How to make an aluminum casting mold

Aluminum casting: features and process, equipment and mold production, operating algorithm

Casting aluminum at home is a process that can be done by a DIYer, but it must be done according to a specific technique. You need to know the characteristics of the material itself and understand how to work with it correctly.

Aluminum is a material widely used in various types of industry; it is also suitable for home casting. Its advantages are:

1. Versatility in use;
2. Good performance characteristics;
3. Relatively light weight;
4. High indicators of ductility and malleability.

It also has disadvantages . In particular, metal does not lend itself well to certain types of processing.

Casting process

Thanks to casting, you can quickly make various devices based on aluminum for domestic or industrial needs.

The process can be performed under pressure or using molds. In the first case you will need:

1. Special equipment;
2. Specialized technological knowledge;
3. Press forms.

The process is also performed using conventional molds, which are made on the basis of a special homemade mixture. The production technology is quite easy to master. Aluminum has high ductility, thanks to which it can take on any shape. Its melting point is more than 600 degrees.

Previously, to make aluminum parts they used molds that were inserted into the ground, then homemade plaster molds began to be used. Now there are special molds from which parts are made under pressure.

At large enterprises, casting is carried out under high pressure and shrinkage is practically absent. Special machines and equipment are used for the work. The technological process is quite complex:

1. The required working pressure is created due to the operation of the piston, and it is driven by compressed air;
2. Oil and emulsion help speed up movement;
3. The material, heated to the melting temperature, quickly enters the mold under pressure and fills it completely.

Products produced in this way rarely have any defects and are highly accurate. This technology is relevant in the manufacture of parts for aircraft manufacturing and instrument making. Molds allow the use of molten metal at any temperature.

To produce aluminum parts for various purposes with high precision under pressure, you will need special equipment: an automatic machine and durable molds. For aluminum casting, they are usually made from steel alloys.

Their casting surface must be almost ideal; no distortion of the geometric configuration and size is allowed. The mold must be equipped with a mechanism thanks to which the finished part can be removed from it without difficulty. In addition, it must also contain movable metal rods, with the help of which the internal cavities of the workpieces are formed.

Future products that you will pour into special molds will need to be given one or another configuration, which mainly depends on the molds themselves. This type of foundry process also uses specialized machines and other equipment.

Casting machines can have a cold or hot chamber in which the mold pressing process is carried out. Typically, hot chamber metal melting machines are used to produce predominantly zinc-based alloys. The required pressure is pumped into them using a piston or compressed air. Under pressure, the molten mixture is slowly forced into pre-prepared molds.

And machines that use cold pressure are mainly used when it is necessary to make castings with the addition of copper and magnesium alloys . In this case, the molten mixture during the casting process enters the molds under very high pressure, sometimes it can be about 700 megapascals.

Thanks to injection molding, it is possible to achieve high performance in terms of productivity, and there will also be no need to subject the parts to additional machining. The machines differ by model depending on their operating parameters.

Production of molds

Special casting machines are practically not used at home. This is not advisable not only due to the high costs of purchasing them, but also because the process is quite technically complex. Moreover, the equipment that operates under pressure is very large.

At home, aluminum-based lost wax products are given the required shape manually. You can also make the form yourself. Many home craftsmen use the “in-ground” casting technique, thanks to which they can ultimately obtain the necessary aluminum parts without special equipment.

You can give the models of forms that you have to work with a certain configuration, and the forms themselves are made using scrap materials with your own hands. In particular, the form can be obtained from simple cement mortar. In such a situation, the lost wax can be given a rectangular or square shape. On the Internet you can find video tutorials on how to properly pour aluminum into cement.

Plaster molds are often used for casting. In such a situation, plaster models can be given almost any configuration. A very important indicator when working with molds is the shrinkage of the material. When it hardens, it should be minimal.

When pouring aluminum, models can be given the desired configuration through the use of wax. But here it must be said that only small parts can be made using wax using aluminum. Thanks to a number of performance characteristics, wax models can be given even complex configurations, but parts can only be manufactured in this way once.

Using the foundry method, you can easily produce parts on a predominantly duralumin base. Dural is a material consisting primarily of an aluminum alloy with a number of other components. But you need to know that the blanks that are smelted on its basis take a long time to harden.

Models that are used for metal casting must be prepared: they will need to be cleaned and oil applied as a lubricant.

Algorithm for working at home

Making aluminum parts using the foundry method at home is not that difficult; the process does not require expensive special equipment. Those models that will take part in foundry work will need to be cleaned from above and lubricated from the inside. Preparation will also be required when you practice the “in-ground” casting method. Be sure to check that the technological recess along its contours strictly corresponds to the contours of the future part.

As mentioned, the shrinkage of molten aluminum is an important parameter during operation. When filling, it should be minimal, otherwise the part will not correspond in size to those that were specified.

In order for the shrinkage to be minimal when the metal hardens, it will be necessary to make a small clay edging on the mold, along which molten aluminum is poured into it.

To melt the metal, a steel container and a special stove are usually used. At the same time, when performing work, do not forget about safety rules. If you decide to engage in the foundry process at home, you must follow personal safety rules. Be sure to wear special clothing that will protect your skin from possible burns.

Below we have discussed the key aspects associated with the aluminum casting process, both in industrial and domestic settings. As you can see, anyone can do this at home; the work does not require expensive equipment; with the help of improvised tools, you can learn how to make all kinds of aluminum parts without leaving home.

