using the BMW M10 motors. The motors were pulled from cars (BMW 2002s) that had around 50 000 miles. The blocks were then left outside of the factory and peed on for a year or so (seasoned) before they were used in the F1 cars.

I just don't see seasoning old castings. But if it worked, it worked!

Interesting.

From my toolmaking trade they taught us that most castings would last a longer time if they were seasoned before machining. We used to buy old running chevy motors for rebuilds, but would run them with no coolant so that they would stress relieve before machining. It worked very well for me as I never did a head gasket or such like ever!

Double interesting! Ran them a short time? I've seen cracked blocks from low coolant.

If it worked it worked! but I'm repeating myself.

Thanks for stopping in guys!!

 

[oldironfarmer]

Didn't get started early, had to go sell a lot. My last one. I did my development in 2002 and it has taken 14 years to get all the lots sold at once. They've all been sold but some returned but right now they're all gone. That feels pretty good!

I went ahead and machined the shrink cracked casting and to my surprise most of the cracks machined out, very shallow.

The right one is the new one, you can see a crack in the upper right.

And my fillet around the hub is too sharp, you can see a crack there.

I tried casting it again. This time I put in a smaller gate and cut a little sand out over the flat face which shrank. Also poked a vent right above the cut.

It's a little hard to see but there is also a little mound in the gate which acts as a choke. This should insure sooth flow into the mold cavity.

The mold hardly took any metal. Less than half what I had melted.

When I cracked it open, I was clever enough to figure out what the problem was

Some dummy had left the pattern in place. What a dunce!! Burned the pattern. I'm thinking I'll remember that bone headed maneuver.

So I salvaged the bottom part and remolded it.

Sweet success! No cracks!! No excessive shrinking.

See the little wire of metal which ran up the vent hole?

Now to machine it and see if there are internal cracks I can't see. Every pour is more experience. It will take a lot of pours. I like making patterns, love playing in the sand and packing it around the pattern, and melting and pouring the hot metal. All around a good thing.

Thanks for stopping by and enjoying it with me

 

[jimreed2160]

Better watch out! The patternmaker is going to skin the hide off those sand monkeys for burning his perfect pattern.

 

[oldironfarmer]

Better watch out! The patternmaker is going to skin the hide off those sand monkeys for burning his perfect pattern.

Hoo boy! The pattern maker is on a tear. He's mad at everybody. I'm having a tough time keeping the peace.

 

[1/2 Cup]

Andy, congratulations on selling your last lot..

We really appreciate your well articulated casting process, absolutely fascinating..

Thank you and well done..

 

[Grumblebum]

Need to get some acres so I can have a shed to home a lathe and a mill and a lift and...

Great work Andy, important tip - remove the pattern before you put the drag and cope together (did I get that right?)

Cheers GB

 

[jbmatth]

Andy,
Leaving the pattern in sounds like something I would do, I probably shouldn't have laughed as hard as I did. Also congrats on selling your last lot in the development.
JB

 

[drivesitfar]

Andy: you went through a pretty tough time with your development and good for you for sticking with it. I bet even your sense of humor was maybe tested more than you wanted it to be back in 2009 to 2011. when the banks shut down land development funds in 2006 it was a pretty big pill for me to swallow let me tell you. congrats on getting everything sold and guessing you have some income coming in from all those contracts now so you can maybe buy a RED, GREEN and any other color car you'd like? or maybe just more foundry stuff.

i'll have to give you a pass on leaving the pattern in the mold cause you just became papa to another calf yesterday. congrats and how many is that total of the little guys/gals now for this year? how many total and just one bull?

you asked on G B's thread about my daughter and new son in law and I'll post their situation over on that thread that i still have a link in my sig line for. they do a lot of face time, but are still not living together cause my daughter has work commitments until June and then she moves. with face time on the phone and Ipads it's like my son in law is in the house most evenings which is sort of cool if you think about it.

anyway i can't speak for the rest of the guys, but i like your cow and bull stories and pictures of your rusty gold you seem to forget about and then sort of find like a long lost friend.

take care and hope all the new foundry stuff turns out with good results.

 

[oldironfarmer]

Andy, congratulations on selling your last lot..

