DIY Casting: High Quality Aluminum from Recycled Cans!

Summary

In this video, the creator embarks on the process of melting and casting aluminum using recycled beer cans. They walk through each step, from shredding the cans to cleaning the aluminum, crushing it into cubes, and finally melting and alloying it with silicon and copper to create a custom, machinable aluminum alloy. After carefully degassing the metal, they successfully pour it into molds, resulting in high-quality castings. The creator reflects on the success of the process and plans further pours, offering insights for improvements and future projects.

Takeaways

• 😀 The creator is excited to melt and pour aluminum from old beer cans, aiming for high-quality castings.
• 😀 The project began 5 years ago when the creator started collecting beer cans, leading to a large accumulation over time.
• 😀 The creator plans to clean and alter the aluminum to make it suitable for casting and machining custom parts.
• 😀 Modifications were made to the shredder to improve alignment, prevent motor flexing, and better handle the aluminum.
• 😀 Scrapers were added to the shredder to prevent aluminum shreds from building up, and a back mounting plate was installed for better motor support.
• 😀 The creator uses a hydraulic forging press to compress the aluminum scraps into cubes, which aids in the melting process.
• 😀 After shredding and washing the aluminum shreds to remove impurities, the next step is to crush them into 2-inch cubes for easier melting.
• 😀 The melt process includes preheating aluminum to avoid thermal shock and steam explosions, followed by skimming off dross and adding flux for cleaner metal.
• 😀 The alloy is altered by adding silicon (7%) to improve fluidity and copper (1%) to enhance strength and hardness.
• 😀 The creator degasses the aluminum with pure argon to reduce hydrogen and improve the overall casting quality.
• 😀 After successfully pouring the aluminum, the creator notes that the result is clean, shiny, and uniform, indicating the quality of the pour for beer can metal.
• 😀 The final step involves machining the cast aluminum into parts needed for a logging winch, with plans for a follow-up video to continue the process.

Q & A

What is the main goal of the project mentioned in the video?

The main goal of the project is to melt and pour aluminum from old beer cans, clean it, and alter its properties to create a custom aluminum alloy suitable for casting and machining parts.

Why did the creator choose to use beer cans for this project?

The creator started collecting beer cans about five years ago, and over time accumulated a large amount of them. The project aims to recycle these cans into usable aluminum for casting, rather than using higher-quality aluminum from engine parts or tire rims.

What modifications were made to the shredder in the video?

The shredder was modified by adding a shaft that runs through the frame to a corresponding bearing for better alignment, adding scrapers in the channels to prevent aluminum shreds from building up, and reinforcing the motor mount to reduce flexing.

What problem did the creator encounter with the shredder, and how was it addressed?

The creator noticed a lot of flexing in the front plate of the shredder, causing the motor to twist under torque. This issue was addressed by adding a back mounting plate that connects the motor to the frame, ensuring better alignment.

How did the creator clean the aluminum shreds before melting them?

The aluminum shreds were soaked in hot water for a couple of days, with the water being changed multiple times to remove impurities. Afterward, the shreds were agitated in hot water, rinsed thoroughly, and left to dry.

Why does the creator crush the aluminum shreds into cubes before melting them?

Crushing the aluminum into cubes helps reduce the surface area, which minimizes oxidation during the melting process. It also makes it easier to preheat the cubes in front of the exhaust, ensuring more uniform melting.

What equipment did the creator build for the crushing process?

The creator built an accessory for their hydraulic forging press, which includes a funnel to load the scraps, a 2-inch cube with a door that moves to compress the aluminum, and a ram to squish the aluminum into the cube form.

What is the purpose of adding borax during the melt?

Borax is added as a flux to dissolve oxides and impurities in the melt, making it easier to remove them as dross and resulting in cleaner aluminum.

What alloying elements were added to the aluminum, and why?

The creator added pure silicon (about 7% by weight) to improve the fluidity, strength, hardness, and machinability of the aluminum alloy. Additionally, 1% copper was added to further enhance the alloy's strength and hardness.

How does the creator improve the quality of the aluminum melt before pouring?

The creator improves the quality of the melt by degassing it with pure argon for 10-15 minutes to reduce dissolved hydrogen and minimize porosity. This process helps improve the overall casting quality by reducing air pockets.

What is the final result of the casting, and how did the creator feel about it?

The final cast aluminum piece had a uniform, glossy finish with no rough or pitted areas. The creator was satisfied with the outcome, noting that the quality was excellent for recycled can metal and that it was suitable for the part needed in their upcoming logging winch build.

What future plans did the creator mention for this project?

The creator plans to do another aluminum pour to complete the part for the logging winch. They also plan to experiment with aluminum from engine heads or other sources in future pours to compare the results with the can metal.