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  1. #1
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    First metal casting

    I finally got to pour the mold that I made about 4 weeks ago in metals class. I had to fill up the crucible full of 6061 T6 aluminum slowly for about an hour, then wait about another half hour until the foundry heated the molten aluminum to about 1600f. Once that happened, I pulled the whole mess out of the foundry, set it in the pouring device, then me and my partner picked it up and poured the metal into the molds. As soon as the aluminum hit the styrofoam, all hell breaks loose. A huge flame shot up, which was highly unnerving, and stayed the length of the pour, filling the air with soot, smoke and awful gasses. This happens about 3 feet from your face, and you have to be very precise as you pour. This was called full-mold casting, where a styrofoam mold is placed in a bucket, then sand is packed around it and metal is poured onto the styrofoam. Whatever is styrofoam becomes aluminum. It is amazing what you can learn in college!

  2. #2
    Non Tribuo Anus Rodentum and off to the next adventure (RIP) Stacey's Avatar
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    College? Man we did that in 8th grade shop!

  3. #3
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    Quote Originally Posted by trekkie820
    I finally got to pour the mold that I made about 4 weeks ago in metals class. I had to fill up the crucible full of 6061 T6 aluminum slowly for about an hour, then wait about another half hour until the foundry heated the molten aluminum to about 1600f. Once that happened, I pulled the whole mess out of the foundry, set it in the pouring device, then me and my partner picked it up and poured the metal into the molds. As soon as the aluminum hit the styrofoam, all hell breaks loose. A huge flame shot up, which was highly unnerving, and stayed the length of the pour, filling the air with soot, smoke and awful gasses. This happens about 3 feet from your face, and you have to be very precise as you pour. This was called full-mold casting, where a styrofoam mold is placed in a bucket, then sand is packed around it and metal is poured onto the styrofoam. Whatever is styrofoam becomes aluminum. It is amazing what you can learn in college!
    that is freakin awesome. whats your major? I wanna do **** like that!

  4. #4
    The Red Lantern Rev.Chuck's Avatar
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    They are teaching this kind of stuff in college courses? That is great! Half the engineers I meet don't know what a capscrew is.
    Are you a registered member? Why not? click here to register. Its free, and only takes 27 seconds!
    Help out the forums, abide by our community guidelines.

    I am in the woods and I have gone crazy.

  5. #5
    2-Cyl, 1/2 HP @ 90 RPM slvoid's Avatar
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    Why didn't you use wax?
    We had a prototype machine like that, it'll make all the parts out of resin and fill in undercuts with wax. Then you warm it up, the wax melts out, and voila, a part.
    Or you can use the machine to "print" a wax model, then you encapsulate it and cast.

  6. #6
    2-Cyl, 1/2 HP @ 90 RPM slvoid's Avatar
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    Quote Originally Posted by Rev.Chuck
    They are teaching this kind of stuff in college courses? That is great! Half the engineers I meet don't know what a capscrew is.
    2 members of my senior design group for MECHANICAL ENGINEERING asked me during the initial design meeting what a worm gear was. Then the next week asked me what a torsion spring was.
    These are 4th year mechanical engineers...

  7. #7
    2-Cyl, 1/2 HP @ 90 RPM slvoid's Avatar
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    Quote Originally Posted by BeeTL
    I should have been an engineer! I knew about lost wax castings when I was 10. Instead, I sell insurance.
    You're that dude from fight club!
    If a plus b plus c is less than the cost of a recall, we don't do a recall...

  8. #8
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    This is all to become a shop teacher! I can't believe those design geeks didn't know about that stuff! Man, in this class we learn how to MAKE worm gears and threaded parts. There are a few of the design weenies in this class, and they are very timid about doing the welding, machining and pouring. Slvoid, we will be doing investment casting soon, so hold tight and I might make you some nice lugs or dropouts . Stacey, no WAY you did this in 8th grade! Maybe my 8th grade teacher was a wimp, but we barely even used saws.

  9. #9
    2-Cyl, 1/2 HP @ 90 RPM slvoid's Avatar
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    These days, kids don't give a damn and stupid parents are too much liability, it's a shame.
    You have engineers who grow up not knowing what pitch is in a thread, what major/minor diameters are, what the spacing should be between an internal and external thread, what tolerances are, how to properly machine something, how to design something that's machineable, designed for x, materials compatibility, etc etc...
    I think the days of seat of the pants, balls to the wall, from 0 - to the moon by the end of the decade, put your life on the line SR-71, x-vehicles, alpha class liquid metal titanium submarines are over, cept for those crazy fools chasing the x-prizes.

  10. #10
    Non Tribuo Anus Rodentum and off to the next adventure (RIP) Stacey's Avatar
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    Quote Originally Posted by trekkie820
    Stacey, no WAY you did this in 8th grade! Maybe my 8th grade teacher was a wimp, but we barely even used saws.

