"W" Pattern Damascus WIP my way

[Mike Turner]

Hi all I was asked by a fellow if I could forge him a "W" pattern damascus bar for a custom folder he is having made after he saw a knife I made using my "W" pattern. I had some of the billet left from the knife he liked but it would not forge to the dimensions that his custom maker needed for the blade so I am making a new billet. So I thought it would be fun to make a WIP of this.

SO lets get the ball rolling.


Well since I had already started this before deciding to do a WIP so I missed the first shots, so I took this one with my next billet in line. The original billet was 23 layers and 1 1/2" thick by over 5" tall and 6" long, just enough billet for this customers knife , just kidding this will make several knives. So here you can see the billet has been welded and then I turn the billet 90 degrees and forge against the layers compressing the layers.

Here is a close up showing the layer edges are now on top and bottom of the billet instead of the sides where they started. This pattern will definitely test your welds as you are putting tremendous strain on them.

Now we have the billet all cleaned up and ready to cut up she is a bit small not sure if she will work out , the billet is 3/4" X 2 1/4" X 22 1/2"

And now we have cut this into four equal parts and I put a little etch on it so you can see how the compression is progressing

Be sure to stay tuned I will be updating this often as this progresses and comments are always welcome.

 

[JGguns]

Very cool Mike. Thanks for the WIP.

 

[Salem Straub]

Excellent Mike, thanks. I always enjoy a good Pweld WIP. I'm staying tuned.

1095 and 15n20?

 

[Frank Niro]

This is great, Mike. Frank

 

[javand]

Just to clarify for those that might not be able to tell, are you doing all this work on the hammer? No squaring dies in a press right?

 

[Mike Turner]

Thanks guys,

Salem, the mix is 1084 and 15N20. I was going to be mean and use CruForge V since I am not finishing it , but did not want the folder maker cussing me LOL.


Javand, I am using a combination of 50 pound Little Giant and my 26 ton press and no I have not used the squaring dies. Basically I get it down to around 2" tall with the press then go to the LG to forge it down to the thickness I am looking for to restack. I prefer the hammer as it draws much faster but it can not handle billets that are 5" tall .




Well I want this billet clean and make sure I have no flux pockets so I am dry welding this. To do this I put it in a can, so here it is already to go into the forge for the second weld.

Forge heating up .

Billet has been welded and now I need to remove the can.

Stay tuned more to come.

 

[Brian Ayres]

Nice!!!! I love watching damascus being made! Thanks Mike!
I just might have to come visit soon!!

 

[Ed Braun]

Do it for me, Brian--Mike's among a handful of folks from here who set my head on straight and had a gentle way of getting it across (without using the hammer)...I'd sweep the man's shop for a year just on then bits of advice here and there, and I'm sure Ryan and the boys who just took his class will agree.

Mike--I knew all that diesel wasn't for any Deere, it was for you. You're a machine, brother, a pure machine. A Turner W? Isn't that an M?

 

[Mike Turner]

Thanks Brian come on down any time during hay season is best .


Ed Well actually if you look at my billets they have "M's" and "W's" .

Here we have it removed from the can.

And drawn out to 5/8" thick and ready to cut up again for the next weld.

Well had some more time to work on this. So I need to back up a couple pictures as I ended up using 2 different cameras and got ahead of myself. So here I am grinding off the scale and also inspecting for any problems,

Then I cut this bar up into four equal sections.

So now for the money shot, here come the "W's"

Thanks for all the comments so far, please stay tuned more updates coming soon.

 

[A C Richards]

very cool Mike. Like your box...

 

[Brian Ayres]

Gene wants some of my forklift tines and I want to raid Mark's store. I'll bring my three boxes of wood to cut up. I'll bring you some tines too. I got a couple hundred pounds more today. Some of the smaller drops would be perfect for dies. I think a weekend in southern oregon is due.

For us city folk, when's hay season?

Do you have weekend time? Or do I need to get down on a Monday, or Friday?

Seriously. I really love WIP's. I soak up everything I see here for future use. I have so many WIP's bookmarked. When people with skills like yours freely share what you know I am very thankful.

 

[Mike Turner]

Thanks Chuck, I like the box too easy to fit less welding than if I welded the sides and ends and also now foreign weld material except the tack welds on the one end to deal with.


Brian this coming Monday is great we are bucking hay I mean forging .

 

[Brian Ayres]

Brian this coming Monday is great we are bucking hay I mean forging .

Uuuuhhhmmmmmm. Uuuhhhhh. Yeah. Kinda busy Monday, errrr. Wish I could forge(buck hay).... but....
I have done more than my share of bucking hay, and harvesting the "new" rocks that grew in the fields every spring around my house on Idaho growing up. I ALMOST miss it.

 

[Mike Turner]

Then I tack weld one end just to hold it together so I can put it into a can.

So now I start prepping the can, first I select a tube large enough for the billet I am working on and cut a piece a 1/2" longer than the billet. I also cleaned up the rebar I had on the billet to attack to the can when ready.

Now I split the tube.

So now we have the tube split.

This tube was a bit wide so I need to trim it some, The sides are not that critical so I leave a small space to put some cardboard in the can.

I then cut some used stainless steel heat treat foil to fit, this keeps my billet from welding to the can.

Now we start assembling the can.

Now we clamp the can together.

Then we tack weld and remove the clamps for welding.

Then we weld the can side to make it air tight.

Stay tuned will be a couple days since I am doing hay right now, so back to haying.

 

[Mike Turner]

Well have not had much time to do anything last couple days, dang farming getting in the way.

I did manage to get this ready to be forge welded, so on with assembling the can. Here I need to make end caps so I have some plate steel I mark and cut these from.

So I weld one end on, I want a nice air tight weld.

I then cut some cardboard to put in the can, I slide it down next to the billet. This is to eat up the oxygen and prevent scale.

Then I weld up the other end and weld a piece of rebar on so I can handle this small billet.

Next we cut the excess flange off,

Time to heat this baby up .

And got this welded.

Stay tuned we have a money shot coming soon .

 

[javand]

Looking good Mike, and I dunno why I never thought of building a can that way. Saves a lot of marking and cutting.

 

[PaMtnBkr]

Is there a reason to cut off the excess flanges on your can? Seems you are throwing away the can after you are done anyway? Sorry if this a totally "newbie" question! Great WIP!!!!

 

[Mike Turner]

Thanks, Javand


PaMtnBkr, the reason I cut the flange off is because it gets in the way when I set the weld with the press. So just for reference the side that is getting squashed in the press is the side next to the bandsaw blade not the face of the can that is on top. Hope that helps.


Well hay is done for the time being, so we should have an update tomorrow on this, thanks for your patience.

 

[PaMtnBkr]

Aha! I knew there had to be more to it than just being anal retentive!!!! Thanks Mike!!

 

[Kentucky]

great work Mike..