metal techniques for craftsmen - mcast - malta college of arts
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METAL TECHNIQUES FOR CRAFTSMEN
: A Basic Manual, for Craftsmen 1
on the Methods of Forming and Decorating Metals
By OPPI UNTRACHT
R O B E R T H A L E L O N D O N
Contents
xiii Aluminum Aluminum alloys. Soldering aluminum. Brazing aluminum. Casting aluminum.
Introduction
Sand casting of aluminum. Plaster mold casting of aluminum. Other casting procedures with aluminum
Part One METALS : BASIC INFORMATION
Nickel METALS : ORIGIN, BEHAVIOR, ' , AND MANUFACTURE l
Considerations in working nickel. Soldering and joining nickel. Polishing nickel and its alloys Origin
Metallurgy 3 Characteristic Physical Properties of
Metals 4 The Behavior o f Metals: Their Mechanical
Properties C
Hardness. Malleability. Ductility. Tensile strength. Compressi n Shear. Toughness. p : Elasticity. Torsion. Bgttleness. Impact resistance. Rigiditv
Nickel alloys Nickel silver. Monel Metal. Nichrome wire. Invar Mercury Amalgam gold plating. Preparing gola amalgam. Applying the amalgam
Ferrous Metals Iron Steel Carbon steel. Alloy steel CLASSIFICATION OF METALS
Nonferrous Precious Metals Gold Gold alloys. Karat gold. Karat gold
THE MANUFACTURE OF METALS
Manufacture of Sterling Silver Sheet Metal
Wire Drawing Procedure for hand drawing wire
solders. Purchasing gold. IJsing karat gold: General considerations. Testing for gold with acid
Annealing the wire. Using the l 1 drawplate
Silver Silver alloys. Purchasing silver. General considerations in the use of silver. Testing for silver. Cleaning silverware by electrolytic action
Mechanical wire drawing The flat rolling mill Adjusting the rolling mill. Using the rolling mill Platinum
16 Sheet and Wire Gauge Measuring
16 Systems 18 Extruded Metals
Shotting l8 Annealing l8 Texture o f Metal Surfaces 19 Toxicity o f Metals
Base Metals Copper Copper-based alloys
Brass Bronze Lead Forms of lead. Casting lead. Soldering lead. Lead welding. Lead wiping. Decorative patina finishes for lead Tin Hot-tinning nonferrous metals.
Part T w o 20 METAL DECORATIVE TECHNIQUES 22
METAL TECHNIQUES
23 THAT DO NOT REQUIRE SOLDERING Antimonial tin solder White metal Zinc Uses of zinc
24 Preparing the Metal for Outline Cutting 25 The Jeweler's Saw 25 Inserting the saw blade in the frame
CONTENTS
Outline cutting with the jeweler's saw
Pierced work: Using a saw frame and blade
Pierced work: Using chisels
Pierced work: Using stamping dies
Bidri Work Casting the hidri base
Bidri sand casting
Bidri inlay process
Coloring the bidri alloy
Damascene Work Kuftgari, A Form o f Dama~cene
The kuftgari process
Finishing kuftgari Coloring the steel. Charcoal bluing of steel. Another steel bluing method
Doming: Using Punched Discs Forming the dome
Punching Tools Punch work Decoration Stamping: For Metal Identification and
Hallmark Applying the stamp METAL TECHNIQUES
THAT REQUIRE SOLDERING Repousse' Preparation of pitch
RepoussC and chasing tools and their uses
RepoussB tools. Chasing tools. Making your own tools i
The Repoussk Process l
l
Removing the work from the pitch
Silver Solders Composition, melting, and flow points
Choosing a solder Melting point and flow point: Solidus
and liquidus
Preparation of solder
Preparing the metal for soldering Fluxes and Their Application
Removing flux after soldering
Placing the solder
Fuels for soldering Simple heat devices. Torches for separate gas and air or oxygen supplies. Single unit heat sources. Plumber's torches. Lighting the flame. Regulating the flame
The Chasing Process Repousse' and Chasing on Deep Pieces Engraving
Engraving tools
Tool preparation and maintenance Applying the design
Using engravlnd tools Correcting engraving errors
