Aluminum Casting?

[MajorPanic]

Anybody have any information on aluminum casting at home?
I want to cast some legs and fittings for a table I'm working on

[Barry_White]

Hi Major Panic

That is fairly big call with out experience.

First of all you need to have to have a pattern that is made with a contraction rule. That means the pattern is bigger to allow the contraction of the aluminium as it cools.

You then you have to have a moulding box and moulding sand to form the mould and then a means of melting the aluminium and that means a furnace and the correct temperature for the metal to run without cooling before it runs right through the mould.

It can be done but maybe cheaper in the long run to go to an Aluminium Foundry and get a Quote.


Regards

The old retired Patternmaker

[rodm]

These publications will give you an insite into casting and backyard foundary work. You can probably get them through your local library as I did. Otherwise details below are from www.minitech.com.au who specialise in lathes, milling machines and model making. Interesting site and worth a browse. After reading these books I decided that it was too difficult to get the right equipment and without the right equipment it is a very dangerous hobby.

Foundary Work for the Amateur
Product Number: WPS-04
Description:
Details:
FOUNDRYWORK FOR THE AMATEUR - B. Terry Aspin
This book is regarded as the perfect introduction to casting work in common metals. This new edition, brings everything right up to date.
CONTENTS:
- About Crucibles
- The Furnace
- Foundry Sand
- Moulding Boxes
- Pattern Making
- Cores and core Making
- Making a Greensand Mould
- Melting Procedure
- A 'Drop Bottom' Cupola
Weight: 0.20 kg
Price: $19.50
Inc. GST: $21.45 (GST is applicable if purchased within Australia)

The Backyard Foundry
Product Number: WPS-25
Description:
Details:
THE BACKYARD FOUNDRY - B. Terry Aspin
This book covers basic principles, materials and techniques, pattern-making, moulding boxes, cores and core boxes, metals, electric, gas and coke furnaces. Step-by-step procedures are also included with examples of locomotive cylinders and wheels. Although written primarily for the model engineer, anyone wishing to make mouldings or castings will profit from its pages.
CONTENTS:
- Introduction
- Patterns
- Plate Patterns
- Cores, Core Boxes and Core Making
- Casting Locomotive Cylinders
- Wheels
- Metal, the Furnace and Melting
- A Solid Fuel Furnace
- Appendix
Weight: 0.20 kg
Price: $19.50
Inc. GST: $21.45 (GST is applicable if purchased within Australia)

[MajorPanic]

Thanks Guys!

This seems like it might be too involved for a one off project :mad: so I might have a talk with the local casting company to see what they will charge :confused:

[jhunt_2000]

It Is a lot of work to set up a home foundry but seems to be a fun thing, check out this site. They have a great series of books on building your own workshop out of home cast bits. Talk about contraction and stuff too. I've got the set but I'm waiting to move to set up a foundry; cant wait... www.lindsaybks.com/dgjp/djgbk/series/

[silentC]

I've got a couple of Dave Gingery's books (How to Make a Charcoal Foundry and How to Make a Metal Lathe). These are the ones from Lindsay Publications.

His claim is that you can build a machine shop from scratch using scrap aluminium and other bits and pieces. You use the foundry to melt aluminium to make parts for the lathe, then you use the lathe to make parts for other machines and so on.

I subscribe to a mailing list at http://groups.yahoo.com/group/gingery_machines/. Quite a few people have built one or more of these machines and the pictures of what they have been able to do are mind boggling. The general concensus though is that Gingery's books are more of a starting point than a definitive how to. If you want to know ANYTHING about melting and casting metal, go there. These guys are amazing.

I'm going to have a go at this myself and one of the reasons is so that I can cast hardware for furniture etc. I think it will be a very useful skill to aquire. I also live right on a beach so there is no end of sand. I just need to find a source for fire clay, bentonite, etc. etc.

BTW MajorPanic, it was you who started me on this little journey when you mentioned trying to turn bronze on your woodlathe with an angle grinder! Funny how one thing leads to another.

[soundman]

A mate of mine used to cast ram tubes for webbers in his back yard a number of years ago

BUT

he was a pattern maker by trade and working in a foundry.

the process is more involved than may first appear. no rocket sience but a lot of fiddle & some specialised bits & materials for consistent results.

Best material
broken mag wheels from the wreckers.

[Barry_White]

Hi Silent C

Just a note you may need to watch using beach sand because of the salt

The retired Patternmaker.

[silentC]

Bazza,

Thanks for the tip. One of the guys on the Gingery mailing list has used beach sand but I think it has to be washed first. I was more worried about the local council ranger catching me filling my buckets ;)

[Barry_White]

Yea probaly a big enviromental fine if caught


Originally posted by silentC
Bazza,

Thanks for the tip. One of the guys on the Gingery mailing list has used beach sand but I think it has to be washed first. I was more worried about the local council ranger catching me filling my buckets ;)

[jhunt_2000]

Majorpanic and SilentC, dont underestimate the Sydney yellow pages, I was able to in one day's ringing around find sources for bentonite, fire clay, and plumbago; all apparently vital ingredients in the mixes, plus people willing to sit down with me and impart their experinces one on one for free(???) It was a truely heartening afternoon and if I was just a little more organised I'd be only too happy to pass the info on. However...

[Grue]

Have a look at the casting links on my page.

Casting videos - Videos for the casting enthusiast.

Ron Reil's Forge & Foundry Forge, Foundry and Burners - build your own. Burner Plans. Ron's burners really work well, and are easy and cheap to build.

Foundry Links Aussie site with links to foundries and equipment.

Castcraft The How to page of casting.

Getting started with Moulding & Casting How to site from Gremlins in the Garage.

Ray - Vin Melting Furnace Build your own furnace.

Lionel's Laboratory This is a FABULOUS page dedicated to melting & casting metal with homemade stuff and a tiny budget! Includes building your own furnace, lathe and lots lots more. Highly recommended.

Join http://groups.yahoo.com/group/castinghobby/

A really great group of people always ready to help

Have fun.
Glenn