I use borax to forge weld & it is the first thing to splash out of the join & fly in all directions.
I use anhydrous borax in some of my forge welding work. However, I avoid using flux as much as possible. Flux creates the possibility of flux entrapment in a weld. My time making damascus is too precious to risk flaws in the steel. My steel pieces for damascus are always ground clean when stacked in a billet. After making a weld, I let the billet cool and then cut it up and grind the weld surfaces clean again before restacking. If I use anything at all for a “flux”, I use kerosene.
Grandaddy told of watching the 'smith weld those broken axles back together using white sand as flux. Isn't sand primarily silica?
Sand or ground glass was often used as a flux. It works quite well, however it requires very high heat to melt. Around 2,600F degrees. Wrought iron can stand these high temperatures, but modern high carbon steel cannot. We weld modern steel at around 2,300F degrees. Most of today’s damascus smiths use propane forges. Propane forges struggle to reach 2,600 degrees. Coal forges can reach 3,000F.
BTW: It is my opinion that Etoile, "Washington", and Chain patterns use similar lopins/methodology.
Etoile and Washington share similarities. But, chain pattern is vastly different. Chain pattern is very complex in how the lopin/billet is assembled. A hint to its complexity; there are six elements that create the chain links, organized around the four sides of the billet.
I’m certain that the old damascus experts were very good at creating new patterns. But chain is so complex, that I wonder if they actually knew how the pattern would turn out in the finished barrels. I don’t know what they were trying to make with that billet arrangement. But, it wouldn’t surprise me if they looked at a barrel made from this billet arrangement and then said; “Hey, it looks like a chain!”
this very odd Smith barrel
A cool pattern indeed! Laying up a billet to create the little square elements would take some effort. But, this really isn’t a complicated pattern to make. I will add this photo to the ones that you already sent to me. I am hoping to publish a book on damascus barrel patterns, describing how each of them were made. One of my reasons for working out how to make chain pattern, is to affirm my knowledge on sorting out damascus patterns. If I can’t make it, how can I state that I understand how it is made?
I understand Bro. Steve is working on a Chain pattern barrel
I am currently working on chain pattern, however it is first to be used to make a knife blade. As soon as I post this reply, I will be going out to the shop to continue my work on it. I am very interested in making a chain pattern barrel and have enough of this billet left to do so. But as a businessman, I have to justify the cost. There’s no point in making a barrel, unless you build an entire gun to install it on and shoot it. That is an expensive proposition. I still have the piece that I made, using the first damascus barrel that I made. Despite all of the attention and publicity that this piece has received, I have found no buyer for it. I’m trying to make a living from my work and cannot justify making expensive pieces that few have the funds to purchase. Without a customer to purchase, my work to actually make damascus barrels could cease.
