Building the Felgiebel

Help Support HMEM:

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
I cannot fiish the cylinders until some material is delivererd. So I'm moving forward to the cylinder head. This will be an alu casted part again. If it works ;) I started creating a computer model and let it print on the 3d printer.

(Don't blame about the printing quality ;-) My 3D printing guy switched to a new filament vendor and this requires some adjustemt to the printing paramters for proper results. In the meantime now I have about 5 cylinder heads and they are looking better from print to print)

IMG_20180314_190851.jpg
 
Last edited:

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
I tried to build the cylinderhead via lost wax technique. Therefore I created a 3D printed model made of Moldlay.

IMG_20180405_182111.jpg


IMG_20180405_182206.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
I put it into some leveling compound and lety it dry. Then I put it into the curing oven and sloooooowly increased the temp to 270°C to let the wax melt out. This took about 2 hours, but the wax dropped out completeley. Great, so far.

IMG_20180406_121925.jpg


IMG_20180407_092217.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Highly motivated, I moved on to the casting process.

IMG_20180409_164104.jpg


IMG_20180409_164251.jpg


IMG_20180409_164307.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
But the result was very disappointing.

It looks to me that the Alu was not able to push out the ambient air. Perhaps I filled it in to fast. I don't think the Alu cooled to fast, it came out very "liquid" from riser. Alu was at 700°C, the mould was pre-heated to 200°C, I used some salt as flux and wash soda for degasing.

I'm not sure where the problem resides. Maybe there is more than one :confused:
Or it is even not possible to make it this way :(

Any comments and suggestions are welcome!

cheers,
Robert

IMG_20180410_083732.jpg


IMG_20180410_083737.jpg


IMG_20180410_083818.jpg
 

RonGinger

Well-Known Member
Joined
Nov 11, 2008
Messages
903
Reaction score
122
Location
Boothbay Maine
I have been told that you must use a vacuum under the flask to pull air out of the investment. I was able to spend a few days in a professional investment shop and all their flasks were perforated and placed into vacuum containers before pour.

For small items jewelers use centrifugal spinners to throw the metal into the mold, but I think your part might be to big for that.

I also saw a write up of a n idea to use s team force. A cover is made for the flask and has a big wad of wet newspaper in it. As soon as the metal is poured the cover is placed over the flask and held down so any steam generated forces the metal into the mold.

Bottom line is gravity alone is not enough to get metal flow fully into the mold.
 

Mechanicboy

Well-Known Member
Joined
Jul 10, 2013
Messages
691
Reaction score
227
Die casting is the last solution.. There is 2 difference die casting: Low pressure die casting with air pressure or high die casting with piston.

low-pressure-die.jpg


high-pressure-die.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Hi Ron,

thanks for your thoughts. Especially the steam method looks interesting dangerours. There are some videos around where they press a can filled with moist paper on the mold. This is only for the brave ones. ;)

The centrifugal method you mentioned looks feasible to me. I will have to do some investigation about this. I think I should be able to handle it.
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Die casting is the last solution.. There is 2 difference die casting: Low pressure die casting with air pressure or high die casting with piston.
Hi Jens,

at the upper picture, there are no ejectors where the air can leave. Does this require a porous mould where the air can get through?
 

Mechanicboy

Well-Known Member
Joined
Jul 10, 2013
Messages
691
Reaction score
227
Hi Jens,

at the upper picture, there are no ejectors where the air can leave. Does this require a porous mould where the air can get through?
It must be ejectors to reduce air pressure inside when the molten meatai is pressed into the mould. Mould an be made of steel or similiar material. The ejectors are smaller than you find in sand casting.
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Thanks for all of that casting hints and tips. I will have to think about this in a quiet minute. In the meantime I will proceed with activities that I am familiar with. I started silver soldering the transfer ports and the intake.

IMG_20180413_154519.jpg


IMG_20180413_154541.jpg


IMG_20180413_163205.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Putting them into 65°C sulfuric acid (about 12%) greatly removes the flux.

IMG_20180413_170057.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Silver soldered the water jacket and pipes.

IMG_20180415_190523.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Mounted and centered it on the lathe and used a fresh sharpened HSS turing tool. Unfortunatley I have no internal grinding tool.

IMG_20180416_212510.jpg


IMG_20180416_214056.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Unexpectedly found some time yesterday :) Time to build the cylinder head for the water cooled version.

IMG_20180418_141816.jpg


IMG_20180418_150357.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Flat countersink and drill the holes on the milling machine and final turning.

IMG_20180418_154726.jpg


IMG_20180418_155802.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Put it all together. Slowly it takes shape.

IMG_20180418_165848.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Now beginning to work on the crankshafts. I will build them of C45 to harden and temper the pin. They will be pre-turned and later grinded.

IMG_20180420_185035.jpg


IMG_20180420_191902.jpg


IMG_20180420_204300.jpg


IMG_20180421_105642.jpg
 

rweber

Well-Known Member
Project of the Month Winner
Joined
Nov 18, 2014
Messages
97
Reaction score
101
Facing and centering the back-side.

IMG_20180421_134337.jpg
 
2

Latest posts

Top