casting a golden horseshoe - lessons in aluminum bronze

[@johnmccanntruth]

That was pretty interesting. I really didn’t expect the horseshoe to be so difficult. And it’s GOLD! 😂

[@swdweeb]

It is gold 😄

[@hiroshimiyaji]

I was about do aluminum bronze casting. I learned a lot form your video thank you!

[@swdweeb]

Thanks for letting me know. Aluminum bronze has its uses. Its really hard so it gets used as things like bushings a lot. A lot of people like the color as well as its more "gold-like" than traditional tin or silicon bronzes.

[@bigstackD]

You old fellas are always making excuses about your shrinkage🤔 😁👊🏻🍻🍻🍻🇦🇺

[@swdweeb]

Just you wait ankle biter. Someday you'll be sitting around comparing your prostate surgery with the other mates your age. It happens to the best of us. 😄

[@donniebrown2896]

HEY!!! I resemble that remark!!!! Lol

[@rockelec]

It's cold in here!! Lol

[@chriswhite4678]

Kinda the reason I live in the south 😎

[@JasonSipe16]

Ouch

[@kensmapleleafretirement]

Thank you for explaining how you can get a void even though you did it all right. Shrinkage... I remember that episode , poor George always the joke of the day... I wonder what that aluminum bronze would forge like? I will give it a go just for fun... I'll bet it crumbles more than it forges... Thanks for the demo and explanations... I was going to use it to make a belt buckle, but I think the tang would break off easily so I will do it in brass. Hope you are happy and healthy...TTYL...

[@swdweeb]

I’d love to see you try and forge al-bronze. It’s hard and I would assume brittle but some heat might change that. Let me know if you try it

[@flyingshards595]

That was a really illustrative video! Thanks for sharing this with us! Learned something new.

[@swdweeb]

Glad it was helpful! Thanks

[@ediesedgwick4462]

Something tells me you have no trouble making friends. Thanx for your entire series of vids. I've learned so much. Some people approach the activity as a hobbyist. Others approach it as a metallurgist. You, my friend, are in the latter group. Keep up the good work. And have a Happy New Year.

[@swdweeb]

Ha, there are plenty of people that don't like me. One of them is even subbed so they can put a dislike up as soon as I release a video. 😄😄 I'm glad the series was useful

[@ediesedgwick4462]

@@swdweeb That disliker is just jealous!

[@airshipguys]

@@swdweeb You definitely have a bunch of fans!

[@victormuckleston]

they used to add a small amount of sawdust to the sand to give the sand a small amount of give to allow for shrinkage

[@TheKnacklersWorkshop]

Hello, Well I've learnt some more today... thank you... Take care Paul,,

[@swdweeb]

Thanks Paul 😄

[@JasonSipe16]

Great explanation on making the parting line.

[@swdweeb]

Glad it was helpful, thanks for watching

[@relyonno1921]

Great effort. Not being able to make the sand mold without having pull the sand apart is because the part has positive drag if I remember correctly. It's been a while since I've learned to do this. Negative drag can be rammed up and removed with no worries.

[@swdweeb]

positive - negative its all based on your point of view 😄 Both the cope and drag saw the draft as "negative" and saw the other guy's draft as positive 😄

[@richardmclean7973]

Learning loads again. Awesome explanation on shrinkage.I shall say something nice to someone as requested. Great tutorial! Thanks

[@swdweeb]

You're welcome... you already said something nice... to me 😄

[@Bat8hitcrazy]

You need more exposure! I am learning so much between you and Bigstackd. I cant wait to start melting and casting, my Devilforge FB2Mb is on the way.

[@swdweeb]

Thanks. I've been at this for four years now, I don't think more exposure is in the cards. That's ok. 😄

[@duff8402]

You make me really want to try casting. I will definitely try it someday, but I already don't have much room for my blacksmith equipment... Will have to wait for somewhere over the rainbow when I can afford to get out of the suburbs.

[@swdweeb]

I do it all in my garage, but you probably figured that out from my videos 😂

[@duff8402]

@@swdweeb I've got a pretty tight 1968 built two car garage with two motorcycles and a grocery gitter takin up all the space. My forge is all portable and I wheel it into the lawn from a little garden shed that's mostly full of garden stuff since I don't have a garden. Recon if a guy would do some possession management, he might could figure somethin out.

[@mortenchristensrn2487]

Thanks... Great explanation for the shrinkage...

