From the Foundry: The Iron Pour

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Buffalo,  New York April 10, 2010

The day of the spring iron pour at Buffalo State College is finally here! After nearly a week of preparation, the iron furnace named ‘Betty’ was lit in the morning and Will and other experienced iron casters fed in measured charges of 7 lbs. of coke and 50 lbs. of iron.  Other parts of the team lined up sand molds, ready for pouring.    Read more

From the Foundry: Part III

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Buffalo, NY: April 9, 2010

An eventful day at the Buffalo State College foundry! Final preparations are underway for the iron pour tomorrow.  The newly constructed iron furnace has been lined with refractory clay and assembled.  Supplies of fuel, in the form of coke, a product of coal combustion, have arrived and Eric and Will joined others in breaking up cast iron radiators into small pieces which are easier to melt down.   Many skilled artists have prepared molds for the pour, but I think its safe to say we are the only team recreating parts of the USS Monitor!   Read more

From the Foundry: Part II

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Buffalo, New York: April 8, 2010

Work on the molds for casting replica Worthington pump parts in iron continues with the packing of sand molds around the plastic replicas of the steam chest cover and damping piston cylinder head made at The Mariners’ Museum before we left Newport News.  The sand molds were made by packing a mixture of fine casting sand and two part resin into wooden boxes in which the replica parts were mounted.  One half is packed and allowed to set overnight, then flipped and the process is repeated, resulting in a two part mold.    Read more