Source: https://tokar.guru/metally/alyuminiy/lite-alyuminiya-v-domashnih-i-promyshlennyh-usloviyah.html

✅Aluminum casting molds

Metal casting molds can be made of any material. Earth molds for aluminum casting remain one of the very first and used today. The process of casting in this way consists of creating a mold from sand and clay according to a specified template, into which molten metal is poured.  

The strength of the molding substance is determined by the percentage of clay present: the more clay, the longer the substance is not destroyed by shocks during the manufacturing process, during transfer and during pouring of the metal alloy.

Clay also affects the plasticity of the molding mixture - the ability, when wet, to reproduce in great detail the imprint of the model being made and to maintain the exact shape of the part when casting aluminum.

Lost wax casting of aluminum in plaster molds.

This method makes it possible to use directional hardening and obtain high-quality small and medium-sized castings at a lower price. The gypsum mold does not warp from the hot pouring metal and is not susceptible to temperature changes, which increases the accuracy of the lost wax casting and makes it possible to produce complex and thin-walled parts.

High-precision aluminum parts are cast under pressure using automatic machines and special equipment. In this case, metal molds are used, which are characterized by high strength and ideal surface quality. The mold for casting aluminum must contain movable steel rods, which participate in the formation of internal cavities of the workpieces.

The melted products in such forms can be given any configuration.

Using foundry equipment at home is not only economically unprofitable, but also inconvenient. Such equipment is large in size, and the technological process itself is labor-intensive.

They give products the desired shape using the method of casting aluminum into molds made of earth and cement. You can create castings of various configurations, since the molds can be created from available materials.

A given part can be obtained by casting aluminum into cement. Only the lost wax blanks will need to be shaped into a square or rectangle.

For home casting, plaster molds are often used. Models can be given any shape; the main indicator is shrinkage, which should be minimal when hardening.

A complex configuration of parts can be made from wax, but the models are disposable.

Using casting, you can create a part based on the material duralumin, presented in the form of an alloy of aluminum and some specific components. Duralumin blanks will have one drawback - time is required during the solidification stage.

It is not at all difficult to set up the production of aluminum parts at home without spending money on the purchase of expensive equipment. Models for casting should undergo preliminary preparation - clean the surface and apply oil to it. When casting aluminum into a cement mold, preparation is also necessary. Care should be taken to ensure that shrinkage of molten aluminum is minimal. Otherwise, the parameters of the received part will not correspond to the specified one.

For melting metal, a steel container and a furnace are used, which can also be made independently from a pan, tank, disk wheel and other household attributes.

When casting aluminum into cement and earth, when casting aluminum into plaster molds, it is recommended not to forget about safety precautions, for example, wear protective clothing to protect the skin from possible burns.

Product Production timePrice

Bronze blank 3 kg	2-3 days	1620 rub.
Cast stand blanks	5 days	450 rub.
Iron casting	5 days	90 RUR/1 kg
Aluminum casting	5 days	290 RUR/1 kg
Bronze casting	5 days	540 RUR/1 kg

Characteristics

Source: https://mos-lit.ru/zakaz/formy-dlya-litya-alyuminiya.html

Aluminum casting at home: making molds, technological process:

As a child, many people tried to smelt lead. The material could be found in used batteries. It melted quickly in the fire and poured well into simple shapes. Casting aluminum at home is also possible. This metal is more practical and is of particular interest to original craftsmen. However, for casting it is necessary to provide twice the temperature, and the flame of a fire will not be enough for this.

Aluminum: characteristics

Before the discovery and implementation of an accessible method of industrial production, this metal was considered precious. At a certain historical stage, it was more expensive than gold. Its properties could be used in many industries.

Aluminum is a lightweight and ductile material. It can be stamped, bends, and molds well into complex shapes, especially under pressure. Its melting point is 660 °C, which can be achieved without industrial equipment.

This means that casting aluminum at home is quite possible.

Who will benefit from this? Aluminum is a proven material. It was used to make dishes and parts for the aviation and space industries. Castings with good thermal conductivity, corrosion resistance and acceptable strength are valued by tinkerers. The material is suitable for making souvenirs, decorative elements of utensils, for repairing or restoring parts and components in equipment.

Aluminum casting at home

The melting point can be reached without the use of industrial technologies in various ways. In the old days, blacksmiths forged steel and heated it with the energy of burning coal. This is the first option, but to implement it you will need a forced air furnace.

The second option is the use of natural or liquefied gas. The process can be organized in a homemade oven. There is another possibility if the melting volumes are insignificant. In this case, you can use a household gas stove.

Aluminum casting at home can also be organized if the household has an acetylene generator and a cutter. An option with an electric muffle furnace is also suitable. Such equipment can already be classified as industrial. But if you don’t want to make a stove, it’s quite possible to rent it and order the service of an operator.

Technological process

In principle, the situation of industrial casting should be modeled with a reservation for home conditions. In any case, it is necessary to prepare the raw materials. Aluminum scrap is cleaned of dirt, foreign impurities, and all kinds of fillers. Large parts are crushed to the desired size.

Aluminum casting technology consists of several stages. The prepared scrap is melted using the chosen method. When the fluid phase is reached, the slag is removed from the surface of the melt. In the final phase, the mold is filled with liquid metal. The disposable form breaks after cooling.

