Melting aluminum is actually pretty easy to do, which is why it’s such a popular metal for beginners at metal casting. Building a foundry that can melt aluminum safely is another matter entirely, and one that benefits from some of the thoughtful touches that [Andy] built into his new propane-powered furnace. (Video, embedded below.)
The concern for safety is not at all undue, for while aluminum melts at a temperature that’s reasonable for the home shop, it’s still a liquid metal that will find a way to hurt you if you give it half a chance. [Andy]’s design minimizes this risk primarily through the hands-off design of its lid. While most furnaces have a lid that requires the user to put his or her hands close to the raging inferno inside, or that dangerously changes the center of mass of the whole thing as it opens, this one has a fantastic pedal-operated lid that both lifts and twists. Leaving both hands free to handle tongs is a nice benefit of the design, too.
The furnace follows a lot of the design cues we’ve seen before, starting as it does with an empty party balloon helium tank. The lining is a hydrid of ceramic blanket material and refractory cement; another nice safety feature is the drain channel cast into the floor of the furnace in case of a cracked crucible. The furnace is also quite large, at least compared to [Andy]’s previous DIY unit, and has a sturdy base that aids stability — another plus in the safety column.
Every time we see a new furnace design, we get the itch to start getting into metal casting. And with the barrier to entry as low as a KFC bucket or an old fire extinguisher, why not give it a try? Although it certainly pays to know what can go wrong before diving in.