Aluminium casting

Hi Can anyone help this old codger trying his first casting please. What I am trying to make is an aluminium block, 150mm square by 52mm thick with a 100mm hole in the centre, hopefully with a decent finish as I am short on finishing equipment. I am planning to weld angle iron into a square to make the sides, use a section of 100mm steel tube for the centre hole and tack weld them onto a steel plate to make the mould. I also want to fill the tube to make a disc. Does this this sound feasible please, also will the aluminium, as it shrink as it cools, get stressed by the centre steel tube. When I have poured the aluminimium into the moulds, do I slide a scraper across the top to get a reasonable finish. Many thanks Keith

Topic by axus4   |  last reply

What to cast?

Hello, I plan on casting some aluminium soon. However, I haven't decided on what to cast.... any ideas??

Question by knutknackebröd   |  last reply


How can i sell in your site an aluminium cast foundry?

Topic by anastasiakariotou   |  last reply

Can I use plaster-of-paris as a mold material for making an aluminum casting?

I do not have access to any proper mold making materials, only items that can be found in a hardware store or a pharmacy. I would like to know if I can use plaster of paris as a mold material for a simple pour type casting using a lost wax type method. Any help will be greatly appreciated.

Question by Wormlamp   |  last reply

lost wax casting

Newkidontheblock. looking for authentic instuctions how to go about making lost wax castings of chess pieces (in aluminium )dozens of them ????

Topic by golodenboy6   |  last reply

lost wax casting: what material is the best for pouring metal into?

So I made a rad Yoda wax figurine recently and I'm looking into converting him into a aluminum via the lost wax casting method. I've seen some other instructables on casting the metal into plaster of paris, but that doesn't seem to preserve the very fine details that I want. There are a few other methods I've seen on other forums, like mixing fine sand with plaster and making a ceramic mold...I have even wackier ideas like using fireproof cement, but I haven't seen anything online to support using it...what other ideas can you think of that don't involve expensive investment powders I have to buy online? 

Topic by jtrainer1   |  last reply

How strong is JB weld compared to cast aluminium by a tensile force?

Hello. How strong is JB weld compared to cast aluminium? A broken lever from the quick snap from a "Supercut 2 Q" oscillating tool from "Fein".

Question by tobias.claren.9   |  last reply

Lost Foam?

Hi guys, I've been messing about with lost foam aluminium casting here in the UK. I've tried packing expanded polystyrene, and Jablite but they seem really difficult to get a good finish on the foam patterns. I want to be able to machine them, or use them in a basic foam lathe. I know that in the States they have a denser finer grained insulation material (blue and pink in colour). These both seem to be better for obtaining surface finish. I've tried to Google the stuff over here but it seems to be silly prices. Does anyone have any links to UK sites that sell a similar product? I was wondering if the harder stuff that you saw up and stick between the rafters for loft conversions would work as this seems a much denser fine grain foam to me. Any ideas or advice would be appreciated.

Topic by marshon   |  last reply

Can anyone help me with metal casting?

I have been working with my friend, setting up a small IT business in our local area providing some software but mainly hardware. Now that I have a furnace and it can melt aluminium my friend has asked me to cast a case for his computers. He said that he will produce a wooden copy of what he would like it to look like, then give it to me to cast. I am wondering how I can convert the wooden copy into a wax copy so that I can continue from my own knowledge. Any help would be greatly appreciated. Thomas

Question by thomas9666   |  last reply

Casting a REALLY complex HOLLOW shape with metal!?

Exactly like casting a 3D print out of metal; I have a airsoft upper receiver which I want to cast out of aluminium cheaply. Made of polymer and quite complex.

Topic by Digital Flame   |  last reply

hairdryer heatingcoils for small aluminum foundry?

Hey guys would it be possible to create a small foundry that is powerfull enough to smelt aluminium cans? i was thinking of building it in a YTONG stone

Question by timothy demaegdt   |  last reply

Has anyone made there own smelting furnace and how did you do it?

I just need one to start my own mini casting house (my garage to be exact). I want to run it on gas and be hot enought to melt copper, brass , and aluminium. but only on a small scale to make castings for projects i have in mind. I know how the concept works but does anyone know any good tips eg what materials, how hot do it need to go, safety, and anyone how has expience in castings, making them or both.