First you need to decide what is to be cast. Even if this is a trial attempt at melting, it makes sense to prepare at least some form. What if it is possible to reach the desired temperature? It is interesting to see the result of melting and evaluate the results: appearance, porosity, cleanliness. Any experience, even a bad one, will be beneficial.

Conditions and necessary equipment

When melting secondary raw materials, the coating burns, fumes are released, and there is smoke. Working in an enclosed space without an intensively functioning hood is problematic. The best option is open space.

Even in this case, an additional source of ventilation will be useful. Molding casting of aluminum into foam plastic is accompanied by intense release of combustion products. A fan with side ventilation of the work area will remove acrid smoke, which will ensure normal conditions for casting.

A well-equipped and well-organized workplace is also important. It is advisable to have sheet metal or another surface as a base on the table that is not susceptible to the high temperature of molten aluminum. The likelihood of splashes and spills of liquid mass is high. With this in mind, you should think about the need to carry out work in a residential environment.

Homemade smelting furnace

The easiest way is to take a few refractory bricks and build a fireplace out of them. It is convenient to do this in a suitable metal container (an old pan), which will be used as a frame. A hole is made on the side for connecting the air supply pipe. You can adapt a piece of metal pipe of suitable diameter. A vacuum cleaner hose, hair dryer or other air supply device is connected to it.

Charcoal (stone) charcoal is placed inside. The fire is lit and the air supply is turned on. The vessel where the aluminum will be melted is installed inside the furnace. It is also lined with coal on the sides. It is advisable to put a lid on the stove so that the heat does not go away in vain, but leave only a hole for the smoke to escape.

Ideally, the firebox is made solid with an oval arch. Special mixtures are used for laying heat-resistant bricks and lining furnaces. Such a structure can easily be built from an old bucket. The inner vault is formed using plastic flower pots of a suitable size. A metal mesh can be embedded inside the reinforcement mass. After the mixture hardens, you will get a high-quality furnace that can withstand more than one heat.

Using a stove

Piece casting of aluminum can be organized without the manufacture of a special furnace. The required temperature is achieved using domestic gas. The smelting process itself takes about half an hour if the volume of aluminum does not exceed 100-150 grams.

A tin of condensed milk, for example, is used as a container. Cleaned and crushed aluminum scrap is poured into it. But you won’t be able to melt it by placing a tin can on the grate over the burner - there won’t be enough temperature. To reduce the loss of thermal energy, the inventors came up with a clever design.

A can of raw materials for smelting is placed inside another tin and placed on spacers so that there is a gap of 5-10 mm from the bottom to the bottom and from the sides to the walls. The second jar, accordingly, should be of a larger diameter. A hole (3-4 cm in diameter) is made in it from below to supply a jet of flame. The divider is removed from the gas stove burner.

The flame is ignited. The structure is installed strictly above its wick. The flame should go inside and heat only the tin with the crowbar. A larger diameter jar acts as a shell and retains heat inside. The opening is covered from above, leaving only a gap for the combustion products to escape. The combustion intensity is adjustable.

Crucible and auxiliary equipment

A tin can can withstand one heat. Its further use is possible, but with the risk of being burned through. In this case, molten aluminum runs the risk of getting inside the stove, which can not only lead to clogging of the burner nozzles.

To work in a furnace running on coal or liquefied gas, and indeed for reusable melts, it is advisable to make a special container - a crucible. It is made of steel. A piece of pipe with a welded bottom will do. A good option is made from a cut-off fire extinguisher or a small-sized oxygen cylinder with an oval arch. It is advisable to make a side gutter for easy pouring of a thin stream.

What additional equipment may be needed for aluminum casting? Reliable pliers or their version with clamp fixation will come in handy. Ideally, the crucible can be equipped according to the principle of industrial designs: with side grips of a removable suspension and a lower fixed stop for ease of turning it over. You need a spoon with a long handle to remove slag from the surface of the melt.

Simple forms

What are the methods for casting aluminum? The easiest way is to pour the molten metal into a metal mold: an old mug, a frying pan, a tin can. After cooling, the blank is removed. It’s easier to do this if you tap the mold while it’s not yet cooled down. If it had grooved sides or reverse corners, the frame will have to be cut. You can simply pour a slightly cooled drop of metal onto a prepared fireproof surface. Such methods are called open.

If there is a need to make a special casting, you first need to prepare a mold to fit it. In order for the metal to acquire clear outlines after cooling, closed molds are made from two or more component parts. One of them is the main one, and the other usually forms the arch or lateral surface. Holes are made in it. Often another part of the form is added above them - funnel-shaped flyers for convenience.

Material

Aluminum casting molds, depending on the method, can be produced using different technologies. There are several simple options. For open pouring into a simple mold, sifted earth (silica) is often used. It is laid in layers and compacted. After removing the forming element, the earth holds its shape and withstands pouring. This material is simple and cheap to use.

There are craftsmen who pour aluminum into sand. When mixing, use liquid glass (silicate glue). There is information about the use of cement. The mixture is mixed, oddly enough, with brake fluid. Knead with your hands and rub through a sieve to avoid lumps. The consistency should be such that when clenched in a fist, a lump forms. When tamping, sand and cement are well held inside the flask and even repeat small details of the workpiece shape.

