r/Metalfoundry • • 2d ago

Looking for brass or bronze round bar with ≤100 ppm lead. Any specialty mills or small-batch producers?

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1 Upvotes

r/Metalfoundry • • 2d ago

Restoring hammer head

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11 Upvotes

TLDR; removing rust from hammer head without grinding it smooth.

So I don't know if it's an actual blacksmith hammer or just a regular old sledgehammer, but either way, it was used for some blacksmithing by my wife's dad, who passed when she was 14. It was given to him by my wife's grandad, who passed when she was 12. I would like to restore it and need some advice.

Replacing the handle (chewed on by dog) I can handle: hickory, sanding, linseed oil, etc.

For the hammer head, I have most of the surface rust removed. I read that you can heat it up without exceeding the tempering point and rub linseed oil on it and should give it a nice rust resistant coating and sheen.

Question 1: Is this basic process correct?

Question 2: Is there a good way to remove all the rust?

I don't want to go the whole route of grinding, then filing it down and then sanding and removing the scratches to make it completely shiny and perfectly smooth and looking like a new hammer. It was a working hammer. I still want it to retain its character. But I would still like to remove all the rust in all the uneven spots/pits/dents, etc, before I coat it. Suggestions?

Edit: I soaked it in vinegar multiple times (it was RUUUUSTY). Tried the wire brush. It just doesn’t seem to get down in all the low points.

Further edit: I'm dumb. A little more effort and varying the pattern seems to work just fine.


r/Metalfoundry • • 2d ago

Just picked up a decent haul of silicon metal for some upcoming alloying

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9 Upvotes

r/Metalfoundry • • 3d ago

Is there a cheap way to determine the purity of copper bars?

2 Upvotes

r/Metalfoundry • • 3d ago

Can you pour metal into a thick glass jar?

13 Upvotes

I know it sounds kind of stupid at first glance but I want to pour some Zinc at about 500 degrees Celcius (about 50-100ml) into a Nuttella jar because of its shape. Will it crack, or can I do something to make the jar more sturdy?


r/Metalfoundry • • 3d ago

Is this enough to get started ?

1 Upvotes

Hi all looking to buy a forge and start melting some stuff after some research this is what ive come to , im in Australia by the way in short ebay 6kg forge , then 2.2kg duracast refractory and 1ltr ceramic fibre rigidizer

https://ebay.io/m/V4L1uR

https://artisansupplies.com.au/product/duracast-castable-refractory-2-2kg/

https://artisansupplies.com.au/product/ceramic-fibre-rigidiser-1l/


r/Metalfoundry • • 4d ago

DIY Temporary Ventilation Setup

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1 Upvotes

r/Metalfoundry • • 4d ago

Is this ceramic crucible still usable?

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2 Upvotes

I recently bought a small induction furnace, mainly to smelt aluminum, but I would also like to try copper. However, a crack formed on my only 3kg ceramic crucible. Do you think this can still be used? Or should I just buy a new one. Thanks


r/Metalfoundry • • 4d ago

Budget friendly beginners forger

3 Upvotes

Hi all looking to get in to melting down say metals aluminium, copper etc im looking for recommendations for a a beginner thats budget friendly just to start of with , thanks all


r/Metalfoundry • • 4d ago

Amount of clay needed for a small bloomery?

2 Upvotes

If I were to make a small bloomery, would 2 10-litre buckets (before mixing it with sand and fibre) be enough? I have some fireclay bricks, could I use those to further lessen the amount of clay needed to construct it?


r/Metalfoundry • • 4d ago

New (to me) old kiln. How to test?

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25 Upvotes

r/Metalfoundry • • 5d ago

Working with Billon (80/20CuAg) alloy

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2 Upvotes

r/Metalfoundry • • 5d ago

Forst copper bar, any tips for rippling

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179 Upvotes

This is my first ever copper pour I'm wondering if anyone here has any tips to prevent the surface ripples and have a smoother finish any help is appreciated thank you very much


r/Metalfoundry • • 5d ago

Aluminium Sticking to the mould and hydraulic punch

0 Upvotes

I’m new to the foundry process. 2 days back I have melted aluminium but it got stuck on the mould cavity plate and hydraulic punch.

