Look Mum - no birds!

@luckygen1001

5 жыл бұрын

And no crows pulling the tails of the parrots?

@ronyerke9250

5 жыл бұрын

I didn't really notice the birds until I read this. 😒

@louiefisher4568

5 жыл бұрын

I always come watch your videos. Good lessons. Very informative. I notice many fewer bird sounds!

@olfoundryman8418

5 жыл бұрын

Lucky, The crows are still around just the parrots have temporarily gone away...Martin

@olfoundryman8418

5 жыл бұрын

Ron, I suspect that those who noticed the birds enough to complain were just looking for something to complain about - people truly interested in the video hardly noticed then and certainly my voice could be heard over them even in the worst bits.. Martin

Why is it that I'm sitting on the other side of the Earth in a different hemisphere and holding my breath watching you work. Man can't wait to see the pour.

@olfoundryman8418

5 жыл бұрын

Craig, Coming soon - within the next week for sure. Yep there are times when I hold my breath too - usually when I try to get a pattern out without ruining the mould😏! .. Martin

I doubt I will ever make pistons but for some reason I am so intriqued with this set of videos you are doing. Keep them coming!

@olfoundryman8418

5 жыл бұрын

Marty, Its not exactly a common thing to make. In all my years (many, many years😏 ) of casting I have only made a couple of different ones. Part 3b will be out within the next week... Martin

instruction and documentation like this keeps these old technologies alive. my grandfather was a master toolmaker, and i'm sure he forgot more than i'll know of that trade. you have my sincere gratitude for taking the time and having the patience to record this for posterity. a bit of immortality, if you will. please keep going! subscribed most enthusiastically!

@olfoundryman8418

5 жыл бұрын

phaeldrusbjb, Thank you for the sub . Taking the time to record and pass this on is my pleasure - I will do my best to keep going... Martin

@phaedrusbjb

5 жыл бұрын

@@olfoundryman8418 Martin, thank you for taking the time to reply. if i may, one request - and realizing that this may take more time than you've allotted. i see a variety of techniques and tools, along with many unfamiliar materials. it would be most helpful if you could post materials used in the video description, perhaps a commonly used or trade name that could be searched. for instance, the mold cores that were solidified with CO2 - not sure the additional material added to the sand (water glass?). and for that matter, do you have a preferred recipe for your sand? if proprietary, please forgive - i know there is so much of value here. i built a CNC years ago and have used it for making miniature plastic injection mold tooling, so your work is similar in some ways, very different in others. sincere thanks, Bryan in NE USA.

@olfoundryman8418

5 жыл бұрын

phaedrusbjb, Yes I think you are right I should be doing this particularly when I use something new. For the moment the recipe is 7.5% sodium silicate (water glass) (5% will do) 0.5 % glucose powder balance 70 AFS sand - cured with CO2 gas at about 15 psi pressure and a flow rate of about 3 litres a minute... Martin

Watched all 3 parts and realized 3b has yet to be posted. The suspense is killing me! Great videos. I work with foundries that produce die cast, permanent mold, lost foam and sand castings. It's great to see the techniques that have lead the way to mass production.

@olfoundryman8418

5 жыл бұрын

snap, Part 3b on the way if I can ever get done with answering comments so I can get to finishing editing it 😏..Martin

Looks like you know what you are doing. A pleasure watching you work. Excited for the next part.

Brilliant! The thought, work and experience gone into that, just wow! Thank you for posting this. Very much appreciated.

I love how skilled and experienced people make stuff look easy.

@olfoundryman8418

5 жыл бұрын

Mindaugas, Its just practice - lots of practice 😏… Martin

Great foundry work - enjoying every minute of it. Thank you.

My hats of to you, enjoy the speed and precision of your work.

Absolutely love your channel, I really want to set up my own foundry but for now I will be soaking up all the amazing knowlage you have so kindly shared for when I do :)

I love this channel!!! I recently found you and i simply can't get enough. I've binge watched all your content. You sir are a true craftsman! Thank you so very much for sharing your knowledge!!

@olfoundryman8418

5 жыл бұрын

Clay, Thank you for your comment - sharing is my pleasure... Martin

This has me on the edge of my chair, can’t wait for the pour. I have a few old engines I’d like to make pistons for. Thank you Martin1

@olfoundryman8418

5 жыл бұрын

Dan, The pour is coming - within a week... Martin

Thanks for sharing your knowledge and experience! Can't wait for the next part.

Martin, as usual a lesson in casting that one would normally take years to learn...Thank you Sir!!!

@olfoundryman8418

5 жыл бұрын

Preston, My pleasure... Martin

Love the vids, I wish you could do one making a 19" sheive/pulley

@olfoundryman8418

4 жыл бұрын

Bradley, I am supposed to be helping someone make a couple of 20 inch band saw wheels but virus lockdown is getting in the way. Not all that difficult (I hope) but damn big and heavy moulds. But one day maybe!... Martin

Your videos are amazing, thanks for putting so much work into showing and explaining what you are doing. You have a new subscriber with me, I had just watched the first 2 videos and was eagerly waiting for this one. I'm looking forward to the next part.

@olfoundryman8418

5 жыл бұрын

Jon, Thanks fpr the sub. Next part is about a week away (maybe a but less if I can ever getaway from replying to comments and back to editing 😀)… Martin

This is fascinating. Thank you for sharing your expertise.

Truly wonderful work, that mould is amazing! I can't wait to see the pour.

@olfoundryman8418

5 жыл бұрын

Plysch, Thank you - the pour video is in preparation next week at most... Martin

Very cool method for setting up the mold. Very touchy though. Requires a steady hand! Good thing you're qualified! :D Can't wait for the pour!

Watching this series has been a great pleasure for me. You are one of a rare breed as you possess a great deal of knowledge and are able to share that knowledge in a clear, concise manner, while actually performing the work. You also display the quiet humility of a true craftsman and mentor. My hat's off to you, sir! I am strictly a student, not a practitioner, but feel as though I have gained a great deal of knowledge of what you are accomplishing without any large gaps in the process nor the sequence. I realize that there is a monumental amount of experience behind this process and most of the background are omitted in order to get to the meat of the project . I wish I were younger and had more time as this is a skill that I would love to possess. So, I will watch, listen, and live vicariously through your videos. Thank you for doing this for us! Ed

Thank for putting these vids up. Fascinating.

