Fluxing a melt, how do you do it

fingers284

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Lots has been said in this forum and the other about "what to use" as a flux but after watching the u-tube vids in the "doing it wrong" thread I noticed a couple or three different methods being used that differ from what I was taught. I searched for some info but there isn't much out there that I could find providing the "how to" info. Even the Fryxel/Applegate book on casting (some consider this the "casters bible") went into great detail on what to use but very little on how to use it effectively.

when I was first introduced to casting (very early 70's) by a buddy, the method he used (taught to him by his dad) was to drop a gob of paraffin into the melt, strike a match to light the smoke (we did this in his house porch, new wives were a lot more "understanding" back then) then mixed it vigorously for 30 seconds or so and then skimmed the crud off & done. Fryxell, in his book states that wax is basically a poor flux (it only accomplishes one of the 3 requirements of a good flux), he says that plain sawdust is the best non-commercial flux to use and he also says (his only reference to " how to") is to mix in a large helping. This brings me back to the vids...most every one of them show the operator using sawdust but they just pour it on top of the melt, smooth it out and then let it smolder for a while then remove the scum...no mixing in at all.

I have used the wax method, the sawdust method and recently, when Monty visited we used his Marvelux . Using the "drop in & mix vigorously method, We did a couple of melts using my sawdust and a couple of melts using his Marvelux. The Marvelux was quicker to use, produced a very clean melt however I will add that Fryxell claims that Marvelux only does two of the flux requirements, the one it misses is that it doesn't facilitate the re-instatement of other metals back into the mix...namely antimony & tin, so it is easy to skim these very important additives from the melt with the unwanted crud. The sawdust was much harder to clean from the surface but when you were done the ingots are very clean.

Enough of my rambling...how do you guys do it, stiring or floating.
 
The only way a flux works is to have it get in contact with the lead. Sawdust a true Flux removes impurities, it must be stirred through the lead. Wax usually used to "re-disolve" oxidized tin back into the mix. No thorough stirring needed as it only affects what is on the surface of the lead.

Marvelux...follow the instructions that come with it.
 
X2 for marvelux.

I also use sawdust, but I'm fussy.... I only use cedar sawdust. And I only use it to coat the top of molten lead in the bottom pour pot. I "think" it helps with keeping the oxidization to a minimum. When it's time to add a bit more lead, I drop it through the ash, stir it in, add marvelux, stir, then skim, then top with a 1/4" thick layer of sawdust.

Cheers!
 
I tried different methods and stopped after getting Marvelux.Amazing stuff and lasts forever.Mo mess,no smoke,no noxious vapours,no flames.Marvelous :)

Tip-use less than you think you should and flux it more often than you think you should.

For me melting lead and preparing it for pour is much like cooking-you have to do things at proper sequence and timing is everything.Once you get it right you will laugh ta how easy it is.

Also just like cooking practice is king.You can't replace it.Do it again,and again until you figure out the pace.
 
I primarily flux to keep the antimony and tin content in my alloy so I use wax. I find it works better if you don't light it, but it smokes bad and if you do it indoors you need LOTS of ventilation.
 
I just read some more info on the Marvelux product printed by Mr Fryxell, a chemist. If I were using Marvelux as a flux I would want to have a supply of clean tin to add to my mix after fluxing. Fryxel claims it (and it is formulated to do so) removes all metal contaminants from a melt including the tin. If you use Marvelux you are removing all the tin from the melt...it cant be avoided according to him.
 
I don't know how you would 'mix' sawdust into the melt. It doesn't mix because it's many times lighter than lead alloy, and it will simply float on top no matter how hard you try to mix it in. You only have to stir the pot with the sawdust on top and let the impurities move to the sawdust, not the other way round. BUT - most of the impurities float because they also are much lighter than the lead alloy. So mixing the sawdust into the melt - even if it were possible - isn't needed anyway.

I don't use Marvelux because I don't want to lose the antimony and tin. Sawdust will also leech the free antimony if you don't let it burn to ash before skimming. Wax is easier that way.
 
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I think I'll source some sawdust to use in my outdoor melter. Does it matter what kind it is hardwood, softwood etc? I suppose anything from laminates should be avoided due to the glues/binders.

M
 
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I go to the pet store and buy pine shavings.

Wood shavings? I though it needed to be fine sawdust that smothers the lead surface?

Have we gone full circle with wood product fluxes and arrived back to "just stir it with a stick"? LOL

M
 
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A lot of people use the wood stick when they are casting bullets. This keeps the mess and fumes out of the house ;)

When I am processing wheel weights and such I use lots of pine shavings, two three times.

I use bees wax in the pot when I'm casting bullets
 
I just melted my first batch of alloy last week, after reading up on casting and melting for a long time across many sites and resources. I have wood shavings to use for flux and what I did was put a decent amount on top and stir my pot enough to make sure much of the melted alloy was exposed to the shavings. The shavings browned and blackened but did not burn, and I was able to scoop them out fairly easily. I did this several times before casting ingots and found the end result to look quite nice, I was happy with the results but have much to learn still... it's great to see discussions like this pop up.
 
Like others said sawdust for smelting, any old stuff i can find two or three times and stirred in scrape sides. I doughted this too, just be patient and you will see, let it go to ash. I have used potato chips too about the best so far but expencive. Also when i added flux core solder i got very clean ingots.
when casting i use wax, good wax like paraffin or bees them cheap candles dont cut it. After i stir it in i leave the dust on top the odd time it gets " gloppy" then i know to re flux, the hotter you cast the more you flux.
Be safe
 
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