Subject: Re: Damascus/pattern-welded steel

From: [email-masked] (Katana ---/-----------)
Date: Tue, 17 Sep 1996 20:49:48 GMT

>> through a second welding heat and then the problem started. 
>> The last layer in the stack has a small 'bubble' or blister where it  
>> is not welded.  Four welding heats did not change this.  How do I fix
this without grinding >> off the offending layer, or is this my only
option? 
>>    I think the problem may be flux, slag, or scale trapped between the  
>layers. 
>>         Any suggestions or comments?  Anyone out there making damascus  
>without the use of power 
>> hammers, presses, or strikers? 
>>  
Welcome to the world of "red shuts". Trapped slag, inclusions, or whatever.
I find that the first weld is the most important. You have to weld slowly
and VERY carefully from one end of the bundle to the other. Make absolutly
sure the individual pieces are clean and free from scale, and fluxed
properly. Make sure the pieces are sanded on both sides right before
welding. Be meticulous like a watchmaker. And then if it fails, grind off
the offending piece. Actually the idea of drilling into it it great if it's
on the outside. Now what do we do if it's in the 4th layer down? The drill
hole should make an interesting oval pattern in the finished product. 

               Bill Wyant 
   Bladesmith / Art Blacksmith 
Avalon Ironworks, Ft. Wayne, IN 
    [email-masked]

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From: George Ezell <[email-masked]>
Date: Tue, 17 Sep 1996 17:11:05 -0500

> Avalon Ironworks, Ft. Wayne, IN

I agree totally.  I was taught to make damascus using a massive power
hammer, and now I've relearned the process using a 3 pounder.  I miss
that hammer....  I was lucky that it was on the outside layer, otherwise
I would have had to scrap it, or as one person suggested, drill through
it and weld in a plug. Now THAT would be a weird pattern!  I know now
that it was caused by improper hammer strikes to the outside edge of the
billet before getting the inside welded.  Trapped flux under a layer. 
I'm still curious about how many others here are making pattern-welded
steel without the luxury of mechanical hammers.  I have a feeling that
using the composite type "Turkish" method, I might be able to get a
piece large enough for a bowie.
	That's next weekend's project.  Learning is painful, exspecially  when
splattering flux is involved!

> Long enough? 
> 
> George, have you checked out Sam Curry's blade in the Guild of Metalsmiths'
> gallery.  160+ hours
> 
Yes, I saw it Gene, he had it at the Batson Symposium before he'd put a
handle on it.  Fantastic work!  
I'm bad about starting a project, loosing inspiration, and then picking
it up 2 months later.  That was the case this time.  I've got about
twenty blades laying around ready to be ground and finished...and then I
went and forged two more last night!  I like the forging part alot
better than the grinding.
	George