@olfoundryman8418

4 жыл бұрын

J, Putting these videos up is my pleasure and I am glad that you enjoy them... Martin

great video cant wait for the final video

Great example of a fairly deep sand mold. I like your gating and feeder setup. This should be a treat to see on the next video. Happy you ate your wheaties on the lift I'm thinking.

@olfoundryman8418

5 жыл бұрын

Audio, Sadly one of the - ahem - "pleasures" of old age is a gradual loss of strength and 3 of those boxes high is now just too much for me -once long ago - yes, but now - no... Martin

@KravchenkoAudioPerth

5 жыл бұрын

Martin you are still a hard working man. And for that you can be happy. Plus you get to educate and entertain a bunch of arm chair viewers who truly appreciate your work. Mark

Good to see the old skills being used so well. Not a bloody CNC in sight. ;)

@olfoundryman8418

5 жыл бұрын

Hugh, A small confession, I do own a CNC but mainly cast things to as near net shape as possible. The CNC is used for small runs of whatever and also for making dies for gravity diecasting work. It was used for machining the chills in part 1. Casting plus CNC can be a very powerful combination... Martin

@shug831

5 жыл бұрын

@@olfoundryman8418 but you use it to add to what your skills have already made. Most people now think engineering is drawing a little picture on 3D software and pressing the green button.

This has been amazingly complex, especially compared to the typical castings I have seen. Very cool!

@olfoundryman8418

5 жыл бұрын

John, Ys, I guess it is a bit more complex than most (but not all) of the castings I have been called upon to make. Quite some sense of satisfaction in being able to do it successfully too.. Martin

very interesting series to watch. spent about 10 years in foundries doing different things. our molds were much different. you definitely have developed quite a skill and knowledge for what you do. thanks for sharing

@olfoundryman8418

5 жыл бұрын

Tinmad, yes I guess I do have my own little methods and many foundries (particularly the older time ones) would think me mad, not that I am biased of course but they are wrong 😀. Sharing is my pleasure... Martin

@tinmaddog3962

5 жыл бұрын

@@olfoundryman8418 all my work was automotive industry using permanent molds with air or water cooling in the cores. very cool to see how sand molds are made/engineered

gracias por su repuesta amigo martin, le deseo mucho exito en su labor. saludos desde venezuela

High stakes sand castle building! Looking forward to the pour.

@olfoundryman8418

5 жыл бұрын

Volcker, Pour coming soon..Martin

Amazing as usual! Thank you!

@olfoundryman8418

5 жыл бұрын

Christoph, Thank you for your comment, I am glad that you enjoyed the video..Martin

It's coming right along..... Can't wait to see how they turn out.

@olfoundryman8418

5 жыл бұрын

Eddie, Spoiler alert! They actually turn out rather well even if I do say so myself 😀. Not perfect mind you (what is?) but oh so very damn close and the customer is very happy - his little 1910 Brush is putting around the country side very sweetly he tells me.. Martin

These are so fun to watch!

@olfoundryman8418

5 жыл бұрын

asicerik, Glad you enjoy them... Martin

Great stuff. Cheers

I love this stuff ! Melting metal in making something so cool there’s something about melting metal that intrigues me !

@olfoundryman8418

5 жыл бұрын

Juan, Careful its addictive.😏… Martin

@juancarrera657

5 жыл бұрын

Olfoundryman Can I come work for you I like addiction I just don’t drink do drugs or smoke , my Addiction have always been sports and work . I love building cars and I had a windsurfing company a built aerospace composite type sailboards . I have the perfect temperament for what you doing and I am careful and detail orientated . I And I need the job I haven’t worked since 2008 when injured on the job I pretty much recovered but I’ve been paralyzed and had a operation to repair that I’m in pretty good health now . Just fascinated by this .

@olfoundryman8418

5 жыл бұрын

Juan, Sadly I am (apart from the good lady wife) a sole worker and I wish to keep it that way as ones problems in any business seem to start when you employ other people... Martin

@juancarrera657

5 жыл бұрын

Olfoundryman worked for myself and I’ve had three businesses . Love building engines !

I loved the lifting jig that was very smart

@olfoundryman8418

5 жыл бұрын

Rabih, It works quite well... Martin

Sir you are a true artist, beautiful work , I now understand part one

@olfoundryman8418

5 жыл бұрын

Pete, Thank you - I thought that part3 would clarify things a bit... Martin

@randomoldbloke

5 жыл бұрын

Considering the early days of what they used to a 2 part piston is still in the realms of possibility, some very weird things were tried in the early days that have not stood the test of time or practically

@olfoundryman8418

5 жыл бұрын

Pete, Often those odd early day things were attempts to get around someone else's patents. This started at the very beginning of the steam era -Watt Bolton Trevithick et al. Many were indeed truly weird and when the patents expired some sense and reason returned with the wacko ideas being dropped... Martin

...perfection is seldom achieved in THIS world-!!

@olfoundryman8418

5 жыл бұрын

Dale, Not yet ready to try and achieve it in the next😏… Martin

Another Great video!! Thanks again

@olfoundryman8418

5 жыл бұрын

Thomas, My pleasure... martin

Martin, Interesting book, I have no piston cast's to do but I always have a ready supply of old pistons to one side ready for refining. I must keep an eye out for that book. You know this already if you watched your own video (I know as I make some of my video's I hear my self saying why didn't I do this/that!) But you could have saved your self the weight and added the riser extensions and pouring basin once assembled! Looking forward to the next video. talk to you soon mate

Superb !

I do like that secret weapon. Nice video.

@olfoundryman8418

5 жыл бұрын

Michael, So do I.. Martin

Parabéns por tanta dedicação!

@olfoundryman8418

5 жыл бұрын

Adilson, Thank you... Martin

Great as always; thanks much.

@olfoundryman8418

5 жыл бұрын

Jim, My pleasure... Martin

From the presence of the cobwebs in your feeder rings, I can only conclude you had them stored in my skull, lol... Ingenious way to put wasted empty space to use Martin!