Thank you!

We really appreciate your well articulated casting process, absolutely fascinating..

And thank you again! You may be able to tell it currently has me somewhat consumed

Thank you and well done..

Need to get some acres so I can have a shed to home a lathe and a mill and a lift and...

Great work Andy, important tip - remove the pattern before you put the drag and cope together (did I get that right?)

I guess that's right?? You can see how ragged the casting was from the do-over.

Cheers GB

Andy,
Leaving the pattern in sounds like something I would do, I probably shouldn't have laughed as hard as I did. Also congrats on selling your last lot in the development.
JB

I know I'm not the first. But it is one of those learning things, like kids and rose bushes, that sticks with you!

Andy: you went through a pretty tough time with your development and good for you for sticking with it. I bet even your sense of humor was maybe tested more than you wanted it to be back in 2009 to 2011. when the banks shut down land development funds in 2006 it was a pretty big pill for me to swallow let me tell you.

Actually the development has been a boon from the beginning. It began paying it's own mortgage from within six months of start of sales, and has financed several other ventures. Since I do my own financing the housing crash was a positive for me, more people needing low down payment financing. I have not tried to sell remaining lots for ten years, they have gone to people coming and asking.

congrats on getting everything sold and guessing you have some income coming in from all those contracts now so you can maybe buy a RED, GREEN and any other color car you'd like? or maybe just more foundry stuff.



i'll have to give you a pass on leaving the pattern in the mold cause you just became papa to another calf yesterday. congrats and how many is that total of the little guys/gals now for this year? how many total and just one bull?

Six kids now, and 16 mommas, with five young ladies looking to date the bull. (they do date, they hang around together for several days until...) One bull can handle up to 30 or 35 cows. They don't have to buy flowers

you asked on G B's thread about my daughter and new son in law and I'll post their situation over on that thread that i still have a link in my sig line for. they do a lot of face time, but are still not living together cause my daughter has work commitments until June and then she moves. with face time on the phone and Ipads it's like my son in law is in the house most evenings which is sort of cool if you think about it.

anyway i can't speak for the rest of the guys, but i like your cow and bull stories and pictures of your rusty gold you seem to forget about and then sort of find like a long lost friend.

I need to get a rooster, **** and bull stories, you know

take care and hope all the new foundry stuff turns out with good results.

Thanks!

And thanks to each and every one. The good comments invigorate me!!

 

[drivesitfar]

Andy: speaking of NO FLOWERS i had to post this and i'll delete it if you think it's not an example of the bull at your farm. it came off the WTF thread and it really didn't need the words did it?

BEE CAREFUL getting a ROOSTER even though i like the sound of **** & BULL STORIES cause i can't tell you how many FREE ROOSTERS are on craigslist in the city i live in.

also congrats on the growing family in the pasture. anymore in the near future or is that it for this year?


cheers and have another GREAT SATUR day!!

 

[Rex_A_Lott]

Since you are fond of handmade things, I found a couple of videos to watch in your spare time:

The first one is kind of a Readers Digest version, the second runs too long, but it has some good details of the tools and the vise, if you can get past the woman yammering on.
Maybe you can get ahold of one of these cats and see if you can swap a home made broom for a pair of shoes.
I actually saw the shoe making done when I was in the Netherlands back in '88, and I was fascinated with that long-handled knife. Saw the "modern" machine process too.
Next time you have on your blacksmith hat, maybe you will make one of those for down on the farm...or the spoon auger , or the hatchet. Not sure exactly what you will use them for, but I dont want you to run out of projects.

 

[jp828108]

OIF,

You have some amazing stuff going on here. I can't believe everything you have accomplished, and all the great projects you have going on. The sock knitter was really cool. I actually just saw one of those on TV on Sunday.

I hope to one day have a small portion of the ability you have. Wood worker, machinist, foundry, general repair, construction, equipment operator, farmer. The list just goes on and on. Subscribing to continue seeing what you have going on around your farm.

 

[oldironfarmer]

Andy: speaking of NO FLOWERS i had to post this and i'll delete it if you think it's not an example of the bull at your farm. it came off the WTF thread and it really didn't need the words did it?

