Huge Aluminum Casting. Hanger

This lost-foam casting will be a little bit harder than my usual projects. It'll be huge aluminum casting of a thing with a very complex shape - clothes hanger. Yes, I know that coat hanger doesn't sound as something very complex but if we think about the shape than you can understand why it's hard.

Step 1: Making a Pattern

To make a pattern I will use polystyrene sheet. To cut the shape of a hanger I'll use my new hot wire cutter.

Step 2: Making a Mold

Making a mold using lost-foam casting technology. For this process I need a flask, green sand, foam pattern and a lot of time.

Step 3: Casting Aluminum

When aluminum is melted it's time to cast. I had a leakage but it's not a big deal.

Step 4: Sanding and Final Result

This clothes hanger looks not bad after sanding though I had some problems during casting and had to use all 4 risers. I understood that I could have some problems during casting of such thing and that was the reason why I've made 4 risers.

Comments

[johnip4]

When I do lostfoam casting I just use regular loose sand. You just have to shake it a bit to make sure the sand gets i all the nooks and crannies.

To avoid blow oats (your leaks) you need to build up Rory mold to the same height as your risers, otherwise the hydrostatic pressure lifts the sand.

[DuralM]

Thanks for commenting. Well, leaks happened because I overfilled it. I know what you mean but this time it happened because I wasn't enough caution :) If green sand is good and the volume is fine than hydrostatic pressure is not a problem but yeah, it happened with me before :)

[buck2217]

I want to have a go at casting at some point (finding the time is an issue at the moment)

However I would have thought that a steel hanger hook could have been better to cast in as part of it as the aluminium one is likely to straighten or break, as ally isn't all that strong

[DuralM]

Yes, this hobby takes a lot of time and some money. This hanger is very strong. It'll be hard to brake it :) Don't forget that steel melting point is more than twice time higher than aluminum. It's not easy to melt steel at home :)

[buck2217]

No you misunderstand me, I meant cast in an already made steel hook (from a plastic coat hanger) as part of your casting, also you could possibly use a whole lightweight plastic hanger as your former rather than a foam one as the aluminium would melt it and displace it

[DuralM]

In my experience, I prefer lost foam casting. I don't like to take away a pattern :) Especially it's hard with big flasks and molds.

[gm280]

I understand the casting part, but why a hanger?

[DuralM]

Well, the answer is simple. Yesterday, Elon Musk called me and told that no need to rush making parts for his new spaceship to Mars. I've decided that if I have some time, why not to make something for a household and made a hanger :):):)

[gm280]

Well that's as good an answer as any. I like your video and contemplation doing the same one day as well. I have the material, just so many other projects going on presently. I need to make "green sand" and a proper foundry container with the fireproof walls and of course the burner setup. Any chance you can post those things as well?

[DuralM]

I'm glad that you like it :) All that you asked is already on my youtube channel and here on instructables. So the links:

1. Two types of green sand based on different clays:

- bentonite (green clay): https://www.instructables.com/id/Bentonite-Green-S...

- brown clay: https://www.instructables.com/id/Green-Sand-Formul...

2. My foundry building guide consist of 3 parts here and on youtube:

- Part 1: https://www.instructables.com/id/Smelting-Furnace-...

- Part 2: https://www.instructables.com/id/Big-Smelter-Proje...

- Part 3: https://www.instructables.com/id/Big-Smelter-Proje...

3. That's my "burner". It's not exactly burner because I use charcoal and coal for casting. So I use a blow pipe, to blow enough air: https://www.instructables.com/id/New-Blowpipe-Meta...

I hope that helped. If you push on my channel (web site) logo you'll see all my instructables and videos. If you have any questions I'll be happy to help. Good luck in any DIY projects :)

[iceng]

+1