@olfoundryman8418

5 жыл бұрын

Luddite, Beware - I am short of storage space always on the lookout for more, now I know where some is 😀. I make these short feeder extensions out of resin coated shell sand and keep them on the shelf, they last forever.. Martin

Another great video thanks - so much more to this than you think. Why is that someone such as yourself who knows what they are doing has so many less subscribers than some that do rubbish jobs with small home made furnaces and no idea what they’re doing? Anyway, keep up the great work, appreciate the time you take to bring us these videos. 👍😊

@markfryer9880

5 жыл бұрын

Ah one of the many and great mysteries of the land of You Tube.

@olfoundryman8418

5 жыл бұрын

Phantom, Mark, A mystery of YT indeed, and a damn frustrating one at that! Sometimes though I think its an entertainment versus learning thing, people want to be entertained by some one pouring metal into some vegetable or other rather than being taught something - sadly (perhaps) most watch YT to be entertained, not to learn..Martin

what a monster cliffhanger!!! I'll be biting finger nails till I find the next video online! =))

One thing my grandfather did on old rigs but won't on new ones was put piston in lathe and cut ring groove wide enough to put two sets of rings instead of buying new pistons.each groove was widened to except two sets instead of being loose with one set

@olfoundryman8418

3 жыл бұрын

Joe, It does not surprise me what was done - I have heard of people fitting pistons made out of a hard local wood to older slower engines. Don't know how long they lasted but maybe long enough to sell the engine 😱... Martin

Loved it, kept me on the edge of my chair, I need to get a life!!!!

@olfoundryman8418

5 жыл бұрын

D.R.M, You have got a life and if you are watching my videos I like to think a good one 😊… Martin

Oh, I miss the birds. No doubt the cnc oriented will go troppo again once they see how much work goes into this mould. They don't seem to understand the customer is always right. There is no doubt, cnc work can replace many castings, as we well know, but it is not always the better way. Many restorers want the part to look original, no matter the cost. Loved the pattern lifter, do hold a patent on that? Can't wait for the fiery furnace part, I want to see the end result of all this work that you have put into this casting. Once again a great video, those with an interest in skilled foundry work must find this most educational, I did and I am a cnc person!

@olfoundryman8418

5 жыл бұрын

Smallcnc, The birds seem to have flown North(?) for the summer at the moment they are in absentia. Being nectar feeders I think the only come in the lean times of the year when there are few flowers about. Part 3b in preparation but you don't see much of the fiery furnace the pour yes, the furnace, not so much. Re the cast versus machine debate, I own a CNC mill and I would not like to have to machine the necessary small radii 5 inches down inside a 3 inch hole whilst dodging around two gudgeon pin bosses. Quite possible of course, but not all that easy and anyway as you intimated the customer (he who is ALWAYS right) wanted a casting so that's what he got... Martin

@dfross87

5 жыл бұрын

And can you imagine how much that sort of machining would cost? The amount of aluminium removed from that sized billet to make that piston would be enormous.

@smallcnclathes

5 жыл бұрын

I must admit, I really have no idea of the cost, my cnc work is limited mostly to turning. I can see difficulties using a long skinny cutter to get right down the inside though. I make some parts where 40% of the billet is turned into swarf, it is very wasteful, but that is what the customer needs to be able to sell the parts. It is easy to see a job as being easy to cnc, but perhaps if some of the folks suggesting it, really sat down and tried to work out how they would do it, the result might be a bit different. When they see the finished part (hurry up Martin) they might more clearly see what they would be letting themselves in for!

@daleburrell6273

5 жыл бұрын

@@smallcnclathes Dont you mean "chips"? Over here, "swarf" is defined as the waste from grinding.

@smallcnclathes

5 жыл бұрын

Dale, so that is why so many videos refer to making chips. I have only ever heard of it referred to as swarf here in Australia and I have been here 55 years, I can't remember what it was called in the UK. Also explains why youtube always under lines it as a spelling error, but then that also happens with aluminium, which of course is easier to get wrong than aluminum. LOL

Olfoundryman, Martin, I think I have watched most all your videos. I enjoy the Canadian TV show how it's made. I find watching your work very informative and just as captivating. I have looked at your flask design during the videos. I am sure many of us would appreciate a quick discussion on the design. One similar to lighting the furnace or the design of the sand conditioner. Your insights are very valuable and would ensure superior results for anyone attempting to make some. I have located a commercial aluminum foundry near me so I anticipate they might have materials or the like you might recommend. Best regards. Louie

@olfoundryman8418

5 жыл бұрын

Louie, Ah a Canadian- Bothe my parents were Canadian dad form Agassiz BC mum from Winnipeg. I guess with a name like Louie you are more likely from a French speaking area? re the flasks I did make these flasks, many years ago and have been very glad of them ever since. Shortly I will have a video out about my journey through flasks discussing what I have tried and what was right and wrong with each of them. Then another video is in plan where I present a design for a versatile flask suited to the hobbyist. I will make such a flask during the video and it will be deliberately done with very limited equipment - the sort of thing that most people would have access too - so stay tuned. To make contact with a local foundry is a great idea if you get on well with them they could be very helpful - be aware though that they might regard my methods as, er, well - eccentric (they would be wrong of course 😏… Martin Reply ·

@markfryer9880

5 жыл бұрын

Martin, eccentric? Perish the thought.

@dfross87

5 жыл бұрын

That's one of irregular verbs, isn't it? I have an independent mind, you are eccentric, he is round the twist!

@louiefisher4568

5 жыл бұрын

That sounds great Martin, you're a top notch guy! Say, you make reference to your home foundry. Would you share a timeline of your experience with us? I know you've been at this for decades. I'm not a nosey guy, but I'm sure many of your subscribers would appreciate a recollection.

@olfoundryman8418

5 жыл бұрын

Louie, I do have an upcoming video on my 50 plus year journey through moulding boxes in preparation. It is to lead to another video on a versatile moulding box design that we have come up with that we think very suited to the hobby caster.This is sort of along the lines that you are suggesting and I guess I could expand on that later - I will give it some thought... Martin

Another possibly helpful thing you can do with your 'secret weapon' to make life a little easier. Have a look at a book press or the device they use to press bearings into things. You could add something like that to your device to make it less of a struggle getting the molds out. Hopefully the mold will be heavy enough that it stays on the table when you use it.

