How to make a forge for forging

DIY forge

Hand forging is becoming increasingly popular - both to meet your own needs and to produce various products to order.

Heating of metal, in order to increase its plastic characteristics, must be performed in special heating devices, the simplest of which is a forge. the task of the forge is to ensure a stable increase in the temperature of the metal to forging temperatures, i.e.

, not less than 1200 °C. How to make a homemade forge, and whether it is possible in principle, is discussed below.

Classification of types of forges

It can be carried out according to the following main indicators:

1. According to the type of fuel used. There are gas furnaces, as well as devices operating on solid (coal) or liquid (fuel oil) fuel.
2. According to the design features, open and closed forges are built.
3. By hearth size (effective surface) – small, medium and large.

Mobile open type forge

Solid fuel furnaces, which require the use of coking coal, are an effective technical solution for video shooting, but an outdated one. This will require not only ensuring a continuous supply of high-quality charcoal, but also coming to terms with technological shortcomings, including:

• uneven heating;
• inability to control the process;
• increased sulfur content, which will increase fragility during the forging process;
• increased fuel consumption, it can be up to 120 - 150% of weight;
• low efficiency of the device, accompanied by significant waste.

Nevertheless, such designs can be used at home in conditions of single production of products, especially if they are mini-forges running on cheap fuel oil.

Forge design

To create more favorable working conditions for a blacksmith, it is more advisable to build closed forges. Although they are somewhat more difficult to manufacture, they are more efficient and provide uniform heating of workpieces, in particular, those with a round or rectangular cross-section. Open forges remain insignificant in terms of product size for artistic forges.

A closed-type forge consists of the following elements:

1. steel support frame with racks;
2. hearth;
3. linings;
4. gate valve;
5. fan;
6. chimney pipes.

If during forging it is necessary to heat the metal not completely, then technological holes are made in the damper. They are equipped with closing eyes, necessary to reduce fuel losses and speed up the heating process.

When setting up a workshop, it is economical to equip the forge with a simple recuperator - a unit that increases the temperature of the exhaust furnace gases. Furnaces with recuperators have a higher efficiency, and the generated heat can be used, for example, for a furnace that performs subsequent processing of forged products - their forge welding, bluing, etc.

Stages of making a homemade forge

How to make a blacksmith's forge, and where to start? To make a closed furnace, you will first need to determine the dimensions of its hearth. They are determined by the desired performance, and depend on fuel consumption and the intensity of the forge. For the gas option, the optimal fuel supply speed can be taken to be 1 - 1.5 m/s: in this case, heat transfer processes in a closed space will proceed quite efficiently.

Closed forge forge

The hearth tension N is related to the productivity of the forge N by a simple ratio:

N = H×F,

where F is the hearth area.

Taking into account the area allocated for the forge, as well as the expected forging productivity (for example, in kg of products), it is possible to establish the actual minimum tension of the hearth (it should not be less than 100 - 150 kg/m2∙h, otherwise the arrangement of even a mini-version of the heating installation will be disadvantageous).

In order to make a forge with your own hands, you will need the following materials:

1. thick sheet heat-resistant steel;
2. refractory brick (fireclay or dinas);
3. rolled steel profiles (angles, channels) for mounting the hearth frame, manufacturing the damper and support posts;
4. steel chimneys for removing gases generated during the heating process of products;
5. fireproof coating for sealing cracks;
6. sheet or wide steel for external lining.

The design of an open hearth is much simpler - it only needs to be equipped with a grate system and provide an air supply that intensifies the heating process. In this case, a conventional ventilation hood made of heat-resistant steel is sufficient to remove combustion products.

In addition, during construction it makes sense to use standard units. Here we should mention a fan for the furnace, which can be used as units produced for high-power double-circuit boilers. Also suitable are ventilation pipes and steel chimneys designed for smoke removal of gases at 300 - 400 ° C. You can set up a forge with your own hands using burners from powerful double-circuit boilers.

Making the support frame

Since the forge is a stationary unit, you should clearly determine its location. At home, not the entire part of the workshop can be used as a forge. But, of course, the forge should be adjacent to one of its walls, preferably one that does not communicate with adjacent buildings, since in this case it is much more difficult to arrange chimneys and install a fan for the forge.

According to fire safety conditions, the structure must be at least 1 m from the main wall of the workshop, and any use of materials with reduced fire resistance (including GKLO plasterboard) is excluded.

When making a support frame, it is advisable to use ready-made drawings that can be purchased or downloaded on the Internet. The dimensions of the forge/mini-forge are consistent with your own capabilities. It would be good if the drawings also included photos and/or videos of the forge in operation.

The support posts and frame are made welded, for which low-alloy steel 09G2S is usually used. It has sufficient strength, is easily and reliably welded, and is resistant to high-temperature corrosion. The pitch of the plate cells of the support frame is determined by the dimensions of the refractory. The finished frame is provided with holes for subsequent fastening of external lining elements.

When choosing refractories for arranging the upper part, they are guided by considerations of durability, the type of heated products, as well as the intensity of use of the forge. Fireclay and dinas are used most often.

Fireclay is manufactured according to the technical specifications of GOST 390-79. Buying uncertified products is very dangerous, since it is sometimes difficult to distinguish fireclay bricks by color from ordinary bricks, which melt at 1200 °C.

Fireclay bricks suitable for masonry should be cream-colored and have low porosity. In this case, its weight is at least 5 kg. There are plenty of demo videos on the Internet that can help you identify quality products.

The brands ShPD, ShA and ShB are suitable for the construction of the forge.

Download GOST 390-79 “Fireproof fireclay and semi-acid products for general use”

Dinas is a refractory with significantly higher refractory characteristics: up to 18000C, but it is more expensive. The material is lighter in color than chamotte because it has a higher percentage of silica. It can withstand intense heat changes better, which is why furnaces made of silica brick are more durable.

When laying, it is worth remembering that the masonry mortar must contain fireclay and crushed fireclay/dinas in a 60/40 ratio. Fan ducts and chimneys are trimmed around the perimeter with steel strips or corners.

The manufacture of the damper and lining is carried out using the same technology as described above. For lining, it is worth using strips or sheets with stiffening ribs: this will reduce heat transfer to the surrounding space and also help increase heating performance.

After completion of the work, the structure is thoroughly dried, after which the fan for the forge is tested, and only then a test run is performed. The duration of stay of products in the finished furnace can be compared with the values ​​​​given in the following table:

Heating time of a rod in a forge depending on its diameter

Diameter of heated rolled products, mm	10	20	30	40	50	60	70	80	90	100
Approximate heating time, min	0,6	1,1	1,7	3,0	5,0	7,0	9,0	11,0	16,0	19,0

Source: https://stankiexpert.ru/stanki/kuznechnye-stanki/samodelnyi-kuznechnyjj-gorn.html

Forges for forging with your own hands: types and features of self-production at home - Machine

The word "horn" comes from the German horn. It's essentially a "horn". They made an ancient forge with their own hands to obtain screaming iron. Its appearance resembles an inverted horn trumpet, which was the reason for calling it a bugle. From him came the blacksmith's forge.

