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PEP BB metalworking.straw.ingot - Make a 6oz Metal Ingot (Excluding Lead)

BB metalworking - straw badge
posted 6 years ago
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This is a badge bit (BB) that is part of the PEP curriculum.  Completing this BB is part of getting the straw badge in Metal Working.

For this BB, you will be making a metal ingot at least 6oz that is not made of lead!

Here is one way to do it:


To document your completion of the BB, provide the photos or video (<2 min) of the following:
 - The supplies you're starting with
 - Partway through the build
 - The finished metal ingot at least 6oz (that is not lead)
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David Huang
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posted 1 day ago
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Approved submission
Today I took advantage of lots of sun, giving lots of power to my solar panel array, to allow me to melt some silver and cast a few billets that will later get forged out into sheets then eventually formed into my artwork of decorative vessels.  When I was getting ready to do my last billet I realized I had intended to document one for this BB.  So here it is submitted for consideration.

I'll go into a bit more detail than might actually be required for this BB since I'm the first one doing it and this might help others understand at least one way a person could do this.

billet1.jpg
This is my equipment all set up outside on a table. I'm using an electromelt furnace with a graphite crucible inside.
This is my equipment all set up outside on a table. I'm using an electromelt furnace with a graphite crucible inside.
billet2.jpg
For this billet I will be using some scrap fine silver I have. I'm weighing it out because I intend to forge this into an 8 inch diameter disk 18 gauge in thickness, so I need the right amount.
For this billet I will be using some scrap fine silver I have. I'm weighing it out because I intend to forge this into an 8 inch diameter disk 18 gauge in thickness, so I need the right amount.
billet3.jpg
The crucible is already hot from prior melts so I can start right in carefully setting some of the silver scrap down in with long tweezers. I don't want to drop it in and risk breaking the crucible!
The crucible is already hot from prior melts so I can start right in carefully setting some of the silver scrap down in with long tweezers. I don't want to drop it in and risk breaking the crucible!
billet4.jpg
The initial silver I had in the prior photo has now melted down and I can add some more.
The initial silver I had in the prior photo has now melted down and I can add some more.
billet5.jpg
In this photo I had just finished adding the remaining pieces of scrap silver. Now I need to wait for it to melt and be fully liquid. I have the unit set for 1015 degrees C.
In this photo I had just finished adding the remaining pieces of scrap silver. Now I need to wait for it to melt and be fully liquid. I have the unit set for 1015 degrees C.
billet6.jpg
The large cast iron pan is to catch any potential spills. Molten metal is dangerous!!! I will be casting into one of the small pans set in the larger pan. The tongs are for grabbing the crucible.
The large cast iron pan is to catch any potential spills. Molten metal is dangerous!!! I will be casting into one of the small pans set in the larger pan. The tongs are for grabbing the crucible.
billet7.jpg
The silver is now fully molten and ready to go!
The silver is now fully molten and ready to go!
billet8.jpg
I'm prepping the pan with my acetylene torch. First heating it up some to make sure all moisture is gone. That's very important!
I'm prepping the pan with my acetylene torch. First heating it up some to make sure all moisture is gone. That's very important!
billet9.jpg
Here I am choking off the air on the torch to alter the flame and carbonize the pan.
Here I am choking off the air on the torch to alter the flame and carbonize the pan.
billet10.jpg
Here you can see the pan with that new layer of carbon. This helps prevent the silver from sticking in the pan.
Here you can see the pan with that new layer of carbon. This helps prevent the silver from sticking in the pan.
billet11.jpg
I do keep the torch on the crucible as I pour to make sure the metal doesn't solidify as I pour. In this shot I've done the pour.
I do keep the torch on the crucible as I pour to make sure the metal doesn't solidify as I pour. In this shot I've done the pour.
billet12.jpg
Here is the billet on the scale weighing in at 353.5 grams. This is 11.37 troy ounces, exceeding the 6 oz required for this BB.
Here is the billet on the scale weighing in at 353.5 grams. This is 11.37 troy ounces, exceeding the 6 oz required for this BB.

You are welcome to check out my blog at http://www.theartisthomestead.com or my artwork at http://www.davidhuang.org

Staff note (gir bot) :

Someone approved this submission.
Note: Great job David!

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