@olfoundryman8418

5 жыл бұрын

MIckk, I have seen this done with an air cylinder. It is only a little time ago that I made this device (for this very job actually) so its still a work in progress. Oh yeah, the mould is MORE than heavy enough to stay on the bench .😏.. Martin

@edbryant4762

5 жыл бұрын

@Mickk, I had the same idea, an arbor press mounted on Olfoundryman's jig and started with the lever in the fully extended position when screwing it to the core. Then a gentle raising of the lever would provide straight upwards pressure with the mechanical advantage of the length of the lever.

@olfoundryman8418

5 жыл бұрын

Mickk, Ed Bryant, A rack and opinion set up is that what you are suggesting - yes? Certainly possible... Martin

it's realy exciting!!!! sorry for my bad english !!!

@olfoundryman8418

5 жыл бұрын

Joao, English perfectly understandable, and way better than my (non-existent) Spanish... Martin

Thank you. A most interesting Video. Please would you say what is the "Filter" made of? How is it made? Do you buy them ready made? What is the releasing compound you paint on: How is it made or obtained? Rob. South Gloucestershire, UK.

@olfoundryman8418

5 жыл бұрын

Rob, The filter is some sort of ceramic foam. I do not know its composition, but I believe that are made by dipping some sort of flexible plastic foam in a ceramic slurry, squeezing out the excess slurry then drying and firing to burn away the plastic and leaving the now fired ceramic foam. I buy them ready made and they are available in a range of sizes of which 50 mm diameter and 50 mm square both 20 mm thick are perhaps the most common. Many foundry supply houses have them, Foseco for example, but mine come from Pyrotek. I am not sure if you can get them in small quantity, mine came in a box of 500 they were about $0.50 each. I assume that by release agent you mean the silver paint that I put in the mould for the CO2 cores. Its not really a release agent its actually a chill coat for moulds and cores it just seems to work as a release agent for me but there are probably better ones out there. It is called "Mouldcote 15" and it is made by "Foseco"....Martin

Just a quick question: You have the plug for the inside surface of the piston and that surface will not be machines at all. Would it not be more effective to have made the outside of the piston using 2 sections that are split vertically? The inside has to be dimension-ally correct but the outside will be machined no matter how good the molded outside surface is so making it bigger just leaves more meat to play with during the machining process and the vertical split mold makes it far less "complicated" to produce the casting mold. Just a thought - this is far removed from the taps and plumbing fixtures which is where my limited experience is.

@markfryer9880

5 жыл бұрын

Valid point and many of us will be interested in Martin's response.

@olfoundryman8418

5 жыл бұрын

The mad, Mark. A vertically split sand mould is a bit harder to make and requires special boxes. But that said it could have been done but you would still have to use the sand core for the piston inside. I don't really see any advantage in doing it with a vertical split. Note that its best to keep metal sections as thin as possible (within reason) any extra nmachining allowance is going to make getting a sound casting just that much harder. For production work of thousands of pistons the mould is metal and is split vertically, the core is a multi segmented metal affair that is pulled out sequentially to allow the casting of the gudgeon pin boss undercut they would make about 1 casting every 1 to 2 minutes.... Martin

Thanks for all the information. I have a few questions about the chill; 1. What is the chill made of? 2. Why does the chill have a cross hatch pattern machined into it? 3. Why did you put the chill into the mold vs. putting it on the core and freezing the inside first? 4. All pistons seem to have this kind of hatch pattern on the inside. I'd always wondered why. I realized after watching your video that they are using chills. But most mass produced pistons are gravity die cast in a permanent metal mold. I understand how a metal chill would work in a sand mold by conducting heat faster than the sand. But how does it work in a metal mold?

@olfoundryman8418

4 жыл бұрын

Sunil, 1. The chill is made from cast aluminium US 356 alloy. It could have been made from steel cast iron or even copper, but aluminium was convenient for me. 2. The cross hatch pattern allows air and gasses to escape better (I think!) Without it the metal being cast will not sit nicely against the chill and you get a most ordinary looking surface. I think that the pattern also helps the metal flow better - sort of like the dimples on a golf ball without them the ball would only fly half as far - its a boundary layer flow effect I think. The pattern may also increase casting chill contact and so provide better chill but I think this a marginal effect 3. Several reasons (a) the chill is heavy would be hard to get it to stick to the underside of the core (b) could not get a chill as big on the end of the core (c) The idea is to solidify the casting from the bottom up this is best achieved by chilling the bottom of the casting (d) the top of the piston (cast down) is the part we want soundest hence its the part cast against the chill. 4.Marks inside pistons are sometimes just left by the joints of the multipiece metal core (typically 5 pieces) plus associated identification marks - I have not seen any inside a piston that I feel would count as true intentional cross hatching - note, hatching is often in just one direction on gravity die castings. Many pistons (gravity die cast) have all sorts of "hatching" on their ODs as cast - mostly gets machined off - I think this is more about flow control that any chilling as a gravity die is effectively one big chill. The thickness of die coat on the die is sometimes locally altered to help control heat flow. I have used dies (not for pistons) that have water cooling at one point to set up areas of the die that will chill faster than the non water cooled areas...… Martin

@SunilSundar

4 жыл бұрын

@@olfoundryman8418 wow! Thanks again for sharing so much knowledge.

excelente su trabajo amigo, una pregunta usted podra hacer cualquier tipo de piston no importando para el tipo de motor, siga adelante con su labor y saludos desde venezuela

@olfoundryman8418

5 жыл бұрын

Amador, Greetings from Australia. Yes, you could probably use this method to make any sort of piston... Martin

This looks so difficult but when a master does it it looks easy

@olfoundryman8418

5 жыл бұрын

jkay, Its just a matter of practice.. Martin

@jkay3161

5 жыл бұрын

@@olfoundryman8418 Out of curiosity how long have you been doing the sand molding for

@olfoundryman8418

5 жыл бұрын

jkay. Too long! Seriously, I started 64 years ago but only got serious about 50 years back mde a living from it or about 30.. Martin

@jkay3161

5 жыл бұрын

@@olfoundryman8418 well it shows it your amazing work I just wish I was in your neck of the woods I have a little one who would love an aluminum Brachiosaurus from an expert. I watch the your videos with her and she is just fascinated with you she calls you the man who plays with sand

If you had molds for john deere G pistons there would be a good demand where I'm from at the moment. Myself being one person in need. Amazing work!

