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Imagemaker Arts & Collectibles
Bronze Foundry
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This is a picture of a slurry tank with the lid removed. It is mixed with a time controlled stir, operating around the clock, keeping it in constant suspension for quality use at any time. It runs about one half of the time, set on 5 minute intervals.
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The wax is dipped into the slurry for the first stucco coating, and any air bubbles removed. Brushing them out has proven the most effective way for us. High detailed artwork can hold a lot of air in the crevices and can create a lot of extra work later.
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With the first solution of slurry drained to a mild drip from the wax, The first coat of stucco is feathered on very evenly and precisely. This is the most important of all of the 10 coats that are being applied. In this case we are using zircon sand, which is probably the finest and heaviest sand you will ever see.
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These three photos show the different stages of stucco application; from the zircon sand to heavy grained fused silica. As explained, the first coat and even the second in many cases are of fine zircon sand. The third is usually of a medium grade of fused silica, with the approximate consistency of sugar. The fourth through the ninth coats are usually a heavy fused silica with the consistency of heavy salt. Each of the ten coats are applied in nearly the same manner; by dipping them into the slurry and then applying the stucco. Each coat gets heavier and much harder to handle . A two pound wax weighs about 20 pounds after it has ten coats applied. The shell is properly dried between each of the 10 coats.
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Finally a seal coat of the slurry is applied, for sealing the stucco and is dried for the wax removal and the burnout cycle of the shell at high temperatures. When properly burned out the shell is as white on the inside as it is on the outside. During the burnout, the high temperature causes the shell to go through a vitreous stage making it a lot stronger for receiving the molten bronze. WAX BURNOUT
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Please E-Mail us or call us at 417-781-3446 for imformation about a free on site tour, or information about collecting our Bronze
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