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Tools/castingcrucible/induction: Difference between revisions
starting to expand into an induction
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{{inductioninfo}}
equipment capabilities
* Types of casting
** Sand casting
** Lost-PLA casting
** Investment (lost-wax) casting
** Metal mold casting
* We're only going to be doing sand-casting today, procedure for others is under development
* Metals we can work with (Tin/Lead/White-metal, Aluminium, Copper/Brass/Bronze, we can't cast iron/steel)
Object designs
* How the mold is mounted to the boards, creates the cavity which can then be filled with metal, what is cope, drag and board.
* You have to be able to align the 2 parts of the mold using pins
* You have to be able to move the mold from the sand without breaking it too badly, so allow tapers. You can't have overhangs
* Using cores if you need complex shapes but we won't cover that
* Consider how the metal will flow, small cavities are hard to fill, there needs to be a path for metal to get in and gas to get out
* Remember the shrinkage allowance, 2% in aluminium, 1.5% in brass
* What are Sprus, Gates and Risers and why you need each of them
* Design them into the mold, or cut them afterwards once you've made the sand form
* The possibility of designing, 3D printing, Casting and then finishing on the boxford.
* Printing out a mold, carving a mold for wood, high surface finish needed
Making the mold
* Mounting the board to the cope and drag
* The sand is builders sharp-sand and bentonite clay with a small amount of water to make it stick together
* Screening the sand to remove lumps
* Power the mold to help with release
* Packing the sand down hard and completely filling the drag
* First sand layer must be very fine and carefully forced into the smallest of gaps, later layers can be larger and less careful
* Leveling off to enable use of a backing board
* Flipping it over and then repeating on the cope
* Tapping and releasing the mold
* Touching up any defects, large defects mean starting again
Safe clothing
Overalls required - NON-SYNTHETICS ONLY!!
Jeans are good
Shoes Leather or natural fabric, NO SYNTHETICS, Steelies preferred. - Trainers NOT acceptable
MIG Welding gloves should be used, nothing else, no others have sufficient insulation and are non-melting
You can get specialized foundry versions of all of this kit, all of which are very effective and very expensive
Googles AND face shield when pouring, remember face-mask will burn if there is an accident
Dust masks
Beware of concrete spalling in case of spill
[copied over from old wiki]
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