The Riddle of Steel... A Brief History of Ancient Metalworking

The Riddle of Steel... a brief history of ancient metalworking https://www.dailykos.com/stories/2017/6/22/1673870/-The-Riddle-o...
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The Riddle of Steel... abrief history of

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Manly compacting of homemade iron bloom... oh, wait... that's just crappy slag. Damnit. From my first smelt.
$ RSS (/user Lets say you need a hammer. You could go to the nearest hardware store and
/AndyT/rss.xml) buy one. After all, that is what most people would do, right?
REBLOGGED BY
Or you could mine/source iron ore, smelt it to get iron, carburize the iron to make steel
and smith yourself a hammer. Guess which method I have chosen?
Community Spotlight
(/blogs/rescue)
Lets leave politics behind for a minute and delve into the RIDDLE OF STEEL
Recommended (/blogs
/recommended)
TAGS
#Archeology (/news
/Archeology)
1 of 31 6/22/17, 1:33 PM
#Bronze (/news
Conan - The Riddle of Steel
/Bronze)
#Community (/news
/Community)
#Copper (/news
/Copper)
#Craft (/news/Craft)
#geology (/news
/geology)
#History (/news
/History)
#iron (/news/iron)
#Metal (/news
/Metal)
Steel remade the world and its tale is a long one but worth reading and Ill do my best
#rescued (/news to make sharp and incisive rather than dull.
/rescued)
#Science (/news
/Science)
DISCLAIMER: this diary is Eurocentric. Thats because that is what I
know; European history from the Bronze Age through Viking Period.
#Steel (/news/Steel)
Also, my genetics, according to 23 & Me, are 99.9% European. Much to
#RescuedtoRecomm my horror I discovered that Im a prime candidate for the so-called
(/news
Master Race. Fortunately, I am also0.2% Ashkenazi Jew ; I am VERY
/RescuedtoRecomm
proud and possessive of that 0.2% of my DNA!! I also have 315 genetic
#IronAge (/news variants associated with Neandandertals!!! Wait, what was I saying? Oh,
/IronAge) yeah, Im Eurocentric because that is where my ancestry and interest
lies, so feel free to ignore this post if you regard this as inappropriate
or exclusionary.
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BEFORE STEEL:
!
Metal entered human usage thousands of years ago, although our predecessors were
" not kind enough to invent a language and system of writing so the event could be
recorded. However, they were kind enough to leave it amongtheir stone artifacts so
# (https://twitter.com/intent/tweet?url=https%3A%2F
that we could correlate its appearance with human activity. Interestingly, it was not just
our species of human that used metal; it was also the Neandertal (http://www.pnas.org
%2Fwww.dailykos.com%2Fstory%2F2017%2F6%2F22%2F1673870%2F-
/content/109/6/1889.full). We were using it in Africa thesame time they were using it in
The-Riddle-of-Steel-a-brief-history-of-ancient-metalworking&
Europe and for the same reason. Iron oxide in the form of red and yellow ochre is an
text=The+Riddle+of+Steel...+a+brief+history+of+ancient+metalworking)
effective pigment. You can color clothing, bones, and cave walls with it. Maybe you
could dye skin with it as well for ritual?
Anyway, humans used iron ore for decoration and painting for about 240,000 years
when, about the time of the dawn of agriculture some 10,000 years ago more or less,
we suddenly got interested in elemental copper and copper ore. Copper ore is
gorgeous. If I was a Mesolithic/Neolithic guy or gal looking to get laid, Id scrounge up
some really beautiful green malachite and gift that to the object of my affection.
Malachite Green copper ore. If that didntget you laid in the Mesolithic, nothing will. Well,
except maybe treating your partner decently, listening to them and meeting their physical
and emotional needs. No? Well, better find some malachite.
Elemental copper, which can be found on rare occasion, is also quite eye catching. And
if you bash it with rocks, you can make bracelets or bangles from it which slowly turn
green as they oxidize.
2 of 31 6/22/17, 1:33 PM
Elemental copper. THE WAY to get laid in

the Neolithic. Unless you treat youroh,
never mind. Dig up some copper.
CHALCOLITHIC AGE (COPPER):

