Melting copper at home - Huge copper ingot - "BIG-OLE COPPER INGOT" │ASMR │ Metal Casting

I melted copper wire at home and made a huge copper ingot! It weighs 12 pounds or 5.7 kilograms. I used old copper wire that had been burned in a fire to remove the insulation. I did not do this. Someone else did. I melted the wire in my DIY foundry furnace and poured the copper into a mold that I made from a 3d printed pattern.
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▬▬▬ WHY DID THE COPPER "GROW"? ▬▬▬
I believe this happened because the copper was left molten inside the crucible for too long. This can cause a build up of gas inside the liquid metal which escapes as the metal is poured.
I also suspect it could have to do with the oil content of the petrobond sand, however I have seen others cast large copper bars in petrobond without issue.
I'm not certain that this was the cause, its my best educated guess. Do you know?

[@robinson-foundry]

If you're interested in any of the tools or equipment I use and you want to help support the channel then don't forget to check out some of the affiliate links in the video description. Thank you for the support!

[@AMBOSS_Silesia]

Copper sucks air, especially nitrogene and oxygene from the atmosphere. To make clean, even cast you need to completely cut the air away. Best way to do that at home is cast copper in lost wax method in airtight ceramic mould. When pouring is done put the ceramic cap on the funnel to minimize air sucking into the copper. In industrial conditions copper is cast in argon atmosphere.

[@theninjascientist689]

That's so interesting! Thank you for sharing.

[@FerrousPhoenix]

Would you be able to use borax in the copper to prevent the air from getting to it?

[@1982Ford1991]

Ferrous Phoenix no borax just makes the impurities stick together and come to the top.

[@StevenWernerCS]

so break a bunch of old burnt out lightbulbs into a tub, and pour your cast into that

[@burritodog3634]

why would you need to make it clean

[@gwendohshidt]

that print time-lapse at the beginning was so cool

[@terminok2015]

Who is to say it was a time-lapse.....? Jk,lol

[@rooey4193]

I've noticed the same thing when melting copper ingots and drew a similar conclusion That the molten metal is at too high of a temperature and at an elevated temperature for too long, allowing gasses to dissolve more readily. Then when cooling the gases become less soluble and bubble out of the ingot. I have a few ingots that are about half its height bubbled up, it makes them hard to stack ...

[@FerrousPhoenix]

Where are you getting the copper for the ingots from? Like copper pipes or wire?

[@rooey4193]

@@FerrousPhoenix Copper tubing

[@AImighty_Loaf]

Why not smelt them again?

[@j0hnf_uk]

I've seen many videos of copper being poured into iron molds that have no problems with expansion, so I suspect it may well have something to do with the petrobond and the fact that the mould is, 'open', at the top allowing the gases created when the hot metal comes into contact with the oil-based sand to rise and create the porosity that you can see. As the metal solidifies, the gases that haven't reached the top of the mould will remain trapped in the metal. If you had a similar mold, but enclosed with a sprue and riser where the metal filled the mold and went up the riser, it could, possibly reduce the porosity down as well as prevent shrinkage.

[@KrakenCasting]

I love the blue/green fire from dirty copper. Have you tried using water-washable resin? It costs and prints nearly the same, but it's way easier to clean.

[@morbiddinosaur]

"Growing" bar- sorry if you've already heard this answer. The gasses that floated to the surface of the bar came from the flame. Smothering it as soon as you could might have prevented it. There was enough gas build up on the bottom of the caste from the oil burning that it was forced to escape through the liquid metal. Two part molds or closed molds smother flames before they can trap gasses around the metal, just smothering it with a wet towel next time will probably work just as well since it's a simple form

[@jamesfreeman8247]

I make my ingots similar to this after pouring whatever I am trying to cast. I thought about buying some ingot molds, but I had scrap pieces of wood, and I have plenty of greensand to make these ingot casts. I simply cut the scrap pieces of wood to the size I wanted with the sides at 5 degrees on the table saw. I've certainly avoided the ingot-stuck-in-the-mold problem that I have seen from time to time among the metal casting channels.

[@jimnickerson9102]

A question for the room, thanks in advance. When melting the copper as in the video, the material was dirty as many here have said. If that ingot was sold at a scrap yard, what grade of copper would that ingot been sold at in comparison to the copper that he started out with that was contaminated? My question basically, is it worth it to melt into ingots if the material you have is contaminated similarly as in the video? Enjoyed the video very much. Thanks

[@nickwoo2]

I usually throw some charcoal on top of the metal in the furnace to prevent oxygen from getting in. The bronze is dense enough the charcoal just floats on top.