Manufacturing of complex shapes

Castings of complex configurations are made using a different technique. The most common material is gypsum (alabaster). Forms without reverse corners and undercuts can be collapsible and consist of two or more parts. They won't last long, but it's quite possible to get a few castings.

A complex knot or decorative three-dimensional model can be made once, but the mold will have to be broken. There are two methods at work. You can make a wax (paraffin) model and fill it with plaster. Later, during the intensive drying process, this material will melt and flow out through the flaps.

Casting aluminum into a plaster mold using foam plastic involves making a model of the future casting from this material. It is filled with the prepared mixture and cannot be removed. Molten aluminum is poured over the top. The temperature of the metal melts the foam, it evaporates in the process, and liquid aluminum fills the space vacated.

Casting errors

Making molds from plaster is a convenient and inexpensive way. But there is moisture in the material. With natural drying it remains. When molten metal is poured, moisture begins to evaporate rapidly. Even intensive oven drying does not guarantee its complete absence. Depending on the amount of moisture remaining in the mold, the aluminum casting may have small pits or large frozen bubbles and craters.

If the metal was not heated up enough or it had time to cool before pouring, the aluminum does not pour out well and does not fill the volume of the mold. In fact, a drop is formed that does not have sufficient fluidity. The same thing can happen when using a small amount of metal in a cold form. Aluminum gives off heat quickly and does not have time to spread.

Experienced craftsmen do not recommend immersing the casting in water to speed up its cooling. In such a material, damage to the internal structure and the appearance of microcracks is possible. Such workpieces may not be suitable for subsequent turning.

Safety

The technological process involves the use of open fire, which imposes additional restrictions. It makes sense to check the availability of fire extinguishing equipment, the serviceability of gas appliances, and ventilation in the room.

Working with molten metal is a dangerous technological process. All operations must be carried out in compliance with safety regulations. Special clothing and respiratory and eye protection are required.

Source: https://BusinessMan.ru/new-lite-alyuminiya-v-domashnix-usloviyax-izgotovlenie-form-texnologicheskij-process.html

Aluminum casting: characteristics and methods of creating an aluminum casting mold

In production workshops, aluminum casting is carried out using automatic machines.

Machines of different models are presented in a large assortment at the IMSTEK company.

All equipment is from the best Chinese and Taiwanese manufacturers. It features a high degree of automation and impeccable quality.

Fig.1. Aluminum casting machine DC-250V4N

Characteristics of aluminum

Aluminum is a ductile, lightweight silver-colored metal. It bends well, lends itself well to stamping, casting, and metalworking.

In air it quickly oxidizes, forming a thin oxide film that protects against corrosion.

Characteristic properties:• low density;• high electrical conductivity;

• low melting point, about 660°C, with a boiling point of 2500°C.

In the molten state, the metal spreads well, filling the molds for casting aluminum.

Its high plasticity allows it to be rolled into the thinnest foil used to create packaging.

Excellent technical and performance qualities allow the use of aluminum in transport engineering, construction, electrical engineering, and the production of consumer goods for various purposes.

Home aluminum casting technologies, materials and equipment

Due to its relatively low melting point, cast aluminum parts can be produced in a handicraft manner.

Products are manufactured in the following order: 1. Melted wax or paraffin is poured into a container having the parameters of the future part and left until completely hardened.2. A mock-up of the future part is cut out from the cast blank, placed in the prepared formwork and secured.3.

A mixture of gypsum or cement, fine sand and water is mixed until creamy and poured into the formwork. In this case, the workpiece must be completely covered with the solution.4. The form with the solution must be slightly shaken to remove air bubbles.5. After gaining strength, paraffin is melted out of the plaster mold, and the gypsum is completely dried.6.

Raw materials are melted in special furnaces or using burners.

7. The oxide layer is removed from the top of the melt, and the hot metal is poured into the finished molds.

For work you will need:• aluminum scrap;• gypsum or cement mortar;• wax, polystyrene foam or paraffin;• a container made of cast iron or stainless steel;

• a furnace for heating metal, a gasoline or gas burner;

To prepare the amount of raw materials required for pouring, you need to determine the weight and weight of the future product using a metal calculator.

Homemade furnaces and methods for melting aluminum

In manufacturing plants and foundries, metal is melted in crucible induction furnaces.

Homemade smelting is possible in homemade furnaces or devices powered by gasoline or gas burners.

The muffle furnace has a special chamber that isolates the molten billet from contact with coal or combustion products.

The heating chamber can be made of fireclay fire-resistant bricks, clay or thermal insulation panels ShPGT-450. To reduce heat losses, the outside of the muffle furnace can be insulated with mineral basalt wool.

Heating in such a furnace comes from coal, gas or electricity.

Electric ovens are the most popular and efficient. They quickly reach the required temperature. They do not take up much space and are distinguished by their clean production.

Fig.2 Homemade electric muffle furnace

Operating principle of coal furnace:1. A container for melting raw materials is installed in a chamber lined with fireclay bricks.2. Coal is placed around and ignited.3. Air is supplied from below to support combustion.

4. Smoke from burning coal is removed into a hole or pipe left in the lid.

Fig.3. Diagram of a homemade stove: 1. Cover with an opening for the exit of flue gases; 2. The walls of the furnace are made of fireclay bricks, clay or slabs; 3. Crucible for aluminum; 4. Cast iron grate; 5. Door for ash removal; 6. Ash chamber; 7. Air supply; 8. Coal chamber.

