In the video "making a casting model" I have shown the first step of how to get an cast iron wheel. Here ist Part 2 with the molding and casting process.
Started working in an Iron Foundry on my 18th Birthday. Seen some tough guys come and go. Some come in and are told to come back with Steel toed boots and they never return. Call that a healthy choice for some. I’ve seen iron accidentally poured down a man’s boots and things of that nature. We’d make the copes and drags in the morning and pour in the afternoon. That job will make you tougher if you’re tough enough to hang in for a few months to begin with.
WOW always something interesting happening over at the Burger house. Thanks for sharing this. Has to be very rewarding to watch your patterns becomes the wheels you need!
I worked in a foundry as a metallurgists assistant in college and the smell of hot sand gets into your hair and skin and it takes weeks to get out. there is a smell of hot casting sand that you do not ever forget.
Great video thanks for sharing it and I'd also like to thank the company for allowing you to film. Those guys are true professionals and make a great team.As someone who's done some sand casting work in aluminum it is amazing at how easy they make it look.
I have noticed that in a variety of skills. Once people are competent and confident there is a relaxed aspect to the work, they "make it look easy" as the saying goes, but as you say there is knowledge and experience there.
Our company can supply silicon metal,silicon briquette,high carbon silicon,silicon carbide,silicon slag, casi cored wire, if you are request about them,please email me: star06@alloyssi.com
I worked at The Chevrolet Grey Iron Casting as a sand wetter. Great place to work and in it's day was the largest Grey Iron Foundry in the world...COOL. She's casting Aluminum now using the lost foam technology. I left when the iron left.
I never worked in a foundry but I did work at a pattern shop and made a lot of that stuff. I've seen patterns larger than cars. mold boxes 8 feet tall and 15 feet square.
Our company can supply silicon metal,silicon briquette,high carbon silicon,silicon carbide,silicon slag, casi cored wire, if you are request about them,please email me: star06@alloyssi.com
That s à very interesting video I did not understood that the sand do get hard.. I work in pianos so iron "plates" are not new to me. But there are cooling deformations and stresses in our parts. However on those wheels the precision looks a little " crude" , I guess they are machined later to get to the nominal dimensions.
Here in the usa that red stuff they are washing the mold with can be expensive. Not sure of that type exactly but the ones for stainless/steel are ;) You would think they would just wash where the molten metal would be hitting the no-bake sand. That excess on the mold adds up really quick.
If the materials used are properly dry, there shouldn't be much splash anyway. Most dangerous are the temperature lances you see at 8:18. They are wrapped in carton and the water in there evaporating throws drops of iron in the air. After tapping the melt is genereally not terribly hot (1300 - 1400°C), so the reaction is somewhat tame. At the furnace the melt goes up to around 1550°C regularly, so there are many more drops of the melt flying around when checking temperature. Also, at 1550°C the melt is radiating so much heat, that you acutally want to wear long sleeves during deslagging, but that also depends on the diameter of the furnace. Whilst your body is alright with the heat, your arm is heating up really fast. It tended to burn the skin on my little finger, cause it was heated much quicker then any other part of my body. It's a fun job though, i really like the look of the liquid metal. I can still be amazed by looking at the melt for hours :)
great work,the work is extremely relaxe and the workers are so so experienced in sand casting, i have some questions? what is the type of this sand mixture? what is the suspension 5:35 what is the type of molten steel
I need to know how a pulley with fancy curved spokes is made. I see them a lot on antique machinery and church bells of iron had giant iron pulleys attached to them to swing them in America. Could you tell me how it was done? I beleive it all was cast in one mold and no latheing done to make the groove in those big pulleys.
The shaped of the patterns determine the final product. Usually complex shapes used a lost wax process where the finished part's shape is held in place by a wax core that melts as the iron, aluminum, etc is added to the mould.
I wonder if spraying your piece with a light coating of mineral or cooking oil would help it come out of the mold when the mold is initially formed or if that would be a bad idea.
We were told to spray the patterns with oil so that the mold would not stick. If sand sticks to the patter it becomes part of the pattern. This happened to me and I did not notice it with the result that a number of my pieces had to be sent to the grinders to have the bump ground off. This was at Lancaster Malleable in 1973. The parts I was making were for commercial oven doors. I was paid 3.23 an hour while the grinders were paid 11.00 an hour.
That was interesting to see the foundry I worked in had a machine to make the mold called the molder 2000 degrees was pouring temperature that's the kind of ladles we had
40 years ago for me James. Did it for a couple of summers while in school. Can you still remember the smell? And the foundry dust getting into everything? I'll never forget the smell of a foundry.
