# Sovereignty Module: Command the Forge

## Complete Metalworking: From Ore to Finished Tool

Metal transforms civilization. This campaign covers prospecting, smelting, forging, casting, and finishing metals from raw ore to finished products.

### Chapter 1: Metal Properties and Uses

| Metal | Melting Point | Hardness | Availability | Primary Uses | Difficulty |
|---|---|---|---|---|---|
| Copper | 1,984°F | Soft | Moderate (native, oxide ores) | Tools, wire, vessels, alloys | Low-moderate |
| Tin | 450°F | Very soft | Rare (cassiterite ore) | Alloying (bronze), plating | Low |
| Bronze (Cu+Sn) | 1,742°F | Moderate-hard | Made (copper + tin) | Tools, weapons, bearings, bells | Moderate |
| Iron (wrought) | 2,800°F | Moderate | Common (oxide ores) | Tools, hardware, structural | High |
| Steel (iron + carbon) | 2,500°F | Hard-very hard | Made (iron + charcoal) | Cutting tools, springs, weapons | Very high |
| Lead | 621°F | Very soft | Common (galena ore) | Plumbing, bullets, solder, weights | Very low |
| Zinc | 787°F | Moderate | Moderate (sphalerite) | Galvanizing, brass alloy | Moderate |
| Brass (Cu+Zn) | 1,700°F | Moderate | Made (copper + zinc) | Hardware, instruments, decorative | Moderate |
| Silver | 1,764°F | Soft | Rare (native, sulfide ores) | Currency, jewelry, antibacterial | Moderate |
| Gold | 1,948°F | Very soft | Very rare (native, placer) | Currency, jewelry, electronics | Low (if found) |
| Aluminum | 1,221°F | Soft-moderate | Common ore, hard to smelt | Lightweight structures (modern) | Extreme (electrolysis) |

### Chapter 2: Prospecting and Ore Identification

| Ore | Metal | Color/Appearance | Streak | Specific Gravity | Location |
|---|---|---|---|---|---|
| Hematite | Iron | Red-black, metallic | Red-brown | 5.0-5.3 | Widespread, sedimentary |
| Magnetite | Iron | Black, magnetic | Black | 5.2 | Igneous rocks, sand |
| Bog iron | Iron | Brown, porous, rusty | Brown | 3.5-4.0 | Swamps, bogs, streams |
| Malachite | Copper | Green, banded | Green | 3.9-4.0 | Near copper deposits |
| Azurite | Copper | Blue, crystalline | Blue | 3.8 | Near copper deposits |
| Native copper | Copper | Copper-colored metal | Copper | 8.9 | Lake Superior, volcanic |
| Galena | Lead | Silver-gray, cubic crystals | Gray-black | 7.4-7.6 | Limestone regions |
| Cassiterite | Tin | Brown-black, heavy | White-brown | 6.8-7.1 | Granite regions, alluvial |
| Sphalerite | Zinc | Brown-yellow, resinous | White-yellow | 3.9-4.1 | With galena (limestone) |

### Chapter 3: Smelting

| Metal | Ore | Furnace Type | Temperature | Flux | Charcoal Ratio | Yield |
|---|---|---|---|---|---|---|
| Copper | Malachite/azurite | Pit or shaft | 2,000°F+ | None (oxide ores) | 3:1 charcoal:ore | 60-80% |
| Iron (bloom) | Hematite/bog iron | Bloomery | 2,200-2,400°F | Limestone | 5:1 charcoal:ore | 20-50% |
| Lead | Galena | Open fire/hearth | 1,000°F+ | None | 2:1 | 70-90% |
| Tin | Cassiterite | Pit fire | 1,200°F+ | None | 2:1 | 60-80% |
| Bronze | Copper + tin | Crucible | 2,000°F | Charcoal cover | N/A (melt metals) | 90%+ |

Bloomery iron smelting: Build shaft furnace (clay/stone, 3-5 ft tall, 12" internal diameter). Tuyere (air pipe) at base. Preheat furnace with charcoal. Alternate layers: charcoal + crushed ore + limestone flux. Pump bellows continuously (4-8 hours). Iron particles weld together into "bloom" (spongy mass). Remove bloom. Hammer while hot to consolidate and expel slag. Result: wrought iron. Requires significant charcoal (100+ lbs per smelt).

