Is forming metal coins (specifically ones with copper, nickel, and zinc) possible with these steps: Carve a wood mold melt sodium chloride pour sodium chloride into the wood mold form a clay mold from the sodium chloride cast scale it down using a machine make a clay base make the rim on both sides of the clay mold fire the clay melt a mixture of copper, nickel, and zinc pour the metal alloy into the clay mold once metal is cooled gently get it out of the clay mold so you can use it again heat but don't melt the metal cool the metal clean the metal dry the metal One of my big concerns of this process is that a copper, nickel, zinc mixture might melt the clay as soon as the metal is poured in but at the same time I don't want to use a metal that you can bend with the pressure from your hand like you can with aluminum.
I'm too lazy for all that, and I don't even know if it would work. Instead, why don't you just contact Daniel Carr and ask what he would charge for his services? Chris
The Lost wax method would be much easier and less risky, and you make new wax replicas from your original each time. Check google. I would shy away from nickel compounds because of temperature. For a few coins, I would use silver or high % copper zinc alloy myself. Most custom jewelers or college sculpture classes have supplies, or from Rio Grande or similar supplier. I would check the local sculpture classes if you are in a metro area.
Some advise to cast in rubber first instead of wood: http://www.stormthecastle.com/how-to-make-a/how-to-cast-a-coin.htm They also advise not to do this unless you really know what you are doing as molten metal is very dangerous. TC
I am very hesitant to give guidance of this type on an open forum. You never know what someone could use the info for. If you want details of the casting process, Google will be able to help you.
MELT Sodium Chloride?? Yeah I guess it can be done, but it should be interesting trying. I does supposedly melt at 1475 degrees F but I wouldn't be surprised if it breaks down first
The clay mold idea can work. I have seen Roman era, clay forger molds for sale several times, but as a metal working hobbyist for the last 30 years, be ware, pouring metal is wildly dangerous. Nickel would needs a 2600 degree F. melting point. Zink fumes can easily kill you. Copper would be the only bet. If you really want to go forward, get some serious education first.
You didn't specify if you were trying to make a "coin" that would mimic an alloy, or just a straight metal. If you are trying to mimic a copper-nickel alloy, you might try first using a commercial Plumber's Silver Solder (e.g 1 lb. Roll of Oatey Sn96/3Ag, available from Home Depot or Lowes for about $25) which melts in the range of 415 to 455-degrees F. This solder is fairly hard and has a high finish when solidified against a smooth surface. If this works for you, you could try other alloys that contain copper or bismuth which are slightly harder.
