Zinc anode manufacture

yoda

yoda

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I am trying to make a new anode which is just a straight bar with 2 fixing holes. I have the old anode which can be reused to provide the steel backing bar, I also have plenty of spare material from old anodes. Question, what is the secret to putting enough heat into the raw material to get it molten. Is the easiest way to break down the zinc to small pieces and start the smelt with a small amount while adding more material slowly before pouring into the mould?

Also apart from sand what other materials can be used to make a cheap single use mould?

Is a regular blow lamp powerful enough to do this?

Thanks, yoda
 
yoda said:
I am trying to make a new anode which is just a straight bar with 2 fixing holes. I have the old anode which can be reused to provide the steel backing bar, I also have plenty of spare material from old anodes. Question, what is the secret to putting enough heat into the raw material to get it molten. Is the easiest way to break down the zinc to small pieces and start the smelt with a small amount while adding more material slowly before pouring into the mould?

Also apart from sand what other materials can be used to make a cheap single use mould?

Is a regular blow lamp powerful enough to do this?

Thanks, yoda
Click to expand...

Probably better to cut the old anode into pieces.

Avoid overheating the zinc or you may produce zinc ( oxide) fume which is hazardous. Work in an area with good ventilation eg outdoors

The melting point is about 418C.

Make sure you are aware of the hazards of handling and casting molten metal. Moisure in a sand mould can be very dangerous.


There is already a thread running on this topic..."Recycling zinc" q.v.
 
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Only ever worked in lead but the melting point of zinc is in the same order of magnitude. I used to use a metal bucket to melt scrap lead in over a large gas ring. I just used to put the bit of scrap lead into the bucket and let it heat up. It'd take a while to get hot and then suddenly melt, pretty quickly - think ice into hot water. I'd say you should be able to do the same with zinc. A blow torch will get hot enough to melt the metal if its a fairly small quantity - I was making diving weights, so was using about 20 - 30 kilos a time.

Sand is OK for mould but it must be dry - the stuff used by professional casters is not really sand at all. If you pour molten metal onto water, it'll boil in a spectacular fashion and spray molten metal all over you, so do take real care about handling it - good gloves, long sleeves, eye protection are essential.

I've used tin cans before now to make moulds. Crimp the seams, as the metal is too hot for solder.
 
Only ever worked in lead but the melting point of zinc is in the same order of magnitude
Click to expand...
.mpt of lead is quite a bit lower than that of zinc. 327C compared with 418C

AFAIK there is no problem with oxide fume when melting lead as there might be when melting zinc.

( I cast my lead sounding weight in a cardboard mould but it would not do for zinc)
 
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