DIY Electric Foundry Upgrades - 1200°C - Melting Copper
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- čas přidán 28. 06. 2017
- In this video I am upgrading my Electric Foundry after over a year of heavy use. The first half of this video is quite dull in my opinion but the 2nd half is really exciting and contains lots of new stuff for me so check out 11:00 if you're impatient.
This video has been in the making for over half a year now so I really hope you can appreciate the amount of work that I've put into it!
Please consider supporting me on Patreon for early access to videos and to help keep quality content like this coming: www.patreon.com/TheArtOfWeapo...
Check out my instagram for more updates: / theartofweapons
All music was used with permission from the creator and is royalty free. - Jak na to + styl
This video has been in the making for over half a year now so I really hope you can appreciate the amount of work that I've put into it! The first half of this video is quite dull in my opinion but the 2nd half is really exciting and contains lots of new stuff for me so check out 11:00 if you're impatient.
TAOW yay your back its been almost a year since you uploaded
TAOW by the way instead of using fire brick replace it with kale wool its far more heat resistant and it will never break
dat boy orly kaowool
dat boy orly Bad spelling makes it very hard to find things online. I didn't insult you, I simply informed you and anyone else who might have been interested what the actual term was. Grow up.
you speed it up tooooo fast that itøs hurting my freaking eyes mate
Good to see an update to this project and glad to know it holds up with time. Also good to know the steel crucible does well
NightHawkInLight I really like your channel and I found this channel through your shout out. You seem like a chill guy
Just remember, "A grinder and paint, makes me the welder I ain't!"
Ryan Burdick ol bumblefuck
Ryan Burdick aye, shoulda used some if the blocks of the water from kunickystan to cool that copper
Love it
I love your DIY Electric Foundry, I watched all the videos five times!!
You're the most legit foundry channel on youtube. Seriously. Thank you for all the information you put in your vids. I'm getting close to being able to build my own foundry setup. And thank you for not succumbing to posting memes for views. Keep it classy!
I work at a copper foundry in Belgium and seeing you granulate the copper in a plastic pitcher did raise my eyebrow :D when we are 'tapping' from the foundry we granulate some liquified copper in a steel cannister with water and newbies tend to pour a bit too quickly, causing tiny steam explosions, launching the cannister straight up into the air, much to our amusement ofc. Great work nonetheless, you are a very knowledgeable and inventive guy.
I plan on going to welding school and starting to forge metal at home once I have my foundry set up, it's people like you that inspire me.
Last night I saw this video and today went out and made something entirely based on your idea. I had 4 of those bricks already here from my waste oil furnace build and just cut them in half, used a straight cut router bit in the drill press to cut the chanels very quickly, ran a one meter length of 5000w wire stretched out a bit into the chanels, connected mains cable and melted 1kg of Ali in exactly 4 minutes. I actually couldnt believe my eyes having been used to spending ages using my other furnaces that use waste oils. I'm so gobsmacked that Ived ordered another coil and I'll get some full size bricks in, having said that I have half a roll of ceramic blanket in the loft that might try out as an alternative or even consiver making a coil for a my existing furnace. The problems thus far is A: I keep blowing 13amp fuses. B: The mains AC wires are getting way to hot and the plastic sheild is starting to melt. But, what with knocking up a complete running furnace in an hour ( I used normal welding wire wrapped around bricks for temp test ) I am as stated amazed at the speed. Ive just ordered a temp PID thing and a probe from Amazon and another coil. I did put an SCR inline to control the inbound AC but unfortunalty blew it up later this evening in another experiment. Might get another dimmer control. For small 1kg jobs its an amazing tool. Having watched you spend 3 hours doing copper I think maybe a syphon nozzle will stay my prefered route for that as its still much faster than the electric. But hey, hats off to you! Really impressed with the sheer speed, the joy of no flames, no messing around, switch on and go. Really enjoyed today. Thank you.
Dude you make awesome content, I always love the videos you put out regardless of the irregularity! I'm slowly making my way into metal casting/working and your ideas and designs have been incredibly helpful for me, keep up the good work!
honestly, don't fret about the welds being ugly. to quote AvE: "Grinder and Paint make me the welder I ain't"
JJXB2004 What kind of paint are you going to use on a crucible? 😂
I like to call it 'CZcams spraypaint'
just spray it on for the video and let it burn off
+Jon Miller automotive header paint should work
i think he does it on purpose to solve the issue of metal expansion from heat. (he has severals angels in a row which would bend out of shape he welded normally)
JJXB2004
Like I always say, "with only a little practice(with emphasis on the words "only" and "a little"), there's a half-assed welder inside each and all of us"!
