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| {{Shop | | [[Category:Tools]][[Category:Wood Shop]][[Category:Vertical Band Saws -- Wood Cutting ]] |
| |shop_title = Casting Shop | | |
| |image = Jan_2024.jpg | | {{ToolBox |
| |caption = View of the Artisans Asylum Casting Shop | | |tool_title = Jet 36x12 Wood Lathe |
| |lead = Tess Faraci | | |tool_subtitle = Jet Wood Lathe |
| |tool_testers = [https://www.artisansasylum.com/tool-testing Sign up here] | | |image = Wood_lathe_in_action.jpg |
| |hours = Same as membership hours | | |caption = Jet Wood Lathe in action |
| | |make = Jet |
| | |model = JWL 1236 |
| | |serial = Various |
| | |manufacturer_specs = |
| | |manual = [https://drive.google.com/file/d/1H_1BjOvjZew7yaS36L0RX-PYn-z3roWJ/view?usp=drive_link Jet JWL1236 Manual] |
| | |location = Wood Shop |
| | |rubric = |
| | |training = |
| | |testing = |
| | |restrictions = red |
| | |tool_categories = |
| }} | | }} |
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| == Shop Description ==
| | '''This is a [[RED]] tool. Training and tool-testing are required.''' |
| '''The Artisans Asylum Casting Shop offers equipment and training for two main processes: Sand Casting and Investment Casting.'''
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| '''The Sand Casting program''' at the Artisans Asylum allows the reproduction of objects in metal with a level of detail suitable for small sculpture, jewelry, and select engineering applications.
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| — This method is suitable for beginners as well as experienced shop users who are interested in producing a cast piece within the time period of a few hours.
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| '''The Investment Casting program''' at the Artisans Asylum involves a two to three day process that allows the reproduction of complex shapes in a way that preserves a high level of fine detail.
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| — This method is suitable for intermediate to advanced shop users interested in achieving exceptionally high quality and precision in their cast objects.
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| The Casting Shop encourages experimentation and knowledge-sharing for the production of jewelry and artwork achievable using equipment appropriate to our shop. Our facilities are oriented toward hand crafted pieces the size of jewelry and slightly larger — we do not have the resources to support larger foundry work.
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| == Casting Techniques ==
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| {| class="infobox" cellspacing="5" style="width: 22em; text-align: left; font-size: 88%; line-height: 1.5em;"
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| ! colspan="2" class="infobox-image" | [[File:bronze_casting_resource_pic.jpg|350px|Bronze at 2000 F]]
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| | colspan="2" | Bronze at 2000 F
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| |}
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| '''Investment Casting at the Artisans Asylum,''' sometimes referred to as Lost Wax Casting, starts with the creation of a jewelry-sized object, or “pattern,” often made with wax.
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| — The pattern is encased in investment, a silica and gypsum based substance that resembles plaster.
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| —Once the investment has set, the wax is then “burnt out” using an overnight kiln program, producing a cavity into which the molten metal can be poured. The kiln program also further hardens the investment.
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| — At a pre-arranged time the next day, the flask containing the investment is pulled out of the kiln and immediately put on a Vacuum Table, where the molten metal is then poured.
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| — Once metal has cooled enough to solidify, the hot flask is then “quenched,” or submerged in a bucket of water that quickly liquifies the investment, allowing the finished casting to be easily retrieved.
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| '''Sand Casting at the Artisans Asylum''' involves the use of Petrobond casting sand, an oil-based sand that significantly reduces the water vapor-produced concerns that come with water-based casting sands.
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| — Sand casting allows the reproduction of the pattern in a matter of hours, without the destruction of the original pattern.
| | ==Description== |
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| | A lathe is a machine tool that turns a round workpiece on a rotating spindle and allows the operator to cut it with a sharp tool. The workpiece is most usually a slender piece of hardwood. The cutting tool resembles a chisel, though it is specialized for lathe use. As the workpiece is turned on the spindle, the cutting tool is braced by hand on a stationary tool rest and applied to the moving surface. |
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| '''A detailed overview of the Investment Casting process at the Artisans Asylum is available here:'''
| | Link to: [https://drive.google.com/file/d/1o6yCWHxnDZQHbvqs4EcqHyN2mkY8zrv0/view?usp=drive_link Wood Turning Textbook] |
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| https://drive.google.com/file/d/1qid-hoZIWx5stFZQGZ09LY4L7qxmhOA8/view?usp=sharing
| | ==Use For== |
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| | * Hardwood rods and blocks, up to 8" diameter and 35" long. |
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| '''Details on mold construction with Petrobond Sand are available here:'''
| | * Wood laminate |
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| https://drive.google.com/file/d/1mP0Iwi35cRk-C8SCcghau3G-CnKU2bwY/view?usp=sharing
| | * Some softwood, though detail isn't as fine |
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| == List of Primary Tools ==
| | * Straight-grained for spindle-turning |
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| '''For Melting Metal:'''
| | * Grain can be irregular for bowls |
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| — Electro-melt(s). '''Link to:''' [[Electromelt Tool Resource Page]]
| | ==Do Not Use For== |
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| — Oxy-Propane Torch. '''Link to:''' [[Casting Shop Oxy-Propane Torch Resource Page]]
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| — The shop provides appropriate graphite and clay-silica crucibles.
