How To Do Aluminum Casting Using Green Sand - Making Plaster Patterns & Casting
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- เผยแพร่เมื่อ 18 ส.ค. 2016
- How To Do Aluminum Casting Using Green Sand in The Backyard Foundry Using A Plaster of Paris Pattern, A Simple Flask, Crucible and a Homemade Aluminum Furnace. I show you in this video how I make my plaster patterns for foundry casting and finish it up with casting the newly made pattern in aluminum. My Greensand is made from sifted play sand, kitty or cat litter and water. A Start To Finish Video. The plaster pattern is made in a vacuum formed plastic mold. Thanks For Watching!
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email: makinsumthinfromnuthin@gmail.com
MSFN = Makin Sumthin From Nuthin ! - แนวปฏิบัติและการใช้ชีวิต
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wow. This has helped me more than you'd imagine. Extremely underrated channel, and I understand that your videos aren't the highest quality, but that's not why I'm here. I'm here for the wonderful process and professional-looking result. Amazing job
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Amazing video bro. Just getting into this hobby myself. Thx!
thats the nicest finish on a casted part ive seen on youtube, nice job
Thanks, I thought I had made Nuthin...but it turned out to be Sumthin! :)
SURPRISE ENDING ON THIS ONE! :)
Comment, Like & SUBSCRIBE!
Nice work.
I felt you failed but I too was surprised to see a perfect pour.
My Ford Boy would be proud of you and your job.
It's actually Myford Boy, named after the English lathe manufacturer.
I liked what you made!
I just got my furnace last week,I’m loving it,great video
Thanks!, have fun!
Beautiful work. This is the first video I have watched on you channel and already learned more then some of the other videos I have watched on other channels.
Been following you for some time now. Of all the channels I follow for sand casting, yours is on my top list. Thanks a bunch for doing these videos! I've learned a lot from you.
Thanks!
Great job I learned something from this.🐥
Thanks for Watching! :)
best pour cam ever!
Thanks Junior! Consider Subscribing! :)
I had a lot of fun watching this video
Pretty neat idea using molds! I need to give this a try once I move on from lost foam.
Thanks!, I think you will like green sand casting!
Kudos, Sir !
Thanks for your vids, getting into casting and this helped a lot
Glad they helped, comsider subscribing! :)
Outstanding! Phillip Hall
very good
Good stuff. I made a belt buckle with that lost foam thing. came out great!
Thanks, I did a vid using that lost foam method....strange stuff...works good :)
another good one, nicely done bud
Much appreciated!
I was watching the pour and I was thinking...OH no, it's fail......but man that casting came out excellent! great video
I was more surprised than anyone! LOL
Amazing job on it, very informative too
Thanks for watching & the kinds words :)
I just started getting into this aluminum casting, I'm about to make my first foundry and I was wondering if I can get your professional opinion on weather to use the perlite/cement mix or the wool/100 lining? trying to make a nice and reliable foundry that can take some high heat too
If just doing aluminum and wanna get off cheap, go with perlite/cement. If you plan on doing aluminum AND higher temp metals like copper, brass & cast iron go with wool. ITC 100 is optional. The latter is more expensive and has advantages...very light weight & longevity if properly cared for. Heats up much quicker as well....is just a matter of how much money ya wanna put into it :)
nicely done sir
Thanks John! :)
Nice casting sr
Thank You! :)
good work
Thanks! I have more casting videos if interested :)
Consider subscribing! 👍🏼
I am NEVER going to be happy until you got 20 neighbor kids hanging around helping and "larning" !!
Good Work
Thanks for the visit
you are awsome love you'r vids
Thanks friend!, consider subscribing! :)
i have i love watching you'r vids giving me some great idea's
I dont get notified of your comments...check your settings
love the name
Mui bien
With plaster casts, use a gentle amount of Pam to release the cast. You can use many layers of plaster, almost water, then thicker. Just let each layer harden before the next. Do not wait any longer for next pour.
Thankyou 😇🙏
Nice Kitty!
Thanks John!....no vet bills as a bonus! :)
Thats a good thing. LOL
It's that sweet sweet hammer action
A simple riser made from a metal cylinder and sand would give you a reservoir of molten metal and ensure a positive pressure fill of your mould.
Absolutely. That entire mold was an experiment and not normally how I would ram one up and gate it. My other vids show how I usually do it
Makin Sumthin From Nuthin but it has to be said you achieved very pleasing results from some simple and quite cheap equipment. If this does not inspire others to have a go then nothing will. Really liking your channel mate
Thanks Andrew, spending $$ on expensive equipment gives me a rash. LOL!
