Warren Heintz on tue 8 aug 06
I don't have an answer,but the first thing that came to mind was the tempertures that are involved and would a claybody be able to withstand repeated useage.
John Rodgers wrote: Can this be done??
Or perhaps ceramic linings for steel molds??
Does anyone have any knowledge about this?
An aluminum can recycling company has approached me about a repair job.
Company currently uses steel molds for casting 1800 lb ingots. The hot
melted aluminum has eroded the surface of the steel and pitted it until
the aluminum ingot now grabs the mold and won't let go. They are having
a devil of a time getting the aluminum ingot free from the molds. They
called a local ceramic store who knows me and the ceramic store in turn
referred the aluminum company to me because of my mold work. But this
is something outside my experience. I'm willing to learn, and hope
someone on Clayart can provide suggestions, directions, etc. about
ceramic liners, castable refractories, relationship to metals, etc, etc.
Thanks,
Regards,
John Rodgers
Chelsea, AL
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Fredrick Paget on tue 8 aug 06
>Can this be done??
>
>Or perhaps ceramic linings for steel molds??
>
>Does anyone have any knowledge about this?
>
>An aluminum can recycling company has approached me about a repair job.
>Company currently uses steel molds for casting 1800 lb ingots. The hot
>melted aluminum has eroded the surface of the steel and pitted it until
>the aluminum ingot now grabs the mold and won't let go.
>
>John Rodgers
Try Ferez at ITC. For technical information and assistance,call or write:
International Technical Ceramics Inc, PO Box=20
1726, Ponte Vedra, FL 32004 =B7 904-285-0200
They don't seem to have a web site.
--
From Fred Paget,
Marin County, CA, USA
fredrick@well.com
Charter Member Potters Council
John Rodgers on tue 8 aug 06
Can this be done??
Or perhaps ceramic linings for steel molds??
Does anyone have any knowledge about this?
An aluminum can recycling company has approached me about a repair job.
Company currently uses steel molds for casting 1800 lb ingots. The hot
melted aluminum has eroded the surface of the steel and pitted it until
the aluminum ingot now grabs the mold and won't let go. They are having
a devil of a time getting the aluminum ingot free from the molds. They
called a local ceramic store who knows me and the ceramic store in turn
referred the aluminum company to me because of my mold work. But this
is something outside my experience. I'm willing to learn, and hope
someone on Clayart can provide suggestions, directions, etc. about
ceramic liners, castable refractories, relationship to metals, etc, etc.
Thanks,
Regards,
John Rodgers
Chelsea, AL
Alan P on wed 9 aug 06
Hello John,
=93 ... someone on Clayart can provide suggestion ...=94 My suggestion is to=
politely decline. Whilst ceramic moulds and crucibles are used in metal
processing the field of refractories is highly specialised: raw materials,
the scienctific principles and shaping techniques are exacting and can be
complex. Just consider the legal and moral consequences if a mold you made
failed when they used it with molten aluminium at above 660oC
Kind regards,
Alan
Tom Witman on wed 9 aug 06
My first reaction would be that a refractory cement would INSULATE the mold
surface and not provide the required cooling to set the aluminum. It would
slow the cycle time down, which means money to any industry.
Second reaction would be that they have gotten the life out of the mold and
it's time to spring for a new mold! Short of that, try refinishing the mold
with fine sandblasting, sanding, or remachining. If it's a cast mold, then
a new mold is required. Trying to solve the problem 'on the cheap' will end
up costing more than spending the money for a new mold. It certainly
couldn't be a complicated one.
Tom
----- Original Message -----
From: "Warren Heintz"
To:
Sent: Tuesday, August 08, 2006 7:26 PM
Subject: Re: Ceramic Molds for casting aluminum ingots
>I don't have an answer,but the first thing that came to mind was the
>tempertures that are involved and would a claybody be able to withstand
>repeated useage.
>
> John Rodgers wrote: Can this be done??
>
> Or perhaps ceramic linings for steel molds??
>
> Does anyone have any knowledge about this?
>
> An aluminum can recycling company has approached me about a repair job.
> Company currently uses steel molds for casting 1800 lb ingots. The hot
> melted aluminum has eroded the surface of the steel and pitted it until
> the aluminum ingot now grabs the mold and won't let go. They are having
> a devil of a time getting the aluminum ingot free from the molds. They
> called a local ceramic store who knows me and the ceramic store in turn
> referred the aluminum company to me because of my mold work. But this
> is something outside my experience. I'm willing to learn, and hope
> someone on Clayart can provide suggestions, directions, etc. about
> ceramic liners, castable refractories, relationship to metals, etc, etc.
>
> Thanks,
>
> Regards,
>
> John Rodgers
> Chelsea, AL
>
> ______________________________________________________________________________
> Send postings to clayart@lsv.ceramics.org
>
> You may look at the archives for the list or change your subscription
> settings from http://www.ceramics.org/clayart/
>
> Moderator of the list is Mel Jacobson who may be reached at
> melpots@pclink.com.
>
>
>
> ---------------------------------
> Do you Yahoo!?
> Next-gen email? Have it all with the all-new Yahoo! Mail Beta.
>
> ______________________________________________________________________________
> Send postings to clayart@lsv.ceramics.org
>
> You may look at the archives for the list or change your subscription
> settings from http://www.ceramics.org/clayart/
>
> Moderator of the list is Mel Jacobson who may be reached at
> melpots@pclink.com.
David Martin Hershey on wed 9 aug 06
Hi John & All,
John, thanks for all your contributions
to ClayArt over the years!
