Sand Casting a Deadpool logo, Car Accident, and New Shop tools!
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- เผยแพร่เมื่อ 2 ธ.ค. 2022
- This video demonstrates the sand casting process of using a different aluminum alloy then I normally use. Also, I have included a car accident that was recorded while I was working and my new shop tool addition.
Disclaimer--Metal casting is dangerous and can cause injury or death. This video is only for entertainment purposes.
damonsmetalcasting@gmail.com
#sandcasting #aluminumcasting #damonsmetalcasting #aluminumcastingprocess #metalcasting - แนวปฏิบัติและการใช้ชีวิต
Great video as always Damon. Great to see your boy partaking in the process.
Thank so much!
Nice medallion! Enjoyed watching, thanks.
Thank you for the comment and watching my video!
I use the same High Performance Paint on most of my helmets, that stuff works great! Congrats on the new printer, it completely changed my workflow with metal casting. I look forward to seeing what you come up with!
Thank you so much! yeah I wish I knew about the High Perfomance Paint earlier. It smooths out better, it seems to have a smoother surface for patterns so it doesn't stick and it appears more resistant to scratching from the sand too.
Nice cast, it came out great 👍. 3d prints sure do take a lot of time to make smooth. As you said sand paint sand sand paint sand. Lol.
I tried your version of the pouring basin and you did it alot better than me. I got tear out on my sand and had to work it in with my fingers.
@@DamonsMetalCasting it's not always perfect. I have to fix it with my fingers sometimes too 👍
Nice, I made one of those out of brass, hard to keep shiny without spraying clear coat over it. Nice channel.
Thank you I appreciate your comment. I bet its hard to keep the brass looking shiny. I haven't cast brass yet, but what type of spray did you use to preserve the shine on the brass?
Aluminum wheels are a great source of cast aluminum, I use them exclusively in my foundry. As long as they are cast and not forged wheels. Some aluminum truck wheels are forged 6061 IIRC. They're a pain to break down but if they're really cast aluminum like most alloy car wheels it's worth the effort. Cast wheels and most automotive engine castings aside from pistons will be A356 cast aluminum, excellent stuff. But check for magnesium! (file a clean spot and test with white vinegar - mag will fizz)
Thanks, I appreciate the info! You got any suggestions for how to easily cut the rims down, mine has thick spokes on it?
@@DamonsMetalCasting there are many ways and they all suck, lol. I built a wood fired stack melter that reduces 3 wheels into small pellets about the size of 3 or 4 sticks of chewed up gum. That is my favourite method. But lately, since part of it rusted out on me, I've done it using a table saw, which was absolutely a white knuckle ride. I don't necessarily recommend that. But wear your best ppe if you try it, face shield and leather from head to toe if you can because hot razor sharp chips will be flying everywhere! Or toss one on a bonfire and wait for it to almost melt, then it'll be easy to knock into pieces with a sledge. Just make sure to drag the pieces out of the fire with a rake or something or they'll just melt and form a giant pool under the fire that you'll have to break up again. I've also heard of people using a big log splitter...
@@DamonsMetalCasting some combination of angle grinder, reciprocating saw, and portable bandsaw can get you there too if you're really in a pinch, but it won't be any fun. (Expect to break a few bandsaw blades, I wish I had a full sized one....)
@@tobhomott WOW! I guess no way around it, its just difficult.
Those vents are fine. When they fill with aluminum, by that time the mold is full. About using tubing to make a clean cut of the pouring basin. I use the thin tubing used for the drain for a sink. It looked like your tubing was a copper pipe/tubing, which has thicker walls. (hard to tell) If it is thicker it would be harder to cut. I think more sand would be pushed outward disrupting the wall. The other thing I wondered is if being Petrobond might be a reason, rather than water/clay based green sand.
Thank you!
I use a thin walled brass sink drain tube to cut my pouring basins too, perfect diameter and works great, and I use petrobond for most molds. Tip for getting the sand plug to come up with the basin cutter: ram it down a little bit with a dowel inside the basin cutter tube after you stick it down into the sand. Then twist the cutter tube while you pull it out. Works every time.
@@tobhomott thanks the drain pipe seems like it might be thinner then what I use and will have less tear out. Thanks again for the advice.
Could you tell me what the diameter of your pattern and the diameter of the final casting was?
I have avoid chrome plated wheels. I'm curious to see what you think of it. So far I have cut up four aluminum rims with a circular saw with a carbide tipped blade. It works okay but I take it really slow and careful. I haven't melted any yet. I got lucky. Someone put a listing up for four free tires with aluminum rims. I was the first one to contact him after his listing went up.
Thanks for posting your videos.