Makin Sumthin From Nuthin there is no correlation between great results and money spent if you have not practiced and learned the skills. Cheap home made kit and good skills will always surpass expensive kit and poor skills! No substitute for getting out there and having a go and learn from your mistakes. The best thing is nearly all the materials can be used over and over again, what you got to loose?
Well said!, glad you like the channel! :)
Lovely casting. I was wondering why you left runner so small and why not a cup on the runner. But your were so right to keep pouring I'm always amazed at how sometimes it starts to run again. Thanks again , great video.
That whole gating system was just an experiment on my part to try different stuff. I was gonna pour until something happened!! LOL :)
Thx for watchin!
Nice 🐱
Thanks!
@@MakinSumthinFromNuthin I like your channel name. I just stared making aluminum ingots from a large supply of scrap I have. Learning to cast is something I am starting to think about….
@@jdnotariano Thats cool, Good luck & be safe!
My theory is that the molten material reaching the air vent started to cool down to a point it stopped the flow from the material getting thru in the other side of the mold. Or maybe some impurities accumulating in that particular part of the volume. A very lucky "failed" pouring, as you said :V
Thank you for the direct and to the point video. My only question is what is green sand, where can I get it and would play sand work?
Thanks for sharing. My next question was going to be how you make the plaster cast I seen in some of your videos. Thanks
I make plaster positives to use as casting patterns from cheap plastic plaster molds....they are available online
Thanks a lot
Yup, I considered making a vacumm former
Yep, they are pretty simple. I just dont have the ongoing need or room for one....nifty devices tho
Oh yeah Thanks Stephen Coyle. I have looked a a few homemade vacuum formers and even one big one made by Adam off the Mythbusters
That was really awesome!! Looks fantastic! Can you re use the sand?
Totally reusable, see my video on making green sand :)
You mentioned in the video that there is no flash on this mold. Is “flash” the rough texture that sometimes happens? Do you know what causes that?
I believe it's time to play some lottery.... you're a lucky guy...😉
LOL!! Thanks! 😊
Great video but I have a question that how long can we keep on using that burner or torch?I mean can we keep on igniting it for hours or do we need to give it a rest?it is dangerous to keep it on ignition for hours because it could get too hot or can we use it for as long as we want?
I like the video and first time seeing this processing. I wish I knew more of the words you were using. Kinda for a newbie who don't understand the language of the trade. Maybe you could explain the sand types and how you made the wood bracket and so on. This video would be more for the intermediate doer. Still non the less thank you.
Watch my video called: SAND CASTING LESSON FOR BEGINNERS, you will find it helpful :)
Can you explain in detail for us "slow" and beginners what you did to slow down the metal velocity?
Ahh,getting sidetracked again from the propane forge lol..Awesome result.
Ha, Getting from point A to point B isnt always a straight line! :)
LMAO!! Maybe you should just stick around here! No butt plugs for my 4,000+ subscribers! :)
Yep,i think you are right although i think i have had enough of youtube for one day.You have some great stuff on your channel so i'll be back...Cheers
It's not a forge, it's a foundry furnace. You don't melt stuff in a forge, you melt it in a furnace.
First of all, great video, congrats on a successful cast...
I've watched a lot of yours & others videos, and I am confused by something...
Shouldn't you have put that ring around the sprue, instead of the vent? To let the pour pool up over it?
The ring is something new I was trying to contain overflow from vent so it doesnt burn the flask if I poured too much in and it started running towards flask. I generally use a pouring cup for sprue as in other videos but didnt on this one. Was trying lotsa new stuff on this cast. A pouring cup woulda avoided confusion in this case :)
...cuz i thought the point of the cup was to create pressure, forcing the metal to the edges of the mould....
that's what I said and I don't know what those things are but I know what you talking about and I'm new but it doesn't feel like it for some reason.
I saw in 1 of your other vids that you melted a hole in your black plastic mixing tub. Have you started to put some sand in its replacement before you break your sand molds now? You got lucky with this pouring. Yay!
Ha!.... I loved that black tub! 😖😂
Our cat uses 1 of those tubs as a litter box. I think she appreciates the extra space because she hasn't done her business on the floor next to this one like she did with the old smaller one. Fortunately, we have another to use for our projects.
I need another one 😊
What kind of powder did you sprinkle on top of that?can we use flour instead?
What do you mix with the green sand to make it stick to itself? Water?
