Casting a Bitcoin in Aluminium silicon bronze Olfoundryman 2018-06-06 | This is a trial on behalf of Swdweeb. He produced the STL file for this part, Smallcnclathes produced the 3D print, and I made the casting just to see if it was possible to cast such small 3D printed detail. The print is just as printed - no smoothing or painting. The result is not perfect but the defects could easily be eliminated by a better pattern removal method. I have to repeat this casting in aluminium as the grandson wants a "silver" one to go with this "gold' one that he will now not let out of his sight. I will do an update when I cast the "silver" one. I will try to make it better. The bronze used is 6.5% aluminium 2.5% silicon pinch iron and Manganese balance copper
A Gravity diecasting journey Part 3:- Complex and hydraulic Olfoundryman 2022-09-27 | A three part video series of my gravity diecasting adventures.Here, in part 3 I discuss and demonstrate more complex work using a hydraulic machine to hold and work the diesLinks to full videos etc. :- Spin casting info tekcast.com Coffee perculator youtu.be/Q4sGl4jOQtA Gas mixer youtu.be/q4wExjpBiz0 Four barrel throttle body youtu.be/R1ZTvsp16zo Smallcnclathes youtube.com/user/smallcnclathes
A gravity Diecasting Journey Part 2 :- Tilt casting Olfoundryman 2022-09-18 | A three part video series of my gravity diecasting adventures.Here, in part 2 I discuss and demonstrate tilt castingLink to video mentioned youtu.be/G48QR90ur5ILink to part 1 youtu.be/82KKr3jGxU8Tilt casting is based on the Durville process developed in France to solve problems of severe oxide skins in aluminium bronze ingots to be rolled into sheet for coin production. Sadly those who adapted the process to more general work were a bit "loose" with their adaption and most machines and foundries make serious mistakes with the method
Gravity diecasting AKA Permanent mould casting Part 1 Olfoundryman 2022-09-10 | A three part video series of my gravity die casting adventures.Here, in part 1 I show the simpler and easier castings Links to videos mentioned:- Runway light video youtu.be/qJiw32DXTeU Coffee percolator nut video youtu.be/Q4sGl4jOQtA From 12 minutes Link to Part 2 youtu.be/pfkIcKx1dnQ
Stirring metal the right way Olfoundryman 2022-07-25 | In my recent video called "Possibilities" youtube.com/watch?v=QCgpVfB4exQ&t=386sI showed an example of incorrect metal stirring. Stirring of metal is something to be avoided but sometimes it is necessary. Here I show the correct way to do it.
Possibilities Olfoundryman 2022-06-18 | This is a video about the possibilities of anyone making a casting as good as this one. It centres on the mistakes and traps that many fall into and that if avoided will lead closer to this sort of result.I have obtained the examples of the traps from other's videos. I do this not to denigrate others but rather to provide helpful clues on how to improve. These others shall remain nameless. I hope that all see this video in this light - if so it is my hope to do further videos explaining in more detail and showing preferred methods. I am indebted to EFI Hardware - my customer for these throttle bodies - who have been kind enough to loan this sample to me - Check out there web site for more information on their products at:-efihardware.comNote that while my comments in this video refer to green sand, my area of expertise - I think they apply equally to petrobond.
Make your own metal moulding boxes Part 6 Olfoundryman 2020-08-07 | Part 6 of making your own metal moulding boxes.The easy stuff:- Filing, sanding, drilling, and bolting together
Basin and sprue design for sand casting in the foundry Olfoundryman 2020-07-17 | Improving your castings by using proper pouring basin and sprue design.My version of the techniques recommended by John Campbell.These are easy to apply and take no more time than incorrect techniques.
Make your own metal moulding boxes part 5 Olfoundryman 2020-07-09 | Part 5 of the series on making your own metal moulding boxes.In this part we cast the moulds for 10 of the box sides.
Make your own metal moulding boxes Part 4 (b) Olfoundryman 2020-06-08 | Part 4(b) of the series on making your own metal moulding boxes. Here I demonstrate the moulding of one of the longer sides both with and without using the odd-side pieces. This is a long video designed to provide all the information needed for you to make your own box sides.
