Question for the Blacksmiths...

Red Bullets · #1 12-16-2018, 07:59 PM

I was watching a couple youtube videos on the process of charcoal and iron ore fired until you end up with an iron 'bloom', which is then hammered and worked into iron bar stock.
I was wondering if any of the blacksmiths do this process because I discovered a nice seam of high grade iron ore. The seam is actually still silver in color because the iron ore has not oxidized. All the pieces of the ore are around an inch or so in size. Doesn't look like there are many impurities in the ore. I did take a piece of the ore to a geologist at the U of A and was told it was about 70% iron. I wasn't sure what it was because it was silver in color. It would be easy to fill a few pails with some but it is really heavy material for the 200 yard walk and carry.

I was wondering if any of the AO blacksmiths smelt their own iron/steel starting with raw iron ore, charcoal and a furnace? If so I am wondering if any blacksmiths would be interested in a pail or two of this ore? The seam I found is 6 to 12 inches thick and who knows how long or deep into the cutbank. I wouldn't want anything for it , I just think it would be nice for a blacksmith to be able to say that their smithed items or blades are definitely "made in & of Alberta".

If a smith wants some good iron ore send me a pm. The ore is located close to Edmonton in a place where no one goes walking. Except me.

Boogerfart · #2 12-16-2018, 08:15 PM

I am by no means a expert but 70% seems impressive! Makes me want to try a few experiments... I've been told that some of the ore being mined in Australia is so pure you can weld the chunks together. Is the ore you're finding quite crumbly? I've got a couple welders...

buckbrush · #3 12-16-2018, 08:25 PM

Not sure about any of this. Interesting idea. I've got a good propane forge if you wanted to try heating a chunk up and see if its workable?

Red Bullets · #4 12-16-2018, 09:05 PM

Quote:

Originally Posted by buckbrush

Not sure about any of this. Interesting idea. I've got a good propane forge if you wanted to try heating a chunk up and see if its workable?

Wonder if a propane forge would work. 1300 degrees celcius needed. A person needs to add a bit of material and fluxing sand as the smelting goes along. I think it takes a few hours.

buckbrush · #5 12-16-2018, 09:47 PM

Quote:

Originally Posted by Red Bullets

Wonder if a propane forge would work. 1300 degrees celcius needed. A person needs to add a bit of material and fluxing sand as the smelting goes along. I think it takes a few hours.

hmm... might have to do some reading. I know my forge will get hot enough to melt steel (found out where the saying 'too many irons in the fire' came from)
I don't have a crucible though. Would be great to be able to say you built a knife from raw materials though. Have done some Damascus and welded cable with my forge but need to track down a crucible..

Boogerfart · #6 12-16-2018, 10:01 PM

Is it possible to make a crusible as well?

Jeron Kahyar · #7 12-17-2018, 10:28 PM

Quote:

Originally Posted by Red Bullets

Wonder if a propane forge would work. 1300 degrees celcius needed. A person needs to add a bit of material and fluxing sand as the smelting goes along. I think it takes a few hours.

A propane forge won't work for this application. In order to get it workable you not only need to get impurities out but also add carbon to the iron ore.

This is done by carbon diffusion. As the melted ore pases down alongside the burning charcoal it picks up carbon. This transforms it into steel or more accurately bloom steel. After that you can work the bloom down and fold it over re welding it to push the impurities out. I have never actually done this but as I understand it is quite a lengthy process and not terribly easy to do. But when you are done you could make one hell of an authentic Katana!

NW Tradegunner · #8 12-18-2018, 09:34 AM

One other thing to consider is other elements contained in the ore that will prevent it's fusion and malleability. One of the old tricks of the trade; when a fellow blacksmith would visit his so called friend blacksmith, he throw a penny in the fire pot of the forge, when the blacksmith wasn't looking. The fumes from the melted penny would prevent the fibers of wrought iron or if forge welding was done; would prevent the fibers or weld from joining. This would sometimes go on for a few days! I'm guessing your case, other foreign elements would do the same. Best to stick to new or scrap known metal, be it old files, springs, etc.

Red Bullets · #9 12-16-2018, 09:01 PM

Quote:

Originally Posted by Boogerfart

I am by no means a expert but 70% seems impressive! Makes me want to try a few experiments... I've been told that some of the ore being mined in Australia is so pure you can weld the chunks together. Is the ore you're finding quite crumbly? I've got a couple welders...

I never tried hammering it but it is solid and dense. In the seam the 'rocks' are very angular indicating they have not traveled far and gotten rounded. Almost looks like you could hammer it flat as it is.

This video is a good explanation of how a bloomery furnace is made and works. https://www.youtube.com/watch?v=uSgk73-W0kY

It work be such a nice skill to go onto the land with nothing but a hammer and an anvil and make your own weaponry and metal needs with the natural materials.