Foundry - Revision history

Dllh: Filling out some TODO sections to wrap up the initial draft of the page.

2024-10-17T01:14:22Z

Filling out some TODO sections to wrap up the initial draft of the page.

← Older revision		Revision as of 01:14, 17 October 2024
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	== Extracting the Casting ==		== Extracting the Casting ==
	~~TODO~~		Remember that everything around you is hot!

			After giving your poured metal a few minutes to cool (this will take shorter for smaller molds, longer for larger molds), carefully pick up your frame and take it to the sand table in the blacksmithing building (as of October 2024, it's in the corner to your immediate left as you walk in the sliding doors).

			Turn the mold over or use tongs to remove the casting from the frame. It may still be very hot, so do this carefully.

			Put the casting aside and make sure the sand-collecting bin is inside the cabinet underneath the table top. Work any sand that has landed on the table top through the holes, so that it falls into the bin. You can also dump directly into the bin, but be sure to make sure you're dumping only the sand mixture and not other potential contaminants.
	<br>		<br>

	== Shutting Down ==		== Shutting Down ==
	~~TODO~~		Pour any remaining metal from the crucible into the ingot mold so that we can use any extra for future pours.

			Place tongs near the sand table and, once cooled, roll the furnace over to that area as well (put these back where you got them).

			Close the propane valve and disconnect the propane tank, putting it back in its place.

			Put away any other things you've used in your casting session (e.g. frames, molds that belong to Knox Makers, etc.)

			Stick around the space for a while to let the furnace cool down so that it can safely be rolled back into the shop. Plan to stick around for at least a half hour or so.

			If no one else is using the blacksmithing area, close the shop according to the usual shut-down procedures for the zone.
	<br>		<br>

	== Sourcing Metal ==		== Sourcing Metal ==
	Please do not melt aluminum cans in the furnace.		Please do not melt aluminum cans in the furnace. They're not a great source of aluminum.
	~~TODO~~
			Around the left side of the blacksmithing building, you'll see big chunks of aluminum in the forms of wheel rims and other components. Feel free to use reasonable portions of this (don't hog it all), cutting off what you need. You can also bring your own metal. Metal Supermarkets in west Knoxville carries aluminum, and other stores may as well. Remember to think about safety, fumes, etc., when sourcing your metal, as covered in the safety section of this document.

Dllh: /* Pouring the Metal */

2024-10-17T00:59:37Z

Pouring the Metal

← Older revision		Revision as of 00:59, 17 October 2024
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	<br>		<br>

	[[https://youtu.be/XUEq-18ibDA Here's a video of this in action.]]		[https://youtu.be/XUEq-18ibDA Here's a video of this in action.]

	== Extracting the Casting ==		== Extracting the Casting ==

Dllh: /* Pouring the Metal */

2024-10-17T00:59:21Z

Pouring the Metal

← Older revision		Revision as of 00:59, 17 October 2024
Line 155:		Line 155:
	<br>		<br>

	Here's a video of this in action:		[[https://youtu.be/XUEq-18ibDA Here's a video of this in action.]]

	~~{{#ev:youtube\|XUEq-18ibDA}}~~

	== Extracting the Casting ==		== Extracting the Casting ==

Dllh: /* Pouring the Metal */

2024-10-17T00:58:06Z

Pouring the Metal

← Older revision		Revision as of 00:58, 17 October 2024
Line 157:		Line 157:
	Here's a video of this in action:		Here's a video of this in action:

