Aluminum cookware is a long-standing kitchen staple due to its low cost and ability to effectively conduct heat. But decades ago, as autopsy reports found unusually high levels of aluminum in the brains of people with Alzheimer's disease, concern arose over the health risks of this metal -- including the safety of cooking foods in aluminum cookware. The U.S. Food and Drug Administration (FDA) reports the amount of aluminum that leaches into food from this cookware is much less than the amount naturally present in foods and other consumer products. But because aluminum is a known toxin to the body, the safety of dietary aluminum and this cookware is still a controversial issue with consumers.
With 50 years of aluminum and titanium forging experience, APP is capable of providing a variety of manufacturing and design services at an expert level. APP is vertically integrated by offering primary forging processing, multiple heat treat facilities, post-forging processing and inspection capabilities, machining, hardware installation, and locally available surface processing (e.g., shot peen/blast, anodize, prime, paint, etc.). We are capable of providing most forged components completely finished and ready to install on your assembly.
Forging Presses
42 Hydraulic Forging Presses
• Tonnage Range from 8,000 to 300
9 Mechanical Forging Presses
• Tonnage Range from 4,000 to 600
3 Spin Forging Centers
• Flow Form up to 24″ in Diameter
42 Hydraulic Forging Presses
• Tonnage Range from 8,000 to 300
9 Mechanical Forging Presses
• Tonnage Range from 4,000 to 600
3 Spin Forging Centers
• Flow Form up to 24″ in Diameter
Press Capabilities
Conventional Forging: Up to 650 Square Inches in Plan View Area (PVA)
Precision Forging: Up to 350 Square Inches in Plan View Area (PVA)
Titanium Forging: Up to 250 Square Inches in Plan View Area (PVA)
Spinner Capabilities: Up to 24″ in Diameter for Wheels, Cones, Etc.
Conventional Forging: Up to 650 Square Inches in Plan View Area (PVA)
Precision Forging: Up to 350 Square Inches in Plan View Area (PVA)
Titanium Forging: Up to 250 Square Inches in Plan View Area (PVA)
Spinner Capabilities: Up to 24″ in Diameter for Wheels, Cones, Etc.
Metallurgy Lab
APP’s state of the art metallurgy laboratory is staffed to test aluminum alloys for strength and hardness, and is Nadcap approved. We are capable of performing the following tests on aluminum alloys:
• Room Temperature Testing (Round & Flat Specimens)
• Hardness
• Electrical Conductivity
• Chemistry
• Microstructure / Intergranular Corrosion Testing
• Grain Flow Testing
APP’s state of the art metallurgy laboratory is staffed to test aluminum alloys for strength and hardness, and is Nadcap approved. We are capable of performing the following tests on aluminum alloys:
• Room Temperature Testing (Round & Flat Specimens)
• Hardness
• Electrical Conductivity
• Chemistry
• Microstructure / Intergranular Corrosion Testing
• Grain Flow Testing
Trim Equipment
• Mechanical Trim Presses (1-50 ton; 2-50 ton)
• Water Jet Cutter 3-Axis CNC 96″ x 144″ x 12″
• Mechanical Trim Presses (1-50 ton; 2-50 ton)
• Water Jet Cutter 3-Axis CNC 96″ x 144″ x 12″
Machining
CNC Milling
Including Horizontal 4-Axis Automated Pallet Cells
An array of 3, 4, 5-Axis
• Kitamura
• Makino
• Mazak
• Mori-Seiki
• OKK
• Okuna
Spindle Speed
• 15,000 RPM
5-Axis Horizontal (Up to 28″ envelope)
4-Axis Horizontal (up to 55″ length)
• No setup time
• Dedicated Tombstones
3-Axis Vertical Mills (Up to 80″ length)
5-CNC Lathes (Up to 34″)
• Close Tolerance Jig Boring & Jig Grinding
• Tol. to 0.0005 dimension/location
CNC Milling
Including Horizontal 4-Axis Automated Pallet Cells
An array of 3, 4, 5-Axis
• Kitamura
• Makino
• Mazak
• Mori-Seiki
• OKK
• Okuna
Spindle Speed
• 15,000 RPM
5-Axis Horizontal (Up to 28″ envelope)
4-Axis Horizontal (up to 55″ length)
• No setup time
• Dedicated Tombstones
3-Axis Vertical Mills (Up to 80″ length)
5-CNC Lathes (Up to 34″)
• Close Tolerance Jig Boring & Jig Grinding
• Tol. to 0.0005 dimension/location
Process & Inspection Capabilities
Thermal Treatment
• Vertical batch heat treat furnaces
• Horizontal continuous heat treat furnaces
• Age ovens
Inspection
• Fully Equipped & Staffed
• DCC-CMM Dimensional Inspection
• Fluorescent Penetrant Inspection
• Ultrasonic Testing (Stock & Parts)
• Certified Metallurgical Lab
Surface Finish
• Shot Peen
• Anodize
• Prime
Thermal Treatment
• Vertical batch heat treat furnaces
• Horizontal continuous heat treat furnaces
• Age ovens
Inspection
• Fully Equipped & Staffed
• DCC-CMM Dimensional Inspection
• Fluorescent Penetrant Inspection
• Ultrasonic Testing (Stock & Parts)
• Certified Metallurgical Lab
Surface Finish
• Shot Peen
• Anodize
• Prime
Engineering
APP utilizes the most advanced engineering platforms for solid modeling, tool design and metal flow simulation in the development and fabrication of forging tooling. We are capable of receiving solid model part designs in virtually any format, translating or transferring them to our platforms and designing the optimum tools for the most economical forging approaches.
