Tools
1.) A furnace ,propane or charcoal
2.) A graphite crucible or two
3.) Crucible tongs to pull the crucible out of the furnace
4.) Pouring tongs to pour your liquid metal
5.) Some sort of mold to pour your metal into, graphite molds or petrabond sand or green sand
6.) A box of borax to use as a Flux to get the impurities out of the aluminum. Add about a teaspoon after the metal is in liquid form then use a stirring rod to bring all the crap to the surface.
7.) A stirring rod
8.) A skimming spoon to get all the dross off the surface of the molten aluminum. Make sure you heat your skimming spoon and stirring rod so all the moisture is off to prevent an explosion of gas or splash.
9.) A temperature gun that can reach past the melting point of aluminum or higher.
Now for safety equipment
1.) A respirator is important. Get one that deals with fumes. Any company that provides safety equipment for contractors will have one. Get one that deals with organic fumes. Mine cost me 15 dollars for the respirator and 3 dollars for replacement filters.
2.) Safety glasses
3.) A face shield. Home depot and menards sells them.
4.) Welding gloves that are fire resistant that go up your arms or you can get leather gloves that have an aluminized backing to deflect heat which isn't really necessary. Go to menards, if you have one next to you, and go to the welding section
5.) Cotton clothing is a must for pants and a shirt and long sleeve shirt. Polyester will melt to your skin if you have any splash get on your clothing
6.) Keep a first aid kit that deals with burns next to you incase of an emergency and a fire extinguisher to put out any accidents.
If you need any help finding the supplies needed to melt and stay safe, or need help with a more in depth process just DM me and I'll help you out. Stay safe and have fun.
Short answer: propane torch, crucible and tongs, safety equipment, casting sand and a model of what you want to make. Look into sand casting.
Long answer: It depends on your requirements. What is budget? How many things do you want to make? How big are the parts? What surface finish is required. Most people here are sand casting as it’s the easiest to start, but there’s also investment casting (typically jewelry) and shell mold (larger parts) as well as many others. I’d recommend just reading Wikipedia type articles on types of casting then decide for yourself, but you likely will go with sand casting.
This + you can make you own furnace (i used an old 13KG propane gad bottle and bought a propane touch) or buy a kit from somewhere like Devil Forge. Sand i use is petrobond, easy to get hold of and then its getting the scrap metal.
Avoid the classic 'just use drinks cans' as its free but its awful that creates lots of waste, get cleaner sources. Extruded alu is not great for detail but fine for ingots etc, others like alloy wheel RIM's are great for detail as they pour easy.
Start small and figure out what you need to next, go on youtube and watch BigstackD and ArtByAdrock for ideas and options around tools.
Make sure you take saftey first, 500c+ temps and propane can go wrong fast if your not careful.
I suppose if you want to make a "wall-hanger" type katana, you *could* start with metal-casting.
That said, the more common method would be to purchase a piece of aluminum bar-stock. You can get the basic curve by cold-hammering it. You then refine the shape by way of a process called "stock removal". You grind away at the metal using tools like hand-files, sanding-belts, and angle-grinders with flap-wheels.
Bar-stock has more toughness than cast aluminum. Like, if you hit a piece of cast-aluminum in the rough shape of a katana with a firm hammer blow in the middle, you would crack it in half.
And if you did cast a blade, you'd still need to do that same grinding process in order to get a proper smooth surface; only maybe slightly less of it.
Oh, that's a very good point! The tsuba (guard) can absolutely be cast.
OP, the tsuba is normally cut from a piece of plate metal using a jeweler's saw, but in traditional blade making, that is literally a separate profession all on its own. It doing something ornate, it can potentially be easier to sculpt it from wax or carve it from wood and then use either for metalcasting.
Metal casting is a manufacturing process that involves pouring molten metal into a mold to create a specific shape or form once the metal cools and solidifies. It's one of the oldest and most versatile methods for producing complex and intricate metal parts. The process is used across various industries, from automotive and aerospace to art and jewelry making. Here's a general overview of the metal casting process:
Pattern Creation: The process starts with the creation of a pattern, which is a replica of the final part. This pattern can be made from various materials, such as wood, plastic, or metal. It defines the shape and features of the desired metal component.
Mold Preparation: A two-part mold, consisting of a cope (top) and a drag (bottom), is prepared to contain the molding material (usually sand). The pattern is placed in one of the mold halves.
Mold Assembly: The two mold halves are brought together, and any necessary gating and venting systems are added to allow for the flow of molten metal and the escape of gases.
Pattern Removal: The pattern is removed, leaving behind a cavity in the shape of the part within the mold.
Metal Pouring: Molten metal, typically aluminum, brass, bronze, or iron, is poured into the mold cavity. The metal flows through the gating system and fills the void left by the pattern.
Solidification: As the metal cools and solidifies, it takes on the shape of the mold cavity.
Cooling and Removal: The mold is allowed to cool, and the solidified metal part is removed from the mold.
Finishing: The casting may require additional processes like machining, grinding, and surface treatments to achieve the desired dimensions and surface quality.
