Non-ferrous metal casting in sand

Today let's talk about casting non-ferrous metals in the sand. In one of the previous articles, I talked about the blacksmith, the temperature of which is enough to melt non-ferrous metals. I melted aluminum. As an example, I will present a small statuette for the uncle’s wedding anniversary.
Casting non-ferrous metals in sand


First, decide what you want to cast. As I said, I will pour the statuette. You need to make a foam form. I use plain white foam, but I advise you to find penoplex, and both are sold in hardware stores.

Nichrome cutter

But to cut such a foam with an ordinary knife is almost impossible. Let's make a small simplest nichrome cutter for foam plastic.You will need:
  • Nichrome wire.
  • Two sticks for sushi.
  • Two clerical pins.
  • Cardboard.
  • Two wires.
We take a cardboard 5 * 6 cm and with adhesive tape attach sticks for sushi.
Casting non-ferrous metals in the sand
Now insert buttons into the sticks,but not fully.
Casting non-ferrous metals in the sand
Next, stretch the nichrome and tie the wires. And we stick the buttons completely. I attached a USB cable to the wires. Now insert the USB into the charger from your phone. The wire is hot and less often foam is like butter!
Casting non-ferrous metals into sand
Casting non-ferrous metals in sand
Now cut out the desired shapes and with the help of PVA, or, like me, melting glue them together as needed.
Casting non-ferrous metals into sand
Casting non-ferrous metals in sand
We also cut the gates and also paste them. Casting non-ferrous metals in the sand

A few words about the crucible

Metal needs something to be melted. This is something called a crucible. I made it from a pipe. From a steel pipe with a diameter of 90 mm and walls of 2 mm I sawed off 40 mm. This height will be the crucible. A steel pancake was welded to the bottom. The handle from the steel corner is welded to the side, but it’s better not to take this handle with your bare hands.A triangular notch is made on the side and the nose is welded from a steel triangle bent in the middle.
Casting non-ferrous metals in the sand


Next, insert the foam mold into the sand so that the tops of the sprues stick out of the sand. Around the sprues need to make small craters of wet sand. But I did not really like this option. Instead of wet sand, I used large nuts. Now we throw aluminum cans, or any aluminum you have in the crucible, melt the forge and melt. Top will accumulate various slag (paint on banks, dust, etc.). If possible, it should be removed.
Casting non-ferrous metals in the sand
Next, pour aluminum into the sprue, the molten metal should appear in the second sprue. After about five minutes, the billet can be pulled out of the sand and cooled in cold water.
Casting non-ferrous metals in the sand
In the photo is an old crucible. It is made of pipe with a diameter of 60mm and a height of 120mm. A steel pancake and a small buttonhole are also welded to the bottom to cling to the crucible with wire. Two more buttonholes are welded on top and steel wire is stretched.It turned out like a bucket. If everything was spilled in the way that we need to start the metalworking. Non-ferrous metals are quite soft. We cut off the sprues with a hacksaw and process it with a file, after a minute the result is something like this:
Casting non-ferrous metals in sand
I do not pretend to quality, my goal is to tell you about various techniques. But if you need precise casting, it is better to use silicone molds and plaster. I tried to cast an amulet with a cat's head, but it shed badly. Maybe this is due to insufficient temperature, but in any case, the plaster molds are much better. Use foam molds for simple models.
Date: 15.10.2018, 12:10 / Views: 95293

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