Making a 100kg / 220lb Steel Anvil - Melting Steel, Pouring Molten Metal, Red Hot Water Quench
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- Опубліковано 28 тра 2024
- #metalcasting #kcast #metallurgy #anvil #foundry
Casting an anvil in steel. This is the big one. Melt Day! Today Bob and Jamie are melting and pouring the steel for their signature anvils. The temperature is up near 1600 degrees celcius, it's so hot! We talk you through hardening and quenching, tapping out, purifying our pour and then crack open the moulds while the anvil is red hot and water quench to harden.
Welcome back to the third in a 4 video series on how make an anvil from steel.
We really appreciate you watching and hope you enjoy the content. Please find us on social media and share our videos and posts around. We are brand new and need your help to spread the word.
Thanks for watching
Aussie Metal Casting
#anvil #metalwork #fabrication #engineering #Australianmade
We are a small boutique foundry based in NSW, Australia. We have over 30 years experience and a successful business casting a variety of custom jobs. We use an electric induction furnace and melt and alloy a variety of metals.
We hope you enjoy it. Stay tuned to follow the process and please leave a like and subscribe to see future videos
The fact you make you own power to melt the metal. The pour is the highest quality .
Cheers!
@@AusMetalCasting before I shut my foundry down we had entertained and should have gotten a generator. Power delivered to us via power lines we were billed 5,000.00 a month for demand charge on top of our use which was 2,500.00 a month for a 350 KW for a total of 7,500.00. Journeyman molder by trade here. Good to see my fellow Foundrymen in action. 59 years old now started at 17.
I'm not crying, I just got sand in my eye😭. How I long for such an anvil. This is my dream that I can't afford. I am from Russia, such an anvil will cost half of my annual salary. It remains to look and be happy for those who will get this high-quality tool.
If you can find any railroad track rails thats almost the perfect alloy it is here in the USA. Dude if Obama hadn't killed my Foundry out with regulations and killing the coal industry I cast some anvils this size. I don't know how hard it would be in Russia to get some railroad track but there us a video of how to make an anvil out of a piece of track.
We cast steel at 2,900 degrees Fahrenheit. Are you talking cellcius?
@@ronniebuchanan6575 I think so Aus is even more metricated than here in the UK so would use Celsius as a matter of course
I thought Russia would be full of old soviet era ironwork tools, I work in a forge here in Australia and we have lots of large Russian lathes, borers and milling machines, mostly Ryazan and Stanko machines, it's funny running machines with USSR and CCCP badges on them in 2021!
@@ronniebuchanan6575 yes he is talking in C
Man you're 100% authentic
Y'all are just built different. I don't think the average person has any frame of reference for how much radiant heat comes off of molten iron like that. I've never even been near molten steel, but I had the pleasure of helping with a large bronze pour one time and learned that's already more discomfort than I care to experience with any regularity. Y'all are the backbone of society. Stay safe, and keep on keepin' on.
oh dang....guess I am gonna need to save up for an Aus Anvil....very nice work guys
Thank you!
thanks people around the world and down under for still manufacturing these blacksmithing keeps spreading around the world thanks 4 sharing : )
Very cool. Watching from the USA. Nothings better than a father and son team. Good to see things done the old fashioned way. Looks like a fun but hot job lol
My granddad worked in a foundry in the 40's and 50's before he retired he made an anvil at home and took the mold with him to work with 20 steel crankshafts from decil trucks and one from a bulldozer. They helped him melt them and his boss used the left over steel to make his own smaller anvil. Gramps weighed 253 lbs. After finishing and it was kelly green. They sold it at the estate sale in 1972 while i was overseas or it would still be in the family.
As a 17 year employee of BHP I can say I've spent 8 years with a manganese mine (GEMCO) on Groote Eylandt (admittedly a couple as a contractor) in the Gulf of Carpentaria, 5 years with BMA, which is a metallurgical coal miner in the Bowen Basin and now almost 6 years with Olympic Dam, a Copper mining/casting company in the far north of South Australia. So I can say legitimately that I have been involved in three of the processes you've demonstrated. I was starting to worry when you seemed to be approaching the pour without proper PPE but you made me proud. Keep up the great Aussie manufacturing tradition. I only wish I was still on the tools so I could justify ordering a Hunchback.
My grandfather would be mesmerized by this. He was a metallurgist who was responsible for designing the steel for the Snowy Hydro Scheme. Imagine the information overload he would have if he were here now in his prime with the depth of technology information we have at our fingertips? I hold a deep reverence for every person who managed to get Australia to the Jewel it has been and will be again soon. Cheers all.
100% mate
Great video! So glad you guys are helping keeping Aussie manufacturing alive. Awesome Anvil's, drooling!!
