Foundry and Aluminum Casting
Goal: Create stronger aluminum parts from 3D printed molds without the need for machining.
Using an old bucket, expired fire extinguisher, plaster, sand and a hair dryer from the thrift store, enough airflow can be pushed through mesquite charcoal to raise the temperature high enough to melt aluminum while keeping steel solid.
Methods: The bucket, insulated by the solid plaster and sand mixture allows air through a hole in the side of the bucket pushed by the hair dryer. I used an old charcoal grill lid to prevent too much heat from escaping. The molten metal was then poured into a prepared mold to cast the aluminum.
Result: The mold was extremely difficult to keep together and would often collapse, especially in fine details. Large primitive shapes were not too difficult, but as objects became more complex they tended to become harder to accurately cast. Overall, while the original goal was not achieved, some decent casts were completed.