@@johnk1955 I really hope you gents were issued with and wore more protective equipment than what we see here...it is virtually non existant. No hand protection while using chain shackles that have pinch points everywhere. The smell you speak of from organics in the Furan sands which emits nasties when heated. If you weree not subjected to medical assesssments over those 40 years make sure you are checked regularly. I was fortunate enough to work in industrial processing but the employer always adhered to strict Health and Safety regulations.
8:46 reminds me of the Foundry level from Tony Hawk's Pro Skater 3, yeah I was looking for Tony Hawk's Pro Skater 3 Foundry in real life and this popped up lol
Excellent video and narration! Very interesting. I am guessing that this company will be forging the other main parts to your cannon also? Must be very expensive? Thanks for sharing!
i'm watching this video to try to figure out how my relative died in the 1920s when a furnace blasted while he was trying to set the stop in the ladle. this was the best visual I could find of the steel being poured into a ladle so it definitely makes more sense now. before the days of ppe or even having the slightest care if your employees got injured or died on the job.
Nice, missed this in college industrial tours decades ago. nice soft, effortless, clear, almost musical way of speaking too, are you Luxembourgish? the river "sure", in "grippingham"?
To understand the whole project you could watch: th-cam.com/video/5-JbTpw_QjA/w-d-xo.html And then there's the video th-cam.com/video/szXCL_lyfHY/w-d-xo.html
How to reuse the sand which is already solidified block by resin? Do we need a crashing machine to crash sand block? Is it easy or difficult to reuse if we use resin in the sand? Thanks,
Basically all of our sand was reused. Some of the sand can be made hard enough you need to use a jackhammer to chip it out. It’s all thrown away. The molding sand was never that hard. The center core sand typically burned up and was returned in the system.
I’d imagine there’s a lot of different options. One we used the most was nickel. It’s been over 20 years so I don’t remember what some of the less used items were.
Great Matthias, I enjoyed this very much. To me molten metal and especially iron is very beautiful. 5:30 you say "this reddish liquid is a suspension of (something)" just curious what that was.
@@matthiasburger2315 chamotte (grog) does not have alcohol base. What alcohol base is added to chamotte? To soften the chamotte, they mix with alcohol instead of water? They can soften with water also. Why do they use alcohol based? Thanks
Hello T12J7: According to what I read in comments here, a one Laura Bartlett (below) states, "He is adding inoculant to the iron in order to form the correct microstructure of flake graphite. The inoculant produces 'seed' particles that help graphite grow instead of hard and brittle iron carbide".
He is adding inoculant to the iron in order to form the correct microstructure of flake graphite. The inoculant produces "seed" particles that help graphite grow instead of hard and brittle iron carbide.
Oh yes i remember the smell it was worse when we used furane and alpha set that burned the throat raw when casting out . bloody hard days. I couldnt do it now . green sand was the best to cast with always was . although in ten years green was never the colour.
I work in a foundry like this, and yes they should be wearing more protection. I wear a hard hat, earplugs, eye wear, a respirator, 2 pairs of gloves, steel toe boots with metatarsals, and coveralls. It doesn't matter what part of the foundry you are in we still have to be fully protected. It's quite nice working for a business that wants to keep us healthy and happy as possible so we can enjoy our golden years.
Para todos aquellos que esten aquí por la tarea de comprensión de sistemas de producción y fabricación industrial, aquí dejo una playlist con todos los videos para que no andeis clickando a cada rato, También decir que hay uno que solo esta en stream y no en youtube, y no se puede incluir en la lista. La lista: th-cam.com/play/PLm0K76kWT2pTIQwQGHMd9pSLiett0NVCQ.html
Started working in an Iron Foundry on my 18th Birthday. Seen some tough guys come and go. Some come in and are told to come back with Steel toed boots and they never return. Call that a healthy choice for some. I’ve seen iron accidentally poured down a man’s boots and things of that nature. We’d make the copes and drags in the morning and pour in the afternoon. That job will make you tougher if you’re tough enough to hang in for a few months to begin with.
That was awesome. It is so cool to see inside a giant factory like that that. I can't wait for the next video of the cannon build.
WOW always something interesting happening over at the Burger house. Thanks for sharing this. Has to be very rewarding to watch your patterns becomes the wheels you need!
I'm glad there was a follow up to the first video this is a really cool series and man do they have some good music playing. Again really cool
Super Video, Matthias! Das ist eine echte Kunst.
I worked in a foundry as a metallurgists assistant in college and the smell of hot sand gets into your hair and skin and it takes weeks to get out. there is a smell of hot casting sand that you do not ever forget.
