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Forge welding is one of the oldest welding techniques, dating back thousands of years.
- Process: It involves heating two pieces of metal until they are at a welding temperature (typically a bright red or yellow heat), then hammering them together to achieve a solid-state weld without the use of any filler material.
- Materials: Traditionally used for welding iron and steel, but can also be applied to other metals like copper or bronze. The metals must be clean, as any impurities can prevent a good bond.
- Heating: The metal pieces are heated in a forge or furnace. The exact temperature varies with the metal type but for steel, it might be around 1,200 to 1,300 degrees Celsius (2,192 to 2,372 degrees Fahrenheit).
- Cleaning: Before welding, the surfaces to be joined must be cleaned, often with flux to remove oxides and prevent new oxide formation during heating.
- Hammering: Once at the correct temperature, the pieces are quickly taken from the heat and struck together with a hammer or in a press. The force helps to forge a bond between the molecules of the two metal pieces.