That would make me third. Anyway, great instructional video MSFN. Those cheap kids/craft plaster molds are a good way to explore more complicated patterns. With regard to your pour puzzle, check out myfordboy's casting videos as he uses greensand filled tin cans to act as aluminium reservoirs, provide head pressure, and act as pouring funnels. Might be a tip worth exploring to improve the consistency of your casting pours. I liked that you explained why you wanted to slow the velocity of the molten metal, and I have been thinking that it would be worthwhile to create a sprue and swirl cup pattern to be included in the ram up. It would provide a consistent means of slowing down the pour velocity as well as catching any debris flowing in the aluminium as well as reduce the risk of dislodged sand flowing in to the casting. A professional casting video I have seen includes all the gating and reservoirs as part of the pattern for the ram up as you wouldnt want any sand included in your turbocharger housing let alone air bubbles.
I generally use a pouring cup as in myfordboy's vids but I thought that might be contributing to the problem with the velocity so tried some new stuff on this one. The mold completely filled with no head pressure at all with no shrinkage on the casting. Luckygen has put up vids about the need for extended risers and head pressure. I have watched a number of vids from both creators....Both them fellas are fine foundrymen :)
Thanks for posting. Will you be doing a 6 pack abs video?
I already did
Lovely casting...Maybe you needed to open up the downsprue a little to make a good target to pour into, and also use slightly bigger ingates. No problem though it turned out fine.
Thanks Kevin!
Working through failures is an essential element to learning to cast, I was casting Aluminum into a mold that was 1/8 thin, After making the necessary adjustments and getting it to cast properly I read not to try a casting this thin as it will not fill out, HA! BS it won't.
Nice Job! Always a way!
beautiful work
How much sand is in the mixture with the bentonite?
Any brand of cat litter will do?
Thank you
I have a video on how to make the sand if you want more info on it.
Great videos, Every bit as as oil based sand if not better, Do you use flux ? Thanks again great job,
Thanks!, I tried a baking soda flux once.....saw no improvement on cast quality. I melt it, skim it and pour it nowadays....I am not making parts to go into space rockets. The aluminum seems fine as is :)
Makin Sumthin From Nuthin A great flux for aluminum is pool chlorinating tablets. Crush them roll some up in some paper and shove it to the bottom. Don't breath it and I didn't tell you this it's roughly the same as foundry flux. it gives off chlorine which combines with hydrogen ( which is the real problem in alum. casting) then bubbles it off. you didn't get that from me.
This guy reminds me of my dad XD
XD
Why is the water yellow? U live in flint Michigan??
Can you make a video about making an aluminum mold? I would even be willing to pay for having a mold made out of a small sculpture
Can you mold mechanical spur gear next time?.
In my opinion gears are easier to purchase than cast
That's a great casting. What is your green sand made from? Proper bentonite or powdered kitty litter?
TY...Here is how I made it th-cam.com/video/2rAQxw6X6uc/w-d-xo.html
Brilliant, thanks!
:)
Do you know any substitute material for plaster of paris? It seems like it's not available here.
I sure dont. its common in the US
Is this kitty still on sale? If it's not too expensive I would like to have it. I'm studying engineering and tomorrow have an exam about casting and other stuff and sick of studies I found you vid great 😻
Thanks Nicole, glad you enjoyed the vid!
Yes, Its still available, You are the 1st to inquire about it. My email address is in the video description if you want to contact me about the kitty cat :)
Would really like to See a Skidoo 277F Snowmobile or Rotax 277UL Ultralight Head done. 377UL/447UL Heads, 503UL Heads.
I dont cast engine components
This is pretty old at this point but where did you get those tongs? It would make pouring much easier to use something like that
I made them
Is there any way to get the dross out of the bottom of the crucible? I've made two crucibles now and each lasted two melts before it became unusable with all that stuff stuck at the bottom (I made the crucibles by welding a bottom onto a 4 inch diameter steel pipe)
Some advice I can give you is to make a scraping tool and immediately after pouring your metal scrape out what remains at the bottom while the dross left in the bottom is still workable. Once it cools its not going anywhere. Another suggestion is using the scraper while the crucible is still in the furnace and full of molten metal....gently work the entire bottom to free up that dross so it floats to the top to join the rest of the slag, then skim and pour.
Thanks MFSN! Unfortunately it's all cooled down and, as you say, going nowhere. I'm thinking of making crucibles with a screw-on bottom. At least then you can ran the stuff through (as long as the thread is on the outside, that is). Also, I bought some borax, maybe adding that would cause the slag or dross to be more 'floaty', making it easier to skim off.