[@swdweeb]

My pleasure 😊

[@AJR2208]

Happy Belated New Year Perry & Family. That was a very good explanation, thanks. Reminds me of a saying - "The worst mistake a person can make is to be afraid of making one" Stay safe and well :)

[@swdweeb]

Thank you sir, same to you as well. 1st mistake, letting someone talk me into casting in aluminum bronze again 😄😄

[@AJR2208]

@@swdweeb Lol - Call it a lesson instead. You successfully proved the why's, how's and limitations of that particular process.

[@cecil6711]

Wow, that is incredible how much it shrinks!! Thanks for the video and Happy New Year! :-)

[@swdweeb]

Thanks, Good year to you as well

[@donniebrown2896]

That's what she sa.... Lol

[@ChristophLehner]

Love your videos, learned a lot from your videos. Greetings from Austria

[@swdweeb]

Austria?? Ever been to the Grassmayr foundry? I will visit there some day 😄

[@ChristophLehner]

@@swdweeb No, had to google it(didnt even know what they do) :) I am suprised you know a bell casting Business in Germany

[@swdweeb]

@@ChristophLehner They have a great video out there on casting a bell. I love bells and really would like to cast more of them

[@ralphmourik]

I was wondering if anyone would ever use that scene from Seinfeld when addressing shrinkage in metal casting, you beat me to it!!! 😋👍👊

[@swdweeb]

I've repeated it in my own words before but never stolen the clip

[@RustyGlovebox]

Every time you you do a project there is always something to be learned from it

[@swdweeb]

That’s the frustrated teacher in me 😂. How’s that printer working out?

[@RustyGlovebox]

I made a cool Tiki handle for a screwdriver with the printer . I have been at work making my furnace behind the scenes. It looking good, Planning to show it soon.

[@swdweeb]

@@RustyGlovebox I'm sure it will be every bit as cool as everything else you make. Looking forward to seeing.

[@rockelec]

I work with tin and silicon/manganese bronze mostly. The Si/Mn pours and flows much better. Has a great color too.

[@swdweeb]

Yeah I prefer tin bronze as well. Never tried manganese

[@rockelec]

@@swdweeb Si/Mnbronze isn't as viscous as Sn bronze. Both have good color and strength. Buff up pretty nice

[@Evanator22742]

@@rockelec it's been a minute since you commented this, but can you share the percentages for the alloy? I have silicon to add to the copper, but not manganese. I need to know how much to order :) thanks!

[@rockelec]

@@Evanator22742 Si 3.3-3.8% fe .8% Mn.5-1.3% balance Cu Typically the Fe is in with the Si and in my opinion is not crucial to the alloy. C65500 bronze

[@Evanator22742]

@@rockelec awesome. I really appreciate the thorough reply. I saw lists and lists of all the silicon/ manganese alloys and had no clue. Your experience is valuable, so thank you for sharing. I'll definitely be trying it out.

[@sirlancer23]

Great Video! I love that you take the time to teach us why something happened. You can count this as my saying something nice to someone today too.

[@swdweeb]

There you go, you've done your good deed for the day and it made me happy 😄

[@joell439]

Thanks for the lesson 👍😎👍

[@swdweeb]

You bet!

[@SilverScorpion]

Great pore! I try to watch and think ahead on the shrinking. It's tough!

[@swdweeb]

Well, you can do like I do so often and not think about it, have it shrink, figure out the fix and pour it again 😄

[@dustinbrosmer6164]

Whoooooooo first again lol. Man I'm so good at this. Love your videos buddy they have helped me out so much with my casting

[@swdweeb]

Congratulations. Glad they are helpful

[@ArtByAdrock]

Can you make me an aluminum bronze horseshoe? 😆 I’m not a fan of al bronze either which is why I don’t really waste my time with it. Great explanation though 👍🏻

[@swdweeb]

How about I just send you a horseshoe and you can cast as many as you want 😄😄

[@ArtByAdrock]

@@swdweeb haha nah I’d rather watch you try it again 🤣

[@airshipguys]

Thank you so much for your valiant attempt! It sure looks nice if you don't worry about the little crack. I was really surprised that it broke when it was dropped, it must be very brittle. I consider the gauntlet thrown. When it stops raining and snowing (probably a few months from now), I will give it a try. I hope 2021 starts getting better in every way. Wishing you all the best from Juneau Alaska, Greg Chaney

[@swdweeb]

I wish you guys would keep that weather up there. Calling for snow here tomorrow. I’ve suspected it can be brittle given how hard it is

[@Lawnmowerman02346]

@@swdweeb Did you quench it or let it cool slowly ? You may have made it brittle from the shock . Try pouring some test strips let them cool overnight , quench some then anneal some . Now try the bend test in a vice . Now that would make a good video .

