EASY Foam Pattern Cutting and Lost Foam Casting.
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- เผยแพร่เมื่อ 26 ม.ค. 2023
- This video demonstrates an easy process for cutting out foam casting patterns from a jig plate put on a hot wire foam cutter. The foam pattern is then prepped with joint compound and cast with aluminum metal.
Disclaimer--Metal casting is dangerous and can cause injury or death. This video is only for entertainment purposes.
damonsmetalcasting@gmail.com
#lostfoam #aluminumcasting #damonsmetalcasting #aluminumcastingprocess #metalcasting - แนวปฏิบัติและการใช้ชีวิต
Good melt and pour.
Thank you so much
Nice to meet you, I always enjoy looking at your work.
I also do aluminum casting, but I can't do it this beautifully, so I thought it was great.
I am looking forward to watching your next video.
Nice to meet you as well. Thanks for leaving such a positive comment for me. Much appreciated.
The heart came out really well! I am trying to understand why there was a hole in the pouring can funnel?
If you move the video to 8:19 there is a little section of foam sticking out of the sand on the outside of the can. I was intending for the aluminum to flow through the foam and back out to help flush impurities and completely fill the void the foam would leave. The only problem is I didn't plan ahead and that small piece of foam should of had another can over to prevent the molten aluminum from running every where. So it wasn't a hole, it was my mistake in not using another can to capture the aluminum after it flowed through the part. Thanks for watching and leaving a comment.
Interesting, thanks for the content.
Not a problem, Thanks again for watching my channel!
Hi, what was your pouring temp, the piece looks very nice.
Rich
I am not sure what my pouring temp was on this casting. I know the internet says pouring temp 1300F-1400F, but I usually take the aluminum out of the furnace when its maybe around 1450F. Sorry I can't give an exact answer. Maybe my next foam casting I will include the temp.
I've noticed when cutting the foam, you sort of have to be fast. Or it melts a wider radius around the wire.
At least that's in my experience. So if you're not in the mood to cut fast... best just leave your project for another day HAHA!
Again, that's just my experience. Do you know of any other way to counter this? Or is it just move steadily the entire time?
Check out my other video "Why you should use a refractory coating for casting and another way to cut foam patterns" I used a router and a PLA pattern from a 3d printer. Just watch your fingers! Also, some people use a CNC machine, I just don't have one yet. Thanks for watching.
Which type of foam use for casting aluminum alloy
XPS foam board for insulation. Mine was purchased from home depot.
I saw your video on hobby metal casting, I’ve been wanting to do a heart shape for at least 2 years but procrastinated since I didnt know how. Couple questions i hope you’re willing to answer: why use joint compound? I dont know what it does bear with me. Was that just normal gravel used in the bucket? What was the metal rod tool used at 8:44? Whats the best tool to use to cut the metal from the shape?
The joint compound is a cheap substitution for the expensive ceramic slurry coatings used in the industry. It provides a shell around the foam and doesn't need a kiln with a long heating process to create it. Just like everything used in casting metal it has to be dry with no moisture content before aluminum is poured into it. The sand in the bucket was just normal sand picked up at my local hardware store, I wanted to get a fine sand but mine says medium on the bag. The metal rod was my temperature probe consisting of a thermocouple(the rod) and a hand held reader(off screen). This tells me when I am ready to pour, I normally pour around 1400F for sand castings. For this lost foam casting I poured closer to but under 1500F. The reason was to give more heat to the aluminum to burn through the foam and still flow through the cavity it left. I use protective gear at all times. I might even buy more for my legs after foam casting because the gases from burning away the foam spatter the aluminum as its poured.
@@DamonsMetalCasting thank you very much for taking the time to explain everything! I'll use this as a guide when I finally make that anniversary present!
Your video I am like ok
Thank you.
Riged foam or expended foam
From looking on the internet it is rigid foam.
Awesome job for your first lost foam cast. The type of aluminum you used for the pattern was perfect. The foam used for the sprue isn't great. It's very gassy and that's why your pour looked the way it did.
You can't see what I mean in this video.
th-cam.com/video/JhwNoe1f5No/w-d-xo.html
Thank you, I watched the video. My thought on using the 2 different foam types was that the styrofoam was less dense and would require less energy out of the aluminum to melt it. The other thought I had was to put an exit flow channel so the aluminum could push any gas or impurities out and have a flow through port. I think the exit flow channel did work it was just sloppy looking because I did not put another can to contain the molten aluminum as it exited the foam pattern. I think the only way I could really tell if this method will improve a casting is to pour a larger foam pattern.
If only styrofoam wasn’t so annoying sounding and feeling. Thanks for the content!
Thank you
Styrofoam