[constant thinker]

I'm currently embarking on a quest to make aluminum ingots aluminum cans. Does anybody know if it would be possible to melt aluminum with a gas (like propane) that is readily available on the market. If not should I build a large oven with bricks, place my aluminum cans in a ceramic crucible, then add wood or coal and use a bellow or fan to make the fire extremely hot. If I have to take the giant oven approach which is better wood or coal?

If anyone here has ever melted down aluminum? Is it easy? Tips are gladly accepted.

[Grumples]

First off, let me say I have never done this before.  However, there are a few things I know that would help:

1) forget about wood.  Even if there is a way to get to 660 C by burning wood (which I doubt) it's going to be very tough.

2) try a microwave: http://www.popsci.com/popsci/how20/15499aa138b84010vgnvcm1000004eecbccdrcrd.html
Contrary to popular opinion, you can put metal in microwaves.  read this article, then maybe go to the link to david ried's website.  Theodore Gray says he manages to bring silver up to 800C, which is more than enough for you.

3) If you want to use gas, try acetylene.  It is cheap and easy to get by combining bangsite (Calcium Carbide) and water.  You can by it online for very little.  Plus, acetylene can go up to a couple thousand degrees (provided you get enough).

4) don't forget to remove the plastic lining on the inside of the cans, or you'll wind up with a big mess.

[Dude]

I would go with your original propane idea and heat it in a steel container, although the microwave idea looks interesting.  The issues are three:

1.  Flame temp - propane and air burns at about 1750 C, acetylene is hotter at about 2200 C - inner cone of flame is the hottest - there should be several sites regarding fuel and flame temp - if not, check an analytical chemistry book

2.  melting temp of aluminum - 660 C

3.  dissipation of the flame heat due to the container holding aluminum.  Steel will conduct heat better than a ceramic material and will not melt until > 2000 C.  You will need an insulating handle for pouring

[jdurg]

At numerous cookouts that I've been to, we've had a bonfire and of course our intoxicated selves decided to put our empty beer cans in the fire.  Sure enough, by the time the fire went out there was a giant blob of melted aluminum cans congealed there at the bottom of the fire.  So I think if you set it up right, a simple bonfire can melt aluminum cans.

[constant thinker]

So this is a feasible idea. Cool. Now I'll proceed by aquiring some jewelers molding stuff. I'm sure it'll suffice for the heat because it says will handle silver casting.

I'm thinking maybe a steel pot coated with carbon (my source would be burnt wood). I put my aluminum in there. Design a steel oven and propane away. My parents aren't to pleased with microwave idea which I've already read about.

Thanks for the help.

[Grumples]

You know, the whole thing about how metal breaks microwaves is just a myth.  The only way you could possibly do any damage is if you put your metal item right next to the microwave generator and turned the thing on for a *very* long time (like an hour or so).

Worst case scenario:
buy a new $50 microwave

[constant thinker]

I know it's a myth but try convincing my parents.  

[Corvettaholic]

The bonfire trick works. The boys and I would drag pallets out into the desert, douse them in 4 gallons of gasoline and toss a match. Pallets have lots of little slats, which is great for air holes and creating quite a draft. Certain parts of that fire got white hot, and when we tossed aluminum cans in there they would melt totally in under a minute. Pretty cool.

[Oldtimer]

I was wondering about that a while back. I found this guys' website and he has posted a few other links. One of them also made his own lathe and turned a few parts out with it.

Anyway, here's the process pretty much from beginning to end.
Tell us if you learn something interesting. I've not done it yet either.

http://www.backyardmetalcasting.com/index.html

Not just Aluminum but iron, brass, and copper can be poured into ingots. They cover a lot of material there.

[billnotgatez]

The web site that Oldtimer posted was great especially the sub-page ----->
http://www.backyardmetalcasting.com/faq.html

[constant thinker]

I've yet to fully browse that page. My expirement will be carried out in winter. My dad won't let me do it until we  have snow on the ground. I don't see why not. Just because I burnt a whole in my lawn when I tried my hand at forging doesn't mean anything. Right guys?

I'll be gathering supplies then doing this in the winter. I'll tell you guys how easy it was, or hard, when I do it so if anyone else wants to try they can.

[savoy7]

just a humorous story:

materials:    1 Al pot
                  water
                  electric stove
                  tired person

Procedure:  
1.  Pour water for making tea into pot.
2.  Place on stove and turn on high.
3.  Sit on couch and fall asleep.
4.  Wakeup 4 hrs later with a metal taste in mouth.
5.  Check stove to find large glowing ball of Al.
6.  Taste buds destroyed for a week and everything tastes like Al.

I forget the rest, maybe it affects the CNS.