F.I.R.E. 2019 on the River (Foundry Invitational & River Exhibition)

Discussion in 'General foundry chat' started by PatJ, May 1, 2019.

  1. PatJ

    PatJ Silver

    Here is what I typically get with resin bound sand and iron.
    I don't know how long I let the resin-bound mold set (this was first resin bound mold), and so part of the surface defects could be from using the mold too quickly after molding it.

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    The parts clean up easily enough, but I would prefer a better finish as-cast.

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  2. PatJ

    PatJ Silver

    Your surface finish looks quite good, although there is a bit of a rough spot on the lower right in the second photo.

    I am interested in what sort of surface finish I can repeatedly get using the Velacoat alone with bound sand (no sand additives).

    I will post photos.
    I guess I could do two small molds, with and without the Velacoat.

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  3. Al2O3

    Al2O3 Administrator Staff Member Banner Member

    The light weight body filler is more similar in hardness to hardwoods and urethane modeling board. I never sand it for fillets any more. Wipe lightweight bondo in with my finger, then drag a ball fillet tool across it. When it starts to kick and is rubbery, peel the rest off with a radius scraper and then wipe it with a rag wetted with acetone.....perfect fillets, no sanding. Fillet in batches so you can stay with it before it kicks so hard you cant scrape it.

    Is the Velacoat permeable or non-permeable wash?

    Best,
    Kelly
     
  4. PatJ

    PatJ Silver

    This is what I am looking for over the entire cast surface (a nice consistent smooth finish without any pock marks, as shown in red circles).

    It may be worth the trouble to try it with more than one layer of Velacoat, to sort of fill in the low spots.

    rrIMG_9925.jpg
     
  5. PatJ

    PatJ Silver

    The surface finish on this part that David cast using the lost PLA method is what I would like to achieve with bound sand and a mold coating.

    The camera amplifies very tiny defects in this casting because it is zoomed way in, but the overall surface finish and consistency of this part is superb, and the accuracy of the holes and tapers is really second to none (in my opinion).
    This is what I am looking in my castings, so that the post-casting cleanup work is very easy and quick.

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    .
     
    Al2O3 likes this.
  6. Melterskelter

    Melterskelter Gold Banner Member

    That is identical to the routine I use. And here is a pic of the scraper I use. It is made from medium hard tempered steel and has a sliggtly turned edge just like a card scraper commonly used in cabinetry. 08772044-26CD-424B-9845-0F05114D210F.jpeg

    The various radii are handy for shaping fillets with between 1/4” and 1/16” radius. The hole is there so it can hang on it’s assigned nail in plain sight.

    Properly sharpened it peels out nice controlled curls of Bondo , not dust.

    Denis
     
    Last edited: May 13, 2019
  7. PatJ

    PatJ Silver

    Not to be picky, but the fumes from bondo don't sit well with me either, especially in a closed shop during the winter.
    The water based patching compound sands easily and does not have fumes.

    I generally make a permanent aluminum pattern from my initial pattern, and thus I don't need the wood pattern or the filler to be particularly long lasting.
    I prefer a quick pattern build with easy hand sanding.

    .
     
  8. PatJ

    PatJ Silver

    The F.I.R.E. event has started down on the river.
    I went down there to scope out a spot for my crucible furnace demonstration, and they had some cool stuff going on.

    A few photos below:

    Red iron oxide for making steel.
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    Charcoal for making steel.
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    Lightweight iron-rated ladles.
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    Resin molds.
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    Flasks for resin molds.
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    The furnace for making steel.
    I think the guy went to Japan to learn this technique (check me on that).
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    A hand carved pattern.
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    Last edited: May 15, 2019
  9. PatJ

    PatJ Silver

    More photos from F.I.R.E. today (Wednesday).


    A 3D scan turned into wax, turned into a bronze casting.
    r20190515_164426.jpg



    Patching the cupolette with "Plastic Super A".

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    r20190515_164652.jpg



    r20190515_174435.jpg


    Guess what these do.

    r20190515_174446.jpg


    This photo is looking into the top of the steel furnace.
    I asked the guy if I could get up on the steps that are used when they charge the furnace to get a better photo, and he took one look at my street clothes and said "No I don't think so".
    I didn't tell I had been in far more dangerous situations than this,
    I understood his concern given that I looked like a total dweeb in my khakis (this is not khaki land for sure).

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  10. PatJ

    PatJ Silver

    You can see how thin the flasks are for the resin sand.
    Resin sand is extremely strong, even without the flask around it (once it sets fully).

    .
     
  11. DavidF

    DavidF Administrator Staff Member Banner Member

    Think they are making a steel "bloom" not sure exactly where that originates from but kind of thinking Europe for some reason. Maybe around the time of the crusades?? Honestly no idea.. lol
     
  12. PatJ

    PatJ Silver

    I am going to get more info on the steel process.
    I guess if there was any doubt about making steel using charcoal only, this erases it.

    I am not sure if this will end up as a Samurai sword or what.

    I also hope to measure the cupolette.
    .
     
  13. DavidF

    DavidF Administrator Staff Member Banner Member

    The question was "casting steel" what comes out of the furnace will not be pourable into a mold, more of a gooey blob than anything....It is then forged into a billet, and then into (everything else)
     
  14. PatJ

    PatJ Silver

    Yes that is what they mentioned today.
    It is a bit deceiving because you can see molten red stuff running out of the bottom of the furnace, but they said that was slag, not steel.

    .
     
  15. crazybillybob

    crazybillybob Silver Banner Member

    My understanding of steel making in cupolette is that in the end you will fish the blooms of steel out of the coals. You will get both high and low carbon steels. The trick is in the forging of them to get billets that you can work with. Knowing what is high carbon and low carbon and how to combine them to get a usable sword/knife etc.
     
  16. PatJ

    PatJ Silver

    As I understand it, they remove the bricks to get at the bloom.
    I think someone said the guy went to Japan to learn this method (I may have mentioned that above).
    I will find out more info.

    I am taking the furnace down sometime today, once I get it loaded up.

    .
     
  17. PatJ

    PatJ Silver

    They are busy like beavers making molds of all sorts of things.
    I would really like to have an alligator, but it may be one of those things that if you have to ask, you can't afford it.

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  18. PatJ

    PatJ Silver

    More molds.
    The art folks are the masters of sculpting the resin-bound sand, and it is the perfect material for the art community.

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  19. PatJ

    PatJ Silver

    They will have two cupolettes running at the same time.
    Coke by the ton.
    These folks are serious about pouring iron.

    It appears that each flask is labeled with the amount of sand needed, and the molds appear to be labeled with the amount of iron that each one requires.


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    Tobho Mott likes this.
  20. PatJ

    PatJ Silver

    A few minor issues cropped up during transportation.
    I am getting ready to put Humpty Dumpty back together again.
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