Making your own metal moulding boxes Part 4(a) Olfoundryman 2020-06-03 | Part 4(a) of the series on making your own metal moulding boxes.In this part we make the first of 10 (of 16) moulds in which to cast the new sides for two complete moulding boxesThe STL and pdf drawing files for the patterns used here are available for download at this sitehttp://www.benchtopcnc.com.au/downloads/Part 4(b), coming shortly, shows the moulding process in intimate detail for a longer box side both with and without using odd-side pieces.
Make your own metal moulding boxes - Part 3 Olfoundryman 2020-04-30 | Part 3 of the series on making your own metal moulding boxes. In this part we cast the trial mould and again lessons learnt here will be used to simplify the process.The STL and pdf drawing files for the patterns are now available for download at this sitehttp://www.benchtopcnc.com.au/downloads/Smallcnclathes has published a short video on the 3D printing of these patterns and you can find it here youtube.com/watch?v=mPeqoJmF5twPart 4 where we make the 16 (hopefully 16!) moulds necessary to demonstrate the making of the boxes and the versatility that the system gives is already under way - 10 moulds made!
Make your own metal moulding boxes - Part 2 Olfoundryman 2020-04-12 | Part 2 of the series on making your own metal moulding boxes.Here we make a trial mould, Lessons learned from this will be used to further simplify the process.The STL and pdf drawing files for the patterns will be released with part 3 where we cast this mould.
Make your own metal moulding boxes Olfoundryman 2020-02-08 | This design has been simplified to make the build as easy as possible, a drill press and some easily available hand tools (via eBay) are all that is required.By swapping sides around (and a few other tricks) boxes can be configured for a wide range of jobs.The STL files for the patterns will be freely available in the near future.
Moulding box journey Olfoundryman 2019-12-29 | This is the story of my journey of 55 years through moulding boxes. It is an evolution of ideas, of things tried, and in some cases failed. I can not of course fit 55 years of experience into one video but the important parts of it are here. There is no "perfect" box here, for I have yet to make one, but based on this experience the ideas are now in place for as close to it as I can envisage. In an upcoming video series and with help from a good friend I will make a box (or two) as close to this ideal as possible. A versatile box suited to the hobbyist
Rapping tool From Sandrammer Olfoundryman 2019-08-28 | I received mail from the US, A gift from a fellow foundryman. His channel is called "Sandrammer" and can be found here youtube.com/user/sandrammerThe gift is a rapping tool to help loosen patterns thus making it easier to remove them without mould damage. I try it out in this video and it works very well indeed.
Casting a four barrel throttle body Part 4:- feeder removal Olfoundryman 2019-08-03 | Casting a four barrel throttle bodyA gravity diecasting (permanent mould) in 601 (US 356) (UK LM25) aluminium alloyPart 4:- Removal of the feeder
Casting a four barrel throttle body Part 3:- Spraying the die and making the castings. Olfoundryman 2019-07-29 | Casting a four Barrel throttle bodyA gravity die casting (permanent mould casting) in 601 (US 356) (UK LM25) Aluminium alloyPart 3 :- Applying the die coat and making the castings
Casting a four barrel throttle body Part 2 :- The die, the furnace, and the machine Olfoundryman 2019-07-24 | Casting a four barrel throttle bodyA gravity die casting (permanent mould) in 601 (US 356) (UK LM 25) Aluminium alloyPart 2:- The die, the furnace, and the machine
Casting a four barrel throttle body Part 1:- The funnel core Olfoundryman 2019-07-19 | Casting a four barrel throttle bodyA gravity die casting (permanent mould) in 601 (US 356) (UK LM25) Aluminium alloyPart 1:- Making the shell core "funnel"
