The guys with the electric foundries, what is the experiance with those ? It seems like a less noisy/intrusive way to melt aluminum,
what kind of quantity are you able to smelt down ?
Do they get hot enough for other materials? (Regarding home job, 30-40a 220)
Do you think it's more or less expensive than propane/oil per kg of melted material ?
I used to use propane with a fan for air. I found it expensive and a pain to get the 100 lb tanks refilled. A 20lb tank would only last for a few sessions.
Once I had natural gas run to the house I had them extend a pipe to where the foundry sits. Changed jet sizes on BBQ and on the foundry. Now it's walk up to it, press the start button and run. The size of the gas meter installed was double the size of the normal household gas meter so I can run a 250K BTU home heating furnace and a 250K BTU foundry at the same time.
Mine is the Gingery Furnace and the refractory is the type rated for cast iron but as yet haven't done that. The highest temp has been for bronze.
I have a kiln now too. Working on an electric control for it (Project #42). The testing I've done suggests it will be fine for aluminum.
I have a 6# silicon carbide crucible which gets the most use. An 8# never used and a 12# pipe crucible for one large casting I need to do and mostly just to reduce large chunks of scrap metal.
I only use green sand. Don't like the smell of oil based sand, don't have a muller to reconstitute it. Don't do lost foam for the same smelly reasons. I do have a sand fluffer I made which breaks down the lumps in drier sand. I find if I add water and mix a few days before I cast that the moisture in the sand evens out over the entire container.