Small workpieces weighing up to 150 grams can be melted using gas or gasoline burners, using tin cans of different sizes.

Fig.4. Melting device with gas burner

Methods for creating molds for aluminum casting

To produce products using the melting method, you need appropriate molds for casting aluminum.

They can be made from gypsum, cement, a mixture of sand and liquid glass.

1. Open casting method

Simple products are made in open molds. For this purpose, adapted containers in the form of tin cans, boxes, frying pans, and homemade plaster molds are used.

2. Closed form

Complex parts and assemblies are created in closed split molds for aluminum casting. They usually consist of a main piece and two or more side or top pieces. Funnel-shaped openings are made in the upper part of the mold to supply metal.

Materials for casting molds

Aluminum casters most often use gypsum or cement mortar to make molds.

The model of the part is made of wax, polystyrene foam or paraffin.

Plaster molds

The wax template is installed in a box or box that acts as formwork, fixed and filled with gypsum mortar.

For making the mold, white plaster, grade G-7, is better suited.

During the process of setting and drying the mold, the paraffin or wax is melted and poured out. Hot aluminum is poured into the resulting cavities.

If foam is used as a model, hot aluminum is poured over the foam, melting it and forcing it out of the mold.

Common mistakes and tips for proper casting

Aluminum casting is a complex process that requires complex operations. If you decide that casting products is within your power, feel free to get down to business.

It is important to soberly assess your capabilities, stock up on the necessary materials and listen to the advice of professionals: 1. It is important to heat the melt to the right temperature to ensure good flow across the mold and prevent voids from forming. Too high a melt temperature can also affect the strength of the finished products.2. It is better to use soft types of aluminum products as raw materials.

Solid samples may contain a large percentage of oxides.3. When pouring metal into plaster molds, you must wait until they dry completely. Otherwise, evaporated moisture can create cavities and pores on finished aluminum parts.4. It is not allowed to harden hot castings in cold water, since sudden cooling may cause internal stress and shrinkage of the metal.

5.

When installing a furnace with electric heating elements, it is necessary to provide grounding of the structure.

When performing the sequence and technology of work, casting is an accessible process for creating aluminum products in artisanal conditions.

Source: https://imstech.ru/articles/lite-alyuminiya/

How to make an aluminum casting mold - Metals, equipment, instructions

Casting aluminum at home is a process that can be done by a DIYer, but it must be done according to a specific technique. You need to know the characteristics of the material itself and understand how to work with it correctly.

Aluminum is a material widely used in various types of industry; it is also suitable for home casting. Its advantages are:

1. Versatility in use;
2. Good performance characteristics;
3. Relatively light weight;
4. High indicators of ductility and malleability.

It also has disadvantages . In particular, metal does not lend itself well to certain types of processing.

Necessary equipment

To produce aluminum parts for various purposes with high precision under pressure, you will need special equipment: an automatic machine and durable molds. For aluminum casting, they are usually made from steel alloys.

Their casting surface must be almost ideal; no distortion of the geometric configuration and size is allowed. The mold must be equipped with a mechanism thanks to which the finished part can be removed from it without difficulty. In addition, it must also contain movable metal rods, with the help of which the internal cavities of the workpieces are formed.

Future products that you will pour into special molds will need to be given one or another configuration, which mainly depends on the molds themselves. This type of foundry process also uses specialized machines and other equipment.

Casting machines can have a cold or hot chamber in which the mold pressing process is carried out.

Typically, hot chamber metal melting machines are used to produce predominantly zinc-based alloys. The required pressure is pumped into them using a piston or compressed air.

Under pressure, the molten mixture is slowly forced into pre-prepared molds.

And machines that use cold pressure are mainly used when it is necessary to make castings with the addition of copper and magnesium alloys . In this case, the molten mixture during the casting process enters the molds under very high pressure, sometimes it can be about 700 megapascals.

Thanks to injection molding, it is possible to achieve high performance in terms of productivity, and there will also be no need to subject the parts to additional machining. The machines differ by model depending on their operating parameters.

Equipment for casting aluminum at home

[Casting aluminum at home] can be done using several different techniques, each of which has its own advantages and some disadvantages.

In general, aluminum is currently widely used in a variety of industrial fields.

This versatile metal is also very popular among home craftsmen.

The high demand for aluminum is explained by the optimal performance characteristics of this material and its relatively low weight.

In addition, aluminum has high ductility and ductility.

Meanwhile, despite a large number of advantages, aluminum is still difficult to handle various types of processing due to some of its characteristic features.

 Casting allows you to quickly produce a variety of parts for industrial and domestic needs from this universal material.

The process itself can be carried out both under pressure and using molds. In the first case, special equipment and technology will be required.

This method involves the use of special molds.

The easiest way to cast aluminum with your own hands is using ordinary molds, for which you should prepare a special mixture.

In this case, a certain technology is also used, which is quite easy to master.

Features of the industrial process

People have been melting and, accordingly, casting all kinds of aluminum parts for many years.

Its melting point, which is just over six hundred degrees Celsius, does not require the use of any specific equipment.

Due to its high plasticity, this material can take on almost any shape.

Initially, to make parts from aluminum by casting it, they used various forms that were inserted into the ground.

