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Producing forged parts by hand forging — Fundamentals

Course metadata	Details
Title	Producing forged parts by hand forging — Fundamentals
Module	Fundamentals of Producing forged parts by hand forging
Jurisdiction	Ireland
Target learners	Vocational learners in blacksmithing, forgework and artistic metalwork
Language	English
Learning setting	Supervised workshop learning supported by classroom, digital and project work
Review status	Ready for expert review; official requirements and workplace instructions must be checked before delivery
Open education	Course text is intended for release as open educational content under CC BY-SA 4.0; embedded media retain the licences stated on their source pages

Introduction

Hand forging is the controlled shaping of heated metal by hammer blows and hand tools, usually against an anvil. In a blacksmithing workshop, you use heat to reduce the force needed for plastic deformation and use accurate hammer control to move material where the drawing or design requires it. Fundamentals include drawing out, upsetting, bending, tapering, shouldering, punching, drifting, cutting and controlled surface finishing.

This module is written for vocational learners who may progress into forgework, repair, architectural metalwork, heritage craft, sculpture or other forms of artistic metalwork. You will learn the vocabulary used in a working forge, how basic forging operations change a section of steel, how to select and inspect core tools, how to plan a simple forging sequence, how to recognise common defects and how to judge a finished part.

No practical activity in this module is an invitation to work alone. Heating, handling and hammering hot metal can cause severe burns, eye injuries, fire, harmful exposure to noise and combustion products, and injury from defective tools or poor handling. Practical forging must be carried out only in an authorised workshop, under the direction of a competent instructor or workplace supervisor, with the local risk assessment, Safety Statement, emergency arrangements and equipment instructions in force.

A blacksmith working hot steel with a hand hammer. Observe the controlled working position and the concentration of force on the anvil face. Source and licence: Wikimedia Commons, File:Blacksmith working.jpg, CC BY-SA 2.0.

Learning Outcomes

By the end of this module, you should be able to explain how hand forging moves metal, distinguish the principal hand-forging operations, name the working parts of common forge tools, identify suitable and unsuitable training stock, describe the main hazards and controls for a supervised forge, plan and observe a simple taper-and-hook demonstration, diagnose common forging errors, apply basic quality criteria, and propose improvements that reduce wasted material and energy.

Jurisdiction, Official Sources and Precedence

Chosen jurisdiction: Ireland. All legal, qualification, safety-duty and standards information in this module refers to Ireland unless a source is explicitly described as general technical media. No cross-country equivalence is claimed or implied.

The principal authorities used for this module are the Health and Safety Authority (HSA) for occupational safety and health, SOLAS and the National Apprenticeship Office for the national apprenticeship system and Further Education and Training, Quality and Qualifications Ireland (QQI) for the National Framework of Qualifications and quality-assured qualifications, and the National Standards Authority of Ireland (NSAI) for Irish Standards and adopted European or international standards.

Precedence rule: Irish law, HSA requirements and guidance, current SOLAS or National Apprenticeship Office rules, QQI award information, current NSAI standards where applicable, the employer's Safety Statement and risk assessments, the equipment manufacturer's instructions, and the competent supervisor's workplace instructions take precedence over this aiMOOC. Requirements can change. The official sources listed below were checked on 1 September 2026 and must be rechecked before course delivery or assessment.

No part of this course creates a licence, trade status, apprenticeship registration, Safe Pass card, QQI award or other certification.

Current Irish Safety and Training Context

The Safety, Health and Welfare at Work Act 2005 is the central Irish workplace safety statute. HSA guidance explains that employers must identify hazards, assess risks and record the results in a workplace-specific Safety Statement. HSA also states that safety instruction, training and supervision must be adequate for the task and given in a form and language reasonably likely to be understood.

The HSA describes the Safety, Health and Welfare at Work General Application Regulations as applying across workplaces. Current HSA material refers to the General Application Regulations 2007 to 2023 and covers matters relevant to a forge such as work equipment, personal protective equipment, manual handling, noise and vibration. Learners and employees must cooperate with safety arrangements, use work equipment and PPE correctly, attend required training and report defects or dangerous conditions.

