What I'm suggesting is that it is probably a molten metal mix of aluminum and something else.
This Instructable shows a quick and cheap setup to melt a few batches of aluminum for casting before the thin metal equipment starts to break down.
For a crucible (the little bucket that holds the melted metal), a 16 oz propane bottle was used; the top was cut off and some bolts were added for grabbing the crucible with the tongs. I am not sure if I should take you seriously because I don't think steel and aluminum alloy together well. Dad and hubby, paleo food enthusiast, solar energy, boating, making stuff, melting stuff, and raising chickens. By clicking "Sign me up!" you are indicating that you have read and agree to the Terms of service. A charcoal forge for casting aluminum electrodes and casings can be made from a blow dryer and some clay bricks.
I really like many of the propane designs I saw but most people don't have a propane burner or nozzle assembly to spare so I decided that design which leveraged existing BBQ technology would be more widely useful. Charcoal or biochar briquets, the charcoal must be sufficiently formed to rest on the fire grill.
I have been looking for an easy way to smelt aluminum and I do believe I will give this ingenious way a try.
Our county currently has a fire ban and im currently in High School so trying to find the time to do this and a secluded place is really hard, but i plan to use a smaller fan. Please do, I agree that you should be able to get higher prices for ingots although you may have to hunt for it.
One day I went to a party and saw that a hefty amount of aluminum soda cans were being thrown in the trash bin.

Before lighting the fire, place the stainless steel cup (crucible) into the center of the furnace.
Now that the aluminum is cooled, you can either show it off or melt a couple cupcakes down for some sand casting projects! I made a similar version and melted through 2 stainless crucibles, one identical to the one used.
After posting this Instructable I realized that Aluminum Soda cans are a tin-aluminum alloy.
Make sure that the aluminum cans are ABSOLUTELY dry, because if ANY other liquid gets under the melted aluminum, it can explode, creating a hydrogen pocket. You'll need tongs for the crucible, some kind of shepard's hook to tip the crucible when pouring, and a plain rod with a little bend at the tip for poking things and skimming out the dross (impurities in the aluminum).
Melting temperature is far greater for steel, not to mention, you would be melting the crucible in the process as well.
With a bounty of discarded scrap people regularly throw away (found a perfectly good, heavy aluminum CO2 cylinder today!), this is virtually a free hobby.
Leave the blower turned off until the coals are established and have some grey ash on the surface. Aluminum scrap comes in a variety of forms, mostly involving impurities of one form or another.
You can pick up a cheap one at Walmart or Target for around $15 or you can use on that you have.
I have a notice from youtube that says this content has been blocked but it doesn't say where. I've been toying with a modified design that uses a gas burner, solves the refueling and fire control issue.

Sometimes if I didnt have time to wait i would cut the bottom of the can and wipe with a paper towel.
This uses BBQ charcoal as the fuel and a hair dryer as the blower, it'll melt a small batch of aluminum in about 10 minutes. Do this outdoors and use it when it's a little windy so the smoke and fumes quickly dissipate, also use this during dry conditions because dripping molten metal on wet surfaces can cause little hot metal explosions (like water and hot oil in the kitchen).
Keep the lids, one lid should have a 3 inch vent hole in it for burning and the other lid should be left unchanged for snuffing out the fire. You should try casting with just the aluminium, you will problably be surprised how strong it is. This scrap can be reduced to (more or less) pure aluminum oxide (what we commonly call aluminum is actually aluminum oxide) by smelting it and removing the impurities which float to the top.
Also what were you trying to melt, I cut up aluminum cans and didn't have much difficulty. All aluminum scrap contains aluminum oxide - which is a clear ceramic with a melting point of 2000 degrees Celsius (3600 degrees Fahrenheit). Other than that, creating an aluminum alloy would be unpractical, expensive, and highly inefficient., rather than buying the prop.

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