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How to Forge Weld

Metal forging is a process that is centuries old. Before the advent of welding torches or electric welding machines, two pieces of metal were joined through forge welding. This process involves heating two metals to their plasticity point, where they are hot enough to become malleable, then hammering and fusing the metals together into one. This technique creates solid bonds that can later be strengthened further, depending on the need.

Things You'll Need

Forge
Anvil
Hammer (sledge)
Tongs
Two pieces of metal
Clamp
Borax
File

Instructions

- 1
  Light your forge and get it to operating temperature. If using a gas fueled forge, there is no need to wait.
- 2
  File down the ends of the two pieces you wish to join so that they each have a diagonal surface where you plan to join them. When welding them together, the diagonal surfaces will mate with each other, providing a stronger bond than with simple butt welding.
- 3
  Place the ends of the two pieces of metal you wish to weld into the forge. Monitor the color of these sections and remove them using tongs once they reach a red-to-yellow color.
- 4
  Dip the ends in borax flux and clamp one piece of metal to your anvil. Hold the other end over the clamped piece in the position you wish to join it with the first. If looking from the side, the two metals' diagonal tips should resemble a "Z" shape where they join.
- 5
  Tap the intersection of the two metals lightly to join them, then tap them slightly harder to complete the bond.
- 6
  Replace the joint of the two metals into the forge when the color fades from a red hue. Add more borax and rotate the joint on the anvil while smoothing the weld site with your hammer. Repeat this step as necessary to obtain the desired result.

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