What is it needed for?

Note: In a forge, the device is used as a tool to heat metal before working it. Therefore, forges are items that are needed by everyone who works in metal.

With its help you can achieve high temperatures - over 1000 degrees. Consequently, he can allow himself to produce various metal structures.

In our case, these can be boilers, chimneys, pipes, decorative elements of fireplaces and other metal products.

There are two main types of equipment:

• stationary;
• desktop

An important feature of forges is that you can make them yourself.

Of course, if you build a unit that runs on natural gas, you won’t be able to get a serious product like a Damascus blade, but you can make the structure in just a few minutes.

This will require some fire bricks and pieces of steel. Such a device will be sufficient for melting or forging.

Homemade portable tabletop forge

Compound

Let's look at the design of traditional equipment for a forge:

• fireproof table;
• hearth;
• lattice;
• air drain and chamber;
• umbrella;
• valve;
• air duct;
• hardening bath;
• removable furnace;
• window for long products;
• chimney.

Operating principle

Let's figure out how to make a forge with your own hands. After all, the traditional design for home use can be simplified without compromising the quality of the process.

The basis of operation is the chemical reaction of carbon combustion, which is effectively used to work with metal. It combines with oxygen, and the metal is released in free form.

The forge also uses the calorific value of carbon. By adding air to the fuel, combustion will occur much faster, given enough carbon.

As a result, the temperature will increase and more heat will be generated.

The flame of a handmade forge

The air supply to the forges is organized in such a way as to ensure a slight lack of oxygen to prevent oxidation of the metal.

If the workpiece is left in the device for longer than the recommended period, the properties of the metal will be impaired. For example, steel sheets can become brittle with increased hardness.

This means that its properties will be closer to those of cast iron.

Fuel

Note: A regular forge runs on coal. However, you can also use firewood. To do this, they are heated to coals. You can simplify the device if you use, for example, butane or propane.

Their composition includes hydrogen and carbon, which, when combined with oxygen, release a lot of heat. Moreover, such mixing can occur in advance, for example, in a burner.

Coal for forge

However, it must be understood that it will be almost impossible to manage natural gas for such purposes, since it consists of different hydrocarbons that require different amounts of oxygen.

Therefore, it will not be possible to organize optimal air supply. In addition, natural gas contains sulfur, which negatively affects the properties of the metal.

Therefore, the mixture requires pre-cleaning or can be used to process non-critical parts.

Kinds

Let's look at what forges can be like. They are the main tool of the forge. Thanks to development and improvement, many varieties have appeared:

• electric or fuel;

Portable electric forge blue

• on liquid, gaseous or solid fuel;

Blacksmith's forge on coals in action

• closed or open type;

Closed forge forge

• with a central lance or with a side nozzle;

A homemade forge of simple design with a side nozzle.
An open forge with a central tuyere in action.

• stationary or portable.

Stationary forge in action

Let's look at the most popular types.

Gas

Making such a forge with your own hands is quite difficult, but possible. The homemade version, like the purchased one, traditionally has a camera and bellows. Operates on propane-butane.

The gas is supplied to the mixing reducer, after which it goes to the gas burner. The latter in some cases may be located on the side.

This format is quite often used in homemade versions used in forges.

Gas portable forge

You can make a gas furnace yourself to heat the ends of small-sized products. Can be used to create decorative solutions in artistic forging.

Portable

These forges are easy to use. The design uses a steel frame, on top of which there is a recess made of fireclay bricks. At its bottom there is a tuyere, with the help of which the air supply is organized (a compressor or fan is used). The tuyere has small slots through which air is forced, but no coal or slag passes through.

Portable gas models of forges

This type of forge is used for processing small items. It can be carried or transported, so the place of work can be ad hoc.

Stationary

Can be open or closed.

The structure of the open version is a frame with a table in the form of a trough about 70 cm high. The hearth is made of fireclay bricks, and there is a tuyere inside it. To cool the device, there is a water tank located at the front. The fan creates pressure to supply air through a duct.

Stationary tabletop forge in action

The lever allows you to adjust the volume, which makes it possible to change the temperature in the fireplace. The damper protects the tuyere from pieces of ash and coal getting into it. Flue gases are removed through an umbrella and an exhaust pipe. The fuel can be charcoal or coke.

The closed type device has the following advantages:

• rapid achievement of maximum temperature;
• high efficiency;
• increased fire safety.

The only problem if you make such a forge with your own hands is that it is difficult to work with large or long products, especially if you need to warm up their middle part.

Stationary Electric Forge

The chamber is made of fireclay bricks located in a metal frame. It has a tuyere, a grate, a window and a firebox hatch.

Creating a stationary device

Let's look at how to make a forge with your own hands of a simple design. To do this you will need six fire bricks. Of course, it is impossible to obtain a very high temperature under such conditions, but it is quite possible to heat the metal, say, for forging or bending.

Recommendations for creating a simple blacksmith's forge

To make grate bars, you can take steel strips about 5 mm thick. Shelves can be made from pipe scraps. Charcoal or coke can be used as fuel. A blowtorch is used for ignition.

However, when exposed to heat from the forge, it may not withstand it, so an asbestos partition must be placed between them. You can also use a burner (gasoline or gas).

Since there is no umbrella with a chimney, the homemade device is used outdoors.

Simple DIY outdoor blacksmith's kit

Creating a portable device

For greater versatility, you can make a portable version with your own hands. It can be built from a goose barn. You can make a homemade boost using a fan from a hand siren or a corrugated pipe.

• Making your own forge
• Of course, such a homemade design has more capabilities than the described stationary version, but there are also disadvantages:

• the temperature is not very high - up to 900 degrees;
• expensive to operate, given the cost of carbon;
• since there is no space for burning in such a homemade device, it operates on charcoal or coke.

Forge made from pipe

Summary

Forges are quite common today, despite consumerism towards things that are easier to buy than to make.

However, if you are not too lazy, make a device with your own hands, build a small forge, you can create original metal products that can be used to decorate private property, create devices for heating rooms, etc. Therefore, making a forge with your own hands is the right decision .

Tips for making your own forge

Source: https://regionvtormet.ru/svarka/kuznechnye-gorny-dlya-kovki-svoimi-rukami-vidy-i-osobennosti-samostoyatelnogo-izgotovleniya-v-domashnih-usloviyah.html

How to make a homemade forge for forging?

