How to Cast a Steel Part

Maybe your steel casting production isn't this involved, but the principle of molten metal is the same.

Steel is most often cast into the desired part shape using the method of sand casting. Sand molds will stand up to the immense heat of molten steel, and they retain their appropriate shapes until the casting is released from the mold. Although they are single-use molds, sand molds have been reliably used for years to produce castings in the automotive industry. The amateur metalworker can enjoy the benefit of reduced cost to produce a part that may only need to be produced once or a handful of times.

Things You'll Need

• Steel ingot or scrap steel
• Casting pattern
• Sand and binder mixture
• Wood or metal box or boxes
• Furnace
• Crucible

Instructions

1. Prepare the furnace and start melting the steel. Add the steel to be melted down and bring the furnace to the operating temperature.

2. Pack the sand and binder mixture. This will depend upon what type of part you are trying to cast. If you have an open-ended mold, then all you need to do is pack the sand and binder mixture into a wooden or metal box and make sure it's level with the top. Running a scrap piece of lumber over the top will work. If you have a top and bottom half, or a cope and drag, respectively, you will need to pack two boxes and level them off at the top.

3. Create the sand mold. Push the pattern into the sand mixture hard enough to make an impression and remove it. Do this for all parts of the mold. If you have a closed mold, carefully take your finger and carve out a pouring cup in the outside portion of the cope to ease the pouring process. If you have internal features to the casting, you will need to secure a sand core with chaplets made from the same metal you are using for the casting. Assemble both the cope and drag for closed molds before producing the casting.

4. Pour the molten steel. Dip the crucible into the furnace and fill it with molten steel. Carefully pour the steel into the mold to minimize flareups. Be sure you have enough to fill the open-ended mold. If you have a closed mold, be sure to pour in enough metal to fill back to the pouring cup.

5. Release the casting from the mold. Knock the sand off away from the casting to release it. If necessary, cut or grind away any extra metal that is not part of the desired casting.

Tips & Warnings

• Wear a face shield, an apron, and long-sleeve gloves to protect yourself from anything that may splash towards you as a result of the casting process.

• Keep a fire extinguisher on hand in case of any fires that may erupt.

References

• BackyardMetalcasting.com
• The ATM Site; A Home-Grown Foundry; Jim Sapp