The phrase "half-assed" is descriptive of the last DIY foundry video I watched before I found this one. That one was also electric, but man did it look sketchy in every possible way! Whereas this^ foundry looks much safer and more reliable. This guy put a lot of thought, time and effort into this. Nice job, and btw, the weld was fine.
It's been a joy to watch your videos over the years and I'm glad you're finished with your exams. Have a great holiday and can't wait to see what you've got planned for when you return!
This is one of the best projects I’ve seen from you so far. Amazing effort in this video. Thanks I’ll be thinking about this method for my own project!
Congratulations you have entered...
THE BRONZE ERA!
Really good job with these kiln vids - thanks for all the work that went into them.
I've been working on my own 120v version for a few weeks, I love seeing that you've added a new video to the series
I love your videos and I was inspired to build one myself. I used a paint can instead with plaster and sand. I finished it last night and I've been messing with it all day. Thanks for the great videos!
fantastic project. I will be making a similar one in the future for my own projects. Thanks for the video and all the hard work.
This couldn't have come at a better time. Me and dad are making our own copy of your foundry. We've just finished the hexagonal frames to hold the interior bricks together and we were pondering the best way to make a base and lid, so we can incorporate these upgrades into our project from the beginning. Perfect timing!
I want to ask a question.With this system, for the fusion of copper.How long does the thread in kanthal 0.8 mm ??
Lots of great info. Thanks for sharing. And yeah....I’m sure there’s a lot of effort involved with everything you posted. Thanks again.
great video.
have been watching your foundry videos as a guide to making my own, have been so informative.
your water cast art pieces look amazing.
Your voice has changed! My how the time flys! Good job mate. Keep creating and learning.
nice video man :) would be a nice project for me aswell, ive build myself a propane foundry but net yet an electric one! keep up the great vids
hey i know you haha i am subbed
Love your videos man 💯💯
Great work, keep up the fantastic films.
wow good work love the vid, i always love checking this channel to see if there's a new upload
Feel like you've been away for ages... Great vid. I enjoy watching you learning.
You are not going to have any problem getting into uni, you are very intelligent and mature for your age, keep it up lad and your going to go far
well done yet again hope you have good results in uni!
another very interesting and informative video. You are one very talented young man .
Good job!
well done mate you put a lot of time and effort into it and I t works great
love this channel!
great job man! big fan
You are awesome. Thanks for a great video.
Good job really appreciate the effort
Cool stuff! I even used mine the other day for annealing a 3D printed plastic part at just 100C or so. It's so much more accurate and stable than a traditional oven.
Copper is fun to pour from a few feet above the water. Pour slowly so it's just a trickle of metal and you end up with what look like copper Corn Flakes. :)
Cheers Chris,
Yeah the PID circuits are great for fine temperature control, and thanks I'll try out that copper technique that you suggested!
Great video, this must have taken you so long. I wish I could support you on Patreon you deserve so many more views and Subscribers. Congrats on 200k
omg new video finally :)
Dang I have been watching your videos (Just started a couple days ago) but it is insane to see your welding improve so much.
One smart lad 👍👌
Quality over quantity, no matter how often you upload the videos are always awesome and very interesting to watch. I'm only a bit concerned with the clearance of the coils to the crucible but in your first foundry video you mentioned you turn it off every time you take the crucible out so i hope that'll be fine.
Also i can't wait for that lathe video, just seeing from the little preview, stuff like bokeh from metal shavings and seeing a smudge of copper get turned into a shiny machined piece right infront of you is amazing.
your first video on this kilm inspired me to build my own oven. i actually wrote my own arduino temperature controller and stuff. the first 3 heating wires i bought were no good and melted within the first few minutes of turning the thing on. but kanthal type D seems to work fine. i calibrated the heating wires to draw 3KW of power, so it's a bit more powerful than yours. the main purpos is heat treating knives, therefor the chamber is very long, thin and flat to accomodate long knives(up to 45 cm). i will post the arduino code somewhere if anyone is intersted, but all the controlles are german and the codequality is extreamly bad, so don't get your hopes up. we also came up with wire staple independently, since i had the same problem of my heating elements falling out of their slots.
your a funny boy. really good pace chock full of info. really good job there
I FINALLY FOUND UR CHANNEL AGIAN IVE LOST IT 1.5 YEARS AGO YES FINALLY
And i thought it couldn't get any better
You are the best!