In the modern world, forged products are very popular. They can be found everywhere. For example, thanks to them, fireplaces take on a more original look, flower stands become an excellent decoration for a room, and wrought-iron staircases make a house look like a castle. And the most interesting thing is that you can do all this with your own hands using a homemade forge. Its various modifications differ only in the type of fuel used. The remaining differences are not significant.

The need to obtain high temperatures (more than a thousand degrees Celsius) at home for forging metal leads craftsmen to the idea of ​​assembling a homemade forge. If you have a great desire and do everything according to the instructions, then no problems should arise.

In forges it is used to heat metal before heat treatment and can take the following forms:

• stationary;
• portable;
• mobile.

Today, classic designs involve the use of coal or wood as fuel, but a homemade forge for forge can also be gas. As practice shows, the most economical fuel is coal, which must be processed before use.

Main parts

The mechanism of operation of the forge is quite simple. The design of the forge resembles an oven with three partitions and one open side. its function is to maintain the highest possible temperature inside.

The design of a self-assembled forge differs little from production equipment.

The classic design should have:

• fireproof table;
• hearth with grate;
• device camera;
• umbrella;
• air chamber, valve and drainage;
• chimney;
• hardening bath;
• hole for feeding workpieces;
• air duct for oxygen supply;
• gas-air chamber;
• the furnace is removable.

How the device works

Before you build a forge, you need to decide on its type. The closed-type forge has a chamber for heating the workpiece. This model is considered the most economical in terms of fuel consumption. But in this case, the blanks are limited in size.

In an open-type forge, fuel is poured from above onto the grate, and an air flow is supplied from below. The heated workpiece is placed on the fuel. This makes it possible to heat large-sized workpieces.

In order to be able to build a homemade forge without losing its quality of work and at the same time saving money, you should understand the principle of its operation. The device is based on a significant increase in temperature due to the chemical method of carbon combustion.

This process gives a high energy yield and has been used for many centuries to smelt various metals. To prevent the cupola from allowing the material to burn, you should supply it with slightly less oxygen than is needed for complete oxidation, otherwise the products will be too fragile and, accordingly, will last only a few years.

Gas horn

This type of forge is not entirely easy to make at home. A homemade forge will function perfectly on gas, but for this you should only take propane, butane or purified monogas. Household blue fuel is not suitable for use in a fryer, since it contains both saturated and unsaturated carbons, which leads to uneven heat release.

Also, household gas contains particles of silicon, sulfur and phosphorus, which can negatively affect the metal. For example, sulfur will only deteriorate steel upon contact, changing its operational advantages into disadvantages. And this can lead to significant financial losses.

Considering the above, a homemade gas forge for forging can operate on household gas only if it is first purified from sulfur. To do this, the gas must be passed through a container with naphthalene, which will absorb all excess. It is also advisable to forge only decorative elements using blue fuel, and not parts that will be subject to heavy loads in the future.

Materials for production

As a rule, a home-made forge differs from the industrial version in large savings on materials. That is why you can freely use fireclay bricks for its lining, rather than quartz. It will also last for quite a long time, because daily use of the device is not required at home. And the cost of making the forge will be significantly reduced.

Purpose of components

The main working body of the cupola furnace is the tuyere, consisting of:

• air chamber;
• firebox;
• grate;
• supply tube;
• drainage;
• valve

At home, all this is assembled into a single non-separable structure, built into the table. In this case, the grate can be perforated with round holes. Drainage in the design is simply necessary to control the supply of oxygen to the workpiece.

Gases are removed by means of a chimney, an umbrella and a forge chamber. Since the tent windows are always open, a homemade forge must be provided with maximum chimney draft.

Depending on the type of forged material, you may not need to equip the roaster with a gas-air cell and a hardening container. Also, the crucible is used only for forging precious or non-ferrous alloys. It is a heat-resistant cap, which at home is folded dry from fireclay bricks.

Firebox rules

The optimal fuel is fine coke, which, although more expensive than regular coal, is consumed in minimal quantities for work. Since high temperature is required to ignite it, a homemade forge for a forge must first be heated with wood. Only after the main fuel has burned out is the preparation introduced into the hearth for ripening, reducing the blast.

In order for the forge to work correctly on ordinary coal, it must first be fried to completely evaporate the coke oven gas, which will become clear by the change in color of the flame. Such fuel is usually used for the manufacture of large original products.

To forge figures from Damascus at home, it is necessary to use charcoal for the firebox, but this fuel requires jewelry work, since it instantly responds to blowing and quickly burns out.

You can also use ordinary hardwood firewood for the firebox, but first burn it in the shell to completely prevent unburned wood chips from getting on the metal. This method of producing heat is considered the most economical.

Mini version

Before you make a homemade forge, you should decide on the optimal dimensions of the future structure. For making small decorative elements from steel or melting precious colors at home, a miniature structure of six fireclay bricks is sufficient.

The grate and the shelves for it in this case are made of steel strips and pipes. In this option, ordinary coal or coke is used as the main fuel, which should be ignited with a blowtorch or burner (gas, gasoline-air).

You can only work on such a device in the open air, and a homemade gas burner for a forge, like a blowtorch, must be protected from the main hearth by an asbestos partition with a hole for the passage of the flame.

In addition, with the help of this forge it will be possible to make small-sized products.

Custom design

Stationary models of the forge should be made taking into account the anthropometric data of the master. This is necessary to ensure maximum comfort during forging, because a red-hot piece of iron weighing several kilograms poses a serious danger to both the master and those around him. The most important thing in the process of work is to ensure maximum safety and comfort.

To correctly determine the size of the workplace, the help of a second person is necessary. So, the height is measured from the floor to the elbow of the master, whose arm is in a relaxed position and whose legs are shoulder-width apart. To the resulting figure you need to add another 5 cm, which will become the optimal height for the workplace.

The shape of the table is best square for the work of one master; for work with an assistant, you can make it rectangular. In the case of a square shape, the length of the side is determined by determining the diagonal.

To do this, the assistant needs to measure the length from the master's abdomen to the end of the largest pliers in an outstretched hand. Another 10 cm is added to the resulting number and half the diagonal is obtained.

Next, if you wish, you can simply multiply the result by 1.414 or determine the length of the entire diagonal and solve the equation from the school curriculum C2 = a2 + a2, where C is the resulting diagonal, and is the side of the table.

Sequence of processes

The first step is to assemble the table frame with the grate in the center. It is important to make it from a single sheet of metal with intersecting grooves to accumulate carbon deposits and ensure uniform air distribution. After this, an air receiver with a retractable damper is assembled at the bottom of the table. The air vent for pressurization can be used from an old car furnace.

Portable forge

This model is the easiest to use. You can assemble it using a gossamer as a base. For this, the supercharger can be a car snail or a fan from a hand siren, which will distribute air through a pipe with holes in the center of the container.