Looks like a cow on top to me. Cows will mount other cows when they are in heat.

BEE CAREFUL getting a ROOSTER even though i like the sound of **** & BULL STORIES cause i can't tell you how many FREE ROOSTERS are on craigslist in the city i live in.

I've never had a rooster and never wanted one. My dog, however, would love for me to get one.

also congrats on the growing family in the pasture. anymore in the near future or is that it for this year?

Seventeen cows I should have seventeen calves. Probably won't but fifteen is reasonable. Had one this morning (7 now), it was early and I had a Doctor's appointment to go to. Just a few hours old and struggling to keep up with mom. Marked like mom.

cheers and have another GREAT SATUR day!!

Thanks! And thank you for the comments!

Since you are fond of handmade things, I found a couple of videos to watch in your spare time:

The first one is kind of a Readers Digest version, the second runs too long, but it has some good details of the tools and the vise, if you can get past the woman yammering on.
Maybe you can get ahold of one of these cats and see if you can swap a home made broom for a pair of shoes.
I actually saw the shoe making done when I was in the Netherlands back in '88, and I was fascinated with that long-handled knife. Saw the "modern" machine process too.
Next time you have on your blacksmith hat, maybe you will make one of those for down on the farm...or the spoon auger , or the hatchet. Not sure exactly what you will use them for, but I dont want you to run out of projects.

Knife is kind of like a drawknife with a pivot on one end. A lot of leverage. When I worked in the Netherlands my work group got me a pair of shoes, and I wear them occasionally. Good for the garden.

Ik heb klompen

OIF,

You have some amazing stuff going on here. I can't believe everything you have accomplished, and all the great projects you have going on. The sock knitter was really cool. I actually just saw one of those on TV on Sunday.

Hmmm... I saw a sock machine this afternoon Was I on TV?

Thanks for the kind words. 1/2 calls me a man of mini talents

I hope to one day have a small portion of the ability you have. Wood worker, machinist, foundry, general repair, construction, equipment operator, farmer. The list just goes on and on. Subscribing to continue seeing what you have going on around your farm.

Thanks for your visit. You know the hardest part is deciding you want to do something. It's all patience and perseverance after that. I hope you got a Coke, dimes are on top of the machine

I appreciate all the visits!!

 

[oldironfarmer]

Well I had a great day today. New calf, and I didn't go to the doctor! I was on my way to Tulsa when they called "we're sorry, we have two Andrew Martins and the appointment was for the other one". "Thank you very much, I wasn't wanting chemo today anyway". She laughed. Cancer doctor stuff

So I turned around to come home and took the opportunity to stop at a pattern shop. Got to sew a dress. No, not that kind of pattern shop. Real life pattern makers, four miles from my house. I knew they were there but never stopped in. Owner working alone. Had 28 patternmakers before the oil crash, of 1985. That's when he left Tulsa and moved to a small building out in the country. Great guy, spent almost an hour showing me around and answering questions. Even gave me a textbook.

and will help me with hard to find supplies

Casting forum suggested I was casting my pattern upside down. So I packed the drag

and put the pattern in the cope with a sprue offset like usual and a riser right out the top of the hub.

I put my blacksmith stamp in the pattern but the letters don't show up, too small.

Poured in the right hand hole and watched the metal rise in the riser. Super cool and you know the pattern is full when it comes out the top!

Here's the bottom of the cope with the casting in (I remembered to take out the pattern, somehow)

So here's a 5" sheave rough casting and 18 muffins. I'm now up to 17 pounds of muffins. I try to make more muffins than I use.

Anyone need a sheave made out of cans?

Thanks for stopping in!! The ideas are flowing. I need a dedicated wrench for my old Craftsman lathe to turn the big nut to get the spur out. Have been using a 12" Crescent wrench, it's overkill. Thinking an aluminum clone of a JH Williams 1930's wrench would be cool.

It's Saturday tomorrow!

 

[Vieux]

Your skill in foundries is growing.

 

[1/2 Cup]

Andy, I am learning a whole new language here, just awesome..

