Welding (and I Don't Mean Forge Welding)

By Albin Drzewianowski

Welding I am not going to teach you how to weld. The purpose of this article (and the ones in the next couple of issues) is to help you make decisions about how to incorporate modern welding into you blacksmithing repertoire. I want to give you the context and vocabulary so that when you read articles, internet postings, etc. about welding you will have some idea of what they are talking about. Modern welding is a vast and complicated subject. But there are parts of it that you can incorporate into your "blacksmith toolbox".

A few blacksmiths totally disdain any welding other than forge welding. Many blacksmiths use welding to make tools and jigs, but not in their actual blacksmith projects ("True Path Blacksmithing"). Others use modern welding as part of their forging process. For example, at the May 2005 Blacksmith Days, the featured demonstrators, the IRONMASTERS, used MIG welding? to assemble their sculptural masterpieces. But, the welds were cleaned up so well, that you could not tell that the pieces had been welded together. On the other hand, when you go to some of the stores like PIER ONE IMPORTS, you see a lot of pretty badly made imported iron work intended to look like forged iron but in fact "glued" together with arc welders. Often no effort is even made to clean up the spatter or hide the welds. (Although I must say, the imported ironwork that I see is getting better and better, as compared to just a couple of years ago.)

Just like most aspects of blacksmithing, the only way to master welding is to: PRACTICE; PRACTICE; PRACTICE. You need to burn up a lot of welding rod or gas to perfect your skills. In the past the Carroll County Community College offered a continuing education class in welding at the local vocational-tech high school. It was 10 Wednesday nights for about 4 hours a night. However, I have not seen that class offered in some time now. Occasionally I hear of such classes being offered in other

places, so depending on where you live, you can check around to see if similar classes are offered elsewhere. If you can't get into a class, the next thing would be to hook up with an experienced welder and have them demonstrate the various techniques and then let them critique you as you try to duplicate the various exercises. The important thing here is getting feedback: what you are doing right and what you are doing wrong. If all else fails, there are books on welding that you can study and practice on your own.

Whatever you weld, stop and think about the consequences if that weld should fail at some point. Could someone get hurt if the weld gave way??? If you have designs that include welds of that nature and you don't trust your own welding 150%, get those welds done by an experienced welder. The last thing you want to is to have a railing or gate give way and have someone get injured. Same thing if you are making a tool or a jig: what happens if the weld separates while you are using the tool?? Welds can be very deceptive. On the surface a good weld and a bad weld can look exactly the same. In industry, quality control for welds is usually done with x-rays.

For the hobby blacksmith the options are usually arc welding? vs. gas welding. The ideal shop would have both. If you have to choose between just one or the other, I lean towards getting an Oxy-Acetylene set-up. Not only can you weld, but you can also cut and spot heat. Over the next few issues, I will introduce each of the different types of welding equipment generally found in a hobby blacksmith shop and discuss their relative merits.

-- RebStaup - 08 Feb 2008