A little later, plaster molds appeared, which were made by hand.

Currently, it is practiced to use special molds, with the help of which a wide variety of aluminum parts are manufactured under pressure.

It should be noted that in both cases, the melted parts can be given almost any desired shape.

In any case, the technology for casting this metal has always remained practically the same, with the exception of some features.

Today, large industrial enterprises practice high-pressure casting, in which shrinkage is almost completely absent.

Of course, special machines and equipment are used for this, which cannot be used at home.

Technologically, the process of casting aluminum billets at industrial enterprises using machines and special equipment looks quite complicated.

IMPORTANT TO KNOW: Technology of electrical discharge machining of metals

The required operating pressure is created by the operation of the piston, which in turn is driven by compressed air.

In this case, an emulsion composition is used, as well as oil, which help accelerate its movement.

Aluminum, heated to the melting temperature, enters a special mold at high speed under high pressure and completely fills it.

In this case, shrinkage of the poured metal is almost completely eliminated.

Casting aluminum parts under high pressure has a huge number of advantages, among which the high productivity of this process stands out.

In addition, one can note the highest accuracy of the products obtained in this way, as well as the almost complete absence of any defects.

This technology is successfully used when it is necessary to produce parts used in instrument making, as well as aircraft manufacturing.

The use of molds in this case makes it possible to use the molten mixture at almost any temperature.

A simple way to cast complex aluminum products: step-by-step instructions

When we hear “foundry” it is always associated with something very complex, accessible only to professionals. But today we will dispel this myth and cast the aluminum part ourselves. Absolutely anyone can do this without having a professional education. Yes, of course, there are some subtleties in this matter; as a rule, they are related to the characteristics of the metal with which you need to work. Aluminum can also be soldered without argon.

• Technical features of aluminum
• Stage one
• Second phase
• Third stage

Technical features of aluminum

Aluminum is considered one of the most popular metals. It is very convenient to work with, the melting point is 658 degrees. It has excellent heat and electrical conductivity and is resistant to corrosion.

Today we will cast a cover for the car's water pump.

Materials used:

• Sand.
• Aluminum.
• Gypsum.
• Plasticine.
• Silicone Grease.
• Steel wire.
• Lego constructor or any children's construction set.

Necessary tools for work:

• Lathe.
• Screwdriver.
• Muffle furnace.
• Drill.
• Pliers.
• Dremel engraver.

Stage one

We divide the broken pump into two sections using plasticine. To do this, we will need plasticine partitions; they are used to separate the pipes into two parts. We remove excess plasticine at the junction of the part with a knife.

The form we will be making consists of three sections. Before filling the first section with the mixture, lubricate it with a separator. The separator can be made from sunflower oil and stearin. Now let's move on to the constructor. We will fill all the empty spaces in the construction set with plasticine.

We will attach the plasticine partitions on the pump to the sides of the construction set. It is necessary that the structure is sealed, otherwise the mixture may leak outside the constructor. In this case, you will have to start all over again.

Let's prepare the mixture itself. Mix gypsum and sand in a container in a 1:1 ratio. You can use river sand or quartz sand, both options are suitable. We took the plaster grade G-16, this is ordinary artistic plaster for sculptures. Add water until you get a fairly thick flowing mixture, reminiscent of low-fat sour cream. Fill the first section of the structure with the mixture, tap on the sides of the structure to distribute the mixture evenly, and wait for it to harden.

Before you start pouring the second section, you need to remove the plasticine partition. Now we will separate the pump pipes with partitions. Don’t forget to lubricate the part and partitions with separator.

Let's fill the next second section with the mixture, and also knock on the walls of the constructor for even distribution. Let's analyze the formwork from the designer. We will make a couple of holes in the resulting product using a 10 mm drill. These are a kind of locks that prevent section number three from moving relative to the first and second.

Let's connect the two resulting forms and insert the blank. Let's restore the formwork from the designer. In this regard, the designer is an irreplaceable thing; you can create any shape from it. Grease the mold with a separator. Let's add one row of the constructor on top. This will be the blank for the third section.

We are all done with filling the mold. Now you need to very carefully disassemble the structure.

Let's reassemble the first and second sections and mark the location for casting. To do this, you need to drill a hole with a diameter of 15 millimeters. It would be enough.

Now you need to assemble all three forms together and fasten them with wire.

Second phase

Firing the workpiece in a muffle furnace. We set the firing mode to 350 degrees, it takes 5 or 6 hours for firing. After six hours, remove the pan from the oven. In this case, no cooling is required. We send aluminum to the furnace to melt. Aluminum is used grade AL-9. This is the most suitable grade of aluminum, excellent for casting products. Fill the bottom of the bucket with sand and place the hot mold there.

We install the sprue on the casting hole. It can be made from sand and liquid glass. Fill the bucket with sand to the border with the sprue. In this case, coarse sand is good; condensation does not form in it, unlike fine sand. You can start casting. All preparatory steps have been completed. Don't forget to remove the oxide film before starting the process. The middle part of the sprue needs to be heated with a burner.

This way the metal will shrink better.

It's time to break the structure.

As we can see, the mold poured perfectly. Of course, there are marks from the joints, but this is not a problem; they can be easily removed with a Dremel. The sprue can be removed, we are preparing for turning the product.

Third stage

Holes need to be drilled and threaded in the pipes.