 

[jbmatth]

That new sheave turned out great, glad it is working out for you with your new fancy book learnin'. So I have to ask as I don't know, what is the difference in a pulley and a sheave? Is a pulley somewhat symmetrical that is meant to be mounted with a bolt or stud through the center, and a sheave meant to be mounted with an offset boss, key, and set screw?

Speaking of sheaves, I've also wondered what the difference is between a shiv and a shank. I heard just last week that if it clanks it is a shank aka metal otherwise it is a shiv. However, google disagreed and made me more confused that I was when I started to look into it, thanks google.
JB

 

[oldironfarmer]

Your skill in foundries is growing.

Thank you! Fortunately, I have lots of room to grow so improvement is easy right now Thanks for stopping in!!

Andy, I am learning a whole new language here, just awesome..

Me too! Never thought you'd find me in a drag outfit But it is easy to cope with once you get started. Now we're out of the gate and off to more casting. Thanks for the visit!

That new sheave turned out great, glad it is working out for you with your new fancy book learnin'. So I have to ask as I don't know, what is the difference in a pulley and a sheave? Is a pulley somewhat symmetrical that is meant to be mounted with a bolt or stud through the center, and a sheave meant to be mounted with an offset boss, key, and set screw?

My definition (academia may disagree) is that a pulley is flat faced (crowned) and a sheave is grooved for v-belts or rope like on a crane hoisting drum or a block. So a sheave is a type of pulley, in my unwritten book.

Speaking of sheaves, I've also wondered what the difference is between a shiv and a shank. I heard just last week that if it clanks it is a shank aka metal otherwise it is a shiv. However, google disagreed and made me more confused that I was when I started to look into it, thanks google.
JB

So you got two-blocked on the sheave-pulley-shiv-shank thingy?

Saturday morning and work to do!!

 

[drivesitfar]

JB: i've only heard SHIV & SHANK in prison type movies and conversations about that. otherwise us on the outside just call them KNIVES don't we? or are those words that apply to pulleys and motors so i'll need to get my other dictionary out and put my URBAN DICTIONARY down.

ANDY: birthing and feeding cows and going to other guy's doctor's appointments cause they have the same name might keep you busy enough, but you still seem to get a pour in almost daily now. not to mention your can to muffin making skills are over the top. you mentioned SLAG when melting the cans so how are you scraping that off? also i think you mentioned since the slag has usable aluminum in it are you melting the slag with the chips from your lathe so you don't waste by usable materials. or are you melting the chips in with the cans or by themself since they are alread somewhat pure?

nice stop in town with the guy in the know and sorry his business is no longer IN BUSINESS, but sounds like you met somebody that will help you to keep improving your foundry skills.

good luck and STAY SAFE!!

 

[BUGTHUG]

Bringing in the sheaves, bringing in the sheaves, we shall go rejoicing bringing in the sheaves.
My singing is lousy!

 

[jimreed2160]

"we have two Andrew Martins..."

Oh mercy me!

 

[Rag Roc]

Andy, I've thoroughly enjoyed every page of this thread, and have lurked without comment to this point. Thanks for taking the time to document your efforts, as I enjoy learning from others. Well done sir!

 

[Guster]

100 pages!!!

Even gave me a textbook.

Oooooooh found the PDF for it… will make some good reading.

Casting forum suggested I was casting my pattern upside down. So I packed the drag

and put the pattern in the cope with a sprue offset like usual and a riser right out the top of the hub.

I put my blacksmith stamp in the pattern but the letters don't show up, too small.

Poured in the right hand hole and watched the metal rise in the riser. Super cool and you know the pattern is full when it comes out the top!

Here's the bottom of the cope with the casting in (I remembered to take out the pattern, somehow)

So here's a 5" sheave rough casting and 18 muffins. I'm now up to 17 pounds of muffins. I try to make more muffins than I use.

Well done getting good results on the last casting! That’s the way I was trying to suggest it to be done. The way I was shown for aluminium and brass anyway.

Looks like a few cans’ worth coming off as chips on the lathe that can also go back in the crucible.

Well I’ve had some recent developments for some marine prototyping that means I now have to make a foundry and find some ‘aluminium scrapbinium’ to do some lost foam casting. Will have to finish fitting insulation on the forge to see how much I have left for a foundry. Sounds like a very good reason to start a thread.

