I would like the furnace be used both for casting as well as tempering parts to large to fit the Kerr 666 burnout oven. This suggests a rectangular shape. Thinking about a shape that is tall, narrow and deep. Big enough to fit a cruciable into and deep enough to temper stock to long to fit in the Kerr 666. Just thinking. Don't want it to be too big and slow heating. If I feel confident about it set it up so it can be rotated 90 degrees to make a wide low instead of a narrow tall.
Lets consider the design from the inside out.
For some time I have been thinking about casting the floor and ceiling with grooves to accept the sides and back. The back would have a groove on each vertical edge to accept the ends of the sides. This design would provide a free standing interlocking shell without casting it in one piece. The channels for the heating coil will be created by gluing Styrofoam strips to the forms. After the refractory dries these can be removed with flame or solvent. The shell will be fairly thick to accommodate the cavities for the coils which I plan to run around the sides and back.
The shell will be surrounded by perlite. I am not sure if it will be loose or bonded with sodium silicate. Maybe a bonded section for the floor to rest on and the rest packed loose around the shell.
I am currently working on a refractory variant of air crete.
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