Metal Casting at Home Part 128. Failed Brass Casting. Part 1.

The casting will later be machined to produce the leg ferrule for a Blüthner Style-VII grand piano c.1908 for
www.hamiltonpianos.com
#hamiltonpianos
Following advice from The Home Foundry forum, I will be trying another method next. The issue really is the limited capacity of the electric furnace not giving enough metal to fill the mould as the metal shrinks as it cools.
Sovol SV01 Pro 3D printer: sovol3d.com/co...

[@toastedone2478]

I appreciate the transparency when a pour goes wrong and your attention to quality. I also like the "Autopsy" to find root cause. You are a man of integrity and why I like following your channel. I learn so much from watching you!!!!

[@thefixerman1]

Still thoroughly enjoying your channel....I've followed since the earliest day's and to the present. It was your steam projects and channel that got me started and the need for buying a lathe and milling machine. First project was making your steam engine and have now progressed to other projects. Thankyou again for sharing your skills with us and producing the excellent videos. Long may they continue to teach us....simply Brilliant!

[@roscoepatternworks3471]

Larger flask at least 1" all around including around the gating. Use a drag runner and an cope ingate. Runner should have an extension beyond the ingate. Use a tapered sprue with a well in the drag. Gating should be sized to the weight being poured. I did a similar part for a steam cylinder looks about the same size. Hope this helps.

[@barthanes1]

When you took it out of the sand I was thinking, damn that looks good for a failure.

[@rickoshea8138]

Blessed with skill, patience; and knees of steel.

[@GrandadIsAnOldMan]

Fascinating to read all the comments, plenty of support and suggestions 👍

[@gth042]

I hope someone sends you a second furnace to review -- and an ultrasonic parts cleaner to help remove those cores. More importantly, thank you for posting. I enjoy watching you pursue a fun hobby. Best of luck!

[@headstocktailstock]

I subscribe & enjoy following your posts David ,casting alloy is one thing but brass is a different ball game it's a dirty metal I used to cast a lot of brass a lot of years ago, still do when required, keep up the good work Graham.

[@Smallathe]

Fascinating project and a very cool autopsy and analysis!

[@davidmilway7886]

I have had the same issue with casting cylinder blocks they look good on the outside but when you start machining voids show up just where you want the steam passages. I ended up with a gate just smaller than the steam chest face. Took 3 or 4 goes to get 1 cylinder which was good. Keep up the good work.

[@RonaldWalters2010]

Very informative as usual.

[@BrianEltherington]

Art revealed as science for all to understand. Thank you! Larger basin?

[@coupdegenie51]

What talent, well done! With such dexterity in sand casting, has lost wax casting never tempted you?

[@myfordboy]

I have done lost PLA with sucess but I prefer sand casting, not so messy!

[@tobhomott]

Some good suggestions for a fix coming in on the forums... You'll get that sucker next time!

[@dennissheridan1550]

When I learned metal casting in high school we always put a vent at the opposite end from the sprue that way trapped gases couldn't cause voids. I am wondering why you don't use one in your molds?

[@myfordboy]

I often do use a riser on larger castings.

[@johnrutzen1861]

I think they are pretty good for a failure! I would have just filled the holes. On the subject of copper alloy casting though, I've done some and there were voids, I had to line cylinders I made. I read in a very old Model Engineer that the addition on phosphorous is very effective in de-gassing. The easiest and cheapest way to do it is to add some phosphorous containing brazing alloy [used for refrigeration copper joining without flux]. This can be bought very cheaply by the kilo on ebay. You don't need much apparently.

[@myfordboy]

Good tip. I don't think filling would be acceptable for these parts on a top quality grand piano. Since the video I have successfully made another with a different pattern and gating design. Look out for part 2!

[@vgofron]

Did you consider soldering/brazing the cavity? There are some brass-like alloys used for this, which should be almost invisible after the repair.

[@myfordboy]

As this going to be highly polished part on a grand piano I don't think that would be acceptable.!

[@ronporteous1411]

I've noticed in your previous casting projects you usually always place canisters of sand sprue on the pouring holes to increase the amount of molten metal input (loading) to prevent casting voids. Which is something I've decided to include in my own projects. But you did not on this project which I found curious.

[@myfordboy]

I did not think there was going to be enough metal in the electric furnace for a extended feeder. I have since mad a sucesful casting though using one. look out for part 2 of this project.

[@BruceRobinson-tz8cj]

Fascinating - only by trial and error is progress realised.

[@CharlieMoDank14]

Thank you

[@532bluepeter1]

Would you like some chilli sauce with the doner brass?

[@bake162]

I’d like to know why you work off the floor rather than a bench or table? Seems uncomfortable but traditional.

[@CraigLYoung]

Don't worry he has knee pads built into his overhauls so it's not as uncomfortable as you would think.

[@realmetallurgist8493]

That looks like simple solidification shrinkage. That little sprue will freeze off before the part itself, and won't be able to feed the casting. You need a riser.

[@myfordboy]

I did not think there was going to be enough metal in the electric furnace for a extended feeder. I have since mad a sucesful casting though using one. look out for part 2 of this project.

[@henrikstenlund5385]

To me it would seem that there is no riser and that will cause some issues. Thanks for this

[@williamokrasinski9840]

Ah, brass melt. Pure or mixed brass & bronze ? Melt temp Cº or Fº ?

[@myfordboy]

1100C pouring temperature. All the metal was from brass piano wheels.

[@CraigLYoung]

Thanks for sharing 👍

[@BeachsideHank]

Why not chuck the workpiece up and saw it with that great powered hacksaw you made years ago, that thing is so sexy. ☺

[@annarboriter]

As much an art as a trade

[@chadgdry3938]

11:20 alloy adventurism

[@mrglasecki]

Riser above the gate needed to be higher

[@myfordboy]

I know this but metal volume is limited with this furnace. I have now sucessfully cast the part with a different set up.

[@mrglasecki]

@@myfordboy ahh, yeah that does it every time 🤣

[@splinky99]

Silicon bronze is so so so much better to cast! Even if the brass is free, it’s not worth casting if you ask me! It’s not worth the breathing in of the zinc smoke and all the porosity!

[@moretimethanmoney8611]

If only there were a way to preheat the mold.

[@fefifofob]

Find the story about Edison and the copper cube.