@olfoundryman8418

5 жыл бұрын

Jason, I seriously doubt that I would be competitive - those Brush pistons should have gone for about $250.00 each which even I have to admit is a hell of a price for an unmachined piston and this does not include the pattern and core box cost. Restoring an older vehicle is a labour of love and an expensive one at that. However if the demand is high enough a combination of sand core and gravity die should produce a much cheaper part. But see my reply to your later comment... Martin

Great videos. What is the white powder you are sprinkling on your mold?

@olfoundryman8418

5 жыл бұрын

Ron, It is finely ground calcium carbonate bought as a commercial parting agent.- 1/3 the price of talc and safer too.. Martin

@ronyerke9250

5 жыл бұрын

@@olfoundryman8418 we use calcium carbonate ( among other things) to melt snow and ice in the winter. I wonder if grinding up some of those pellets would yield a suitable parting agent.

ya me he suscrito a tu canal gracias amigo

@olfoundryman8418

5 жыл бұрын

Amador, Thank you for the subscription... Martin

What kind of sand do you use? ... did you buy it or did you make it?

@olfoundryman8418

Жыл бұрын

Niko, I use a natural green sand. Apart from sieving to remove the few little quartz pebbles that it contains and tempering with the right amount of water I use it as dug out of the quarry. I bought a truck load many years ago from a quarry now closed down. I do grind some of this sand a bit finer to make my facing sand.... Martin

I know this may sound stupid, but what is the Black Powder you put on top? What's it's purpose?

@olfoundryman8418

5 жыл бұрын

Just Me, The powder (its actually a dark red) I put on top of the feeders immediately I have finished the pour is an exothermic called "Ferrux NF" it is made by "Foseco" although no doubt other foundry supply companies will have an equiovalent. It catches fire and generates a lot of heat. This keeps the metal in the feeders liquid for longer so they are better able to provide liquid feed metal for the solidifying casting underneath...Martin

@JustMe-bu8pu

5 жыл бұрын

@@olfoundryman8418 That's kinda what I was thinking, just never seen anyone use it. Thanks.

What is the exothermic? What purpose does it serve? Apologies if this is a dumb question.

@olfoundryman8418

5 жыл бұрын

Skully, Its not a dumb question but it is a common one! It seems I am the only person of YT to use it. Here is my standard answer ;- The spoonful on the top of the feeders is an exothermic compound, its job is to catch fire and generate a lot of heat. This keeps the feeders liquid for longer so they are better able to provide liquid feed metal to the solidifying casting underneath. It is called "Ferrux NF" and it is made by Foseco. I find it is a great help in the production of shrinkage free castings and I use it almost on every sand casting.. Martin

I've watched your videos now for a while and I have to admit that you are amazing with the way that you explain everything in detail. But while watching you ram up the pattern for this & seeing you struggle with the way that you had to tuck the sand underneath the bit at the top of the 2nd frame could you have had that 1 bit removable to make it easier to put the sand in place then fitted the other piece in place to finish raming the pattern up . I don't know anything about this sort of thing but I just thought it may help you.

@olfoundryman8418

5 жыл бұрын

Steve, Yes, indeed we could have had a loose piece for the flange section of the pattern. I have in fact done a lot of work exactly like that (Riley water pump pulley kzread.info/dash/bejne/nYFq0ch7dc-2edo.html ) Very astute of you to have thought of it!... Martin

I want to watch this, I just need to find 30 mins alone so I can enjoy this.

@olfoundryman8418

5 жыл бұрын

Brandon , Come on, share it around - watch it with a friend 😏.. Martin

Where do you get the sieve from?

@olfoundryman8418

5 жыл бұрын

Henry, CMT Equipment in Brisbane Australia (www.sieves.net.au)… Martin

@eleventeenmachine5991

5 жыл бұрын

Thanks Martin. I'll check them out. Seems hard to fine them here in the U.S..

Excellent video thanks. KZread is swamped with casting videos of simple parts showing poor foundry techniques. Your videos are the opposite. How long can you leave a finished green sand mould before you pour it? Can you wait days, or does it dry out and loose strength?

@olfoundryman8418

5 жыл бұрын

Rotary, Yes, I got onto YT in response to what I saw in the sort of bad information / technique being demonstrated. I am trying to correct the information. I prefer to pour my moulds the same day as they are made but it is not necessary to do so. It can wait for days, you just need to cover the feeder and sprue holes so that nothing falls down them during the wait. They will dry out but only very slowly and it does not mater anyway they will not fall apart. In fact it used to be common practice to oven or at least flame surface dry moulds before pouring. Solidification is a lot slower in dry moulds...Martin

I enjoy your videos very much. But I wonder why you are in such a hurry when you make molds? Is there a deadline?

@olfoundryman8418

5 жыл бұрын

Stephen, No, no deadline -well not with this one. I guess its a hangover from many years of having to get a certain number of moulds done in the morning so I could pour them in the afternoon....Martin

Would it be better to re-tamp an area after inserting nails? By my thinking, that should help stabilize the mold in that area by setting the nails and sand. Then again I make no claims as to knowing anything about casting, just me being curious.

@olfoundryman8418

5 жыл бұрын

Ian, I find that simply pushing the nails in fairly firmly so the top of the sand is compressed a bit when I do so seems to work quite well. There could be a danger in re- tamping to much as it would make the sand so hard that it would not give a little when the pattern was rapped, instead it would break away - last thing we need. Curiosity is a good thing... Martin

Where do you get the core from

@olfoundryman8418

4 жыл бұрын

Yousef, I make the core myself. This is shown in this video kzread.info/dash/bejne/iXyum9infr3eqtY.html … Martin

Excellant work ! You don't need to spend much time editing your videos, they are good as is! Can you share your exothermic recipe?