One theory holds that pottery led to smelting of copper. Heres how it goes: weve had
pottery for about 28,000 years but your color range was basically black, brown, reddish
brown, yellowish brown and other brown variants. Some enterprising ceramics artist
saw the awesome colors of copper ore and said: I want beautiful pots! Those will out
trade the pots of the losers round the river bend. They incorporated blue and green
copper ore into a pot despite elders saying Dude, been there, done that, you wind up
with green rocks and ceramic bits. This potter had a plan crush the copper ore into
small chunks, fire the pot super-hot and melt the green into the pot. So they popped
that sucker into the best clay oven they have and with some help kept feeding charcoal
into the fire and pumping those bellows to keep the air going and what actually
happened is they created areducing atmosphere an atmosphere where all the
oxygen was incorporated into carbon monoxide or dioxide and water gassed off. This
freed up some of the the copper atoms (probably in an impure state) which pooled as
a liquid in the bottom of the kiln.
The potter was probably disappointed and those bastards round the river bend
laughed at him or her for wasting time and energy on foolishness. But somebody was
curious about that pool of orange gold liquid at the bottom of the kiln (brief digression:
lead and tin may have been smelted earlier than copper. Tin melts at 450F/232C; lead
at 621F/328C so campfire temperatures could have done the job and bits of each have
been found at the atal Hyk site in Anatolia (Turkey), and dated from about 6500
BCE but apparently no specialized use was made of them).
It didnt take long to figure out copper made lots of nifty shit like arrowheads, knives
and axes. But for all that, copper did not supplant flint as the major tool making
material. First, copper was harder to obtain than stone. Second, its edge is inferior to
stone. The one big advantage copper had over stone was that although brittle, it is less
brittle than stone. So a copper arrowhead could be shot multiple times before
breaking whereas every time a stone arrowhead strikes any remotely hard surface, it
shatters.
3 of 31 6/22/17, 1:33 PM
Reproduction early European copper age knife. Surprisingly sharp.
BRONZE AGE:
Around 6,200 years ago somebody remembered the soft, semi-silvery stuff they
smelted from the black rocks (cassiterite) and tossed some in with the copper and
BANG! Just like that it was the Bronze Age.
Smelting tin
Video showing smelted tin being poured into ingots in Cornwall, UK. This does not show the mining of the
ore, the crushing of the ore, the sifting of the ore with water. Just taking the final bits of ore, some charcoal
and smelting the tin from them. Im the dude with the sexy legs working the bellows. The guy pouring the
tin is Nik Megalithic of Shamanic Bronze.
Much like America today, being rich in the Bronze Age was pretty fucking cool. If you
were a dudette you might get these mysterious, massive golden-colored bronze belt
plates that shone in the sun, necklaces and bracelets of actual gold, amazing brooches.
If you were a dude you might get an axe that holds an edge for a pretty long time and
isnt brittle. If you were a priest or possibly priestess you might get a funny looking gold
hat. Musicians had the option of amazing, wonderful horns.
4 of 31 6/22/17, 1:33 PM
A re-enactment of the Egtved Girl from Denmark. You see that bronze plate around her waist? That was
a kings ransom at least. Something that large of metal from that time was invaluable. You aint gettin
her attention with colored rocks. You better have metal bling. And see that horn? That, my friends, is a
bronze lur. Incredibly hard to reproduce even with modern technology, it produces a deep resonant
sound.
5 of 31 6/22/17, 1:33 PM
Gold hats of the Gods? German Bronze Age hats covered in incredibly thin gold foil decorated with
breathtaking detail...
And warriors
Elite warriors were pretty much Gods. Imagine, you have your best stone axe and
spear, some furs to protect you and you walk out on the battlefield and the guy across
from you pulls out a sword of gold that blindingly reflects the sun that must have
been terrifying.
Illustrations of northern European Bronze Age warriors with typical weaponry.
6 of 31 6/22/17, 1:33 PM
Bronze Mindelheim sword by Neil Burridge of Bronze Age Swords (http://www.bronze-

age-swords.com/); hilted and polished by Jeroen Zuiderwijk of Barbarian Metalwork (http://1501bc.com
/metalworking/).
Bronze changed virtually all the cultures and peoples Africa, Europe and Asia. It was
not due to the properties of bronze itself. Not because bronze is easier to work than
copper (though it is), because it can be more easily resharpened (it can) or because
larger objects can be made of it. Nor was it due to everybody getting bronze, because
very few actually did. Nor because bronze allowed massive armies and military
campaigns to take place (though it certainly helped; look up the Sea Peoples and Troy),
but rather because in order to have bronze you have to have tin. And tin is not
common, which forces the extension and expansion of the already impressive trade
routes throughout the world. The hunger for tin to make bronze revolutionized trade
and travel. Neolithic peoples traded; we find flint hundreds of kilometers from its
source mine. But not like they did in the Bronze Age. Boats came of age in this time. No
more hollowed out logs;now you get ships, sails and so on. Wheeled carts became a
lot more sophisticated, and interest in animals to pull them boomed.
Less positive side effects took place also. Slavery boomed. Think about it. You want to
spend all day in a sunless hole breaking rocks for tin and copper? Or do you want to
stand in the warm sun with some mead and fur and point a spear at other people and
make them work all day in a sunless hole breaking rocks for tin and copper? (I probably
would have been the guy lying on the beach under the sun with wine telling everybody
loudly how we should really get around to improving working conditions for the poor
bastards in the mines breaking rocks maybe send a set of stern hieroglyphs on
papyrus to the head thug at the mines liberalsnever change.)
7 of 31 6/22/17, 1:33 PM
NOTE ON THE AMERICAS
When I talk about this online,somewhere in here some racist moron

