June 16, 2024 by Heather
Gas Vs. Coal Forge
Understanding Gas and Coal Forges: Energy Source and Mechanism
Introduction to the Fundamentals of Forge Types
In the world of metalworking and bladesmithing, the choice of forge plays a crucial role in shaping the quality and efficiency of the craft. Forges are essential for heating metals to high temperatures, making them malleable for shaping. The two primary types of forges are gas forges and coal forges. Each type operates differently and offers distinct advantages and challenges. Understanding these differences is key to selecting the right forge for your needs.
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Comparison of How Gas and Coal Forges Convert Energy into Heat
Gas Forges
Gas forges, powered by propane, liquefied petroleum gas (LPG) or natural gas, utilize burners to produce heat. The gas is ignited in a combustion chamber, where it mixes with air to create a controlled, consistent flame. The chamber is usually insulated to maintain high temperatures efficiently. This mechanism allows for precise temperature control and quick heating. Occasionally a forced air draft is used. You can see the colour, thus judging the temperature of your steel at all times. https://amzn.to/3Wa0WFo have a variety of gas forges for sale.
Coal Forges
Coal forges, on the other hand, use coal, coke, or charcoal as fuel. The fuel is burned in a firepot, and air is supplied via bellows or an electric blower to intensify the heat. The blacksmith can control the temperature by adjusting the airflow and the amount of fuel. This method allows for achieving extremely high temperatures, making it suitable for working with various metals. Often the steel is hidden from view which makes it difficult for beginners to use as they cannot see the color and therefore judge the temperature of the steel. Different designs of coal forges, blowers and forging coal can be found for sale here https://amzn.to/4cOeTye
Environmental Impact of Using Gas vs. Coal as Fuel
Gas Forges
Gas forges are generally considered more environmentally friendly than coal forges. They burn cleaner, producing fewer pollutants and greenhouse gases. Additionally, gas forges do not produce smoke, making them a better option for indoor use and for maintaining a cleaner workspace.
Coal Forges
Coal forges produce more smoke and pollutants, including sulfur and particulates that can be harmful to both the environment and the blacksmith. The burning process releases a significant amount of carbon dioxide, contributing to air pollution and climate change. Proper ventilation is crucial when using coal forges to mitigate these environmental and health impacts.
Maintenance and Convenience: Everyday Use of Gas and Coal Forges
Gas Forges
Gas forges are known for their convenience and ease of use. They require minimal setup and maintenance, primarily involving regular checks of gas lines and burners for leaks or blockages. The consistent heat output and quick ignition make gas forges highly efficient for everyday use. It is easy to “set” a specific temperature, reducing the possibility of melting your steel.
Coal Forges
Coal forges require more hands-on maintenance. The blacksmith needs to manage the fire, remove clinker (a byproduct of burning coal), and ensure proper ventilation. Starting and maintaining a coal fire can be time-consuming and demands more skill and attention compared to gas forges.
Cost Analysis: Upfront Investment and Running Expenses
Gas Forges
- Upfront Investment: Gas forges generally have a higher initial cost due to the burners, insulation, and gas setup.
- Running Expenses: The cost of propane, LPG or natural gas can add up, especially for frequent use. However, the efficiency of gas forges can offset some of these expenses. The “clean” fire results in a better carbon steel blade.
Coal Forges
- Upfront Investment: Coal forges can be less expensive to set up initially, especially if using simple, traditional designs. Simple construction makes it easy for the bladesmith to make his own forge.
- Running Expenses: Coal, coke, or charcoal can vary in price, and the cost of continuous fuel can be significant. Additionally, coal forges require more frequent maintenance, which can add to the overall expense. Some coal contains too much sulpha which is bad for carbon steels which are used for blades.
Choosing the Right Forge for Bladesmithing: Gas or Coal?
Defining Bladesmithing: The Art and Science Behind It
Bladesmithing involves the crafting of knives, swords, and other cutting tools. This craft requires precision, skill, and control over the heating process to ensure the steel achieves the right properties for durability and sharpness.
