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12/6/2019 7:27:02 PM
Posted: 12/20/2016 8:16:08 PM EST
I am particularly interested in sand casting aluminum replica M49a2 shells for my 60mm mortar. Is this possible to do accurately without destroying a shell to do so?
Link Posted: 12/20/2016 8:30:23 PM EST
Hello Mr DEA!













Link Posted: 12/20/2016 8:34:06 PM EST
[Last Edit: 12/20/2016 8:36:55 PM EST by mean_sartin]
Yes. You need Green sand.


Take two wood frames, load them with green sand. Place the shell in between them and now you have a mold. No need to damage a shell!



It's a lot more involved than that, but that's the gist. Lots of stuff on YouTube about sand casting.


You'll also need to build a foundry.
Link Posted: 12/20/2016 8:38:28 PM EST
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Originally Posted By mean_sartin:
Yes. You need Green sand.


Take two wood frames, load them with green sand. Place the shell in between them and now you have a mold.



It's a lot more involved than that, but that's the gist. Lots of stuff on YouTube about sand casting.


You'll also need to build a foundry.
View Quote



After watching a few videos online, it looks relatively simple. Since aluminum is much lighter than the steel shells I use now, is there a way to make it hollow? I'd like to be able to adjust the weight of the rounds with sand, or possibly even figure out a fuze timed smoke round.
Link Posted: 12/20/2016 8:39:53 PM EST
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Originally Posted By mean_sartin:
Yes. You need Green sand.


Take two wood frames, load them with green sand. Place the shell in between them and now you have a mold. No need to damage a shell!



It's a lot more involved than that, but that's the gist. Lots of stuff on YouTube about sand casting.


You'll also need to build a foundry.
View Quote


don't forget the sprue hole.
Link Posted: 12/20/2016 8:42:29 PM EST
[Last Edit: 12/20/2016 8:44:48 PM EST by LightningII]
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Originally Posted By RockHard13F:



After watching a few videos online, it looks relatively simple. Since aluminum is much lighter than the steel shells I use now, is there a way to make it hollow? I'd like to be able to adjust the weight of the rounds with sand, or possibly even figure out a fuze timed smoke round.
View Quote


look at how-to on making a sand core for the mold. it puts a void in the cast part.
are you making an exact projectile replica with fins and everything?
Link Posted: 12/20/2016 8:43:19 PM EST
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Originally Posted By reyloxdm40:
Hello Mr DEA!
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That's the ATF ding dong
Link Posted: 12/20/2016 8:43:22 PM EST
[Last Edit: 12/20/2016 8:44:22 PM EST by LightningII]
nvm
Link Posted: 12/20/2016 8:45:50 PM EST
How concerned are you with an accurate reproduction vs a functional body? It wouldn't be too hard to turn something like that on a lathe.
Link Posted: 12/20/2016 8:45:56 PM EST
Hollow?

Centrifugal casting. Sling that molten shit around in a circle!
Link Posted: 12/20/2016 8:50:18 PM EST
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Originally Posted By JoEnge1136:

That's the ATF ding dong
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A 10'er at that
Link Posted: 12/20/2016 8:56:58 PM EST
Green sand that was mentioned above would give you the best finish on the aluminum once cooled down. I've read comments before that you can make it cheaply with kitty litter.
Link Posted: 12/20/2016 9:04:24 PM EST
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Originally Posted By MHIDPA:
How concerned are you with an accurate reproduction vs a functional body? It wouldn't be too hard to turn something like that on a lathe.
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Mostly want functional and relatively consistent. Losing expensive bodies sucks.
Link Posted: 12/20/2016 9:04:26 PM EST
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Originally Posted By RockHard13F:



After watching a few videos online, it looks relatively simple. Since aluminum is much lighter than the steel shells I use now, is there a way to make it hollow? I'd like to be able to adjust the weight of the rounds with sand, or possibly even figure out a fuze timed smoke round.
View Quote


I don't think sand would be a good weight for the projectiles. I think you'd be better off drilling them out and putting in some lead or steel.

Link Posted: 12/20/2016 9:06:49 PM EST
[Last Edit: 12/20/2016 9:11:28 PM EST by 1Andy2]
You could do an investment casting for a hollow core shell. 3D print a master pattern, then use that master to make mold haves out of silicone rubber. Cast resin or something into the rubber mold halves to make subsequent investment casting patterns.

Dip the patterns into slip material, cure, then pack in a sand flask with a sprue up to the surface with plenty of height to apply enough pressure to fill the pattern well.


eta: For consistency, this is going to be complete garbage.

You need a die for making aluminum extrusions. Then you could put a steel backer inside the extrusion and swage it into a die so you'd effectively have a bullet jacket with an open end and a pointed end or round nose or whatever your die combo is.
Link Posted: 12/20/2016 9:08:06 PM EST
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Originally Posted By JoEnge1136:

That's the ATF ding dong
View Quote View All Quotes
View All Quotes
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Originally Posted By JoEnge1136:
Originally Posted By reyloxdm40:
Hello Mr DEA!