	~~TODO~~: ~~FIGURE OUT WHERE TO UPLOAD VIDEO TO AND LINK HERE~~		{{#ev:youtube\|XUEq-18ibDA}}

	== Extracting the Casting ==		== Extracting the Casting ==

Dllh: /* Environment Setup */

2024-10-17T00:55:09Z

Environment Setup

← Older revision		Revision as of 00:55, 17 October 2024
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	# Ensure that the furnace is on the outside on the pavers, and the gas is on the inside of the door, as mentioned and depicted above. This is a safety issue.		# Ensure that the furnace is on the outside on the pavers, and the gas is on the inside of the door, as mentioned and depicted above. This is a safety issue.
	# Connect the furnace gas supply to the propane tank. Remember that the threads are reversed (so twist backwards from what you normally would). Ensure that the valve is tightened properly, passed visual inspection, and appears undamaged. If uncertain, '''please ask'''. Folks familiar with the foundry chat in our Foundry and Blacksmithing channels on Mattermost. Please do '''not''' adjust the burner that goes into the furnace -- it is already calibrated as needed, and changing it could upset the air/fuel mixture required for casting.		# Connect the furnace gas supply to the propane tank. Remember that the threads are reversed (so twist backwards from what you normally would). Ensure that the valve is tightened properly, passed visual inspection, and appears undamaged. If uncertain, '''please ask'''. Folks familiar with the foundry chat in our Foundry and Blacksmithing channels on Mattermost. Please do '''not''' adjust the burner that goes into the furnace -- it is already calibrated as needed, and changing it could upset the air/fuel mixture required for casting.
	# Open the furnace (~~see~~ [https://youtu.be/XUEq-18ibDA this video]~~) and load the crucible (see photo below~~). Your metal should be in the crucible. Use the correct crucible for the metal being used.		# Open the furnace and load the crucible, as seen at the beginning of ([https://youtu.be/XUEq-18ibDA this video]). Your metal should be in the crucible. Use the correct crucible for the metal being used.
	# Turn on the propane tank to 10 psi.		# Turn on the propane tank to 10 psi.
	# Light the furnace using the hand-held propane torch.		# Light the furnace using the hand-held propane torch.

Dllh: /* Environment Setup */

2024-10-17T00:54:09Z

Environment Setup

← Older revision		Revision as of 00:54, 17 October 2024
Line 78:		Line 78:
	# Ensure that the furnace is on the outside on the pavers, and the gas is on the inside of the door, as mentioned and depicted above. This is a safety issue.		# Ensure that the furnace is on the outside on the pavers, and the gas is on the inside of the door, as mentioned and depicted above. This is a safety issue.
	# Connect the furnace gas supply to the propane tank. Remember that the threads are reversed (so twist backwards from what you normally would). Ensure that the valve is tightened properly, passed visual inspection, and appears undamaged. If uncertain, '''please ask'''. Folks familiar with the foundry chat in our Foundry and Blacksmithing channels on Mattermost. Please do '''not''' adjust the burner that goes into the furnace -- it is already calibrated as needed, and changing it could upset the air/fuel mixture required for casting.		# Connect the furnace gas supply to the propane tank. Remember that the threads are reversed (so twist backwards from what you normally would). Ensure that the valve is tightened properly, passed visual inspection, and appears undamaged. If uncertain, '''please ask'''. Folks familiar with the foundry chat in our Foundry and Blacksmithing channels on Mattermost. Please do '''not''' adjust the burner that goes into the furnace -- it is already calibrated as needed, and changing it could upset the air/fuel mixture required for casting.
	# Open the furnace (~~TODO~~: ~~VIDEO LINK HERE~~) and load the crucible (see photo below). Your metal should be in the crucible. Use the correct crucible for the metal being used.		# Open the furnace (see [https://youtu.be/XUEq-18ibDA this video]) and load the crucible (see photo below). Your metal should be in the crucible. Use the correct crucible for the metal being used.
	# Turn on the propane tank to 10 psi.		# Turn on the propane tank to 10 psi.
	# Light the furnace using the hand-held propane torch.		# Light the furnace using the hand-held propane torch.