[@swdweeb]

@@Lawnmowerman02346 It cooled in the sand and in the air for several minutes. I didn't put water on it for probably 10-15 minutes. It was still to hot to hold in my hands.

[@ollysworkshop]

Hot spot shrinkage eh? What you need is to email that old American guy that does casting videos, software dweeb or something, he's always a great help! 😋

[@swdweeb]

That idiot??? He doesn't know anything 😄

[@Thewulf56]

Great work on the video, sucks about it breaking. Was still a good watch.

[@swdweeb]

Thanks

[@Nagas4]

Thanks, got some useful info!

[@swdweeb]

Some?? 😂😂 Thanks for letting me know

[@KrakenCasting]

Ohhh, so you're saying if we hound you enough you'll do what we ask? Then you should make me a million dollars. XD Great vid, always a pleasure.

[@swdweeb]

Yeah if only it worked that way 😄😄

[@KrakenCasting]

Ehh, it was worth a shot. XD Already can't wait for the next one. Are you still planning on doing the I Can't Cast That series?

[@swdweeb]

@@KrakenCasting I never got any responses to the question so the "I cant cast this" is kinda dead. I'm going to try and some up with some unique things to cast that will provide teaching moments. I've got a few ideas

[@garyhuston]

Very good video, shame about the shoe but nice explanation of the problem.

[@swdweeb]

I like what someone said "shoe a horse with them and it'll look like bambi on ice" 😄😄 Of course to the trained eye, I'm sure you recognized them as "traction" shoes

[@kmestee]

Basic question. say you forget to put the runner and gate in, can you hand cut/dig/form them without any issues for the pour?. Talking about a smaller pour here. Great videos, I'm on #5 of your learning to cast series.

[@swdweeb]

Absolutely you can cut your runner and gate in by hand. If you watch any of olfoundryman's videos, he hand cuts all of his runners and gates. Just do your best to make sure they are close to the size of your sprue.

[@thomasfretz9684]

Have you ever tried epoxy-sand to make like a fillet in the undercut part of the shoe. After casting the epoxy-sand fillet can be removed easily.

[@swdweeb]

I've never used any of the epoxy or resin-based sands. I would like to try them but I'm afraid I'll be completely spoiled by them 😄

[@iGotchu671]

BigStackd sent me here. New subscriber ;)

[@swdweeb]

Thanks for the sub! Gotta love that bigstackd 😄

[@RICARDO49311]

Subscribed! Great channel. BigstackD recommended and sent me over!

[@swdweeb]

Thanks for the sub! Gotta love that bigstackd 😄

[@MrNothing38]

Thanks for sharing!

[@swdweeb]

Thanks for watching! 😄

[@tobhomott]

It was a good try and the casting did look quite nice. Bummer that it broke, maybe you can TIG it back together? I can vouch for al-bronze being sort of a pain to cast, whether it's a homebrew 90-10 or purchased alloy. Have you tried pouring yellow brass? I have not, but maybe it's easier to cast as well as being shiny and yellow... 😁

[@swdweeb]

I try to stay away from brass. I don't want to haul the furnace outside and I don't have good ventilation to get rid of the the zinc fumes.

[@tobhomott]

@@swdweeb I get that. I've been avoiding it too

[@shadowmihaiu]

Hi, have you ever considered adding bismuth into the aluminum bronze alloy? I have not, but have seen papers suggesting it may resolve shrinkage, as bismuth itself expands when cooling, as well as enhancing some of the desirable properties of the aluminum. I have seen that copper-bismuth-aluminum alloys are a thing, bit don't know the uses. Just a thought, it might be intriguing for your inquisitive nature.

[@swdweeb]

I've never considered it. Truth be told I'd never heard of it. It would be nice to be able to compensate for the shrinkage without needing large feeders on every mold. I wonder where I can get bismuth 😕

[@BrianDaleNeeley]

I'm actually surprised that you aren't going to attempt this again. I would expect you to say, "I'm not going to let this #$%* Al @$@%!! Bronze **)(!@ horseshoe kick *MY* rear!", and then proceed to engineer an appropriate solution. But I also understand why you don't. Or, I can at least think of reasonable reasons why you wouldn't mess with it again. Excellent explanation of why the problem occurred. It makes perfect (or near enough perfect) sense.

[@swdweeb]

Hey, if you say anything with authority people will believe it 😄😄😄 The biggest problem with the bronze is my furnace just isn't getting hot enough. I've got to fix that problem before I attempt any bronzes. Then there is always the thing of me wanting to make more bells. I'd rather devote the energy to pouring some bells than redoing the horseshoe.