#2019openersopen Prize Winners Olfoundryman 2019-06-12 | Announcement of those I judge the winners of the #20190penersopen challenge. Overall winner for his octopus opener -Julian HGHighly commendable for his double ended precision machined opener - WargradeHighly commendable for his hammer powered opener -WhatdennisdoesA big thank you to all who took partand a special thank you to Perry - Swdweeb for organising it alland also to Nigel - smallcnclathes - for generously paying the postage.Relevent links:-Nigel smallcnclathes channel youtube.com/channel/UCSFn1_FsFGmUSrXjDR--S0ASwdweeb channel youtube.com/channel/UCAyW0r-deFC-GmzbuG3j3dQWhatdennisdoes opener youtube.com/watch?v=4TxRPkKOGq0&t=716sJulian HG octopus opener youtube.com/watch?v=KBOiYNpyWdEWargrade double ended opener (part 1) youtube.com/watch?v=BOfsybQtlto
Caustic Soda etching to reveal porosity in aluminium alloys. Olfoundryman 2019-04-08 | The true extent of porosity in aluminium alloys is not always easy to see. Much of it, typically hydrogen gas porosity, can be very fine and the smearing action of machining operations can easily cover it up. However sanding to a reasonably fine finish followed by an etch in caustic soda (sodium hydroxide) solution and then a quick re-sand to remove the etch discolouration reveals all.The hydrogen gas bubbles in these samples measured about 0.15 mm (0.006 inch). Such small holes are almost impossible to see on even a well machined surface but the etching used here shows them in all their infamous glory!Swdweeb did a series of three videos on the subject of porosity in aluminium castingsThe first is at youtube.com/watch?v=OmmEXUnL4_8&t=3sThe second at youtube.com/watch?v=VcQ0hH9D94UThe third at youtube.com/watch?v=jQwUG2Sblr8&t=1sCheck them out they are all worth a look for the serious caster trying to improve his castings.
Make an Opener Olfoundryman 2019-04-01 | Have a go at this collaboration / competition being organised by swdweeb check out his information video on it youtube.com/watch?v=6HP8InAPOHsMake an opener, do a video of the process, upload the video on May 24th. Use the tag#2019openersopenI will giver a prize to who I judge to be the winner, see my video above. But remember your opener must work.Get amongst it for a bit of fun. GOOD LUCK
Cast Aluminium experimental plenum adaptor for a V12 Jaguar Olfoundryman 2019-02-01 | Sand Cast aluminium experimental plenum chamber adaptor for a V12 Jaguar. These parts go with the Jaguar V12 throttle bodies that I cast previously, a link to the throttle body video is included.The pouring basin used here is an older outmoded design and efforts are under way to produce the more modern offset ridged basin that I now prefer to use. The unusual parting line on this part requires the use of an oddside.
Sand Casting an Aluminium Vacuum Cracker for Jars Olfoundryman 2018-12-11 | Sand casting an aluminium vacuum cracker for jars. An example of a simple, easy, and quick job that illustrates some of the factors in achieving a very good surface finish.
Casting a piston for a 1910 Brush car. Part 3b Casting, breakout, and discussion Olfoundryman 2018-11-27 | Sand casting an aluminium piston for a 1910 Brush car. Part. 3b Pouring the sand mould. This final part of the video series also includes a "post casting" discussion centred on the gating system used. In addition it addresses the oft asked question of "why not just CNC machine the piston from billet".I recommend watching parts 1, 2, and 3a first.
Casting a Piston for a 1910 Brush Car. Part 3a making the sand mould. Olfoundryman 2018-11-19 | Sand casting an aluminium piston for a 1910 Brush car. Part. 3a making the sand mould. I decided to split this, the final part of the series, into two as I wanted to show the "nitty gritty" of the moulding process and with this included it would have been a very long video unless split into two parts.Part 3b which is yet to come will cover the pouring of the moulds plus a short discussion / explanation and including a look at the finished machined piston
Casting a piston for a 1910 Brush car. Part 2:- The CO2 silicate core Olfoundryman 2018-11-12 | Sand casting a piston for a 1910 Brush car. Part 2 Making the sodium silicate/CO2 cores and pouring basins.Here I make the cores that will be used to form the inside of the pistons. Also I make some John Campbell inspired pouring basins to sit atop the sprue. Later, in Part 3 of this video series, I put these components together with a rammed sand mould and the chills made in part 1 and cast the pistons.
