Techniques and Procedures for Hot and Cold Shaping of Hand-Forged Pieces

TEACHING UNIT 1. TECHNIQUES AND PROCEDURES FOR SETTING UP AND PREPARING THE FORGE IN ARTISANAL FORGING WORK.
The structure and operation of a traditional forge:
- Systems: manual and electric.
- Components: the hob, the extractor hood and the flue.
- Fittings: bellows or fan, heat output and ventilation control.
Structure and operation of a gas forge: installations, systems and components.
Fuels used in the forge:
- Types: coal and gases (oxygen, acetylene, propane, butane).
- Effectiveness.
- Collection and storage: the requirements for coal compared with those for gases.
Forge ignition systems.
Procedures for temperature control using air supply.
Temperature control via colour.
- Calda.
- Colour and temperature.
- Factors affecting the rate of heating.
Cleaning and maintenance of the forge.
Quality, occupational and environmental risks associated with techniques and procedures for fitting out and preparing the forge.
TEACHING UNIT 2. TECHNIQUES AND PROCEDURES FOR THE CONDITIONING AND PREPARATION OF CUTTING TOOLS AND EQUIPMENT IN ARTISAN FORGING WORK.
Tools used in blacksmithing: types and characteristics.
- Anvil, tongs and other tools.
- Blacksmith’s hammers and screws.
- Other blacksmith’s tools: tongs, forks, punches, bending templates.
- Auxiliary tools: rulers and tape measures, set squares and compasses.
Tools, machines and systems used in the sharpening, hardening and honing of cutting tools.
- An anvil, a hammer and a pair of sharpening tongs.
- Tools for tempering: water, mineral oil, lead and files.
- Sharpening first with a file and then with an electric grinder.
Sharpening techniques: applications in the preparation of cutting tools.
- Sharpening techniques for the manufacture of cutting tools.
- The manufacture of chisels and engraving tools.
- Punches.
- Stands.
- Axes, pruning shears, knives and swords.
Tempering process: applications in the preparation of cutting tools.
- Tempering process using various materials.
- Increased strength, hardness and brittleness of the components.
Sharpening procedure: applications in the preparation of cutting tools.
- Sharpening chisels: straight and curved.
- Sharpening of engraving tools.
- Sharpening punches.
- Sharpening of chisels: annealed, filed and tempered.
- Sharpening of axes, loppers, knives and swords.
Quality, occupational and environmental risks associated with techniques and procedures for the conditioning and preparation of cutting tools and equipment.
TRAINING MODULE 2. HOT FORMING TECHNIQUES AND PROCEDURES FOR ARTISANAL FORGED PIECES
TEACHING UNIT 1. THE BEHAVIOUR OF IRON IN FORGING PROCESSES.
The malleability and hardness of iron.
- Malleability: the ability to be rolled.
- Hardness: Mineralogical scale (Mohs scale) and metallurgical scale.
Tenacity:
- Deformation.
- Flexibility.
- Iron breakage.
How iron behaves when heated:
- Thermal conductivity.
- Change in colour.
- Degree of malleability.
Colour references for controlling the working temperature in a forge.
- Non-malleable: black – blue.
- Modelling clay: red – orange – yellow.
- Casting: white.
TEACHING UNIT 2. APPLICATION OF HOT FORMING TECHNIQUES AND PROCEDURES FOR ARTISANAL FORGED PIECES USING DIMENSIONAL CONTROL.
Tools used in the forge: types and specific characteristics for dimensional control.
- Anvil, tongs and auxiliary tools.
- Blacksmith’s hammers and screws.
- Other blacksmith’s tools: tongs, forks, punches, bending templates.
- Auxiliary tools: rulers and tape measures, set squares and compasses.
Sharpening techniques: applications in the shaping of pieces in traditional blacksmithing.
- Sharpening technique.
- Conical and pyramid-shaped blades.