chimes in with: Indians never figured Bronze out! Thats why
Europeans kicked their ass! As usual, the racists are dead wrong and
totally ignorant as to why. The issue is TIN. To make bronze you need
it. And Native Americans didnt have it. There was anitty-bitty deposit
from the place we now call Mexico and a larger deposit known in what
we call Bolivia today. Contrast that with Southeast Asia and Europe
dotted with major tin deposits. Of course Native Americans never
entered the Bronze Age; they did not have the necessary ingredients. It
had nothing to do with intelligence.
By the way many Native American tribes had an awesome copper

culture
Native American copper artifacts from the great lakes region.
Tin was also the downfall of bronze. People got sick of kissing up to those who had the
tin. They wanted a more democratic, less elite metal. And what the people want, the
people get! (Thats actually nonsense; its really what the elites want that they get. And
thats who wanted to break from bronze. Nobody cares what the people think. They
never have and, unless we make them, never will.)
IRON:
QUIZ TIME! Both of these daggers were in the tomb of Egyptian King Tutankhamun. The one on top is
made of SOLID GOLD. The one on bottom is made of crappy iron, not even steel. Which dagger was
regarded as more valuable at the time of Tuts death? IRON baby. That is meteorite iron, from before
the dawn of the Iron Age in Egypt.
So we are back to the hammer I started the diary with. I want to make a tool from dirt.
My goals are actually a little more ambitious. I want to make a hammer, an anvil and
tongs a complete Iron Age blacksmithing kit. And I want to make them myself,with
iron I have made myself by my own hands. How could this be done?
8 of 31 6/22/17, 1:33 PM
Iron age tongs, spoon, hammer and anvil.
As you can see above, archeologists, metallurgists, and geologists have ideas and
theories that make sense about how and why humans might have stumbled upon
copper smelting. Tin, lead, silver these all follow as well. Iron doesnt.
Smelting copper, tin, silver, lead can all be done in a relatively small furnace with
moderate billows to provide air. See tin smelting video above. Easy peasy.
Temperatures required to melt bronze (1832F/1000C) and Copper (1983F/1084C)
are also manageable with moderate billows and not too much effort. Twenty
minutes pumping the bellows shown in the tin smelting video and you have liquid
bronze. Thirty minutes, forty minutes, liquid copper. Iron is a totally different
animal. It never becomes liquid in smelting and you need to hit 2282F/1250C to
smelt it. You will never reach that temperature with the bellowsin the tin smelt
video. Never. And from experience using manual bellows, increasing the
temperature the 151F/66C from molten bronze to molten copper feels incredibly
difficult. You have to maintain a higher bellow speed and cannot lose rhythm or it
will not melt.
Iron needs time for the smelting reaction to take place which means a long,
vertical chimney through which the iron travels slowly. None of the other metals
require that.
Smelting copper, tin, silver, lead are all resource intensive. Irons use of resources
dwarfs all of those metals. You are using several times the amount of charcoal to
succeed.
So basically, we know how to smelt iron take iron ore and convert it to actual iron -
because we live 3,300 years after the discovery of iron smelting (China may be a
couple of hundred years earlier than that. Their progression was the opposite of the
west in China they produced high carbon cast iron and only later decarburized the
iron to make forgeable steel and iron. In the west low carbon iron was made which
needed to be carburized to make steel).We have no clear understandingof HOW this
process was discovered, refined and perfected. But we do know, from archeology,
from writings, from experimental archeology and from lunatic blacksmiths like
me,what the steps are to make tools from dirt. So lets abandon discussions of history
and talk about how its done!
As we discussed above, I will need a chemical reaction chamber with a reducing

atmosphere. I will use burning charcoal which is carbon and ash to break the bond
between oxygen and iron in the ore. The oxygen will gas off into the atmosphere as
carbon monoxide or dioxide (either way, Im helping give you a warm summer, if only
in a minor way). Meanwhile the free iron atoms will be carried by molten silica down
through the reaction chamber (which looks a lot like a chimney) to form a loose
agglomeration of iron, silica and some other impurities that is called a bloom of iron.
This is how a bloomery furnace operates to make iron from dirt.
9 of 31 6/22/17, 1:33 PM
Why dont I just buy the friggin iron and make my hammer, anvil and
tongs? In Europe that would be relatively straightforward. There is a
tremendous amount of wrought iron available from centuries of
ironwork. In the Americas, it is harder. In the 1850s the Bessemer
process (and Gilchrist-Thomas converters) skipped the whole iron
stage and went straight to steel. It is not easy or cheap to get actual
iron nowadays. However, you can get mild steel (low carbon steel)
easily. But if I did that, I wouldnt get to play with fire in a constructive
way nearly as much.
STEP ONE: IRON ORE

