Application2018-06-08T09:10:09+00:00

ALWA MOULD D Application

Patterns and its preparation

A wide range of materials are appropriate for the cast (wood, plaster, plastics, leather, metal, acrylic, etc.). Polystyrene is less appropriate since it requires special precautions. Any material must be dry. In order to cast the material a casting box must be built around the pattern. The sides of the casting box are fixed with screws. Porous master patterns of plaster or wood must be sealed. We recommend to use our ALWA ACRYLIC SEALER (art. no. 9535000). Any pattern must be pre-treated with ALWA SURFACE TENSION REMOVER (art. no. 9500000), which removes the surface tension and ensures a smooth coverage of ALWA RELEASE LACQUER (art. no. 9510000). First, a thin layer of ALWA SURFACE TENSION REMOVER is applied on the prepared patterns with a cloth. After approx. 5 – 10 min. the ALWA SURFACE TENSION REMOVER is vented. Then, ALWA RELEASE LACQUER is applied with a brush or a spray gun. For fine structures several layers (min. 3 – 4) should be applied with a spray gun. ALWA RELEASE LACQUER is soluble in water, therefore, moisture penetration should be avoided. Hot air can accelerate the drying of the release film (the drying of the release film takes approx. 30 min. at RT).

Before casting, make sure that the pattern and the mixture of casting resin and aluminium powder have a temperature between 19 – 22 °C. At temperatures above 22 °C shrinkage may arise and at temperatures below 19 °C the cast material expands.  

Calculation of a batch quantity

a) Calculate the casting volume in litre. In order to compensate casting losses and miscalculations, we recommend increasing the batch quantity by approx. 5 %
b) Multiple calculated casting volume by 1.7 to receive the batch quantity in kg.
c) Batch quantity in kg corresponds to

  • 40 kg resin content ALWA MOULD D, comp. 1 + 2 and
  •  60 % aluminium spray grit, < 65 mµ.
d) Example: 20 litres x 1.7 kg = 34 kg casting compound

ALWA MOULD D component 1,
ALWA MOULD D component 2,
Aluminium spray grit, < 65 mµ,
Hardener powder( 3 % on the resin content)

Art. no. 6000…
Art. no. 6001…
Art. no. 4065025
Art. no. 5100001
13,33 %
26,67%
60,00%
3 % on the resin content
4,53 kg
9,06 kg
20,41kg
0,41 kg

Processing

Mix the resin components well. Afterwards add the filler into the resin and stir until you reach a homogeneous mixture and no aluminium lumps are left. Leave the finished mixture for venting until no more air bubbles appear. After airing, carefully stir the mixture. Then thoroughly mix in the hardener powder (3 % on the resin content) for approx. 3 – 5 min. Lumps of the hardener powder must be crashed before adding it into the mixture. Please note that as little air as possible should be stirred into the mixture. For larger batch quantities mix the resin compound in two or more mixing containers. In this case, the hardener powder must be added simultaneously. For homogenisation, the resin compound of two or more mixing containers has to be mixed among each other to achieve a simultaneous curing of the mixture. Only then you get a homogeneous hardener and temperature distribution (same reaction behaviour of the total mixture).

As the resin contains flammable solvents, ex-proof mixers should be used. We highly recommend using our ALWA SPECIAL MIXERS since they ensure that as little air as possible is stirred into the mixture. After the hardener has been stirred into the mixture and vented for 3 – 5 min., the mixture must be cast in a thin stream within 8 – 10 min. on the prepared pattern. First, the mixture is poured slowly into the deepest part of the pattern. In order to prevent that aluminium lumps are cast into the mixture, a sieve can be used. When the pattern is completely covered with the mixture, the rest of the material can be added faster. The curing process should be protected from the effects of cold and heat. After adding the hardener powder, the resin gel time starts after approx. 18 min. and a fast temperature increase can be noticed. The resin compound cures just as quickly. Reaction temperatures up to 130 °C can be reached. Since the resin compound cures quickly, patterns of wax can also be moulded. After the resin compound is cured, approx. 50 min. after the hardener powder has been added, the backside of the mould is sprinkled with aluminium spray grit, which then is spread with a hand brush (prevents a sticking at the back of the surfaces). Tools and containers should be cleaned with a solvent (e.g., acetone) directly after using. Before the temperature peak has been reached, the mould expands in length. Therefore, the screws of the casting box sides are removed to enable a free expansion. Cast drive-in nuts are very useful for demoulding. Depending on the master pattern it might be reasonable to wait until the cast has been cooled down to 60 °C or to RT.