    Way. What readon do I have to lie to you. We did 'lost pattern' and 'cavity' casting in 8th grade... 1970-71. Again, why whould I lie?

  11. #11
    2-Cyl, 1/2 HP @ 90 RPM slvoid's Avatar
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    Quote Originally Posted by Stacey
    College? Man we did that in 8th grade shop!
    Sweet! You're the man!

  12. #12
    Non Tribuo Anus Rodentum and off to the next adventure (RIP) Stacey's Avatar
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    ^ Um, er yeah... whatever

  13. #13
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    Quote Originally Posted by Stacey
    Way. What readon do I have to lie to you. We did 'lost pattern' and 'cavity' casting in 8th grade... 1970-71. Again, why whould I lie?
    I guess I didn't mean "no way" as in "you're lying", it was more like amazement. I came from a sheltered, sweet little suburban junior high.

  14. #14
    I couldn't car less. jeff williams's Avatar
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    Quote Originally Posted by trekkie820
    Stacey, no WAY you did this in 8th grade! Maybe my 8th grade teacher was a wimp, but we barely even used saws.
    8th grade metalshop. I made the logo for the band KISS in 3D, cast alu, styro packed in sand.
    We welded in grade 9.

    He..I hated my woodwork teacher, he lifted me up by the throat one day in the hallway.
    So later that year, this stupid kid, just after we told him to put the guides and guard back on the table saw, choppes his thumb nail off.
    Little end, no bone.
    Anyway jerk teacher is out of the class, up the hallway doing what ever -wrong. He's supposed to supervise.
    So when he strolls in all casual i'm like "Billy just cut his whole thumb off, Where the hell were you!"

    Jerk started crying. Started doing his job too.
    Last edited by jeff williams; 02-15-05 at 09:48 AM.

  15. #15
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    Quote Originally Posted by MERTON
    yeah. but have you welded yet? i could make my own bike frame if i had a welder and some pipes...
    Yes, we have welded. I can weld aluminum, too, but not very well (yet). One requirement of the class is to write our names in a braze bead, and I am almost done with it.

  16. #16
    Senior Member Ebbtide's Avatar
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    Come home and I'll show some places that will pay you to do that 12 hours a day all summer long.

  17. #17
    Flatman RoadToad's Avatar
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    Quote Originally Posted by Rev.Chuck
    They are teaching this kind of stuff in college courses? That is great! Half the engineers I meet don't know what a capscrew is.
    What's a capscrew?

    Joking...RT
    BRING THE HEAT

  18. #18
    2-Cyl, 1/2 HP @ 90 RPM slvoid's Avatar
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    Cap, as in: "I been itching to bust a cap in yo dome."

  19. #19
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    Quote Originally Posted by Ebbtide
    Come home and I'll show some places that will pay you to do that 12 hours a day all summer long.
    That would be cool. I would love to do that more than clean windows all day.

  20. #20
    2-Cyl, 1/2 HP @ 90 RPM slvoid's Avatar
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    Don't get mesmerized by the little green pool when you're welding and burn through the AL...

  21. #21
    Senior Member Ebbtide's Avatar
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    The foundries along E.55th, Bessemer, and Woodland hire "labor" nearly daily. If you are not shy for busting your butt for 7-8 bucks an hr for a summer job, this might be for you.

    Another "cool" option is working around the new food terminal, all refrigerated!!

    Even consider doing some research over spring break and set something up for the summer. I use those industries as a referral source for those who can't find work elsewhere.

  22. #22
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    I make 9 an hour cleaning glass, even though I hate the job. My girlfriend's step-dad works in a foundry making aerofoils, so I might try that. They get some good money there. I'll check it out.

  23. #23
    2-Cyl, 1/2 HP @ 90 RPM slvoid's Avatar
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    Chief Financial Officer

    New York, NY 10013 25th%ile Median 75th%ile
    Base salary $248,948 $316,651 $411,934
    Bonuses $313,254 $429,707 $632,067
    Total median benefits: $518,735

    So assuming you're the median... $429,707+316,651+518,735 a year...
    And you work 8 hours a day + 2 hours over time and take 1 week off a year.
    That's 50 hours a week for 51 weeks = 2550 hours.
    So that's $496.12/hr.

    Son of a bit....

  24. #24
    Senior Member Ebbtide's Avatar
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    Quote Originally Posted by trekkie820
    I make 9 an hour cleaning glass, even though I hate the job. My girlfriend's step-dad works in a foundry making aerofoils, so I might try that. They get some good money there. I'll check it out.
    PCC Airfoils in Wickliff? If so get on board there, they pay great- cha-CHING BABY!!!! My cousin worked there as labor/maintenance and made over 50K his first year with OT and bonuses.

  25. #25
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    Actually, PCC in Mentor, but same company. I was going to try to get a job there after school, until I can find a teaching job. I'm not sure how they feel about seasonal employees.

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