Where to get iron? Im in Texas and ironically, considering how big Texas is, Texas is
relatively iron poor and Ive learned that some property owners who have iron
deposits on their lands would rather shoot you than let you take home a bunch of
reddish rocks. However, a fellow blacksmith in the Carolinas sent me about 80lbs of
limonite ore which he has found easy to smelt. I also found that a local ceramics shop
sold powdered hematite ore in 50lb bags as a colorant for clays.
Turns out that either way you go you have some work to do. Large hunks of rock are
not easily smeltable and if you try to put powder into a chimney into which you are
blowing air it blows out!
PREPPING ROCK ORE

Surface area is important; the more surface areathe material has, the more
opportunity there is for the reducing reaction of the burning carbon (charcoal) to steal
the oxygen atoms from the iron ore (FeO3). So you are going to want to bust up your
rocks into small, roughly 1 cm pieces. But rocks are damn hard to break unless you
cook them in a fire first. Water within them turns to steam and fractures the rocks and
the heat itself makes them more friable. A couple of hours in the fire followed (after a
cooling off period) by a couple of hours with a hammer and you have rocks the
consistency you need.
Hey neighbor! Bar-B-Q?

Naw, just roasting iron ore.
Whut?
10 of 31 6/22/17, 1:33 PM
Thats the size Im going for!
PREPPING POWDERED ORE

I thought this would be easy. I was wrong. The solution to avoiding the powder blowing
out is to make a bread of sorts out of it by cooking it into flour. My girlfriend and her
friends Cris and Lana volunteered to do this and used a corn flour,and mixed about
10lbsof ore to 1.25cupsof flour producing hematite brownies,which were popped
into the oven for an hour and a halfof cooking. Over four days they did 100lbs of ore.
But while they were doing that, like a typical sexist lout I was lounging around
spending days playing with my big, damp, sticky, fuzzy balls
Ummmm. Yummy hematite brownies.
STEP TWO: BUILDING THE FURNACE

get your mind out of the gutter. I was mixing 300lbs of sand in with 150lbs of clay and
40lbs of peat moss (our ancestors preferred horse manure) to make hundreds of clay
balls. These balls would become briquettes for the walls of the furnace. I used a
foundation of brick and built a chimney shaped furnace. I firedthe sucker to make it
hard (yeah, there is a lot of phallic imagery in this, but wait, the birthing chamber is
coming) and shrink the clay so it is ready for the multi-thousand degree ordeal ahead
of it.
11 of 31 6/22/17, 1:33 PM
Mixing clay for the stack. I recall sweating a lot.
Pictures of my balls. Still more to go. But like I told you: big, damp, sticky and fuzzy. At least with the
peat in place of the horse manure they were not overly smelly.
12 of 31 6/22/17, 1:33 PM
When we finished an angel came and blessed our bloomery smelting furnace. Im not sure why. The
runes on the furnace dedicate it to Odin...
Firing the rst smelting stack.
So, I might have gotten carried away when firing the the first smelting stack. I might also have met three of
the local fire department and been told not to do this EVER AGAIN. I might also have kinda ignored them
STEP THREE: PREPPING THE CHARCOAL