- Sharpening the tips and edges of bars, rods and flat bars.
Drawing techniques: applications in the shaping of pieces for handcrafted wrought ironwork.
- Stretching techniques using an anvil and other tools.
- Types of stretching at the ends and in the centre of the bar.
Flaring techniques: applications in the shaping of components for hand-forged pieces.
- Techniques for widening, rolling, flattening or deburring.
- Laminated ends on the bars.
- Rolled products for forming sheets and coils.
Shaping techniques: applications in the formation of pieces in traditional blacksmithing.
Templates and dimensional control references.
Quality, occupational and environmental risks associated with hot forming techniques and procedures for hand-forged components, as determined by dimensional control.
TEACHING UNIT 3. APPLICATION OF HOT FORMING TECHNIQUES AND PROCEDURES FOR SHAPING PARTS IN ARTISANAL FORGING THROUGH SHAPE CONTROL.
Tools and equipment used in the forge: types and specific characteristics for shape control.
Hammering techniques: applications in the shaping of handcrafted forged pieces.
- Heating the iron.
- Hammering.
- Resizing methods: on the anvil or in the vice.
- Types of reinforcement at the ends and in the centre.
- Production of forged nails.
Chipping technique: applications in the shaping of pieces for handcrafted wrought ironwork.
- Bars.
- Plates.
Notching and grooving techniques: applications in the shaping of components for handcrafted wrought ironwork.
Splitting techniques: applications in the shaping of pieces for handcrafted forged works.
- With an anvil-type cutter.
- With a hand-held chopper.
- Single buttonhole slit.
- Split in a compound buttonhole.
- Perforated and punched.
Hot-bending techniques: applications in the shaping of pieces for handcrafted wrought ironwork.
- Heating the iron.
- Hammering.
- Resizing methods: on the anvil or in the vice.
- Coils and spirals.
- Elongated volutes.
- Knotted and tangled.
Hot-forming techniques: applications in the shaping of components for hand-forged pieces.
- Heating the iron.
- Hammering.
- Resizing methods: on an anvil or using a special tool.
- Layered and folded in the corner.
- Clamps.
- Braids.
Hot-twisting techniques: applications in the shaping of pieces for hand-forged works.
- Profile twisting.
- Single-eyelet twist.
- Six-piece pineapple twist.
- Double-eyelet twist.
Fluting and notching techniques: applications in the shaping of pieces for handcrafted wrought ironwork.
Stamping technique: applications in the shaping of hand-forged pieces.
Templates and formal control references.
Quality, occupational and environmental risks associated with hot-forming techniques and procedures for crafting hand-forged components through shape control.
TRAINING MODULE 3. COLD FORMING TECHNIQUES AND PROCEDURES FOR ARTISANAL FORGED PIECES
TEACHING UNIT 1. DRILLING AND EMBOSSING PARTS FOR HANDCRAFTED IRONWORK.
Tools and equipment for general use.
Piercing techniques: applications in the shaping of components for handcrafted forged pieces.
- Sheet metal cutting.
- Drilling holes in parts for riveted joints.
Embossing techniques: applications in the shaping of components for handcrafted forged items.
- Embossed on a lead cup.
- Embossed on paper.
- Embossed on a stake.
- Chiselled.
Templates and control references.
Quality, and associated occupational and environmental risks.
TEACHING UNIT 2. BENDING, PERFORATING AND COLD TWISTING IN TRADITIONAL FORGING.
Tools and equipment for general use.
Cold-bending techniques: applications in the shaping of components for handcrafted forged items.
- Bent using clamps.
- Bent using an anvil.
- Manufacture of mandrels for bending rods or flat bars.
- Roller bender.
- Hydraulic bending machine.
Cold-forming techniques: applications in the shaping of components for handcrafted forged pieces.
Cold-twisting techniques: applications in the shaping of pieces for handcrafted forged works.
Templates and control references.
Quality, and associated occupational and environmental risks.