Florentine finish with liners Soldering surf aces
General soldering considerations Soldering gold
Visual judging of approximate temperatures during the soldering of silver and gold
Annealing and pickling gold
Basic soldering situations Joining flat surfaces. Perpendicular joints. The use of soldering jigs. Butt joints. Soldering wire to sheet
Controlling the flow of solder Solder inhibiting pastes
The use of stick solder
Unsoldering
Spelter solders
Splitting Carving Filing Pickling
Common pickling bath Pickle containers
Stripping Stripping solution
Etching Acid resists or covering agents Etching fluids or acid solutions
Containers for acid in use Etching procedure
Acid etching solutions for particular metals
Bright dip
Matte dip Sof t Solders
Soft-solder fluxes
Soft-soldering procedure
Soldering coppers or irons Metal Fusing
DECORATIVE TECHNIQUES
EMPLOYING CONTRASTING METALS Tinning the soldering copper Using the tinned soldering copper
Sweat soldering
Soft-solder removal Soft-solder stripping solution
Metal Encrustation or Applique' Tanjore Swami Work
Procedure for swami work Positive and negative mold stamping
Inlaying or encrusting the medallions Mokume Mexican Married Metals
CONTENTS
Niello preparing metal for niello
preparing niello for metal
Charging the niello
Fusing the niello
Finishing niello
Niello formulas
Wire Hand-drawn gold-plated silver wire
Filigree
Granulation Granulation technique: Making the
granules
Joining the granules
General considerations
Making Shot i
COMBINING METALS i
WITH NONMETALLIC MATERIALS
Metal Inlay in Wood Tarkashi Work Wood as a Filler Tortoise Shell and Pique' Work Piquk Work with Tortoise Shell, Horn.
Ivory, and Bone The pique process
! Leather and Cloth Stones Abalone Shell Inlay
Part Three METHODS OF METAL FABRICATION
SILVERSMITHING
Metals Used in Forming Processes 240 Use of the Hammer when Raising 244
Stakes and anvils 245
Annealing or Softening Work-Hardened Metal
Annealing Temperatures of Some Metals Use o f the Annealing Torch Quenching Annealed Metals Compressed Metal Forming Methods
Metal raising Angle raising
Edge thickening
Planishing
Squaring a bottom
Dutch raising
Crimping
Stretched Metal Forming Methods Sandbag
Blocking
Pressing
PEWTER: BRITANNIA METAL
The Forming o f Pewter Soldering Pewter
Soft solders Low-melting soft solders
Polishing Pewter Decorative Treatments for Pewter:
Applique' Other decorative possibilities
Casting Pewter Low-melting metals
Slush casting of pewter
FORGING
Wrought Iron Forging Wrought Iron and Steel Forging Tools Forging Operations Forge Welding Other Joining Methods General Considerations in Forging Cold Forging
OXYACETYLENE FUSION WELDING
Equipment Procedural Preparations for Welding
Adjusting the regulators for pressure Oxygen. Acetylene
The torch Regulating the flame
The Welding Process Welding rods
Braze or bronze welding
Flame-cutting metal
COLD METAL SPINNING
General Considerations Lubrication Spinning Lathes Spinning Tools and Their Functions
The chuck: The spinning form
Basic Spun Shapes The technique of spinning Before the disc is in motion. After disc is in motion. Trimming
General considerations
the
JOINING WITH RIVETS,
NAILS, AND SCREWS
Riveting Choosing the rivet
The riveting process
How to avoid riveting faults
Riveting wire for jewelry findings
Rivet wire used to hold pierced stones
CONTENTS
Nails Joining with Screws
The female thread The male thread Two-piece dies
CASTING
Casting an Ingot Casting a Lead Block Vocabulary o f Casting Sand Casting
Casting sand Preparing the mold Preparing the metal Pouring the metal Finishing the casting
Metal Casting with Two-Part kaster Molds 330 Materials for patterns 1 331 Parting compounds 331 Preparing the plaster 33 1 Placing the pattern: Symmetrical shape 332 Setting of the plaster 332 Drying the mold 333