APP utilizes the most advanced engineering platforms for solid modeling, tool design and metal flow simulation in the development and fabrication of forging tooling. We are capable of receiving solid model part designs in virtually any format, translating or transferring them to our platforms and designing the optimum tools for the most economical forging approaches.
Our engineering personnel are available for co-located or concurrent engineering activities with your engineers in the nascent stages of design development that can save time on project development adjustments often incident to new forging designs.
• CATIA V5-5R2014 • CATIA 4.3.2 • CATIA Enovia DMU V5-5R2014 • INVENTOR • SOLIDWORKS 2015 • MSC Simufact 12.0 | • Forge NXT Cluster • Master-CAM 12.0 • PC-DMIS 4.0 • Vericut V6.0 • Calypso • Calypso off-line |
Die Shop
Our CNC die sinking centers make up the backbone of our die manufacturing facility. Our die fabrication capabilities are augmented by in-house EDM (Electrical Discharge Machining) for difficult tooling features. APP operates one of the largest in-house forge die shops in the aluminum forging industry in terms of number of dies produced.
Our CNC die sinking centers make up the backbone of our die manufacturing facility. Our die fabrication capabilities are augmented by in-house EDM (Electrical Discharge Machining) for difficult tooling features. APP operates one of the largest in-house forge die shops in the aluminum forging industry in terms of number of dies produced.
Metal is a great material to work with. It's rigid, tough, malleable and conductive, but sometimes the part we need doesn't exist in any store. In order to create custom pieces, you need to either melt the metal and cast it in a mold, or heat it until it's soft enough to shape with your hammer. Properly melting metals can be a bit dangerous in our home shop, but we can make a coffee can forge for all of our home blacksmithing needs.
Materials
- Coffee can
- Ceramic wool (1 inch thick)
- Metal strips
- Propane torch
- Firebricks
- Hammer
- Anvil
Step 1 Picking a Torch
You want to find a propane torch that has a permanent ON button. Without the gas held in the ON position, you would have to hold the propane torch with one hand while using the forge. That's not very efficient. You can see my torch below. The red button is the trigger; the small metal button locks the trigger into the ON position.
Step 2 Prepare the Can
Strip any plastic or paint from the outside of the coffee can. Drill a hole in the side of the can large enough to fit the nozzle of the propane torch.
Photo by ironring1
Cut your ceramic wool to length so that it covers the inside of the coffee can. Note that you will need a separate round piece of ceramic wool to cover the far end of the can. Once all of the wool is in the can, it should keep its form without any adhesives or fasteners. Be sure to cut a hole in the ceramic wool where the propane torch nozzle will be.
Step 3 Construct a Base
Technically, your coffee can forge is all ready to go right now. However, with this thing heating up to a few thousand degrees Fahrenheit, we may want to make a stand to keep it off our nice tables and floors.
Photo by Jim Wilson
Depending on the angle of your torch and the angle of the hole in the can, you might need to have a separate base to prop up the propane torch in the correct position.
Step 4 Set Up Firebricks
The firebricks provide a tough solid surface for resting our metals on while the heat. They also help cover up the gap in the front of the can to keep heat in. Also, the propane hole should be facing the bricks. In mine below, the hole in the top right of the wool is facing directly at the firebricks.
Step 5 Try It Out!
Outside away from flammable objects, turn on your propane torch making sure it's in the constant on position. Place the nozzle of the torch into the can via the hole in the side. Try to train the end of the flame directly on the firebrick surface inside the forge.
Photo by Lloyd_E
Let it heat up for a few minutes and place your metal object into the forge using a long pair of pliers or tongs. When the metal is red hot all of the way through, it's ready to work!
Photo by Lloyd_E
Remove the metal with the tongs and place it on a hard surface. A real anvil works best, but a large rock or concrete block will do in a pinch.
With the metal placed flat on the anvil, strike it several times with a hammer. You will notice the metal flattening out as you hammer.
Step 6 Become a Blacksmith!
Now it's just a matter of time and practice before you are whipping up homemade blades, bolts, and bayonets. There's really no substitute for practice, but this article can show you some of the basic metal shaping techniques.