 

[oldironfarmer]

JB: i've only heard SHIV & SHANK in prison type movies and conversations about that. otherwise us on the outside just call them KNIVES don't we? or are those words that apply to pulleys and motors so i'll need to get my other dictionary out and put my URBAN DICTIONARY down.

No, that was a new subject. I started to ask the difference between skunk and *****, but I'm not sure I know myself.

ANDY: birthing and feeding cows and going to other guy's doctor's appointments cause they have the same name might keep you busy enough, but you still seem to get a pour in almost daily now. not to mention your can to muffin making skills are over the top. you mentioned SLAG when melting the cans so how are you scraping that off?

A little spoon I made with a three foot handle to skim slag. It works pretty well. The slag sticks together but also traps aluminum.

also i think you mentioned since the slag has usable aluminum in it are you melting the slag with the chips from your lathe so you don't waste by usable materials. or are you melting the chips in with the cans or by themself since they are alread somewhat pure?

The chips are clean so they will melt with the muffins, risers, and sprues, second melt material. You know me too well though. I need to quit reclaiming slag. I'm pretty sure I'm burning more propane than the reclaimed material is worth. I'll save it until I get a waste oil furnace built. The slag looks like this

Probably 10% is aluminum. The black pile at the far end is recycled slag.

nice stop in town with the guy in the know and sorry his business is no longer IN BUSINESS, but sounds like you met somebody that will help you to keep improving your foundry skills.

good luck and STAY SAFE!!

He is still in business, just a much smaller one. And as he says, he is making more money with fewer headaches. A really nice guy.

Bringing in the sheaves, bringing in the sheaves, we shall go rejoicing bringing in the sheaves.
My singing is lousy!

OK, everybody bounce to the tune of "Bringing in the Sheaves"

"we have two Andrew Martins..."

Oh mercy me!

My wife just hung her head and wept...

Andy, I've thoroughly enjoyed every page of this thread, and have lurked without comment to this point. Thanks for taking the time to document your efforts, as I enjoy learning from others. Well done sir!

Thanks for your comment! But, "buyer beware", I just describe how I do things. Probably not the right way. You should hear the cows moan when I feed them wrong.

100 pages!!!

Oh, yeah!! Where did the time go?

Oooooooh found the PDF for it… will make some good reading.

It is pretty good book, and there are some loose assignment papers in mine.

Well done getting good results on the last casting! That’s the way I was trying to suggest it to be done. The way I was shown for aluminium and brass anyway.

I'm a little dense sometimes. It is starting to make sense. Thanks for your help.

Looks like a few cans’ worth coming off as chips on the lathe that can also go back in the crucible.

I've got a cardboard box filling up with chips. I throw some away when they are contaminated with steel or brass chips. They should melt down just fine, even with a little oil.

Well I’ve had some recent developments for some marine prototyping that means I now have to make a foundry and find some ‘aluminium scrapbinium’ to do some lost foam casting. Will have to finish fitting insulation on the forge to see how much I have left for a foundry. Sounds like a very good reason to start a thread.

Well it's about time to start a thread!!

My fire brick furnace is really working quite well. I'm going to make a refractory one, but the brick works good if you can find some 2,600F (1,400C) brick. They are about $3.50 each here. I'm using a 304 SS crucible which is holding up very well. I measured my chimney temperature at 1,600F today.

Thanks for stopping by guys!

 

[oldironfarmer]

I'm just having one great day after another!

Made a refractory plinth to set the crucible on in the furnace. It gets the crucible up off the floor. It needs to cure for about three days before I start heating it slowly to 450F then it can go into the furnace for a slow rise in temperature.

Here's the shrinkage for the last pour

Also made a form out of plaster of paris to make a core in.

The core goes inside a pattern cavity to provide a hole in the casting. The core material is strong and heat resistant but when hot metal hits it, it gets brittle and collapses when the casting cools and shrinks onto it.

Made a new wheel for my sheave pattern, 4" this time. And I relieved it to speed cooling and reduce machining.

Put a really big riser right on the pattern and twin gates to feed the heavy rim first.

Poured fine. The riser *****, though.

No cracks, no shrinking damage, no joke!

