Find me on the web Kennedy Custom Metal or Kennady Custom Metal

Some additional information about blacksmithing and wrought iron is presented below. There are also much more information provided on my Links page.

Commissioning Work

Below is an article which provides an overview of how to commission work. It provides a general description of commisioning decorative wrought iron. Please feel free to contact me to talk about your project.

Working with an Artist Blacksmith

By Peter Parkinson

Podcasts

Looking for Podcasts? Blacksmith podacsts are available below or on iTunes.

ArtMetalRadio.com

AnvilTalk.blogspot.com

Anvil Talk home page is at http://home.flash.net/~dwwilson/ntba/podcasts/anviltalk.html.

You may subscribe to Anvil Talk at http://home.flash.net/~dwwilson/ntba/podcasts/anviltalk.xml, or itunes at http://phobos.apple.com/WebObjects/MZStore.woa/wa/viewPodcast?id=129058670&s=143441

The Hofi Hammer And The Ergonomic Technique For Moving Metal

http://www.youtube.com/watch?v=9SAWr0c_wpo

Forging Wrought Iron

The process of creating a piece of wrought iron typically begins with a solid piece of metal 20 feet long. First, the metal is cut to the desired length, then it is heated in a forge. Then the red hot iron is hand forged using a hammer and anvil until the desired shape is achieved. Individual forged pieces are then joined together to produce the finished item.

The finished work can then be coated with a variety of protective finishes. For indoor use, a variety of natural finishes can be applied to reveal the color of the metal, which can range from shiny silver to flat black. For outdoor use, the metal can be protected from rusting with a clear acrylic coating, traditional paints or an industrial powder coating. Alternatively the metal can be left uncoated and a rust colored patina will develop. A rusty patina is nice for garden trellis

Items for Home, Garden, Backyard, Barn or Cabin include: Trellises, Plant Stands, Arbors, Tables, Benches, Hooks, Trivets, BBQ Tools, Plant Hangers, Picture Frames, Paper Towel Holder, Mirror Frames, Monitor Stands, Wine Racks, Barstools, Bells, Lamps, Pot Racks, TV Tables, Fireplace Tools, Butterfly Mobile and Unique Gifts. Kennady Custom Metal can create almost any custom forged metal.

Custom ironwork can offer a decorative touch to your home or garden.

Beginning Blacksmithing

I became interested in blacksmithing in 1999. I found a large amount of information on the internet. If you are interested in learning more about blacksmithing check out my Links. One can spend many hours reading about how to set up a shop, light a fire and forge hot iron. After reading many books and surfing the internet, I have found that hands-on learning at NCABANA meetings and blacksmith classes at the John C Campbell Folk School to be the best way to learn. I would like to thank all the authors, webmasters, demonstrators and instructors who have freely shared their knowledge.

If you are interested in learning more about blacksmithing you can find a great deal of information on the internet. On my links page you can find out more on Damascus knives, how to blacksmith, blacksmith classes, blacksmith instructions, blacksmith plans, anvils, forges, ABANA, local blacksmith chapters, clubs, and organizations, NCABANA, SOFA, SBA, forged art, smithy, iron, steel, tools, coal, hammers, chisels, punches, hardie tools, fuller, mandrel, swage block, flux, borax, boric acid, tongs, hot cut, post vise, scroll jig, forge welding, kaowool, insulating firebrick, burners, plans and designs. All the information is free. Check out the Top 50 Blacksmith web sites or browse the Blacksmith's Ring. Find were to buy blacksmith tools and what is on sale. I think one the best place to start surfing is www.anvilfire.com.

Flux for Forge Welding

The role of flux in the welding process is to help clean off inpurities which can hinder the welding process. There are many different products sold for forge welding.  Borax is widely used as a flux for variety of welding and soldering applications.  The products sold to the blacksmiths and ferriers contain borax (anhydrous or hydrated sodium borate) and/or boric acid.  A few product also include iron particle, which are intened to help the welding process.  Although, the iron particles do tend to show in the final piece.

Borax laundry powder is a common forge welding flux.  It contains powdered hydrated sodium borate along with a few other chemicals.  It is the cheapest welding flux you can buy.  The water should to be remove from the hydrated sodium borate before use.  This can be done by baking in an oven at 375 degrees for 1 hour, stirring every 20 minutes to remove clumps.  This can also be acheived by direct contact with a red hot piece of steel.  The problem you can experience with the later approach it this; the powder 'foams' up as the water is rapidly removed.  This can make it difficult to see if the flux is penetrating to the welding surfaces.  In pratice more powder than neccessary is applied, just be safe.

Boric acid is another common welding flux.  This is typically sold as an alternative to sodium borate for use in gas forges.  The boric acid is less corrosive to the refractory lining of the gas forges.  Boric acid is a powder and is sold as roach killer.

In my experince both of the fluxes will work.  Some products are a combination of both laundry powder and roach killer.  The type of flux is not the most important part of forge welding.  The preparation of the metal and temperature of the metal are the most important things.  In fact, you can forge weld without flux.

Several years ago I was introduced to MagiWeld, made by Swan Products.  This welding flux is granular anhydrous sodium borate with iron particles.  It is different from almost all other powdered fluxes.  It is also the most expensive flux I know.  This granular flux is supplied in a plastic bottle with a small pour spout.  The granules are like sand and freely pour out of the bottle.  It is difficult to describe the difference between powdered and granular flux.  I suppose it is similar to powdered sugar versus regular sugar.  Since it is anhydrous it does not 'foam' up like borax laundry detergent.  You can clearly see the flux melt and cover your weld.  This means you use much less flux.  If you use a gas forge, then also means less flux going back into your forge.

Z Weld is a product very similar to Magi Weld, but without iron particles.  This is a free flowing flux that performs just like MagiWeld, but at about half the cost.  Z Weld is pours freely from a bottle and does not 'foam' up link the powdered laundry detergent.  I use Z Weld and would reccomend it.  It is hard to describe how much better Z Weld is, but seeing is believing.  Once you see Z Weld in use you will be sold.  Larry frequently demonstrates forge welding.  Catch him in action at one of his local meetings or invite him to your local blacksmith meeting.  He is also usually at QuadState and the Madison GA conference.  

For more information on see weld visit Zoeller Forge:  http://zoellerforge.com/zweld.html

Below is a video of three types of flux poured from their continers.  The Borax laundry powder flows out of the box, but only about 1/5 if the contents flows out.  The rest is hard as a rock.  The best flowing flux in this video is Z Weld. 

Note:  A metal cone top can is a nice way to dispence Z-Weld.  Also, an aluminum pie dish makes a great catch can when you are fluxing your work (not shown in video)

Click Photo for Video (3 MB WMV file)