Ducks in a Row and Bevel Gears.

by John

Another small bronze pour yesterday, and it was my best one yet.  No bubbles.  No voids.  And excellent surface definition.  What did I do that was different?

First, the 3D parts were printed already attached to the tree.  So the trunk and branches were 3D printed with the parts attached.  That meant that I could determine more accurately the bronze flow, the gaps, the spaces.  The only “failure” was that I added some wax air vent sprues as an afterthought.  And those wax parts were the only part of the pour which failed.  Fortunately, the absence of the gas vents did not seem to matter.


The 3D printed tree. There are 9 PLA brackets ready to be replaced by bronze. I increased the height of the trunk for extra melt pressure. The air vents failed, and were not needed anyway.

Next, I painted the tree with a slurry of investment. The slurry was much more watery than the normal investment, but it was thick enough to leave a thin layer of investment on the surfaces, paying particular attention to the corners and internal edges.

Then I used my new, 1 hp vacuum pump to degas the investment mixture. It took about 15 seconds to reach maximum negative pressure, compared with about 1-2 minutes which the 1/4 hp unit was taking.

Then, after pouring the investment, I placed the full flask containing the tree and investment, and degassed the entire unit. I was shocked at how much extra air bubbled out.

The rest of the process was as usual, drying for 4 hours (except that this time it started at 6am, having put the process on an automatic start timer), burnout 2 hours, and baking 3-4 hours.

The cast tree was looking hopeful. And not much surface oxidation to see. (I had given the 15% phosphor copper a full 2-3 minutes to work this time.)
….and there are my brackets. 9 ducks in a row. They need a bit of filing, and some time in the gemstone tumbler.


Top is a bevel pinion as it arrived, and a mandrel which I made. Middle row is an unmodified bevel gear which is too big for the case. Bottom row is a machined bevel gear which now fits into the case, and a pinion on shaft, which also fits into the case.

While the investment flask was cooking, I experimented with the bevel gears which move the cannon barrel elevation. I had cast some bronze gears, teeth and all, some weeks (or was it months?) ago, but was not happy with the result. So, I had bought some bevel gears on Ebay. They are spare parts for an RC model car. Not quite the correct size, but close. The metal is HARD. Sintered? But, machinable with carbide cutters.

It all now fits.

Now before you all start shouting at me to make the bevel gears from scratch, let me just say that I might do just that. Not yet decided.