Sand Casting weapons TROUBLE

[Zcoberly]

Hello everyone, I have been working on replicating some weapons from Xena Warrior Princess and The Lord of The Rings. I am sand casting weapons in aluminum. For the most part they turn out great, but I continuously have a problem with the aluminum sinking in on one side.

I have attached a couple images, when the mold is laying flat, the top of the sword (facing up towards the sky) is the side tht comes out deformed. The side that would be face down on the table comes out perfect every time, HIGHLY detailed.

Anyone know what I am doing wrong?

 

[Duncanator]

Beautiful work!

I am not an aluminum casting expert, but my first guess would be the metal contracting as it cools.
That area looks to be the thickest part of the casting, so it would be cooling last. Gravity is keeping the "down" side in place, but the "up" side is sinking as the metal shrinks away and contracts into other areas of the casting as they cool sooner.

Just a guess.

 

[Duncanator]

Maybe a taller/thicker fill spout to keep pressure in the mold while it cools?

 

[Zcoberly]

You are definitely right about it cooling... I will definitely try a larger pour spout area

 

[funboy1013xx]

send a pm to board member Jamie staff. maybe he will see this post, he should be a world of help to you.