filled the mold with C87300 silicon bronze (Everdur). A stress analysis resulted in the
recommendation to add support to the inverted cap inside the torus assembly, to better distribute its weight. Te pattern for each buttress was hand fitted, and these stiffeners as well as the cap were cast from the same al- loy as the sculpture to ensure consis- tent welds and joints. “Cutting polystyrene panels and hand-fitting inside the sculpture was easy to manage, compared to heavy bronze sheets,” Danko said. “Once fit to size with a knife and scissors, it was sent to the foundry to ram up as a pattern for sand casting.” The large bronze cap casting inside the sculpture was produced from a traditionally made hard- wood pattern with a machined foam corebox. The cap was machined at Danko Arlington and included a variety of tapped holes for locking bolts and leveling screws.
Assembling Infinity New Arts Foundry craftsmen
straightened and welded nine cast panel pieces and assembled individ- ual 22.5-degree bulkhead sections on top of each other, piece by piece, a process Danko likens to shipbuild- ing. Eight bulkheads were welded together to produce a half torus for transport to the university before final, permanent assembly onsite. The entire sculpture was placed on a stainless steel post, which was part of the foundation for the sculpture. Each section joint and 3-adic curve was textured to match the as-cast surface. “Te silicon bronze was finished in
a light green verde patina, which will take on its own color as it weathers,” said Danko. Te sculpture is surrounded by
a base consisting of nine slabs of Lake Superior granite built in the shape of a circle and deltoid section, engraved with the associated equa- tions. Dedicated on October 25, 2012, Ferguson’s Umbilic Torus SC sand cast sculpture epitomizes the lifetime achievement of an innova- tive mathemetician and sculptor.
May/Jun 2013 | METAL CASTING DESIGN & PURCHASING | 37
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