What did you guys produce?
Great video thanks for sharing it and I'd also like to thank the company for allowing you to film.
Those guys are true professionals and make a great team.As someone who's done some sand casting work in aluminum it is amazing at how easy they make it look.
Yes, I noticed that, too. They do it in a relaxed way but there is much knowledge and experience in the background.
I have noticed that in a variety of skills. Once people are competent and confident there is a relaxed aspect to the work, they "make it look easy" as the saying goes, but as you say there is knowledge and experience there.
Our company can supply silicon metal,silicon briquette,high carbon silicon,silicon carbide,silicon slag, casi cored wire, if you are request about them,please email me: star06@alloyssi.com
@@matthiasburger2315 do you have the contact for this company?
That was SO relaxing to watch; I could watch videos like this all day long.
जूद
Amazing and beatiful work!!!
That factory has some age, but the quality is still way, way better than films of the modern Indian and Chinese factories I've seen.
That guys are doing an increddible hard job. I hope they get paid properly!
There's something beautiful about how molten metal flows.
Best casting movie on the internet!
Really enjoyable video!
I worked at The Chevrolet Grey Iron Casting as a sand wetter. Great place to work and in it's day was the largest Grey Iron Foundry in the world...COOL. She's casting Aluminum now using the lost foam technology. I left when the iron left.
I never worked in a foundry but I did work at a pattern shop and made a lot of that stuff. I've seen patterns larger than cars. mold boxes 8 feet tall and 15 feet square.
Keep these video's coming, Matthias
👍 Making good casting has been and continues to be a matter of hand skills ..
Absolutely fascinating!
Great guys! professional!
땡큐"Thank you so much~~super great!!!!~Fighting
Usefull video to get familiar with casting process...
Great video! Thank you
would like to see more on sand compacting. does this resin almost completely eliminates the need.for compacting?
Very interesting. I would wear a mask if I worked casting a mold.
Silica is no joke
Just perhaps they have health insurance that pays them more if they're sick (need to stay at home) than they earn working.
Best part was the voice of lenny kravitz singing on the background, 8:52 only them I was able to trust on the workers...
Alex Dullius Siqueira I love steel work please can someone help me out
Our company can supply silicon metal,silicon briquette,high carbon silicon,silicon carbide,silicon slag, casi cored wire, if you are request about them,please email me: star06@alloyssi.com
trust those workers*. You don't trust "on" workers but you can place trust on the workers.
I'm also worker in isgec foundry department
Du bist cool mach weiter so.
Ich finde deine Videos cool.
Bitte um antwort.
Ich bin dein Fan......
That s à very interesting video I did not understood that the sand do get hard.. I work in pianos so iron "plates" are not new to me. But there are cooling deformations and stresses in our parts.
However on those wheels the precision looks a little " crude" , I guess they are machined later to get to the nominal dimensions.
Hi dear sir:what is the name of resin mixed with sand whitch dried by itself,ive heard waterglass already is used but that needs co2 to dry
Love these video
tool and die markers made everything this way. Skilled labor, nasty dirty work but when finished they could say I made that.God Bless
Very realistic for what happens, Sufficient to learning.
Awesome video
I love the music thanks
Here in the usa that red stuff they are washing the mold with can be expensive. Not sure of that type exactly but the ones for stainless/steel are ;) You would think they would just wash where the molten metal would be hitting the no-bake sand. That excess on the mold adds up really quick.
Lowell Roemer what is that stuff exactly?
Loved working in iron foundry, was a grinder for couple months before i moved up.
Wait, so they have a resin pre mixed with the sand that hardens when condensed or when it meat the airs?
When it meets the carbon dioxide in the air specifically, the resin is called sodium silicate.
So so so cool !! thank you
a very helpful video
very cool. I was surprised by the short sleeves.
If the materials used are properly dry, there shouldn't be much splash anyway. Most dangerous are the temperature lances you see at 8:18. They are wrapped in carton and the water in there evaporating throws drops of iron in the air. After tapping the melt is genereally not terribly hot (1300 - 1400°C), so the reaction is somewhat tame. At the furnace the melt goes up to around 1550°C regularly, so there are many more drops of the melt flying around when checking temperature. Also, at 1550°C the melt is radiating so much heat, that you acutally want to wear long sleeves during deslagging, but that also depends on the diameter of the furnace. Whilst your body is alright with the heat, your arm is heating up really fast. It tended to burn the skin on my little finger, cause it was heated much quicker then any other part of my body. It's a fun job though, i really like the look of the liquid metal. I can still be amazed by looking at the melt for hours :)
What is the red liquid stuff called?
understood casting watching this easier to watch and learn rather than listen write and read.
great work,the work is extremely relaxe and the workers are so so experienced in sand casting, i have some questions?
what is the type of this sand mixture?
what is the suspension 5:35
what is the type of molten steel
casting sand
chamotte
cast iron
I need to know how a pulley with fancy curved spokes is made. I see them a lot on antique machinery and church bells of iron had giant iron pulleys attached to them to swing them in America. Could you tell me how it was done? I beleive it all was cast in one mold and no latheing done to make the groove in those big pulleys.