| | * Painted wood, especially lead-base |
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| | * Pressure-treated |
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| '''For Investment Casting'''
| | * Split or cracked wood |
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| — Investment Hood
| | * Plastics or composites |
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| — Kiln. '''Link to:''' [[Sentry Kiln Tool Resource Page]]
| | * Metal |
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| — Vacuum Table. ''' Link to: ''' [[Vacuum Table Tool Resource Page]]
| | ==Safety Notes== |
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| — The shop provides Ransom & Randolph Ultra-Vest investment and casting flasks in select sizes.
| | '''Personal:''' |
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| | * '''Always wear safety glasses.''' Eyeglasses are not safety glasses. |
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| The product sheet for Ultra-Vest investment can be found here:
| | * No loose clothing. Tie up long hair. No jewelry. |
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| https://drive.google.com/file/d/1IVs3M5fmvPaCoeO9CmTQ55ZyzfqehWEH/view?usp=sharing
| | * Wear non-slip shoes and keep a stable stance. |
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| | * '''Do not wear gloves.''' |
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| '''For Sand Casting'''
| | * Do not turn hazardous materials such as pressure-treated lumber. |
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| — The shop provides Petrobond sand, metal mold-making flasks in select sizes, and mold-making tools.
| | '''Tool:''' |
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| == Tool Documentation ==
| | * Tighten all locks before starting. |
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| {| class="wikitable"
| | * Rotate the workpiece by hand to ensure clearance. |
| !| Tool Info
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| !| Class
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| !| Tool Tester(s)
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| {{ ToolTableItemRed | link=[[Vacuum Table Tool Resource Page]] }} || Alethea Jones
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| {{ ToolTableItemRed | link=[[Sentry Kiln Tool Resource Page]] }} || Alethea Jones
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| {{ ToolTableItemRed | link=[[Electromelt Tool Resource Page]] }} || Alethea Jones
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| {{ ToolTableItemRed | link=[[Casting Shop Oxy-Propane Tool Resource Page]] }} || Alethea Jones
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| |}
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| | * Use the right tool at the correct speed. Do not force a tool or attachment to perform a job for which it was not designed. |
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| | * Never leave the machine running unattended |
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| For a YouTube video on how to use the shop's vulcanizer:
| | * Never operate with guards or cover plates removed. |
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| https://www.youtube.com/watch?v=XasXISlbQoI
| | {| class="infobox" cellspacing="5" style="width: 22em; text-align: left; font-size: 100%; line-height: 1.5em;" |
| | | ! colspan="2" class="infobox-image" | [[File:wood_lathe_workpiece.png|400px|Wood lathe workpiece]] |
| == Shop Safety ==
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| {| class="infobox" cellspacing="5" style="width: 22em; text-align: left; font-size: 88%; line-height: 1.5em;" | |
| ! colspan="2" class="infobox-image" | [[File:buddy_up.jpg|200px|Buddy Up!]] | |
| |- | | |- |
| | colspan="2" | Buddy Up! | | | colspan="2" | A turned wooden spindle. |
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| |} | | |} |
| '''[[Always Cast with a Buddy!]]'''
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| For safety purposes, the Casting Shop requires that shop users work in pairs when pouring molten metal.
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| — '''Experienced Casting Buddies can be found through the shop’s Google groups email listserv.'''
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| To subscribe, send a request email directly to the list: castingshop-users+subscribe@artisansasylum.com
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| Send and email to the Casting Shop Lead requesting to be manually added: castingshop@artisansasylum.com
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| '''Proper attire and PPE are required, especially when pouring molten metal:'''
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| — '''Proper Attire:''' Long Sleeves and Long Pants in Natural Fibers (cotton works well), Closed-toe Shoes (preferably leather). No loose hair or jewelry.
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| Remember: Cotton will not prevent burns. Natural fibers are a way of ensuring that melted synthetics like polyester do not complicate a burn.
