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.
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.
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!
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.
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".
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.
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.
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'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.
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
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"?
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
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.
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.
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.
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.
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 :)
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.
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.
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
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!
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
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
Although very interesting….my thoughts are with the workers and their health who are not provided the proper safety clothing to include face masks, protective gloves, aprons, and etc. I now understand the importance of the laws of OSHA.
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.
@@josephastier7421 Sorry man! I meant no offence. I have worked 10 years on metallurgical plant and usually we were using personal protective equipment (coverall, gloves, glasses etc). This is no good to keep all industrial mud on you.
@@kanatmukatov2730 No offense taken, and indeed they do look a bit like workers in an east European reeducation camp. I have never worked in a foundry but I do know that if molten metal finds water that it will explode. To work in such a place you would want PPE up to and including a full proximity suit.
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
yet its everywhere! most of the industrial machines like lathes and drill presses milling machines are made with it, pretty good at damping and easy to cast!
Great too see but seriously the PPE has a lot left to be desired!! I used to work in a cast iron Foundry and I worked directly with molten metal and there's absolutely no way we would get away with wearing a short sleeve shirt. Just saying
It is a canon wheel. (I found this detail: 'In the Fort Oberer Kuhberg Fortress Museum, the Förderkreis Bundesfestung Ulm has faithfully recreated a complete fortress gun from around 1850 - with all accessories and in a historical setting')
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.
sounds like hell. would rather sit in an air conditioned office
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.
That was SO relaxing to watch; I could watch videos like this all day long.
जूद
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?
Best casting movie on the internet!
Really enjoyable video!
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!
That guys are doing an increddible hard job. I hope they get paid properly!
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?
There's something beautiful about how molten metal flows.
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.
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.
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.
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?
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?
👍 Making good casting has been and continues to be a matter of hand skills ..
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.
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.
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......
would like to see more on sand compacting. does this resin almost completely eliminates the need.for compacting?
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.
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.
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
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"?
ނނނނ
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
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.
Loved working in iron foundry, was a grinder for couple months before i moved up.
Amazing and beatiful work!!!
Usefull video to get familiar with casting process...
What are you doing of wastage slag
Please reply
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.
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.
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
@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.
Absolutely fascinating!
How much did it cost to get these cast?
Could you tell me what the reddish liquid is?
tool and die markers made everything this way. Skilled labor, nasty dirty work but when finished they could say I made that.God Bless
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.
Sou moldador manual a 20 anos .. Da vontade de desafiar o ferro em outros paises
Great guys! professional!
When this video was made? 1930?
Give not the civil servants but these craftsmen a high salary
May I know what kind of sand type
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 :)
I wonder how they made when no resin or sealant or alcohol based...
And of which material the filter placed in the mould is made of?
Ceramic
Sir plz tell this red liquid those liquid has pasting on the mould
Low temperature
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.
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.
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.
guys please help what are the three safety practises of this video
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.
How do you make this Sand
Probably a good idea to wear a respirator around all that dust?
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
So so so cool !! thank you
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.
Keep these video's coming, Matthias
Nice Work
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
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
Although very interesting….my thoughts are with the workers and their health who are not provided the proper safety clothing to include face masks, protective gloves, aprons, and etc. I now understand the importance of the laws of OSHA.
Very realistic for what happens, Sufficient to learning.
What is the red liquid stuff called?
What about shift precaution
Love these video
What is the red liquid sprayed on the mould?
Clay mixed with methanol alcohol.
understood casting watching this easier to watch and learn rather than listen write and read.
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,.
What's that liquid technical name can you reply
The paint like stuff they put on before they put the mold together? Im not sure what thwy used but we use a kind of water-based paint on our molds.
Which type of casting is this
Green sand casting.
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.
Good job
What project?
Great video! Thank you
땡큐"Thank you so much~~super great!!!!~Fighting
What is the name of this red liquid
Schlichte (ger), that means a suspension of fire proof cement
Awesome video
Which type of sand
I feel respect for those working in that foundry
Where sir ?????
Hi dear sir can you tell me about green sand how it make please
Such a small foundry thats crazy.
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.
Does that molder ever wash his face
0:15 - wtf? where is it happening? do they still use slaves???
Those are normal workers in a steel plant. These are jobs millennials would run away from.
@@josephastier7421 Sorry man! I meant no offence. I have worked 10 years on metallurgical plant and usually we were using personal protective equipment (coverall, gloves, glasses etc). This is no good to keep all industrial mud on you.
@@kanatmukatov2730 No offense taken, and indeed they do look a bit like workers in an east European reeducation camp.
I have never worked in a foundry but I do know that if molten metal finds water that it will explode. To work in such a place you would want PPE up to and including a full proximity suit.
@@josephastier7421 It is NOT a steel plant.
@@flamingfrancis Oh right, casting. Indeed.
a very helpful video
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
Thanks !
8:26 close call??
9:49 Steel toe hiking boots?
cast iron is so dirty. and it powders when you cut or turn it.
yet its everywhere! most of the industrial machines like lathes and drill presses milling machines are made with it, pretty good at damping and easy to cast!
@@random-kc8gx Doesn't warp either.
Great too see but seriously the PPE has a lot left to be desired!! I used to work in a cast iron Foundry and I worked directly with molten metal and there's absolutely no way we would get away with wearing a short sleeve shirt. Just saying
Nice video 👌
Great vid but I had an easier time understanding how a Plumbus was made compared to this.
I will be stealing this comment from you. It's that good. 👍😁
what wheel is that?
It is a canon wheel. (I found this detail: 'In the Fort Oberer Kuhberg Fortress Museum, the Förderkreis Bundesfestung Ulm has faithfully recreated a complete fortress gun from around 1850 - with all accessories and in a historical setting')
I love the music thanks
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