[@Eziobrock]

Do you remove the charcoal before pouring or does it float to top of pour as well? I’m assuming you remove as much as you can beforehand.

[@nickwoo2]

@@Eziobrock yeah I get most of it off before the pour.

[@chrisjames6349]

I came here to say the same thing. Thought I’d check to see if anyone said it first. I swear by it!!!

[@plywoodcarjohnson5412]

Have u been running around nighttime collecting copperwires from bridges? It turned out nicely. Might be worth the adventure on a summer night. Looking forward to the next one. In gold.

[@rachelg552353]

I am enjoying the mid week melt series. Thanks for sharing.

[@Serbianguy432]

Nice. Beats the heck out of that old grungy copper wire!

[@underdogmelting6058]

Very cool melt love molten copper colour thanks for sharing just getting into melting and you learn something every day thanks for sharing very cool

[@kleetus92]

Only thing I could offer would be to put a thermal probe in the copper to see what temperature you're actually at. So it's like 1000C or 2000F... being a couple of degrees above shouldn't be an issue, but if you were cooking along at 500 degrees hotter... maybe that was in fact your issue. Did you use any kind of flux to remove impurities and or create a gas barrier? Being that you melted dirty copper it would not surprise me that if you were way high on temperature that you actually melted the copper oxide and other impurities, that once cooled down was starting to show up. Copper oxide melts at 2500F, 1300C (rounded off) so yeah it's likely you were casting more than just copper in that melt!

[@tylociraptor8131]

Kind of curious! When you added additional wire on top of the other stuff, how can you be sure it wasnt going to fall off and drip into the furnace instead of going down in to the... crucible? Is that the right word? lol

[@Kamal_AL-Hinai]

Because the wire collapses inwards first

[@JamesMiddletonIV]

The molten copper is the hottest thing in the crucible so the copper that is exposed to the puddle will melt first and draw the rest downwards with gravity.

[@geordannik]

Repairing the text was super interesting to watch!!

[@oneshotme]

Enjoyed your video and I gave it a Thumbs Up

[@FerrousPhoenix]

That's an interesting defect you had, my only guess would be impurities in the copper. But you were using copper wire so you should have mostly pure copper.

[@sydniusalminia5364]

Thank you so much for being of the few people who explains what you're doing and why at each step

[@Phantomthecat]

Despite the imperfections, it is still a thing of beauty. 👍👌😊

[@ddtc.w.o.3055]

I would really love to have and Ingot Mold pattern similar to that made. Would you make one for a fee? Or could you point me in the right direction of obtaining one? I don't have CAD skills nor do I own any printer capable of it. Very nice work, and very nice shop/foundry set up you have.

[@darensworld2221]

Very nice. I like how you set up the resin print. I feel like watching this would have helped some of my previous attempts at resin printing.

[@kaliba692]

you´re a master. this is so fun too watch.

[@andreipendle1778]

Nice! Loving the new Midweek Melt.

[@georgep.dennis2003]

Hello, excellent videos. What type of propane regulator do you use? Thank you.

[@ashwynn4177]

Great video. Please tell me what type of gas bottle and crucible you using thanks

[@mcwolfbeast]

Petrobond is usually not rated for over 900°C -- copper at pouring temperature will be (well) above that, especially in a gas fueled furnace. As others have remarked the oil will burn and rapidly release and dissolve gas into the molten copper (which has already been aerated by using a gas furnace too) -- this can lead to the foaming you see, specifically if you have a larger volume of molten metal that doesn't cool rapidly.

[@spearpaintingone]

Hi what sort of burner are you using at the end of your gas line? I have no end of trouble getting that sort of heat with 2 burners and natural piped in gas!

[@XYZdude00]

You ought to cast a bunch of regular ignots just to store your copper better

[@krisj.parker5679]

Brilliant mate, I really do love the way you have a great sense of attention to detail. One of a very few who do so. Well done mate. 😀

[@calebquintana5724]

Idk if you know this, but you can hang the build plate sideways to let it drip into the container

[@nickhollister9483]

Random Question: what do you do with the sand that is burnt and blackened? Do you discard it or is it reusable?

[@robinson-foundry]

It’s reusable. I scrape it away from the un-burned sand and rehydrate it with oil. It degrades slightly but not too much.

[@boomer150]

cardboard will prevent your firebrick from sticking, I heard that somewhere.....

[@petar.dj98]

Nice save!

[@justinbanks2380]

Just found your channel and loving your videos! Will definitely have to try as I've been wanting to for awhile. I have a question though, in the video it looks like the filters you have on your respirator are for particulates not vapors. I thought for things like this where toxic gases could be present you had to go with the cartridge type? Am I missing something? Is there a different type or were you wearing it for some part of the process other than gases? I look forward to going through all your videos and learning and being inspired along the way!