@olfoundryman8418

5 жыл бұрын

S Bell, The exothermic is a propriety material so I don't know its make up. However if you google "foundry exothermic" you should get some idea of a recipe. Editing takes about 2 days per video! Without it you would be watching well over an hour each time much of it boring and repetitive... Martin

That had me holding my breath.. looks really good though. Can't wait to see how it pours

@EmmaRitson

5 жыл бұрын

@Wayne Coke haha.. I'm in awe

Looks like a laboratory sieve. How much was that?

@olfoundryman8418

5 жыл бұрын

Douro, It is not actually a lab sieve as it is not certified - they tend to be quite expensive. This sieve came from CMT Equipment in Brisbane who also carry certified sieves. It is stainless steel and I think it was around $90.00 but don't hold me to that... Martin

Love your stuff. Magnificent. Air pressure,~PSI? Just a couple of pounds? when you blow shit from the mould box.

@olfoundryman8418

5 жыл бұрын

aubreyaub. Air pressure about 15 psi. I have a separate cheap little regulator in the line to be sure of this. Also I am careful how I squeeze the trigger of the air nozzle slowly at first as the sudden rush of first air can be damaging, often too I will point the nozzle away until the flow is established. It does take a little practice... Martin

@aubreyaub

5 жыл бұрын

Olfoundryman Thanks mate.

Did you record this at night when the birds were asleep, or are they migratory? I did hear the odd bird, but nothing like some of your other recordings. I held my breath a bit when you said, "Oops" (25:04). It would have been heartwrenching had that mold tipped off the bench.

@olfoundryman8418

5 жыл бұрын

Ron, Its happened and more than once but not this time. as I have got older moulds like this have got heavier (a lot heavier) so I tend to be a bit slow and deliberate handling them.. Birds are nectar feeders and when is spring with lots of flowers (like now) they don't come as much, preferring - I guess - their natural food... Martin

@davidjohnson6588

5 жыл бұрын

Same here

Dear Martin, 1: I like the birds. 2: The suspense is killing me.

Isn't all the sprue and such lose quality? Certainly alot of silicon and magnesium have been lost to oxidation and what not. How much work is required to re smelt and bring back to original metal properties? CNC chips have contamination but otherwise are metallurgically more closely related to the billet I started with.

@olfoundryman8418

4 жыл бұрын

Mr Wolf, Sorry, but I have to disagree with you here. A quick look at the Ellingham diagram shows that both aluminium and magnesium would be protective for Silicon. Both have far greater affinity for oxygen than does silicon and would thus oxidise in preference. We can thus be reasonably sure that any oxidation of the silicon would be insignificant. Magnesium should oxidise in preference to the aluminium but the difference in affinity for oxygen is not as great between these two as it is between them and silicon. However, as there is about 85 times as much aluminium as there is magnesium, we can expect some oxidation of both. However, the big determinant is that aluminium forms a protective film of oxide instantly on exposure to air. This film, while initially very thin, thickens up to the point that it protects the aluminium underneath from further oxidation. It is this simple fact that allows us to use a metal as reactive as aluminium in real life - without this film the aircraft industry (and many others) would simply not exist. With proper attention to how a casting is made this oxidation will be restricted to the surface of the casting. Considering the bulky nature of this casting there is a lot of metal for little oxide film but, yes, this oxide will be lost on remelting. My experience at a large aluminium gravity die foundry with in house analytical facilities was that provided the ratio of new ingot to returns (feeders runners etc) was maintained properly the analytical difference between new ingot and in-house melt containing about 50% returns was negligible However, if we consider machining the same part from billet the situation is very different, we would need a piece of billet weighing 3.5 KG to produce this part weighing 1.5 Kg thus 2 kg would be converted to chips. Considering milling cutter feed rates chip thickness is likely to be less than 0.1mm. 2 kg of chips that thin will have an absolutely massive surface area all of which will have an oxide film on it - a film that is NOT recoverable and is difficult to almost impossible to separate out from the unoxidized chip interior in remelting operations. Chips are about the worst metal feedstock known; losses are very high. My own experience from many years ago when I was silly enough to try it gave about 30% LOSS of material. The loss is highly unlikely to be in line with the analysis of the billet so the metal produced is NOT going to be like the original ingot. And this is before we consider the problems of chip contamination with other metals or aluminium alloys - I have never seen clean one alloy chips come off the sort of jobbing operation that would be entailed here. In short whilst I feel confident about reclamation of foundry returns from all aspects including metallurgical concerns I will not (again) try remelting chips as it is a specialised business and needs the backing of in-house analytical facilities to correct the composition of the end product. Worse still chip remelting even by competent facilities inevitably produces an inferior alloy contaminated with many unwanted tramp elements e.g. iron ….. Martin

@mordantly

4 жыл бұрын

@@olfoundryman8418 that is an interesting point the surface area of oxides ratio is massive for mill chips thereby altering the net material composition. I take it 100% reclaimed foundry scrap would be high enough to also alter the net composition. Probably why we get like $0.18/lb chips and around $0.75/lb for billet 6061.

@olfoundryman8418

4 жыл бұрын

Mr Wolf, Yep, the price says it all. Chips are hard to reclaim not only all that surface area but they are wet with coolant etc - everything reclaimers do not like! Yes, I think 100% reclaim a bad idea one that will lead fairly rapidly to a state of "who knows what alloy".😊 Of course many hobbyists only ever melt down other castings and returns so what they wind up with is very much an unknown 😱. As far as possible I strictly adhere to a reasonable mix (50:50 usually) of new certified ingot and in house returns, I never use outside scrap or castings. I won't even use alloy wheels because they can be any one of several alloys apart from 356.... Martin

As I am not a native speaker, I think I did not get what exactly the purpose of this thick metal disk is t 13:08 (this is the part which was casted in part 1 of this series). Could somebody explain?

@olfoundryman8418

4 жыл бұрын

Sebastian, The thick disc is a chill. ITs function is to rapidly cool the part of the piston that forms against it this makes the metal freer of shrinkage and gas porosity sounder and finer grained and thus stronger..... Martin

@SoaringExperience

4 жыл бұрын

@@olfoundryman8418 Thanks a lot!

Rotating the pattern 45° relative to the flask would give a bit more room for ramming.

