Ceramic Forge

Stacy E. Apelt - Bladesmith

Stacy E. Apelt - Bladesmith

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I was going through the projects in my "Book Folder" and came across one project I have the parts for but haven't built yet. It is something for those who like the look and feel of a coal forge without the mess and smell of coal. I think it would work best for metalworking projects more than bladesmithing, but it sure could be a nice compliment to a larger shop with an experienced smith.

I drew up plans for a Ceramic Chip Forge. It is a soft firebrick pan with the round center depression filled with ceramic chips/chunks. It is heated from below by a round mulit-port burner ( sort of like a round ribbon burner). The chips can be heated to as high as 1500C/2700F. The localized heating advantage of a coal forge is available this way.

Here is a link to a commercial unit:
http://flamefast.co.uk/wp-content/uploads/2013/05/FLAMEFAST_DS430A_V1_LORES.pdf


Anyone used one of these?
 
Very cool. Stacy, do you know what temp vermiculite is good to? I have used it as an insulator and it held up fine, but that was only 1600°f or so.

-Eric
 
Very nice idea. The one thing I hate about propane forges is how limiting they are when you want to get into blacksmithing. I learned forging in a coal forge and love the smell and smoke of it (very primal), but I'm in a situ now where such things are verboten.

A ceramic chip forge looks to be the best of both worlds.

How does the forge work? What types of ceramic chips? Could you rig a system to idle the fuel/fan while you're away at the anvil? I'm assuming it's a forced-air burner system.

The only problem I see is working the metal into a neutral zone so you don't get a lot of scale. I guess you could just mound up the chips like you would coal..... right? Definitely something I'm keen to explore. Thanks for the link.
 
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The "chips" are pieces of Mullite... the same ceramic stuff that melting crucibles and the insulators for TCs are made from. What I planned on trying first was breaking up some of the ceramic briquettes used in a gas grill.

I suspect that the manufacturers of mullite and other ceramic products have tons of "chips" and broken chunks available if one does some contacting. If the forge seems workable in alpha testing, I would eventually order a 20# box of TC insulator pieces from a manufacturer. Something like these:
http://www.ebay.com/itm/High-Temper...301?pt=LH_DefaultDomain_0&hash=item5afdb4c17d

Vaughn,
I am sure it would be wise to throttle down the gas if stepping away from the forge for a few minutes or more, but I would not do it for short periods as in forging. The heat-up/cool-down time for chips is different than with burning coal. In coal you just reduce or increase the air flow to make it hotter or cooler. The chips have to physically heat up or cool off. A chip forge will best run at a consistent setting. One could easily insert a ceramic clad TC in the hot area and read the temperature of the "coals". The forge should be able to produce a neutral zone by adjusting the gas/air mix.
 
So how does this work? Is it simply a burner shooting up into a pile of ceramic?

Is it Venturi ? Forced air?

How deep is the fire pit that can heat stock?
 
That's cool! If you figure how to make one I'll have to try that! One question though...is there a metal mesh in the bottom to keep the ceramic chips from falling into the burner or something?
Thanks for sharing
 
Definitely interested in something like this just to get away from my propane forge issues.

How does it handle clinkers and scale build up? Is there a clinker breaker like on a coal forge? Would this be better as a "side blast" forge instead of a bottom blast? How will it handle flux if you want to forge weld?

I get the impression that she'll be a gas hog because there's nothing really to trap the BTU's of the propane, but definitely a far sight easier to manage oddly shaped pieces in.
 
Instead of Mullite can you use the ceramic that's used in deburring machunes ?
 
VaughnT said:
Definitely interested in something like this just to get away from my propane forge issues.

How does it handle clinkers and scale build up? Is there a clinker breaker like on a coal forge? Would this be better as a "side blast" forge instead of a bottom blast? How will it handle flux if you want to forge weld?

I get the impression that she'll be a gas hog because there's nothing really to trap the BTU's of the propane, but definitely a far sight easier to manage oddly shaped pieces in.
Click to expand...

Aren't clinkers just from coal?
 
You guys are running ahead too fast. This isn't a welding forge for damascus billets, nor is it going to create clinkers ( because it has no coal ). It is merely a small heating forge for the shop that acts somewhat like a pan forge.

I have buckets of de-burring ceramics and was also going to try them.

There is a ceramic grate under the chips and the burner heats from below.
 
I seriously doubt any silica dust or ceramic particles will become air born. I would worry far more in tumbling metal parts with ceramic media....which I don't worry about at all.

Those who worry about the possibility of fine particulate matter should unplug the grinder and disc sander, and switch to files and stones. Air filtration, evacuation, and wearing respirators when working should take care of crystalline dust, but it infiltrates the entire shop to some degree no matter what you do.
 
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I was just imagining a pile of ceramic chips that is repeatedly shuffled around and stabbed with metal bars.
I met too many old guys with "potter's lung" when I worked for a ceramics company, now I wear a mask for most operations. It's definitely a neat idea, high-tech nostalgia sort of.
 
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