A forge is a hot-work environment because it intentionally produces high heat, hot material, sparks and scale. HSA fire-prevention guidance states that hot work requires stringent controls and may require a permit system, supervision, fire-resistant protective clothing, control of sparks and heat, suitable fire-fighting arrangements and a fire watch. The site's own hot-work procedure determines what applies to a particular forge.

Hammering on an anvil can create high and impulsive noise. HSA noise guidance identifies lower and upper daily or weekly exposure action values of 80 dB and 85 dB. Do not guess whether hearing protection is adequate: the employer's noise risk assessment and chosen controls determine the required action.

SOLAS is the state agency responsible for Further Education and Training and manages the national apprenticeship system with the National Apprenticeship Office. Current national apprenticeship information lists Metal Fabrication at NFQ Level 6. That apprenticeship is a distinct national programme; this blacksmithing fundamentals module is not a substitute for it and must not be presented as a Metal Fabrication apprenticeship award. QQI remains the authoritative source for the NFQ and quality-assured qualifications. NSAI publishes Irish Standards and adopted European and international standards; where a drawing, customer specification, PPE requirement, material specification or product standard applies, use the current edition identified through NSAI rather than relying on memory or an outdated workshop copy.

Official Sources Checked

Health and Safety Authority: Safety, Health and Welfare at Work Act 2005: employer duties, training, supervision and emergency arrangements.
Health and Safety Authority: Safety Statement and Risk Assessment: Sections 19 and 20, hazard identification, risk assessment and workplace-specific Safety Statements.
Health and Safety Authority: The Law: current overview of employee duties and the General Application Regulations.
Health and Safety Authority: Fire Prevention: hot-work controls and permit-system principles.
Health and Safety Authority: Noise: exposure action values and employer actions.
SOLAS: Who We Are: current role in Further Education and Training and apprenticeship.
SOLAS: National Apprenticeship Office: national apprenticeship governance and information.
Generation Apprenticeship: current apprenticeship directory and learner information.
Quality and Qualifications Ireland: National Framework of Qualifications: authoritative information on NFQ levels and award types.
National Standards Authority of Ireland: Search and Buy Standards: current Irish, adopted European and adopted international standards.

Core Concepts of Hand Forging

Plastic Deformation and Material Flow

When heated into a suitable forging range, steel becomes easier to deform plastically. Hammer blows compress the material locally. Because the metal is not simply disappearing, a decrease in one dimension is normally accompanied by an increase in another. This is why drawing out makes a section longer and thinner while upsetting makes it shorter and thicker.

Good forging is not random hammering. You control where the metal moves by choosing the hammer face or peen, the anvil feature, the orientation of the work, the area struck, the force of the blow and the number of heats. Efficient work combines accurate blows with timely reheating rather than trying to force steel after it has become too cold for the operation.

The Main Forging Operations

Operation	What happens to the metal	Typical use	Quality cue
Drawing out	Length increases while section thickness or area decreases	Tapers, stems, points, handles and scroll ends	Even taper, straight centreline, no folded edges
Upsetting	Length decreases while section thickness or area increases	Heads, bosses and local thickening	Material remains centred without buckling
Bending	The bar changes direction around an anvil horn, former or other approved support	Hooks, scrolls, brackets and curved components	Smooth radius without kinks or cracks
Tapering	Section reduces progressively toward an end or transition	Hooks, leaves, terminals and decorative details	Consistent rate of reduction and clean end
Shouldering	A controlled step or local change in section is created	Tenons, transitions and defined decorative zones	Square or deliberately radiused shoulder as specified
Punching and drifting	A hole is initiated with a punch and brought to shape or size with a drift	Eyes, lugs and tool components	Hole centred and free of tearing
Fullering	Material is spread or isolated with rounded top or bottom tools	Local reduction, transitions and preparation for drawing	Smooth, controlled groove without sharp stress raisers
Cutting	Hot or cold stock is separated using the approved cutting method	Blanks, shoulders and decorative cuts	Clean cut and no damage to the anvil face

Practitioner Myth Check

Forging does not "compact molecules" in a magical way. The important metallurgical effects come from plastic deformation, temperature history, alloy, grain structure and subsequent heat treatment where relevant. In a beginner artistic-metalwork exercise using known low-carbon steel, the first priorities are controlled material flow, dimensional accuracy, defect avoidance and safe handling.

