Smelting

[MF294-4]

Has any one done any smelting? I have a lot of tractor pistons and I need to make some mower parts. Just trying figure out the quality. I do have some aluminum semi wheels which I assume would be very good quality. Thinking about getting a furnace. Thanks

 

[Charles in Aus.]

I have mucked about with aluminium casting a little , mainly making components for light fitting . Nothing really serious though .
The type of alloy is crucial , at first I used drink cans as the thin alloy melted quickly . That type of alloy doesn't cast particularly well , it won't produce fine detail no matter how good the mould is . Use cast alloy to cast alloy , old two stroke brush cutter engines are my favourite .

 

[Tony in SD]

Others will give you advice on the fine art of casting aluminum but I will touch a bit on safety. Make sure you are fully leathered up with a face shield that can withstand the temperature of the molten alloy. Make sure your roof does not leak or any other water source above you furnace. One drop of water in the molten metal will cause a violent eruption. Been there seen that. A drop of water will cause the molten metal to explode all over and if any of it hits you nnalert you will have an instant third degree and possibly fourth degree burns.

 

[circus]

I once used a stainless steel pot on a 20k btu kerosene heater to melt about four lbs. of aluminum. Guess it depends how much and how quick you need it. Note: the pot was just above the burner.
PS "Smelting" usually involves making metal.

 

[SkipperII]

Out here in the Northwest, we have a little silver fish, called Smelt. I thought you were going smelt fishing.

 

[drsportster]

In metal shop a mold exploded once the cause was said to be too much moisture in the sand . A blob ricocheted off the teachers head and another hit his shoe which instantly burned through burning his foot It was a fairly severe accident They make covers for your boots which i would wear for sure

 

[scootergmc]

I'm assuming these mower parts are outrageously expensive or obsolete, yes?

 

[560Dennis]

There’s a guy here that molds lead. Maybe he can do it or help you out.

 

[chvet73]

In metal shop a mold exploded once the cause was said to be too much moisture in the sand . A blob ricocheted off the teachers head and another hit his shoe which instantly burned through burning his foot It was a fairly severe accident They make covers for your boots which i would wear for sure

As a retired shop teacher I never had a furnace in my room. But did work with them in college and where I student taught. In the early 70s safety was a big topic in schools. But when it came to furnaces there was very little attention paid to it. Today I don’t think you could find a shop with a furnace in it.

 

[Richard G.]

Has any one done any smelting? I have a lot of tractor pistons and I need to make some mower parts. Just trying figure out the quality. I do have some aluminum semi wheels which I assume would be very good quality. Thinking about getting a furnace. Thanks

I have poured a lot of babbitt.
I poured some huge bearings for a coal conveyor years ago.
I have melted aluminum and poured thick bearings for syrup mills.
I melted aluminum cans to pour thick bearings and the finish was pretty smooth.
For heat, I have used a propane burner on a 20 pound tank, coal fire in a blacksmith forge, acetylene torch, and a small furnace that used propane.

 

[Steve in VA]

Has any one done any smelting? I have a lot of tractor pistons and I need to make some mower parts. Just trying figure out the quality. I do have some aluminum semi wheels which I assume would be very good quality. Thinking about getting a furnace. Thanks

Regardless of how you go, for the love of heaven, have a grade A respirator. Please.

 

[Stephen Newell]

You would still have to turn it on a lathe. I would think it would be easier to get a piece of round stock and turn a new aluminum to make a piston. You would be certain there is no air pockets in it.

 

[Andy Wickiser]

Has any one done any smelting? I have a lot of tractor pistons and I need to make some mower parts. Just trying figure out the quality. I do have some aluminum semi wheels which I assume would be very good quality. Thinking about getting a furnace. Thanks

Anyone remember Lindsay Publications? I bought this book from them but never got around to founding anything. Anyway it is an excellent reference to all aspects of making one-off parts via the casting process. I checked and it's still available on Ebay and other sources.

 

[drsportster]

As a retired shop teacher I never had a furnace in my room. But did work with them in college and where I student taught. In the early 70s safety was a big topic in schools. But when it came to furnaces there was very little attention paid to it. Today I don’t think you could find a shop with a furnace in it.

You can't find a school with a metal shop class anymore

 

[drsportster]

I have a letter from a CW AMMEN a foundryman expert . He said so many foundries went out if we have a war we are screwed He wrote " The COMPLETE BOOK OF SAND CASTING He also wrote a periodical called Foundrymens news . Fastinating guy

 

[JWA]

I have a letter from a CW AMMEN a foundryman expert . He said so many foundries went out if we have a war we are screwed He wrote " The COMPLETE BOOK OF SAND CASTING He also wrote a periodical called Foundrymens news . Fastinating guy

That can be said of many industries that have cut back or moved off shore. They can't be regenerated overnight.

 

[Hemmjo]

I have enjoyed metal casting since I was in the 8th grade back in 1964. Became a "shop teacher" stilll find the process fascinating.

Smelting is the process of extracting the desired metal from raw ore.

There is more to casting good parts than just melting some old cans and pouring the liquid into a mold. LOTS of variables come into play.

You might take a look at the Homemade Tools Forum. There are a few metal casting threads on there.

i have posted a few threads. These are somewhat detailed explanations of How I made a home foundry;

First furnace

https://www.homemadetools.net/forum/electric-crucible-furnace-106650

Elements

https://www.homemadetools.net/forum/crucible-furnace-heating-elements-106811

Final Furnace

https://www.homemadetools.net/forum/electric-crucible-furnace-update-106880

Casting parts

https://www.homemadetools.net/forum/casting-aluminum-parts-109156

There are many more on the HMT site;

https://www.homemadetools.net/forum/

 

[Mark-Ia]

You can't find a school with a metal shop class anymore

My Grandson attends a school here in Iowa that he takes metal working class. He loves it.

 

[38 Sears Roebuck]

Shop classes have pretty much disappeared around here also. What a shame.

 

[Tony in SD]

You can't find a school with a metal shop class anymore

My nephews daughter is welding in high school. Does that count as metal shop class ? In fact she intends on going to a VoTech to continue her welding education.