Mixing table:

Weight of batch quantity ALWA MOULD D Aluminium spray grit, <65 mμ Hardener powder
comp. 1 comp. 1
kg kg kg kg gr
1 0,134 0,268 0,600 12,00
5 0,667 1,334 3,000 60,00
10 1,334 2,668 6,000 120,00
20 2,667 5,334 12,000 240,00
30 4,000 8,000 18,000 360,00
40 5,334 10,668 24,000 480,00
50 6,667 13,334 30,000 600,00
60 8,000 16,000 36,000 720,00
70 9,334 18,668 42,000 840,00
80 10,667 21,334 48,000 960,00
90 12,000 24,000 54,000 1080,00
100 13,334 26,668 60,000 1200,00

Place the warm casting (especially flat moulds) immediately on a flat surface for cooling. For thin moulds a closed casting box should be used. Alternatively, they can be clamped on a level surface. While the mould is cooling, it shrinks to its original shape. Leavings of ALWA RELEASE LACQUER can be easily removed with warm water. The moulds are easily machinable (e.g., drilling, milling, grinding, planing, sawing, turning, etc.). Holes can be drilled in the mould and threads can be cut. But it is more effective to pour screws or nuts in the mould. Due to the dust development during the application, an extraction system should be used. After wet sanding and applying a polishing paste by using a polishing wheel, you get a metallic shiny surface. Small repairs can be conducted with our ALWA REPAIR FILLER (art. no. 3050001). The damaged area should be roughened and cleaned before applying ALWA REPAIR FILLER. In order to drill vacuum holes, we recommend using our ALWA DRILLS (art. no. 9006000).

Please consider the different thermal coefficients of linear expansion if something is screwed on the mould or the mould is screwed on a plate. Drill larger holes for the screws into the material, so that the moulds can expand.

Tips & Tricks:

