Foundry - Revision history

AlexN: /* Safety */

2024-01-28T01:39:17Z

Safety

← Older revision		Revision as of 18:39, 27 January 2024
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	==Safety==		==Safety==
	*'''DO NOT USE BEFORE GETTING PERMISSION FROM THE GENERAL MANAGER'''
	*'''ONLY USE OUTSIDE'''. Ensure fumes will not enter the building. Do not stand down-wind from the fumes.		*'''ONLY USE OUTSIDE'''. Ensure fumes will not enter the building. Do not stand down-wind from the fumes.
	*'''Wear appropriate clothing for hot work'''		*'''Wear appropriate clothing for hot work'''

AlexN: /* Safety */ fixed list format error

2023-05-17T17:53:19Z

Safety: fixed list format error

← Older revision		Revision as of 10:53, 17 May 2023
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	**'''Limit how much you travel with hot metal'''. Set up all equipment so it is close by and easy to pick up.		**'''Limit how much you travel with hot metal'''. Set up all equipment so it is close by and easy to pick up.
	**'''Have fire extinguisher on hand'''. Know where the nearest water source is.		**'''Have fire extinguisher on hand'''. Know where the nearest water source is.
	**'''Have bucket of water to cool down tools and molten metals.		**'''Have bucket of water to cool down tools and molten metals.'''
	'''**'''Ensure any potentially flammable objects are at least 30 feet away.'''		**'''Ensure any potentially flammable objects are at least 30 feet away.'''
	**'''Prepare a spot to put down hot objects, use fire bricks, sand, or items that can withstand 2000F.'''		**'''Prepare a spot to put down hot objects, use fire bricks, sand, or items that can withstand 2000F.'''

AlexN at 00:34, 17 May 2023

2023-05-17T00:34:18Z

← Older revision		Revision as of 17:34, 16 May 2023
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	[[File:foundry.jpg\|400px\|thumb]]		[[File:foundry.jpg\|400px\|thumb\|The foundry]]
	[[File:foundrycart.jpg\|400px\|thumb]]		[[File:foundrycart.jpg\|400px\|thumb\|The cart for all tools and accessories. The top contains green sand.]]
	[[File:foundrycrucible.jpg\|400px\|thumb]]		[[File:foundrycrucible.jpg\|400px\|thumb\|The main crucible]]

	==About our machine==		==About our machine==
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	**Leather apron and chaps to protect against splashing metal.		**Leather apron and chaps to protect against splashing metal.
	*'''Treat all metal like it is hot metal!''' You can't tell just by looking if a piece of metal is hot enough to burn you. Always use the tongs for moving metal until it has fully cooled down.		*'''Treat all metal like it is hot metal!''' You can't tell just by looking if a piece of metal is hot enough to burn you. Always use the tongs for moving metal until it has fully cooled down.
	*'''~~EXERCISE~~ EXTREME CAUTION WHEN WORKING WITH ZINC AND CHROME ALLOYS'''. Use additional ventilation or wear a respiratory.		*'''USE EXTREME CAUTION WHEN WORKING WITH ZINC AND CHROME ALLOYS'''. Use additional ventilation or wear a respiratory.
	**Zinc fumes can cause "metal fume ever", leading to severe chills and many health problems.		**Zinc fumes can cause "metal fume ever", leading to severe chills and many health problems.
	**Chrome fumes can result in respiratory irritation and other severe health problems.		**Chrome fumes can result in respiratory irritation and other severe health problems.
Line 29:		Line 29:
	**'''Limit how much you travel with hot metal'''. Set up all equipment so it is close by and easy to pick up.		**'''Limit how much you travel with hot metal'''. Set up all equipment so it is close by and easy to pick up.
	**'''Have fire extinguisher on hand'''. Know where the nearest water source is.		**'''Have fire extinguisher on hand'''. Know where the nearest water source is.
	**Have bucket of water to cool down tools and molten metals.		**'''Have bucket of water to cool down tools and molten metals.
	**Ensure any potentially flammable objects are at least 30 feet away.		'''**'''Ensure any potentially flammable objects are at least 30 feet away.'''
	**Prepare a spot to put down hot objects, use fire bricks, sand, or items that can withstand 2000F.		**'''Prepare a spot to put down hot objects, use fire bricks, sand, or items that can withstand 2000F.'''

	==~~Casting Process~~==		== Igniting the Foundry ==
	This is ~~only an overview of~~ the ~~process~~.		# Adjust the flow valve so it is fully closed
	* Setup, ~~melting~~, ~~cooldown~~		# Light a stick or small scrap of paper and place inside empty foundry
	* Cart location and ~~contents~~		# Slowly crack open the valve on the tank, then open at least 3 full turns
	* Foundry staging		# Slowly open the valve on the regulator until flame ignites
	* Tank location and ~~connecting~~		# Turn valve up to 30 psi
	* Important tools and ~~gear~~		# Turn on air assist
	* Molds		# Ensure flame is stable
			# Put items you want to melt inside crucible
			# Place crucible inside
			# Place a small piece of firebrick on the rim of the foundry (this will leave a small gap when the lid is on)
			# Place the plug in the lid's hole, then place lid on top of foundry. This will allow heat to build up.