### Chapter 4: Forge Work

| Operation | Temperature (color) | Tools | Purpose | Difficulty |
|---|---|---|---|---|
| Drawing out | Yellow-white (2,000°F+) | Hammer, anvil | Lengthen/thin metal | Basic |
| Upsetting | Yellow (1,800°F+) | Hammer, anvil | Thicken/shorten metal | Basic |
| Bending | Orange-yellow (1,600-1,800°F) | Hammer, vise, forms | Create angles/curves | Basic |
| Punching | Orange (1,400-1,600°F) | Punch, anvil (hardy hole) | Create holes | Basic-moderate |
| Splitting | Orange (1,400-1,600°F) | Hot chisel, anvil | Divide metal | Basic-moderate |
| Welding (forge) | White (2,300°F+) | Hammer, flux (borax) | Join two pieces permanently | Advanced |
| Twisting | Orange-red (1,200-1,400°F) | Vise, wrench | Decorative, strengthen | Basic |
| Scrolling | Orange (1,400-1,600°F) | Scroll jig, hammer | Decorative curves | Moderate |
| Fullering | Yellow (1,800°F+) | Fuller tool, hammer | Create grooves/necks | Moderate |
| Swaging | Yellow (1,800°F+) | Swage block/die | Shape to form | Moderate |

Heat colors (critical reference): Black heat = below 900°F (no work). Dark red = 1,000°F. Cherry red = 1,400°F. Orange = 1,600°F. Yellow = 1,800-2,000°F. Light yellow = 2,100°F. White = 2,300°F+ (welding heat). Work metal at yellow-orange for most operations. Never hammer cold (cracks). Never overheat (burns/crumbles).

### Chapter 5: Heat Treatment

| Process | Purpose | Procedure | Result |
|---|---|---|---|
| Hardening | Make steel hard | Heat to critical temp (cherry red), quench in oil/water | Very hard but brittle |
| Tempering | Reduce brittleness | After hardening: reheat to specific color, air cool | Tough + hard (balanced) |
| Annealing | Make soft (workable) | Heat to cherry red, cool very slowly (in ash/vermiculite) | Soft, easy to file/drill |
| Normalizing | Relieve stress | Heat to cherry red, air cool | Uniform grain, stress-free |
| Case hardening | Hard outside, soft inside | Pack in charcoal, heat 2-4 hours, quench | Wear-resistant surface, tough core |

Temper colors (steel): Pale straw (430°F) = razors, engraving tools. Straw (450°F) = knives, chisels. Dark straw (470°F) = axes, punches. Brown (490°F) = scissors, cold chisels. Purple (520°F) = swords, springs. Blue (570°F) = springs, screwdrivers. Light blue (600°F) = soft springs. Gray (640°F) = too soft for tools.

### Chapter 6: Essential Projects

| Project | Steel/Iron | Skills Used | Time | Difficulty | Priority |
|---|---|---|---|---|---|
| Knife (from file) | High carbon steel | Drawing, grinding, heat treat | 4-8 hours | Moderate | Critical |
| Axe head | Medium carbon steel | Drawing, punching, welding | 8-16 hours | Advanced | Critical |
| Nails (hand forged) | Mild steel/iron | Drawing, heading | 2-5 min each | Basic | High |
| Hinges | Mild steel | Drawing, punching, bending | 1-2 hours | Basic-moderate | High |
| Tongs (blacksmith) | Mild steel | Drawing, bending, riveting | 4-8 hours | Moderate | Critical (make first) |
| Hooks and hardware | Mild steel | Drawing, bending, scrolling | 30 min-2 hours | Basic | High |
| Plow point | Medium-high carbon | Drawing, hardening | 4-8 hours | Moderate-advanced | Critical |
| Hammer head | Medium carbon | Drawing, punching, heat treat | 4-8 hours | Moderate | Critical |

### Reference Card

1. Heat colors: cherry red = 1,400°F (general work). Yellow = 1,800°F (heavy work). White = 2,300°F (forge welding only).
2. Never hammer cold steel: it cracks. Return to forge when color drops below dark red. Patience prevents waste.
3. Quench in oil for most tools (less shock than water). Water quench for maximum hardness but higher crack risk.
4. Temper after hardening: ALWAYS. Un-tempered steel shatters. Straw color for knives, purple for springs, blue for screwdrivers.
5. Charcoal for smelting: 5:1 ratio (charcoal to ore for iron). Make charcoal first. Enormous quantities needed. Plan ahead.
6. Bog iron: free iron from swamps. Brown, porous, rusty lumite. Collect, dry, smelt in bloomery. Renewable (regrows in 20-30 years).
7. Forge weld: surfaces must be clean (wire brush), fluxed (borax), and at white heat. Strike fast, firm, center first.
8. First project: make tongs. You need tongs to hold everything else. Borrow or use pliers for the first pair.