Cast iron, like steel and wrought iron, is an alloy consisting primarily of iron and carbon but has a carbon content usually in the range of 2- 4%, which appears as flakes of graphite intermixed within the material. Commonly, when cast iron is submerged in a marine environment, the iron component corrodes away, leaving behind [...]

Buffalo, NY:  April 4, 2010 Success!   After letting the molten iron cool and solidify, we cut the metal strapping and began to break open the sand molds.  It was an amazing feeling as replica Worthington pump damping piston cylinder heads and valve chest covers began to emerge from the molds, just as they would have [...]

Buffalo,  New York April 10, 2010 The day of the spring iron pour at Buffalo State College is finally here! After nearly a week of preparation, the iron furnace named ‘Betty’ was lit in the morning and Will and other experienced iron casters fed in measured charges of 7 lbs. of coke and 50 lbs. [...]

Buffalo, NY: April 9, 2010 An eventful day at the Buffalo State College foundry! Final preparations are underway for the iron pour tomorrow.  The newly constructed iron furnace has been lined with refractory clay and assembled.  Supplies of fuel, in the form of coke, a product of coal combustion, have arrived and Eric and Will [...]

Buffalo, New York: April 8, 2010 Work on the molds for casting replica Worthington pump parts in iron continues with the packing of sand molds around the plastic replicas of the steam chest cover and damping piston cylinder head made at The Mariners’ Museum before we left Newport News.  The sand molds were made by [...]

Preparations for Replica Worthington Parts Casting Buffalo, New York:  April 7, 2010 Today Will and Eric are continuing preparations for casting replicas of two components of the port side Worthington pump.  As a first step, multiple replicas have been cast in polyurethane plastic by taking two part rubber molds of the original artifacts.  The plastic [...]