Casting a piston for a 1910 single cylinder engined Brush car, Part 1 Olfoundryman 2018-11-08 | Sand casting a piston for a 1910 Brush car. Part 1 casting the chillsHere I cast some chills that will be used to improve the structure and decrease the porosity of some pistons to be cast later in Part 3 of this video series. The chills them selves will also be chill cast as they are quite thick and "chunky". The chill casting is a definite aid in making such castings much sounder and finer grained.Part 2 of this series - to be released soon - will cover the reinforced Silicate CO2 core that will form the inside of the piston mould.
Maserati long pulley half casting Olfoundryman 2018-09-11 | Sand casting a long pulley half for a rare Maserati car. The casting uses two CO2 silicate cores, one of which is placed inside the other. This "inside" core is made from two identical pieces and is glued up around a central brass tube that itself forms part of the core in contact with the metal being cast. The brass tube provides much of the necessary venting for the core.This was not the easiest job that I have ever done!
Maserati long pulley half casting short version Olfoundryman 2018-09-11 | Sand casting a long pulley half for a rare Maserati car. The casting uses two CO2 silicate cores, one of which is placed inside the other. This "inside" core is made from two identical pieces and is glued up around a central brass tube that itself forms part of the core in contact with the metal being cast. The brass tube provides much of the necessary venting for the core.This was not the easiest job that I have ever done!
Maserati long pulley half. Part 1: The cores Olfoundryman 2018-09-02 | Preparing the CO2 silicate cores for casting the Maserati long pulley half. Rather unusual cores that I would have preferred to have made using the shell process as it produced stronger and less outgassing cores but that would have required metal core boxes - not justifiable for just 2 off castings.The blue wash put on the "doughnut" cores is "Isomol 185" by "Foseco" It is an alcohol based zircon wash and it helps to improve the otherwise rough surface finish that silicate cores givePart 2, coming soon, shows these cores being used to make the Aluminium castings
Sand cast Aluminium Trophy Diamond Olfoundryman 2018-08-22 | Under instructions from my 7 year old grandson I cast this "Trophy Diamond" in aluminium. Why did he want it? He is 7 years old, what more is there to say? A 3D print, smoothed with body filler and primer surfacer paint, followed by sanding, was used as the pattern.A quick easy casting.
Lens Blank Gravity Die Casting Olfoundryman 2018-06-12 | Part 4 of Casting an aluminium die for casting aluminium into. This part shows the actual casting of the aluminium lens blanks using the aluminium die made in parts 1 and 2.Part 1 "Casting the lens blank masters" can be seen here youtube.com/watch?v=hVdLDFAgJBgPart 2 "Casting the lens blank die" can be seen here youtube.com/watch?v=mYM0Swgd5lIPart 3 "Tilt casting explanation" can be seen here youtube.com/watch?v=rEHr9yCvz_0
Tilt casting explanation 1 Olfoundryman 2018-06-02 | Part 3 of "Casting an aluminium die for casting aluminium into".This video is an explanation of the tilt casting process that I use to do this castingPart 1 of this video - Casting the lens blank masters, can be seen here youtube.com/watch?v=hVdLDFAgJBgPart 2 of this video - Casting the lens blank die, can be seen hereyoutube.com/watch?v=mYM0Swgd5lIPart 4 of this video - Lens blank gravity die casting, can be seen here youtube.com/watch?v=G48QR90ur5I
Lens Blank Die Olfoundryman 2018-05-30 | Casting the aluminium die for casting aluminium lens blanks into.Three blocks were cast in a piston alloy; One was the die block containing two cavities for the lens blanks, the other two were for the top half of the die into which the feeder cavities will be cut. Part 1 of this video , "Casting the lens blank masters" can be found here youtube.com/watch?v=hVdLDFAgJBg&t=176sPart 3 of this video , An explanation of tilt casting can be found here youtube.com/watch?v=rEHr9yCvz_0Part 4 of this video - Lens blank gravity die casting, can be seen here youtube.com/watch?v=G48QR90ur5I