@olfoundryman8418

5 жыл бұрын

Ssmith. Very observant of you to have noticed this! I sized it up and, yes, it would work rather well it certainly would give more ramming room, corners of feeders a bit close but that's no problem. Would have to make a new oddside though, but have a tame patternmaker who will do that for me. Thank you... Martin

wow how complex is that mould. That’s probably why they pay you the BIG BUCKS!

@olfoundryman8418

5 жыл бұрын

SEa, Sigh - if only they did 😏… Martin

There's a lot of preparation in this mould Martin,lucky the Brush is not a V8.

@daleburrell6273

5 жыл бұрын

...well, if it was- it would simply be a lot more work, and it would take longer(!)

@danielcrawford7315

5 жыл бұрын

@@daleburrell6273 , and more excellent videos! Martin is truely good and informative as well as entertaining as he takes us thru the process. Blessed days sirSir,Crawford out

@daleburrell6273

5 жыл бұрын

@@danielcrawford7315 YOU BETCHER LIFESAVERS-!!!

if this was an ongoing product. id get a steel mold made if the price was reasonable

@olfoundryman8418

3 жыл бұрын

donny, There was recently a rally held for Brush cars here in Australia it turned out to be the biggest rally held for them in many a long year as apparently there are more of them here in Australia then even in the US where they were originally made. Just 14 vehicles attended, so the market is small - vanishingly small! Way too small to justify a metal mould. However I do agree that if the demand was there (thousands) a metal mould would be the only way to go.... Martin

You shhould make a stand with a handle that you twist and it rises ans pulle the part out.

@olfoundryman8418

5 жыл бұрын

Brian, On a coarse sort of thread do you mean? or on a straight lever principle… Martin

@brianclark17

5 жыл бұрын

@@olfoundryman8418 Something like a mini gantry crane attached to a table, with maybe allthread to a handle. turn the handle at the top and raises the part. Or a gantry crane with a pully in the middle with small chain that would attach to a screw in the part, and pull rope through the the pulley to lift it up.

@olfoundryman8418

5 жыл бұрын

Brian, I am actually contemplating a gantry type crane across the bulk of my work area so I can lift and transport the moulds to where they are poured and back again for breakout. Might even use it for holding the crucible when I pour Its a work/thought in progress… Martin

Martin I thought you might enjoy Douglas Adams description of our " Home" Australia Tony from the West Douglas Adams on Australia This gem is by Douglas Adams (of Hitchhikers Guide to the Galaxy fame) Australia is a very confusing place, taking up a large amount of the bottom half of the planet. It is recognizable from orbit because of many unusual features, including what at first looks like an enormous bite taken out of its southern edge; a wall of sheer cliffs which plunge deep into the girding sea. Geologists assure us that this is simply an accident of geomorphology and plate tectonics, but they still call it the "Great Australian Bight" proving that not only are they covering up a more frightening theory, but they can't spell either. The first of the confusing things about Australia is the status of the place. Where other landmasses and sovereign lands are classified as either continent, island or country, Australia is considered all three. Typically, it is unique in this. The second confusing thing about Australia are the animals. They can be divided into three categories: Poisonous, Odd, and Sheep. It is true that of the 10 most poisonous arachnids on the planet, Australia has 9 of them. Actually, it would be more accurate to say that of the 9 most poisonous arachnids, Australia has all of them. However, there are curiously few snakes, possibly because the spiders have killed them all. But even the spiders won't go near the sea. Any visitors should be careful to check inside boots (before putting them on), under toilet seats (before sitting down) and generally everywhere else. A stick is very useful for this task. Strangely, it tends to be the second class of animals (the Odd) that are more dangerous. The creature that kills the most people each year is the common Wombat. It is nearly as ridiculous as its name, and spends its life digging holes in the ground, in which it hides. During the night it comes out to eat worms and grubs. The wombat kills people in two ways: First, the animal is indestructible. Digging holes in the hard Australian clay builds muscles that outclass Olympic weight lifters. At night, they often wander the roads. Semi-trailers (Road Trains) have hit them at high speed, with all 9 wheels on one side, and this merely makes them very annoyed. They express this by snorting, glaring, and walking away. Alas, to smaller cars, the wombat becomes a symmetrical launching pad, with results that can be imagined, but not adequately described. The second way the wombat kills people relates to its burrowing behavior. If a person happens to put their hand down a wombat hole, the wombat will feel the disturbance and think "Ho! My hole is collapsing!" at which it will brace its muscled legs and push up against the roof of its burrow with incredible force, to prevent its collapse. Any unfortunate hand will be crushed, and attempts to withdraw will cause the wombat to simply bear down harder. The unfortunate will then bleed to death through their crushed hand as the wombat prevents him from seeking assistance. This is considered the third most embarrassing known way to die, and Australians don't talk about it much. At this point, we would like to mention the Platypus, estranged relative of the mammal, which has a duck-bill, otter's tail, webbed feet, lays eggs, detects its aquatic prey in the same way as the electric eel, and has venomous barbs attached to its hind legs, thus combining all 'typical' Australian attributes into a single improbable creature. The last confusing thing about Australia is the habitants. First, a short history: Some time around 40,000 years ago, some people arrived in boats from the north. They ate all the available food, and a lot of them died. The ones that survived learned respect for the balance of nature, man's proper place in the scheme of things, and spiders. They settled in, and spent a lot of the intervening time making up strange stories. Then, around 200 years ago, Europeans arrived in boats from the north. More accurately, European convicts were sent, with a few deranged and stupid people in charge. They tried to plant their crops in Autumn failing to take account of the reversal of the seasons when moving from the top half of the planet to the bottom), ate all their food, and a lot of them died. About then the sheep arrived, and have been treasured ever since. It is interesting to note here that the Europeans always consider themselves vastly superior to any other race they encounter, since they can lie, cheat, steal, and litigate (marks of a civilized culture they say) - whereas all the Aboriginals can do is happily survive being left in the middle of a vast red-hot desert, equipped with a stick. Eventually, the new lot of people stopped being Europeans on Extended Holiday and became Australians. The changes are subtle, but deep, caused by the mind-stretching expanses of nothingness and eerie quiet, where a person can sit perfectly still and look deep inside themselves to the core of their essence, their reasons for being, and the necessity of checking inside your boots every morning for fatal surprises. They also picked up the most finely tuned sense of irony in the world, and the Aboriginal gift for making up stories. Be warned. There is also the matter of the beaches. Australian beaches are simply the nicest and best in the entire world. Although anyone actually venturing into the sea will have to contend with sharks, stinging jellyfish, stonefish (a fish which sits on the bottom of the sea, pretends to be a rock, and has venomous barbs sticking out of its back that will kill just from the pain) and surf boarders. However, watching a beach sunset is worth the risk. As a result of all this hardship, dirt, thirst, and wombats, you would expect Australians to be a dour lot. Instead, they are genial, jolly, cheerful, and always willing to share a kind word with a stranger, unless they are an American. Faced with insurmountable odds and impossible problems, they smile disarmingly and look for a stick. Major engineering feats have been performed with sheets of corrugated iron, fencing wire, and mud. Alone of all the races on earth, they seem to be free from the 'grass is greener on the other side of the fence' syndrome, and roundly proclaim that Australia is, in fact, the other side of that fence. They call the land "Oz", "Godzone" (a verbal contraction of "God's Own Country") and "Best bloody place on earth, bar none, strewth". The irritating thing about this is they may be right. There are some traps for the unsuspecting traveler, though. Do not under any circumstances suggest that the beer is imperfect, unless you are comparing it to another kind of Australian beer. Do not wear a Hawaiian shirt. Religion and Politics are safe topics of conversation (Australians don't care too much about either) but Sport is a minefield. The only correct answer to "So, howdya' like our country, eh?" is "Best {insert your own regional swear word here} country in the world!". It is very likely that, on arriving, some cheerful Australians will 'adopt' you on your first night, and take you to a pub where Australian beer is served. Despite the obvious danger, do not refuse. It is a form of initiation rite. You will wake up late the next day with an astonishing hangover, a foul-taste in you mouth, and wearing strange clothes. Your hosts will usually make sure you get home, and waive off any legal difficulties with "It's his first time in Australia, so we took him to the pub", to which the policeman will sagely nod and close his notebook. Be sure to tell the story of these events to every other Australian you encounter, adding new embellishments at every stage, and noting how strong the beer was. Thus you will be accepted into this unique culture. Most Australians are now urban dwellers, having discovered the primary use of electricity, which is air-conditioning and refrigerators. Typical Australian sayings: · "G'Day!" · "It's better than a poke in the eye with a sharp stick." · "She'll be right." · "And down from Kosciusko, where the pine clad ridges raise their tornand rugged battlements on high, where the air is clear as crystal, and the white stars fairly blaze at midnight in the cold and frosty sky. And where, around the overflow, the reed beds sweep and sway to the breezes, and the rolling plains are wide. The Man from Snowy River is a household word today, and the stockmen tell the story of his ride." Tips to Surviving Australia: · Don't ever put your hand down a hole for any reason whatsoever. We mean it. · The beer is stronger than you think, regardless of how strong you think it is. · Always carry a stick. · Air-conditioning. · Do not attempt to use Australian slang, unless you are a trained linguist and good in a fist fight. · Thick socks. · Take good maps. Stopping to ask directions only works when there are people nearby. · If you leave the urban areas, carry several litres of water with you at all times, or you will die. · Even in the most embellished stories told by Australians, there is always a core of truth that it is unwise to ignore. See Also: "Deserts: How to die in them", "The Stick: Second most useful thing ever" and "Poisonous and venomous arachnids, insects, animals, trees, shrubs, fish and sheep of Australia, Volumes 1-42"