			== Melting ==
			# Allow sufficient time for crucible to warm up (approximately 10 minutes)
			# Occasionally inspect contents of crucible.
			## Put on goggles
			## Carefully remove plug from the lid to look into crucible
			## Use a metal rod to push on the material to check if it is liquid
			## If it is not, close the plug and put the hot tool down somewhere safe.
			# When melt is molten, use a metal rod to stir the contents. This helps mix up impurities and allow them to reach the surface.
			# Gently scoop surface-level "slag" and undesirable oxides out of molten metal and scrap into a steel container. Repeat this process multiple times until metal looks clean


			== Casting ==
			# Before pulling out crucible, ensure the following conditions are met:
			## the path to your mold is unobstructed
			## the tools necessary for pouring are handy and easy to pick up quickly and safely
			## there is a place to set the crucible down when you are switching between tools
			## you can go through these steps quickly without interruption. time is critical once the crucible is out and the metal is cooling, delays will result in pre-mature cooling and a bad pour
			## you have a back-up mold in case the main mold breaks. you still need to empty the crucible if things go wrong, so pour remaining into an ingot mold.
			# Remove the crucible using tongs
			# Place on insulated pad
			# Grab tools for pouring the crucible
			# Lift crucible by hinge pins
			# Place hook into loop on bottom of crucible
			# Bring crucible over to mold and pour

			== Teardown ==
			When you are done, ensure the following conditions are met:
			# Close valve for propane tank.
			# Be on Fire Watch for 1 hour after the flame has been put out. Stray embers or unseen hot metal could start a fire well after the flame has gone out.
			# Wait 2 hours after the flame has put out for the Foundry to cool down enough to go back in storage.
			# Ensure all tools and items have cooled down and can be stored safely back on the cart.
			# Return fire extinguisher to its stored location.

AlexN: Created page with "thumb thumb thumb ==About our machine== Details: Custom made foundry. Built from small propane tank and lined with furnace cement Fuel: Propane Location: on a cart with the Rolling Workbenches For use outside ONLY This tool requires a safety checkout ==Safety== '''DO NOT USE BEFORE GETTING PERMISSION FROM THE GENERAL MANAGER''' *'''ONLY USE OUTSIDE'''. Ensure fumes will..."

2023-05-17T00:26:37Z

Created page with "400px|thumb 400px|thumb 400px|thumb ==About our machine== *Details: Custom made foundry. Built from small propane tank and lined with furnace cement *Fuel: Propane *Location: on a cart with the Rolling Workbenches *For use outside ONLY *This tool requires a safety checkout ==Safety== *'''DO NOT USE BEFORE GETTING PERMISSION FROM THE GENERAL MANAGER''' *'''ONLY USE OUTSIDE'''. Ensure fumes will..."

New page

[[File:foundry.jpg|400px|thumb]]
[[File:foundrycart.jpg|400px|thumb]]
[[File:foundrycrucible.jpg|400px|thumb]]

==About our machine==
*Details: Custom made foundry. Built from small propane tank and lined with furnace cement
*Fuel: Propane
*Location: on a cart with the Rolling Workbenches
*For use outside ONLY
*This tool requires a safety checkout

==Safety==
*'''DO NOT USE BEFORE GETTING PERMISSION FROM THE GENERAL MANAGER'''
*'''ONLY USE OUTSIDE'''. Ensure fumes will not enter the building. Do not stand down-wind from the fumes.
*'''Wear appropriate clothing for hot work'''
**All cotton or natural fiber clothing. SYNTHETIC CLOTHING WILL MELT TO YOUR SKIN.
**Leather boots or shoes are preferred. NO OPEN TOED SHOES.
*'''Wear appropriate safety gear'''
**Shaded goggles or lens. Always wear when looking at glowing objects to protect from intense IR light that can burn your eyes.
**Thick leather gloves. These should be heavier than welding gloves. Note - the gloves do not permit you to directly hold hot metal, and only serve as a temporary barrier.
**Leather apron and chaps to protect against splashing metal.
*'''Treat all metal like it is hot metal!''' You can't tell just by looking if a piece of metal is hot enough to burn you. Always use the tongs for moving metal until it has fully cooled down.
*'''EXERCISE EXTREME CAUTION WHEN WORKING WITH ZINC AND CHROME ALLOYS'''. Use additional ventilation or wear a respiratory.
**Zinc fumes can cause "metal fume ever", leading to severe chills and many health problems.
**Chrome fumes can result in respiratory irritation and other severe health problems.
*'''Check hoses and fittings for leaks before operating'''. Use soapy water and look for bubbles at all connections and valves
*'''Prepare for hot metal and open flames'''!
**'''Limit how much you travel with hot metal'''. Set up all equipment so it is close by and easy to pick up.
**'''Have fire extinguisher on hand'''. Know where the nearest water source is.
**Have bucket of water to cool down tools and molten metals.
**Ensure any potentially flammable objects are at least 30 feet away.
**Prepare a spot to put down hot objects, use fire bricks, sand, or items that can withstand 2000F.

==Casting Process==
This is only an overview of the process.
* Setup, melting, cooldown
* Cart location and contents
* Foundry staging
* Tank location and connecting
* Important tools and gear
* Molds

[[Category: Tool]]
[[Category: Safety Checkout]]
[[Category: Metal Shop]]