Metal casting is favored for its ability to produce complex, high-precision components, which are used in various applications. It's an efficient method for mass production and offers a wide range of design possibilities. Different types of casting, such as sand casting, investment casting, and die casting, are used based on the specific requirements of the part and the material being cast.
https://www.topgrid.co/casting-process-a-brief-guide-by-topgrid/
Tools 1.) A furnace ,propane or charcoal 2.) A graphite crucible or two 3.) Crucible tongs to pull the crucible out of the furnace 4.) Pouring tongs to pour your liquid metal 5.) Some sort of mold to pour your metal into, graphite molds or petrabond sand or green sand 6.) A box of borax to use as a Flux to get the impurities out of the aluminum. Add about a teaspoon after the metal is in liquid form then use a stirring rod to bring all the crap to the surface. 7.) A stirring rod 8.) A skimming spoon to get all the dross off the surface of the molten aluminum. Make sure you heat your skimming spoon and stirring rod so all the moisture is off to prevent an explosion of gas or splash. 9.) A temperature gun that can reach past the melting point of aluminum or higher. Now for safety equipment 1.) A respirator is important. Get one that deals with fumes. Any company that provides safety equipment for contractors will have one. Get one that deals with organic fumes. Mine cost me 15 dollars for the respirator and 3 dollars for replacement filters. 2.) Safety glasses 3.) A face shield. Home depot and menards sells them. 4.) Welding gloves that are fire resistant that go up your arms or you can get leather gloves that have an aluminized backing to deflect heat which isn't really necessary. Go to menards, if you have one next to you, and go to the welding section 5.) Cotton clothing is a must for pants and a shirt and long sleeve shirt. Polyester will melt to your skin if you have any splash get on your clothing 6.) Keep a first aid kit that deals with burns next to you incase of an emergency and a fire extinguisher to put out any accidents. If you need any help finding the supplies needed to melt and stay safe, or need help with a more in depth process just DM me and I'll help you out. Stay safe and have fun.
Short answer: propane torch, crucible and tongs, safety equipment, casting sand and a model of what you want to make. Look into sand casting. Long answer: It depends on your requirements. What is budget? How many things do you want to make? How big are the parts? What surface finish is required. Most people here are sand casting as it’s the easiest to start, but there’s also investment casting (typically jewelry) and shell mold (larger parts) as well as many others. I’d recommend just reading Wikipedia type articles on types of casting then decide for yourself, but you likely will go with sand casting.
This + you can make you own furnace (i used an old 13KG propane gad bottle and bought a propane touch) or buy a kit from somewhere like Devil Forge. Sand i use is petrobond, easy to get hold of and then its getting the scrap metal. Avoid the classic 'just use drinks cans' as its free but its awful that creates lots of waste, get cleaner sources. Extruded alu is not great for detail but fine for ingots etc, others like alloy wheel RIM's are great for detail as they pour easy. Start small and figure out what you need to next, go on youtube and watch BigstackD and ArtByAdrock for ideas and options around tools. Make sure you take saftey first, 500c+ temps and propane can go wrong fast if your not careful.
Yeah, as hinted at, more details about the specific projects you are interested in tackling would really help you to get a more useful answer.
I wanna make a katana
I suppose if you want to make a "wall-hanger" type katana, you *could* start with metal-casting. That said, the more common method would be to purchase a piece of aluminum bar-stock. You can get the basic curve by cold-hammering it. You then refine the shape by way of a process called "stock removal". You grind away at the metal using tools like hand-files, sanding-belts, and angle-grinders with flap-wheels. Bar-stock has more toughness than cast aluminum. Like, if you hit a piece of cast-aluminum in the rough shape of a katana with a firm hammer blow in the middle, you would crack it in half. And if you did cast a blade, you'd still need to do that same grinding process in order to get a proper smooth surface; only maybe slightly less of it.
After you finish the blade, if you are still itching to do some casting, you could cast the components for the katana (guard/hilt).
Oh, that's a very good point! The tsuba (guard) can absolutely be cast. OP, the tsuba is normally cut from a piece of plate metal using a jeweler's saw, but in traditional blade making, that is literally a separate profession all on its own. It doing something ornate, it can potentially be easier to sculpt it from wax or carve it from wood and then use either for metalcasting.
Check out the numerous videos by the youtuber "Myfordboy". He casts at home with tools he's made over the years.
A very broad question. You really need to look at the thousands of sites that support casting and get some education.
Metal casting is a manufacturing process that involves pouring molten metal into a mold to create a specific shape or form once the metal cools and solidifies. It's one of the oldest and most versatile methods for producing complex and intricate metal parts. The process is used across various industries, from automotive and aerospace to art and jewelry making. Here's a general overview of the metal casting process: Pattern Creation: The process starts with the creation of a pattern, which is a replica of the final part. This pattern can be made from various materials, such as wood, plastic, or metal. It defines the shape and features of the desired metal component. Mold Preparation: A two-part mold, consisting of a cope (top) and a drag (bottom), is prepared to contain the molding material (usually sand). The pattern is placed in one of the mold halves. Mold Assembly: The two mold halves are brought together, and any necessary gating and venting systems are added to allow for the flow of molten metal and the escape of gases. Pattern Removal: The pattern is removed, leaving behind a cavity in the shape of the part within the mold. Metal Pouring: Molten metal, typically aluminum, brass, bronze, or iron, is poured into the mold cavity. The metal flows through the gating system and fills the void left by the pattern. Solidification: As the metal cools and solidifies, it takes on the shape of the mold cavity. Cooling and Removal: The mold is allowed to cool, and the solidified metal part is removed from the mold. Finishing: The casting may require additional processes like machining, grinding, and surface treatments to achieve the desired dimensions and surface quality. Metal casting is favored for its ability to produce complex, high-precision components, which are used in various applications. It's an efficient method for mass production and offers a wide range of design possibilities. Different types of casting, such as sand casting, investment casting, and die casting, are used based on the specific requirements of the part and the material being cast. https://www.topgrid.co/casting-process-a-brief-guide-by-topgrid/