Beaten Metal work (Score – 6 points)

This area of the metalwork craft involves the beating of malleable metal, in sheet form, to the required shape with a mallet or hammer. The metals which are commonly used for this type of work are aluminium, Copper, Gilding Metal and Brass and suitable sheet thicknesses would be between 0.7 and 1.2mm. To facilitate the shaping process the metal should be frequently softened by annealing as the metal will become work-hardened from being struck repeatedly with a mallet or hammer.

Copper is annealed by heating to a dull red and cooling either by quenching in water or by leaving it for a sufficient time to cool in the air. After annealing the copper sheet will need cleaning to remove the oxides that will have formed on the surface. The copper is dipped into a bath of dilute sulphuric acid (one part acid to eight parts water) and is left to 'pickle' for five to ten minutes. The copper is then thoroughly washed, scoured with pumice powder, rinsed and dried before continuing with the shaping process.

To prepare the metal for beating the shape of blank required is cut from the sheet with snips and the edge is filed smooth. Any scratches on the surface of the metal should be removed before shaping commences and during the shaping process itself care must be taken to protect the metal from being scratched. The actual shaping process which will be used to beat the metal to shape will depend on the required design. There are three main beating methods and these are illustrated in the diagrams opposite.

Sinking

The sinking process is used to form a shallow tray or dish with a flat rim. The metal is struck with a bossing mallet or a blocking hammer on a stepped hardwood block. Nails or dowels fitted into the hardwood block control the width of the rim and the step in the block controls the depth of the sinking. The metal blank is turned as it is struck inside the rim and as it becomes necessary the rim and base of the dish are flattened with mallet blows onto a flat surface.

Hollowing

The hollowing process is used to form shallow trays by stretching the metal with blows from a mallet or hammer. As shown the work may be carried out on a hollowed wooden block with a blocking hammer, or on a sandbag with a bossing mallet. Starting from the outside blows are made slightly in advance of the point of contact between the metal and the block or sandbag so that the metal is stretched into the hollow below it. Hammering is continued around in circles, each ring of blows being 10 mm or so inside the last until the desired shape is achieved. (Concentric pencil lines drawn on the blank will act as guides to the position of each ring of blows).

Raising

The raising process allows the shaping of deep articles as the result of the blows made with the raising mallet or the raising hammer is to contract the metal, rather than stretch it as with sinking and hollowing. As shown the raising mallet is used for shallow shapes which can be worked over a domed stake and the raising hammer is used for deep shaping over a raising stake. Concentric pencil lines are required to guide the positioning of the blows and work is started from the centre of the blank. The metal should be held such that the hammer or mallet strikes the metal in advance of its point of contact with the stake and care must be taken not to punch the metal between the hammer and the stake as this will stretch the metal and distort the shape.

II. Answer the questions: (Score – 3 points)

1. What metals are used in the area of the metalwork craft?

2. How is copper annealed?

3. What will the shaping process depend on?

Ш. Choose the Ukrainian equivalents from the box. (Score – 10 points)

1.blank, 2.annealing; 3.pumice; 4.boring; 5.to rinse; 6.shaping; 7.dowel; 8.drawing; 9.allowance; 10.ingot.

a).припуск, b) обпалення; c) штир; d) промивати; e) злиток; f) заготівка; g) формування; h) волочіння; i) пемза; j) розточка