This video introduces soluble fiber blanket as a healthier and more environmentally friendly alternative to traditional ceramic fiber blanket for constructing high-temperature chambers, noting its 1200°C rating. The creator demonstrates a refined process for building a metal melting chamber, highlighting key changes such as avoiding boric acid due to its potential to degrade fiber and sanding the chamber with the internal support cup in place for better shape retention. The newly built chamber is then rigorously tested. It performs exceptionally well for melting aluminum over multiple uses, showing minimal wear. However, when attempting to melt iron, the soluble fiber chamber catastrophically melts and forms a large hole, preventing the iron from reaching pouring temperature. The video concludes that while soluble fiber blanket is an excellent and preferable choice for aluminum melting, it is not a suitable replacement for ceramic fiber when dealing with the higher temperatures required for iron. The creator plans to use soluble fiber for larger, less intensely heated microwave kilns and possibly a larger aluminum melting chamber.
Exploring Soluble Fiber for Metal Melting Chambers
0:00 Introduction to Soluble Fiber Blanket: The video introduces soluble fiber blanket as a healthier and more environmentally friendly alternative to ceramic fiber blanket, stating that its dust is easier for the body to break down if inhaled. It has a temperature rating of 1200°C, similar but slightly lower than ceramic fiber.
0:48 Witkas Sponsorship & Refractory Materials: The creator thanks Witkas for providing the blanket and mentions they offer various refractory materials, including ceramic fiber, fire bricks, and other fiber blankets.
1:17 Purpose of the Video: The goal is to build a new metal melting chamber using the soluble fiber blanket and test its performance against ceramic fiber, particularly for melting different metals.
1:30 Updated Chamber Making Process: The video outlines the creator's current chamber-making process, highlighting changes from previous videos.
1:56 Boric Acid Omission: A key change is the decision not to use boric acid in the process. Boric acid can "eat away" ceramic fibers if used excessively and is only employed in rare cases where softening fiber walls need hardening.
2:57 Wrapping the Fiber Blanket: The process involves cutting the fiber into a wedge shape, wrapping it around a 3D-printed cup, and tightening it after an initial wrap to ensure a flat bottom for easier sanding.
3:57 Kapton Tape Application: The chamber is secured with Kapton tape. The creator emphasizes the importance of using high-temperature resistant Kapton tape, demonstrating how cheaper tapes can melt under high heat.
5:01 Easier Cutting: Soluble fiber is noted to be easier to cut than ceramic fiber, requiring less effort from the knife.
5:15 Cleaning for Adhesion: Kapton tape is wiped with alcohol to remove dust and ensure proper adhesion.
6:22 Improved Sanding Process: The creator now sands the top of the chamber while the 3D-printed cup is still inside, preventing the hole from closing and eliminating the need to re-cut it later.
6:51 Water-Only Solution: Plain water is used instead of a boric acid solution for hardening the fiber, reaffirming the negative effects of boric acid.
7:50 Cup Removal & Post-Sanding: The cup is removed after sanding, with a recommendation not to sand the bottom again immediately to prevent the hole from closing. Final sanding can be done after a few uses when the material hardens.
9:00 Additional Bottom Insulation: A circular piece of fiber blanket is cut and added to the bottom for extra insulation and to help maintain the chamber's shape.
9:59 Microwave Drying & Blowtorching: The chamber is microwave-dried, with a warning not to overheat. An optional step is blow-torching exposed fiber surfaces to make them firmer.
11:07 Kiln Wash Application: Homemade kiln wash is applied to the base and bottom of the chamber, letting it air dry or microwave dry.
12:09 Base Construction: The base is made from three sheets of 25mm fiber, cut to size using a cup or 3D-printed circle.
14:35 Minor Imperfections Are Normal: The creator notes that minor imperfections like lifted kiln wash or small gaps between the chamber and base are common and can be fixed after initial use and hardening.
15:04 Aluminum Melting Test: The new chamber is first used to melt scrap aluminum. Initial tests involve burning out PLA molds for casting.
17:30 Aluminum Test Results: After melting aluminum three times, the chamber shows minimal wear, with a few normal cracks in the kiln wash and a slight dip, indicating excellent performance for aluminum.
17:54 Iron Melting Test: A sand mold is prepared for casting iron to test the chamber's high-temperature limits.
19:11 Catastrophic Failure with Iron: During the iron melt, after about 23 minutes, the top of the chamber starts glowing red, sparks appear, and upon inspection, a large hole is found where the chamber melted. The iron did not melt completely.
20:50 Soluble Fiber Not for Iron: Despite another attempt with a new chamber yielding the same result, the conclusion is that soluble fiber cannot handle the temperatures required for melting iron.
21:21 Key Takeaway: Application-Specific Use: Soluble fiber blanket is suitable for melting aluminum and potentially for less demanding applications like microwave kilns, but not as a direct replacement for ceramic fiber for iron melting.
21:46 Future Plans: The creator plans to use soluble fiber blanket for building larger microwave kilns and potentially a larger aluminum melting chamber.