My Refractory is melting...

Joined
May 15, 2015
Messages
43
So for the past for weeeks ive been getting the materials together to build a forge. I heard vertical forges get hotter so i have i large pipe that my forge is made of. I got my koawool off ebay and it said the ratting was 2300 degrees F. i dont have any ITC-100 to coat it but i figured it would be okay untill i get some. So i fired it up and the refractory melted (no it wasnt from flux). I do like to have my forge as hot as possible so my steel will get up to heat faster (but i pull it out before i burn it) i dont really want to give having a really hot forge so Anyways my question is where can i buy some higher temp refractory and how do i know how high quality it is before i buy it.
 
So for the past for weeeks ive been getting the materials together to build a forge. I heard vertical forges get hotter so i have i large pipe that my forge is made of. I got my koawool off ebay and it said the ratting was 2300 degrees F. i dont have any ITC-100 to coat it but i figured it would be okay untill i get some. So i fired it up and the refractory melted (no it wasnt from flux). I do like to have my forge as hot as possible so my steel will get up to heat faster (but i pull it out before i burn it) i dont really want to give having a really hot forge so Anyways my question is where can i buy some higher temp refractory and how do i know how high quality it is before i buy it.
High Temp Tools sells the stuff you want. That being said, the Kaowool that you had sounds like the right stuff. I had a similar problem the other day. I used Backyardmetalcasting.com's homemade refractory on a charcoal forge. Worked relatively well until I tried to forgeweld with it. Melted it into a puddle of glass, sealing off my tuyere. I know, different material, but there enough of of us that are impatient or cheap (I happen to be both) that if it worked, someone would have tried it already.
Everyone else that is using ceramic fiber coats it with satanite. If I'm not mistaken, that is what protects the ceramic blanket - ITC100 is just there to boost performance by reflecting IR heat.
I thing we both learned an expensive lesson the hard way - don't try to cut corners. Experimenting should be preceded by extensive research.
 
Your forge is running at 2500-2600°F and your wool melts at 2300°F ... what could possibly go wrong? Using Hi-Z wool, which is rated at 2800F°F is a better idea if the forge is to be welded. But there is more to your problem as described - read on:

A forge needs two things -
#1 is a insulating lining. Inswool and kaowool are the normal ones used. 1" of wool works for a small utility forge, 2" of wool is better for larger forges and required for a welding forge.
#2 is a refractory coating to cover and protect the wool lining. The standard coating is Satanite. Other refractories can be used, and some can be cast. The satanite or other refractory is applied over the wool blanket to a thickness of 1/4-1/2". It must be dried for a few days and then slowly fired to attain hardness and refractory properties. The refractory coating is usually rated at 2800-3000°F.

A welding forge (all forges IMHO) should have a final coat of ITC-100 ( or equivalent) to make the forge run more efficient and at a higher temperature. The ITC-100 is applied to the fired refractory coating to a thickness of 1/16" to 1/8". It also is slowly fired to attain its properties.

A floor made from a high temp and flux resistant material is also a god idea. Bubble alumina, Missou, or Castolite -3000 are all good choices. Some folks use kiln slelving or fire brick for the floor. In a vertical welding forge, an inch or two of kitty litter in the bottom will work quite well.

Notes:
A cast liner should be about 1" thick and have at least 2" of wool around it. A sheet metal shell is wrapped around the whole thing very similar to how a HT oven is constructed.

Forge ends can be easily made from 1" Ins-board. This is easy to cut and fit. Some commercial rectangular chamber forges are made entirely from ins-board. Ins-board is very reasonable and can be bought in sizes from 12"X12" up to 4X8 foot sheets.
 
Your forge is running at 2500-2600°F and your wool melts at 2300°F ... what could possibly go wrong? Using Hi-Z wool, which is rated at 2800F°F is a better idea if the forge is to be welded.
Stacy, I just ordered Insulwool HP from High Temp Tools to build a proper forge. Now I'm concerned that I may have ordered the wrong stuff. I'm planning on a horizontal oil fired forge, lined with Insulwool, satanite, bubble-alumina, and ITC-100. Burner will be based on the "Brute" by Backyard Metalcasting, though sized down a bit. I do intend to forgeweld in it if it gets hot enough. HTT has not shipped yet, should I contact him, and swap the plain Insulwool HP for the Insulwool HTZ?
My apologies, Jack, for hijacking your thread.
 
I like the extra resistance and temp range of the HiZ wool for a welding forge. The regular wool will work, but the cost difference isn't all that much, so why not get the extra bang for the buck. The HiZ only comes in 1" thick, so plan accordingly.
 
Also the added issue of "hotter is better" could be an issue. You do need to soak the billet for good welding. By soaking I mean time at temp, and it's hard to soak 15 minutes at 2300° when the inside of your forge is 2600°.
 
Also the added issue of "hotter is better" could be an issue. You do need to soak the billet for good welding. By soaking I mean time at temp, and it's hard to soak 15 minutes at 2300° when the inside of your forge is 2600°.

I agree.

There are ways to save time, but cranking a forge full blast to save a couple of minutes here or there is not necessarily the best option.
 
Back
Top