[mercenaria]

For those who have done it, how does the quality of cast al. alloys rate? Such as final strength compared to original, machinability and general porosity? Can you forge (compact I guess) cast al., maybe in a hydraulic press?

[ESjaavik]

If you don't intend to machine the part or it is a stuctural component, getting it in contact with steel is no big deal. But if machining it, it will kill your tools. And if not degassing, it may look fine on the surface, but it will not after machining. And it will not be strong, so not good for structural parts.

But if making plaques and other purely decorative items, don't bother. If it looks good, it is good. If you get blow holes or visible pososity, degas. If you don't get a smooth surface, try oil sand, at least close to the part.

For starters I suggest casting Pewter parts. It involves fairly low temperatures, can be cast in steel crucibles and will allow you to learn some basics. Use oil sand to make it easier to progress to Mazak and aluminum and even cast iron if your furnace can stand the temperature.

[chronon1]

pyroracing85 .... ummm.. that looks like a $million machine .. that you would need a warehouse/factory for .. ... i think it's beyond your needs ---
perhaps if 50% of the members pooled together here, we could have a community melter .. but this picture is a joke of sorts .. this is the kind of
melter you see when you go on a tour in a large factory ...

[tool_man]

A few points I would like to make on this subject.You don't need a controlled atmoshere furnace.If you burn gas,set the blower to give you an oxidizing atmosphere.Aluminum oxided will form on top of the melt,protecting the metal below from further oxidation.The size of the furnace should match the size of the castings you wish to make.There are several manufacturers of crucible furnaces in the U.S. if you do not wish to roll your own.Try johnsongas.com or mifco.com.Another source is E-Bay.I bought a Johnson Model 900 crucible furnace that retails for $3100 plus shipping and paid $250 for it.Can't buy the parts and refractory for that.Uses a #16 crucible for 16 pounds of molten aluminum per melt.Anyway....take your time....do the research.....be carefull....and above all......have fun.

[jacarpen]

I found a great place to buy a "start-up kit" including the furnace at Foundry101.com. My total cost delivered was $500. I will be receiving it on friday