Green Sand Casting

**CAL G** · 23-09-09, 03:16 PM

Last week myself and a another knife maker Kevin took on a casting project.
Neither one of us had ever done any casting before. Here are the results of a lap wheel we made. We were pleased,learned a lot and look forward to improving our technique.

**wildiesel** · 23-09-09, 03:31 PM

Nice job that, never cast anything that big. Always wondered why more knifemakers are not into casting. It's easy, cost effective and opens up a whole spectrum of creativity regarding sheath fittings, guards, bolsters etc.
Here is a centirfugal caster but simpler ones are so easy to make.

**narsil** · 23-09-09, 03:38 PM

Good setup

One thing I would suggest for next time is to add vents (risers) to the mold these allow gas to escape from the mold cavity, helping it to fill quickly and completely. They are particularly important on more complex patterns where metal may be flowing along more than one path and there are significant variations in height.

**CAL G** · 23-09-09, 03:45 PM

Originally Posted by narsil

Good setup

One thing I would suggest for next time is to add vents (risers) to the mold these allow gas to escape from the mold cavity, helping it to fill quickly and completely. They are particularly important on more complex patterns where metal may be flowing along more than one path and there are significant variations in height.

Chris,we will do that . We had about 10 little 1/16 inch holes "poked" in the sand over the pattern with a welding rod. But the next time there will be a large vent hole.

**narsil** · 23-09-09, 04:06 PM

Yes blind vents can also be effective, especially in green sand which is quite porous.

**DCL** · 23-09-09, 06:49 PM

very cool

DC

**a6cjn** · 23-09-09, 07:49 PM

Well done and a pleasing result.
I've done a fair bit of this and can I offer a couple of sugestions.
Green sand works well but have a try with 'Petrabond', it's an oil based sand which can give a superb finish and detail.
Venting has been mentioned and poking vents with 1/16 wire is fine but I would use a 'riser' - the hole you pour the metal in is called the runner and you really need another hole, opposite the runner which allows the metal to rise up once the cavity of the mould has been filled.
A note of caution if you are using scrap Ally for the melt, it can be an unknown alloy can cause a few problems, indeed. I once saw a crucible 'blow' because of this this. I would go for LM4 or LM6 as they both cast and machine very well.
Thanks for posting the pics, brought back a few happy memories

Chris

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