[TheForge] pattern welded steel

[Jason Nass]

Bruce, Dry welding is indeed a method of welding without flux. Generally it is done during restacks, as it would suck to tig weld all 25 layers of a billet. Basically, once it is cut and stacked, you would run a TIG bead, (mig, arc, and torch also work, but have to be cleaned up before drawing unless you like ugly lines) around the perimeter of your join leaving only a tiny gap for oxygen to escape... This kind of welding works by preventing any O2 from reaching the surfaces to be welded, which is exactly what flux does. A hydraulic press also works wonders to prevent mass loss. JW Randall and several others have been using this method and it works great. 

As for scale in a propane forge, that is indeed a matter of adjustment. With a little tinkering you can get a perfectly neutral flame and not have to worry about excessive scaling. When I am adjusted to welding, I get more scale from my coal forge now, than I do my gasser.

Jason Nass – MacTalis Ironworks
me at wargoth.com

-----Original Message-----
From: theforge-bounces at mailman.qth.net [mailto:theforge-bounces at mailman.qth.net] On Behalf Of Bruce Freeman
Sent: Sunday, April 03, 2011 9:50 AM
To: Blacksmithing List Sponsored by ABANA
Subject: Re: [TheForge] pattern welded steel

Steve,

By "dry welding" do you mean without flux?

If so, could you give us your reasons for dispensing with flux.  What thickness material do  you use in your billets?  Do you use an induced-draft forge or a blown-air forge?  Do you do anything special to adjust your flame conditions?

I've heard arguments on both sides of the debate, and am curious.

Gas forges are notorious for producing scale.  My take is that this means the burner is adjusted wrong.  (Or you're using a blown-air forge!  Do I reveal my prejudices? 8^)  If you heat a piece of metal with a torch flame, you can actually remove the oxide (not heavy scale, necessarily, but thin oxide) using the reducing portion of the flame in the center -- a simple demonstration.  (In an oxygen atmosphere, this is a transient effect -- the oxide will reform when you remove the flame.)  Hence, it seems to me that proper adjustment of the burner could result in conditions inside the forge that are not scale-producing.  (Let me hasten to point out that if the gas doesn't burn completely INSIDE the forge, then it will finish its burning OUTSIDE the forge, and may produce high levels of carbon monoxide.  We can deal with these things if we're ready for them.)

On Sun, Apr 3, 2011 at 9:30 AM,  <doveknives at aol.com> wrote:
>
> As mentioned before, the amount of loss is dependent on your approach.  I have moved to dry welding in propane fire with multiple re stack.  Lose less than 3% of weight, only re stack once. Please consider some of your options for forge welding.  I am glad to help if you like.  Making pattern welded steel is one of the most exciting and full filling experiences around at least for me.
>
>
>
> Trusting HIM,
> Steve Rollert
> keenedgeknives.com
> doveknives.com
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--
Bruce
NJ
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