@olfoundryman8418

5 жыл бұрын

Tony, Very interesting and amusing read. Thank you for sending it... Martin

@MoondyneJoe

5 жыл бұрын

Your welcome Martin though he got some wrong and omitted our snakes and Drop Bears

Wouldn't it make it easier if the parts that you used the screws to grab on to when pulling them out, if there were another screw on the same piece that went all the way through but you would remove that screw before pulling it out so air could be pulled through that screw hole to reduce the suction when removing the piece? I don't know if I worded that correctly to figure out what I was trying to say. Thank you for your time and knowledge.

@olfoundryman8418

5 жыл бұрын

Dano C, I think I have figured out what you are suggesting. The sand is porous and thus air will move through it so there should not be any suction. This job was tight to pull out because it is very high and the rapping of it only moved enough at the top to loosen it, so most of the pattern is still more or less tightly rammed into the sand. A I mentioned in a caption an air powered vibrator would have helped... Martin

@Ottonic6

5 жыл бұрын

Oh yes, you're right... Thank you for the quick reply.

Brilliant, and btw, anybody that doesn't like bird sounds is a crackhead!

@olfoundryman8418

5 жыл бұрын

Gysbert, Sadly a few crackheads around - they are wastes of space and of good food... Martin

Hi Martin. Another great video. Have lost your phone number, will send email so we can catch up before Xmas. Have got a young (to you and me he is young) friend who wants to pick your brain about casting as he is just getting into casting.

@olfoundryman8418

5 жыл бұрын

John, Sorry mate, did mean to send phone number but have absolutely got overrun with comments etc - for some unknown reason my subscriber and view levels have absolutely exploded - from 5 new subs a day to 500 yesterday! Next chance I get will send email - happy to have brain picked... Martin

@johnwp111

5 жыл бұрын

It's no wonder that new subs are increasing with the excellent content that you provide. @@olfoundryman8418

That core better not float when you pour in the aluminium.

@olfoundryman8418

5 жыл бұрын

Aleksander, In part 3b when you will see the pour keep your eyes out for the lead weight sitting on the top of the core to stop it floating. Without the weight it most likely would have floated - been there done that 😏… Martin

@aleksandersuur9475

5 жыл бұрын

@@olfoundryman8418 Yeah, seems like a really easy thing to overlook even though it's simple. Only reason I bothered to mention it.

Your lifting device needs someway to pull up without you doing the work

@olfoundryman8418

5 жыл бұрын

Charlie, I have seen people do this with a long air cylinder providing the power, but that was on hard sand moulds they are way less delicate. I sort of like to have the "feel" of what is going on but as I mentioned in a caption an air vibrator would have helped a lot..Martin

@dfross87

5 жыл бұрын

A section of threaded rod so you can slowly wind the pattern out? With some alignment mechanism to prevent the twisting motion being transferred, of course.