Its sides are finished with a lining of fireclay sand and marl. The advantage of this design is that it has more options than a mini-forge and the ability to move, unlike a stationary table.

The master is not tied to the place of activity and can safely travel to various part-time jobs.

Among the disadvantages:

• there is no way to disassemble for cleaning;
• low operating temperature;
• high fuel consumption;
• work only on coke or charcoal.

Foot drive

Previously, it was these designs that were used to forge horseshoes for horses during military campaigns. For this purpose, the forge was mobile and more convenient, since both hands of the master were free to work with the product. This was ensured by a crank mechanism, which was activated by pressing a foot pedal.

A modern version of such a forge can be assembled at home using a foot-operated sewing machine.

Conclusion

Above, a homemade forge, a burner for the forge, possible types of fuel for work and other features of forging metals at home were described in detail. It is important to remember that a homemade design cannot fully replace professional equipment, and therefore is not suitable for all types of work and metal.

Forges are quite a popular phenomenon these days, despite the huge market for things that are easier to buy than to make. However, if you wish, you can make the device at home using improvised means. Thanks to a small forge, it will be possible to create unique steel products that can be used to decorate private yards.

In fact, it’s easy to assemble a forge with your own hands from scrap materials. The most important thing is to follow the instructions, have a tool, follow safety precautions, and then everything will work out.

Source: https://FB.ru/article/314398/kak-sdelat-gorn-samodelnyiy-dlya-kovki

The most popular types of forges for forging

Forging metals has been known to mankind for many millennia. During this time, modern equipment has appeared that allows mass production of metal products without human effort. However, manual processing technology is still used. A forge for forging is considered an essential element of the workshop, which is used for heating, changing shape, and further working with workpieces.

Device and principle of operation

To understand how to assemble a homemade structure for heating metal parts, you need to know the structure of the forge and the principle of operation. The equipment consists of the following elements:

1. Metal base. Must be stable so that the equipment does not tip over during operation.
2. Hearth and work table made of fireclay bricks. A grate is fixed to the hearth.
3. Cover, walls. They are made of the same material as the hearth.
4. Chimney for removing fuel combustion products.
5. Fan, air supply system.
6. An umbrella is a part to improve traction.
7. A lance is a connecting element through which air is supplied from the fan to the grate.
8. Hole for feeding workpieces with a closing door.

You can make a design with a natural air supply or install an electric blower on the forge. The second option is considered more effective. It allows you to reach high temperatures in a short period of time, regardless of environmental factors.

We must not forget about the features of the household forge. The principle of its operation is that the hearth is filled with flammable fuel, which must be set on fire. Then you should wait until the temperature rises to the desired level.

Using blacksmith tongs, place the workpiece on the work area. It should warm up to the required state. Then the blacksmith pulls out the part and continues working on the anvil.

When working with a forge, we must not forget about the use of high-quality charcoal. It's better to use coke.

Types of designs

Forges are divided according to various factors. If we talk about design, we can distinguish two groups:

1. Open models. Allows you to assess the condition of the workpiece from different angles.
2. Closed models. The advantage over open structures is the ability to reach higher temperatures.

The division according to design features concerns the size of the working surface.

Stationary forges are divided according to the type of fuel used:

1. Equipment operating on solid fuel.
2. Models using liquid fuel - fuel oil.
3. Gas forges.

Purpose of the forge

Blacksmithing is still popular today, although it is considered an outdated technology. The main elements of any blacksmith's workshop are an anvil, a forge, and a work table. Equipment for heating metal is a must. Metal products without heat treatment are durable and difficult to process. The blacksmith heats up the workpiece to make it easier to work with. Heated metal is easily subject to mechanical stress.

Selection principles

When choosing purchased equipment for a blacksmith shop, you need to consider a number of factors:

1. The size of the heated surface. The possible size of the processed workpieces will depend on this.
2. Type of fuel used. It is necessary to take into account the characteristics of the consumable material.
3. Air supply option. Equipment with an electric compressor allows you to work faster and more productively.
4. Dimensions of the forge.

It is necessary to remember about the reliability of removing combustion products from the structure. To do this, you need to check the chimney and the holes that create draft.

Stages of making a homemade forge

Making a forge for forging yourself is a step-by-step process. To manufacture the equipment, it is necessary to prepare consumables:

• thick sheets of heat-resistant steel;
• refractory clay for external coating of the structure;
• fireclay bricks;
• metal corners, channels;
• metal pipe for the chimney;
• a metal grate that acts as a grate;
• construction sand;
• metal door with hinges;
• old vacuum cleaner to create air flow.

If the heating device will operate on fuel oil, you need to consider a combustible mixture supply system. Stages of making a homemade heating device:

1. Draw a drawing with exact dimensions marked with holes.
2. Assemble a support structure from metal channels. To connect individual elements you need to use a welding machine. The seams are cleaned and covered with an anti-corrosion coating.
3. Assemble a chamber with a door for filling solid fuel. Air must be supplied through it for the coals to produce heat. Install the grate.
4. Build a chamber from fireclay bricks to heat the workpieces. Make a hole on the top and secure the chimney pipe.
5. Connect an old vacuum cleaner that can blow out to the air supply system. Install the door on the window used for feeding workpieces.
6. Coat the outside of the bricks with refractory clay so that the heat is retained in the heating chamber.

After assembling the structure, you need to check its functionality. To do this, you need to conduct a test run and light the fireplace.

Features of working with a forge

In order not to encounter difficulties when working with homemade heating equipment, you need to take into account a number of features:

1. Always clean the grate and ash container from waste generated after work.
2. Light the coal using a rag. It must be soaked in advance with a flammable liquid.
3. Add fuel in small portions when the main batch burns out.
4. When the fuel burns out, you need to turn on the air supply to maximum.
5. The crust that forms on the surface of the coal indicates that the heating procedure of the workpiece can begin.
6. An additional hood installed above the equipment increases draft.
7. Further processing after heating is carried out using a forge hammer on an anvil. The hammer should weigh no more than 1000 grams.

Coal and coke can be bought in specialized stores. They allow you to achieve optimal forging temperatures in a short period of time.

A forge for forging should be in any blacksmith shop.
With its help, metal workpieces are heated. In order not to spend money on a purchased model, you can assemble the equipment yourself. To do this, you need to draw up a drawing, prepare materials, and put them together. Conduct a check, identify shortcomings, correct errors. We assemble a forge in an hour without welding homemade forge

The most popular types of forges for forging Link to main publication

Source: https://metalloy.ru/obrabotka/kovka/gorn

Making a forge with your own hands

Forged products have long been used in industry and in everyday life. They are used to build beautiful fences, decorate indoor fireplaces, and canopies over the front door. Forged flower stands find their place in the rooms of the house. All of these things can be made in a home workshop with some equipment.