Remember how important surface area is with the iron ore? Same deal with the
charcoal. Our ancestors had to gather up gather a couple hundred or more pounds of
hardwood, set it on fire then bury the pile in dirt to make charcoal. Monitor it over a
couple of days then harvest the charcoal before chopping the charcoal lumps into
small (3cm on each side) bits.I just had to go to Home Depot (Lowes sells crap
charcoal) and buy 100lbs of charcoal and chop it into chunks.
13 of 31 6/22/17, 1:33 PM
Whohoo! Only 90 more pounds to go!
ACTUAL SMELTING
Preheat the furnace for an hour or so by burning scrap wood in it. Get your air supply
going either by beating the serfs so they pump the bellows or, as in my case, turn on
the shop vac set on BLOW rather than VACUUM. Then, fill the furnace halfway with the
charcoal you have been chopping up. Give it a few minutes to get going then fill to the
very tip top with charcoal. Let it burn down to about six oreight inches. Throw in more
charcoal. Do this two or three times and then
14 of 31 6/22/17, 1:33 PM
Adding charcoal. By the way, those are authentic Iron Age plastic buckets and leather apron in the
picture not.
Start adding iron. Youll add iron, then charcoal, then iron, then charcoal and on and
on.
15 of 31 6/22/17, 1:33 PM
Adding hematite pellets.
At some point you need to tap for slag by hammering an iron rod into the furnace and
letting the slag (molten silica) drain out.
Molten silica, or slag, flowing from the tap. I should have tapped more. A LOT more.
16 of 31 6/22/17, 1:33 PM
Finally the burn rate slows which hopefully means you have a large lump of iron at the
bottom of the furnace. Time to open her up and see what is inside!!!
It is possible that my first smelt got a little out of hand at times
Furnace has the English Fire Heart transliterated into Elder Futhark runes on it.
DIGRESSIONON ALCHEMY
Alchemy (transforming base metals to gold) doesn't sound so nutty

after reading this does it? Without chemistry, but KNOWING this rock
turns to copper, this one to tin, this one to iron, this one to silver... well,
cooking rocks to find gold might be a logical progression...
And for my second smelt this past weekend, thiswas the grand finale:
Opening bloomery smelt chamber
Which was actually a terrible thing. The river of flowing slag indicated that I had not
tapped and drained a significant amount of slag and the iron marinated in the slag,
never forming a bloom. The correct way a smelt is supposed to end is below:
17 of 31 6/22/17, 1:33 PM
Photo courtesy of Mark Green, from 2013 Magnetite smelt.
Once you have the bloom of iron, youre pretty much done and it gets easy from there.
All that is left is:
compacting the bloom with sledges to squeeze out the slag and impurities
compress it into a kind of puck
cut it (while hot! Dont let it cool) so it will fit in your forge
make a billet of iron out of it (If it crumbles you may have cast iron over 2%
steel and that is useless)
refine the billet by folding and reforging several times
test the billet for usefulness by twisting till it breaks (3.5 turns hot is good; 0.5
turns or less when cold indicates brittleness)
determine (roughly) carbon content. If you have good steel,yea for you!!! If you
have no sparks, that means wrought iron and you may need to make an Aristotle
furnace and carburize your material
forge a tool, sculpture or whatever out of it! Easy!
Epilogue
So Ive tried twice and not gotten a bloom of smelted iron. Will I try again? Oh, hell yes.
Im a Texas Democrat; my kind doesnt give up in the face of failure. I will make iron.
Then steel. Then I will forge an anvil as illustrated below, and a hammer and tongs
and its only about 100 hours of labor each time...
And then I will make swords the proper way my ancestors did Valhalla calls!
Homage to the Vehmaa sword found in Finland by Jesus Hernandez. (http://jhbladesmith.com/homage-

to-the-vehmaa-sword/) One of the most complex pieces of metalwork from the viking age. Look at the
patterns in the blade do you see the serpent?
18 of 31 6/22/17, 1:33 PM
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36 COMMENTS Comment Settings
( f ) Recommend ( r ) Reply ( p ) Parent ( o ) Open/Close ( j ) Next Unread ( k ) Prev Unread More hints...
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(/user/AndyT)
AndyT (/user/AndyT) Jun 22 09:21:29 AM (/comments/1673870/66911873#comment_66911873)
Tip Jar
! 34 Recommend
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(/user/radicalink)
radicalink (/user/radicalink) Jun 22 09:51:24 AM (/comments/1673870/66912079#comment_66912079)
Fabulous diary. My highest recommendation!
! 11 Recommend
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(/user/River Rover)
River Rover (/user/River Rover) & radicalink
Jun 22 10:49:27 AM (/comments/1673870/66912644#comment_66912644)
Mine too
21 of 31 6/22/17, 1:33 PM
! 5 Recommend
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(/user/oslyn7)
oslyn7 (/user/oslyn7) Jun 22 10:03:28 AM (/comments/1673870/66912200#comment_66912200)
Fun read! Thanks. When we were working in Zambia in the 80s we camped near an ancient iron
smelting site. If i remember correctly, it had been in use for hundred of years but was shut down in
the 1800s by the British colonists who outlawed domestic iron, instead forcing Zambians to buy
imported iron and steel--British, of course.
! 6 Recommend
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(/user/Scruffy Looking Nerf Herder)

