Survey on Coating Treatment for Metals (link)

Survey on Hard Anodizing (Type III) for Aluminum

Burnish

Case Harden

Diffusion Harden

Mask

Oil Impregnate

Shot Peen

Thermal Spray

Anodize

Black Oxide

Cadmium

Chrome Plate

Electroless Nickel

Hard Anodize

Painting

Passivation

Tungsten Disulfide

Lubricant, Dry Film, Molecular Bonded

Department of Defense assist.dla.mil

SAE International

How to apply

Cleaning - Glass Bead Air Blasting

Hone (fine abrasive blast to obtain a uniform matte appearance)

Air Blasting with Tungsten Disulfide (WS2)

Tape Test

SAE International

ASTM D 2511 - Lubricants, Film, Dry Solid, Thermal Shock, Sensitivity of

ASTM D 2649 - Corrosion Characteristics of Solid Film Lubricants

ASTM D 7091 - Nondestructive Measurement of Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nonconductive Coatings Applied to Non-Ferrous Metals

Bureau of Reclamation

Mining

ALB Materials - https://www.albmaterials.com/ in Henderson NV

Lower Friction a division of M K Impex Canada

Dicronite - proprietary modified disulfide coating with proprietary application process

Atlantic Equipment Engineers

Rose Mill Co.

Tungsten Solutions Group Intl in West Hartford CT

ASTM A36 Mild/Low Carbon Steel

AISI 1018 Mild/Low Carbon Steel

Pacific Steel

Aluminum Alloy Series - see Aluminum Alloys 101

Aluminum Association 356 is the most common alloy used in prototyping die-castings

Aluminum - 1941 Mining, Production and uses of Aluminum

Brass (Copper with Zinc and trace elements)

Iron

Steel

Benefits

Lead-Tin

Lead-Antimony

References

Care of Aluminum by The Aluminum Association

Aluminum Standards and Data US 2017

“The boehmite treatment is very simple. Aluminum materials are treated with boiling water or steam. Aluminum is converted to aluminum oxide by oxidation. It is an environmental friendly treatment as there are no specific chemicals required such as chromium based chemicals and no need for waste water treatment. This process is applied to aluminum tableware, aluminum heat exchangers and electrolytic capacitors. In the industry, deionized water with triethanolamine and/or aqueous ammonia are used. The treatment temperature is normally from 90°C to 100°C and treatment time is from 10 to 30 min.” (Handbook of Aluminum Vol 2 Alloy Production and Materials manufacturing, edited by George E. Totten and D. Scott MacKenzie, Chapter 13 - Surface Modification by Kiyoshi Funatani, p. 495-6)

“Anodizing is used to improve the corrosion resistance and appearance of aluminum and is achieved by making the parts to be treated the anode in an electrolytic bath such as sulfuric acid. This process produces a tough, adherent coating of aluminum oxide (Al₂O₃), usually 0.4 mil (0.01mm) thick or greater. 'The Surface Treatment and Finishing of Aluminum Alloys' by P.G. Sheasby and R. Pinner, provides useful information on anodizing. Any welding should be performed before anodizing, and filler alloys should be chosen judiciously for good anodizing color match with the base alloy…Two-step electrolytic coloring, produced by first clear anodizing and then electrolytically depositing another metal ozide, can produce shades of bronze, burgundy, and blue. Anodized aluminum is used for lighting fixtures, automotive trim, cosmetic cases, and aluminum wheels.” (Marks' Standard Handbook for Mechanical Engineers, 11th Ed by Eugene a. Avallone, p. 6-57 (421 of 2305))

How to Anodize Aluminum by Bill Gilmour

EngineerGuy

“In general, the anodizing process of an aluminum or aluminum alloy specimen consists of pretreatments (degreasing, etching, and polishing), anodizing, coloring, and sealing.

Chemicals

Problems

Step 1 - cleaning - remove self-protecting coat of aluminum oxide

Step 2 - make 1 gallon of chemical bath

Step 3 - dip

Step 4 - wash

References

Anode (Oxidation, lose electrons, positively charged)

Cathode (Reduction, gain electrons, negatively charged) - object being plated such as utensils, bowls, platters

Electrolyte Solution

“Cast irons are most commonly plated with chromium, nickel, copper, cadmium, and zinc.” (ASM Handbook Vol 5 - Surface Engineering, p. 1844)

Reference

Benefits of Heat Treatment (Aluminum Alloys by The American Foundry Society Technical Dept. Schaumburg Illinois)

Heat Treatment Practices

Blanchard Metal Processing - www.bmproc.com - Commercial Heat Treat Capabilities

Metal Prices - Kitco Metals

Pacific Metals

Pacific Steel

Pacific Machinery & Tool Steel Company

Liberty Salvage Material 702-880-1299, 130 W Owens Ave

Alaska

Nevada Mining Association

Utah Mining

Martin Koch, Lecturer, Dept of Industrial and Manufacturing Engineering, mkoch@calpoly.edu