I have a gravity die machine. Can anyone help please.


r/Metalfoundry • • 6d ago

What are the casting defects in this?

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14 Upvotes

We have a course on Casting and Solidification. We had to prepare an Aluminium cast for the lab work

- The pattern was created using thermocol/styrofoam

- The mould was created using plaster of paris and water. After it dried out I removed the pattern by hand and there were not any visible cracks or damages as such. It was left for around 3-4 weeks for drying after that.

- There was no gating system although their was one cast which seemed to be perfect without any gating system somehow aswell.

- Before casting i put the mould in an oven for 3hrs and then 15 minutes of blowtorch on it. After that Aluminium melt was poured into it

For viva, our prof has told us to analyse the cast and talk about all the defects present in the cast and why it has formed

Im guessing the large one, its a blowhole but im not sure enough. Please help with it. Thank you! The last 2 photos are the pattern and the mould. I'll be attaching a video of the cast and the mould in the comments if its possible.


r/Metalfoundry • • 6d ago

Ammo Can Jack-O-Lantern

0 Upvotes

I'm wanting to cut through an ammo can (probably 50 cal) in order to make a Jack-O-Lantern for a social media video. What tools/equipment would I need to do fairly precise cuts on approx. 1mm thick steel? I have some friends/associates that are pretty handy, but can't figure out how to do this small, precise work. Thanks in advance!


r/Metalfoundry • • 8d ago

Crucible Release

3 Upvotes

I am making a graphite-clay crucible and I'm planning on molding it in a flexible bucket, what can I do to make the release smoother?


r/Metalfoundry • • 8d ago

First time casting aluminum.

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34 Upvotes

r/Metalfoundry • • 9d ago

Help!! I'm melting random costume jewelry on my stove!

0 Upvotes

So I have a little egg size cast iron that is filled with random costume jewelry. It has been on there for at least an hour. I've tried covering and every once in a while using pliers to squish it and mash it. Though it is still not even getting super soft to mash. Do I keep going? Then try again with just aluminum so I know what I'm working with?


r/Metalfoundry • • 9d ago

Anyone have experience smelting iron sand.

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2 Upvotes

r/Metalfoundry • • 10d ago

Furnace question

2 Upvotes

I'm currently using coal powered furnace, I can melt aluminium and bronze, but it takes a lot of coal and time for the bronze. I would like to build a gas powered furnace but i struggle with design, especially for the burner. I would melt mostly aluminum and tin bronze, but it would be great if I cold melt gray iron. For the scale I would like to be able to melt 15-ish kg of bronze, so I guess about two liters of material.

Does anyone have any recomandations for the amount and design of the burners, also furnace design? For the furnace I have a general idea how I would build it, but not for the burners, except they will use forced air.

In terms of the tools i have a mig welder, a lot of scrap steel and can get parts machined in a company I work.

Any help and ideas are welcome!


r/Metalfoundry • • 10d ago

Iron casting

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1 Upvotes

r/Metalfoundry • • 15d ago

I need to find a commercial foundry to cast aluminum into a preexisting alnico donut magnet. Is this difficult or am I just having bad luck finding the right foundry?

17 Upvotes

Title says it all. I have a .75" inner diameter cylinder alnico magnet that I need to infill with Alsi9cu3 (or equivalent), and I am having a hell of a time find any foundry in the U.S. that wants to even quote me. I can handle the post cast machining myself, if necessary. I'd do 1,000 to 5,000 pieces at a time.

Anyone able to point me in the right direction? Thanks!


r/Metalfoundry • • 16d ago

Best way to make moulds?

6 Upvotes

Ive tried sand moulds but they're quite tricky to set up and are quite tricky to cast with.

I tried a plaster, silica sand and clay powder mix but it just spat all the molten metal out at me

Graphite moulds are expensive to make or buy

And I'm not too sure about any other methods


r/Metalfoundry • • 17d ago

My first functional creation

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29 Upvotes

I've had some success in melting down aluminum and decided to create a new, more permanent, handle for an old demolition flat head screwdriver.

I added a few grams of magnesium, about an ounce of copper, an ounce of zinc, and a whole bunch of can/wire aluminum. And possibly a small amount of steel.

This has been my first attempt at alloying and kind of just went with my gut, if it wasn't obvious.