Re: pitted mold surfaces
There is an industrial process that is called
flame spraying or plasma jet spraying
that is I believe designed for applications
like repairing or protecting the surface
of objects like the molds you are looking at.
I don't know much about it, but it involves
spraying specific liquefied metals
onto various surfaces.
It's kind of like
welding with a spray gun ;-)
I believe it can be used with ceramic glazes too...
Best, DMH
Beautiful Hermosa Beach CA USA
where the ocean is
warmer than it's been
in the last 10 years
Overall's on wed 9 aug 06
This brings up my machinist dna (dad, first husband,
me via metals, hair and now clay).
What if the mold were spray lined with another metal
like titanium or ITC 213? It seems like through time,
the impurities in the aluminum are corroding the steel
molds pitting them. They just need resurfacing as
economically as possible - spraying to be the easiest
application which might be accomplished on site after
cleaning first.
Kim in Houston
http://www.houstonpotters.com
--- Warren Heintz wrote:
> I don't have an answer,but the first thing that came
> to mind was the tempertures that are involved and
> would a claybody be able to withstand repeated
> useage.
>
> John Rodgers wrote: Can this be
> done??
>
> Or perhaps ceramic linings for steel molds??
>
> Does anyone have any knowledge about this?
>
> An aluminum can recycling company has approached me
> about a repair job.
> Company currently uses steel molds for casting 1800
> lb ingots. The hot
> melted aluminum has eroded the surface of the steel
> and pitted it until
> the aluminum ingot now grabs the mold and won't let
> go. They are having
> a devil of a time getting the aluminum ingot free
> from the molds. They
> called a local ceramic store who knows me and the
> ceramic store in turn
> referred the aluminum company to me because of my
> mold work. But this
> is something outside my experience. I'm willing to
> learn, and hope
> someone on Clayart can provide suggestions,
> directions, etc. about
> ceramic liners, castable refractories, relationship
> to metals, etc, etc.
>
> Thanks,
>
> Regards,
>
> John Rodgers
> Chelsea, AL
>
>
______________________________________________________________________________
> Send postings to clayart@lsv.ceramics.org
>
> You may look at the archives for the list or change
> your subscription
> settings from http://www.ceramics.org/clayart/
>
> Moderator of the list is Mel Jacobson who may be
> reached at melpots@pclink.com.
>
>
>
> ---------------------------------
> Do you Yahoo!?
> Next-gen email? Have it all with the all-new
> Yahoo! Mail Beta.
>
>
______________________________________________________________________________
> Send postings to clayart@lsv.ceramics.org
>
> You may look at the archives for the list or change
> your subscription
> settings from http://www.ceramics.org/clayart/
>
> Moderator of the list is Mel Jacobson who may be
> reached at melpots@pclink.com.
>
http://www.houstonpotters.com
Frank Colson on wed 9 aug 06
If this is what you are looking for,here it is: Metalizing Company of
America. Or, better yet: TAFA. BondArch www.tafa.com
You can spray nearly any kind of metal and other materials onto any surface.
Why bother with clay, when you can spray the surface of cardboard (box?) ,
ceramics, or many types of surfaces. Why not spray yourself a kiln. Just
take a cardboard box, cut some burner holes in it, spray it with stainless
steel, line line it with ceramic fiber, and start firing your pots! All of
it will endure for years!
You can have your own personal Model 8830 Arc Spray System for something
like $10,000 and up!
Frank Colson
----- Original Message -----
From: "David Martin Hershey"
To:
Sent: Wednesday, August 09, 2006 3:11 PM
Subject: Re: Ceramic Molds for casting aluminum ingots
> Hi John & All,
>
> John, thanks for all your contributions
> to ClayArt over the years!
>
> Re: pitted mold surfaces
>
> There is an industrial process that is called
> flame spraying or plasma jet spraying
> that is I believe designed for applications
> like repairing or protecting the surface
> of objects like the molds you are looking at.
>
> I don't know much about it, but it involves
> spraying specific liquefied metals
> onto various surfaces.
>
> It's kind of like
> welding with a spray gun ;-)
>
> I believe it can be used with ceramic glazes too...
>
> Best, DMH
> Beautiful Hermosa Beach CA USA
> where the ocean is
> warmer than it's been
> in the last 10 years
>
> ______________________________________________________________________________
> Send postings to clayart@lsv.ceramics.org
>
> You may look at the archives for the list or change your subscription
> settings from http://www.ceramics.org/clayart/
>
> Moderator of the list is Mel Jacobson who may be reached at
> melpots@pclink.com.
>
Ivor and Olive Lewis on thu 10 aug 06
Dear John Rodgers,
I would be unsure about recommending a ceramic solution for this =
problem. There could be a problem with entrained slag that might react =
adversely with a ceramic coating
My preference would be for a metallic welding solution. No doubt the =
ingot moulds are substantial. Such corrosion and erosion as there may be =
could be ground out and the depressions filled with a suitable welding =
alloy to match the original steel. excess weld could be ground back to =
the original contour.
In the glass industries it has been a long established practice to =
repair steel moulds in which glass bottles are blown with heat, erosion =
and corrosion resistant nickel base self fluxing alloys.
Ivor and Olive Lewis on thu 10 aug 06
Dear David Martin Hershey,=20
These processes were improvements in the 1960's of existing flame =
spraying techniques used much earlier. Deloro Stellite in Ontario and =
Wall Colmonoy in Detroit developed self fluxing heat, corrosion and =
impact resistant alloy powders. I think the industry is now controlled =
in the main by Stoody and BOC.
Best regards,
Ivor Lewis.
Redhill,
South Australia.
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