Or is it the Starship Enterprise-Can?

Also found a cast wheel to use. I understand the proper metallurgical term is "wheelium".

I assume I can cut it up with the plasma torch.

And found some pistons out in the pasture. I haven't identified the aluminum on top of the fuel tank, but it looks like pot metal.

I think my next pattern will be the wrench. Just for fun!

I am learning and it is getting easier.

Thanks for visiting!

 

[dlcwent]

"Also found a cast wheel to use. I understand the proper metallurgical term is "wheelium"."



If you're going to teach us a new language, at least keep it legit.

Your talent is only outdone by your humor.

Working with slag in a previous life I found that there is still a lot of usable material than can be reclaimed with a second melting. What is actually gained from the process is debatable as to whether or not it is worth your time.

 

[drivesitfar]

Andy: your new foundry skills combined with your natural thriftyness and shop skills is providing us all with a great read.

pretty soon your castings will be made by some machine you'll make out of an old rusty machine in the field and everything will be automated while you watch while making a few more brooms.

just curious since i'm pretty sure you get a bit of wind are you putting up any sides on your new carport/shed addition? since you pour everyday do you heat it up outside and maybe pour inside the shop or do tell?

hope you had another baby calf today. are the current ones behaving?

cheers

 

[Guster]

I'm a little dense sometimes. It is starting to make sense. Thanks for your help.

Nah, didn’t really take my time to explain it in best terms either. Sometimes you can blame the 2nd rate consultant! OK 3rd rate… but I’m free. I don’t even drink Cola.

The last pour came out very nice and that wheelium might introduce a little magnesium to your canium which is a good thing in moderation. It reduces the amount of shrinking by almost 1% if I understand the literature correctly. Nice plinth too. You know you could just chip one from a fire brick like us mortals . Though if you makin’ socks, brooms and new shiny things you might as well make a fancy plinth I guess. What are you planning to use for the cores? Ever planning to experiment with adding sodium silicate to your sand and set it with some CO2 welding gas?

Don’t think I didn’t spot the addition to the signature though. Very sneaky, sly ol’Andy. I have some fire brick that is rated to about 2000C if I recall. However my reason for building the foundry may have vanished again as the brief changed a bit. But the alternative solution is just as fancy, still requires some pattern making and still screams “start a blinkin’ thread already”.

 

[krcoomer]

Andy: I was out of town without connectivity most of the past week. Read about 3 pages tonight to catch up with casting aluminum. One of the questions that has churned around in my brain was how long it takes for the aluminum to cool before the casting is set. I understand it is relevant to the size of the item, but the curiosity is there for me.

Also, my father in law trained as a welder during the Vietnam era for his stateside National Guard motorpool duty. Welding choppers back together necessitated a lot of time being spent on aluminum welding. He has told me many times that aluminum starts oxidizing as soon as it is produced (in this case cast). I presume the alloys and additional elements are to combat this oxidation.

 

[dchance]

Andy things are looking good. If you can show new sheaves/pulleys I would think new calves would also fit.

Looks like somewhere down the road you will need to start casting pistons for some of your projects.

Dwight

 

[oldironfarmer]

"Also found a cast wheel to use. I understand the proper metallurgical term is "wheelium"."



If you're going to teach us a new language, at least keep it legit.

Not my fault!! This is the term the guys on the casting forum call it. I called my metal can-o-lite and was immediately corrected that it is candemonium as in pandemonium. And ladderite is not much better.

Your talent is only outdone by your humor.

I'm on to you! My mediocre humor exceeds my talent. So maybe I'm not a man of mini talents like 1/2 says but micro-mini talents according to Dan. Well I'll have you know I'm watching your thread closely. (primarily for any other views of the fishnets) This is not a threat, it's a promise.

Working with slag in a previous life I found that there is still a lot of usable material than can be reclaimed with a second melting. What is actually gained from the process is debatable as to whether or not it is worth your time.

I am very curious what prompted you to remelt slag? Please elaborate!

My time is not as much of an issue as the fuel cost.

Thanks for taking the time to stop in!

Andy: your new foundry skills combined with your natural thriftyness and shop skills is providing us all with a great read.

