Melting metal and casting objects

[niget2002]

Hello GJ members.

I've been contemplating getting into melting metal and casting objects. I'd like to use my 3d printer to print molds, cast them, and then finish them on the mill. Probably mostly aluminum.

I've watched quite a few youtube videos, but does anyone have a link to a good wiki or instructional website that can walk you through what all you really need to get started? Would it be best to just start with one of the 'kits' you can find out there?

 

[roguegts]

What size parts are you thinking?

It’s quite fun and Aluminum is super easy to pour. Find some old beat up car wheels for nearly free and have at it.

 

[niget2002]

What size parts are you thinking?

It’s quite fun and Aluminum is super easy to pour. Find some old beat up car wheels for nearly free and have at it.

Maybe some items around the size of a large Yeti cup (not the super duper large one).

 

[tstaude]

Are you looking to cast with sand molds or investment castings?
I have done both....as a career....for the last 15 years.
Let me know if you need any help.

 

[Firebrick43]

Are you looking to cast with sand molds or investment castings?
I have done both....as a career....for the last 15 years.
Let me know if you need any help.

I have a question for you. I have done petrobond and green sand aluminum casting but not investment.

I am familiar with the process and have watched several videos on pine tree castings process (ruger) and wonder if the slurry they dip it into multiple times is available for sale? If so how long and what temp is it baked at? I think it would be pretty easy to regulate and time an air cylinder to dip a single part.

 

[tstaude]

I have a question for you. I have done petrobond and green sand aluminum casting but not investment.

I am familiar with the process and have watched several videos on pine tree castings process (ruger) and wonder if the slurry they dip it into multiple times is available for sale? If so how long and what temp is it baked at? I think it would be pretty easy to regulate and time an air cylinder to dip a single part.

We use a slurry/stucco known as fused silica. This has to go through a phase transformation in order to gain strength, this occurs at about 1400F. Some aluminum parts we do not need to bake the molds over 1200F, usually a 3 hour soak time at full temp.
I am not sure what home brew slurry is available at this very moment, I have only ever worked with huge batches personally.

 

[niget2002]

Are you looking to cast with sand molds or investment castings?
I have done both....as a career....for the last 15 years.
Let me know if you need any help.

I'm not really sure. I guess that's where my research needs to start

 

[Firebrick43]

To the OP, Steve Chastain has a 2 volume book set on sand casting that I would recommend. He also has a book on a waste oil furnace for aluminum, a sand muller, and a

Also there is the Gingery charcoal furnace book, not great but still not a bad place to start for small batches and get you feet "wet" for little money.

All of these books are not "polished" but especially Steve Chastain's books the info is solid and backed by engineering/math. Just wish his welding skills were a little better

https://stephenchastain.com/store/index.php?main_page=index&cPath=1&zenid=a8db196d32a36bf53f2397e726770c50

 

[tstaude]

I would go investment if you can. You just need slurry and some stucco. Put a little riser and a pour cup on top and you have a mold.
You will have to burn out the plastic. Make it hollow if you can print that way. Then submerge your setup in water to make sure it is water tight.
If you send me a 3D cad file I may be able to sketch a quick and dirty setup for you.

I’ll be in this business a long time, so just let me know if you need help along the way.

 

[justanengineer]

I would recommend finding a few hobbyists local to you that can help you learn the basics and get some hands-on experience. There are also a few artisan casting groups around the country that can provide the same. Personally I wouldn’t buy much beyond safety equipment until you’ve done a pour or two. LOTS of folks want to build their own equipment but IME there’s quite a lot of small, professionally manufactured prototype/school equipment perfect for the hobbyist on the used market for not much above scrap. Realistically, it also doesn’t take much, aluminum can be melted in a frying pan over a hot fire and poured into wooden boxes if your casting isn’t too big.


Sent from my iPhone using Tapatalk

 

[MushCreek]

That would be one hot fire! The melting point of aluminum is 1220 F. I have some car parts I'd like to reproduce, but they'd probably have to be die cast. The cost of the tool, plus getting permission from the OEM would make it impractical, though.

 

[bdbecker]

Making molds was one of my motivators for buying a 3D printer as well. Here's a pretty good read on the process. I have more pages saved, but can't seem to find them at the moment.

http://3dtopo.com/lostPLA/

Also, don't discount zinc alloys as an option when it comes to casting. Depending on your application, it could be a good alternative to aluminum.

 

[nadogail]

For entertainment do a Google Search "Backyard metal casting"

 

[Firebrick43]

That would be one hot fire! The melting point of aluminum is 1220 F. I have some car parts I'd like to reproduce, but they'd probably have to be die cast. The cost of the tool, plus getting permission from the OEM would make it impractical, though.

What parts do you want to reproduce? Other than something that explicitly includes the model name(if they have maintained copywrite) or brand name/emblem you can reproduce it.

This is of course that the car/part is older than the patent life(7-20ish years)

 

[MushCreek]

Inside rear view mirror holder for a '67 Ford pick-up. It's a one-year-only part. I have one, but they're hard to find. Luckily, the mirror head itself is the same as a 64-66 Mustang, and re-pops are readily available. If I had access to a full machine shop with CNC equipment I'd build a die (mold) That's what I did for a living, so I know what's involved. I doubt that there's a big enough market to make it worthwhile.

 

[dogdog]

I like this guy,

too bad, my area doesn't allow home build furnace...

you should also look up the Ron Reil burner out of black pipes....and green sand.