Hobbies And Interests
Furnace
The most important basic component will be the furnace. The dimensions and configuration of the furnace depends upon the size of the metal pieces that will be melted. Furnaces can have square or cylindrical dimensions, but must be made of heat-resistant materials like clay or ceramic blocks or bricks, which will contain heat. A four-side brick furnace with a thick base foundation and vented lid is a very common design. The furnace will typically have a torch hole in one side wall, placed about 1/3 up from the bottom of the base. The inside of the furnace dimensions can range from 12 inches and up for larger volumes.
Ladle or Crucible
A ladle, also called a crucible, performs the function of containing the metal pieces that will be reduced to a liquid, molten material. A ladle must be able to fit comfortably inside the walls of the furnace, and able to withstand extreme temperatures without melting. Ladles typically have cylindrical designs with pour spouts and hooked ends, so they may be lifted out of the furnace and manipulated. Black steel is commonly used as a ladle or crucible material, although other heat-resistant materials can be used.
Blowtorch
A gasoline blowtorch, high temperature propane torch or other heat source must be used to raise the temperature high enough to melt metal into a molten form. Portable torches have pressurized cans that hold combustible fuel. The fuel discharge is metered through a valve, adjusted by a knob, so that variable temperatures can be used for different metal materials. The nozzle of the blow torch must be placed in the furnace wall hole to apply and distribute the heat inside the furnace.
Molds
Molds consist of wooden box-like frames that contain oil-bonded sand or homemade bonding sand. Castings can be fabricated by fashioning desirable shapes in the sand's surface to achieve varying lengths and depths. The molten metal is then poured into the casting shapes and allowed to cool. Small wooden boxes with an open top are very common for pouring casts. Any mold size can be custom built, depending upon the desired shape of the object. Pre-built molds can be purchased and filled with oil-bonded sand. Commercial two-piece molds can be purchased and used immediately for small decorative and jewelry objects.
Ladle Hook and Skimming Spoon
Ladle hooks consist of long rods, equipped with grasping handles on one end and hooks on the other. Two ladle hooks are commonly used together, with one hook engaging the front eyelet on a ladle, while the other connects to the rear eyelet of the ladle. The operator lifts the heated ladle from the furnace, and by manipulating the two hooks, tilts the ladle and pours the melted contents into a mold. Skimming spoons have long handles, with one end fashioned into the shape of a shallow ladle. Skimming spoons are used to remove top slag and impurities from the melted material in the ladle.
Ingot pans
Ingot pans have several small recessed compartments, similar to muffin baking pans. Ingot pans provide extra storage molds for excess casting metal which is not used in the original mold.
Safety Gear
Safety gear provides a safe environment for the metal worker during all aspects of melting and casting. Heavy canvas gloves, protective eye goggles and a particle mask or professional respirator should always be used during the metal melting process. Most melting should be performed outdoors, away from combustible materials and confined areas where fumes can collect.
Metal Stock
Metal stock, regardless of the material, should be cleaned, sized and stripped before any melting procedure. The metal stock can be stored in a small bin next to the furnace to allow ready access and placement into the ladle. Metals such as raw gold and silver can be kept indoors for security reasons, while other metals can be stored outside. Rust should be removed from metals prior to melting.