Your videos are great.
Glad you like them :) I would be concerned about a threaded crucible due to "leakage" potential. Give my method a shot on next melt and let me know the results. The scraper doesnt have to be anything fancy as long as its made of steel and not aluminum. LOL
I’ve been looking as best I can and can’t find where you find the patterns you cast. If you could tell me that would be appreciated😁
I bought cheap plastic plaster molds from the internet and made plaster patterns for casting from them. Google it
I thought he said that he designed that one. or maybe that was in a different video that I was watching trying to get the same information.
Didn't flip the drag? How'd ya cope with that?
Ha! Casting Humor...nice! 👍🏼
is it possible to sand cast deer antlers? Cold you do a video on that?
Only using the lost foam method of casting could that be done as there is no way to remove the antlers from the sand without destroying the sand mold. I do have two videos of casting a deer plaque if ya wanna check them out :)
Part1: th-cam.com/video/ys9T7ehl6F8/w-d-xo.html
Part2: th-cam.com/video/iaAyM0BTMPo/w-d-xo.html
thank you for the reply. I was trying to do a set of antlers that my uncle shot along time ago to be put at his head stone. He passed away a year ago and was going to do this for Memorial Day.
I am very sorry to hear that, sorry I couldnt help :(
thank you for your time and the reply. Your videos are very helpful.
shocker7100 if you want, use silicone or alaginate to do a 1 piece mold of the antlers, you can find a medium to then fill the cavity with. they have foam you pour (i hear it doesnt work well with aluminium casting, polyurathane foam that is), you can possibly use wax, which most likely wont work. worst case scenario, you melt out the polyuruthane foam, to hollow the sand mold, then pour aluminium, or buy a good castong resin from smooth-on and that will work, it just wont be aluminium
Logic to me would be to use a metal funnel to make the shape in sand. You therefore have a wider aperture to pour in the liquid Ali...
I actually do just that in all my other castings, this mold setup was totally just experiment trying a different technique
When is the Green sand mix making video going to be out? Was about a month ago or more when you said you were going to post it :)
It's been out....for about a month+. Check my recent uploads Mike. That one has been pretty popular :)
Ok uhm 2 more question:
1. How can u make aluminum stronger?
2. Does melting any aluminum ingot leave anymore slag or just 100% clean reusable molten liquid aluminum?
I wont pretend to know the answer to question #1, I am not a metallurgist. Making an aluminum alloy using multiple metals would be my best guess on making it stronger. there are ways to harden and temper aluminum but not an expert on the process. To question#2, you will always have slag, but much less using previously melted ingots than you would get melting a bunch of misc scrap aluminum for the first time. Hope that helps, thanks for watching....good questions :)
I can Answer the second question, I have melted aluminum a fair bit, and when dealing with slag you have to separate it from the aluminum. the slag will often always float to the top making it rather easy to clean out while its still molten. However, if you want to minimize the slag all together then i recommend tin foil which is actually just aluminum. hope this helps
In some aluminum casting videos i observed, the poring metal looked light red in colour, unlike in your video which is in shiny silver colour..
What is the difference? Is my observation wrong?
I'm new to casting, please let me know.
Camera settings cause it to look red. It is always a silver color
Hey not to say first, but First
SECOND!
Hi. May I know what grade of the aluminum using for this casting process?
Cast aluminum, extruded, beer cans, whatever I come across for free :-)
I would have put the sprue cup over the larger hole & poured there.
But it turned out fine. Go get a Lottery ticket.
Thats what I normally do...that entire mold set up was just an experiment trying out new stuff but worked out in the end (whew) LOL :)
You probably could sell just the plaster cast also, so people could paint them and use them as whatnots
Thats mainly what the plaster casts are used for. They make good patterns tho :)
how do you make sand stay in place ?
The sand has clay in it and it packs down nice. I have a video on how to make it here th-cam.com/video/2rAQxw6X6uc/w-d-xo.html
ohhh thank you :D you earnd a sub :D
welcome aboard! :)
i am looking for a place where i can buy the plastic molds
I forgot where I got mine from but they are available online...just search for plaster molds :)
THANKS!
U R Welcome, thanks again for watching my channel! :)
Hey have you ever castes Bronze?
I Have cast brass before....i havent put up a video showing it done....yet! :)
Bronze and Brass are not the same however
+Makin Sumthin From Nuthin Yeah I was just going to make a sword out of Bronze for my Grandpa and I was wondering if you knew the ratios of Copper to Tin.