Colour is an approximate workshop cue, not a calibrated thermometer. Apparent colour depends on lighting, surface scale and the observer. Use the approved forging range for the known steel and the instructor's process, and stop to reheat when the work is no longer responding correctly.

Tools and Workshop Equipment

Public-domain diagram of an anvil and blacksmith's hammer. Source: Wikimedia Commons, File:Blacksmith anvil hammer.svg.

The Anvil as a Working Surface

Anvil feature	Typical function	Beginner note
Face	General forging, straightening and planishing	Keep the work over supported mass and do not strike the bare face
Horn	Bending curves, rings and scrolls	Work progressively; protect hands from the hot end and from pinch points
Heel	Supports work near the hardy and pritchel holes	Keep tools and work stable before striking
Hardy hole	Receives compatible square-shanked bottom tools such as a hot-cut hardy	Only use tools that fit correctly and are authorised for the task
Pritchel hole	Clearance for punching and drifting operations	Align the punch and ensure the path below is clear
Step or table	Provides a lower surface on some anvils for selected cutting or support operations	Anvil designs vary; follow the instructor's method for the specific anvil

Core Hand Tools

A basic supervised hand-forging station may include a forging hammer or cross-peen hammer, correctly fitted tongs, a wire brush, punches, drifts, fullers, set tools, hot-cutting tools, a leg vice or post vice, measuring tools, templates and approved cooling arrangements. Tool selection depends on the task and the learner's control, not on using the heaviest hammer available.

Hammer condition matters. The head must be secure, the handle sound, and the striking face maintained so that chipped edges do not launch fragments. Tongs must fit the stock. A poor grip encourages the work to twist, drop or eject. Bottom tools must seat securely and be compatible with the anvil.

A documented design of blacksmith's tongs. Compare the long reins, boss and jaws with modern shop tongs. Source: Wikimedia Commons, File:Orison Daeda, Blacksmith's Tongs, c. 1942, NGA 20922.jpg.

Technical-media note: this Black Bear Forge video discusses common blacksmithing tools. It is general craft media from the United States and is not a source for Irish law, Irish qualifications, PPE selection or workplace procedure. Your Irish workplace instructions take precedence.

Forges and Heating Equipment

Common workshop heat sources include solid-fuel forges, gas forges and, in some settings, induction equipment. Each has different fuel, ventilation, ignition, maintenance and emergency requirements. Learners must use only the forge for which they have been trained and authorised.

A traditional solid-fuel forge showing the relationship between fire, fuel and moving air. Source and licence: Wikimedia Commons, File:Traditional Blacksmith Forge.jpg, CC BY-SA 4.0.

Combustion forges require effective ventilation as specified by the workplace risk assessment and equipment instructions. Fuel systems, burners, blowers, chimneys, ductwork and fire controls must be inspected and maintained by competent persons. Learners must not improvise repairs, alter fuel systems or bypass safety devices.

Materials for Fundamental Exercises

Recommended Training Stock

For a first hand-forging exercise, use known, clean low-carbon steel supplied or approved by the training provider. It is forgiving compared with many alloy and tool steels and is suitable for practising drawing out, tapering and bending.

Higher-carbon and alloy steels can require tighter temperature control and defined heat treatment. Stainless steels and non-ferrous alloys may have different hot-working ranges, surface hazards and tooling requirements. These materials should be introduced only when the instructor has provided the correct process and controls.

Do not use unknown scrap, sealed objects, pressurised items, containers with uncertain previous contents, or painted, plated, galvanised, oily or chemically contaminated stock in this fundamentals module. Unknown composition can create unpredictable forging behaviour, and coatings or residues can create hazardous fumes or fire risks. HSA guidance on hot work around drums and containers is especially clear that contents and fire or explosion risk must be established before heat is applied.

Scale and Oxidation

The dark flakes that form on hot steel are commonly called scale. Scale forms as the steel surface oxidises. Excessive soaking at high temperature wastes material, can damage surface quality and increases the amount of scale. In practical work, manage heat efficiently, remove loose scale only with the approved method and keep your face and other people out of the path of flying particles.

Risk Controls for a Supervised Forge

Control Principles

Risk control begins before the forge is lit. The instructor or employer establishes the Safety Statement, task risk assessment, competent supervision, emergency plan, hot-work arrangements, ventilation, fire controls and safe layout. PPE is the final layer, not a replacement for elimination, engineering controls, good layout or competent supervision.