Dllh: /* Skimming Dross */

2024-10-03T03:12:59Z

Skimming Dross

← Older revision		Revision as of 03:12, 3 October 2024
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	<gallery>		<gallery>
	Dross Bin.jpg\|Dross bin with cooled dross fragments		Dross Bin.jpg\|Dross bin with cooled dross fragments
	Dross Skimmer.jpg\|Skimmer for removing dross from the molten metal		Dross Skimmer.jpg\|Skimmer for removing dross from the molten metal, loaded with flux
	</gallery>		</gallery>

Dllh: /* Skimming Dross */

2024-10-03T03:12:30Z

Skimming Dross

← Older revision		Revision as of 03:12, 3 October 2024
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	Once your metal has melted, you'll want to clean it up a bit by applying flux (salt or borax) liberally to the skimmer and gently stirring and prodding the molten metal. You'll want to skim the top particularly, and you know you're done when the metal is shiny with little or no crud floating on top. As you skim, occasionally deposit dross into the dross bin to cool. Do this carefully, as you don't want to spatter hot metal waste on anyone or anything. Pictured below you'll see the dross bin currently in use and the "skim" end of the skimmer.		Once your metal has melted, you'll want to clean it up a bit by applying flux (salt or borax) liberally to the skimmer and gently stirring and prodding the molten metal. You'll want to skim the top particularly, and you know you're done when the metal is shiny with little or no crud floating on top. As you skim, occasionally deposit dross into the dross bin to cool. Do this carefully, as you don't want to spatter hot metal waste on anyone or anything. Pictured below you'll see the dross bin currently in use and the "skim" end of the skimmer.
	<br>		<br>



	<gallery>		<gallery>

Dllh: /* Skimming Dross */

2024-10-03T03:09:46Z

Skimming Dross

← Older revision		Revision as of 03:09, 3 October 2024
Line 121:		Line 121:

	== Skimming Dross ==		== Skimming Dross ==
	~~TODO~~		Once your metal has melted, you'll want to clean it up a bit by applying flux (salt or borax) liberally to the skimmer and gently stirring and prodding the molten metal. You'll want to skim the top particularly, and you know you're done when the metal is shiny with little or no crud floating on top. As you skim, occasionally deposit dross into the dross bin to cool. Do this carefully, as you don't want to spatter hot metal waste on anyone or anything. Pictured below you'll see the dross bin currently in use and the "skim" end of the skimmer.
			<br>

			<gallery>
			Dross Bin.jpg\|Dross bin with cooled dross fragments
			Dross Skimmer.jpg\|Skimmer for removing dross from the molten metal
			</gallery>


	<br>		<br>

Dllh: /* Environment Setup */

2024-10-03T02:54:42Z

Environment Setup

← Older revision		Revision as of 02:54, 3 October 2024
Line 77:		Line 77:
	# Make sure that both doors on the blacksmith shop are open.		# Make sure that both doors on the blacksmith shop are open.
	# Ensure that the furnace is on the outside on the pavers, and the gas is on the inside of the door, as mentioned and depicted above. This is a safety issue.		# Ensure that the furnace is on the outside on the pavers, and the gas is on the inside of the door, as mentioned and depicted above. This is a safety issue.
	# Connect the furnace gas supply to the propane tank. Remember that the threads are reversed (so twist backwards from what you normally would). Ensure that the valve is tightened properly, passed visual inspection, and appears undamaged. If uncertain, '''please ask'''. Folks familiar with the foundry chat in our Foundry and Blacksmithing channels on Mattermost.		# Connect the furnace gas supply to the propane tank. Remember that the threads are reversed (so twist backwards from what you normally would). Ensure that the valve is tightened properly, passed visual inspection, and appears undamaged. If uncertain, '''please ask'''. Folks familiar with the foundry chat in our Foundry and Blacksmithing channels on Mattermost. Please do '''not''' adjust the burner that goes into the furnace -- it is already calibrated as needed, and changing it could upset the air/fuel mixture required for casting.
	# Open the furnace (TODO: VIDEO LINK HERE) and load the crucible (see photo below). Your metal should be in the crucible. Use the correct crucible for the metal being used.		# Open the furnace (TODO: VIDEO LINK HERE) and load the crucible (see photo below). Your metal should be in the crucible. Use the correct crucible for the metal being used.
	# Turn on the propane tank to 10 psi.		# Turn on the propane tank to 10 psi.