I wanted to build a melter for aluminum for a long time but had nothing to make with the molten aluminum so didn't build one. Now a need came up so in a few hours this is what I put together.

Here is the crucible:

http://img469.imageshack.us/img469/4650/crusibleex9.jpg
http://img117.imageshack.us/img117/8121/crusible2bq9.jpg
http://img265.imageshack.us/img265/9941/crusiblenewtd9.jpg

here is the inside weld:
http://img265.imageshack.us/img265/4328/crusible3au9.jpg

The pink thing came from the chimney that we took apart in the house when we bought it, there was 8 of them but I saved two just for this day:)

http://img117.imageshack.us/img117/4898/cuttingceramiccw6.jpg

Here is what all of it looks like:
http://img253.imageshack.us/img253/7507/overalloq2.jpg

I bought the Beckett burner on eBay for like $60 shipped, the things is perffect for this type of setup. Starts nice every time burns with no smoke. The fuel is No2 heating oil or Dyed diesel fuel or off road diesel or farmers diesel all the same. It took about 10 min to get to melting temp. That used about three cups of fuel. Latter I want to experiment with used motor oil for fuel as I have mechanic shop next door there is a unlimited supply of used oil.

For the bottom I cut a peice of granite that fitt tight inside pink chimney thing, but when it got hot enought the granite expanded and cracked the pink thing.

http://img20.imageshack.us/img20/1520/crackto4.jpg
http://img116.imageshack.us/img116/8454/crack2xz1.jpg

Got another one to make it right this time.


Here is the molten aluminum:
http://img297.imageshack.us/img297/1811/moltenincs5.jpg

And the first pour:
http://img106.imageshack.us/img106/2817/firstpourdf4.jpg

Next thing is to put it all on a cart and make the temp controll automatic with this:

http://img20.imageshack.us/img20/7296/tempcontrolat4.jpg

More to come...

that is just looking SOO nice,
i will have to make myself also such an oven.
nice picture's

Beautiful work Dennis....

plz be carfull when poring on concreat cus there is still water left in it when it fulley hard and u spill some on there and it will flash bole the water and explod in your face cusing u to drop the crucible with i contens. saftey frist. i really like your idea of using a old frenis hearter to get your heat. i have just used coal and a blower my self

I'm careful I have a full apron and face shield:)

What kind of mold is that? Is it steel? Currently, I'm experimenting with pouring aluminum into steel molds, with very good results, it's fast with excellent surface finish.
At the very least you should use a pile of dirt underneath the mold to separate it from the concrete. The danger of exploding concrete is very real and very dangerous.

^^ Can you snap a pic of the steel mold you use and a poured part?

Made my first real part.

Pics of the wooden part:
http://img253.imageshack.us/img253/5843/picture6ab8.jpg
http://img146.imageshack.us/img146/3421/picture8it8.jpg


Here it is poured:
http://img255.imageshack.us/img255/1765/picture7ci7.jpg


Part removed:
http://img146.imageshack.us/img146/881/picture4zo4.jpg
http://img404.imageshack.us/img404/6585/picture5pj7.jpg

I milled it on top and bottom today and ran a fly cutter on top and it's looking good!

Nice one!
I hope to be starting my furnace soon :)

nice looking :) Any pictures of it after its milled?

Another poured part, I routed the part out of foam and then packed it in sand and poured the aluminum and this is what I got. It's a little rough, I didn't use any type of shell coating. On the next part I will try the ceiling popcorn compound after filtering out the popcorn, some one said it work better then other things like drywall mud and plaster.

DennisCNC ,

I am thinking about building an Electric Furnace , but need to know if I am better off building the type you have made. Please let me know the time it took to reach the melting point (ballpark it!) and the type of metal you used.

Thank you

It takes about 10-15 minutes, metal is all kinds of scrap around the shop.

Very nice job, ive always wanted to cast ally. May i ask what type of sand you use? does it have anything mixed into it

Does anybody have pic of cast aluminium and machined and polished.

Very nice job, ive always wanted to cast ally. May i ask what type of sand you use? does it have anything mixed into it

I used the finest sand that was at Home Depot and bentonite mixed in to it. I bought the bentonite online don't have the link at the moment.

Dennis,

Sorry for the super late response, but I haven't been to the site in a while. Anyway, I'll post some photos of my "experiments" as soon as I get my camera back, (about a week).
By the way, that's great work on those wooden patterns.

if you want more info on the sand there are links on this site ( http://www.backyardmetalcasting.com/ ) on what parts to mix and how but there is also a link to buy refactory pre-made at 55lbs for 87.00 US.

Also I plan on cutting wood to make mold on my cnc but I have seen a way to CNC styrofoam and then sink that into plaster then pour the ally into the styrofoam which melts it away and settles whats left on top. Remove the ally with plaster on it and break off plaster and BAM part made!

This was from a guy here in the CNCwood area that was inventing his own bearings and I have to say he has down very well with this styro-plaster solution. I think I may try it too!

Coog

i have seen the a guy make the part he wished to modle out of styro and the ram it up in green sand and just pore in the al and he said all the styro is bruned up from the heat and has not had any inclushion in his casting. so i think it will work. i plan on trying it someday my self