Newsboy Sculpture for the Texas Press Association


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March 8-15, 2005
The Metal Pour

The oven melts the ingotsIt was exciting to get a call from the foundry, “We are going to pour tomorrow, if you want pictures come on by.”

The foundry was a buzz with activity. The furnace roared in the corner announcing the event. The craftsmen had just poured one set of bronzes, which were glowing red on the pouring table. I shot some pictures of the glowing bronzes and then spoke with Scott, the foundry owner, about the rest of the process.

The furnace is heated up to 1,950-2,150 degrees. Everdure bronze ingots consisting of copper 95.0%, manganese 1. %, silicon 4%, and other trace elements were resting on top of the lid of the furnace. I was told that it was important to heat them up and make sure there was not any moisture in the ingots. If there happened to be any moisture in an ingot when it was added to the molten bronze, a steam explosion could happen causing molten bronze to go everywhere. We had to wait a good 45 minutes for more bronze to melt before we could see the second pour.

The oven melts the wax from the shellsMeanwhile, remember our dipped pieces of wax that were covered in a shell? The wax is burned out of the shell in a furnace, thus the term “lost wax method” of bronze casting. Once the shells are heated up again (the 1,200 degree furnace is shown to the left) they are ready to receive the molten bronze.


Pouring into the shellThe heated shells are poured while they are balanced in a pouring table. This table, filled with sand, helps to contain any bronze that should come out of cracks, should our shell have some problems.

The crucible holds about 140 pounds of molten metal. Scott tells me that it is not just the heat of the process that is tiring but also the lifting of the heavy crucible. For safety reasons they only pour 3-4 crucibles a day. It takes three people to pour. Someone guides the crucible – the lead pourer, while the second person helps with balance- the deadman. A third person is there for safety and skims the crucible of impurities before it is poured.

hot shell after pourBefore we knew it the pour was done! Our shells had no problems and held all of the bronze quite nicely. After an hour or so the pieces are removed from the sand pit for devesting. With hammers and chisels the shells are carefully broken off of the newly cast bronze pieces. All of the gates and cups that poured with the bronze art will need to be removed and the pieces will be sandblasted.
After the pieces are cleaned, up the next step is welding these puzzle pieces together.





If you would like to read more about the bronze casting process Sarah Malone has written a very informative article about the Bronze Casting Process which includes historical information and the Artworks Foundry website has a detailed description of the traditional process.

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