Hazard	Typical consequence	Fundamental controls
Hot metal and scale	Burns and eye injury	Clear hot-work zone, eye protection selected by the risk assessment, fitted tongs, designated cooling area, clear warning that metal can remain hot after it loses visible colour
Hammer and tool failure	Impact injury or flying fragments	Pre-use inspection, secure hammer heads, dressed striking faces, sound handles, correctly seated bottom tools, defective tools removed from service
Poor tong fit or grip	Dropped or ejected hot stock	Choose tongs that match the section, test grip before heating, keep hands clear of pinch zones, stop if the work becomes unstable
Fire and sparks	Fire, burns and smoke exposure	Hot-work procedure, remove or protect combustibles, suitable fire-fighting arrangements, supervision and fire watch where required by the site
Combustion products and fumes	Acute or chronic respiratory harm	Use approved clean stock, effective ventilation or extraction, maintained forge systems, no heating of unknown or coated material
Noise	Hearing damage and communication failure	Noise assessment, quieter methods where practicable, maintained tools and anvils, hearing protection where required, clear communication signals
Manual handling and repetitive hammering	Strain and fatigue	Suitable hammer mass, working height, material supports, planned heats, job rotation or rest as appropriate, mechanical aids for heavy stock
Congestion and poor housekeeping	Trips, collisions and accidental contact with hot work	Defined working radius, stock racks, clear floors, designated hot-material locations and one controlled workflow around each anvil
Unsupervised or unapproved work	Increased severity of any incident	Authorised workshop access only, competent supervision, stop-work authority and no lone practical work by learners

PPE and Inclusive Fit

PPE must be selected from the Irish workplace risk assessment and must fit the individual learner. Typical hot-forging arrangements may include safety eye protection with side coverage, task-appropriate face protection where there is a high particle risk, hearing protection where the noise assessment requires it, robust safety footwear, and close-fitting non-melting or flame-resistant work clothing suitable for hot-metal work. The exact ensemble is a workplace decision.

Gloves are task-dependent. They can protect against some radiant heat or brief contact risks but may reduce dexterity, retain heat or create entanglement risk around rotating equipment. Follow the instructor's task-specific rule rather than assuming gloves are always required or always prohibited.

Inclusive practice means selecting PPE in sizes and shapes that actually fit, choosing a hammer mass the learner can control accurately, adjusting anvil or work height where practical, using material supports and mechanical aids, and offering alternative ways to demonstrate knowledge where a learner cannot safely perform a particular physical task. Strength is not a substitute for technique.

Stop-Work Conditions

Stop immediately and inform the instructor if the hammer head is loose, the handle is split, tongs do not grip securely, the work falls to the floor, the forge flame or fuel system behaves abnormally, ventilation is not operating as required, a combustible enters the hot-work zone, eye or hearing protection is missing or damaged, another person enters the striking radius, the steel shows signs of severe overheating or burning, or you are unsure of the material or the next operation.

Planning the Forging Sequence

A good blacksmith plans the sequence so that the largest material movements happen efficiently and later heats refine the form. Think from the final geometry backwards. Ask which dimensions must be preserved, where the section must be reduced or thickened, where a bend will consume length, where a shoulder or hole will be located, and which surfaces must remain clean enough for later finishing.

Plan stage	Question to answer
Read the drawing or design	What are the finished dimensions, tolerances, radii, texture and functional requirements?
Choose stock	Is the material grade known and is the starting section large enough without excessive waste?
Mark datum points	Where do tapers, bends, shoulders, holes or decorative transitions begin?
Choose operations	Which material-moving operations give the shape with the fewest unnecessary heats?
Choose tools	Which hammer, tongs, anvil feature, fuller, punch, drift or former is approved?
Define quality checks	At which points will you check straightness, section, length, symmetry and surface condition?
Define safe cooling	Where will the finished part cool, and how will others know that it is still hot?

Step-by-Step Demonstration: Square Taper and Hook

Purpose: This demonstration combines drawing out, tapering, straightening and bending in a simple artistic-metalwork form. It is for observation and supervised practice only.

