Cincinnati Shaper

[dallen]

here's a couple of photos of the casting after I found an insert that I would cut thru the hard corner edges, the middle machined great last night.

the more I look at this the more I'm thinking its steam from using the green sand and it being so fine that the steam couldn't escape and the fact that I didn't put any vents in the mold, which is something that I usually do even if the mold doesn't need it.


This think looks like Swiss Cheese the deeper you get into it the bigger the holes get.

I ended up using a big TPG 432 I don't know any thing more then that about the inserts I was given them by the guy at the local supply house they were a sample that had been dropped off, he knows I like samples so he tosses some my way every now and then, just so happened I had a bar that I had milled down from 1" square to 1X.5 that a friend had pawned off on me saying he couldn't use it.

Right photos of swiss cheese

[Jammer]

David, did I send you any of those TiBor rods? I'm not sure if they would help with porosity or just alloy strength.

[dallen]

no are they for cast iron? I think this is from steam, I had to empty my muller out to move it and instead of putting the oil bonded sand back in I mixed up some new greensand for kicks and grins but I think the sand it was too fine for cast iron it needs to be a little corser so it will breath. anyway thats my thoughs and I'm not gonna chisel them in stone.

all the other iron I have melted never did this, yes I had problems at times but not this. I even put in about and ounce of FeSi just a little bit cause I didn't melt much iron and not FlouroSpar or limestone, I got a 5 gallon bucket of limestone dust from Ft Belle outside of St Louis powder fine and it melts really good or it used to been a while since I been in the bucket. sure fluidize the slag thou.

Now back to getting the dead bugs out of the fuel lines.
DA

[Jammer]

Oh, I forgot you were casting this in Cast Iron. The TiBor is for Aluminum.

[dallen]

might help with the aluminum parts that I been making, but not with this part, I think I have everything noodled out, anyway I'm going to stick a core in it so I don't have to drill a hole thru 2.5 inches of iron and hope it vents some of the steam. cause I'm going to use greensand again.

DA

[Jammer]

I haven't got my petrobond mixed up yet. But, I think I would prefer Green sand for Iron. Lost foam also seems to work great with Iron.

[dallen]

I've done it both ways, in petrobond and greensand. believe me it can be a little scary when you go to shake it out and the iron is way too hot and the sand has a little too much oil in it and it catches on fire, or you go to pick the mold up after its set for 30 minutes and move it and the damn thing falls out because the sand is hot and lost its strength.

But here because of the heat and the cold I prefer the oilbonded sand.

I got some grain modifier from one of the big supply houses one time as a sample I just emailed them and told them I was a hobbist didn't know squat about what I was doing but that they sold stuff and they sent me a couple rolls of flux and the grain modifier I think they are in a can somewhere been a while since I have seen them.

I add copper to my aluminum and try to degas it and use flux that I got from Harry on it but I still have most of the time gummy to me its gummy aluminum. not sure what I'm doing wrong I try to stick mainly with car wheels as my source of supply (have a nephew thats a Mech who hauls home all the aluminum he takes off) so its not from having a mixed metal supply, yes there's some extrusion in it window frames from the house as I have replaced some of them and taken the old storm windows off.

Anyway glad to hear that your getting underway with your shop/garage/storage facility.

I'm going to try to pour this nut again today in Cast Iron,

OH YEA when you mix your petro hope you have a muller, and very slowly and carefully add the oil cause a little goes a LOOOOOOOOOOOOOONG way in the stuff

DA

[dallen]

I present you with today's failures

I should of know that today wasn't going to be worth a damn when I had to dump this in the muller to keep it from freezing in the crucible.


anyway after above fiasco of running out of propane due to oil line on burner not wanting to cooperate and me getting some more propane I continued with the day of casting fun, oh yea the PID in the burner control box with the thermal couple laying in the grass said it was a balmy 119 degrees.

I fired up and started for the second time today, I achived pouring temp and in the hast I forgot to turn on the video camera so sorry no video.
But I was really happy with the way the mold filled. Even after I shook it out of the flask heres a shot of the gating the part broke off in my rolling it around cleaning sand off of it.



see that little place there were the parts suppose to be at that should of been all the hint that I needed that this wasn't going as good as it looked

and heres the part that I was after a replacement for the swiss cheese one I did on Saturaday.


a different shot of the part


I should of know that it felt a little light but and after cutting into it here is what I get for all my troubles. All I can do is laugh and get ready to do it again, the core did what it was suppose to it left a hole in the part.


damn good thing I didn't have to pay for this or I would be really PO'd

David Allen

[dallen]

I started the flat belt pulley pattern that I am wanting to make today, only thing is I think I have already messed it up by not making the sections wide enough to offset them the way that I need to get the strength in the build up so I can turn it on the lathe.

right here's the photo.

you should be able to see the problem I mentioned above


DA

[latzanimal]

Dave, you should need to clamp the segments down. I've seen guys clamp a whole ring up with a band clamp, tho, I've never tried it myself. I usually glue up 3 segments at a time. I also only use 6 segments for a ring.

When gluing, if you hold the segments together for 60 seconds, the bond will be good enough to hold. I hold the 2 segs for 60 seconds, then do 2 more. after I fill my gluing area, I move the first ones. After 15 minutes, the glue is set up enough to check. If your angles are off, they'll fall apart. If you have good angles, it will hold.





Here's how they ended up...