The shaped of the patterns determine the final product. Usually complex shapes used a lost wax process where the finished part's shape is held in place by a wax core that melts as the iron, aluminum, etc is added to the mould.
watched this as i am using info from it for my first assignment in level 3 btec engineerring thx for the vid
accent hard to understand xd
I wonder if spraying your piece with a light coating of mineral or cooking oil would help it come out of the mold when the mold is initially formed or if that would be a bad idea.
Liquids of any type would contaminate the sand causing imperfections in the finished part.
We were told to spray the patterns with oil so that the mold would not stick. If sand sticks to the patter it becomes part of the pattern. This happened to me and I did not notice it with the result that a number of my pieces had to be sent to the grinders to have the bump ground off. This was at Lancaster Malleable in 1973. The parts I was making were for commercial oven doors. I was paid 3.23 an hour while the grinders were paid 11.00 an hour.
That was interesting to see the foundry I worked in had a machine to make the mold called the molder 2000 degrees was pouring temperature that's the kind of ladles we had
30 years ago i worked in this industry and its not changed at all. Oh memories.
40 years ago for me James. Did it for a couple of summers while in school. Can you still remember the smell? And the foundry dust getting into everything? I'll never forget the smell of a foundry.
@@johnk1955 I really hope you gents were issued with and wore more protective equipment than what we see here...it is virtually non existant. No hand protection while using chain shackles that have pinch points everywhere. The smell you speak of from organics in the Furan sands which emits nasties when heated. If you weree not subjected to medical assesssments over those 40 years make sure you are checked regularly. I was fortunate enough to work in industrial processing but the employer always adhered to strict Health and Safety regulations.
Give not the civil servants but these craftsmen a high salary
8:46 reminds me of the Foundry level from Tony Hawk's Pro Skater 3, yeah I was looking for Tony Hawk's Pro Skater 3 Foundry in real life and this popped up lol
Excellent video and narration! Very interesting. I am guessing that this company will be forging the other main parts to your cannon also? Must be very expensive? Thanks for sharing!
MRrwmac Yes, the cannon barrel is made by Nehr&Saurer, too. That's a much bigger project.
Like the fire at 6:03
8:30 I think some PPE would be in order when pouring 1350C degree molten metal that will mame you should a mishap occur.
i'm watching this video to try to figure out how my relative died in the 1920s when a furnace blasted while he was trying to set the stop in the ladle. this was the best visual I could find of the steel being poured into a ladle so it definitely makes more sense now. before the days of ppe or even having the slightest care if your employees got injured or died on the job.
@@annesiac3265 Sorry for your loss. That would not have been a pleasant experience.
Nice, missed this in college industrial tours decades ago. nice soft, effortless, clear, almost musical way of speaking too, are you Luxembourgish? the river "sure", in "grippingham"?
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What did you do with the wheels? I didn’t see a follow up video in your list.
To understand the whole project you could watch: th-cam.com/video/5-JbTpw_QjA/w-d-xo.html
And then there's the video th-cam.com/video/szXCL_lyfHY/w-d-xo.html
How to reuse the sand which is already solidified block by resin? Do we need a crashing machine to crash sand block? Is it easy or difficult to reuse if we use resin in the sand? Thanks,
Basically all of our sand was reused. Some of the sand can be made hard enough you need to use a jackhammer to chip it out. It’s all thrown away. The molding sand was never that hard. The center core sand typically burned up and was returned in the system.
Thank God I work in a modern Iron foundry where our Molders use patterns/cores/ pinlifts to make a mold....Give kudos to these guys though.
Yea no kidding, the foundry I work for can produce over a thousand castings per shift. It's really cool seeing these guys do it by hand though.
8:50 *yeah yeah yeah* lol
Sir plz tell this red liquid those liquid has pasting on the mould
Low temperature
What about shift precaution
Could you tell me what the reddish liquid is?
Nice video 👌
I feel respect for those working in that foundry
Where sir ?????
