Sovereignty Module: Shape the Metal
Shape the Metal
Complete Metalworking Fundamentals: Identification, Properties, and Working Methods
Complete Metalworking Fundamentals: Identification, Properties, and Working Methods
Metal is the backbone of tools, weapons, and machinery. This campaign covers identifying metals, understanding their properties, and the fundamental techniques for working them.
Chapter 1: Metal Identification
| Metal | Color | Weight | Magnetic? | Spark Test | Melting Point | Hardness |
|---|---|---|---|---|---|---|
| Iron/steel (low carbon) | Dark gray | Heavy | Yes | Long yellow sparks, few branches | 2,750F | Moderate |
| Steel (high carbon) | Dark gray | Heavy | Yes | Short white sparks, many branches | 2,600F | High |
| Cast iron | Dark gray (rough) | Heavy | Yes | Short red sparks, many fine branches | 2,100F | Very hard (brittle) |
| Copper | Reddish-orange | Heavy | No | None (no sparks) | 1,984F | Soft |
| Brass | Yellow-gold | Moderate-heavy | No | None | 1,700F | Moderate |
| Bronze | Reddish-gold | Heavy | No | None | 1,900F | Moderate-hard |
| Aluminum | Silver-white | Light | No | None | 1,220F | Soft |
| Lead | Blue-gray | Very heavy | No | None | 621F | Very soft |
| Stainless steel | Bright silver | Heavy | Sometimes | Short orange sparks | 2,600F | Hard |
| Zinc | Blue-white | Moderate | No | None (greenish flame) | 787F | Moderate |
Chapter 2: Steel Carbon Content and Uses
| Carbon % | Classification | Properties | Best Uses | Heat Treatable? |
|---|---|---|---|---|
| 0.05-0.15% | Very low carbon (mild) | Very soft, ductile, weldable | Wire, nails, sheet metal | No |
| 0.15-0.30% | Low carbon (mild) | Soft, tough, weldable | Structural steel, bolts, chain | Barely |
| 0.30-0.60% | Medium carbon | Harder, less ductile | Axles, gears, rails, hammers | Yes |
| 0.60-0.95% | High carbon | Hard, holds edge, less tough | Knives, springs, chisels, saws | Yes (excellent) |
| 0.95-1.50% | Very high carbon | Very hard, brittle | Files, drill bits, taps, dies | Yes |
| 1.50-4.00% | Cast iron | Extremely hard, very brittle | Cookware, engine blocks, anvils | No (too brittle) |
Chapter 3: Joining Methods
| Method | Metals | Strength | Equipment | Skill Level | Reversible? |
|---|---|---|---|---|---|
| Forge welding | Iron, steel | Excellent | Forge + anvil + flux (borax) | High | No |
| Brazing | All metals | Good | Torch + brazing rod + flux | Moderate | Difficult |
| Soldering (soft) | Copper, brass, tin, steel | Low-moderate | Soldering iron or torch + solder | Low | Yes (reheat) |
| Riveting | All metals | Good | Hammer + rivet set + bucking bar | Low-moderate | Destructive only |
| Bolting | All metals | Good (removable) | Drill + tap + bolts | Low | Yes |
| Arc welding | Steel, iron | Excellent | Welder + electrodes + power | Moderate | No |
| Oxy-acetylene welding | Steel, iron, copper, brass | Excellent | Torch + gas tanks + filler rod | Moderate-high | No |
Chapter 4: Basic Forging Operations
| Operation | Description | Tool | Temperature | Purpose |
|---|---|---|---|---|
| Drawing out | Making metal longer and thinner | Hammer + anvil face | Cherry-orange | Lengthen stock (tangs, points) |
| Upsetting | Making metal shorter and thicker | Hammer (hit end) | Cherry-orange | Thicken for bolt heads, joints |
| Bending | Changing direction of stock | Anvil horn or bending fork | Cherry-orange | Hooks, curves, rings |
| Punching | Making holes through hot metal | Punch + anvil (over hole) | Cherry-orange | Bolt holes, decorative |
| Drifting | Enlarging/shaping punched holes | Drift (tapered tool) | Cherry-orange | Eye holes for hammers, axes |
| Splitting | Dividing metal into sections | Hot chisel + anvil | Cherry-orange | Forks, decorative elements |
| Scrolling | Curling end into spiral | Anvil horn + scroll jig | Cherry-orange | Decorative ironwork |
| Forge welding | Joining two pieces permanently | Hammer + flux (borax) | White-yellow (sparking) | Strongest joint possible |
Chapter 5: Heat Colors and Temperatures
| Color (in dim light) | Temperature (F) | Workability | Operations Possible |
|---|---|---|---|
| Black heat (barely visible) | 400-500F | Cannot forge | Tempering only |
| Dark red | 1,000-1,100F | Barely workable | Light bending only |
| Cherry red | 1,300-1,500F | Good working heat | All forging operations |
| Bright cherry / orange | 1,500-1,700F | Excellent working heat | Drawing, bending, punching |
| Orange-yellow | 1,700-1,900F | Maximum workability | Heavy drawing, upsetting |
| Light yellow | 1,900-2,100F | Danger zone (burning) | Forge welding only |
| White (sparking) | 2,100-2,300F | Burning/ruined | STOP — metal is being destroyed |
Rule: Work metal at cherry red to orange. Below cherry = cracking risk. Above yellow = burning (grain damage, permanent weakness). Forge welding requires white heat but only for seconds.
Chapter 6: Essential Metalworking Tools
| Tool | Function | Material | Priority |
|---|---|---|---|
| Anvil (or substitute) | Work surface for hammering | Cast iron/steel (or railroad track section) | Critical |
| Cross-peen hammer (2-3 lb) | General forging | Tool steel head + hickory handle | Critical |
| Tongs (various) | Hold hot metal | Mild steel (forged) | Critical |
| Forge/fire pot | Heat metal | Firebrick + blower/bellows | Critical |
| Vise (post or leg vise) | Hold work for filing, bending | Cast steel | Very important |
| Files (bastard, smooth, round) | Shape cold metal | High carbon steel | Very important |
| Hacksaw | Cut metal cold | Steel frame + HSS blade | Important |
| Punch and chisel set | Make holes, cut hot metal | Tool steel | Important |
| Quench tank | Cool metal (water or oil) | Any container (metal preferred) | Important |
| Wire brush | Clean scale from hot metal | Steel wire | Basic |
Reference Card
- Spark test: high carbon = many branches, short sparks. Low carbon = long sparks, few branches. No sparks = non-ferrous.
- Work steel at cherry red to orange (1,300-1,700F). Below = cracking. Above yellow = burning (ruined).
- Forge welding: heat to white (sparking), apply borax flux, hammer immediately. Must be fast.
- High carbon steel (0.60%+): heat treatable. Can be hardened and tempered for tools and blades.
- Mild steel (below 0.30%): cannot be hardened. Use for structural work, brackets, non-cutting tools.
- Anvil substitute: section of railroad track (set on end for small work, flat for large).
- Flux for forge welding: borax (20 Mule Team from grocery store works perfectly).
- Never quench mild steel in water (unnecessary). Only quench high-carbon steel for hardening.
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