Q:

How do you make an aluminum mold?

A:

Quick Answer

To make an aluminum mold, prepare the oven furnace, flask and molding bench. Fill the flask with a paste of sand and water, and prepare the pattern. Melt aluminum scraps in a furnace, and pour the molten aluminum on the sand pattern. Allow it to cool, and lift the fully formed aluminum mold out.

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Full Answer

Use a 6-gallon bucket and an open-head stainless steel drum to build an aluminum melting furnace. Build a simple molding bench with a plywood seat and two molding boards on which to place the pattern. Use an open wooden box to act as a flask and hold filtered sand.

Light the furnace with charcoal, and place a bucket with aluminum scraps in the foundry. Sprinkle some pumice powder on the mold pattern after placing it on the molding bench. Set the drag with its wrong side on the pattern, sift sand on it, and pat it well. Brush away any extra sand, and create a vent in the mold with a sharp wire. Turn the drag upright with the pattern inside it, and place the cope on it and a riser on the pattern.

Create a 1-inch deep impression in the sand, vent the pattern, and remove the riser, cope and drag. Brush water around the patterns, tap it out, and remove any excess sand on the mold. Use tongs to lift the molten aluminum from the bucket, and pour it on the pattern after adding the cop back, taking care not to pour from too high. Allow the casting to cool for about half an hour, and lift the formed mold off the pattern.

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