California State University, Chico - Metal Casting Lab by Scott Brogden, sbrogden@csuchico.edu

“Sand molding. Irregular or odd-shaped parts that would be difficult to make from metal plate or bar stock may be cast to the desired shape in sand molds. A pattern may be a wood or metal model of the part so constructed that it may be used to form the impression, called a mold, in the sand. Molten metal, when poured into this mold and solidified, will form a casting of the desired part. The sand for the mold is held in place in a wood or metal frame, or box, called a flask. The assembly of the entire flask is shown in Figure 14.1. The opened flask is illustrated in Figure 14.2. Figure 14.3 shows a simple pattern, and Figure 14.4 shows it as it is used to form the mold.” (Blueprint Reading for Machinists, Intermediate, 6th Edition by David L. Taylor, p. 112)

“11.2 Sand Casting. A typical drawing as received in the shops is shown in Fig. 11-2. To product the part shown, a rough sand casting must be made, as shown in Fig. 11-3(a). The part is then machined, as shown at (b). The casting is made by pouring molten metal (iron, steel, aluminum, brass, or some other metal) into a cavity in damp sand. The metal is allowed to cool until it hardens. Then it is removed from the sand. The cavity is made by placing a model of the object, called a pattern, in the sand and then withdrawing it. This leaves an imprint of the model in the sand. Patterns are usually constructed from a durable and dimensionally stable wood. (Basswood and mahogany are often used.) In some cases, duplicate patterns are made of metal or from casting resins with very low shrink characteristics. A wood pattern of the bearing in Fig. 11-2 is shown in Fig. 11-3©. Since shrinkage occurs when metals cool, patterns are made slightly oversize. The patternmaker uses a shrink rule. The units on a shrink rule are slightly oversize. Since various metals shrink different amounts, a different rule is used for each metal. For example, cast iron shrinks 1/8” per foot. the detail drawing, Fig. 11-2, shows the object in its final state and does not allow for shrinkage. this is taken care of entirely in the pattern shop by making the pattern oversize. Draft, or relief angle, is the taper given to a pattern to permit it to be easily withdrawn from the sand without damaging the shape of the mold. Draft is taken care of by the patternmaker. It is not shown on the drawing unless it is also a feature of the design. Only a slight draft on each side of the flat base is needed for this object, Fig. 11-3(a). The patternmaker must also make the pattern oversize in certain places to provide additional metal for each surface that is to be machined. For example, the bottom surface of the base of the casting of Fig. 11-2 it to be finished or machined. The patternmaker must provide extra thickness to the bottom of the base so that there will be from 1/16“ to 1/8” of metal to be removed. For details on proper use of finish marks, see Sec. 10.7.“ (Basic Technical Drawing, 8th by Spencer, p. 227-8)

“The rough casting is sent to the machine shop. There the cored hole will be enlarged by boring and reaming. The top and bottom surfaces will be machined. The small holes will be drilled and counterbored, Fig. 11-3(b).” (Basic Technical Drawing, 8th by Spencer, p. 229)

“Sand casting is the most commonly used method of making castings. There are two general types of sand castings: green sand and dry sand molding. Green sand is specially refined sand that is mixed with specific moisture, clay, and resin, which work as binding agents during the molding and pouring procedures. New sand is light brown in color: the term 'green sand' refers to the moisture content. In the dry sand molding process, the sand does not have any moisture content. The sand is bonded together with specially formulated resins. The result of the green sand or the dry sand molds is the same. Sand castings are made by pounding or pressing the sand around a split pattern. The first or lower half of the pattern is placed upside down on a molding board, and sand is then pounded or compressed around the pattern in a box called a drag. The drag is then turned over, and the second or upper half of the pattern is formed when another box, called a cope, is packed with sand and joined to the drag. A fine powder is used as a parting agent between the cope and drag at the parting line, or the separating joint between the two parts of the pattern or mold. The entire box, made up of the cope and drag, is referred to as a flask (see Figure 4.5).” (Engineering Drawing and Design, 5th Edition by Madsen and Madsen, p. 135)

“The action of a solid surface designed to just touch the surface of the falling melt changes everything. Friction is now introduced for the first time. The natural frictional back-pressure now builds up along the length of the sprue (and all the subsequent channels if contact with the walls is maintained by appropriately narrow sections, as illustrated in Fig. 5*b), casuing the liquid to gently pressurize the walls of the channel. This natural pressurization is of enormous value in assisting to keep air out of the system and is a fundamentally important feature of the naturally pressurized design. (In contrast, the traditional oversized running systems illustrated in Fig. 5a do not benefit from the fiction to reduce the velocity of flow and usually cannot be pressurized. As a consequence, the systems introduce copious quantities of air and oxides.)” (ASM Handbook Vol 15 - Casting, p. 509 of 1196)