A forge can heat up to high temperatures, so its main purpose is forging decorative metal products.

To forge metal, the main thing is to heat it to the required temperature. This is done using a blacksmith's forge. If there is a barn on your summer cottage in which you can set up a home workshop with a forge, then it is recommended to make a forge with your own hands. Its different designs differ only in the type of fuel used. The remaining differences are not of fundamental importance.

Blacksmiths often use fuel in the form of coke; it gives a high temperature and produces little waste.

How to make a forge for heating metal before forging?

Assembly diagram of a mobile forge.

Before making a forge, you need to choose the type of forge. The closed-type forge has a chamber for heating the workpiece. This design is the most economical in terms of fuel costs. But the size of the workpieces has limitations associated with the size of the heating chamber.

In an open-type forge, fuel is poured from above onto the grate, and an air flow is supplied from below. The heated workpiece is placed on the fuel. This makes it possible to heat large-sized workpieces.

Holes are drilled into the steel plate grid and then inserted into the center of the table.

The sequence of actions when making a forge can be as follows:

1. The base of the forge is its table. This is where the construction of the structure begins. Its lid is made of metal 4-5 mm thick. The height of the table is 700-800 mm. Its surface is most often made in dimensions ranging from 80x80 to 100x150 cm. You can weld a frame from a corner into which to lay fire-resistant bricks and a grate. The grate is usually placed in the center of the table. It can be made from a cast iron frying pan or from a steel plate 8-10 mm thick, in which holes with a diameter of 10 mm are drilled.
2. The grate is inserted into the hole in the table and lined with refractory bricks. The height of the table is made comfortable for the home craftsman, usually up to the level of his waist.
3. The air blowing mechanism is installed. It can be foot operated, but it is better to use an electric fan. An old vacuum cleaner is often used for this purpose. Its power is quite enough to produce a jet of air of the required strength. It's good if there is a speed controller. If it is not there, you can install an additional valve to regulate the air supply. Instead of a vacuum cleaner, some craftsmen use a manual siren drive.
4. The whole structure comes together. You can start testing.
5. Fuel is poured onto the grate. First, wood chips and larger firewood are placed, then coke is added. The blower is turned on, the workpiece is placed on the coke. You can also add a little coke on top of the heated iron. Then a small arch with a huge temperature inside it forms in its thickness. Instead of coke, it is quite acceptable to use wood waste.

A homemade forge can be supplemented with various devices inherent in industrial installations. Sometimes these devices cost practically nothing, but add convenience to work.

Let's compare an industrial forge with a homemade device

Image 1. Diagram of an industrial forge.

Industrial forges include (Image 1):

1. Air supply nozzle. In our case, its functions are performed by a hose from a vacuum cleaner.
2. Fireproof bricks that accumulate and maintain temperature. In a homemade forge, they can also be present on the desktop.
3. The grate bars that hold the fuel. In the homemade version they are usually also present.
4. Socket for loading solid fuel. This device can be equipped with a homemade forge if it is often used in the work of a home craftsman.
5. The bricks that make up the frame. The homemade device does not have them.
6. A fan that supplies air to the furnace. In the homemade version, its role is played by an old vacuum cleaner. But you can also install a separate fan.
7. Metal frame holding the desktop. It is available in a homemade version.
8. Air chamber. It can eventually be made for a home forge.
9. Ash pit. A useful addition to a homemade forge for home use if the forge is used frequently.
10. Air duct. To begin with, its functions in a homemade forge can be successfully performed by a vacuum cleaner hose.
11. Casing.

Some useful tips

For the mechanism for blowing air into the forge, an old vacuum cleaner with speed controllers is most often used.

Now you can clearly see how you can complement your home blacksmith’s forge. In the meantime, you need to acquire a simple anvil and blacksmith pliers, without which it is impossible to work.

1. Charcoal and stone coal, firewood and coke can be used as fuel. Coke is more expensive than coal, but its consumption is 5 times less. Combustion of coke produces less slag and soot. It's better to use coke. This is what professionals call coke of fine fractions, which does not need to be pre-cracked, wasting time on this.
2. You can use mains or bottled gas as fuel. This fuel will allow us to eliminate the need for grate bars. The heating temperature can be adjusted. Fuel is quite cheap and available.
3. It is recommended to install an exhaust hood made of sheet metal 4 mm thick on top. The joints of the parts are well welded to ensure the tightness of its internal volume.
4. It is necessary to make a hole in the side wall of the forge for a gas burner. A smoke removal system is also needed. This is a pipeline with a cross-section of approximately 30x30 cm. Its height is about 5 m.
5. Instead of a vacuum cleaner, you can use a fan from a car heater.
6. A hole cut in the back wall of a homemade forge will significantly improve the ventilation of the installation. Using this hole, it will be possible to heat longer workpieces.

You can make a homemade forge for blacksmithing yourself in a small room at your summer cottage. This device will make it possible to produce unique forged parts to create canopies, fences, gates and other things to decorate the interior of the site and the house.

Source: https://moyakovka.ru/instrumenty/kuznechnyi-gorn-svoimi-rukami.html

DIY forge. Blueprints. Step-by-step instruction :

In the old days, blacksmithing was held in high esteem. Not everyone could master it, not everyone had the opportunity to purchase the necessary tools and set up a workshop. Nowadays you can make a forge with your own hands without involving serious funds. Even a simple design will give you the opportunity to heat the metal to the required temperature and try your hand at forging.

Forge

People with creative inclinations who are engaged in design work are often faced with the desire to use handmade decorative metal elements. You can make such things using forging.

Thin sheet metal can be stamped, bent or minted without heating. It will not be possible to process a thick workpiece without this. There is no point in trying to make a tool from carbon steel.

If you equip your blacksmith's workshop with a hearth and a massive anvil, you don't have to pay much attention to the thickness of the workpiece. When hot, it will be able to forge, bend and flatten. The main thing in this process is a properly equipped forge.

Perhaps not everyone can do it with their own hands, but for a true connoisseur of the craft who is familiar with the structure, features and operating principle of the device, it will be possible. As experienced craftsmen assure, a simple forge can be built even from six bricks.

Construction of a forge

You should start by choosing the type of base. Brick is suitable for a stationary hearth; metal structures are suitable for a mobile hearth. The base should be located at the optimal height for ease of use. A fireplace for solid fuel requires the presence of a working combustion zone. It can be lined with fire bricks, lined or made of steel plate.

Source: https://www.syl.ru/article/198017/new_kuznechnyiy-gorn-svoimi-rukami-cherteji-poshagovaya-instruktsiya

Do-it-yourself gas forge drawings

A closed gas forge with your own hands is the most common technical solution for a small forge in the household. The presence of a main gas pipeline is not uncommon in modern houses, and the ease of regulating the parameters of the propane mixture, combined with the high calorific value of the gas, determines the appropriate efficiency of heating the metal for forging.