Scruffy Looking Nerf Herder (/user/Scruffy Looking Nerf H
This is way better than any Wiki-Wormhole Ill go down today, thank you!
! 3 Recommend
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(/user/DyedInTheWool)
DyedInTheWool (/user/DyedInTheWool) Jun 22 10:16:53 AM (/comments/1673870/66912326#comment_66912326)
Thank you for a practical story that is as informative as it is humorous. In the course of my studies
about fifteen years ago, I found occasion to attempt what you have done here, but was daunted by
the challenge; I realize now that I missed an opportunity to learn if only from failure by doing:
a valuable experience.
It is unfortunate that you feel obliged to apologize for writing a diary that includes a European
cultural focus. For a publisher to focus overwhelmingly on European history in a World
Historytextbook is Eurocentric; writing an article about your own experience with historical
references is not. Your side focus on the scarcity of tin in America is insightful and factual as well as
culturally sensitive.
Likewise, no one need feel shame (or pride either) at the misdeeds or contributions of ancestors.
We are responsible for ourselves, not our forebears, and there is not a human being alive whose
ancestry is diabolical or divine. Judging people for the circumstances of their birth is irrational and
wrong, even if they descend from Europeans. My children, many of whose ancestors practiced
human sacrifice a few centuries ago, have no more cause for shame on that account than do you
for the evil behavior of others long dead whose genetic configuration aligns more closely with your
own by a few scattered peptides. Some of my ancestors were brutal and vicious, while others were
generous, kind and creative. What glory or shame is that of mine?
Assigning worth to a person based on that persons ethnicity ignores and devalues the individual.
This is never right.
You bear craft in your hands and wisdom in your heart. Surely Odin reserves a seat for you in
Valhalla.
! 7 Recommend
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(/user/Kitsap River)
Kitsap River (/user/Kitsap River) Jun 22 10:37:25 AM (/comments/1673870/66912503#comment_66912503)
Terrific diary, Andy! Fascinating story, well-written...but I hope youll give attributions for those pics
which arent yours.
! 5 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & Kitsap River
All wikimedia. Will do after work tonight.
! 2 Recommend
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22 of 31 6/22/17, 1:33 PM
AndyT (/user/AndyT) & Kitsap River