Great to see anvils being made. I own two that are about 220 pounds each and use them a lot. Its important to keep the old school ways alive. Don't know what the future holds but with the proper tools we will do ok.
What if China invades mate?
@@teeess9551 Well its a what if that definitely could happen. Perhaps that is why the liberals in our government that work for China, want to disarm us so bad. Things are not looking to good on the Russian front either. Its a scary world we live in these days but look up, our redemption draws near.
While I'm quite familiar with backyard quantities, these industrial-scale melts fascinate the hell out of me. Most people don't take the time to show or describe such things. 👌
Thank you, reminds me of my 33yrs in the steel making industry where we would make and pour 500ton heats at a time. I could almost feel the heat and smell the smells!
Awesome!
Still mills are awesome. We cast a lot of door jamb castings for the coke ovens a high chrome grey iron for heat resistance for US steel and several others. A friend of mine was telling me a bout a 20 ton ladle developed a carbon boil and boiled out in the floor. They was spraying it down and rolling it up with D9 dozers. I have had furnaces to boil on me hut them with aluminum to lay them down. Of course that was only 2,000# not 20 ton.
Spectacular! !
I've casted lead for decades and soon to do aluminum, brass, and copper. Not sure if I will get to cast iron or steel ever though. All the precautions are the same and there is absolutely no clowning around casting any metals. Thumbs Up!
Had no idea there was a foundry in OZ that cast anvils! Wish I had known a year ago, would have become a customer! Quenching with a hose is not something I expected but thinking about it it makes sense, keeps the body a little softer!
Bob, FYI - 350kva generator would be struggling to power 70 homes here in Australia, probably closer to 50 being realistic! Also, that generator appears to be turbocharged, not supercharged as you stated.
I really really appreciate you sharing this amazing process
This is a first for me, I've never seen an anvil made.
I love this! I worked in a foundry. We actually had railroad cars come in full of crushed cars. We would melt whole car frames after they stripped them down. Just the bodies and frames. We actually made the wheels , frames and knuckles for trains. I was what was known as a ladle follower. I had to knock the molten off of the frames we used.
That's cool!
At 9:20 when you said "me and my son" my already growing respect for you increased but with a tinge of envy. It is good.
Wow! What a good job.
This should be in the all books, nice job, enjoyed every second of the videos. Stay safe and use proper gear always.
Totally amazing and fascinating great work guys thanks for sharing the process ❤
I really enjoyed the video. Back in the old days(about 60 years ago) I worked in an small iron foundry, so I can recognize and understand the steps and processes you go through. It was pretty crude even by the standards of the day. It's a wonder nobody ever got killed there, but vey exciting. That's when I was 20 years old and immortal.
Ah to be that immortal 20 year old again
Amazing steel production unit
That's a heck of a process. I got to see cars being turned to rebar when there was a steel mill here in Hawaii. That was some heat coming off the steel and you guys are right up there with it. Good to know that these things are still being made.
done all that stuff about 40 years ago making clay for the furnace, make the sand, grinding, interesting work .
This is why I melt my own cast iron because most foundries have closed down in Australia and the ones that are left are too far from where I live.
Waiting to see that cleanup and finished product in use.
Editing the clean up at the moment
I added a video this week of how hot my stuff in my home shop gets just being close to a hobbyist's crucible full of aluminium-- I can only imagine how effing hot that steel ladle and anvil was! Haha!
Great job good to see Australian made🇦🇺🇦🇺🇦🇺
Fantastic!
This is exactly why anvil prices are so high, so much care and complexity goes into making one
So much! Our prices are alright though A$550 for the 25kg and up to A$1100 for the 100kg in the video
@@AusMetalCasting that's incredibly fair priced for the size.
@@AusMetalCasting People who complain about the price should try casting their own white hot liquid steel in 150kg batches. ;)
Damn, that is a good price. Had to change it over to USD, being a yank, but I would bet the shipping would probably be double that by itself. Ah well, tis to dream
Damn .. my brother scored a mint 175lb hay budden few years back for 500$ .. I messed up not going with him to check it out .. could have got a 150lb h.b. for 450.. .. coulpe guys didn't get paid by owner when shop went belly up.. so they went and uhhh "collected" their pay when no one was looking from the shop..
Fascinating
Also scary
You earn your pay
Thanks for showing this
Frank
(Virginia, US)
Thanks Frank! We work hard for the money buddy. Love it though
Amazing video. Thank you.
Nothing like the sound of an old 8v92 Turbo G.M. diesel...music to my ears!
