Subject: Re: Damascus/pattern-welded steel

From: [email-masked] (Bill Fiorini)
Date: Tue, 2 Apr 1996 13:06:45 -0500

>Hey guys,
>        I've got a problem.  I've been experimenting with damascus steel and
>general forge-welding,
>and though I have no power hammer I've been seeing what I can do without it.
>I've been having
>pretty good luck on small pieces, but something happened last night I've never
>seen.
>        The billet consists of seven layers of O-1 and six layers of L-6.  It
>is about 1" wide by
>4" long.  The first welding heat worked great, the billet seemed to weld
>together fine.  I put it
>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?
>
>        Thanks,
>          George Ezell (good knives are supposed to rust!)

George,
I think you may have a flux pocket which created the bubble.  Especially if
it got larger as the metal cooled.  A good way to solve it is to make a cut
with a hot cut horizontal to the length of the bar on the bubble, re-flux
and weld pushing the bubble out from the end.  The captured flux will come
out of the pocket and the billet will weld.  I would always try to weld
from one end to the other.  This helps in preventing such inclusions.  Also
while welding layers try to keep the width of the bar to one inch.  On
final weld stretch the bar to the required size.
Bill Fiorini

---

From: [email-masked] (Raymond Coon)
Date: Tue, 2 Apr 1996 14:07:27 -0800 (PST)

general forge-welding,
>and though I have no power hammer I've been seeing what I can do without
it.  I've been having
>pretty good luck on small pieces, but something happened last night I've
never seen.  
>	The billet consists of seven layers of O-1 and six layers of L-6.  It is
about 1" wide by
together fine.  I put it 
>	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
>	  George Ezell (good knives are supposed to rust!)
Weeeelll, there's probably a better answer than this but I guess I'd try
drilling into the bubble with a very small bit to relieve or release
whatever is causing it.  Guess you could drill it either way, through the
top or through the side.  There will of course be some effect on the
pattern.  Hell, I dunno, maybe it won't work at all.  Free advice is worth
what you paid for it!!

I've been making by hand also, and am about to graduate to a 50# Little
Giant.  I _hope_ some of these problems will go away with the power hammer's
ability to hit harder and oftener during a heat.  Besides my arm is getting
very sore.

Good luck