The key element of a gas furnace is the correct selection (and sometimes manufacturing) of a fuel-burning device - a burner.

Types of burners used for gas combustion

The choice of the optimal design of the forge burner is related to the issues of the amount of metal waste during heating for forging, the intensity of surface scaling, as well as the total gas consumption. Closed-type furnaces require short-flame burners that provide rapid and intense mixing of the combustible mixture. It is then that the efficiency will be maximum, and the removal of combustion products from the working chamber of the forge will be uniform and efficient.

Thus, the gas burner must provide:

1. The greatest angle of inclination of the finished gas-air mixture at the entrance to the working space of the forge.
2. High jet exit speed with a low height and large width.
3. Gas ignition safety.
4. Stability of the combustion process.
5. Insensitive to high humidity inside the forge.
6. Safety during the so-called “reverse strike”, when a sudden change in the direction of thrust can extinguish the torch, which almost immediately leads to an explosion of the flammable mixture in the furnace.

Gas burner drawings

Thus, for burning propane (from a cylinder or gas pipeline) the following are used:

• Injector burners providing self-suction of gas. Despite their simplicity, they are characterized by low efficiency, since they allow adjustment of the ratio of components for a relatively small range of values. Regarding a home-made forge, this most often leads to the need to work with a lack of air;
• Burners are tangential type (point jet), when the gas flows along the axis and the air flow tangentially to the mixer body. Mixing here occurs quite intensively, but pressure losses due to turbulence are also large. This affects the unevenness of the amount of air supplied to the forge, and it is greatest where the heated metal comes into contact with the hearth bottom. Accordingly, waste and scale formation increase. The positive quality of tangential burners is their simplicity and reliability;
• Vortex burners, where spiral guide plates are used to mix the flows. In such options, complete mixing occurs only at the mouth, so control by operation in this case is the best, and there is practically no pressure loss. Some of the disadvantages are the design complexity, which is why, even with drawings, making a vortex burner for a forge in a home workshop is very labor-intensive;
• Combined burners that combine tangential and direct-flow supply. The adjustability of the combustible mixture is the best, since by changing the amount of air supplied between the internal and external channels, you can adjust the length of the torch in the forge and, therefore, control the heating time of the workpieces for forging. The disadvantage of such designs is their large dimensions, which may be unacceptable for small forges. Also, the technical complexity of manufacturing a dual-flow burner can be considered a minus.

Manufacturing and installation of a burner in a closed gas furnace

Let's consider two options - make a burner from scratch, using the recommendations of experienced home craftsmen, or use a ready-made design, adapting/modifying some of its characteristics. It should be noted that in the first case you should have very high qualifications, as well as have experience in setting up and, at a minimum, repairing such devices. Otherwise, the matter may end in an explosion, burns, and other troubles.

1. Confusion bell made of heat-resistant steel type X18N9T.
2. Steel tubular body shaped like a double truncated cone.
3. Gas supply head.
4. Air supply head.
5. Mouths.
6. Regulators for the amount of gas-air mixture.

To make such a burner you need: 1.5-inch pipes, a sheet blank with a thickness of at least 1.2 mm for the confuser, two fittings and three flanges for connecting the elements. It is better to make a welded structure from heat-resistant steel, and welding must be done under submerged arc or using inert gas.

High-pressure hoses can be used as air and gas supply pipes, the diameters of which will correspond to the connecting dimensions of the housing. Fixing clamps and high-quality seals made of gasoline-oil-resistant high-temperature rubber are also required.

All other elements are connected using threads.

Horn with a homemade gas burner

On some websites there are recommendations for making a burner body by rolling a tubular blank. But at high jet pressures, plastic hardening of the material can lead to the emergence of zones of internal stress, which, when starting the burner, often cause cracking in the body metal.

The option of installing a burner from a used gas stove is much simpler.
You will first need to determine the fuel costs required to quickly heat the metal for forging. When selecting a finished design, the power of the main unit (boiler, stove, etc.) for which the device was used is established. The product of this value by the efficiency (for gas it is 0.890.93) gives the desired power value W. It is a little more difficult to establish the gas consumption T. The calculation algorithm is as follows:

• The calorific value of the fuel Q is determined (for propane, 3600 kJ/m3 can be taken);
• Using the formula T = 3.6W/Q, the flow rate is determined.
• Based on the calculation results, all the necessary shut-off and control valves are selected: valves, tees, o-rings, etc.

Installing a burner in a forge for forging with your own hands is done as follows. First, a confuser is inserted into the prepared lining hole, and the burner mouth is attached to it through a sheet gasket made of heat-resistant steel.

The product itself is attached to it, and tubes for supplying air and gas are screwed in. They check the effectiveness of the regulators, after which they carry out a test run of gas from a cylinder or a stationary network. All work must be carried out in a well-ventilated area.

At the slightest smell of gas, installation work is stopped and the source of possible leaks is determined.

Source: https://moy-instrument.ru/chertezhi-i-shemy/gazovyj-kuznechnyj-gorn-svoimi-rukami-chertezhi.html

Forges for forging with your own hands: types and features of self-production at home

A special device designed to heat workpieces to forging temperature during metalworking is known as a forge. There are several types of forge, each of which has its own characteristics.

It is possible that you can make a forge with your own hands in several simple ways.

Design and purpose of the device

The first do-it-yourself blacksmith's forge was invented by the ancient Khalibs. Nowadays, there are several design options for this device. When classifying them, they are guided by the following forge factors:

1. Fuel used for ignition (coal, gas, coke, fuel oil).
2. Forge design.
3. Device dimensions.
4. The purpose for which it is intended to be used (heating for forging, heat treatment of the workpiece).

The fuel can be fuel oil, gas or coal. As a rule, coal is most often used. This fuel option is safe and low cost. As for fuel oil or coke, these types of fuel are expensive and also polluting.

The use of gas provides a high level of efficiency, but at the same time requires more careful maintenance of the installation.

Coal forges

Furnaces that use coal as fuel are distinguished by their simple design and practicality of use. The design of this type of device consists of the following working parts:

1. Roof and walls. For their construction, bricks with fire-resistant properties are used. It can be chamotte or dinas.
2. Nest. It is here that the workpieces are heated.
3. Umbrella. Consists of curtains, folding type. Its main purpose is to improve the natural traction of the workspace.
4. Back wall. Special holes are made in it through which the outgoing air flow is supplied.
5. Air valve. By using it, air is supplied to the forge socket.
6. Box For its implementation, heat-resistant steel is used. With its help, the inlet and socket are connected.
7. Tempered container. It can be made of either brick or steel. Its main purpose is to lower the temperature of workpieces after their heat treatment. Thanks to this, it is possible to eliminate the formation of thermal cracks on them.
8. Chimney. Fuel combustion products are removed through it.