Now all that remains is to clean up the marks from the joints. For this we use a Dremel and metal cutters.

If you need to remove many layers of metal, it is better to use an emulsion. In this case, dust and shavings will not fly throughout the room. Drill holes for fasteners in the pump cover.

Our workpiece is completely ready. The products turned out to be practically indistinguishable from each other. Only our part is made of aluminum and will serve the owner for a long time. This casting method is quite simple and almost anyone can use it. I hope this instruction helped you, good luck in your endeavors.

Source: https://remboo.ru/dizajn/remeslo/kak-plavit-alyuminij.html

Aluminum casting at home

instrument.guru > Uncategorized > Aluminum casting at home

As a child, many people tried to start smelting lead. The material could be taken from used batteries. It melted easily in the fire and poured perfectly into simple shapes.

Aluminum casting can also be done at home. This metal is more profitable and is of some interest to many craftsmen. However, for casting it is necessary to create twice the temperature.

• Aluminum: main characteristics
• Aluminum casting at home
• Technological process
• Homemade melting stove

Aluminum: main characteristics

Before the discovery and implementation of an accessible method of industrial production, this metal was precious. Once upon a time, this material was considered more expensive than gold bars . Its properties could be useful in various industries.

• Aluminum is a simple and ductile material. It can be stamped, bent, and is perfectly cast into complex shapes, especially under pressure. Its melting temperature is 660 °C; it can be achieved without special equipment. This means casting aluminum in the house is quite possible.
• Who will need it? Aluminum is a high-quality material. It was used to create dishes and parts for the aviation and space industries. Castings, which have excellent thermal conductivity, great durability and excellent strength, are adored by tinkerers. The material is suitable for creating souvenirs, interesting items of utensils, for repairing or restoring items and knots in technology.

Aluminum casting at home

It is possible to reach the melting temperature without the use of special technologies using different methods. In the past, blacksmiths forged steel and heated it with coal . This is the first method, but to perform it you will need an oven with a special air supply.

The second method is the use of natural or liquefied gas. The process can be done in a homemade stove. There is another possibility if the melting volumes are small. In this case, you can take a simple gas stove.

Do-it-yourself aluminum casting at home can also be done if the household has an acetylene generator and a cutter. The method with a special electric stove is also suitable. Such equipment can already be classified as industrial type. But if you don’t want to make a stove, you can rent it for a certain time and order the services of an operator.

Homemade melting stove

The easiest way is to take a couple of fire bricks and make a fireplace out of them. It is convenient to do this in a certain metal container (an old saucepan), which will be taken as a frame. A hole is created on the side to remove the air supply pipe. You can supply a suitable piece of metal pipe. A part of a vacuum cleaner, hair dryer or other air supply device will be connected to the segment.

We will put charcoal (stone) inside. Let's light the fire, and then the air supply will turn on. The vessel where we will melt aluminum is placed inside the stove. It is also lined with coal on the sides. It is best to put a lid on the stove so that the heat does not go in vain, but leave only a hole for the smoke to escape.

Ideally, the firebox is created in one piece with a round arch. The necessary mixtures are used for laying heat-resistant material and lining stoves. This design can definitely be made from an old bucket. The internal vault is created using plastic flower pots of the required size.

A metal mesh can be inserted inside the reinforcement mixture. After the mixture hardens, a wonderful stove will emerge that can withstand more than one melting and casting of molds. It's not that difficult to cast aluminum and make molds if you practice a little.

The main thing is to work and not forbid yourself to experiment out of fear.

Source: https://instrument.guru/bez-rubriki/lite-alyuminiya-v-domashnih-usloviyah.html

How to make an aluminum casting mold

There are several aluminum casting techniques that are used in production on an industrial scale. But if we are talking about work at home, then the most acceptable way is to pour liquid aluminum into homemade molds. This is the technology we will talk about.

Before understanding the nuances of casting, it is advisable to remember some of the characteristics of this metal. Aluminum melts at a temperature of about 660 ° C (depending on its purity), and boils at 2,500. Another feature that needs to be taken into account is rapid oxidation upon direct contact with air.

There are quite a lot of different “engineering solutions” that can be implemented when casting aluminum yourself at home. “Craftsmen”, knowing its characteristics, select the necessary devices and materials themselves. One of the main problems is what and how to make a mold for pouring. This is where people who have no practical experience most often stumble. Therefore, we will consider only one of the simplest options, since it is unrealistic to cover all the methods in one article.

Let's start with what you need to prepare for casting:

Aluminum scrap

Each of us has encountered this metal. But has everyone noticed that, for example, aluminum wire can be different? One bends easily, like plasticine, and the other is harder, less pliable. For casting, it is advisable to choose the one that is softer, since such a material, relatively speaking, contains less oxides and more “pure” aluminum.

Gypsum

The easiest option for working from home. Its best brand is sculptural (marked “G – 16”). But it has yet to be found, and the cost of such a high-quality product is quite high. Therefore, in domestic conditions, white gypsum (designated “G - 7”) is more often used, which is not in short supply. It can be purchased at any specialized store that sells building materials.

It is very similar in appearance to alabaster, and the two can easily be confused. In addition, the seller, not knowing why the buyer needs plaster, may offer this “analog” instead. In the construction industry, materials often replace each other, since many of their characteristics are similar. But alabaster is definitely not suitable for making molds! This needs to be taken into account.

