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Metal Casting

DIY Casting takes a certain amount of skill and knowledge not to mention the appropriate tools of the trade. Luckily, anyone can learn metal casting and the tools are widely available and some can even be crafted right at the home workshop.

Most of the Metal Casting tools are pretty standard and can be used for the different casting processes. If you already familiar with metal work then the chances are pretty good that you already have some of the tools in your garage or workshop. In fact, it is possible to make many of the tools that are commonly found in small foundries.  If you are unable to make your own tools then there are many online resources where you can buy tools and even home improvement stores will have the tools.

The absolute must have metal casting tools will be used for safety. Safety in the home foundry is a must since any accidents that can occur will more then likely result in devastating injuries, remember safety first.

Gloves will be necessary when pouring the molten metal or picking up the crucible with the aid of heavy strength tongs. Its important to always practice safety and you will have extreme heat coming from these molten metals so its best to have protective clothing on your arms and legs. Jeans and work boots will help prevent any injuries in case of spills. Sometimes people aren’t aware of this but if you spill metal on places that are wet or have been wet recently, then it will splatter and it can be dangerous. Even concrete can cause molten metal to splatter that is why metal casters always keep a muffin tin on hand where any excess molten metal can be safely stored. Always wear goggles when working with intense flames to avoid eye damage. Without the appropriate safety gear injuries are pretty much guaranteed. 

The furnace is the most important tool of the trade when it comes to metal casting. This tool does not necessarily have to be large and can even be as small as a flower pot. Size does not matter and even the smallest of furnaces can melt your alloy. The individual tools used in the furnace can differ. Not all of them will use a crucible but all of them will use a fuel source and require a refractory of some sort to help shield the furnace and direct the heat.

The crucible is where you place the metal to be melted. It pools inside the crucible and with help of tongs which can be made in a workshop is transported to the mold to be poured. Sometimes you will need a ladle in order to transport the mold if you have a furnace that doesn’t use crucibles. The desired shape of the molten metal bascially is caused by the mold that the metal is poured into. The mold consists of two pieces a cope and drag. Cope and Drag are used to describe the mold and the cope is the top part of the mold and the drag is the bottom part of the mold. The sprue is where the molten metal enters the mold. After the metal solidifies the sprue is cut away from the cast.

Metal Casting involves many other tools some of which are used for all processes and some are not. The tools needed change from job to job. When you start out in metal casting make sure you gather all the needed tools before you begin. As you start new jobs or look at doing new projects then you can start o gather more tools in your inventory.

 
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Casting

Metal Casting has endured through the ages since the time of Ancient Egypt, possibly longer. Since then small foundries have developed to meet the needs of the individual caster. There are several reasons that people choose to create their own home grown foundries. A top reason is the need to create parts and pieces that are no longer available on the market or that are just too expensive to purchase. Those who get into Metal Casting for this reason are usually interested in restoration projects, home improvement projects, or hobby building like model planes and trains. Artists are the other group that see metal casting as a cheap and easy way to create sculptures from small to large. Jewelers even use metal casting to create complex pieces that would just otherwise be impossible to create.

Given the wide scope of metal casting there are several methods and techniques that have developed. For those new to metal casting or for those wanting to try some of these other methods may find it difficult to find information on your own. Luckily, there are several metal casting associations and groups that are more then willing to share information and exchange ideas, projects, and pictures of the goings on in the their home foundries.

On the internet, Metal Casting associations and groups are either message boards full of casters where they can ask questions, post ideas, and pictures or are websites that are maintained by a set group of people offering general information and educational resources.

Both of these types of websites are incredibly helpful to metal casters who can benefit from the educational purposes of some of the sites tempered with the real life applications and experiences of the message boards.

The majority of the information that will be easy to find will be geared at industrial and manufacturing foundries versus the small home foundry. Industrial metal casting sites can be wonderful sources of information so do not skip by these. Use both small metal casting sites and industrial sites to your advantage.

If you are looking for a great group online, you should visit the Casting Hobby Group found through Yahoo Groups. This casting group was developed and maintained by experienced metal casters and enjoys a high amount of activity. If you are looking for quick simple information, lots of ideas, photos of furnaces, and potentially some furnace building plans, then you’ve hit the right spot by going here.

The Casting Hobby Group can be found at http://groups.yahoo.com/group/castinghobby/

The Association of Backyard Metal Casters is located at http://www.abymc.com/.  This online metal casting association has an extensive membership complete with informative articles, forums, and even live chat. Of course, pictures are posted on the site to give visitors ideas about what other furnaces and foundries look like. Don’t worry if you’re foundry isn’t pretty, there actually doesn’t seem to be very many of them that are.

Now, The American Foundry Society is mainly for the industrial metal casters and companies but they also promote information and education to consumers. The information provided on the site is great for anyone wishing to follow advancements in metal casting technology. There is even an online store.

http://www.afsinc.org/ is the online home for the American Foundry Society.

For the most part metal casting associations and groups exist on the local level more than a unifying force on the web. What does exist on the web is a great source of information, ideas, and insight. It is a great idea to join any of the groups you can in order to share and find knowledge.
 
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