Capability for making a large casting?

Ceramics
1

I was wondering if we have the tools necessary to make an aluminum casting this large.

It is a ring, ~14 5/8" OD, 12" ID x 2 3/4" wide.

This would make the casting approximately 110 cu. in. of aluminum ~ 11 lbs

I realize the measurements in these drawings are somewhat conflicting, but it’s ok to use your imagination a bit.
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2

Looks as though it could be milled out of plate on the Haas, or even the Bridgeport, if casting doesn’t work out for you.

3

Unfortunately a plate that size in 6061 would be over $250

4

I did aluminum casting in high school and making a mold wouldn’t be a problem size wise but you would probably have to have a furnace that would melt 15# or 20# of aluminum. Come to think about it by the time you gat the casting sand for a mold that big the $250 might not look so bad.

Do you have a source for the aluminum to melt? That’s a lot of beer cans. Your best bet might be to cast a rough piece and machine it on the Bridgeport.You could probably make a rough casting with play sand and then machine the shape you want.

Russell Ward

2 Likes
5

Is 6061 really necessary? If you’re talking about casting, I wonder. The application here is mighty opaque.

And, yes, machining a rough casting could make life much easier.

6

Sand shouldn’t be all that bad. Green sand is basically 90% silica sand (playsand) and 10% finely ground kitty litter (clay), plus just enough water… Tons of youtube vids on how to make your own

Casting vessel (flask/cope/drag) can be made to size easily enough out of 2x4s in the wood shop.

7

Does the space have a crucible that big ? 20# is a pretty good sized volume.

8

No, but other types of aluminum were MORE expensive. I guess 6061-T6 is just more commonly used.

This is a decorative/ceremonial item – not structural – otherwise I definitely wouldn’t be casting it!

Is it possible to do a casting in multiple pours? Or does that just make a mess?

9

I wouldn’t try multiple pours. With aluminium, because of the oxide, I’d expect quite poor results.

10

I think that publius is on the right track. I would milled out the part. The personal kiln I have demo at the space I got for http://www.foundry101.com. Note it will only do app 4lbs of aluminum. They have a good description of how to cast if you need more details.