Casting an irregularly shaped pattern 333
Core Casting , Creating the core '
Lost- Wax Casting 338 Benin bronze casting: Primitive lost-wax
casting 338 Lost-wax casting of sculpture 341 Small, solid castings Making the mold. The burnout kiln. 341 Pouring the mold. Finishing the casting 344
Centrifugal Investment Casting Casting waxes Mineral waxes
Petroleum waxes Vegetable Waxes Wax additives Centrifugal casting waxes
Tools for shaping wax Spruing the model Mounting the model Positioning the model Debubblizing the wax model The investment material
Preparing the investment
Preparing the asbestos flask liner Applying the investment, and pouring
The burnout Recommended burnout cycle Measuring the metal
The centrifugal casting machine
Heating the metal 372 Removing investment and sprues 374
ELECTROPLATING AND ELECTROFORMING 379
The Electroplating Process 3 79 Electric power 380 Electroplating and electroforming
equipment 381
Electroplating and Electroforming Procedures
Electrocleaning Electrostripping Electrolytic plating solutions Gold baths. Silver baths. Copper baths. Nickel baths. Rhodium baths. Chromium
baths 384
Electroforming on Metal Models 386 Nonmetallic models 387 Solid or hollow objects 387 Elec{roconductive coatings 389
Plating Miscellany 390
Part Four METAL FINISHING
POLISHING AND GRINDING
Polishing Hand polishing Motor polishing' Polishing compounds The natural abrasives The artificial abrasives General polishing and buffing
considerations Polishing and buffing wheels
Polishing and buffing practice Bristle brushes Wire brushes Burnishing Common polishing and buffing situations Polishing hazards and precautions
Grinding and A brasives Grinding wheels Tool maintenance Sharpening stones Judging steel composition by spark
observation
COLORING METALS
Cleaning the Metal before Coloring Chemical Coloring
Formulas for chemical coloring
Coloring by Heat
CONTENTS
part Five HAND TOOLS AND THEIR USES
BASIC TOOL GROUPS
Basic metalwork and jewelry-making tools
Decorative metalwork tools Basic soldering tools and equipment Hard soldering. Soft soldering Basic forming and raising tools
The Hand Tools Marking and measuring tools and
materials Cutting and piercing tools and materials Forming tools and materials Special stakes Holding tools and materials Stone-setting tools I I
The flexible shaft and motor Heat treatment for small tools
Part Six CHARTS AND TABLES
Periodic Table of thq Elements Weights and Measures Equivalent of Measures Comparison of Standard Gauges Sheet Metal: Weight per Square Inch
by B. & S. Gauge Round Wire: Weight in Pennyweights or
Ounces per Foot in B. & S. Gauge Approximate Length per Troy Ounce of
Sterling Silver Wire
Sterling Silver Square and Half Round Wire; Weight in Ounces per Foot 454
Sterling Silver Sheet Weight in Troy Ounces per Square Inch 454
Silver and Gold Wire Forms Available in Standard Millimeter Sizes 454
Sterling Silver Seamless Tubing 455
Circles and Squares; Circumferences and Areas 455
Comparison of Measurements (Inch, Mm., B. & S. Gauge, Stubbs Steel Wire, Drill No.)
Fractional, Decimal Inch, and Millimeter Equivalents
Comparison of Saw Blade Sizes and Drills
Jeweler's Saw Blades, Thickness and Width in Inches
Straight Shank Twist Drills, Wire Gauge Sizes
U. S. Standard Ring Sizes, Length and Diameter in Inches
Standard Copper Sheet Thickness: Rolled to Weight
Temperature Conversion Tables: Fahrenheit to Centigrade Centigrade to Fahrenheit
The Melting Points of Selected Metals
Coefficients of Linear Expansion of Metals Table of Specific Gravities and Weights
Relative Characteristics of Common Metals
Sources of Supply
Glossary of Terms
Bibliography
Index
CONTENTS