Tools/castingcrucible: Difference between revisions

Content added Content deleted

Inline

Latest revision as of 15:49, 9 November 2023

CM450PB Safety Tilt Crucible Furnace

This tool requires induction

Owing to it's dangerous nature, delicate nature, or expense, this tool requires that you be inducted on it's proper handling before use.

Introduction[edit]

The casting crucible in use with aluminium. The molten metal is being poured into a lost-PLA sand mold

Our casting crucible can melt up to a maximum 2 litres of brass, bronze or aluminium which equates to about 10Kg of copper alloys or 2.9Kg of aluminium and pour it into a variety of molds to form cast metal objects. It's rated for a maximum temperature of 1100C which is sufficient for aluminium, brass, bronze, lead, zinc and tin, but is not suitable for any type of steel, The high-temperature thermocouple from the Forge can be used to check what temperature it's operating at and make sure that it is not over-heated. Owing to the obvious safety needs when working with large ammounts of hot metal, this tool requires induction. The crucible is normally kept in the main workshop, under the workbench on the west side of the the hackspace, and some of the sand and accessories are kept underneath the storage shelves in the lobby area. The casting tray is kept outside behind the rear fire escape door. The manufacturer's instruction manual for the casting crucible can be found here

Current Status[edit]

Date	Status	Comment
10th September 2018	Fully Functional	No reported issues.

Costs[edit]

There's no official charge for using the casting crucible, but it does have some costs when it's in use. It consumes gas at the rate of approximately 1Kg/hr, which at 2018 prices is about £2/hr. The crucibles cost approximately £100 and last for a few dozen casts. If you're using scrap metals from around rLab for casting then scrap Aluminium is 75p/Kg (July 2018) so a full crucible would be about £2.25, scrap brass is around £2.80/Kg (July 2018) making a fully charged crucible worth £28. We ask that you consider these costs and think about an appropriate donation in the downstairs honesty pot.

Casting Caretakers[edit]

Inductions[edit]

Ian-P provides inductions on the casting equipment

Workshops[edit]

None yet, want to start one?

Maintainers[edit]

Ian-P and Steve-R maintain the casting equipment and should be contacted to report any issues.

Recent Changes[edit]

None found - Casting equipment fully functional and no immediate changes planned or expected

Image Gallery[edit]

Forming a conventional impression sand-mold using a 3D printed former
Ian(left),Rupert(centre) and Steve(right) positioning the mold and preparing the pour
Ian's completed casting of a candlestick, ready to remove sprus and risers
Steve packing down sand around a PLA mold of a burr for lost-PLA casting
Burning out the PLA in a lost-PLA casting of a burr
The finished burr cast in aluminium, the dull grey surface is a result of contact with burning PLA during the casting
Aluminium beginning to melt as the crucible heats up

