In the video "making a casting model" I have shown the first step of how to get an cast iron wheel. Here ist Part 2 with the molding and casting process.
Started working in an Iron Foundry on my 18th Birthday. Seen some tough guys come and go. Some come in and are told to come back with Steel toed boots and they never return. Call that a healthy choice for some. I’ve seen iron accidentally poured down a man’s boots and things of that nature. We’d make the copes and drags in the morning and pour in the afternoon. That job will make you tougher if you’re tough enough to hang in for a few months to begin with.
WOW always something interesting happening over at the Burger house. Thanks for sharing this. Has to be very rewarding to watch your patterns becomes the wheels you need!
I worked in a foundry as a metallurgists assistant in college and the smell of hot sand gets into your hair and skin and it takes weeks to get out. there is a smell of hot casting sand that you do not ever forget.
I worked at The Chevrolet Grey Iron Casting as a sand wetter. Great place to work and in it's day was the largest Grey Iron Foundry in the world...COOL. She's casting Aluminum now using the lost foam technology. I left when the iron left.
Great video thanks for sharing it and I'd also like to thank the company for allowing you to film. Those guys are true professionals and make a great team.As someone who's done some sand casting work in aluminum it is amazing at how easy they make it look.
I have noticed that in a variety of skills. Once people are competent and confident there is a relaxed aspect to the work, they "make it look easy" as the saying goes, but as you say there is knowledge and experience there.
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I never worked in a foundry but I did work at a pattern shop and made a lot of that stuff. I've seen patterns larger than cars. mold boxes 8 feet tall and 15 feet square.
That s à very interesting video I did not understood that the sand do get hard.. I work in pianos so iron "plates" are not new to me. But there are cooling deformations and stresses in our parts. However on those wheels the precision looks a little " crude" , I guess they are machined later to get to the nominal dimensions.
Here in the usa that red stuff they are washing the mold with can be expensive. Not sure of that type exactly but the ones for stainless/steel are ;) You would think they would just wash where the molten metal would be hitting the no-bake sand. That excess on the mold adds up really quick.
That was interesting to see the foundry I worked in had a machine to make the mold called the molder 2000 degrees was pouring temperature that's the kind of ladles we had
40 years ago for me James. Did it for a couple of summers while in school. Can you still remember the smell? And the foundry dust getting into everything? I'll never forget the smell of a foundry.
@@johnk1955 I really hope you gents were issued with and wore more protective equipment than what we see here...it is virtually non existant. No hand protection while using chain shackles that have pinch points everywhere. The smell you speak of from organics in the Furan sands which emits nasties when heated. If you weree not subjected to medical assesssments over those 40 years make sure you are checked regularly. I was fortunate enough to work in industrial processing but the employer always adhered to strict Health and Safety regulations.
If the materials used are properly dry, there shouldn't be much splash anyway. Most dangerous are the temperature lances you see at 8:18. They are wrapped in carton and the water in there evaporating throws drops of iron in the air. After tapping the melt is genereally not terribly hot (1300 - 1400°C), so the reaction is somewhat tame. At the furnace the melt goes up to around 1550°C regularly, so there are many more drops of the melt flying around when checking temperature. Also, at 1550°C the melt is radiating so much heat, that you acutally want to wear long sleeves during deslagging, but that also depends on the diameter of the furnace. Whilst your body is alright with the heat, your arm is heating up really fast. It tended to burn the skin on my little finger, cause it was heated much quicker then any other part of my body. It's a fun job though, i really like the look of the liquid metal. I can still be amazed by looking at the melt for hours :)
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8:46 reminds me of the Foundry level from Tony Hawk's Pro Skater 3, yeah I was looking for Tony Hawk's Pro Skater 3 Foundry in real life and this popped up lol
great work,the work is extremely relaxe and the workers are so so experienced in sand casting, i have some questions? what is the type of this sand mixture? what is the suspension 5:35 what is the type of molten steel
i'm watching this video to try to figure out how my relative died in the 1920s when a furnace blasted while he was trying to set the stop in the ladle. this was the best visual I could find of the steel being poured into a ladle so it definitely makes more sense now. before the days of ppe or even having the slightest care if your employees got injured or died on the job.
I need to know how a pulley with fancy curved spokes is made. I see them a lot on antique machinery and church bells of iron had giant iron pulleys attached to them to swing them in America. Could you tell me how it was done? I beleive it all was cast in one mold and no latheing done to make the groove in those big pulleys.
The shaped of the patterns determine the final product. Usually complex shapes used a lost wax process where the finished part's shape is held in place by a wax core that melts as the iron, aluminum, etc is added to the mould.
Nice, missed this in college industrial tours decades ago. nice soft, effortless, clear, almost musical way of speaking too, are you Luxembourgish? the river "sure", in "grippingham"?
Excellent video and narration! Very interesting. I am guessing that this company will be forging the other main parts to your cannon also? Must be very expensive? Thanks for sharing!
I wonder if spraying your piece with a light coating of mineral or cooking oil would help it come out of the mold when the mold is initially formed or if that would be a bad idea.
We were told to spray the patterns with oil so that the mold would not stick. If sand sticks to the patter it becomes part of the pattern. This happened to me and I did not notice it with the result that a number of my pieces had to be sent to the grinders to have the bump ground off. This was at Lancaster Malleable in 1973. The parts I was making were for commercial oven doors. I was paid 3.23 an hour while the grinders were paid 11.00 an hour.
How to reuse the sand which is already solidified block by resin? Do we need a crashing machine to crash sand block? Is it easy or difficult to reuse if we use resin in the sand? Thanks,
Basically all of our sand was reused. Some of the sand can be made hard enough you need to use a jackhammer to chip it out. It’s all thrown away. The molding sand was never that hard. The center core sand typically burned up and was returned in the system.
Para todos aquellos que esten aquí por la tarea de comprensión de sistemas de producción y fabricación industrial, aquí dejo una playlist con todos los videos para que no andeis clickando a cada rato, También decir que hay uno que solo esta en stream y no en youtube, y no se puede incluir en la lista. La lista: ru-vid.com/group/PLm0K76kWT2pTIQwQGHMd9pSLiett0NVCQ
To understand the whole project you could watch: ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-5-JbTpw_QjA.html And then there's the video ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-szXCL_lyfHY.html
Oh yes i remember the smell it was worse when we used furane and alpha set that burned the throat raw when casting out . bloody hard days. I couldnt do it now . green sand was the best to cast with always was . although in ten years green was never the colour.
Although very interesting….my thoughts are with the workers and their health who are not provided the proper safety clothing to include face masks, protective gloves, aprons, and etc. I now understand the importance of the laws of OSHA.
I’d imagine there’s a lot of different options. One we used the most was nickel. It’s been over 20 years so I don’t remember what some of the less used items were.
Great Matthias, I enjoyed this very much. To me molten metal and especially iron is very beautiful. 5:30 you say "this reddish liquid is a suspension of (something)" just curious what that was.
@@matthiasburger2315 chamotte (grog) does not have alcohol base. What alcohol base is added to chamotte? To soften the chamotte, they mix with alcohol instead of water? They can soften with water also. Why do they use alcohol based? Thanks