[new]
% (/user/AndyT) Jun 22 10:48:37 AM (/comments/1673870/66912635#comment_66912635)
Except the Conan movie clip... do I have to credit that or is the fact that it has bend up on
YouTube for 8 years okay?
! 2 Recommend
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(/user/libera nos)
libera nos (/user/libera nos) Jun 22 10:37:59 AM (/comments/1673870/66912513#comment_66912513)
Gimme smelter!
! 4 Recommend
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(/user/Wee Mama)
Wee Mama (/user/Wee Mama) Jun 22 10:39:11 AM (/comments/1673870/66912529#comment_66912529)
I suspect metal working is addictive. Tall Papa started out learning to weld last year and this year
built his own forge:
The thrill this weekend was a friend giving him an anvil-Iike object:
23 of 31 6/22/17, 1:33 PM
Before that he was using the head of a sledge hammer as a mini-anvil. Not much fun for me as I
stabilized it, so I am happy to welcome the rail anvil.
! 8 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & Wee Mama Jun 22 10:42:09 AM (/comments/1673870/66912554#comment_66912554)
Rails are great ways to start!
! 5 Recommend
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(/user/semiot)
semiot (/user/semiot) Jun 22 10:47:03 AM (/comments/1673870/66912614#comment_66912614)
Dont let go of the handle. The corpse hall awaits. (Touches his Thors Hammer amulet.)
! 4 Recommend
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(/user/River Rover)
River Rover (/user/River Rover) Jun 22 11:05:16 AM (/comments/1673870/66912828#comment_66912828)
This is my just completed forge,
MISS GERTIE
24 of 31 6/22/17, 1:33 PM
25 of 31 6/22/17, 1:33 PM
This is a bronze thing I cast in green sand
from the San Jacinto River
You diary is the best thing Ive seen here in quite a while
We need to meet each other, I live in Friendswood.
! 10 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & River Rover Jun 22 11:30:49 AM (/comments/1673870/66913121#comment_66913121)
Nice! How are the belt buckles coming?
! 3 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & River Rover Jun 22 11:38:04 AM (/comments/1673870/66913225#comment_66913225)
Actually much nicer than mine. You using kaowool or isulwool? What are you using so flux
for forge welding does not eat up the lining?
I used satanite but that did nothing. Mizzou refractory has been recommended instead.
! 3 Recommend
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(/user/River Rover)
River Rover (/user/River Rover) & AndyT
Jun 22 12:03:25 PM (/comments/1673870/66913611#comment_66913611)
2 of Kaowool
.25 Satinite
aint tried welding
when I do itll be with
wrought iron, which I got
a pretty good supply of and
dont need flux. The first buckle
is inthe pattern making stage
26 of 31 6/22/17, 1:33 PM
while I learn to cast bronze
! 5 Recommend
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(/user/River Rover)
BTW , Satanite seems to
work well for me
so far, but I ain't
got many hrs
on Gertie
! 3 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & River Rover
27 of 31 6/22/17, 1:33 PM
Its great till you forge weld. Then it kinda falls apart from the flux.
! 2 Recommend
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(/user/River Rover)
Ive gotsome ITC 100 HT but I'm waitin
to put it on till I get more experience,
also got some bubble alumina
but don't know what to do
with it. I'm gonna forge
some tools and do
some heat treating
but MISS GERTIE is
primarily gonna be a
foundry furnace for casting.
BTW, Madison County, where I
was born and raised, has quite a
bit of iron bearing pea gravel sized
well,pea gravel, in the creek beds.
! 1 Recommend
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(/user/Ohiodem1)
Ohiodem1 (/user/Ohiodem1) Jun 22 11:25:51 AM (/comments/1673870/66913054#comment_66913054)
I have read many times that to make steel, you need trace amounts of manganese. I dont know
for sure if this is true, but I believe it to be true. AndyT, can you confirm and if so, where did the
early steel makers get theirs? I am aware that a major place where manganese is mined is South
Africa.
! 4 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & Ohiodem1 Jun 22 11:33:35 AM (/comments/1673870/66913151#comment_66913151)
Manganese is incredibly useful in the industrial production of steel - the Bessemer
Process - because it removes sulfur and oxygen. For smelting it is not critical.
! 3 Recommend
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(/user/SethRightmer)
SethRightmer (/user/SethRightmer) Jun 22 11:27:47 AM (/comments/1673870/66913084#comment_66913084)
Very nice work, and an eminently readable diary on the subject as well.
Ever thought of trying the Tamilakam method of making wootz steel? I know its not really a
European method but hey, its an Indo-European method so thats close, right? You end up with
some very pretty steel in the end with all those lovely wavy ferrite and cementite bands. Just roll
some magnetite ore (and a few secrete ingredients like green crown flower twigs) inside clay
ballsand fire them. How hard could it be?
! 2 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & SethRightmer
28 of 31 6/22/17, 1:33 PM
One of my swordsmithy pals, Jeff Pringle, does wootz. It is on my agenda, but I have to
confess, I'm a primitivist at heart. Wootz is all newfangled technology to me.
! 2 Recommend
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(/user/Ohiodem1)
Ohiodem1 (/user/Ohiodem1) Jun 22 11:30:52 AM (/comments/1673870/66913122#comment_66913122)
There is a state park in southern Ohio that has a civil war iron forge, and its output was pig iron
ingots that went elsewhere for making into implements of destruction, rails for railroads, etc. This
furnace was huge.
I have also seen the worlds first Bessemer Converter Furnace, which is in a waterfront park in
Pittsburgh. Much smaller.
! 4 Recommend
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(/user/Ohiodem1)
Ohiodem1 (/user/Ohiodem1) & Ohiodem1
The park is at Station Square on the opposite bank from Downtown Pittsburgh.
Unfortunately, I have no pictures of either facility or I would have put them up here.
! 3 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & Ohiodem1 Jun 22 11:39:27 AM (/comments/1673870/66913248#comment_66913248)
COOL!!
! 3 Recommend
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(/user/aur ganuz)
aur ganuz (/user/aur ganuz) Jun 22 11:35:17 AM (/comments/1673870/66913183#comment_66913183)
Fascinating diary. Thank you from a fellow native.
! 3 Recommend
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(/user/miriam)
miriam (/user/miriam) Jun 22 11:36:42 AM (/comments/1673870/66913201#comment_66913201)
Wonderful. . .I loved this. A side note. The woodland Iroquois didnt have the wheel until the
Europeans arrived. . .because they didnt need it. What is now central and western New York State
is awash increeks, streams and rivers. When you could build an amazinguseful canoe, who needs
wheels (and horses). A canoe, unlike a horse, will travel many moons without rest or food. Only
needs water.
! 6 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & miriam Jun 22 11:40:23 AM (/comments/1673870/66913262#comment_66913262)
Makes perfect sense to me. You make what you need and have resources for.
! 1 Recommend
29 of 31 6/22/17, 1:33 PM
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(/user/7th term is small)

