Henley's Twentieth Century Formulas, Recipes and Processes. Various

be compressed as little as possible, and hard ramming must in every case be avoided, particularly where the metal surrounds the sand. The molds must be very freely vented, and not only at the joint of the mold, but by using the vent wire freely through the body of the mold itself; in fact, for brass the venting would be considered excessive. With aluminum it is, however, necessary to get the air off as rapidly as possible, because the metal soon gets sluggish in the mold, and unless it runs up quickly it runs faint at the edges. The ingates should be wide and of fair area, but need careful making to prevent their drawing where they enter the casting, the method of doing this being known to most molders.

      If it is considered desirable to use a specially made-up facing sand for the molds where the metal is of some thickness, the use of a little pea or bean meal will be all that is necessary. To use this, first dry as much sand as may be required and pass through a 20-mesh sieve, and to each bushel of the fine sand rub in about 4 quarts of meal, afterwards again passing through the sieve to insure regular mixing. This sand should then be damped as required, being careful that all parts are equally moist, rubbing on a board being a good way to get it tough, and in good condition, with the minimum of moisture.

      The molds should not be sleeked with tools, but they may be dusted over with plumbago or steatite, smoothing with a camel’s-hair brush, in cases in which a very smooth face is required on the castings. Preferably, however, the use of the brush even should be avoided. Patterns for aluminum should be kept smooth and well varnished.

      In melting the metal it is necessary to use a plumbago crucible which is clean and which has not been used for other metals. Clay or silica crucibles are not good for this metal, especially silica, on account of the metal absorbing silicon and becoming hard under some conditions of melting. A steady fire is necessary, and the fuel should reach only about halfway up the crucible, as it is not desirable to overheat the crucible or metal. The metal absorbs heat for some time and then fuses with some rapidity, hence the desirability of a steady heat; and as the metal should be poured when of a claret color under the film of oxide which forms on the surface, too rapid a heating is not advisable. The molding should always be well in advance of the pouring, because the metal should be used as soon as it is ready; for not only is waste caused, but the metal loses condition if kept in a molten state for long periods. The metal should be poured rapidly, but steadily, and when cast up there should not be a large head of metal left on top of the runner. In fact, it is rather a disadvantage to leave a large head, as this tends to draw rather than to feed the casting.

      With properly prepared molds, and careful melting, fluxes are not required, but ground cryolite—a fluoride of sodium and aluminum—is sometimes used to increase the fluidity of the metal. In using this, a few ounces according to the bulk of metal to be treated is put into the molten metal before it is taken from the furnace, and well stirred in, and as soon as the reaction apparently ceases the pot is lifted and the metal at once skimmed and poured. The use of sodium in any form with aluminum is very undesirable, however, and should be avoided, and the same remark applies to tin, but there is no objection to alloying with zinc, when the metal thus produced is sold as an alloy.

      Aluminum also casts very well in molds of plaster of Paris and crushed bath brick when such molds are perfectly dry {83} and well vented, smoothness being secured by brushing over with dry steatite or plumbago. When casting in metal molds, these should be well brushed out with steatite or plumbago, and made fairly hot before pouring, as in cold molds the metal curdles and becomes sluggish, with the result that the castings run up faint.

      To Increase The Toughness, Density, And Tenacity Of Aluminum.

      —For the purpose of improving aluminum, without increasing its specific gravity, the aluminum is mixed with 4 to 7 per cent of phosphorus, whereby the density, tenacity, and especially the toughness are said to be enhanced.

      Working Of Sheet Aluminum:

      The great secret, if there is any, in working aluminum, either pure or alloyed, consists in the proper lubricant and the shape of the tool. Another great disadvantage in the proper working of the metal is that, when a manufacturer desires to make up an article, he will procure the pure metal in order to make his samples, which, of course, is harder to work than the alloy. But the different grades of aluminum sheet which are on the market are so numerous for different classes of work that it might be advisable to consider them for a moment before passing to the method of working them.

      The pure metal, to begin with, can be purchased of all degrees of hardness, from the annealed, or what is known as the “dead soft” stock, to the pure aluminum hard rolled. Then comes a harder grade of alloys, running from “dead soft” metal, which will draw up hard, to the same metal hard rolled; and, still again, another set of alloys which, perhaps, are a little harder still when hard rolled, and will, when starting with the “dead soft,” spin up into a utensil which, when finished, will probably be as stiff as brass. These latter alloys are finding a large sale for replacing brass used in all classes of manufactured articles.

      To start with lathe work on aluminum, probably more difficulty has been found here, especially in working pure metal, and more complaints are heard from this source than from any other. As stated before, however, these difficulties can all be readily overcome, if the proper tools and the proper lubricants are used, as automatic screw machines are now made so that they can be operated when working aluminum just as readily as when they are working brass, and in some cases more readily. To start with the question of the tool, this should be made as what is known as a “shearing tool,” that is, instead of a short, stubby point, such as would be used in turning brass, the point should be lengthened out and a lot of clearance provided on the inside of the tool, so as to give the chips of the metal a good chance to free themselves and not cause a clogging around the point of the tool—a similar tool, for instance, to what would be used for turning wood.

      The best lubricant to be used would be coal oil or water, and plenty of it. The latter is almost as good as coal oil if enough of it is used, and with either of these lubricants and a tool properly made, there should be no difficulty whatsoever in the rapid working of aluminum, either on the lathe or on automatic screw machines.

      To go from the lathe to the drawing press, the same tools here would be used in drawing up shapes of aluminum as are used for drawing up brass or other metals; the only precaution necessary in this instance being to use a proper lubricant, which in this case is a cheap grade of vaseline, or in some cases lard oil, but in the majority of instances better results will be secured by the use of vaseline. Aluminum is probably susceptible of deeper drawing with less occasion to anneal than any of the other commercial metals. It requires but one-third or one-fourth of as much annealing as brass or copper. For instance, an article which is now manufactured in brass, requiring, say, three or four operations before the article is finished, would probably have to be annealed after every operation. With aluminum, however, if the proper grade is used, it is generally possible to perform these three operations without annealing the metal at all, and at the same time to produce a finished article which, to all intents and purposes, is as stiff as an article made of sheet brass.

      Too much stress cannot be laid on the fact of starting with the proper grade of metal, for either through ignorance or by not observing this point is the foundation of the majority of the complaints that aluminum “has been tried and found wanting.” If, however, it should be found necessary to anneal aluminum, this can be readily accomplished by heating it in an ordinary muffle, being careful that the temperature shall not be too high—about 650° or 700° F. The best test as to when the metal has reached the proper temperature is to take a soft pine stick and draw it across the {84} metal. If it chars the stick and leaves a black mark on the metal, it is sufficiently annealed and is in a proper condition to proceed with further operation.

      Next taking up the question of spinning aluminum, success again depends particularly on starting with the proper metal. The most satisfactory speed for articles from 5 to 8 inches in diameter is about 2,600 revolutions a minute, and for larger or smaller diameters the speed should be so regulated as to give the same velocity at the circumference. Aluminum is a very easy metal to spin and no difficulty should be found at all in spinning the proper grades of sheets. Several factories