Thanks for the positive words!

pretty soon your castings will be made by some machine you'll make out of an old rusty machine in the field and everything will be automated while you watch while making a few more brooms.



Actually I have no desire for automation, just learning new crafts.

just curious since i'm pretty sure you get a bit of wind are you putting up any sides on your new carport/shed addition? since you pour everyday do you heat it up outside and maybe pour inside the shop or do tell?

I keep thinking about a wind break however the setup works well as is. Ventilation is extremely important. furnace doesn't seem to care about wind, and the crucible does not cool too fast to allow me to pour. The worst thing has been my sheet metal heat shield blowing off in a gust before I pour. So I put two screws in it and push them down into the sand.

Hot metal on concrete can cause it to explode. And with a potential of noxious fumes I'm doing everything outside. I did install two overhead doors in the foundry room thinking I would pour inside but its not working that way.

hope you had another baby calf today. are the current ones behaving?

Actually I did. Here he is

not. I've spent an hour waiting for PhotoBucket to upload my pictures. I think their ads are using up all my bandwidth. Maybe tomorrow.

And here's the little girl. Like momma like daughter!

Tune in later for cute calf caricatures.

cheers

Nah, didn’t really take my time to explain it in best terms either. Sometimes you can blame the 2nd rate consultant! OK 3rd rate… but I’m free. I don’t even drink Cola.

The last pour came out very nice and that wheelium might introduce a little magnesium to your canium which is a good thing in moderation. It reduces the amount of shrinking by almost 1% if I understand the literature correctly. Nice plinth too. You know you could just chip one from a fire brick like us mortals . Though if you makin’ socks, brooms and new shiny things you might as well make a fancy plinth I guess.

Magnesium and silicon. The silicon apparently lowers the viscosity aiding in the actual pour. And the metal is called candemonium.

I have all this 3,500F refractory and I think it will hold up better than a fire brick. I have read about plinths failing and damaging the furnace. I'm hoping this one will last.

What are you planning to use for the cores? Ever planning to experiment with adding sodium silicate to your sand and set it with some CO2 welding gas?

I said ca-si but I meant na-si. But I don't have a MIG welder so I have no CO2. But I do have vinegar and soda. And I have sodium silicate. I also plan to try baking linseed oil treated sand.

Don’t think I didn’t spot the addition to the signature though. Very sneaky, sly ol’Andy.



I have some fire brick that is rated to about 2000C if I recall. However my reason for building the foundry may have vanished again as the brief changed a bit. But the alternative solution is just as fancy, still requires some pattern making and still screams “start a blinkin’ thread already”.

I have an automatic search set up to look for your thread every time I open my laptop. I'm wasting away in frustration.

Andy: I was out of town without connectivity most of the past week. Read about 3 pages tonight to catch up with casting aluminum. One of the questions that has churned around in my brain was how long it takes for the aluminum to cool before the casting is set. I understand it is relevant to the size of the item, but the curiosity is there for me.

About four or five minutes, maybe. I really don't know. If it is too hot to handle the sand is hot too and may damage the plastic tray I keep it in. So after I pour I melt a batch of cans (to replace muffin stock) and it's ready when I'm done with the cans. And the casting is still too hot to handle.

That reminds me, did you know "Too hot to hoot" is an anagram? Just as I suspected!

Thanks for stopping in!

Also, my father in law trained as a welder during the Vietnam era for his stateside National Guard motorpool duty. Welding choppers back together necessitated a lot of time being spent on aluminum welding. He has told me many times that aluminum starts oxidizing as soon as it is produced (in this case cast). I presume the alloys and additional elements are to combat this oxidation.

The moisture in the sand turns to steam and helps drive air away from the casting. But it definitely continues to oxidize while melted. Thanks for the visit!!

Andy things are looking good. If you can show new sheaves/pulleys I would think new calves would also fit.

Spot reserved for beautiful baby bovine images.

Looks like somewhere down the road you will need to start casting pistons for some of your projects.

Dwight

Pistons for projects! Not out of the realm of possibilities!

Pictures and an update tomorrow, I promise!!

 

[1/2 Cup]

Pictures and an update tomorrow, I promise!! [ quote]


Andy, looking forward to it..

