something for the tourists...

 

First test cast of a "sugar skull" in aluminum bronze.  Working on casting this with customizable text on the back.  73,81,58,0,B

A heavy pour...

 

A bit sloppy with the molten metal, but I think it worked.  

Going to clean it up and polish it tomorrow.  Video Monday.

56,63,57, .27",C  

test and a half...

Did a parting test on the property marker today to see if the pattern would release OK from the mold (it did).  Wasn't planning on pouring into it but decided to go ahead as long as it was sitting there even though I knew it wouldn't work very well.  Open pours rarely completely fill a mold with fine detail unless it's a heated graphite mold.  This pour will need to be into a closed mold with enough head pressure to fill all the nooks and crannies.  At least now I know for sure how much molten metal I will need to fill this pattern (12 ounces). Nice thing about casting metal is that failed pours can be remelted for another try.  74,78.45,0,C

Two masters...

Two master patterns to cast from this weekend.  The pattern making takes a lot longer than the actual casting.  After 3D printing, they get about 10 coats of primer over several days to soften the edges of the pattern so they will release from the casting sand and leave good impressions.  It's always important to leave a good impression... 61,68,41,0,W

for larger casting projects...

 

Petrobond isn't quite as fine as delft clay - 

but it's a heck of a lot cheaper.

$65.95 only buys 4.4 lbs of delft clay.  

73,79,54,0,B

First batch...

...cast and ready for cutting, grinding, sanding, and polishing.  

90,94,56,0,B 

Golden Skull

 

88.92,56,0,B

copper bars

My steel mold works fine with aluminum but I discovered molten copper likes to fuse with it so I milled out a chunk of graphite to pour 200 gram copper ingots.  They drop right out of this mold no problem.  68,72,56,0,W

the pour...

junk yard find...

100 pounds of copper and 15 pounds of aluminum - enough to cast over 1000 coins in aluminum bronze.  I decided not to cast with brass...it's too toxic in its molten state.  This was my first test cast with aluminum bronze and it only had a few flaws.  But I am encouraged by how well the detail held up with this alloy.

82,87,44,0,B

 

Don't touch!

 

Tempered a few more new crucibles today at about 1400°. 

84,88,39,0,B

moldy...

Broke out the welder today for the first time in years.  Fabricated a steel ingot mold for batches of melted alloys I will use for coins.  70,75,49,0,B

The bronze age at TFL...

Fabricated some pouring tongs...

 

84,92,57,0,B

Ordered this crucible...

 

Graphite Foundry Crucibles are made from a combination of graphite and clay, and are recommended for melting precious, or non-precious metals and can handle large batches of material. Their thick inner walls can handle direct heat and open flame foundries. They can be used with propane melting furnaces as well as a standard torch method. Rated to withstand temperatures up to 2912°F (1600°C). Measurements: 5-1/4" high x 4-3/4" in diameter (exterior dimensions); 4-3/4" deep x 3-3/4" in diameter (interior dimensions). *The "#" in title represents the amount of aluminum that the crucible can accommodate (in pounds); the "Kg" is for the amount of kilograms of brass and copper capacities.

51,59,42,0,B