For casting aluminum, you need a finished model, "in the image and likeness" of which the Viking sword will then be cast. In this case, an ordinary cheap Chinese plastic toy is used as a prototype, which will first need to be divided into two halves.
A sand mold and a molten aluminum mixture into which molten aluminum will be poured will require a wooden flask. You can do it yourself - for this you need boards of a suitable size, from which a rectangular box without a bottom is made. As fasteners, you can use nails or screws.
The main stages of work
To prepare the molding mixture, quartz sand is required. Unlike the river, its granules have sharp edges, which positively affects the strength of the form. It is also necessary to prepare liquid glass and a suitable container for kneading. When adding liquid glass to sand, the main thing is not to overdo it. You need to add it in small portions, mixing the solution until a homogeneous wet mass.
Ideally, the model of a Viking sword should be divided into two halves: one is laid on a flat surface and tamped with sand from above, after which it is turned over and joined with the second half (for example, using double-sided tape). Then it is covered with the second part of the flask and is also rammed with sand.
If you cannot split the toy sword in half, then you can go the other way - the model will have to be pressed into the already compacted sand, after which it is covered with the second part of the flask and covered with sand. In order for the moldable mixture to become solid, it must be "blown" with carbon dioxide. Then the surface is sprinkled with talc.
Aluminum casting process
After drying (about 12-15 hours), the finished form is disassembled and holes for the sprues are drilled. Then you need to melt the aluminum and pour the mass into the sprues, starting from the narrow part - the blade of the sword. This is followed by a stage of machining, during which all sagging and irregularities on the surface are removed. At the last stage, a layer of copper is electrolytically applied to the handle.