Heat Forge For Sale
Free download inpage urdu 2010. Photo by Popular Mechanics
My first project was a spearhead. If you want a fun challenge for your first project, try making a small spade head with a cylindrical bottom for fixing onto a wooden handle. The metal can be tricky to work with, but after a few tries you get a feel for the malleability of the metal and how much heat is necessary for it to be shaped properly.
That's It!
Have you always wanted to be a blacksmith? What would you make with your own coffee can forge? Let us know in the forum or in the comments below. Having trouble? Feel free to ask the community members or message me personally with questions.
Don't forget! We are currently accepting entries into our photo contest for a chance to win your very own lucid dreaming goggles kit! Just post a picture on the corkboard of a project you have made or are currently working on. All projects are welcome. Here is my example entry.
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Yes, aluminum is a toxic metal and you definitely don’t want it in your food for fear of long term health implications like Alzheimer’s Disease. But, that is no reason to toss out your perfectly good aluminum cookie sheets, cake pans, and muffin tins!
You see, aluminum as it relates to bakeware is only released if you scratch it. This I remember quite vividly from college Chemistry class.
Forging Temperature Of Aluminum
Therefore, when removing cookies and the like from your aluminum bakeware, just take care not to use metal utensils that can easily scratch the aluminum and release this metal into your food. Wooden spatulas would be the best choice for handling the food when working with aluminum.
There also is no risk from aluminum vapors when baking with aluminum bakeware. The heat used for at home baking is not nearly high enough to cause inhalation dangers like what workers at aluminum plants experience. Heating of aluminum must approach its melting point for vapors to be released (1220 F). My oven doesn’t even get that hot when on “self cleaning” mode.
Using Aluminum Bakeware Safely
If you want to be extra careful, use unbleached parchment paper as a cover on top of the bakeware and have your food touch that instead. For aluminum muffin tins, use unbleached baking cups.
This same approach would be advised for aluminum foil. I see folks putting vegetables and butter in foil and wrapping it tightly to roast them . all of which is perfectly safe. The problem arises when they open the foil after cooking and scrape the veggies into a bowl with a metal fork! This is a no-no. Make sure you use only wood or plastic utensils when dealing with foil!
Watch out for store bought pie crusts that come in aluminum pie pans too. While there is nothing wrong with baking your pie in a decent quality pie crust from the healthfood store, it becomes a problem when you cut that pie with a metal knife which scratches the aluminum pie pan underneath the food! I’ve been to many a potluck where I wouldn’t eat a piece of pie in an aluminum pie crust pan that had been cut with a metal knife!
One last word of caution – watch out for ice cream machines. My Cuisinart ice cream machine has an aluminum interior as do many other models. Again, this is fine and safe as long as you don’t use a metal spoon to scrape out the last bits of homemade ice cream that get stuck to the sides! A small wooden spatula or spoon works great here and will not scratch that aluminum in the least.
Make Sure to Ditch Aluminum Cookware Though!
Of course, cookware is another issue entirely. Aluminum should be avoided in that case as cooking acidic foods in aluminum can leach the metal into the food.
Stainless steel cookware poses similar leaching issues, although for neutral pH or alkaline foods, it is fine. For acidic cooking, ceramic coated cast iron such as Le Creuset and Lodge are a good idea. Glass cookware is an excellent and very affordable option as well. Copper cookware is safe too, though it is rather pricey. For longer cooking and acidic foods, such as tomato based sauces or slow simmering of bone broths, safe options include certified toxin free clay pots (such as Vita-Clay), glass, or ceramic coated cast iron. While convenient, stainless steel pressure cookers are not ideal for cooking acidic foods either.
While cookware is a bit tricky, as for bakeware, I still am using the same aluminum equipment I’ve used for years. What’s more, I have no plans to replace it with expensive stainless steel or any other material for that matter.
Teflon and Silicone a No Go for Cooking in Any Form
While it’s possible to salvage your aluminum bakeware (not cookware) and still use it safely, make sure you ditch all Teflon kitchenware. While you’re at it, toss any silicone molds that you use for baking or cooking too.
Note also that shiny pasta from the store was shaped in teflon. This article explains how to identify healthy pasta shaped in traditional bronze dies instead of toxic teflon.
Here’s a great article on why you should not use Teflon cookware OR bakeware.
Sarah, The Healthy Home Economist
Since 2002, Sarah has been a Health and Nutrition Educator dedicated to helping families effectively incorporate the principles of ancestral diets within the modern household.
Sarah was awarded Activist of the Year at the International Wise Traditions Conference in 2010.
Sarah received a Bachelor of Arts (summa cum laude, Phi Beta Kappa) in Economics from Furman University and a Master of Government Administration from the University of Pennsylvania.
Mother to three healthy children, blogger, and best-selling author, her work has been covered by USA Today, The New York Times, National Review, ABC, NBC, and many others.
Posted under: Green Living