Archeologists report that forge welding was first used by Egyptians as far back as 4000 B.C. In about 3000 B.C., during the Bronze Age, it appears that people were building cities, learning to write, and using forge welding to join pieces of metal, primarily copper and bronze. Evidence of this was found in an Egyptian tomb of a pharaoh where a gold bowl was discovered with a handle welded to its wall. A gold goblet was also found that had a fillet brazed on the outside.
By 2000 B.C., people were using forge welding to make cooking utensils, jewelry and weapons. They were also making small gold boxes by joining the boxes together using the forge welding process.
As the years passed, not only the Egyptians were using forge welding to join metals together, but the Irish, the Chinese, the Japanese, and finally, almost all countries were making items using forge welding.
Finally, in 60 A.D., Pliny the Elder provided the first written record of the forging process. He even discussed the use of salt as a flux in the gold brazing process.
Now, in the 20th Century, when many different welding processes have been developed that are used with different types of metals and for various applications, there is still a place for forge welding.
What is forge welding, what is the forge welding process, and what is it used for in today’s modern times? Let’s take a further look.
What is Forge Welding?
Forge Welding involves the use of heat and a hammer. First, the separate metal pieces are heated to a high temperature. While they are still hot, they are merged together by pressure or pounding with a mallet or hammer. The modern-day blacksmith uses attention to detail and hand-eye coordination coupled with speed to join the metal pieces. By this method, small pieces of metal can be joined together to make one large piece.
Traditionally, forge welding has been used to make swords, create gates, and forge railroad spikes. The ability of a welder to understand the temperatures needed for forging various metals is an essential skill.
How Does the Process Work?
The process seems relatively simple: heat the metal pieces and hammer them together before they cool, however, it is a bit more involved than that.
The metals must be scrupulously cleaned and coated in flux before they are heated. The hammering must be done with precision so it won’t cause the flux to escape from the joint when the first blow hits the metal. Hammering continues until the weld is finished and no weld lines are created.
The process can be done manually, with welders actually using a hammer and walloping the metal with their hands. There are also mechanical hammers that are now frequently used. Another method is to heat the metal pieces and then place them in a die where pressure is applied.
The temperature used for heating the metal ranges from 50 to 90 percent of the melting temperature of the metal, and both metal pieces must be heated to the same temperature. They must be joined together quickly before they cool down.
The temperature used for heating the metal ranges from 50 to 90 percent of the melting temperature of the metal, and both metal pieces must be heated to the same temperature. They must be joined together quickly before they cool down.
Advantages of the forge welding process:
- High quality, strong welds can be easily and quickly produced.
- The process does not require inert gases.
- It does not require special equipment.
- It is basically a simple process.
- It can be done by hand without special equipment.
- It can be used for heavy-duty applications.
- It can be used to create art and other special shapes.
Disadvantages of the forge welding process:
- It is a slow process, so it is time-consuming.
- Requires heating the metal to the exact temperature followed by exactly correct hammering. If the temperature is not right, or the hammering is too hard or too light, the weld will be ruined.
- When welding large items, it is difficult to hammer the pieces together before the metal cools down.
Modern Applications for Forge Welding
Forge welding is the ideal process for forging smaller pieces of metal into one larger piece. It is also used for:
- Creating cookware.
- Joining steel pipe for plumbing uses.
- Making armor or swords by joining together sheets of steel.
- Creating decorative scrolling on furniture.
- Creating art in general.
- Creating jewelry.
- Repairing machine parts.
- Manufacturing farm equipment.
Contact Arizona’s Vern Lewis Welding Supply for More Information About Forge Welding
Vern Lewis Welding Supply has eight locations throughout the state of Arizona. Our professionals will help you choose the proper tools and other materials that you need as well as answer any questions you may have regarding your welding practice. For more information, contact us online or call 602-633-7481.
Sources:
- https://www.twi-global.com/technical-knowledge/faqs/what-is-forge-welding
- https://www.thecrucible.org/guides/blacksmithing/forge-welding/#:~:text=Developed%20in%20the%20Middle%20Ages,a%20large%20piece%20of%20metal.
- https://weldguru.com/welding-history/#metalworking-and-welding-timeline
- https://www.fairlawntool.com/blog/history-of-welding/
