Open Mold Casting with Aluminum at home using my Propane Foundry 

Want to use your 3D printer to learn Sand Casting in your home shop? paulsmakeracademy.mykajabi.com/joinus

Love metal casting 😉 great video!!!

Cheers for the informative and engaging video!

I've seen other RU-vidrs cast using this method, and they always press the sand into the object they're casting early on. Then dump all the sand they can to fill it. So I think you should be doing that. Makes sense. Another great video. You're my favorite!

You're welcome on the baby power tip! Corn starch works well too.

Hey Paul, another cool video! Open face casting is another technique I need to try.

another entertaining video, thanks

Finally built my own furnace, excited to try it out. I have some of that HIPS filament I mentioned once before so will give it a go and let you know how it turns out.

You are a funny guy, very entertaining. Thanks man you did a good job, didn’t die and still made me laugh.

Now that I've seen that 2 flasks 1 fun video I can never un-see it...

Great Video ;)

I'm glad you did this open mold casting, I kept wondering if it would be a way to easily make flat-backed pieces. Now I know, ram up the second flask... is that what you call the sand in a box...? and pour it using risers to get that pressure . Thanks

I wish I was your brother. Keep up the good videos and keep learning so I can learn.

This is the kind of casting I'm doing when I finally try out my foundry

Cool video Enjoyed !.

Double-side glue pads(the cheap foam ones that's umpteen in a pack for next to nothing), work great at the end of something to remove patterns and other things from tricky places....

That baby powder has asbestos when he blew it and caughed I about died lol

I have seen people pre-drill shallow holes in the back of the design so they can put a screw in the and lift it straight up out of the mold leaving a cleaner cavity to pour into

You are fun to watch and informative. People need to subscribe! Beat the King of Random in numbers.

Damn son your casting sand is awesome in Australia to buy petrobond sand it's about the price of a new kidney ☹️😒. And I recon your failed castings look better than some of my successes 😁. Either way keep it up my friend 😉🤘🏻

Not sure how you have no views... RU-vid must be against sand casting

Oh! Oh! Additional suggestion for shielding gas during casting: argon is king, of course, a most noble of gases, but nitrogen is must cheaper, if you have a means by which to entrap it upon the casting. Argon's additional advantage over nitrogen is that it is slightly heavier than the surrounding atmosphere and tends to lie quietly in low places until blown away. Be aware that argon can fill large spaces and suffocate humans if contained too effectively in too large of a space. I knew four guys who are all now deceased (two different episodes of industrial fatality). Actually, a helium/argon mix is not a bad choice if you need to surround the items above and below.

I love your channle soooooooo much keep it up

You can add a little hook to remove your items straight up.

Interesting to watch your trial of open face casting. I am hoping to get my electric furnace (patterned after TAOW's) up and running thus weekend so I am glad you talked about degassing with washing soda. I wonder chemistry is going on to remove the hydrogen from the aluminium. Greatly enjoyed your video!

so, the large head, ill fitting hats situation is my life. in completely unrelated news, i purchased a bunch of crap this weekend at junk sales, literally called the "junk jaunt" and i'm now beginning to restore/refinish/make shiny some old saws and a few hatchets, maybe these will help me not suck at some of the skills needed to then begin forging with aluminum. it looks like fun, even though you continue to point out how it probably isn't "fun" in the strictest definition. thanks for the video!

1:00 it's called "elephants foot" when the first layer sticks out from the rest of the print.

3:25 if they ever recast Deadpool, I think you'd be a good fit. Hahaha

Do you think hot glueing the positives to a surface before putting the sand in could work? I figure when you lift the mould off, the positives would stay stuck to the surface and so you'd avoid all the damage around the edges caused by knifeing them out

Great video, Paul, very entertaining! Quick suggestion: beeswax is very helpful when grinding aluminum. Apply the beeswax to the grinding wheel. Greatly improves the efficiency and smoothness.

Could i place a thick piece of steel ontop af the sand to make them les lumpy and get a flat side? If you find the time please try this.

Quick question about aluminum. if I'm melting aluminum car parts and say a steel dowel pin is inside the aluminum. once the aluminum is melted will the steel come up to the top?

drill some small holes and u can use screws to remove parts from sand and maybe sand edges first

Together the cope and drag make a flask.

Love the DUCK!

I recently saw a casting video that recommended using aquarium sand for things that you want a lot of detail from. IDK if that was good advise or an attempted prank, but aquarium sand from pet stores costs more than play sand. Go to the salt water section. The fresh water section is usually more like gravel. I guess it just depends on how badly you want more detail. I think you might still like open faced casting for making ingots, if you enjoy a specific shape that you don't have a better mold for.

I have a Datsun...it's a forklift...it's kinda ruff and lumpy...I NEVER use pool chlorine on it..

Reeeeally old video but quick question...Im looking to get some oil casting sand but I have no clue how dense it is. Could you tell me roughly how many pounds of sand that is in the flask? Also maybe you said in another video but I forget, where did you buy it from? Thanks paul!

Are you saying I need a respiratory when smelting aluminium ? I’m new to this and haven’t melted yet ! How about copper and tin and brass ?

Help! I have a highly detailed Bas Releif plaque about 3.5" X 5" that I would like to use in an 'open casting' project using .999 silver. Is it possible? Any tips?

Hey Paul I found out actually how yo get a piercing blue flame!! You just need one of those big red propane regulators

sand and prime the 3d prints, also drill small holes in back and use screws to screw into the back to pull it. Also the holes in the logo that came out put screws in there when pounding the sand and try that.

Learn a lot from watching your vids. Question for you what should I use for flux? Borax or light salt? Keep up the great work.

I want to do that. But I wonder if you could use a tuna, or sardines can to make a top just over the cast?