[@BrianDaleNeeley]

@@swdweeb Build a Waste Oil Burner, and you won't have any problems with melting bronze, of even cast iron. Once you have it working properly that is. Assuming your refractory will handle it, which it probably will. Plus, the fuel for them is generally free.

[@swdweeb]

@@BrianDaleNeeley did you see this? kzbin.infoUgwV2GYoJF9o8sVKzUl4AaABCQ

[@jimintaos]

Well...this is good to know. I had hoped for better news about Aluminum Bronze and its workability. Oh well. I'm just about half way there and just ran into my first real glitch. The new little foundry melts aluminum like a charm. It melts down copper nearly as fast. So far so good. YeeHaw, I'm on my way to making a batch of aluminum bronze-- Then..oops. I poured the molten copper into my muffin tin and oingo boingo-I have copper muffins fused solidly to the muffin tin. Short of remelting or grinding away the muffin tin I have hit a snag. What do you recommend as a good ingot mold for molten copper? Thanks

[@swdweeb]

My mold is steel but made from angle iron so much thicker than the muffin tins. BTW, I did exactly the same thing on my first copper melt. what a royal pain. Like you , I tried cutting them out, I tried peeling the muffin tin away, I may have even tried melting the coper out of the trays but I'm not sure I recommend that as. You can see my ingot mold here. kzbin.info/www/bejne/nHekda2rlqinh9U I made it from angle iron scrap I picked up. I also have some wash that could be painted in the molds called frankote but so far I haven't had a problem with copper or bronze releasing from this mold. For what its worth, aluminum bronze seems to be a rite of passage for most of us. I think its because s) we have the metals and b) its cool to make an alloy. I really don't like it and would only make it again if somebody was to pay me for it 😄

[@jimintaos]

@@swdweeb I was out walking the dog and thinking about this and remembered that when I make molds for casting glass in the kiln I make up a 50/50 mix of plaster of paris (hydrocal works better) and 200 mesh silica flour. I mix in enough water to make a pourable batter, let it cure overnight and then put it in the kiln with the glass. For foundry casting it would have to be dried out in an oven and then further heated by the foundry to drive off the moisture. When glass is molten it is very sticky and I have never had it stick to one of these molds. Sometimes I can get 4 or 5 castings out of the mold before it is so fractured it is useless. I'm going to have to try this.

[@swdweeb]

@@jimintaos I expect that will work just fine. I've never painted my mold but I have painted my furnace with the stuff and spilled melted metal doesn't stick to the wash I use. I painted on two thin coats, let it air dry for a day and then applied a little heat to finish drying it out

[@scroungasworkshop4663]

That was very good and I learnt a lot so thanks. A question if I may, if you had to cast 20 or 30 horse shoes like that in say aluminum would you make a master mould in two pieces, a lower and upper half or would you cast them all the way you did the horse shoe? Thanks in advance. Cheers Stuart 🇦🇺

[@swdweeb]

Hey Stuart, if I had to cast 20-30 of anything I'd look to build a match plate that would do exactly that. This process of "loose" casting is fine for one or two molds but beyond that you have to think in terms of production and a match plate or a die is the way to go.

[@scroungasworkshop4663]

@@swdweeb Thanks for the advice I really appreciate it. I’m casting my own C clamps 🗜 and your advice confirms I’m on the right track. Your a good man. Cheers Stuart 🇦🇺

[@swdweeb]

@@scroungasworkshop4663 Thanks Stuart. Hey if you get them cast, I'd love to see pictures [e-mail]

[@scroungasworkshop4663]

@@swdweeb OK, your on. When and if I get them made I’ll send you the pics. Cheers my friend 👍👍

[@metalmeltingmark4655]

Thanks for sharing

[@swdweeb]

My pleasure

[@volgnit]

Hey, you're a southpaw. Who knew. You'd need a left handed coffee mug in that case. Might have to modify the "one." Oops, did I just let you know it hasn't left yet ?? Darn !!

[@swdweeb]

I was going to ask you if you have any better luck shipping things over seas. I sent a package to Israel before Christmas took 5 weeks to get it delivered. Sent two package to the UK the same day as the Israeli one. They sat in Los Angeles for two plus weeks before leaving the country. Took over three weeks for them to get delivered

[@Preso58]

Ok, I'm glad I've never attempted a part from aluminium bronze now. I'll stick to brass.

[@swdweeb]

I like tin bronze much more. Never tried silicon bronze but I have some silicon to try it with. Brass scares me with the zinc smoke

[@askquestionstrythings]

I won't do Brass unless it can't be avoided. Bronze is the route to go, no risk of metal fume fever. Zinc fumes are bad news.