The Influence of Heating Consistency and Temperature Control on Bladesmithing
Consistent heating and precise temperature control are vital in bladesmithing. They ensure even heat distribution, prevent overheating, and allow for accurate hardening and tempering processes.
Pros and Cons of Using a Gas Forge for Blade Making
Pros
- Consistent Heat: Gas forges provide a steady and controllable heat source.
- Ease of Use: They are straightforward to operate, ideal for beginners and professionals alike.
- Clean Operation: Gas forges produce less smoke and pollutants, making them suitable for indoor use.
Cons
- Fuel Dependency: They rely on propane or natural gas, which may not be readily available everywhere.
- Operating Costs: Continuous use can be expensive due to fuel costs.
- Carbon Monoxide: When used indoors without proper ventilation, there is a risk of carbon monoxide poisoning. A carbon monoxide detector should be installed in your shop. https://amzn.to/45SZtX6
Pros and Cons of Using a Coal Forge for Blade Making
Pros
- High Heat: Coal forges can achieve higher temperatures and are suitable for a variety of metals.
- Versatility: They offer greater control over the heating process, allowing for nuanced temperature adjustments. Large or unusual-shaped blades and axes can be forged in a coal forge.
- Traditional Experience: The sensory engagement with coal forges connects blacksmiths to traditional techniques.
Cons
- Environmental Impact: Coal forges produce more smoke and pollutants.
- Maintenance: They require regular cleaning and skill to operate effectively.
- Safety Concerns: Open flames and the need for ventilation pose additional risks.
Expert Opinions: What Seasoned Bladesmiths Prefer and Why
Many seasoned bladesmiths have a preference based on their personal experiences and specific needs. Some appreciate the traditional aspects and control of coal forges, while others prefer the convenience and consistency of gas forges. The choice often depends on the type of work, the working environment, and individual skill levels and the availability of clean forging coal.
Safety Considerations When Working with Gas and Coal Forges
Gas Forges
- Ventilation: Ensure proper ventilation to prevent gas buildup and ensure a safe working environment.
- Leak Checks: Regularly inspect gas lines and connections for leaks.
- Fire Safety: Keep a fire extinguisher nearby and follow standard fire safety protocols.
- Protective Gear: Wear appropriate protective gear to handle high temperatures and sparks.
Coal Forges
- Smoke Ventilation: Use proper ventilation to avoid smoke inhalation.
- Fire Management: Manage open flames carefully and have firefighting tools readily available.
- Protective Gear: Wear appropriate protective gear to handle high temperatures and sparks.
Final Verdict: Which Forge Aligns Better with the Needs of a Bladesmith?
Choosing between a gas and coal forge depends on various factors, including your environment, budget, skill level, and personal preferences. Gas forges offer convenience, ease of use, and cleaner operation, making them ideal for beginners and those who prioritize efficiency. Coal forges provide higher heat, greater control, and a traditional experience, which may appeal to those who value the artistry and depth of skill development in bladesmithing. Ultimately, the best forge for you is the one that aligns with your specific needs and goals in the craft.
In the good old days!
On a personal note, I love a coal forge mainly because that is where I started my career as a farrier, blacksmith, and bladesmith. When you have enough experience with a coal forge, you can utilize the different temperature zones within your fire to your advantage.
I used my traditional coal forge from 1983, when I qualified as a farrier, right up until 2003, when I attained my Master Bladesmith rating with the American Bladesmith Society, where I made my damascus performance test knife as well as my 5 knives for submission in my coal forge.
The only reason I stopped using my coal forge is that we cannot obtain good-quality coking coal in South Africa, and I ran out of the coke I had obtained from the old gas works in Johannesburg.
We now only use my coal forge with charcoal when we have to evenly heat a very long or unusual-shaped sword for heat treatment. It is also great for making large axes, as they will not fit into our gas forge.
If you can obtain high-quality forging coal, I strongly suggest that you try forging in it. Kevin and I teach at the bladesmithing school in Arkansas, U.S.A., which has excellent coal, 6 coal forges, and 6 gas forges. We rotate our students so that they get equal experience using both types of forges. Most modern bladesmiths only use gas forges.
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