@@ Line 1: / Line 1: @@
-{{toolsneedingattention}}
 <big><big>'''CM450PB Safety Tilt Crucible Furnace'''</big></big>
 {{thistoolneedsinduction}}
+== Introduction ==
-{{TOC left}}
+[[File:crucibleinuse.jpg|250px|thumb|The casting crucible in use with aluminium. The molten metal is being poured into a lost-PLA sand mold]] Our casting crucible can melt up to a maximum 2 litres of brass, bronze or aluminium which equates to about 10Kg of copper alloys or  2.9Kg of aluminium and pour it into a variety of molds to form cast metal objects. It's rated for a maximum temperature of 1100C which is sufficient for aluminium, brass, bronze, lead, zinc and tin, but is not suitable for any type of steel, The high-temperature thermocouple from the [[tools/forge|Forge]] can be used to check what temperature it's operating at and make sure that it is not over-heated. Owing to the obvious safety needs when working with large ammounts of hot metal, this tool requires [[tools/castingcrucible/induction|induction]]. The crucible is normally kept in the main workshop, under the workbench on the west side of the the hackspace, and some of the sand and accessories are kept underneath the storage shelves in the lobby area. The casting tray is kept outside behind the rear fire escape door. The manufacturer's instruction manual for the casting crucible can be found [https://www.flamefast.co.uk/fileuploader/download/download/?d=0&file=custom%2Fupload%2FFLAMEFAST_CM450PB_V5_LORES.pdf here]
+__TOC__
 == Current Status ==
 {|class="wikitable" style="margin: auto;"
@@ Line 12: / Line 12: @@
 | 10th September 2018 || Fully Functional || No reported issues.
 |}
-== Introduction ==
-Our casting crucible can melt up to a maximum 2L of brass, bronze or aluminium which equates to about 15Kg of copper alloys or just under 5Kg of aluminium. It's rated for a maximum temperature of 1100C and the high-temperature thermocouple from the [[tools/forge|Forge]] can be used to check what temperature it's operating at. It consumes gas at the rate of approximately 1Kg/hr, which means it has a use charge of £?/Hr and required [[tools/castingcrucibleinduction|induction]]
+== Costs ==
-[[Category:Tools]]
+There's no official charge for using the casting crucible, but it does have some costs when it's in use. It consumes gas at the rate of approximately 1Kg/hr, which at 2018 prices is about £2/hr. The crucibles cost approximately £100 and last for a few dozen casts. If you're using scrap metals from around rLab for casting then scrap Aluminium is 75p/Kg (July 2018) so a full crucible would be about £2.25, scrap brass is around £2.80/Kg (July 2018) making a fully charged crucible worth £28. We ask that you consider these costs and think about an appropriate donation in the downstairs honesty pot.
+== Casting Caretakers ==
+=== Inductions ===
+Ian-P provides [[Tools/castingcrucible/induction|inductions]] on the casting equipment
+=== Workshops ===
+None yet, want to [[Workshops|start one]]?
+=== Maintainers ===
+Ian-P and Steve-R maintain the casting equipment and should be contacted to report any issues.
+== Recent Changes ==
-[From old Wiki]
+None found - Casting equipment fully functional and no immediate changes planned or expected
-The space has acquired a FlameFast Tilt Crucible with the aim of casting aluminium.
+== Image Gallery ==
-Due to the temperatures involved, casting is a dangerous process, and the following precautions should be taken before using the furnace.
+<gallery mode="packed">
+File:Impressionmold.jpg|Forming a conventional impression sand-mold using a 3D printed former
+File:castinginprogrees.jpg|Ian(left),Rupert(centre) and Steve(right) positioning the mold and preparing the pour
+File:candlestickfinished.jpg|Ian's completed casting of a candlestick, ready to remove sprus and risers
+File:packingplamold.jpg|Steve packing down sand around a PLA mold of a burr for lost-PLA casting
+File:burningout.jpg|Burning out the PLA in a lost-PLA casting of a burr
+File:finishedburr.jpg|The finished burr cast in aluminium, the dull grey surface is a result of contact with burning PLA during the casting
+File:Metling metal.jpg|Aluminium beginning to melt as the crucible heats up
+</gallery>
+[[Category:Tools]]
-contents
-Setting Up The Crucible
-Pouring Aluminium
-Cleaning Up
-Risks and Mitigations
-setting up the crucible
-The crucible should be used outside, and should not be used in the rain. There is a steel tray that should be placed outside and then filled with sand. Place the crucible furnace on the tray and then connect it up to the butane, ensuring that all of the pipes and the regulator are fitted tightly and correctly. Once the butane is connected correctly, connect up the mains lead, and turn on the butane. <process for melting ali..... I assume the metal goes in cold?)
-pouring aluminium
-When using the crucible when it's hot, you should use the PPE provided (leather gloves, apron and face mask/shield). Ensure that there are no people crowded around the crucible when you're pouring, and ensure that anyone keeps a safe distance. When you start to pour the aluminium, the flame on the crucible will go out. This is expected behaviour!
-cleaning up
-Pour any remaining aluminium into the ingot mold and let it cool down. Let the crucible cool down as well and unplug it from the mains, and turn off the butane.
-Once everything is cool, put the crucible away on the shelf, and then put the sand back into the bin. Put away the tray tidily and sweep any spilt sand up.
-risks and mitigations
-Risk	Mitigation
-Water entering the hot melt
-Do not cast in the rain
-Ensure that anyone with drinks are kept well clear of the crucible when in operation
-Ensure others in the Hackspace are aware when approaching the area
-Open flame on crucible causing atmospheric dust to ignite
-Only cast outside
-Ensure no major dust creating activities are running while the crucible is in operation
-Hot melt hitting a cold surface (such as concrete) causing the melt to spread erratically, or potentially causing the concrete to explode.
-Only cast in the sand tray with the crucible on the sand.
-Ensure the sand is dry before beginning to cast.
-Fire
-Ensure all fire exits are clear of any obstructions or trip hazards.
-Ensure the correct fire extinguisher is available within reach
-Ensure gas bottles are kept at a safe distance
-Gas leak
-Ensure the area is well ventilated
-Ensure emergency shut offs work and are accessible at all times
-Check hoses and connections before use
-Burns from splashes/hot metal/hot equipment
-wear appropriate PPE (gloves, goggles, aprons) at _all_ times
-do not approach the crucible without the appropriate PPE
-Fumes might be given off by lost casting processes or melting aluminium
-only cast in a well ventilated space
-Do no inhale fumes
-Adding cold metal to hot melt can cause the metal to freeze and crack and/or damage the crucible
-Warm cold metal before adding it to the hot melt pool