Pure aluminum can be used for other projects.You can make fun or useful shapes with pure aluminum.You can easily melt aluminum with a propane torch, since it has a low melting point.Make sure you wear proper safety equipment, such as heavy leather or Kevlar gloves, leather boots with reinforced toes, a long-sleeved shirt, and long pants.
Step 1: Take the aluminum cans and crush them.
The cans melt faster.The cans will melt more easily if you crush them more.There will be a layer of paint on top of the melted aluminum if you don’t clean the cans.This can be removed and thrown away.
Step 2: Sand is placed in a large glass bowl.
The sand insulates the bowl from the torch’s heat.The melting chamber will remain in place.A steel bucket is better for melting aluminum.
Step 3: There is a small steel cup in the center of the bowl.
To melt cans, the steel cup needs to be at least 3 inches in diameter.The edge of the cup is visible over the top of sand if you push it deep enough.There is a cup that is plain steel.The heat of the propane torch can cause these materials to catch on fire.A steel cup, pot, or pan can be placed directly onto a nonflammable surface like a cinder block.
Step 4: Put the can in the cup and use the blowtorch to heat it.
The first piece of metal will take a long time to melt.You can add more cans once the first has melted.If there is a fire, always have a bucket of cold water with you.
Step 5: Take the aluminum and put it into muffin tins.
Once the aluminum is melted down, pour it into a muffin tin to make ingots.The pure aluminum ingots will stick to the steel cup.You can remove the metal from the muffin tin after it cools down.If you have a steel mold, you can pour melted aluminum into it.Don’t handle materials that are still hot.
Step 6: In a steel pail, surround a pipe with perlite and cement.
The pipe is cut down to the same height as the bucket and Portland cement mix.Without the pipe inside, fill the bottom 3 inches of the bucket.Once the mixture dries, place the pipe on top and fill the rest of the bucket with the same mixture.This is the mold for the melting chamber.It’s important to use steel because it won’t melt in the extreme temperatures you’ll use.Perlite can be found at gardening centers for less than at hardware stores.Depending on the climate, the perlite and cement will take anywhere from 4-7 days to dry.Sand and plaster of Paris can be used to surround the pipe.
Step 7: The lid should be created for the foundry.
The mixture of perlite and Portland cement should be put on the lid of the bucket.To make handles, place the ends of the U-bolts with the nuts in the mix.Wait until the mixture has dried and then slide it out of the lid.An electric drill is used to drill a hole in the top of the lid.If you didn’t get a lid for your bucket, use a second bucket.The mixture should be filled to around 2 inches.
Step 8: Remove the inner pipe and drill a hole for the air supply.
The pipe needs to be removed.You might need a pair of pliers.Then, drill a hole from the top of the bucket.A hole saw is connected to an electric drill and can be used to cut a hole into a bucket.After cutting through the bucket, position the blade at a 30-degree angle and drill.You should look for a drill that can cut through metal.
Step 9: Attach steel tubing to a pipe.
The steel tubing is 1 inch ( 2.5 cm) in diameter.Then, slide the pipe into the end of thecoupling.The metal end of the pipe needs to be moved.The hole should be easy to slide into.If it does, you can either drill a bigger hole or find a smaller piece of tubing.The source of air will be attached to the pipe.
Step 10: The steel crucible should be placed in the foundry with charcoal.
The best way to melt aluminum cans is with a plain steel cup around 3 inches in diameter.Use a plain cup.There is a chance that paint or decoration will catch on fire.The foundry should be filled with charcoal briquets.It works perfectly for grilling.The foundry should be filled around the crucible.You can use an old fire extinguisher to make your own crucible.Make sure the steel you use is strong enough to melt aluminum at high temperatures.If you want to melt cans more effectively, place a few charcoal briquets underneath the melting chamber.It’s a good idea to use your foundry in aventilated area.
Step 11: Attach a hair dryer to the air pipe.
The flames will be hot enough to melt aluminum if the hair dryer is used.If you want to support the hairdryer, place it on top of something stable.You can slide the hair dryer onto the PVC pipe if you duct tape it.It will be easier to remove the hair dryer.
Step 12: Turn on the hair dryer when you light the charcoal briquets.
If you have a propane torch, use it to quickly and evenly light the charcoal.You can get the charcoal to be hot by turning the hairdryer on low.Keep the heat inside and warm up the coals by using the foundry’s cover.
Step 13: When it’s glowing orange, use steel tongs to place cans.
The inside of the foundry will start to glow orange after 10 minutes.You can use steel tongs to remove the lid and place a single aluminum can into the crucible at this point.You can add more cans once the first has melted.If you add more cans, the crucible will be full of liquid aluminum.
Step 14: Steel tongs are used to remove the full crucible.
Use your tongs to get a secure grip.To make sure you can get a good grip without spilling aluminum, you may want to test out removing the crucible using tongs.This is the most dangerous part of the process.Make sure you wear heavy leather gloves, leather boots with reinforced toes, a long-sleeved shirt, and pants.
Step 15: Attach the aluminum to the steel mold.
Use muffin tins to make bricks.A steel cake pan or a steel mold can be used to make a design out of aluminum.Steel cake molds can be found at thrift stores for less than a dollar.The aluminum won’t pour out if there is any dross in it.You will be left with pure aluminum ingots because it will act as a strainer and hold back more dross.
Step 16: Place hardened aluminum into a bucket of cold water.
It is too hot to touch with your bare hands once the aluminum has hardened.To cool it down quickly, place the aluminum into a bucket of cold water.It is safe to touch the aluminum with your bare hands after about 10 seconds.The aluminum will cause the water to boil.Fresh water is required for each brick.