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If the scarf were to be formed with one or more of the edges touching each
other at the same time or before the centers did so, the scale would be
imprisoned within the body of the weld and would cause the finished work to
be weak, while possibly giving a satisfactory appearance from the outside.
_Fluxes._--In order to assist in removing the scale and other
impurities and to make the welding surfaces as clean as possible while
being joined, various fluxing materials are used as in other methods of
welding.
For welding iron, a flux of white sand is usually used, this material being
placed on the metal after it has been brought to a red heat in the fire.
Steel is welded with dry borax powder, this flux being applied at the same
time as the iron flux just mentioned. Borax may also be used for iron
welding and a mixture of borax with steel borings may also be used for
either class of work. Mixtures of sal ammoniac with borax have been
successfully used, the proportions being about four parts of borax to one
of sal ammoniac. Various prepared fluxing powders are on the market for
this work, practically all of them producing satisfactory results.
After the metal has been in the fire long enough to reach a red heat, it is
removed temporarily and, if small enough in size, the ends are dipped into
a box of flux. If the pieces are large, they may simply be pulled to the
edge of the fire and the flux then sprinkled on the portions to be joined.
A greater quantity of flux is required in forge welding than in electric or
oxy-acetylene processes because of the losses in the fire. After the powder
has been applied to the surfaces, the work is returned to the fire and
heated to the welding temperature.
_Heating the Work._--After being scarfed, the two pieces to be welded
are placed in the fire and brought to the correct temperature. This
temperature can only be recognized by experiment and experience. The metal
must be just below that point at which small sparks begin to be thrown out
of the fire and naturally this is a hard point to distinguish. At the
welding heat the metal is almost ready to flow and is about the consistency
of putty. Against the background of the fire and coal the color appears to
be a cream or very light yellow and the work feels soft as it is handled.
It is absolutely necessary that both parts be heated uniformly and so that
they reach the welding temperature at the same time. For this reason they
should be as close together in the fire as possible and side by side. When
removed to be hammered together, time is saved if they are picked up in
such a way that when laid together naturally the beveled surfaces come
together. This makes it necessary that the workman remember whether the
scarfed side is up or down, and to assist in this it is a good thing to
mark the scarfed side with chalk or in some other noticeable manner, so
that no mistake will be made in the hurry of placing the work on the anvil.
The common practice in heating allows the temperature to rise until the
small white sparks are seen to come from the fire. Any heating above this
point will surely result in burning that will ruin the iron or steel being
handled. The best welding heat can be discerned by the appearance of the
metal and its color after experience has been gained with this particular
material. Test welds can be made and then broken, if possible, so that the
strength gained through different degrees of heat can be known before
attempting more important work.
_Welding._--When the work has reached the welding temperature after
having been replaced in the fire with the flux applied, the two parts are
quickly tapped to remove the loose scale from their surfaces. They are then
immediately laid across the top of the anvil, being placed in a diagonal
position if both pieces are straight. The lower piece is rested on the
anvil first with the scarf turned up and ready to receive the top piece in
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