Problem Cause Solution
Long pot life The mixture was too cold and the filler sedimented. Pour the mixture at a recommended temperature of 19 °C – 22 °C.
Too little hardener was used. Be aware of using the right quantity of hardener.
Resin content at the backside The mixture was too cold and the filler sedimented Pour the mixture at a recommended temperature of 19 °C – 22 °C.
Weak edges
Deformed casting This effect may occur for flat moulds, which were openly cast. Due to the open casting the heat escaped too fast Cast in a closed casting box and demould the casting whilst they are cold or demould whilst they are hot and clamp them on an even surface.
Narrow edges and bars break Strength of the casting compound was insufficient. Attach aluminium perforated sheets to the casting box as reinforcement material and, afterwards, recast with casting resin.
Cracks in the casting Material was cast in a closed metal frame or big steel  or iron parts were poured in. Open metal frames diagonally after gel time
Use aluminium as reinforcement material.
Blow-holes in the casting Mixture was not mixed homogeneously. Lumps or residues were cast. Pour through a sieve. Mix batch and hardener homogeneously.
Casting has a great shrinkage Mixture was too warm or mixed incorrectly. Work exactly according to the mixing table. Pay attention to the temperature.
Thermic expansion was not considered and the mould was not given enough space for expansion. Open the casting box at an early stage in order to ensure a flawless expansion.
Sides of the casting collapse at the backside Mixture was too warm. Mix at required temperature.
Distortion This effect can occur with flat moulds. Attach aluminium perforated sheets to the casting box as reinforcement material and, afterwards, recast with casting resin. After demoulding clamp the casting.
While curing, open capillaries and indentations occur (after the reaction has been completed) Hardener was not cast homogeneously. Mix the hardener homogenously into the batch. Do not scrape off the floor and wall residues and use them for the cast.
While using several mixing containers, the content was not mixed together. When several mixing containers are used, mix the content together in order to get a homogeneous compound.
Cracks occur during production Materials with different thermal conductivity were used. Drill larger holes for the screws, so that the different thermal expansion coefficients can expand.
The backside of the casting was not plane. Backside of the casting must be plane.
The surfaces of the edges of the vertical walls are very rough The ALWA RELEASE LACQUER was not dry or too many wax residues were left. Dry ALWA RELEASE LACQUER with hot air (e.g., hair dryer). Remove the wax residues from the edges of the vertical walls before casting. Plaster should be dried and sealed.
Porosity of the mould Material was not sufficiently vented. Vent the material long enough. This is especially important for big batch quantities. We recommend using our ALWA SPECIAL MIXER (which prevents that air is stirred in).
Problem
Long pot life
Cause
The mixture was too cold and the filler sedimented. Too little hardener was used.
Solution
Pour the mixture at a recommended temperature of 19 °C – 22 °C. Be aware of using the right quantity of hardener.
Problem
Resin content at the backside Weak edges
Cause
The mixture was too cold and the filler sedimented
Solution
Pour the mixture at a recommended temperature of 19 °C – 22 °C.
Problem
Deformed casting
Cause
This effect may occur for flat moulds, which were openly cast. Due to the open casting the heat escaped too fast
Solution
Cast in a closed casting box and demould the casting whilst they are cold or demould whilst they are hot and clamp them on an even surface.
Problem
Narrow edges and bars break
Cause
Strength of the casting compound was insufficient.
Solution
Attach aluminium perforated sheets to the casting box as reinforcement material and, afterwards, recast with casting resin.
Problem
Cracks in the casting
Cause
Material was cast in a closed metal frame or big steel or iron parts were poured in.
Solution
Open metal frames diagonally after gel time
Use aluminium as reinforcement material.
Problem
Blow-holes in the casting
Cause
Mixture was not mixed homogeneously. Lumps or residues were cast.
Solution
Pour through a sieve. Mix batch and hardener homogeneously.
Problem
Casting has a great shrinkage
Cause
Mixture was too warm or mixed incorrectly. Thermic expansion was not considered and the mould was not given enough space for expansion.
Solution
Work exactly according to the mixing table. Pay attention to the temperature. Open the casting box at an early stage in order to ensure a flawless expansion.
Problem
Sides of the casting collapse at the backside
Cause
Mixture was too warm.
Solution
Mix at required temperature.
Problem
Distortion
Cause
This effect can occur with flat moulds.
Solution
Attach aluminium perforated sheets to the casting box as reinforcement material and, afterwards, recast with casting resin. After demoulding clamp the casting.
Problem
While curing, open capillaries and indentations occur (after the reaction has been completed)
Cause
Hardener was not cast homogeneously. While using several mixing containers, the content was not mixed together.
Solution
Mix the hardener homogenously into the batch. Do not scrape off the floor and wall residues and use them for the cast. When several mixing containers are used, mix the content together in order to get a homogeneous compound.
Problem
Cracks occur during production
Cause
Materials with different thermal conductivity were used. The backside of the casting was not plane.
Solution
Drill larger holes for the screws, so that the different thermal expansion coefficients can expand. Backside of the casting must be plane.
Problem
The surfaces of the edges of the vertical walls are very rough
Cause
The ALWA RELEASE LACQUER was not dry or too many wax residues were left.
Solution
Dry ALWA RELEASE LACQUER with hot air (e.g., hair dryer). Remove the wax residues from the edges of the vertical walls before casting. Plaster should be dried and sealed.
Problem
Porosity of the mould
Cause
Material was not sufficiently vented.
Solution
Vent the material long enough. This is especially important for big batch quantities. We recommend using our ALWA SPECIAL MIXER (which prevents that air is stirred in).

Important notes to ALWA MOULD D:

ALWA aluminium powder
Our aluminium powder does not sediment during the pot life. Therefore, only our ALWA aluminium powder should be used.

ALWA mixer
With our mixers nearly no air is stirred in. The material is mixed from bottom to top. The hardener is stirred in quickly and homogeneously.

Temperature resistance of additional materials
The expansion coefficient of materials which are attached to or in the casting box should be equal to that of, for example, copper pipes and perforated aluminium sheets. No steel or wood shall be used.