By H. Hoffman
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Extra info for Casting Metal Parts
It's a tough metal to cast, and requires considerable experience. It is best melted in crucibles and poured at the highest possible temperature to prevent the excessive production of zinc fumes. High temperatures are also recommended to reduce the risk of flaring flames shooting up from the surface of the molten metal. Yellow brass will flare at about 185 degrees Fahrenheit. Approximately 1% pounds of zinc will be lost for every 100 pounds of alloy melted; this must be replaced. ALUMINUM ALLOYS Aluminum alloys are melted and handled much the same as copper based alloys; melt under oxidizing conditions, and gate for progressive solidification with a minimum of turbulence.
The upper mold is called the cope, the lower, and the drag. For more accurate work, the two halves of the pattern may be, mounted on match plates, which provide for exact alignment of the two halves. In this case, 58 CASTING METAL PARTS the pattern and the plates usually are made of metal. The mold material may be moist úgreený sand, or may be held together by a binder and dried or baked (dry sand). Dry-sand molds cost more, but they give a better finish, sharper detail, and greater accuracy. Holes or cavities are formed by cores that are molded separately of special sand mixed with a binder and baked for added strength, and are located in recesses in the mod before the metal is poured.
This is done by using a plastic bottle that is half filled with borax. Squeeze the bottle to put a small amount of borax to the metal; a large quantity of borax is not needed. About a ü teaspoon of borax is sufficient to cleanse the oxides and Impurities from the molten metal. Preheating, applying borax and reheating the metal should be done as quickly as possible to prevent excessive loss of heat from both the metal and the invested flask. Again apply heat until the metal is completely molten, or when the metal has a shiny, glasslike appearance.