Training stock example: a short length of known low-carbon square steel selected by the instructor. The exact section, length, forging range and number of heats are set by the training provider.

Stage	Instructor-led action	What the learner observes or practises	Quality checkpoint
Prepare	Confirm risk controls, PPE, clear striking radius, safe hot-material area, tool condition and a pair of tongs that fits the stock	Test the cold grip and rehearse the movement from forge to anvil without striking	Stock cannot twist or slip in the jaws
Heat	Heat only the working end to the approved forging range for the known steel	Watch how the instructor recognises a usable heat while avoiding unnecessary soaking	No signs of burning or excessive scale
Start the taper	Place the hot end on the anvil face and use controlled overlapping blows	Strike the target area rather than chasing the whole bar	End begins to reduce evenly
Turn the section	Rotate the square bar in regular quarter-turns while drawing	Coordinate hammer blows with orientation	Taper remains centred and sides remain balanced
Refine	Reduce hammer force as the taper approaches size	Use lighter planishing or finishing blows to remove unnecessary high spots	Smooth transition with no abrupt neck
Reheat as needed	Return the work to the forge before it becomes too cold for efficient controlled deformation	Recognise that reheating is part of good technique rather than a failure	No forced blows on unresponsive steel
Straighten	Correct sideways bend or twist while the steel is still in an appropriate working condition	Sight along the bar and use the anvil face as a reference	Centreline is straight before forming the hook
Form the bend	Use the anvil horn or an approved former to create the hook progressively	Keep the taper aligned while bending and avoid pinching the inner radius	Curve is smooth and lies in the intended plane
Final correction	Make only the minimum corrections needed for symmetry and fit	Compare against a template or drawing	Hook opening, plane and overall length meet the task criteria
Cool and inspect	Place the part in the designated safe cooling area and label or control it as hot until confirmed otherwise	Inspect only when the instructor confirms it is safe to handle	No cracks, laps, severe scale pits or unintended sharp edges; dimensions recorded

Do not quench simply to make the part safe to touch. Quenching can create steam and, with some steels, can change hardness or create cracking. Use the cooling method specified for the known material and task.

Technique media: this video demonstrates drawing out. It is not a substitute for supervised practice or the Irish workplace risk assessment.

Technique media: this video demonstrates bending. Use it to analyse hammer placement and material flow, not as permission to reproduce the activity without instruction.

Understanding Upsetting

Upsetting is the opposite material-flow idea to drawing out: you deliberately make a section shorter and thicker. In practice, the main challenge is keeping the stock aligned so that it does not buckle. The material must be at the approved forging heat, the end must be presented square to the support, and the blows must remain centred.

Technique media: the video focuses on upsetting as a fundamental forging operation. Jurisdiction-specific safety or qualification statements in any external video do not replace Irish requirements.

Authentic Examples from Blacksmithing and Artistic Metalwork

Example	Main operations	Vocational learning value
S-hook	Tapering, drawing out, bending and straightening	Teaches symmetry, repeatability and control of bend radii
Gate latch element	Drawing out, shouldering, bending and sometimes punching	Connects forging to functional fit and assembly
Decorative leaf	Tapering, peening, texturing and controlled spreading	Connects material flow to artistic surface language
Fire poker	Drawing out, tapering, bending and optional twist	Teaches long straightness, balance and handle design
Rivet or upset head	Local upsetting and finishing	Demonstrates volume control and centred blows
Scroll	Progressive tapering and bending	Develops visual rhythm and smooth curvature

A blacksmith forging a decorative candlestick form with hammer and anvil. Source and licence: Wikimedia Commons, File:Blacksmith forging a candlestick.jpg, CC BY-SA 4.0.

For structural, lifting, pressure-containing, safety-critical or load-bearing parts, a fundamentals exercise is not enough. Use the applicable design documents, material specifications, standards, competent engineering input and inspection regime.