7th term is small (/user/7th term is small) Jun 22 11:42:22 AM (/comments/1673870/66913295#comment_66913295)
Great diary. One of the best summers of my life was spent in a forge...but I cannot imaging the
work of making my own tools. Impressive!
! 3 Recommend
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(/user/daddybunny)
daddybunny (/user/daddybunny) Jun 22 11:52:00 AM (/comments/1673870/66913428#comment_66913428)
Now THIS is a "flame war" that I can get behind. I'd love to tinker with this but sadly I live in an
urban condo and don't even have a deck much less a stretch of dirt to play on/with.
Well done!!
! 3 Recommend
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(/user/AndyT)
AndyT (/user/AndyT) & daddybunny
Maybe find a local Makers Space and see if they offer classes or anvil time?
! 1 Recommend
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(/user/Desert Denizen)
Desert Denizen (/user/Desert Denizen) Jun 22 12:13:51 PM (/comments/1673870/66913770#comment_66913770)
That sounds like hot work! When you got done I bet you smelt.
! 2 Recommend
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(/user/worldlotus)
worldlotus (/user/worldlotus) Jun 22 12:58:54 PM (/comments/1673870/66914562#comment_66914562)
A bazillion recs for a fantasticwritten account! Transported me and will leave me pondering
foreverthe sheerness of the history. Ill neverlook at any metal object the same way again
I hope you share all your future adventure endeavors& I am lucky enough to read them.
! 1 Recommend
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(/user/The Marti)
The Marti (/user/The Marti) Jun 22 01:06:01 PM (/comments/1673870/66914670#comment_66914670)
Jaysus, Andy!!! This is far more complete than your FB entries...and btb...thanks to your ancestors
from mine. Red hair and metal work...we rock. Well, you do. I have to depend on people digging
up rock to impress me. ;-)
! 0 Recommend
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(/user/Indexer)
Indexer (/user/Indexer) Jun 22 01:28:31 PM (/comments/1673870/66915004#comment_66915004)
This is very cool! Ive recently gotten into making my own woodworking tools and find that the
mysteries of hardening, tempering, and shaping the edge are quite enough for me,when addedto
the shaping of the wooden bodies. My forgecan besmaller, too!
! 0 Recommend
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(/user/houyhnhnm)
30 of 31 6/22/17, 1:33 PM
houyhnhnm (/user/houyhnhnm) Jun 22 01:28:50 PM (/comments/1673870/66915007#comment_66915007)

I metallurgy. The chemistry of metals was my favorite thing to teach when I was a chemistry
teacher.
Actually copper is my favorite metal. When I was in north Wales about a decade ago I toured a
copper mine thought to be 4000 years old. The workers used rushlights and bone tools. Some of
the passages were so small, it is thought children were used to work them. Probably slaves. :-(
Thanks for the diary.
! 0 Recommend
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31 of 31 6/22/17, 1:33 PM

The Riddle of Steel... A Brief History of Ancient Metalworking

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The Riddle of Steel... a brief history of ancient metalworking https://www.dailykos.com/stories/2017/6/22/1673870/-The-Riddle-o...

Steel Testing Lab

The Riddle of Steel... abrief history of

Elemental copper. THE WAY to get laid in

CHALCOLITHIC AGE (COPPER):

Reproduction early European copper age knife. Surprisingly sharp.

tin is Nik Megalithic of Shamanic Bronze.

Illustrations of northern European Bronze Age warriors with typical weaponry.

Bronze Mindelheim sword by Neil Burridge of Bronze Age Swords (http://www.bronze-

NOTE ON THE AMERICAS

When I talk about this online,somewhere in here some racist moron

By the way many Native American tribes had an awesome copper

Native American copper artifacts from the great lakes region.

Iron age tongs, spoon, hammer and anvil.

As we discussed above, I will need a chemical reaction chamber with a reducing

STEP ONE: IRON ORE

PREPPING ROCK ORE

Hey neighbor! Bar-B-Q?

Thats the size Im going for!

PREPPING POWDERED ORE

Ummmm. Yummy hematite brownies.

STEP TWO: BUILDING THE FURNACE

Mixing clay for the stack. I recall sweating a lot.

Firing the rst smelting stack.

STEP THREE: PREPPING THE CHARCOAL

Whohoo! Only 90 more pounds to go!

Adding hematite pellets.

It is possible that my first smelt got a little out of hand at times

Alchemy (transforming base metals to gold) doesn't sound so nutty

Opening bloomery smelt chamber

Photo courtesy of Mark Green, from 2013 Magnetite smelt.

Homage to the Vehmaa sword found in Finland by Jesus Hernandez. (http://jhbladesmith.com/homage-

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36 COMMENTS Comment Settings

(/user/Scruffy Looking Nerf Herder)

All wikimedia. Will do after work tonight.

AndyT (/user/AndyT) & Kitsap River

This is a bronze thing I cast in green sand

from the San Jacinto River

We need to meet each other, I live in Friendswood.

aint tried welding

when I do itll be with