Wax

This material is mentioned in almost all recommendations for do-it-yourself metal casting. Indeed, this is the best option, but only if we are talking about the manufacture of small parts. Pure wax is quite expensive, and there is no point in buying it in large quantities. Moreover, it is unlikely to be used again.

In practice, you use ordinary candles, which are found in any household goods department. Whether they are stearic or paraffin is not important. The quantity depends on the dimensions of the required part, the “blank” of which will be prepared from them.

You'll need a few more things as you go along. This will become clear when considering casting technology, and the choice of specific materials depends on the ingenuity and capabilities of the craftsman.

Melting containers

You can also melt candles in a regular tin. But for aluminum, the cookware needs to be stronger, since it will have to be heated quite strongly.

Source: http://ooo-asteko.ru/kak-sdelat-formu-dlya-litya-alyuminiya/

Technology

The technology for casting aluminum parts at home is quite simple, but requires careful fulfillment of the requirements and great attention to detail. The simplest technology is to pour molten aluminum into prepared molds. In this case, it is necessary to have a minimum set of necessary equipment.

The main task is to melt the wax or paraffin inside the mold and replace the voids with aluminum, after which the cooled part can be easily removed. The first thing you need to do is prepare the formwork, which can be any cardboard box, for example, a shoe box, or made from plywood. Paraffin or wax is poured into it.

Paraffin mold for casting

When working with paraffin, some features should be taken into account:

1. Paraffin poured into a mold cools very quickly, so this process should not be accelerated. The part must cool on its own, this will maintain a homogeneous structure. For complete cooling, you need to wait about a day, after which you can proceed to processing it.
2. Paraffin can sag significantly in the center of the workpiece, so you need to take this fact into account when assessing the required dimensions of the workpiece.

Cutting the correct shape from a workpiece is a very difficult task. Therefore, a person who does not have the proper experience will not be able to cope with it.

In order not to waste time, it is recommended to make several blanks at once, so that in case of failure you can quickly fill a new mold.

The mold for pouring aluminum should be made of plexiglass, which is firmly held together with sealant. After this, at the bottom of the prepared “aquarium” there is a blank that needs to be secured so that it does not move during the process of pouring plaster. This can be done using plasticine.

Then you should prepare a gypsum mixture, which is prepared with the addition of fine-grained sand (in a one-to-one ratio). This is very important, since pure plaster contains a lot of moisture, which evaporates when the part is cast and affects the quality of the finished product.

The mixture should be homogeneous, the thickness should resemble sour cream. It is important that the mixture completely covers the paraffin workpiece.

It is worth remembering that gypsum hardens very quickly, so work must be done at a fast pace. After filling the mold completely, shake it to get rid of air bubbles.

After the plaster has hardened, the plexiglass form must be removed. This is followed by removal of paraffin. This can be done by placing the mold upside down on a hot sheet of iron heated over a fire. You can also boil the mold in water, which will remove the paraffin more thoroughly. After this, the plaster mold must be dried.

There are several ways to melt aluminum, but casting technology at home involves making a crucible furnace yourself or using a muffle furnace. The crucible furnace is made only from refractory bricks.

Melting aluminum at home

Once the metal is melted, the aluminum casting process can begin. Use a stainless steel spoon to remove the oxide film. You can try to melt the metal using a gas burner, which will be sufficient for a small volume.

After hardening, the mold is removed from the plaster, cleaned and polished.

The technology may change depending on the requirements for the finished product and the available tools. Through trial and error, you can achieve the optimal technology.

Home casting requires special preparation, as well as the availability of certain tools, among which we should highlight:

1. Aluminum scrap. Many products can be used as scrap, including wire. But you should choose a softer one, as it contains less oxides.
2. Gypsum. Molds for casting aluminum at home are best made from sculptural plaster. But its cost is quite high, so ordinary white plaster is quite suitable. It is easy to find at any hardware store. The main thing is not to confuse it with alabaster, which looks like white plaster, but is absolutely not suitable for casting.
3. Wax or paraffin. Wax is the best option, but paraffin is cheaper and easier to find. You can use regular candles by removing the wick and melting them.
4. Melting containers. To melt paraffin, you can use ordinary tin containers, but for melting aluminum it is recommended to use containers made of stainless steel or cast iron.

Source: https://stankiexpert.ru/spravochnik/litejjnoe-proizvodstvo/lite-alyuminiya-v-domashnikh-usloviyakh.html

Do-it-yourself molding mixture for casting aluminum

There are several aluminum casting techniques that are used in production on an industrial scale. But if we are talking about work at home, then the most acceptable way is to pour liquid aluminum into homemade molds. This is the technology we will talk about.

Before understanding the nuances of casting, it is advisable to remember some of the characteristics of this metal. Aluminum melts at a temperature of about 660 ° C (depending on its purity), and boils at 2,500. Another feature that needs to be taken into account is rapid oxidation upon direct contact with air.

There are quite a lot of different “engineering solutions” that can be implemented when casting aluminum yourself at home. “Craftsmen”, knowing its characteristics, select the necessary devices and materials themselves.

One of the main problems is what and how to make a mold for pouring. This is where people who have no practical experience most often stumble.

Therefore, we will consider only one of the simplest options, since it is unrealistic to cover all the methods in one article.

Let's start with what you need to prepare for casting: