FOUNDRY STUFF

Casting metal would be a rather daunting undertaking, or so I thought.  I had built a furnace several years ago for hot glass work, but barely used it.  It was made from a 20 gallon barrel, lined with 3" of Kaowool.  Since the material was expensive, I brought it with me when I moved.  The burner I made for the original furnace was not very good, so I built a new one from information obtained from various sources on the net.  Actually I would have been totally lost without all the resources available here.  So far all my casting has been done using Aluminum, and some Zamak.  One of these days I hope to graduate to Brass. The pages will be broken down to cover : The Furnace ; Crucibles & Tongs ; home-made Muller ; Bench and Flasks, and  Lost Foam.

THE FURNACE

Looking into the top.  Sitting on top is a ring used to close the top somewhat.  Inside dimensions are  11" dia, by 14" deep.  There is 3" of Kaowool around the sides and on the bottom, with a 1/2" round piece of steel for a platform on the bottom.   The Kaowool is coated with ITC-100, for improved heat reflection, as well as to bind the Kaowool surface.  A piece of C channel is used for a plinth to raise the cruciible.  Rather than a solid lid, I made a ring out of Kaowool, wired to an angle iron frame.  It takes no effort to remove.

The furnace outside, melting Aluminum.  I made an angle iron frame with castors. to ease moving it around. One of these days (nights) I will take a pix of the inside of the furnace during a melt.  It does not show up very well in full daylight.

The jet tube (to which I added a small shutoff valve).  The nozzle tip was made from brass, with  .055 orifice (#54 drill).  I experimented with different orifice sizes, this one seems to work best for me.

The burner parts.  Jet tube on the bottom, the burner tube on top.  This is a type of "sidearm" burner, using a rotating disk for a choke.  The disk pivots, allowing more or less air to be aspirated in. I run it wide open.  The end flare was machined from a piece of stainless, with the recommended 1:12 taper.

The burner assembly, with the jet tube inserted into the burner tube.  a small set screw locks the jet tube in place.

Burner installed in the furnace body.  The stainless flare nozzle is positioned just about flush with the inside face of the furnace wall.  A small piece of angle was tack welded to the side of the drum, so the burner tube rests in the "V".  A hose clamp holds the burner in the angle.  I keep the choke to the top, it seems to reduce the effects of wind if any is blowing.

Home Foundry work is inherently dangerous.  The risk of personal injury / damage / fire etc can not be disregarded.  I assume no responsibility for the use or activity of any foundry-related items.  Just because I am nuts enough to do this does not mean you should !