You could squish the copper tube in the vise to flatten it. This way it is easy to bend back and forth and break off. Faster than a hacksaw and no copper loss as saw dust.
ur vidios are the best
Fantastic
Great vid.
Ooooh, I didn't knew this was your new video!!!
Thanks for the pointers. Here's some ideas I have. 1. I don't like the way the elements are wired. Theyre too close to the metal frame and could bump and short there causing an electrocution off the frame. The proper way I think is an insulating porcelain plug the wire passes through to insulate the metal frame from the element. Think mushroom shape with a hole down the center of the cap and stem. 2. If you want readings over the max out temp. a harbor freight 11 function multimeter will display "a" temp. It's not rated in the manual to display a temp. over a certain temp. but it will display a temp. I haven't double checked it using a control meter like a pyrometric cone to gauge accuracy above its stated temp. but it looked pretty accurate where I topped out at 2193F. The actual probe the meter comes with would need a ceramic insulator or would need to be replaced with a probe that has ceramic insulators. Just cut back the insulation to expose enough of the probes wire. then replace with a few links of ceramic tubing. 3. having the busted firebricks laying around. I would have casted those into the lid and floor to create porosity. Better yet I would have added a burn out material such as styrofoam granule(3.7% by weight) or blendered leaves(44% by weight, I achieved 28% ). I have tested both and they seem to burn out at camp fire level temps and have created porosity similar to the firebrick with no discernible preference over either burnout material. I have not tried this with plaster as the ceramic tho. But assume it would work, just a poor quality ceramic choice for a temp. shock resistant material. A better recipe would be 50% clay and 50% coal ash. The coal ash quality im not sure about. It seems to be determined by eye for acceptable unacceptable based on the coal source and thus ash produced. Here's a primer on my hypothesis on that material selection recipe, this may be more cost efficient than the recipe I am currently using:
www.researchgate.net/publication/316192663_Research_into_Coal-Clay_Composite_Ceramics_of_Sichuan_Province_China
also kiln repair cement is not that costly for repairing cracked bricks
i love you're calm voice xD in all of you're videos
and awesome video taow :D
great job awesome foundry cant wait to see what is possible with this foundry and what items you can cast with it just be careful pouring molten metal in water because it can cause a steam explosion
Good project; very clearly explained. To help you understand why your nichrome element burned out, here's a useful calculation. I'll make some estimates: let's suppose your coil was 500mm long before you stretched it, and the coil diameter is around 6 to 7mm. Each coil is then about 20mm, so the total length of wire, were it straight, would be about 10000mm. What is the total surface area of the wire? If it is 0.8mm wire then the total surface area is about 24000 square mm, or 240 square cm. Now divide 1800 watts by 240 square cm to get 7.5 W/sq cm. That's too high; the wire should be emitting around 3 or 4 watts per square centimeter if you want it to last a long time at aluminium melting temperatures. Your kanthal solution will likely have both a longer wire and a larger circumference, so it will last longer.
holy crap your a great engineer
Milo you're*
I like this project what i need tools for do it in my country very hard buy it and expensive
Nice video bro
yay new video
Super inspired by your handy-work! How many feet of the 16g Kanthal wire did you use in this build?
Do you think that eventually you could make a foundry for melting steel for maybe making knife blanks?
nice video buddy
I enjoy watching your videos. Just wondered whether you'd added any safety feature as you're adding conductive metals to the crucible whilst it's live? Cheers.
for a different cooling liquid use what blademakers use...
peanut oil or transmission fluid for the copper cooling. you can probably even use used fluid OK. i remember seeing your vids years ago and you've matured into some great interests and useful manskills. keep it up!
Have you had any problems with the element deforming/sagging into the centre and shorting out through the crucible?
I recently started making a furnace to your design, haven't had a chance to experiment with it much yet though.
Thanks for the videos!
hi there the heater coils in a dyer . it is prefect i think. al you hav eto do is sat them in place and run the wires.... tell me what you think... my dyer got wet so i had to can it.. so i think it will work..
Awesome video!
