Lesson 1

Read the text: Hand Forging and Welding. Part 1

Smithing, or blacksmithing, is the process of working heated iron, steel or other metals by forging, bending or welding them.

The Forge. The metal is heated in a forge consisting of a shallow pan for holding the fire, in the center of which is an opening from below through which air is forced to make a hot fire.

Air is forced through this hole, called a “tuyere” by means of a hand bellows, a rotary fan operated with crank or lever, or with a fan driven from an electric motor. The harder the air is driven into the fire above the tuyere the more oxygen is furnished and the hotter the fire becomes. Directly below the tuyere is an opening through which the ashes that drop from the fire may be cleaned out.

The Fire. The fire is made by placing a small piece of waste soaked in oil, kerosene or gasoline, over the tuyere, lighting the waste, then starting the fan or blower slowly. Gradually cover the waste, while it is burning brightly, with a layer of soft coal. The coal will catch fire and burn after the waste has been consumed. A piece of waste half the size of a person’s hand is ample for this purpose. The fuel should be “smithing coal.” A lump of smithing coal breaks easily, shows clean and even on all sides and should not break into layers. The coal is broken into fine pieces and wet before being used on the fire.

The fire should be kept deep enough so that there is always three or four inches of fire below the piece of metal to be heated and there should be enough fire above the work so that no part of the metal being heated comes in contact with the air. The fire should be kept as small as possible while following these rules as to depth.

To make the fire larger, loosen the coal around the edges. To make the fire smaller, pack wet coal around the edges in a compact mass and loosen the fire in the center. Add fresh coal only around the edges of the fire. It will turn to coke and can then be raked onto the fire. Blow only enough air into the fire to keep it burning brightly, not so much that the fire is blown up through the top of the coal pack. To prevent the fire from going out between jobs, stick a piece of soft wood into it and cover with fresh wet coal.

Tools. The hammer is a ball pene, or blacksmith’s hammer, weighing about a pound and a half.

The sledge is a heavy hammer, weighing from 5 to 20 pounds and having a handle 30 to 36 inches long.

The anvil is a heavy piece of wrought iron, faced with steel and having four legs. It has a pointed horn on one end, an overhanging tail on the other end and a flat top. In the tail there is a square hole called the “hardie” hole and a round one called the “spud” hole.

Tongs, with handles about one foot long and jaws suitable for holding the work, are used. To secure a firm grip on the work, the jaws may be heated red hot and hammered into shape over the piece to be held, thus giving a properly formed jaw. Jaws should touch the work along their entire length.

1. Match the left part with the right:

1. The metal is heated in a forge consisting of a shallow pan for holding the fire,	a) shows clean and even on all sides and should not break into layers.
2. A lump of smithing coal breaks easily,	b) the jaws may be heated red hot and hammered into shape over the piece to be held, thus giving a properly formed jaw.
3. To prevent the fire from going out between jobs,	c) in the center of which is an opening from below through which air is forced to make a hot fire.
4. To secure a firm grip on the work	d) stick a piece of soft wood into it and cover with fresh wet coal.

2. Complete the sentences with the suggested words: metal, below, enough, heated

The fire should be kept deep _______ so that there is always three or four inches of fire _______ the piece of metal to be _______ and there should be enough fire above the work so that no part of the _______ being heated comes in contact with the air.