“Before the molten metal can be poured into the cavity, a passageway for the metal must be made. The passageway is called a runner and sprue. The location and design of the sprue and runner are important to allow for a rapid and continuous flow of metal. In addition, vent holes are established to let gases, impurities, and metal escape from the cavity. Finally, a riser (or group of risers) is used, depending on the size of the casting, to allow the excess metal to evacuate from the mold and, more importantly, to help reduce shrinking and incomplete filling of the casting (see Figure 4.6). After the casting has solidified and cooled, the filled risers, vent holes, and runners are removed.” (Engineering Drawing and Design, 5th Edition by Madsen and Madsen, p. 135)

“Sand casting is the most common type of casting method. The major components of the molds used to make sand castings are shown in Figure 20-1 and include the flask, pattern, and green sand. The flask is a two-part box, or frame, used to contain the sand. The top half of the flask is called the cope and the bottom half is called the drag. Occasionally, a third section may be installed between the cope and drag. This section is called a cheek, and is used where a deep or complex shape must be cast. In sand casting the mold is prepared by ramming the green sand around a model of a part, called the pattern. The model is then removed to form the cavity for the molten metal. The plane of division between the cope and drag is called the parting line. In many castings, the parting line occurs at the approximate middle of the part. The parting line can be seen on most castings by a ragged line that is usually ground off. The molten metal enters the mold through the sprue hole and is directed to the cavity by one or more gates. The sprue hole is formed by installing a sprue peg in the cope. This peg is then removed after the final ramming of the cope. The riser is used to vent the mold and to allow gases to escape. The riser also acts as a small reservoir to keep the cavity full as the metal begins to shrink during the cooling process.” (Technical Drawing, 4th by Goetsch and Chalk, p. 722)

Society of Manufacturing Engineering

Bentonite Clay on Thomasnet.com

“Starting Point - In order to learn anything new, you must learn the very basics, and the only place to do this is at the beginning. Let's not think of brass (copper + zinc), bronze (copper + tin), aluminum or cast iron or the mixes etc. Let's start at the basic business of making a sand mold and pouring it. The equipment listed would be the minimum required as a starter.” (Complete Handbook of Sand Casting by Ammen, p. 212-3)

Charcoal Furnace

Electric Furnance

PID = Proportional, Integral, Derivative

Newark Electronics

Type K Thermocouple Block

Binder - Sodium Silicate (aka waterglass, water glass, or liquid glass)

Pumice Concrete

Hess Perlite

Burner - https://www.youtube.com/watch?v=fUV6qJEuKic

Crucible

Ladle

1) shutoff valve

1) Ceramic Fiber Insulation\Kaowool\Cerachrome

3) Natural gas pressure regulator

4) gas manifold/burner - outdoor natural gas burner

5) brass natural gas orifice

240volts, 50amps

Kanthal A1

Spools

Ceramic Support Material

TEMCo Industrial - Kanthal Wire

Omega.com - Thermocouples

Amazon - 50amp 3-wire range power cord

NEMA 14-50 (50AMP) used by RV outlets and Tesla

NEMA 10-50 (50AMP) used by welders

Home Depot - 50 Amp 2-Pole Circuit Breaker

Starlite Formula

Greg Page, g.page@neomaterials.com, 432-940-0187

Hi Valley Chemical Inc. (aka High Valley Products, Inc)

Borax 20 Mule Team - Working with Borax.com

The Lords' Thermal Insulating Coating (1000 grams)

Manufacturing

Spray-Applied Fire-Resistive Material (SFRM)

IBC 2018

Lucifer Furnaces

Bico Inc Burbank CA

Metal Melting Furnace by Devil Forge

Baker Furance

MIFCO Electric Bench Top Melters

Hot Pot II Lead and Tin Melting Pot for $55

Goss Inc

Lyman Big Dipper Casting

RCBS Pro Melt Furnance

Craigslist.org North American Outdoor Fryer

Standard Plumbing

Shop vac

Xiamen Kingray Industrial & Technology Co.