That's the ATF ding dong


Maybe OP is planning on launching dimebags over Trumps border wall?

Better make the wall 10 feet taller.
Link Posted: 12/20/2016 9:08:29 PM EST
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Originally Posted By LightningII:


don't forget the sprue hole.
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He'll have a hell of a time casting without one.
Link Posted: 12/20/2016 9:14:31 PM EST


Do a google on "David J. Gingery" ----------------------- he had a whole buttload of how to do metal-working books in the 1980's that were killer...


https://www.amazon.com/Books-David-Gingery/s?ie=UTF8&page=1&rh=n:283155,p_27:David Gingery&tag=vglnk-c102-20




Link Posted: 12/20/2016 9:17:29 PM EST
Link Posted: 12/20/2016 9:20:40 PM EST
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Originally Posted By CPT_CAVEMAN:
http://www.gunbroker.com/item/606298147
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"D'oh! I just lost my $300 noise maker round..."

I've lost expensive projectiles. I am trying to avoid buy, firing, and then subsequently losing, more expensive projectiles. I like the TRUMP round idea, but not at that price. That is more than real HE rounds cost.
Link Posted: 12/20/2016 9:22:39 PM EST
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Originally Posted By reyloxdm40:
Hello Mr DEA!
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Da fuq?
Link Posted: 12/20/2016 9:29:18 PM EST
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Originally Posted By JoEnge1136:

That's the ATF ding dong
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Lol I'm a retard.
Link Posted: 12/20/2016 9:34:56 PM EST
Link Posted: 12/20/2016 9:39:25 PM EST
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Originally Posted By RockHard13F:



Mostly want functional and relatively consistent. Losing expensive bodies sucks.
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PM sent
Link Posted: 12/20/2016 10:07:06 PM EST
Sand would not be a good material to use to adjust the weight; many many years ago when I was a young airman we filled empty MK82  bombs with sand so the pilots could drop inert MK82s that were the correct weight.  The sand shifted inside the bomb body and drastically changed the center of gravity; very strange things happened when the sand filled bombs were released.

To remedy that situation we dumped all of the sand and replaced it with a mixture of concrete and vermiculite.  The mixture was adjusted to get the correct weight and the correct CG; I think an engineer did the math.

For your purposes you could use zinc instead of aluminum to make the rounds.  Zinc will pour as easily as aluminum and it weighs just about the same as iron. 

The downside is the fumes are toxic; you need to be very careful and aware of where the fumes are going and take the appropriate safety measures.  If you go this route make sure you have lots of milk on hand; milk will mitigate the effects of the zinc poisoning.  Do not underestimate the dangers of zinc.

If you do go ahead with this project read up on pattern making.  A split pattern and a core will make your life much easier.
Link Posted: 12/20/2016 10:10:13 PM EST
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Originally Posted By krpind:
Just wanting to do a one off?

Watch this.

Be warned though. Be prepared to watch this guy build this big ass boat in his yard.

https://www.youtube.com/watch?v=qPnSb3yzytE
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Well I had plans. Now I'm watching this guy build a big ass boat in his yard
Link Posted: 12/20/2016 10:18:59 PM EST
Would a rfid tracker hold up to being launched?
Link Posted: 12/20/2016 10:20:58 PM EST
Subscribed so I can watch the Big Ass Boat build and wait fir the OPs mortar rounds.

I built the big ass propane furnace for melting aluminum, and have sand cast an: 1 inch Aluminum round rod from beer cans, which I turned in a lathe.

It had a lot of voids.

This is one of my back burner projects, eventually I would like to cast a chassis for a precision rifle.

Attachment Attached File
Link Posted: 12/20/2016 10:37:59 PM EST
I've done a couple small projects. Mostly motorcycle parts. Sand casting is fun as shit.

I don't know how critical the dimensions are for what you are trying to make, but the stuff I've cast out of aluminum always winds up being slightly smaller than the model. The aluminum shrinks as it cools I guess.

And I use red sand. It uses oil to bond the sand together as opposed to green sand where you need to add water to get it the right consistency. But I'm not experienced enough to know which is better.
Link Posted: 12/20/2016 10:46:36 PM EST
[Last Edit: 12/20/2016 10:50:30 PM EST by von_landstuhl]
A home foundry and aluminum casting is on my bucket list.



Link Posted: 12/21/2016 1:08:06 AM EST
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Originally Posted By krpind:
Just wanting to do a one off?

Watch this.

Be warned though. Be prepared to watch this guy build this big ass boat in his yard.

https://www.youtube.com/watch?v=qPnSb3yzytE
View Quote



Well, I've been watching for 3 hours now
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