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colu41

colu41

Joined
Dec 24, 2014
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So, I brought my forge back out this winter. Forged a few blades, a few damascus billets etc. Now I'm not huge into forging. I would say 1 out of 10 blades I make are actually forged. I do it mainly in the winter because well, its good heat for the shop. :) Anyways, I'm looking for something different to try and forge. I was thinking about San Mai, but to me it just seems like a low layer damascus with a hard steel sandwiched in between. But, I may be 100% wrong on that. Another one I've always thought was neat was the copper layered damascus? That has always peaked my interest but, it seems copper would be tough to forge weld to steel. Especially since I do all my forging by hand, no power hammer.
Any suggestions on some different (different to me), fun things to try with the forge?
 
I'm pretty sure you can't weld copper to steel due to the much higher welding temp that steel has and the copper will melt.
What about using pattern welded stuff to make guard material out of. I'm starting to play around with using pattern welded billets to do animal heads and other non-blade stuff, but my journey to knife-making started as general blacksmithing and I originally never intended to get into blades.
I've also done quite a few bottle openers.

If you want, check out Darryl Nelson's animal heads on google. Also, as a member of the NWBA (our local backsmithing organization) I'm sure there's one in Michigan.
But really, just pick something, do it and have fun. Another thing that works id to take a chunk of clay and push it around to try to get the shape you want. Pretty much the same as blacksmithing.
~billyO
 
Maybe try some mosaic Damascus. That stuff is pretty cool. It looks very decorative, and it could be interesting to try making different patterns.
 
Thanks guys. Weo, as I dont know much about the process, the copper/steel layering has been done. I've seen it multiple times. Just google copper steel damascus. Most of it looks production made but, it is doable.
 
I'm not 100%, but I believe the copper is inlaid into the steel after forging. As for San mai check out Salem Straub on instagram, he's been doing some really nice work and he's a member here on the forum

Sent from my SM-N915V using Tapatalk
 
I would love for someone who maybe has a bit of experience to explain how this is done.
Materials-CopperWave.jpg
 
I do know that if you contaminate your ferric acid etching bath with copper, it will leave a copper patina on the steel. I've heard it isn't very durable, however.
~billyO
 
I have done the copper once or twice. First its not forged into the steel its a chemical bond. There are two ways to do this one is put some copper like a piece of wire an older penny something copper basically, but put it in your ferric chloride and let it dissolve for a day or so. Make you damascus billet and get it to your shape and polish you like and then etch it in the copper ferric chloride when you put it in first stir it up and stir it throughout your etching process this will plate the damascus with the copper usually to the nickel bearing steel wich if i remember why its because steel and copper don't bond as well. In my experience, it will bond to just high carbon steel but not near as much as the high nickel steel. the other way is while your etching dip your copper source in the ferric while etching the knife and run it over the knife. That is the way I know to make copper damascus.
 
The pictured blade certainly looks like it is alternating layers of steel, copper, and brass. It's interesting that there don't appear to be any steel-steel welds in it: each layer is alternating steel/non-ferrous. Could they just be "forge brazed" kind of like making mokumegane?
 
One thing where a forged blade has a plus apposed to stock removal (imho) is a blade forged out of round stock
Like Markman makes them, or gaucho knives

IMG_4436.jpg


Imagem032.jpg
 
Those knives are cool. If you don't mind me asking, how do you forge weld by yourself without a power hammer? Really big hammer? A ton of pounding to get it to weld? I haven't done it yet so I'm curious.
 
voodoolord said:
Those knives are cool. If you don't mind me asking, how do you forge weld by yourself without a power hammer? Really big hammer? A ton of pounding to get it to weld? I haven't done it yet so I'm curious.
Click to expand...

3Lbs hammer and a lot of time. That's it
 
Copper and steel can be forge welded in vacuum i.e. hermetic package. I piled steel and copper plates and carefully electric arch welded the sides so that they were air-tight. Then I forged this package. The copper and steel surfaces did not oxidize, metal to metal contact took place, and strong bond between different metals formed.
 
You should look into making mokume gane for pendants, bolsters, guards and even jewelry. people make and sell damascus and mokume rings for good money.
you could also try to come up with your own original damascus patterns.
 
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