Common Errors and Corrective Thinking

Error	What it looks like	Likely cause	Better response
Crooked taper	Point runs off the centreline	Uneven blows or irregular turning	Re-establish the centreline early and use balanced quarter-turns
Fish-lipped end	End spreads or folds rather than drawing cleanly	Poor end geometry or uncontrolled edge spreading	Correct the end while there is still enough material and avoid folding a thin lip into the work
Lap or cold shut	Folded surface traps a seam	Metal has been folded over instead of moved cleanly	Stop and assess; do not simply hammer the seam closed and call it sound
Necked transition	Sudden thin spot behind a taper or shoulder	Too many blows in one narrow zone	Spread the reduction over the intended transition length
Twisted plane	Hook or scroll does not lie flat	Work rotated unintentionally in the tongs	Check plane during each heat and correct while the section is still controllable
Heavy scale and pitting	Rough oxidised surface	Excessive heat or long soaking	Heat only the length needed and work efficiently within the approved range
Hammer marks	Deep dents remain in a surface meant to be smooth	Overly heavy finishing blows or poor hammer-face condition	Reduce force, maintain the hammer face and planish only as needed
Overheating or burning	Abnormal sparking, crumbling or damaged surface	Excessive temperature or prolonged exposure	Stop work, isolate the piece and follow the instructor's disposal or evaluation procedure

A key vocational habit is to diagnose the cause rather than conceal the symptom. Filing or grinding a defect away can remove material without solving the underlying process problem.

Quality Criteria for a Fundamental Forged Part

A satisfactory beginner forged part should meet the drawing or template, remain free from visible cracks and folded seams, show a controlled taper and bend, lie in the intended plane, have transitions that are deliberate rather than accidental, and have no dangerous burrs or unintended sharp edges. Decorative hammer texture is acceptable only when it is a deliberate design feature.

Use simple gauges, rules, squares, templates or callipers as instructed. Final dimensional checks should be made only when the part is confirmed safe to handle and when thermal expansion will not invalidate the required measurement.

Quality area	Evidence
Dimensions	Recorded measurements compared with the drawing or template
Geometry	Straightness, symmetry, bend radius and plane visually and mechanically checked
Surface	No cracks, laps, cold shuts, severe scale pits or unintentional deep marks
Transitions	Tapers, shoulders and local reductions are smooth and correctly located
Function	Part fits or moves as the design requires without forcing
Process discipline	Learner follows the approved sequence, reheats appropriately and maintains a controlled work area

Sustainability and Resource Efficiency

Sustainable forge practice starts with process planning. Select stock close to the required section, calculate useful blank lengths, reuse only traceable offcuts of known material, and avoid unnecessary heats. A smaller correctly managed fire or correctly adjusted approved forge can reduce wasted fuel, but the most suitable system depends on the workplace, energy source, production pattern and ventilation requirements.

Do not treat coated or contaminated scrap as "free material" for the forge. Avoiding hazardous coatings protects people and reduces contaminated emissions and waste. Separate clean ferrous scrap, spent abrasive material, ash, refractory waste and other workshop waste according to local procedures. Maintain equipment so that burners, blowers, insulation and extraction operate efficiently.

A useful sustainability question is: Can the same quality be achieved with fewer heats, less stock removal and less rework without reducing safety? Efficient hand forging is often a matter of moving metal accurately rather than forging oversized and grinding the excess away.

Glossary

Term	Practitioner meaning
Anvil face	Hardened upper working surface used for general forging and straightening
Billet	A piece of stock prepared as a starting blank for forging
Cold shut	A seam-like defect formed when a fold or lap is forged into the surface without sound consolidation
Cross-peen	Hammer with a narrow peen set across the handle axis, used to direct material flow
Drawing out	Forging operation that increases length while reducing cross-section
Drift	Tool used to enlarge or shape a punched hole
Forging heat	Temperature range in which the known material can be forged effectively under the approved process
Fuller	Rounded tool used to spread, isolate or locally reduce material
Hardy hole	Square hole in an anvil that receives compatible bottom tools
Heat	One working cycle between taking the steel from the forge and returning it for reheating
Lap	Folded-over surface defect that can become a seam
Leg vice	Heavy blacksmith's vice with a supporting leg that carries hammering loads toward the floor
Peen	Narrower part of a hammer head used to concentrate and direct deformation
Pritchel hole	Round hole in many anvils used as clearance for punching and drifting
Scale	Oxide layer that forms on heated steel and can flake away during forging
Shoulder	Deliberate step or change in section
Stock	Raw bar, rod, plate or other known material from which the part is forged
Taper	Progressive reduction in section toward an end or transition
Tongs	Forging tool used to grip and control hot work
Upsetting	Forging operation that shortens and thickens a section

Reflection

Consider how your hammer placement changes material flow rather than simply changing surface appearance. Identify one point in the taper-and-hook sequence where reheating improves both quality and safety. Explain why a well-fitting pair of tongs can be as important as the hammer. Compare an efficient forging sequence with an inefficient one that relies on repeated reheating and grinding. Finally, write one sentence describing when you would stop work and ask the instructor for help.