I have an aluminum and brass foundry here on my place.. I have learned a lot over the years from trial and error. Best way to learn..I usually make bells. My foundry is mostly a bell foundry here in the state of Virginia USA
Really enjoyed your video. Its amazing what goes into making a quality anvil. Thank you.
In our plant in Indianapolis IN, USA we ran the molds on conveyers past the furnace and poured right from it.
Looking forward to watching your other videos
Awesome, thank you!
Awesome pour. Thanks for posting.
Thanks Jason!
Those of us trying this at home seriously envy you pros!
thankyou for making this content :)
brutally hot dangerous work. glad I'm thousands of miles away
Waooooooo that was like dream i love that you make may dream anvil
Glad to see someone making things that will last several lifetimes
I want one !!!
email us at ausmetalcasting@gmail.com
Lots of good information thanks guys for making these videos!
Thank you for sharing your hard work. Greetings from Karachi, Pakistan.
Great to see keep it up we need it for the next generation so they understand not everything is computerised and the best products are handmade.
Extremely fascinating. Can't wait to see more
Thank you! We've got to machine and finish the castings and make a new hammer next
@@AusMetalCasting Great, l can't wait to see!
Outstanding! I once worked at Alamo Iron Works here in San Antonio, Texas, USA (not defunct) repairing rebar benders. I had a chance to look into the massive induction furnace there. All I could think of was "This is what the mouth of hell must look like!" They would use crucibles to hold the molten metal that must have been a meter and a half across.
Awesome job guys! Answered a bunch of my questions.
I love this channel. Thanks for sharing your knowledge and experience.
That was so cool! Thank you great video!
At 9:51 you used a term when you were further cleaning off the dross from the ladle. I could not quite catch what it was that you called it. Watching the documentation of this process has been quite mesmerizing! Thank you for the series.
It's anti-slag - Clean A Met
That is really cool!
Cheer Ty!
Very cool!
Cheers!
Enjoyed the entire process, well done thanks for sharing ! 👍👍
Это точно , осталось только мечтать и радоваться за тех кому такая будет помогать в работе 😊
Great stuff! Hope to see more soon!
Thank you!
fantastic video, thank you for sharing.
Great for recycling the steal. Thanks 😊
dont know why this popped up in my vid list but im glad i watched it. Very informative of the process involved when making your anvils. Not to many place around in Australia that make their own products anymore. Great vid you just picked up another subscriber
Amazing process guys🤠👍
Great video guys!!!! Good show!!
Thankyou! Finished product was just uploaded!
Mad respect!
I work on detroit diesels. My old crown school bus has a 6L71 turbo charged detroit. My boat has twin 6v53 engines. I just rebuilt an 8v92 like the one running that furnace.. such power from a simple 2 stroke engine
Good to see this is still being done here in Aus,Can we get some videos of rebound tests and final product?
Next anvil might be one of these.
I'll ask Bob about the tests. Final product just uploaded
Would love to have one. Beautiful workmanship
There was a foundry (foundary) nearby here at one time named Murphy's. They made so many steel covers that these are all over the country still, maybe thirty years later. New services and repaired stuff now has friggin plastic covers. When a manhole cover broke they'd get a new one in and drop the broken one for recycling at the same time. Fletchers don't want to know about damaged plastic covers. Landfill. That's rubbish instead of repair. Bean counters are destroying the world we knew previously. And now if it's not done on computers it is likely to not be recognized.
i realy liked your vidio making that anvel top noch buddy,thanks for sharing your work .
Coool. Tnx
Seeing you put on all the safety gear and then I watch videos from over in India and Pakistan and they are pouring cast iron wearing sandal and flip flops! LOL
very cool;)
Cheers
Very nice
Thank you!
Grear work dudes!!! Love and reapects from Pakistan. 😍
Good ol Detroit 2 stroke diesel. .. turns diesel directly into noise the noise turns into power through osmosis lol
'Turns diesel into noise'....
Almost as good as 'uses fuel to burn more fuel to create pollution'....
brilliant
Thank you!
I loved to watch your iTunes video on casting a anvil glad to see there’s still some old craftsman still carrying on . I live in Sheffield which as you know we’re famous for making steel now it’s gone there’s only a few foundry’s that make steel owned by a Indian company this is a country that we give 100s of millions to in aid they spend it on sending rockets into space and buying British company’s .anyway I worked in the steel industry in a foundry making segments for London tunnel we also made pipes for the world it’s was called Stanton and staveley I was in India a few years ago and behold there was a sewage pipe going into jungle made in staveley 1932 anyway I was watching you casting a anvil and noticed you were tying on gaters while you were casting we were supplied with work boots which already had these on this is in 1968 and we had a apron which covered our legs and had to wear safety glasses all the time you were sacked if you wasn’t wearing them .I’m sure you can still get these boots I would buy some as molten metal takes no prisoners . All he best and keep up the good work.