Question by jonjon1978   |  last reply

metal laptop

Just finished "Idoru" by william gibson.The main character has a laptop with a cast aluminium case made from reclaimed soda canswirh semi precious stones as switches and buttons and reclaimed ivory keys. I suppuse its possible to do, but difficult... but wouldnt it be deadly? Anyone ever tried that?

Topic by maninamousesuit   |  last reply

Solvent that 100% dissolves gorilla glue? need castable material to chemically to "burn out" for a ceramic shell casting Answered

Hello. I am working on doing an aluminium lost foam casting of a small part. I read although hazardous, some had gotten successful results from using polyurethane foam (great stuff) in a mold, and proceeding as usual. I don't normally use great stuff, so I mixed gorilla glue with 1/3 water, stirred till I had small bubbles, poured into a silicone mold, and got a pretty good few castings that were VERY dense and hardly burned at all. In fact it was practically fire resistant. I threw it on hot coals and it took a long time to shrivel into a hard little mass So next time, I used dollar store foam board next, a la Grant Thompson, but with terrible failures. It seemed the foam board didn't burn very well either. A foam board riser had actually melted off and looked like it floated away in a bubble, although a regular styrofoam block I had cut to shape cast perfectly, but was too thick and the texture was too poor as the foam was so much less dense. It was mentioned in this blog post that someone used acetone to burnout a tricky patten for a lost foam casting, so I figure I have to do the same. My pattern is curing at the moment. But my silicone molds are far more precise and more detailed than my 2d representation I made with a wire cutter. So my question is there another material that is castable but water resistant, like styrofoam, that I could use a solvent to melt out. I can't really do  lost wax because I don't have the equipment and live in an apartment and have to do this stuff out on the beach. Also due to family reasons I can't be away from home for the time it takes to do burnouts, 6 hours for a full flask, but that's also the reason why I am doing the shell casting because I can't spend too much time away from the fam. Thanks for your time, sorry if I rambled. And thanks for all here and elsewhere who teach and inspire, even if they don't know they are doing it.

Question by sk8er6   |  last reply

How can i focus a magnetron beam from a microwave , to make a small metal forge?

hello I have been looking for a number of ways to cast my zinc with, along with just melting other metals namely aluminium. I have come across the microwave method, however i feel that just using a microwave is a wasteful and hazardous means of meting metals like zinc , since the metal vapors are very flammable, even explosive, even as a dust I thought, since the microwave is basically just a box which the magnetron beams microwaves into, why not build a forge, which consist of a crucible laying in the center-point of a magnetron beam. all this would sit outside, done at a distance to avoid exposure to rouge microwaves. I dont wish to introduce anything new into the equation, just use prexisting things form the microwave, and probably some aluminium sheet. Anyone know if it will work better than just using a microwave? and how i should focus the beam? i want to keep the whole thing as compact as possible, probably which the crucible being no further than 10-20cm from the magnetron. Thanks

Question by oldmanbeefjerky   |  last reply

Polycarbonate panel thickness for secure windows? Answered

I need to glaze 16 small panes (430 x 275 mm) in very strong, cast aluminium window frames (8 per frame, either side of the door). Is 3 mm frosted polycarbonate going to be impact resistant enough to keep people out? The building these windows are part of is in a fairly remote place, so security is a concern but for cost and aesthetic reasons we don't want to glaze with glass and install a metal security screen. The current ugly solution is boarding them up and securing with screws but this doesn't allow us light inside. Cost is a consideration since I've been given permission by the company that owns the land to reglaze them and if I provide the labour they will supply the materials. 16 off 3 mm sheets, £3.85 each = £61.60 16 off 4 mm sheets, £5.14 each = £82.24 16 off 6 mm sheets, £7.70 each = £123.20 I've found lots of sites shouting "yeah polycarb is badass! It's unbreakable!" but not one that gives an idea for thinner sheets. Am I wasting money by going for thicker sheets? Or if someone's trying to get in might a 3 mm sheet be breakable?

