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Imagemaker Arts & Collectibles
Bronze Foundry
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Shells are heated to temperatures near 1800 F. for elimination of carbons and other impurities, and to accept a 1950 degree F. pour of molten bronze. Without this stage, the hot bronze would freeze short of it's final destination in the mold, thus leaving little or no detail.
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When the bronze temperature attains it's pouring temperature, the shell molds, are removed from the burnout oven, and placed correctly into the pour-bay shown on down below. This must be done very swiftly, leaving no excess time for the shells to cool to an undesirable temperature. This is a very hot operation, and requires a lot of heat protection. Kevlar gloves, face and neck shield, etc.
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The bronze is then removed from the induction furnace that is glowing to the right of the crucible, and hoisted onto a refractory cement pedistal in the pour-bay with a hand crane that I designed and built for handling 50 to 100 lbs. of molten bronze safely by myself. I have nearly a 5 to 1 torque ratio placed on 1 arm, while I position the crucible in the correct direction with the other arm. There is a flash fender installed on the left front of the crane which will prevent spill or burn hazard (Not shown here) The cart also is bottom weighted for stability. This crane has been tested to 400 lbs.
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The last step prior to pouring, is to remove the slag impurities which float to the top and sides of the crucible. A rock will float in bronze, as the bronze is a much heavier mass of elements. Thus plasters, dirt, carbons, unwanted gases lightweight elements, and the flux which you use to collect these impurities, can be "dredged" from the top, leaving a clean and pure pour. Again their is to be no waste of time.
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"The Pour" is probably the most interesting to the onlooker, but with all bases covered by the founder, is the easiest part. The pour is slow and constant into the two shell molds, but probably doesn't take over 20 seconds. I have worked 28 hours on this sculpture at this point, so all I want is a good bronze. Notice in this photo how the shank has been glided along a railway rail allowing me to handle this 50 # of bronze. The entire process takes just a little over 1 minute.
CHASE TO FINISH
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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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