If it is melting anything; It's the SD card.... lol 😆

hey paul im actually debating what i want to cast for the first time i actually found some softball sizish skulls at the dollar tree and iv been trying to decide how to possibly cast them their cheap thin plastic and well im not worried about money loss a few decent sized aluminum or copper skulls or whatever you would like to use would be a nice go for Halloween and well yea.....btw dunno if anyone else noticed the pepper in the back ground was that for extra heat? yea corny i know but hey figured id shoot it out their

lol never heard of that ;D

Hey Paul, I got a 1 at solo and ensemble this year, lol.

What If you print the hodor door stopper on its side so the "teeth" or the ridges aren't on the side where it would get stuck in, also when I did stuff with aluminum I was told dust can give you Alzheimer's not really sure how true that is but it always made me be safe with it

Hey um I'm remaking my furnace and I got a paint can in the plaster of Paris and I was wondering how to get it out

I heard you say "Jeep Stuff". I think I know what RU-vidr you watch.

Where do you buy your aluminum? You mention you can buy it all over the internet but I can’t find any to buy?

Anyone else loving that duck toy?

haha the duck do xD

You have said several times that you have musical background. Did you compose the theme song for your channel?

Hey do you know if you can use a cast iron as a cubicle?

for easy smoothing of surface just dipp the parts in molten wax

I've actually read that some people use Morton's light salt in place of the washing soda

I was think you could have used hot glue and something thing to pull those out

Love your vids Paul. Have you checked out olfoundryman?

I thought aluminium steals oxygen not hydrogen coz for thermit you use iron oxide 3 so when the aluminium gets contact it'll take the oxides creating pure iron and aluminium oxide 3

Try clay carve mold casting

I work in an aluminum foundry. We degass it with nitrogen.

You've got the affinity of aluminum wrong. Aluminum (and other reactive metals like titanium) has a very strong affinity for oxygen and to a lesser extent carbon, not hydrogen. Because of this, it will pull oxygen out of most things and leave whatever's left to fend for itself. This is usually hydrogen. Hydrogen has a low but significant solubility in molten aluminum, so it stays dissolved and bubbles out as the metal solidifies. The typical way of extracting hydrogen from aluminum is to use an inert carrier like nitrogen or argon: this extracts the hydrogen out since hydrogen is also obviously soluble in nitrogen gas and so it slowly diffuses out into the carrier. Degassing with most other things won't work well. The problem is molten aluminum is EXTREMELY reactive: it really wants to go back to aluminum oxide, so as you mentioned it will pull water vapor apart to release hydrogen. Thus, almost any other carrier gas imaginable (carbon dioxide, oxygen, nitrous oxide, etc) will immediately be broken down before they can properly draw the hydrogen out. (Plus, the aluminum oxide byproduct will cause other flaws in the metal). By the way, in industry chlorine gas is added to the nitrogen or argon stream to remove sodium and lithium-- it is not necessary to remove hydrogen. Degassing with solids is not a fantastic idea either. Sodium carbonate has a deceptively high affinity for water in storage, and so by adding it to your melt you may actually worsen the hydrogen pitting. It also reacts with molten aluminum to some degree. Adding pool chlorinators is also not a great idea: the common ones either contain hydrogen in their active ingredient or in their filler (calcium hydroxide in calcium hypochlorite shock, for example). Plus, aluminum itself reacts with with oxidizers vigorously (hence why it breaks water apart), and in the solid state and with powdered degassing agents such a reaction could be explosive. (The principle itself is that aluminum reacts with an active chlorine source to release aluminum chloride. This is volatile at aluminum melting temperatures, and so it acts as a carrier gas to remove dissolved hydrogen. However, these substances contain no hydrogen to avoid worsening the problem, and further the aluminum chloride produced is extremely corrosive-- imagine muriatic acid fumes but worse.) Something you might try is to add sodium chloride salt to try and act as a degasser. No idea if it'll work, but it might be worth a shot.

Hey Paul, not really having to do with this vid except, well it IS about Aluminum melting. You were right-yellow flame not enough air. Finally added a hair dryer and now I can melt the legs off the neighbors dog...uh, off the neighbors Aluminum siding. Yeah, that's it. Do you still use Morton Lite to lessen your dross? Reason I ask is I've just been spooning it off but last night I melted a big aluminum pan the wife gets frozen lasagna in. Still had remnants of whatever grand-it does NOT smell like lasagna when you subject it to 1500 degree heat-it also left a puddle of floating ashy, volcanic rock-like stuff that took me 20 minutes of burning my hands to get scraped off. Oh and last but not least, if you go to remelt something fairly thick and large and you realize you should have a pool of Al to melt it into? Don't forget 30 minutes later it was in the furnace and grab it bare-handed. Causes a severe 'Ouchie-oh S**T! Motherhumper! Da...dang!" Just sayin'.

🖒😎

heeeeeeeey paul, how are you going

And every time I melt metal the charcoal gets in my mouth and nose and when ever I eat I taste charcoal:'( the food flavour is lost

Wow no views and ten comments, nice.

Sodium carbonate....soda ash

I need information about that duck... for reasons... yeah. totally not looking for one for me to play with. absolutely not.

I would like to subscribe to your discord channel. Just created an account. Where do I find your email address to request....

BAM! 1st lol Say NO to open face casting.

2nd😥😓😓😓

Don't breathe too much baby powder, it's nasty stuff for your lungs :(

Borax works for a lot of metals wear a face mask if you’re worried about dust stop telling people that the cast they enjoy casting do you enjoy their foundries do you showBe more interesting be helpful first time I watched you you’re funny as hell don’t know you must’ve had an off day anyhow good luck with casting take more time in it and yeah you can get your metals pure enough at least I do

stop talking

I appreciate you but i wish you would stop rambling all the time dude. thank you.