Question by Jayefuu   |  last reply

John Cleese's "Letter To America"

Forwarded along by an Aussie. Enjoy.Dear Citizens of America,In view of your failure to elect a competent President and thus to govern yourselves, we hereby give notice of the revocation of your independence, effective immediately. Her Sovereign Majesty, Queen Elizabeth II, will resume monarchical duties over all states, commonwealths and other territories (except Kansas, which she does not fancy), as from Monday next.Your new prime minister, Gordon Brown, will appoint a governor for America without the need for further elections. Congress and the Senate will be disbanded. A questionnaire may be circulated next year to determine whether any of you noticed.To aid in the transition to a British Crown Dependency, the following rules are introduced with immediate effect:1. You should look up "revocation" in the Oxford English Dictionary. Then look up "aluminium," and check the pronunciation guide. You will be amazed at just how wrongly you have been pronouncing it.2. The letter "U" will be reinstated in words such as "colour", "favour" and "neighbour." Likewise, you will learn to spell "doughnut" without skipping half the letters, and the suffix "-ize" will be replaced by the suffix "-ise."3. You will learn that the suffix "burgh" is pronounced "burra"; you may elect to spell Pittsburgh as "Pittsberg" if you find you simply can't cope with correct pronunciation.4. Generally, you will be expected to raise your vocabulary to acceptable levels (look up "vocabulary"). Using the same twenty-seven words interspersed with filler noises such as "like" and "you know" is an unacceptable and inefficient form of communication.5. There is no such thing as "US English." We will let Microsoft know on your behalf. The Microsoft spell-checker will be adjusted to take account of the reinstated letter "u" and the elimination of "-ize."6. You will relearn your original national anthem, "God Save The Queen," but only after fully carrying out Task #1 (see above).7. July 4th will no longer be celebrated as a holiday. November 2nd willbe a new national holiday, but to be celebrated only in England. It will be called "Come-Uppance Day." 8. You will learn to resolve personal issues without using guns, lawyers or therapists. The fact that you need so many lawyers and therapists shows that you're not adult enough to be independent. Guns should only be handled by adults. If you're not adult enough to sort things out without suing someone or speaking to a therapist then you're not grown up enough to handle a gun.9. Therefore, you will no longer be allowed to own or carry anything more dangerous than a vegetable peeler. A permit will be required if you wish to carry a vegetable peeler in public.10. All American cars are hereby banned. They are crap and this is for your own good. When we show you German cars, you will understand what we mean.11. All intersections will be replaced with roundabouts, and you will start driving on the left with immediate effect. At the same time, you will go metric immediately and without the benefit of conversion tables. Both roundabouts and metrification will help you understand the British sense of humour.12. The Former USA will adopt UK prices on petrol (which you have been calling "gasoline") - roughly $8/US per gallon. Get used to it.13. You will learn to make real chips. Those things you call french fries are not real chips, and those things you insist on calling potato chips are properly called "crisps." Real chips are thick cut, fried in animal fat, and dressed not with catsup but with malt vinegar.14. Waiters and waitresses will be trained to be more aggressive with customers.15. The cold tasteless stuff you insist on calling beer is not actually beer at all. Henceforth, only proper British Bitter will be referred to as "beer," and European brews of known and accepted provenance will be referred to as "Lager." American brands will be referred to as "Near-Frozen Gnat's Urine," so that all can be sold without risk of further confusion.16. Hollywood will be required occasionally to cast English actors as good guys. Hollywood will also be required to cast English actors as English characters. Watching Andie MacDowell attempt English dialogue in "Four Weddings and a Funeral" was an experience akin to having one's ear removed with a cheese grater.17. You will cease playing American "football." There is only one kind of proper football; you call it "soccer." Those of you brave enough, in time, will be allowed to play rugby (which has some similarities to American "football," but does not involve stopping for a rest every twenty seconds or wearing full kevlar body armour like a bunch of Jessies - English slang for "Big Girls Blouse").18. Further, you will stop playing baseball. It is not reasonable to host an event called the "World Series" for a game which is not played outside of America. Since only 2.1% of you are aware that there is a world beyond your borders, your error is understandable and forgiven.19. You must tell us who killed JFK. It's been driving us mad.20. An internal revenue agent (i.e. tax collector) from Her Majesty's Government will be with you shortly to ensure the acquisition of all monies due, backdated to 1776.Thank you for your co-operation.John CleeseLink

Topic by canida   |  last reply