The pattern is 3.120" in diameter and the casting is 3.084" in diameter. Thanks letting me know about cutting rims with a cirular saw, I will try that, I already have a blade that should work and stick wax for lubrication. I was worried about the chrome plating also so I looked up the melting point of chrome which is 3,465F. Dont take my word for this but I am assuming from what I saw is that the chrome layer is real thin and didn't interfere with the casting process. I don't think it burns off like a gas like Zn due to the high melting point, I bet it just forms an oxide in some of the dross just to be discarded. You are lucky you got free rims, what score! Thanks for watching and leaving a comment!
I forgot to mention the stick wax lubricant. It makes a big difference. You still have to be very careful. I still had the tires on the rims. I wasn't able to break the beads so I left the tire on. It made it easier to hold the time securely but made it more difficult in that I could only cut at limited exposure angles. I cut the spokes and hubs out. I then cut the rim portion as best I could. I then used an angle grinder with a 4 1/2" carbide blade to cut the small remaining parts that couldn't get to with the circular saw. It would have been easier if I didn't have the tire on the rims. But then I would have to figure out how to hold the rim securely.
Some time after I cut the rims I found this video. th-cam.com/video/QOkbl61Hsiw/w-d-xo.html
He is cutting a lot faster than I was. I was going maybe a third as fast. I was new to cutting aluminum with a carbide blade. I was using a regular carbide blade for wood so I was being careful. There are special blades for aluminum but they cost quite a bit more.
I had previously cut up a 4 cylinder Ford aluminum block. I did that dry. I was lucky with that also. My 92 year old mother was in the hospital. I had been staying with her about 20 hours, getting a break when her granddaughter came to visit. I was sitting/sleeping in the chair in her room. When she was doing better, on the fifth day, at 6:30 am I decided to take a walk down the street that the hospital is on. This is right beside a river so there is a couple of parks with pathways. Eventually I got to the end of the park paths. There was a trail I followed for a bit until it go too muddy. So I decided to go straight to the street rather than follow the park back. Heading toward the street, from the river bank, was a parking lot. Just as I got to the parking lot I saw something white metallic in the bushes. Someone had dumped what I thought was a motor cycle engine. I was going to have to come back later for this.
When my niece came that evening, and I was able to go home for a couple of hours, I took the car and went to pick up that engine, or whatever it was. When I got there I dragged it out of the bushes. It wasn't a motorcycle engine. It was a 4 cylinder auto engine block. Later I found that it was a Ford engine from no older than 2010. Someone had removed the head. One section at the bottom of the block had a hole in it. Part of the oil pan was broken. But otherwise it was a big beautiful hunk of aluminum casting. It was a gift from the Gods. 😇 I don't know why someone would dump it, rather than bring it to a scrap dealer.
That was my first try at cutting aluminum with my circular saw, with the carbide blade. No lube. It was a horrible job. When you cut the rim, make sure you are fully clothed, gloves, face protection, a hat. The aluminum chips are small but are they hot. After a few minutes of getting burnt I went and got clothed properly. Cutting up the block was hard. It was like cutting up a carcass. Trying to get the thing cut up to good usable chunks. Small enough to fit into a crucible. Trying to cut mainly thinner sections. Thinking of how I could cut it, as far as I could with the circular saw, and how to break chunks off using a hand sledge hammer and chisels.
I ended up with about 80 pounds of AlSi9Cu3(Fe), Aluminum, 9% Silicon, 3% Copper. The AlSi9Cu3(Fe) was cast into the part. Nice of Ford to show the alloy used.
If you are going to buy car parts for the aluminum, pass on the engine blocks. Wheels are much easier. I saw on one forum a guy who buys heads. That might be a better option than the blocks. Easier to cut up. I still think wheels would be easier. But if the block is free, then I would still do it. (but bitch the whole time)
As far as the chrome plating on the wheels. It shouldn't melt. Some of it could dissolve in the molten aluminum, and it will be a contaminant in the alloy. A lot of aluminum alloys will list a maximum contaminant amount by element. Chromium is often listed with a maximum allowable limit. Fish out what you can as soon as you can. I have not done it with aluminum but I have with chrome plated zinc parts. Like bathroom sink faucets. I like to cast with zinc because of the lower melting temperature. Good for some items.
I bet this will be the longest comment that you will probably ever get.
@@rudycandu1633 I am sorry your mom had to be in the hospital. I appreciate you writing all your experiences with cutting down aluminum and I also watched the video you posted too. I am taking your advice and will pass up on engine blocks, that sounds like a heck of a challenge. Thanks again for taking all that time to write back!
Mom is fine. She has since had a pace maker operation. As I said, she is 92 years old. She is not so steady. She is still living in her own house, with her granddaughter. I hope I will make it to that age and be as healthy as she has been. I expect that she will be with us for a few more years.