[@Ankhubuntu]

Hi i luv your channel! ! i don't have much Exp workin with iron n' stuff.. would u recommend A guide how to build up A foundry? i haven't Even bought An Angle Grinder but i built A wall from stone block(concrete) n' A few other stuff. It = A beer barrel ur foundry?

[@mrtaylorrose]

just a heads up if your not aware.. I've seen several of your videos on facebook but with no mention of you channel. someone may be stealing your content

[@kmcgz]

Try putting lithium in before you pour tobkeep air bubbles down and maybe graphite in crucible while it melts to keep ot hot

[@DrEnginerd1]

How do you prevent bubbles in the middle of the casting?

[@BethAppleton-4]

I had heard that copper is weird and requires its own special flux. I came here hoping to see what flux you were using to prevent that bubbling. Decades ago, big smelters like Kennecot Copper used raw green logs to stir the copper.

[@travismiller5548]

"Someone" burnt the insulation off 🤣

[@mikebashford8198]

When you pour the liquid metal, around 4:21, there are flames - what is it that's burning?

[@Metalstacker]

Nice one ✌🏻👊🏻

[@SakibLH44]

Wait! What sorcery was that at the beginning!! Lol

[@joneastman5627]

Awesome bar man thanks for the video

[@alanstanley8226]

nice smelter

[@SurShoot]

What is that red sand looking thingy

[@travpots6318]

Good job

[@rickydona919]

your explanation of why the copper grew is wrong, your furnace cannot possibly introduce enough gas to molten copper to cause this reaction, it would take an oxy ecetylene flame to introduce enough oxygen gas to cause a reaction, it is more likely that your sand had so much moisture that it caused the water to boil and to escape through the molten copper while it was cooling, I learned from tito4re that your copper should be almost hot enough to boil to get the best pouring results

[@robinson-foundry]

I wondered whether or not it was the oily petrobond but I have seen others cast large copper ingots using petrobond without any problems. I’ve cast very heavy bronze objects in the same sand without any problems. I may try again with greensand.

[@catholic3dod790]

Wow, where did you buy a computer printer like that? What is that name? Thank you

[@zeusthedrumlord547]

Sorry if I’m too late but that’s a resin 3D printer, pretty sure all resin ones print like that.

[@Will-dn9dq]

Someone burned off the insulation? Yeah you're Someone lol. Glad you didn't use pennies that be a big problem.

[@olivierdussault9080]

Ya he simply found burnt wires on the ground , that SOMEONE left after burning the insulation 😂

[@Will-dn9dq]

@@olivierdussault9080 they'd not want that valuable copper just wanted "watch the world burn." Lol 😆

[@Aaron_b_c]

Why does the pretty flame go from green back to orange

[@metalmeltingmark4655]

Thanks for sharing

[@amilcarmoncada1801]

Estupendo video, muy buen resultado este lingote enorme de cobre Big-OLe obtenido de esta fundicion, respetos desde Venezuela.💯🤜🔥🤛👍🙏💯💯

[@Mistertbones]

It's got some character.

[@snkolson]

Awesome thank you for sharing

[@Chocolatnave123]

why didnt you spend 1/4 of the time and make a hollow mould?

[@wolffram1]

Great vid, enjoyed...apart from the spelling mistake - ol' - ; )

[@joesask857]

nice

[@petertimowreef9085]

But... Its brand new?

[@brendanmorrison327]

really new to 3D printing, why print at an angle that that?

[@robinson-foundry]

It helps alleviate suction while printing.

[@kelvin1316]

@@robinson-foundry Just as an aside, that angle is only needed for resin printers, if printed on a filament printer it could be printed flat. Of course that would lead to either layer lines or a massive print time if you went higher resolution 😄

[@boxhawk5070]

The green flame looked like it was from Lord of the Rings.

[@draggy76]

you should have made a plain blank flat side and made it a full mold instead of an open back....

[@RedWhiteBlueYo]

How much is that worth for sale on open market?

[@plywoodcarjohnson5412]

Nine USD per kg. (9!) (worthless)

[@canadiangemstones7636]

Well, it’s a collector’s item, or even art. You’d charge what the market would bear. Like 10x the actual value of the copper.

[@caclesi]

What kind of machine is in the begin? I don't know

[@JamieBainbridge]

Resin 3D printer

[@puzzleheaddesign3789]

Something about holding a chunk of even semi precious metal.

[@Shreyam_io]

print numbers and mod every next time with a new number for indexing ...

