I picked up a wonderful little book called "Casting Aluminum" by C.W. Ammen.
Put out by TAB books. ISBN 0-8306-1910-0. Get this book. It tells you
everything you need to know about casting aluminum including building
your furnace and crucibles and molds. He also has a companion book
on Brass/Bronze.
From what he says, I doubt charcoal would be practical. He recommends
smelter coke, natural gas or oil. He shows how to built several suitable
gas burners and furnaces.
I have melted aluminum, a couple of pounds at a time, in our glass/ceramic
kiln. Works well but is slower than a true metal furnace. I made the
crucible out of Lizella Clay (red pottery clay) but an iron pot should
work well, something like a Dutch Oven or something. I had the clay but
no iron pot.
I doubt pistons would work very well. Too much silicon. Aluminum blocks
and heads DO work well. A source of green sand and refractories is
A.P. Green, a national distributor that has offices in most major cities. [/QUOTE]
Then Here?
Aluminum Melting
And more information here.
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