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| — '''PPE:''' Safety Glasses (shade 3 when torch melting metal or looking into a hot kiln), Leather Apron, Heat Resistant Gloves. Dusk mask or respirator when mixing or cleaning dry investment.
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| [[IMPORTANT: Please keep tools and work surfaces reasonably clean of dried investment, which contains silica and poses a respiratory hazard when airborne and inhaled.]]
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| At minimum, dust masks are required when mixing investment and when cleaning dry investment spills. Respirators may provide additional protection. The shop maintains a supply of dust masks. For better fit and protection, frequent shop users may want to supply their own respiratory protection.
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| == Approved Materials ==
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| '''Pattern Materials approved for use in the Artisans Asylum Casting Shop'''
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| — Wax (injection or carving)
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| — Organics - generally approved, especially for plant materials, but ask first.
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| — PLA
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| — Ask first on Castable 3D printing resins.
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| — To add materials to the Approved Pattern Materials List, discuss with a shop steward and propose a workable, clean melt‐out/burnout profile.
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| '''Metals approved for use in the Artisans Asylum Casting Shop'''
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| — Brass, Bronze, Copper, Silver, Argentium, Gold, Aluminum, Pewter, Bismuth
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| — Metals we cannot do, given high melting points: Titanium, Steel / Iron, Platinum
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| — Disallowed Metals: Lead, Magnesium, Anything else with flammability / toxicity issues.
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| '''No random scrap and no unknowns'''
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| == Bismuth and Pewter ==
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| Our tools for melting bismuth and Pewter are privately owned and therefor considered red tools. A light training session is required to review shop safety protocols and to familiarize yourself with shop procedures.
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| Since the temperatures involved are equivalent to that of a hot kitchen oven, no casting buddy is required as long as the shop user knows where first aid supplies can be found, should a burn occur. THIS IS THE SHOP'S ONLY EXCEPTION TO THE SHOP'S RULE OF CASTING WITH A BUDDY WHEN POURING MOLTEN METAL.
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| When pouring molten bismuth and pewter alone, it is suggested that someone else in the building be made aware that metal is being poured, as a safety backup.
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| To receive training and testing, contact a tool tester, the Assistant Casting Shop Lead,
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| or the Casting Shop Lead. Training for bismuth and pewter can take place during the Casting Shop’s monthly Drop-by Hours.
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| For more information:
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| https://drive.google.com/file/d/11BUyXPz6xNDHGcTSYjh7JpLnMkvn-KYE/view?usp=sharing
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| == Contact Us ==
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| — Send an email to the Casting Shop Lead at: castingshop@artisansasylum.com
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| — To stay informed, subscribe to the CastingShop-Users Google groups email list.
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| 1. Send a request email directly to the list: castingshop-users+subscribe@artisansasylum.com
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| OR
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| 2. Send an email to the casting Shop Lead requesting to be manually added: castingshop@artisansasylum.com
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| == Backup Kiln ==
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| For Instruction Manuals to the shop's backup kiln:
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| https://drive.google.com/file/d/193pKW-FTew5FPsyBq6F8W6TltbeG5V4S/view?usp=sharing
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| https://drive.google.com/file/d/1oHWqy9EYykvq1yl_T-0AVxZ3M8zRIbRW/view?usp=sharing
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| == Shop Calendar ==
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| Click below to Visit The Casting Shop Class and Special Event Calendar
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| <iframe src="https://calendar.google.com/calendar/embed?height=600&wkst=1&ctz=America%2FNew_York&bgcolor=%23ffffff&src=Y2FzdGluZ3Nob3BAYXJ0aXNhbnNhc3lsdW0uY29t&src=cGtxYjlzOXNmYnVwZTl0NmM2cGRydmdwYTh0ZWlxMXZAaW1wb3J0LmNhbGVuZGFyLmdvb2dsZS5jb20&src=cmlqYmhmc29rbnA5dWNuNDg5dXUwbXRsZ2VoZGt2NWJAaW1wb3J0LmNhbGVuZGFyLmdvb2dsZS5jb20&color=%23039BE5&color=%23D81B60&color=%23795548" style="border:solid 1px #777" width="800" height="600" frameborder="0" scrolling="no"></iframe>
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| == Notes ==
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| This page and all of the subordinate pages were created using a minimal set of Wiki features. If you want to get started with adding content and you think this page looks acceptable, the features used are described in a brief text file located here:
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| https://www.dropbox.com/scl/fi/c3fervdzz27gsvfzt81ri/Brief-Instructions-on-Wiki-page-creation.txt?rlkey=cyo0gkyty1hiysfsgs6u7cuvq&dl=0
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