Nice Work
Hi dear sir can you tell me about green sand how it make please
Sou moldador manual a 20 anos .. Da vontade de desafiar o ferro em outros paises
Very nice thx a lot
Wondering what is added to the molten steel at 7:55? Flux or something else? :)
I’d imagine there’s a lot of different options. One we used the most was nickel. It’s been over 20 years so I don’t remember what some of the less used items were.
And of which material the filter placed in the mould is made of?
Ceramic
Which type of sand
Thanks
14 nov 2019 5:26 pm est:thanks
Such a small foundry thats crazy.
How much did it cost to get these cast?
What can hold melted iron? Wouldn't it melt whatever they poured it in?
graphite, it has higher melting temperature than iron and some other metals
The ladles are coated with 6 inches or so of refractory which is a special preparation of cement.
What are you doing of wastage slag
Please reply
Good job
Great Matthias, I enjoyed this very much. To me molten metal and especially iron is very beautiful.
5:30 you say "this reddish liquid is a suspension of (something)" just curious what that was.
awldune That's chamotte (or grog, I think, see en.wikipedia.org/wiki/Grog_%28clay%29)
Matthias Burger Thanks Matthias, that makes sense.
+awldune It's a mould wash with alcohol base..
@@matthiasburger2315 chamotte (grog) does not have alcohol base. What alcohol base is added to chamotte? To soften the chamotte, they mix with alcohol instead of water? They can soften with water also. Why do they use alcohol based? Thanks
What is the red liquid sprayed on the mould?
Clay mixed with methanol alcohol.
I wonder how they made when no resin or sealant or alcohol based...
Thanks !
Which kind of resin is used in sand ?
I have cast iron foundry in india . If you want to make a video I will give you permission for that.
Very rarely does the radio in the background line up with the footage perfectly.
How did I end up watching this? 😁👍
Deep down you seek out poor editing.
May I know what kind of sand type
What did they add to the molten iron there at 07:55?
Hello T12J7: According to what I read in comments here, a one Laura Bartlett (below) states, "He is adding inoculant to the iron in order to form the correct microstructure of flake graphite. The inoculant produces 'seed' particles that help graphite grow instead of hard and brittle iron carbide".
@@wmc9722 مع احترامي أظن أنها ثيرمو كابل لمراجعة درجه حراره المعدن قبل الصب
@@MohamedMostafa-fd7hx
shukran limusahamatik huna. ealaa al'arjah 'anak ealaa sawabi. shukran lika.
@@wmc9722 تحياتي لحضرتك
@@MohamedMostafa-fd7hx Do you know English?
'
what is this iron wheel about...
pulley wheel or rim wheel or train wheel or another purpose
@8:00 during pouring iron into ladle, what does that man put into ladle apart from pouring.
He is adding inoculant to the iron in order to form the correct microstructure of flake graphite. The inoculant produces "seed" particles that help graphite grow instead of hard and brittle iron carbide.
@@laurabartlett6060 thank you.
What project?
Good manufacturing
How do you make this Sand
Very cool video! I feel like these guys should be wearing dust masks... are safety measures like this less regulated in Europe?
John Aldrich in india worker does not wear helmet hand gloves mask and any other safety equipments!!!
use to work conditions, it was ok,still had safty cocerns but greatr fellas to work with,and we make food,maybe a drinky once,.
Nice
same my work
I need a job shift in charge sir pls give me a hint
guys please help what are the three safety practises of this video
Oh yes i remember the smell it was worse when we used furane and alpha set that burned the throat raw when casting out . bloody hard days. I couldnt do it now . green sand was the best to cast with always was . although in ten years green was never the colour.
Shouldn't these guys wear gloves, respirators or at least eye protection?
Alex Lito shouldn't you worry about something else?
that's how MEN work
You back into your swamp..
Hemant YEAH!!!
I work in a foundry like this, and yes they should be wearing more protection. I wear a hard hat, earplugs, eye wear, a respirator, 2 pairs of gloves, steel toe boots with metatarsals, and coveralls. It doesn't matter what part of the foundry you are in we still have to be fully protected. It's quite nice working for a business that wants to keep us healthy and happy as possible so we can enjoy our golden years.
Health and safety?
Para todos aquellos que esten aquí por la tarea de comprensión de sistemas de producción y fabricación industrial, aquí dejo una playlist con todos los videos para que no andeis clickando a cada rato,
También decir que hay uno que solo esta en stream y no en youtube, y no se puede incluir en la lista.
La lista:
th-cam.com/play/PLm0K76kWT2pTIQwQGHMd9pSLiett0NVCQ.html
nice
"Fire, Fire!!"
9:49 Steel toe hiking boots?