If we talk about the disadvantages of a solid fuel forge, we should note the complexity of the ignition process. Ignition becomes more difficult, especially when the forge has been left unused for a long time. To do this, a blacksmith must have certain skills.

Preparing the forge for use should be carried out in the following sequence:

• clean the nest from any remaining ash and burnt coals;
• blow out the chimney and the channels through which air passes using compressed air. You can use a regular vacuum cleaner for this;
• pour some coal into the bottom of the forge nest. In this case, you should pay attention to the fact that the hole located at the bottom of the box must remain open;
• To facilitate the ignition process, it is recommended to place a small rag moistened with firelighting fluid on the surface of the coal. Instead of rags, you can use sawdust;
• when the coal burns well, you can gradually add coal in small portions;
• now you need to open the air supply valve and set it in the middle position;
• as soon as the coal begins to burn out, you can increase the intensity of the air flow;
• When a crust forms on the surface of the coal, you can begin to warm up the workpiece and prepare it for work.

Since the temperature under the crust is higher than on its surface, the workpiece is placed directly under the crust. If the thickness of the crust reaches more than 5-10 mm, it is recommended to destroy it. Otherwise, the level of thermal conductivity becomes lower.

In order for the workpiece to heat up evenly over the entire area, it must be turned over periodically. It is also worth paying attention to the color of the fire. It should be uniform and also have the same color.

Under no circumstances should the metal be allowed to overheat. At the same time, it will be much more difficult to process.

A distinctive feature of this type of forge is that it is much easier to prepare them for work than forges that run on solid fuel.

If we talk about the design of gas-type forges, it consists of the following elements:

1. Camera. For its manufacture, a material with fire-resistant properties is used. The outside of the chamber is lined with steel with heat-resistant properties.
2. Front flap. Its opening is ensured by using a counterweight or hinges. In order to be able to observe what is happening inside the chamber, a small viewing window is mounted in one of its walls.
3. Under. For its manufacture, fireclay bricks are used, which have heat-resistant properties.
4. Burner. Several types of burners can be used. When determining the type of burner, the main factor is the type of gas that is used. For example, if a propane-butane mixture is used as fuel, a diffuse type burner is used. Burners of this type guarantee uniform heating of the workpiece, as well as the formation of a minimum amount of waste.
5. Mixing reducer. Air enters the gas mixture, which is located in the cylinder.
6. Nozzle. Its shape is directly dependent on the shape of the workpieces that will be used in the work process.
7. Grate grate. Its purpose is to increase the traction rate, as well as to ensure the collection of scale.
8. Fan. With its help, air is forced into the burner.

To ensure the operation of gas forges, the presence of an energy source is required. In this regard, forges of this type are used to heat long workpieces to forging temperature. In such furnaces, the heating process occurs much faster.

The use of gas forges is possible subject to the following safety rules:

• The blacksmith's room must be periodically ventilated to prevent gas accumulation;
• It is not allowed to place devices containing oxygen or mixtures containing it near the forge;
• By using a gas analyzer, it is necessary to check the final combustion of gas before starting the furnace again.

Only if the rules of use and safety of a gas-type forge are observed, its use will be justified.

Self-production

Before making a forge, you need to decide on the type of device. Homemade forges can be of two types:

1. Closed. Its design is equipped with a special chamber in which the workpiece is heated to the required temperature. It should be noted that in closed-type forges you can work with workpieces whose size does not exceed the size of the chamber itself.
2. Open. Fuel is poured onto the grate from its top. Air is supplied from the bottom. The workpiece is placed directly on the surface of the fuel to heat it. Thanks to this, you can use workpieces of quite large sizes.

First you need to take a steel plate and drill holes in it. After this, it can be inserted into the central part of the table, which acts as the base of the forge.

In order to make a table, it is recommended to take a metal plate, the thickness of which ranges from 3-5 mm. The dimensions of the table should be taken into account: 700 mm is the height of the table. The tabletop measures 80 x 100 cm.

It is possible that a frame is being welded from the corner into which the grate and refractory bricks are placed. To make the grate, you can use a regular old cast iron frying pan with holes drilled in the bottom. It should be taken into account that when determining the height of the table, it is necessary to focus on the height of the blacksmith.

Now you can begin installing the air supply mechanism. It is possible to create such a mechanism powered by a foot drive.

The best option for creating a mechanism is to use an electric fan from an unnecessary vacuum cleaner . Its power is enough to supply the required air flow. It would be useful to equip the design with a power regulator.

It is possible to use a manual siren drive instead of a vacuum cleaner.

After this, all parts of the structure are assembled into one whole device. Now you can begin your first test run. A homemade forge for forging can be supplemented with various types of additional devices that increase the ease of working with it.

After making a forge, you need to learn how to use it. To do this, it is recommended to adhere to the following rules:

1. The beginning of working with the device is to load fuel onto the grate. Some blacksmiths recommend placing a workpiece on a heated layer of coal, and pouring another layer of coal on top of it. In this way, it is possible to achieve the highest possible temperature in the chamber.
2. If wood is used as fuel, an additional ring (21 cm in diameter) must be placed on the grate.
3. To ensure good traction over a homemade forge, it is necessary to install a special hood. You can also do it yourself.
4. In order to heat the workpiece to the temperature required for forging, it must be kept in the middle of hot coal. It is important not to overcook the workpiece. This can deteriorate the properties of the metal, which will complicate the process of working with the workpiece or make the metal very brittle.
5. For forging, it is recommended to use a special hammer whose weight does not exceed 1 kg. During work, eyes must be protected with goggles. This will help prevent hot metal from getting into your eyes.
6. A large metal thing can be used as an anvil. This could be a rail or a sledgehammer.

A homemade forge has significant advantages over a purchased one. It is much cheaper, easier to use and maintain.

Source: https://tokar.guru/samodelkin/kuznechnyy-gorn-svoimi-rukami-dlya-kovki.html

DIY forge: homemade gas and coal burner, how to make, instructions

Well, how much we love wild abstruse definitions: special heating devices for the purpose of increasing the plastic characteristics of the metal. Let's try to translate all this disgrace into human language.

A forge is essentially a stove. It is clear that it has its own characteristics, varieties and technological nuances, but it is still a stove. It is needed to heat metal parts to a temperature so that they can be forged, that is, subjected to deformation.

This is the main and general fact for all kinds of forges - from primitive country crafts on bricks to industrial furnaces with many technological features of application and purpose.

Heating the workpiece in a forge

Two main and only properties are required from a forge furnace: to produce a very high temperature, up to 1200 – 1500°C, and the ability to maintain the desired temperature for a certain time. In other words, we need strong and even heat.

