Getting into smelting and casting

[Joebobber]

My oldest son got a smelting kit for Christmas so we've been melting down everything. We tried to sand cast a skull from a carved rock skull and it turned out ok. We did 2 more and I drilled and tapped then to fit the knobs on my drill press.

Is it possible to do pens/pen parts from just sand casting or do we need to do a lost wax or lost styrofoam?

Anyway, its been alot of fun. We took apart my old ice auger and pressure washer and a few other things along with pop cans. We just got up the nerve to do some brass.

 

[Kenny Durrant]

Pretty cool. I remember in my high school days casting with aluminum. You've brought back old memories. Thanks for sharing.

 

[Joebobber]

Pretty cool. I remember in my high school days casting with aluminum. You've brought back old memories. Thanks for sharing.

I've never done it before. My oldest son is autistic and was super interested in it so Im trying to help him.

 

[Kenny Durrant]

Sounds like a good way to interact with your son. Enjoy your time.

 

[egnald]

The sand casting "features" on the skulls made them exceptionally scary looking . Really cool! - Dave

 

[Amihai]

My oldest son got a smelting kit for Christmas so we've been melting down everything. We tried to sand cast a skull from a carved rock skull and it turned out ok. We did 2 more and I drilled and tapped then to fit the knobs on my drill press.

Is it possible to do pens/pen parts from just sand casting or do we need to do a lost wax or lost styrofoam?

Anyway, its been alot of fun. We took apart my old ice auger and pressure washer and a few other things along with pop cans. We just got up the nerve to do some brass.

There is a new thing today called "lost PLA casting", essentially using 3D printed parts as molds for the metal casting process. simple 3d printers are very affordable today, so you may check that out.

 

[derekdd]

Very cool!

The pen part casting I've seen on YT is using delft clay. Like Kenny, I remember doing sand molds while casting aluminum in MS.

Good luck!

 

[Joebobber]

I guess by the time I was in middle and high school it must've been considered too dangerous. I am a millennial afterall. Too bad, i would've loved to learn this before now.

Lost PLA casting hmm? That sounds interesting, but then I have to convince my wife we need a 3d printer. Lol

 

[Joebobber]

The sand casting "features" on the skulls made them exceptionally scary looking . Really cool! - Dave

Yeah there was some sand that must've fallen in the hole but its pretty cool I think.

 

[TDahl]

I do cast my own pent parts (clips, rings, cabochons), but have not done any casting with delft clay or lost wax. I use a rolling mill to get my metal blanks to the thickness I want (usually 1.5 to 2 mm) and then use basic jewelry tools to shape the parts. It looks like your casting system has great potential. Keep at it. Once you get your system down, the possibilities are endless.

 

[Woodchipper]

Interesting projects and good to spend time with your son. May be a market here for your castings. How big or small can you cast?
I remember driving by the US Pipe foundry in Chattanooga in the morning. They would be pouring off with the stream of iron glowing red/orange. Anyone seen where people pour molten aluminum down old ant hills?

 

[Joebobber]

I've seen the anthill pours. They are very interesting pieces of art! Right now we have a small 6x6 flask I made and out in the garage is an 18x18 i also made but we don't have enough sand for it.

As for size I really don't know. I mean bigger is easier but we've only done those skulls and then a pair of crosses for my grandma. My PSI tailstock isn't locking anymore so I was thinking I could try to make the lock lever and insert that holds the tightening nut but the lever was too big by a smidge. I don't know how Id make the vent or channels for really small parts like pen tips, unless I just did a small round blank and machined it into a tip. Might be neat to have a pen from my old fishing net and ice auger.

 

[Lmstretch]

I have been experimenting with casting, 3D printing and using silver clay to make military rank and symbols to make a Suto what parts pen with these items incorporated in the pen. I have not had much luck yet, because I am still learning. But the silver clay seems to show the most promises.

 

[Joebobber]

I have been experimenting with casting, 3D printing and using silver clay to make military rank and symbols to make a Suto what parts pen with these items incorporated in the pen. I have not had much luck yet, because I am still learning. But the silver clay seems to show the most promises.

What is that? Ive never heard of that. Is it like a milli-put or modelling clay that gets hard?

Eventually I'd like to try to make a receiver for a 10/22 or some other .22 out of brass. I am fairly certain it woukd be totally fine with lower velocity or even cb caps.

 

[Lmstretch]

The silver clay is like putty. You can make a mold using silicon or other materials and then you put the silver clay in the mold to achieve the shape you want, take it out of the mold, let it dry and then clean it up, after it is dry you heat it up to make it hard like silver. Some jewelers us it to make rings and pundits. The silver clay is expensive, the copper clay is a bit cheaper.