I was working on a small bronze statue in my garage... the details were always blurry in the finish. After some trial and error, I added more clay to my molding sand, just a bit extra. The difference was night and day... sharp edges and smooth surfaces all around. It's a basic tip, but it really saved my project. Might be worth a shot if you're dealing with similar issues.
It showed up after we cast a big batch of bronze. This could mean metals are getting into the water system. What tests do you run for runoff quality?
Back when I started, we still used hand bellows to stoke the furnace fire. The old crew dared me to give it a hard pump to impress the boss. I pulled too hard and the thing snapped, sending ash everywhere. Everyone just stared while the foreman sighed and fetched the spare. Now with electric fans, new guys don't get hazed like that anymore, which is probably for the best lol.
It cuts down on slag like nothing else.
My uncle always asks if I just stand by a big fire all shift. I used to give a full rundown on pouring and molds, which bored everyone. Now I just say I make metal puzzles that get really hot. It's vague, but it shuts down the follow-ups. They usually just nod and talk about sports instead. Saves us both from a pointless chat.