[@andyf1235]

Do you use a good casting alloy when you make your alloy bronze? Like mag wheels or other cast items from auto parts? I was wondering if that would help with shrinkage. Pure alloy is bad for shrinkage and would probably do the same in your alloy bronze.

[@swdweeb]

I use A319 aluminum alloy. Pure alloy?? An alloy is a mixture of metals 😄

[@andyf1235]

@@swdweeb By pure alloy I was meaning just straight Aluminum without additives to help casting. You already use casting aluminum in your mixes so that wont help. Great cast and video though I am learning a ton from your channel

[@swdweeb]

@@andyf1235 Hi Andy, I knew what you meant I was just making sure you had the correct terminology. By definition an alloy is a mix of different metals. I'm not sure you can get "pure" aluminum. I don't know, maybe you can. Even the metal used in wheels and motor castings is some sort of alloy and not pure aluminum. Just be glad you didn't say you're "smelting" metal. Gaaa I go crazy on that one 😄😄 Thanks for your question bud, I always appreciate it when people are thinking about this stuff.

[@Boosted98gsx]

Shoulda had the main sprue go down the center of the horseshoe, gating outwards at 2-3 locations

[@clayastoys]

Hello friend Your video's cool. keep it up Friendship greetings Always be successful Let's be friends.....

[@swdweeb]

thanks

[@SculptyWorks]

Great video! 👍 I HATE aluminum bronze! The stuff does whatever it wants even when you try to account for its idiosyncrasies!

[@swdweeb]

It's definitely a pain if you're doing anything of any size.

[@henri1511]

Just out of curiosity(mostly because I'm having nothing but fails lately), what is your pour temperature before you cast the Aluminum bronze . I'm getting lots stuck frozen in the crucible after the pour. Maybe I'm too impatient.

[@swdweeb]

My bronze, which was still too cold, was like 2010F for this pour. I don't remember exactly as I didn't write it down. I know I waited until I was above 2000F and it seems like I might have seen 2020F but don't hold me to it. According to a doc that a sub sent me here are the recommended temps for al-bronze Pouring Temp., Light Castings................ 2050-2200F Pouring Temp., Heavy Castings.............. 2000-2100F They list the melting temp well below the pouring temp at Melting Range, °F...1907-1913

[@henri1511]

@@swdweeb Thanks for the reply. I'll have to give those numbers a try. You're having much better luck then I am. My last pour was 1980F. Way too cold from what i can see. Not enough time in molten state to work with it.

[@richardmclean7973]

Is it possible to do a curved plate in the same way ? In aluminium and at least 6x6" . Trying to make a mandalorian helmet without great success. Sorry I'm being stupid..

[@richardmclean7973]

Also are you going to build a bigger burner to increase temp or purchase one?

[@swdweeb]

You mean like this? kzbin.info/www/bejne/fn2wpHWNrZeJjNE

[@swdweeb]

I'm looking at moving to a hybrid propane/diesel burner. Get things warm with the propane then switch to diesel

[@richardmclean7973]

Yes exactly like that cheers. Watching and learning.

[@richardmclean7973]

Can I ask why diesel?

[@tmophoto]

kzbin.info/www/bejne/d2HXfmePl5eKias this is what i had to go with for a burner, no amount of time or propane was hot enough to get my furnace up to temp for copper, bronze etc. Running on diesel works great

[@MarkATrombley]

Horseshoes are supposed to be lucky, you didn't add enough luck so the mold didn't fill completely. Try adding 3% luck next time.

[@swdweeb]

They're only lucky if you keep the tips up. If they face down all the luck runs out. 😄 I was lucky, the problem gave me something to talk about in the video 😄

[@CraigLYoung]

@@swdweeb : Next time cut the gates at the ends😆. I was going to say something on the lines of what you said.

[@swdweeb]

@@CraigLYoung Ah but then I'd have a nice bifilm where the two streams of metal came together. Then it'd probably crack in the middle of the shoe... hey wait a minute

[@CraigLYoung]

@@swdweeb : We're having to much fun with this.

[@swdweeb]

@@CraigLYoung 😄

[@Lawnmowerman02346]

That’s why they make super glue. Stick it together and hang on the wall 😁 .

[@swdweeb]

yeah... or throw it in the pile that might get melted again.

[@NicheEngineering]

I've heard breaking a horseshoe brings you 4 years of bad luck ;)

[@swdweeb]

No doubt 😄

[@CraigLYoung]

Thanks for sharing! It all looked good until you polished it. Next time don't polish it. I never saw a ferrier polish a horseshoe. It would be like watching a deer on ice.

[@swdweeb]

Ha!! I never thought of that, good point 😄😄