The recipe (ratios) can be found online if you google it. A quick google search states:
Bronze is an alloy consisting primarily of copper, commonly with about 12% tin and often with the addition of other metals (such as aluminium, manganese, nickel or zinc) and sometimes non-metals or metalloids such as arsenic, phosphorus or silicon.
___
There are a variety of bronzes so you will have to see whats best for your specific application
when making my furnace how much space should be between my crucible and the walls
oh and what were you using as crucible
+Nathan Saier and can I get the dimensions if possible
thank you
A minimum of 1" or so Nathan to allow the flames and heat to circle the crucible. A 2" - 2.5" space gives you the xtra room for a larger crucible down the road. The furnace interior dimensions cant be too large unless you have a well designed burner.
Those measurements are from the "side of the crucible to the furnace wall"
I make my crucibles from steel fire extinguishers. Here is a video I did on how I make them
th-cam.com/video/RMWexVPIpeo/w-d-xo.html
Can you reuse your green sand?
yes, can be used year after year. sometimes you need to add more clay. I have a video on making the sand
it looks like you put the riser on your vent pipe.
That entire mold was just an experiment, worked out in the end tho :)
Itu pasir apa yang di gua akan dan campuran apa saya ingin membuat ya juga pliss
th-cam.com/video/2rAQxw6X6uc/w-d-xo.html
What is your sand thank you
I made it: th-cam.com/video/2rAQxw6X6uc/w-d-xo.html
@@MakinSumthinFromNuthin thank you
Video starts at 0:34
Awesome, thanks!
Why didn't the molten Aluminum come out of the vent?
Nothing went properly on this one....I tried a screwy mold & gating system on this one as an experiment. I didnt think the casting would turn out well after the pour....got lucky I guess 😊
Turned out great.......
Thanks!! ~ Richard
Why didn't it come out the other side?
dude the can is to contain the fluid, try to pour it on the can side and wait for the aluminuim to go out the other side, that way you leave some material for when it shrinks
The entire mold was an experiment, the ring was just just to contain the overflow so it didnt burn the flask if it was excessive. I normally do a pouring cup to pour into if ya wanna check one of my other videos...but I know what you are saying...this pour was kinda a disaster but the casting turned out good...LOL :)
i was trying to be nice, im watchin alot of videos on the subject, im planning on making 1, the best tip so far is to dip the styrofoam in plaster then pour the aluminuim. lol wtf
LOL, keep me posted. Hint, dont use crappy styrofoam :)
Pouring rate seems to be an important factor here.
I HAVE TO MAKE A QUESTION ABOUT THE ALUMINUM. THERE ARE VARIOUS TYPES OF ALUMINUM. WHICH ITEMS ARE MADE WITH THE MOST PURE ALUMINUM?-
If you at all can use aluminum that has been previously casted and avoid extruded aluminum and soda cans. Lawn mower engines, many car parts...etc is a good source of furnace food
Why do you need to slow down the metal velocity?
it was washing out the fine details in the casting as the metal entered
@@MakinSumthinFromNuthin I see. Thanks for the explanation
Your riser vent was so small it probably solidified the aluminum before it could reach the surface.
I did a lot of experimenting with that mold, casting turned out good after all the trubbles tho 😊
All that counts.
Some ass hole keeps taking my hood ornament how could I cast one to so they take a cheap one.
I would have to see it to be able to determine if it can be cast in aluminum. Nothing worse than a thief! 😡
Makin Sumthin From Nuthin it's a Mack truck you can google mack truck hood ornament and see them.
Damnnnn, they are over $100 to replace. I couldnt make one using sandcasting but I would make friends with someone who has a 3D printer, have a few made of plastic and spray paint them silver :)
I know they do cost a lot and I have had 6 go missing so far I put a camera on my truck and it took one guy less then 30sec to get it off and gone. But cops got him. I'm tired of playing games with damn thief I'm looking into how to electrify it so I at least get a kick out of it and can start posting them lol. But thinks for your help.
I would watch that video! :)
it seem like you're pouring it into the wrong hole. I would have put it in the end that had a place for the excess to sit and wait for it to come out the other side. I don't think it was hot enough when you were pouring it. even though it worked out to your advantage, I think this could frustrate a newcomer.
Why didn't he pour the metal into the ring in the first place? I thought the whole point of the ring was to help guide the metal into the hole.
The hole the ring was around was just the vent. If you watch again how I made the sand mold you will see
from other videos i agree with you, the ring is used as a funel
Too low temperature.
Experimental ramming of mold was the major issue, metal was hot enough
You needed a small amount of aluminum