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

being polished, in order thoroughly to clean these objectionable cavities; and the polishing should be pushed to an extent sufficient to obliterate the smaller sand holes, if possible, as this class of work looks very unsightly, when plated and finished, if pitted all over with minute hollows. The larger holes cannot, without considerable labor, be obliterated; indeed, it not infrequently happens that in endeavoring to work out such cavities they become enlarged, as they often extend deep into the body of the metal. An experienced hand knows how far he dare go in polishing work of this awkward character.

      Black Wash For Casting Molds.

      —Gumlac, 1 part; wood spirit, 2 parts; lampblack, in sufficient quantity to color.

      How To Make A Plaster Cast Of A Coin Or Medal.

      —The most exact observance of any written or printed directions is no guarantee of success. Practice alone can give expertness in this work. {151} The composition of the mold is of the most varied, but the materials most generally used are plaster of Paris and brick dust, in the proportion of 2 parts of the first to 1 of the second, stirred in water, with the addition of a little sal ammoniac. The best quality of plaster for this purpose is the so-called alabaster, and the brick dust should be as finely powdered as possible. The addition of clay, dried and very finely powdered, is recommended. With very delicate objects the proportion of plaster may be slightly increased. The dry material should be thoroughly mixed before the addition of water.

      As the geometrically exact contour of the coin or medal is often the cause of breaking of the edges, the operator sometimes uses wax to make the edges appear half round and it also allows the casting to be more easily removed from the second half of the mold. Each half of the mold should be about the thickness of the finger. The keys, so called, of every plaster casting must not be forgotten. In the first casting some little half-spherical cavities should be scooped out, which will appear in the second half-round knobs, and which, by engaging with the depressions, will ensure exactness in the finished mold.

      After the plaster has set, cut a canal for the flow of the molten casting material, then dry the mold thoroughly in an oven strongly heated. The halves are now ready to be bound together with a light wire. When bound heat the mold gradually and slowly and let the mouth of the canal remain underneath while the heating is in progress, in order to prevent the possible entry of dirt or foreign matter. The heating should be continued as long as there is a suspicion of remaining moisture. When finally assured of this fact, take out the mold, open it, and blow it out, to make sure of absolute cleanness. Close and bind again and place on a hearth of fine, hot sand. The mold should still be glowing when the casting is made. The ladle should contain plenty of metal, so as to hold the heat while the casting is being made. The presence of a little zinc in the metal ensures a sharp casting. Finally, to ensure success, it is always better to provide two molds in case of accident. Even the most practiced metal molders take this precaution, especially when casting delicate objects.

      How To Make Castings Of Insects.

      —The object—a dead beetle, for example—is first arranged in a natural position, and the feet are connected with an oval rim of wax. It is then fixed in the center of a paper or wooden box by means of pieces of fine wire, so that it is perfectly free, and thicker wires are run from the sides of the box to the object, which subsequently serve to form air channels in the mold by their removal. A wooden stick, tapering toward the bottom, is placed upon the back of the insect to produce a runner for casting. The box is then filled up with a paste with 3 parts of plaster of Paris and 1 of brick dust, made up with a solution of alum and sal ammoniac. It is also well first to brush the object with this paste to prevent the formation of air bubbles. After the mold thus formed has set, the object is removed from the interior by first reducing it to ashes. It is, therefore, allowed to dry, very slowly at first, by leaving in the shade at a normal temperature (as in India this is much higher than in our zone, it will be necessary to place the mold in a moderately warm place), and afterwards heating gradually to a red heat. This incinerates the object, and melts the waxen base upon which it is placed. The latter escapes, and is burned as it does so, and the object, reduced to fine ashes, is removed through the wire holes as suggested above. The casting is then made in the ordinary manner.

      Casting Of Soft Metal Castings.

      —I.—It is often difficult to form flat back or half castings out of the softer metals so that they will run full, owing mostly to the thin edges and frail connections. Instead of using solid metal backs for the molds it is better to use cardboard, or heavy, smooth paper, fastened to a wooden board fitted to the back of the other half of the mold. By this means very thin castings may be produced that would be more difficult with a solid metal back.

      II.—To obtain a full casting in brass molds for soft metal two important points should be observed. One is to have the deep recesses vented so the air will escape, and the other is to have the mold properly blued. The bluing is best done by dipping the mold in sulphuric acid, then placing it on a gas stove until the mold is a dark color. Unless this bluing is done it will be impossible to obtain a sharp casting.

      Drosses.

      —All the softer grades of metal throw off considerable dross, which is usually skimmed off; especially with tin and its composition. Should much of this gather on the top of the molten {152} metal, the drosses should all be saved, and melted down when there is enough for a kettle full. Dross may be remelted five or six times before all the good metal is out.

      Fuel.

      —Where a good soft coal can be had at a low price, as in the middle West, this is perhaps the cheapest and easiest fuel to use; and, besides, it has some advantages over gas, which is so much used in the East. A soft-coal fire can be regulated to keep the metal at an even temperature, and it is especially handy to keep the metal in a molten state during the noon hour. This refers particularly to the gas furnaces that are operated from the power plant in the shop; when this power shuts down during the noon hour the metal becomes chilled, and much time is lost by the remelting after one o’clock, or at the beginning in the morning.

      Molds.

      —I.—Brass molds for the casting of soft metal ornaments out of britannia, pewter, spelter, etc., should be made out of brass that contains enough zinc to produce a light-colored brass. While this hard brass is more difficult for the mold maker to cut, the superiority over the dark red copper-colored brass is that it will stand more heat and rougher usage and thereby offset the extra labor of cutting the hard brass. The mold should be heavy enough to retain sufficient heat while the worker is removing a finished casting from the mold so that the next pouring will come full. If the mold is too light it cools more quickly, and consequently the castings are chilled and will not run full. Where the molds are heavy enough they will admit the use of a swab and water after each pouring. This chills the casting so that it can be removed easily with the plyers.

      II.—Molds for the use of soft metal castings may be made out of soft metal. This is done with articles that are not numerous, or not often used; and may be looked upon as temporary. The molds are made in part the same as when of brass, and out of tin that contains as much hardening as possible. The hardening consists of antimony and copper. This metal mold must be painted over several times with Spanish red, which tends to prevent the metal from melting. The metal must not be used too hot, otherwise it will melt the mold. By a little careful manipulation many pieces can be cast with these molds.

      III.—New iron or brass molds must be blued before they can be used for casting purposes. This is done by placing the mold face downward on a charcoal fire, or by swabbing with sulphuric acid, then placing over a gas flame or charcoal fire until the mold is perfectly oxidized.

      IV.—A good substantial mold for small castings of soft metal is made of brass. The expense of making the cast mold is considerable, however, and, on that account, some manufacturers are making their molds by electro-deposition. This produces a much cheaper mold, which can be made very