Dangerous Biggest Heavy Duty Hammer Forging Process, Fastest Hydraulic Steel Forging Machine
Tin melts before it gets red hot. Aluminum melts at red hot, about 1200 degrees. Brass melts at bright red hot, about 1600 degrees. Gold and silver melt at low orange heat, 1800-1900 degrees.
Iron melts at white hot. Really really hot. Upwards of 2200 degrees, that is so hot you can't see it because your eyes can't deal with that bright an intensity. You need sunglasses. It's really very hot.
You will need forced air, and some fuel, a crucible, and a forge or furnace... Propane just won't do the job very well, it will get you close— but not where you need to be. Acetylene will get you there with air or oxygen, but that is an expensive way to do it. You can use a huge amount of charcoal, — not brickettes, real regular wood charcoal. Or a reasonable amount of bituminous coal, to melt a small amount of iron. Both the charcoal and coal will need the forced air. (You can use a vacuum cleaner with the hose at the other end, or a squirrel cage blower. … Of course if Money $$$ is no object, you can make things happen faster by adding Oxygen to the fire to speed things up. That's for getting the iron hot enough.
How hot? Well iron rusts just when water gets on it. It loves oxygen, that's why it's always painted or galvanized. The hotter it gets the better it likes oxygen. The celebratory sparklers people wave around? The sparks that go flying off are burning iron. When you get iron melting, it is very close to burning if the oxygen can get at it. YouTube has some videos of foundries pouring iron, it sparks a lot. It's very dramatic. You will have to deal with some drama if you spill some or have an accident.
Next you will need protective gear for two people, not for one, for two. Buy welding gloves — the leather kind that come up by your elbows - that kind. A leather apron - not a cloth apron, not a plastic apron, a heavy leather apron to protect your body. And leather shoes, not sandals, not running shoes, hightops, or sneakers, leather shoes. I recommend a padded cloth hat with a shoulder apron so that sparks landing on your neck won't burn you. A welders' face mask. Welders' goggles alone will Not do the job, you will need full-face-protection. And sunglasses won't protect your eyes from the high frequency light radiation. The guys who do this for a living wear insulated mirrored suits, to reflect the heat (infrared radiation) away so they can get near the stuff. It's really unimaginably hot.
Next question is what will you melt the iron in? This is not something to take lightly. There is nothing I know of around the house that can take the heat. Remember that melted iron is phenomenally hot. Unless you have seen it in action, it is Very difficult to imagine just how hot. You will not want a homemade crucible, you will want a commercially made crucible. And you will want a rig to hold the crucible when the melted iron is ready to pour. This is usually a rig a little like this: c—0—c. The O holds the crucible, and the bars are to keep you away from the phenomenally hot and very dangerous metal. The C is where your hands hold the rig- one person at each end, because it is phenomenally hot. Shaped like a U or a C so you can tip the rig with both hands, you will want precise control.
next you will want something to pour the iron into once it's melted. Some sort of mold. A metal box with sand in it is a fine thing. You will want the correct sand, which is not beach sand. Buy casting sand, and keep it dry. Even better, when you make your mold, keep it indoors so that no moisture can get into the sand.
Go ahead, have fun, be safe, and better yet — try casting bronze or brass. Mistakes you make with brass and bronze can go to the doctor, not the hospital. Mistakes with iron go to the emergency room, or the mortuary.
ARTICLES SOURCES : https://www.quora.com/Is-is-possible-to-melt-iron-at-home-If-so-how