The best one of all foundry.
You should probably use some welder glasses because all of the IR and light.
Great video! Kanthal. BTW
He must be talking about Kanthal wire. If you have trouble finding it, it's basically a trademark FeCrAl (Iron-Chromium-Aluminium) alloy. So you can search for that instead if you have trouble finding anything. Be aware that Kanthal is well known for being the highest quality FeCrAl alloy out there, so alloys not branded Kanthal might not reach the same temperatures or last as long.
They'll be significantly better than NiCr wire though.
Anyone know where you can buy the wire he was using? I couldn't find it.
i wonder if you hit the coils with the steel crusible , that would be bad as you could create a short
do you switch the foundry off before taking the crusible out ?
Awesome!
You can melt copper now!
I get copper pretty easily here.
America is fulla scrap metal. lol
oh and how did you cast the rippled aluminium sculptures?
That last Aluminum pour you could call that London during rush hour
Better to use ceramic crucible than the 100% graphite?
TAOW, really enjoy your videos and the effort you put in to being very succinct while remaining instructive. I have one question though. I have watched you make large holes by using small drills and then filing. An acceptable practice for sure, but why not use hole saws? Look forward to your future projects.
curious so when buying this different types of kiln wire do they give you the max resistant ratings so you can work out the 240 volt/ 33 ohm where did you get the 33 ohm rating all else is easy to compute from there. Also how do you know what power rating works well with what size/shape kiln your building ? How many kiln wire coils do you need for a given size volume kiln and given power rating to heat the chamber to desired temps in reasonable amount of time.
you know you have to preheat the crucibles. Nice to see you back is it aloud to welled at home?
Nice work, have you measured how many kw this uses while heating up?
What are the dimensions of your new crucible?
wow. great result.. i also have final task about electric foundry. it takes almost 3hrs to get 700°C. when the temperature goes to 400°C, increasing of the temperature goes slowly. do you have any idea whats wrong with that? thanks for your kindness
Nice
right, this thing. i bought a few meters of heating coil when i saw the first one of these videos, but never actually built one myself. i just couldn't find any heat resistant material to make it out of. but i do have a big bag of plaster, maybe that'd work mixed with some sand?
I'm also having troubles with graphite crucibles.
Have you found another source or is the crucible becoming a "consumable" regarding casting.
Sir, if we want to go for steel iron furnace then whats a changes is taken in it... Please tell me..
wonder if a hybrid foundry with coals and air along with electricity would get it up to steel melting temps
Can you use ceramic tile for more heat
did you found solution for crucible?.....what if i want to make mass production?
Question on the PID controller, got the same model as yours, is there a way to adjust the temperature faster? Seems to take forever.
Use both crucibles depending on how much you need?
Great idea but I may have missed it but did you Earth or ground it????
Hi there I like watching your videos but there is 1 thing that I would like to ask and is that can you melt car battery cells in this as I have tried every thing and just can not get the lead to belt please let me no what you think thanks x
I hope you can answer me this, is there any way to build something similar but with a little extra so i can reach 1400-1600º to melt glass?
Trying to make a glory hole furnace but the temp in this won't reach to melt glass (also will have to put it sideway)
Excellent video Artof... I'm still impressed with these things you do and how you happily jump from one tool or machine to another. It's pleasing to see how your welding skills are growing too. However, I think I spotted a redundant Earth wire in your mains lead, which suggests that you haven't earthed the metal work... Might be a good idea to rig something up - just in case. Where will your ideas take you next?
what is the other alloy called again
is there a link to the new coil so that those of us who have made your furnace can purchase one?
Amazing project I'am traing to do somthing similiar. I have heard that the nicrom resist up to 1200°c. how do you write the name of the new resistence material? I think i will not find it in my country, but any way I will try. Thank you! and congratulations for your project!
Nice video and channel. Can you tell me pls how many electricity your are use for a one melting 1kg copper
Yo man been watching since ur squeaky slingshot vids (no offense) but yesterday u thought ur channel was dead but now the your channel is back i lived all ur vids my favourite vids are u rambone slingshot videos and i really want to see more of your channel in my feed again keep up the good work i acutely btried to make your forge but failed and i made yor bowie knife and rambone slingshot design
🍌
To anyone curious. After a quick google search, this upgrade will let him cast Aluminum, Lead, Copper, and Brass. May be possible for others but haven't checked.