[Jewelry making - Article 00446] - Re: [Orchid] Ingots for rolling

[Ken Newman]

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Hi!

    Ingot molds can be made by bending wire into a "U" and holding it
    between two pieces of steel. Bend the tops of the "U" out a bit to
    form a funnel. Cut little notches every 3mm or so along the edges of
    the wire that will contact the steel for vents. Use wire up to 10ga.
    or so, then go to sawn strips of metal to make the "U" if you want a
    thicker ingot. Lightly oil (avoid hydrogenated oils for health
    reasons!) the wire and steel plates. Assemble with "C" clamps, using
    one or two to hold the mold closed and two more at the base to hold
    it up vertical. If you stagger the steel plates so one is a little
    higher than the other you will have the higher to pour against. Heat
    the plates until the oil smokes. With your third hand melt the metal
    and pour very quickly into the mold. Sometimes it takes a couple of
    tries to get a usable ingot. Use a metal pan to catch spills.
    Instead of oiling, the plates can be coated with soot from your
    acetylene torch. Wear safety glasses, leather shoes, long pants, keep
    your hair away from the hot stuff, and use positive ventillation. I
    cast ingots one by two inches by 10ga. reliably this way. Charcoal
    works well instead of steel plates, but is expensive. Warm the
    charcoal to drive off any water before using. The ingot seems to be
    more workable if you forge it with a hammer and anneal before
    rolling. 

    It is usually more cost effective to send scrap to a refiner and
    order what you want unless you need non-standard alloys. 

    No, that purple gold alloyed with aluminum in not mallable. Not at
    all. 

Ken Newman
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