SUPER
Aussie pride mate!🇦🇺🇦🇺👍👍🤟👍U got another subscriber buddy
nice job
:D
Thank you!
Absolutely first class Ozzie! That has to be one of the most dangerous work environments there is. When I was a boy my father worked in a foundry during the dark days of Carter and it was not uncommon to hear the stories of explosions and severe burns... Apparently the shop he worked in had more than one leaky roof.....
Side note to viewers: Am I the only one getting "Climate Change" commercials while viewing this video?
Kick it in the guts, how aussie is that? Love it! Keep up the great vids and work guys. Thank you.
Thanks Daz! What a legend! Thank you for watching mate
Great to see, About twenty years ago there was three foundaries here in Invercargill New Zealand and now there are none. Thank you
That's sad to hear but also the case here. Bob is one of the few remaining boutique foundries
Invercargill. Sometimes spelled with one L to save ink 😬
@@AusMetalCasting sane here in the USA there were three foundries in a 30 mile radius now not a one I have to drive at least 90 miles.
You guys have a pretty sweet set up
Bob has worked hard to get the foundry to where it is today
Wanna bet I owned a foundry anytime you quench steel or iron it hardens it. Its about freezing the matrix before the nuclei parciptates out and expands the grain. It has to be a carbon steel mind you not a 1018 or 1020 it has to be a tool steel with slughtly higher carbon, chrome and Moly. My anvils quenched at 65 on the c scale.
That was Amazing thankyou. One day i might be able to afford one. Lol
Gotta love a good induction furnace.
Wow really enjoyed your video. I worked in the Berlin, WI foundry and I worked with air set at that time. I see you paint the cope and drag, I would guess because the sand will not allow fine and course sand to mix well. We had a large sand hopper that had baffles inside about 2 feet apart. The baffles were sheets of metal with holes drilled about 3 inches apart in rows. The sand would drop through a few of these baffles before going to the auger where it would mix with fluid. It helped alot. We casted 4 cyl. Motor engine blocks. We did have to coat the molds with a spray to cover and problems with imperfections.
F##K me made in Australia SO proud it's a honer to subscribe mate .Cheers .(:
All the way mate. 100% Aussie Owned, Designed, and Made
A rooly big Honour.
This sort of small induction furnace bring me hope that I can cast in my backyard
Fascinating stuff, I'm interested in making wrought iron anvils with a steel face (assuming I can get enough iron) but this may be a way forward assuming I can find a foundry in the UK
Good luck
OS MESTRES EM AÇÃO. .
COMO GOSTARIA DE ESTAR AI👏👏👏👏👏👏👏👍👍👍👍👍
If i had a means of getting it out to me, id get my anvil from you guys knowing it was made by hand by you guys. Down side is the shipping cost to the states would be astronomical!
I won't lie it is, but if we keep getting the interest it might be worth sending a container load over...
@@AusMetalCasting Just wondering, what's the cost of a container? How about shipping an anvil to the US? I can't even imagine the costs.
I don't have a need for an anvil right now, but I'd be curious as well as to the final cost is.
There's something about smelting and casting that is incredibly satisfying. I working at the Copper Smelter up in Mount Isa for 5-6 years in my 20's. Did a lot of basic casting of copper when I was bored babysitting the anode wheel.. similar to this on a smaller scale. Ran a PS-1 converter an, anode furnace and anode wheel for a couple of years.. molten metal can be VERY treacherous, especially copper foam-overs.
You're right about molten splash.. I used to shave my chest hair. It was too hot to keep the buttons done all the way up to your neck, and those hairs are great for catching a splash ball and letting it burrow into your skin while you dance around like an idiot.
You should show them what happens when you pour molten metal on water in a mold. :)
With all due respect to someone whose heavy duty gloves are smouldering, all I can say is that they make ‘em tough in Oz, and that’s just the Sheila’s! As for the Bruce’s, great bunch of mates to have a tinny (or three) while watching the footy (go Saints! Better luck this season, from a Yorkshire fan).
This is fascinating. I really appreciate the insights into this process. I'm only using a little propane furnace so I'm not going to be casting any anvils :)
Thanks for sharing. I have a load of forklift tines, I wish you were in England.
So do we! We'd love to get our hands on them!
Thank you very much for taking the time to create this content! As a blacksmith I find this very interesting. That generator you have is pretty remarkable how many psi/bar of does the supper charger feed to the motor? So awesome.
Thank you! I'm glad you enjoy it! I'm not sure I'll have to check with Bob and get back to you.