At what temperature do metals become forgeable, that is, begin to be ductile? This is different for all metals and alloys. But the visual sign that the metal part has heated up to the required temperature is also common - this is the orange color of the part.

The only metal that behaves quite meanly and does not change its color when heated is aluminum. It is not the easiest metal to forge and weld in principle; with aluminum you need to know and apply many special requirements.

So, the absence of an orange color while it has already warmed up for forging is a significant factor that makes it difficult to work with this capricious metal and its alloys. After all, you can’t overheat. Underheating is also no good.

Classification of forges

There are several criteria by which you can classify all these stoves into neat types.

Most often, forges are divided according to the type of fuel on which they operate:

Solid fuel forges

They run on coal. Their use is becoming less and less common, since coal is a fuel that does not provide a stable and even fire, which is the most important requirement for a forge. Not only that, such stoves require not just coal, but high-quality coking wood coal or hard coal of the same quality.

There are lovers of such exotic things, so below we will focus on a couple of tips for arranging such a stove.

Gas forges

We will talk about this type of stove in detail: they are the most common in both home handicraft workshops and professionally equipped forging centers. The gas forge is, without a doubt, the favorite tool of domestic blacksmiths.

Liquid

Here the main type of fuel is fuel oil.

https://www.youtube.com/watch?v=4H4BIrPWZjw

According to the design decision, forges are divided into closed and open. In size they come in small, medium and large. That, in fact, is the entire classification of forges. A homemade forge for forging is a very real thing and, most importantly, necessary on the farm.

The main thing is to decide which kind of forge suits you. And to do this, you must clearly know what kind of forging products you are going to make, for whom and in what quantity.

Basic design of a homemade forge

The first question is: what kind of forge should I make - open or closed? The answer will depend on your plans - what are you going to do in your blacksmith shop? If this is a hobby in the form of artistic forging in small quantities exclusively for the home and gifts for relatives, then it will be quite enough for you to acquire an open forge.

If you plan to work with metals seriously, for example, to earn money, then we would advise you to build a closed forge with your own hands.

These are the parts that make up a well-assembled forge:

• frame on racks for support, everything must be made of steel;
• under – bottom or lower part of the wall of the hearth;
• slide-type damper with special holes to accelerate metal heating and save fuel;
• fan;
• smoke exhaust pipe
• linings – thermal protection of the stove in the form of fireclay bricks;
• recuperator - a special device for returning the generated heat in the form of furnace gases and, thus, efficient use of resources.

Building a solid fuel forge

The main disadvantage of solid fuel forges is that coal itself cannot produce the required temperature above 1000°C. Therefore, such stoves always require an air stream. Previously, these were bellows, now more often the air is supplied through a pipe with a welded end, also made of steel.

Grate for the forge.

The table plate must be made from a blank with a thickness of at least 5 mm. If you install an open design forge outdoors, you will not need to deal with special ventilation.

Here are the main steps for building a homemade coal-fired forge:

• Build a platform for the foundation with concrete and reinforced rods.
• Fold the bricks into a rectangular base; the table surface can be of any height.
• Make a hole in any wall of the base for the blower.
• Assemble the floor from special refractory bricks onto the base.
• Install a grate with holes, which must also be made of fire-resistant material, for which a cast-iron door from an old stove is perfect.
• After installing the grate, add walls made of the same refractory brick.
• Do not forget to leave a hole in one wall for air supply; it is better to do this immediately when laying bricks.
• Install a fan into the air supply pipe.
• If you are making a closed structure, be sure to build a chimney, which is absolutely necessary for draft.

Such a forge can be made mobile - it all depends on you. An old gas stove can serve as an excellent frame for a solid fuel forge.

Building a gas forge

Before you start building a gas forge with your own hands, you need to determine the parameters of the hearth - its area.

There is a clever formula for this:

N=H×F

N is the productivity of the hearth, which depends on the tension H and the hearth area F. It has been calculated that the gas supply speed in the range from 1 to 1.5 m/sec is sufficient to optimally maintain the required temperature in the hearth.

Diagram of a gas burner for a forge.

You know the area of ​​your workshop and the approximate number of forging parts in kilograms that you plan to produce. With this data you derive the hearth tension with a maximum permissible upper limit of 150 kg/m².

Necessary materials you need to get started:

• fire-resistant brick such as dinas or chamotte;
• plates with a thickness of at least 5 mm made of heat-resistant steel;
• steel profile for the racks, frame and valve of the hearth;
• pipe for the chimney and ventilation duct made of steel;
• putty for sealing cracks between bricks with heat-resistant properties;
• sheet metal or an additional layer of refractory bricks for lining on the outside;
• burners from high-power double-circuit boilers;
• fan;

Gas forges can also be open. With it everything is much simpler; it will be enough to install grate bars with air supply for greater heating efficiency. In this case, combustion substances are removed by a fan made of heat-resistant metal.

It is better to place the support frame close to one of the walls of your workshop. The choice of wall must be made taking into account the fact that a chimney and ventilation pipe will be needed, so it is better not to use adjacent walls, if any.

It is better to weld the racks and the frame itself from low-alloy steel according to drawings that can be downloaded on the Internet. Low-alloy steel is strong, lightweight and, most importantly, resistant to specific high-temperature corrosion. The external lining must be thought out in advance so that holes for its fastening are immediately made in the support frame.

Now about refractory bricks and masonry. It is important to buy real certified fireclay bricks made in accordance with GOST 390-79. If you purchase a brick that does not meet the standard, you risk that ordinary bricks will begin to melt at a temperature of 1000°C.

Construction of a forge.

The second type of refractory bricks is dinas. These bricks are more expensive, but more resistant to high temperatures: they can withstand temperatures of 1800°C. They are lighter than fireclay bricks due to the high proportion of silicon salts in their composition.

If you have the opportunity, it is better to line the forge with silica brick: forges made of refractory silica brick are more durable and can withstand the most severe temperature conditions.

The bricks are laid with a mortar of refractory clay with the addition of chamotte and silica powder in a precise proportion of 60:40. Treat the chimney and fan around the perimeter with metal corners.

The most important final stage is drying the entire structure. After this, you need to check how the fans for the forge work. And only then will it be possible to perform a test run.

How to make a burner for a gas forge

In addition to general instructions on how to make a forge, there are rules for installing a gas burner. A gas forge burner can be purchased at a store, or you can make it yourself.

You need to make a gas forge burner yourself, taking into account the requirements for it:

• ignition of gas should be completely safe;
• combustion must be stable;
• resistance to humidity inside the furnace;
• safety in case of changes in thrust and the risk of explosion of a flammable substance.

Gas is supplied to the burner from a cylinder or network under the control of regulators. A test run of gas is carried out to check the regulators and pressure, and monitor the smell.

Source: https://tutsvarka.ru/oborudovanie/kuznechnyj-gorn