Lens Blank Masters Olfoundryman 2018-05-22 | This is part 1 of a video series about making and using an aluminium die for casting aluminium into. The eventual castings are Lens blanking prisms. I used to cast these in sand but the number required increased dramatically To see the original sand castings being made see youtube.com/watch?v=99n1fDkBEPwPart 1 covers; Casting some bronze masters for casting an aluminium die aroundThe bronze is 6.5% aluminium 2.5% silicon balance copper with maybe just a dash of iron and manganese.Pauls garage video for that small sprue exampleyoutube.com/watch?v=BoJhtdGVSw0Part 2 of this video series - Casting the lens blank die can be seen at youtu.be/mYM0Swgd5lIPart 3 of this series - An explanation of tilt casting, can be seen here youtube.com/watch?v=rEHr9yCvz_0Part 4 of this series - Lens blank gravity die casting, can be found here youtube.com/watch?v=G48QR90ur5I
Furnace Light Up Olfoundryman 2018-05-21 | Lighting the furnace for a small bronze melt and taking a bit of a risk with my cameraLots of furnace to heat up for a little molten Bronze!
Casting an aluminium gang tooling block for a small CNC lathe Olfoundryman 2018-04-30 | The addition of a Gang tooling block to the cross slide of a small CNC lathe greatly enhances its versatility. Although designed primarily for the Hercus PC 200 lathe it should fit any similarly sized CNC lathe Dyna 3000, Seig, Boxford, etc. These blocks can be seen in action at smallcnclates channel and in particular in the videos youtube.com/watch?v=ssFoMpOdWGA youtube.com/watch?v=7XhiCxoUunU youtube.com/watch?v=mOfkQPmX2sE&t=5sThe casting is first bolted and doweled to the cross slide and than drilled/reamed in place to ensure correct tool height.This block is offset so that it can be (initially) positioned with the length of tooling in mind.The weight of 2 Kg mentioned is the as cast weight. Alloy used was 601 (356) (LM 25) and it was given a T5 heat treatment.
Solidification Curiosity Olfoundryman 2018-04-16 | Just something a bit different. Solidification of a 12% silicon aluminium eutectic alloy showing the strange formation of eutectic cells from within the middle of the liquid surface. I find it fascinating but then I am known to be a little, ahem,"strange"
Casting another Aluminium lens blank. Part 2 Pouring, breakout, and discussion. Olfoundryman 2018-03-31 | In pouring castings turbulence is our great enemy. It increases gas and oxide content and thus lowers mechanical properties. It increases inclusions thus reducing machinability. It roughens surface finish. And by chaotic stream division it causes misruns.The pouring basin used here is designed ;- to give the pourer a decent target to aim at to reduce metal velocity at the sprue base to do so with the minimum metal turbulenceThe basin should be close to one side of the mould and needs to be poured from that side with the crucible lip as close to the top of the basin as possible. The pour needs to be steady and must always keep the basin full.This design was much used around 1900 however the need to use properly sized and tapered sprues was unknown until around 1950. As a result the good effects of this basin design were largely destroyed by placing it atop a large parallel sprue that was often also unnecessarily high. In an exercise reminiscent of throwing out the baby and keeping the bathwater the use of the basin was abandoned but that of the large parallel sprue continued and sadly, in many cases it is still in use.John Campbell revived the use of this basin design and it features in many of his books. The basin that is used here is our interpretation of his designs. The sprue that is used here has a bottom diameter of 8 mm and a taper of 1.3 degrees per side.We have available two STL files of this basin they are male and female so they give a good idea of what the basin should look like. If you would like a copy of these files please PM me with an email address that I can send them to.