Propane Furnace

Harbor Freight Cement Mixer

Recommend adding two objects in the cement mix to breakup the petrobond clumps

Lead - make 6“ ball/sphere

References

Simpson - Simpson Mix-Muller for small to medium sized sand systems, Model LF weights 750 lbs

Qingdao Henglin Machinery, Co., Ltd. - Bryan Hong - bryanhong2049@gmail.com

Qingdao Huachuan Machinery Co., Ltd. - Kevin - huachuanmachine2009@qdhcgroup.com

Homemade Muller by Allen Powell

“Basic Flask - The top frame of the flask is called the cope and the bottom frame is called the drag. In some molding operations you need one or more sections between the cope and the drag. These sections are called cheeks. The pins and guides that are used to hold the sections together can be purchased in a wide variety of types and configurations… Both pins and guides have attached mounting plates by which they can be bolted, screwed or welded to the halves which make up a complete flask set.” Complete Handbook of Sand Casting by Ammen, p. 53

“In this respect it would be a wise strategy in the first place to have all your moulding boxes to the same dimensions or, at least, to the same pin centres.” (The Backyard Foundry by B. Terry Aspin, p. 27)

Commerical Flasks

BHS currently has a System 96 Hot Start Pro - Classmaster L1 Kiln by Skutt

Larsen Foundry Supply in Salt Lake City, Utah, 801-972-1111

Petro Bond Mix Ratios by weight (see Bentonite Corporation - Petro Bond on slideshare or Metal Casting Vol 1 by Chastain, p. 154-5)

Petro Bond Suppliers

“A local foundry has been casting Aluminum and bronze for about 50 years using the mix shown below”

Jeff Jensen Green Sand in Las Vegas NV

PW Gillibrand No. 90 Silver Sand - don't know if this is the same as silica sand or if it can be used in green sand. Appears to be sold at Lowes.

Baroid Industrial Drilling Products sells Bentonite Clay, untreated and no chemicals added, use Aquagel Gold Seal sodium bentonite.

Diatomaceous Earth

Fill any seams or gaps

Northern White Pine (Pinus strobus) - strongest of the pines, straight and closed-grained, carves readily across the grain and is very stable dimensionally. (Patternmaker's Manual, 2nd by American Foundry Society, p. 21)

Hard Woods - available www.craftwoodwizard.com

“It must not be supposed that parted patterns are built in one piece and then sawed in two afterward; Fig. 75 shows two pieces planed and fitted together with dowel pins, the regular pins that remain in the pattern, and temporarily secured by counter-sunk screws at the ends. Enough material should be allowed at the ends for the pattern to be turned to shape and finished at the ends without running into these screws; the assembled piece must be wide enough to allow of its being turned to correct diameter. Great care is necessary in placing the work between centers, for the centers should fit directly into the parting line; otherwise the halves will be found unsymmetrical… The dowel pins must always be fitted first, before turning to shape, for it would be most difficult to put them in accurately afterward. They should fit loosely, so that the parts will fall apart of their own weight, but not so loose that the pieces can shift sideways.” Model Making by Raymond Francis Yates, p. 114

Loctite binder

“Pattern are needed to form the cavity in the sand mold into which molten metal is poured. They may be made of wood, metal, plaster of Paris, or wax. A metal pattern lasts longer and keeps its shape better. Metals commonly used are aluminum, cast iron, steel, and brass. Woods generally used for patterns are white pine, mahogany, cherry, maple, birch, and fir. White pine is usually preferred because it works easily, is readily glued, and is reasonably durable. Wood patterns should be varnished to protect them against moisture. Coloring powders can be added to the varnish to identify various parts of the pattern.” (Metalworking by T. Gardner Boyd, p. 76)

FOUNDRY PATTERN MAKING part 4 Steam Engine metal casting tubalcain

Making and Applying ABS/Acetone Solution for 3D printing by Maker's Tool Works

TIP: Shiny Ceramic-like ABS parts with Acetone and Metal Can by Airwolf 3D

Sand Cores & Casting by doubleboost

Sodium Silicate - foundry core binder (water glass) combine with silica sand

Core Mixture 1 from Tubal Cain - Casting a Foundry Matchplate Pattern 2:03 min

“The various parts of a pattern should be painted in contrasting colors so that there may be no doubt as to their function. There has always been some confusion as to the colors associated with the various pieces; but the American Foundrymen's Association (A.F.A.)has endorsed a system of standard designations which might very well be universally adopted. According to this system patterns should be identified as follows:

Matchplate Inserts with 3D Printer

Refractory Cement

Fire Brick (aka thin brick or cory title)

American Foundry Society 800-537-4237

Chemical Coaters Association International (CCAI) - ccaiweb.com

The Crucible

Jiten Shah

Sairam Ravi

David Palmer

Walter Evans

Edward Marczyszak

Desert Rose High School - North Las Vegas

Skip

Other Equipment

US Government

California State Polytechnic University, Pomona - Industrial & Manufacturing Engineering

University of Wisconsin - Platteville - Industrial Studies

Case Western Reserve University - Case Metal Processing Laboratory (CMPL)

Northeast Wisconsin Technical College

Arizona

Nevada

California

Idaho

Illinois

Utah

Pennsylvania

Minnesota

Ohio

Oregon

Texas

Vermont

Wisconsin

A Career in Die Casting - College

How its Made Engine Blocks - Discovery Channel and nemak.com