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Sand casting question? (1 viewing) (1) Guest
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TOPIC: Sand casting question?
#4052
Re:Sand casting question? 2 Years, 3 Months ago  
The portland cement is what holds the water and causes it to spall if heated too fast. Quick setting concrete has alumina in it so it's closer to a refractory cement but at a lesser cost.quikrete.com/ProductLines/FastSettingConcreteMix.asp

I used the Mt Savage Super-Heatcrete 32.mtsavage.com/PDF/Section%2002%20Extreme%20Temperature%20Castables.pdf
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#4053
Re:Sand casting question? 2 Years, 3 Months ago  
So the quick setting concrete would work fine as a refractory material to melt aluminum alone? Or would i need to add something to the mix?

I also heard that perlite is a good moisture retaining element that many add to there refractory mix.. is this soo??

Thanks
Stoney
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#4060
Re:Sand casting question? 2 Years, 3 Months ago  
Okay, here's the lowdown on portland cement in refractory mixes. Or any portland-based cement product, quickset included. Will they work? Yes. Will it occasionally work for brass/bronze temps? yes. Will it last? Probably not. I must confess, i built my first furnace from portland, sand, and vermiculite. I used it for almost three years before it deteriorated to the point that it was pretty well worthless. It had been repeatedly patched, and chunks fell out every time I went to use it. Portland undergoes a chemical change at high temp and loses strength. At a high enough temp(brass/bronze, or very close to it) it turns into a flux and the liner turns to a gooey glassy mess. Ask me how I know. It will work for a first furnace. The perlite (or vermiculite) acts as insulation in the mix, unfortunately they are also a flux at high temps and aid the portland in its catastrophic downfall.
If you can, and can afford it, get commercial refractory. Get the highest temperature rated stuff you can, this way if you do attempt iron in the future your furnace will hold up. Try to get at least 2600F, 3000F+ would be better. Don't bother with the insulating castable, get dense castable and add ground up foam to the mix to get the same insulating qualities. if you can really swing it, and where you are using propane you want the best insulation you can get, go for Kaowool with a thin hotface to prevent mechanical damage. It will also heat up the fastest, and your time to the first melt will be reduced.
if you can't find a refractory supplier (check with mason's suppliers) check with pottery places and get some clay. Fire clay is fairly common, Kaolin (EPK is one type) is a purer clay with a higher temp rating. Use the shredded foam trick with this too. The only problem with clay is that it tends to shrink some on drying, this can be counteracted by adding sand, grog, and alumina (the pottery place will/should have that as well). It can also take a while to fire it initially, but if you do it right, you will have a furnace that will last indefinately.
Hopefully I didn't confuse you worse, but honestly, I would skip the portland-based stuff and try to find something else. it will ease future frustration and you will be more pleased with the results. It's like asking if you can tear down an engine with tools from the dollar store. Yeah, it can be done, but the right tools make it a lot easier.
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#4068
Re:Sand casting question? 2 Years, 3 Months ago  
That's a good explanation OddDuck. I was about to buy a bag of portland and build a furnace just to see how much it would take.
QSPSB, go with what you can afford or want to put into this, just to see if you want to cast metal. If your going to keep it up, I just wanted you to have a furnace that would hold up for a while.
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#4069
Re:Sand casting question? 2 Years, 3 Months ago  
Thanks for the replies guys.. I have contacted a refractory supplier and spoke with a guy about the type of refractory material i need,, He stated he has many types of refractory materials that will suit my needs.. I'm going with one with a temp range of up to 3000 degree... I had to look into how many cubic feet of material i needed for the casting furnace and finally located the specs on the old keg.. It holds 15 liquid gallons.. which comes out to 6.5 cubic feet of refractory materials.. It runs from $45.00 to $65.00 a 60lb bag... So needles to say at that rate I'm going to purchase a few bags.. just in case i need more at a later date.. Here is the site URL... www.michiganrefractory.com/?gclid=CNn_kYWe4p0CFQ4MDQodjCkWDg
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#4070
Re:Sand casting question? 2 Years, 3 Months ago  
O.K. guy's take a break from your casting jobs and reply to my messages..

Here is the data sheet on the refractory material i plan on using... Take a look at it guys and let me know what you think of this stuff.. I think it will hold up quite well myself.. but then again I'm a rookie at this
File Attachment:
File Name: Plicast_Al_Tuff_3100_Special_KK.pdf
File Size: 15924
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#4072
Re:Sand casting question? 2 Years, 3 Months ago  
that material should work just fine for you
when you cure it or burn it out i recommend you do it slowly
if you raise the heat too quickly there is a chance the refractory will crack
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Aluminum, brass & bronze sand castings since 1908
 
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