[@tarekno3man]

يوجد كثير من الاخطاء وانت تفعل هذه القطعة اول خطأ عندما تريد صنع القالب من الرمل عليك ان تخفف ضرب بطريقة ان الرمل يخرج البخار من داخله الخطأ الثاني عليك تنشيف الرمل الرمل بالنار اي عليك تمرير النار داخل القطة كي الماء يصبح بخار ويخرج من القالب

[@Neg-Ros]

🔥🔥🔥

[@qc5467]

Big brother why u can't craft a whole endo skeleton of any dino.

[@Cletus.223]

Do you have an Instagram for the channel by chance? Or somewhere you can be messaged?

[@dayanson6920]

You should just print all items now with NGot.

[@zawhtetkhine6837]

I'm not familiar with foundry but I'm one of your biggest fans. Let me suggest why the copper is growing. I'm really amazing that you are not attaching sprue to this one. And I'm shocking that you are pouring huge amount of liquid metal into the mold as I thought that amount of metal would deform alphabets. And the copper is growing as there was a open space to grow. I'm simply thinking if you are attaching sprue and using enclosed mold, this issue would be solved.

[@ImmortalLemon]

Wait I’m sorry what the heck was that 3D printer? That’s some magic shit you just pulled an ingot out of a pool of stuff? What?? How?!

[@jagboy69]

Straight copper sucks doesn't it?

[@robinson-foundry]

It sure does!

[@olfoundryman8418]

Not if you do it right... Martin

[@jagboy69]

@@olfoundryman8418 We are just mere mortals Martin.😉

[@olfoundryman8418]

@@jagboy69 Sadly we are all mortal mate 😊... Martin

[@exxon47_]

It's a little too many colors of fire

[@olfoundryman8418]

Ah, another in the long line of "loaf of bread" copper ingots. Your guess is sort of right and sort of wrong. It happens to most people who melt copper because they do not know what they are doing. In your case it was worse because of the very dirty nature of the copper and how it had been made that way. Should I ever get well again I will demonstrate how to melt copper properly. Don't be too embarrassed - it took me a failed melt to get it right..... Martin

[@Timothyh3nry]

In the meantime would you be able to explain what went wrong and how to avoid it?

[@generaldisarray]

C'mon, tell us what went wrong???

[@robinson-foundry]

No, Im not embarrassed at all, we all learn from our mistakes. Did you see how smoky the crucible was after the pour? There was a reason I hadn't used that wire for anything nice. Please let use know what happened so I can update the description.

[@Saki630]

@@generaldisarray hes going to ask Reddit for the answer for he himself does not know. I think Robinson is right that it was gas build up. Maybe its steam or a byproduct of whatever is in the sand. Even if the Copper was not pure, it would not make that bubbly top. I thought you were going melt the bar and let it cool somewhere else to show that its not the copper by the sand/mold causing it.

[@generaldisarray]

@@Saki630 In fairness Olfoundryman actually has his own YT channel, so he probably knows a thing or two. kzbin.info/door/90RoN_IjSRF18jAG0HIA6gvideos

[@BornOfAsh]

Thank you in Advance whoever responds. I would like to know "Where the scrap yards are selling their metals too, that they buy from us"? It seems they would have to buy it from us for lower then sell to someone else for Higher. It seems that us citizens could skip this middle man (The Scrap yard), and sell directly to the higher bidder being (The ones who buy from the scrap yard). Could someone enlighten me? I can't seem to find anything about it online.

[@canadiangemstones7636]

The big boys are not interested in buying small amounts.

[@BornOfAsh]

@@canadiangemstones7636 Who are these "big boys"? What is their job title or where do we find them.

[@unicornhal]

I like the other side. The one without the words.

[@KevinVidomski]

This doesn't look like a copper melting video....

[@SHOINOFF]

I would of re melted it and started over.

[@amosbieler5201]

Nice ingot and video 👍 However, since it's a contraction of “old”, it should be spelled “ol’”, with the apostrophe taking the place of the “d”. Kudos on an otherwise excellent execution of a great idea 👍

[@CalineBRUNO]

That most be really hot !

[@timothywhieldon1971]

USE FLUX please!

[@KyleBrinkerhoff]

about 50 bucks worth of copper

[@user-mo3wh6vk2m]

?

[@LickingKoala]

your channel is AWESOME, just subbed :D

[@JoJoAcrylicArtwork]

Awesome! Wow I didn't know leaving it molten too long could cause that. @trinityjmg

[@pinakibhome3075]

i can make it better

[@eldavo2266]

Better? How so?

[@lindapastori84]

Kind of curious! When you added additional wire on top of the other stuff, how can you be sure it wasnt going to fall off and drip into the furnace instead of going down in to the... crucible? Is that the right word? lol