 

[dlcwent]

I am very curious what prompted you to remelt slag? Please elaborate!

My time is not as much of an issue as the fuel cost.

Thanks for taking the time to stop in!


Andy, first I must clarify as to what I was referring to. Years ago I worked as am Optical Lab Tech. In order to cut glass in the generators ( glass lathes) you first had to attach a lead alloy block to it so it could be held in the chuck. This lead alloy had a melting point of 117* F. The lenses were taken through the process of grinding the proper curve to refining and finally polishing of the glass. At that point the blocked lens was placed in a reclaim tank and the lead alloy was melted off. When returned to the blocking machine that was kept around 120* F the impurities (slag or dross) would form on the top of the lead alloy. When it got to the point of covering the entire top surface it would have to be scraped off to maintain the 120* F. After a month or so of scraping you would have a fairly large amount of dross or slag (whatever you chose to call it). By putting the can that had been collecting it into a double boiler set up it would re-melt and the pure metal could be poured off back into the blocker. The reason we even went through this process was because of the cost of the lead alloy. If memory serves me right it was going for around $100 for 5 lbs. ( And we all know how heavy lead is). So even if we could only reclaim a couple of lbs., it was worth doing.

 

[oldironfarmer]

Pictures and an update tomorrow, I promise!! [ quote]


Andy, looking forward to it..

They are trying to upload again. Yesterday, three times, pictures uploaded to 90% and would not finish. Even tried one picture. I'm a computer has been

I am very curious what prompted you to remelt slag? Please elaborate!

My time is not as much of an issue as the fuel cost.

Thanks for taking the time to stop in!


Andy, first I must clarify as to what I was referring to. Years ago I worked as am Optical Lab Tech. In order to cut glass in the generators ( glass lathes) you first had to attach a lead alloy block to it so it could be held in the chuck. This lead alloy had a melting point of 117* F. The lenses were taken through the process of grinding the proper curve to refining and finally polishing of the glass. At that point the blocked lens was placed in a reclaim tank and the lead alloy was melted off. When returned to the blocking machine that was kept around 120* F the impurities (slag or dross) would form on the top of the lead alloy. When it got to the point of covering the entire top surface it would have to be scraped off to maintain the 120* F. After a month or so of scraping you would have a fairly large amount of dross or slag (whatever you chose to call it). By putting the can that had been collecting it into a double boiler set up it would re-melt and the pure metal could be poured off back into the blocker. The reason we even went through this process was because of the cost of the lead alloy. If memory serves me right it was going for around $100 for 5 lbs. ( And we all know how heavy lead is). So even if we could only reclaim a couple of lbs., it was worth doing.

Interesting job. Isn't it amazing how similar activities transfer across industries. After I remelt my slag and pour off what I can, I find if I pound the remaining slag down with a tool I'll get more liquid metal out and am left with a uniform black residue that comes out as a powder when scraped. It is a waste of money but I love reclaiming.

 

[Toothaker]

Andy - or to anyone who knows - what is slag? No, don't say, "the stuff that floats to the top of melted metal" - I know that. But what is it? Next somebody will say "impurities". Yes, I know that too.

When I was in school I took metal shop, and school had a small foundry that would melt aluminum. We melted old pistons, and made all sorts of useful things like ladle rests and ashtrays. I still remember the smell of the hot sand and oil as we poured the hot aluminum.

 

[jimreed2160]

Photobucket is back up and accepting uploads...for now. Their quality of service has been down lately.

 

[oldironfarmer]

Andy - or to anyone who knows - what is slag? No, don't say, "the stuff that floats to the top of melted metal" - I know that. But what is it? Next somebody will say "impurities". Yes, I know that too.

When I was in school I took metal shop, and school had a small foundry that would melt aluminum. We melted old pistons, and made all sorts of useful things like ladle rests and ashtrays. I still remember the smell of the hot sand and oil as we poured the hot aluminum.

I sure don't know! A lot of carbon from various contaminants, for sure.

Photobucket is back up and accepting uploads...for now. Their quality of service has been down lately.

I'm glad it wasn't me. It looks like my photos finally uploaded. Company today and they're stirring so I'll post later.