Casting a lens blank - an example of good pouring basin design. Part 1, Making the mould Olfoundryman 2018-03-31 | In pouring castings turbulence is our great enemy. It increases gas and oxide content and thus lowers mechanical properties. It increases inclusions thus reducing machinability. It roughens surface finish. And by chaotic stream division it causes misruns.The pouring basin used here is designed ;- to give the pourer a decent target to aim at to reduce metal velocity at the sprue base to do so with the minimum metal turbulenceThe basin should be close to one side of the mould and needs to be poured from that side with the crucible lip as close to the top of the basin as possible. The pour needs to be steady and must always keep the basin full.This design was much used around 1900 however the need to use properly sized and tapered sprues was unknown until around 1950. As a result the good effects of this basin design were largely destroyed by placing it atop a large parallel sprue that was often also unnecessarily high. In an exercise reminiscent of throwing out the baby and keeping the bathwater the use of the basin was abandoned but that of the large parallel sprue continued and sadly, in many cases it is still in use.John Campbell revived the use of this basin design and it features in many of his books. The basin that is used here is our interpretation of his designs. The sprue that is used here has a bottom diameter of 8 mm and a taper of 1.3 degrees per side.We have available two STL files of this basin they are male and female so they give a good idea of what the basin should look like. If you would like a copy of these files please PM me with an email address that I can send them to.
Jaguar V12 Throttle Body Olfoundryman 2018-01-28 | Casting aluminium throttle bodies for a 1972 E type Jaguar V12
Airport runway light frangible coupling Olfoundryman 2018-01-19 | Sand casting an aluminium airport runway light frangible coupling.
Maserati Pulley Half Olfoundryman 2018-01-07 | An Aluminium pulley sand casting for an older Maserati car. This casting shows close to modern thinking on correct running and gating methods for castings. It could be further improved by forming the runner and gate better - more uniformly by perhaps making a patterns for these parts of the mould. Also a ceramic filter placed between the bottom of the sprue and the gate would further help by slowing metal speed (but not increasing fill time)and by removing some of the inevitable oxide films contained in the metal.Despite these possible improvements the gating shown here is a reasonable and practical attempt at good practice - it is applicable to the casting of most metals.NOTE:- The reference book title shown at 2.14 should be "Complete Casting Handbook".
Sand cast aluminium Brake fluid Reservoir Olfoundryman 2017-12-20 | Sand casting a brake fluid reservoir using a small threaded shell core.This part was developed to solve the problem of refilling the fluid reservoir on an "under the floor " brake master cylinder. The part mounts under the bonnet on the fire wall and a pipe connects it to the top of the original master cylinder reservoir.
Casting Runway Landing Lights Part 1 The threaded shell sand cores Olfoundryman 2017-11-26 | A large runway at a busy airport can easily have over 1000 lights. Some at each end, some down each side and even some set in the runway surface itself. The lights made here in part 1 and 2s sit on short stands at the end of the runway. They were originally made from a filled plastic but the strong UV light in Australia shortens the life of the plastic so these are made from aluminium and are powder coated to produce the required yellow finish.
Casting runway landing Landing lights. Part 2 The aluminium casting Olfoundryman 2017-11-26 | Making an aluminium runway light casting with an as cast thread. In service a coloured glass cover screws into the thread and down onto a sealing gasket. The resulting light sits glass uppermost with the casting underneath.
Moulding Sand Reprocessing Olfoundryman 2017-07-23 | Reprocessing my moulding sand at the end of a days casting.This is done while the sand is hot from casting - old timers believe that adding the water while the sand is still hot "steams" the sand and this helps reinvigorate the clay. I think they are probably right.
Sand aerator, mixer, reprocessor. Olfoundryman 2017-07-23 | This is the machine I use to reprocess my moulding sand after each days casting. Unfortunately this video is a bit disjointed but it took about 2 hours to disassemble and reassemble this machine so to get a watchable length video a lot of it had to hit the "cutting room floor". This machine can clog if the sand is very strong - typically when the sand is new or a bit too wet. However once the sand has been used a few times it processes quite quickly without any clogging. I suspect that if the machine was that few inches bigger this clogging would not occur.I do not know if this machine would reprocess petrobond properly but my guess is that it would particularly if that little bit bigger.