Media and Open Licensing

The course text is intended as openly licensed educational content under CC BY-SA 4.0. Embedded Wikimedia Commons media remain under their individual licences, and their file pages provide the authoritative attribution and reuse conditions. YouTube videos are embedded for viewing and remain subject to the creators' rights and YouTube terms; embedding does not convert them into OER.

File:Blacksmith working.jpg: CC BY-SA 2.0.
File:Blacksmith anvil hammer.svg: public-domain or CC0 source material as documented on Commons.
File:Traditional Blacksmith Forge.jpg: CC BY-SA 4.0.
File:Orison Daeda, Blacksmith's Tongs, c. 1942, NGA 20922.jpg: see the Commons file page for the authoritative rights statement.
File:Blacksmith forging a candlestick.jpg: CC BY-SA 4.0.
Black Bear Forge: What tools do you need to start blacksmithing: supplementary tool overview.
Black Bear Forge II: Fundamentals of Blacksmithing - Drawing out: supplementary technique video.
Black Bear Forge: The Fundamentals of Blacksmithing - Bending: supplementary technique video.
Black Bear Forge: The Fundamentals of Blacksmithing - Upsetting: supplementary technique video.

Expert Review Checklist

Before formal delivery, a competent blacksmithing or forgework instructor should review tool terminology, forging sequence, material choice and quality criteria. A competent Irish workplace safety professional or responsible employer should verify the Safety Statement, task risk assessments, hot-work controls, ventilation, fire arrangements, PPE, noise controls and emergency procedures. A vocational curriculum reviewer should confirm that any claimed alignment to a programme is evidenced and that this module is not misrepresented as a QQI or SOLAS award. A standards reviewer should confirm any standards cited in local versions against the current NSAI catalogue.

Interactive Tasks

Quiz: Test Your Knowledge

What best describes the difference between a hazard and a risk? (A hazard can cause harm and risk reflects likelihood and severity) (!A hazard is always an injury and risk is always a tool) (!A hazard is a certificate and risk is a workshop rule) (!A hazard is only heat and risk is only noise)

Which material is the most suitable starting stock for this fundamentals module? (Known low carbon steel) (!Unknown coated scrap) (!Sealed container steel) (!Unidentified alloy offcuts)

What does drawing out normally do to a bar? (Makes it longer and thinner) (!Makes it shorter and thicker) (!Makes it colder and harder) (!Makes it wider without changing length)

What does upsetting normally do to a section? (Makes it shorter and thicker) (!Makes it longer and thinner) (!Removes scale only) (!Cuts the section in two)

Which body is the principal occupational safety and health authority for this Irish module? (Health and Safety Authority) (!National Standards Authority of Ireland) (!Quality and Qualifications Ireland) (!National Apprenticeship Office)

What qualification does completion of this aiMOOC automatically confer? (No national qualification) (!Metal Fabrication craft certificate) (!Safe Pass certification) (!Blacksmith trade licence)

What is the correct way to control a short hot bar at the anvil? (Use properly fitted tongs) (!Hold it with bare hands) (!Use loose pliers) (!Balance it on the horn)

What should you do when the steel becomes too cold for controlled forging? (Reheat under the approved workshop procedure) (!Strike harder until it moves) (!Quench it and continue) (!Change to unknown scrap)

Which defect is created when metal folds over into a seam? (Lap) (!Taper) (!Scale) (!Datum)

What takes precedence over this aiMOOC during practical work? (Official rules and workplace instructions) (!A social media video) (!A personal habit) (!An old workshop rumour)

Memory Game

Anvil face	Main flat surface used for general forging
Cross-peen	Hammer feature used to direct material flow
Tongs	Tool for gripping and controlling hot stock
Fuller	Rounded tool for local spreading or reduction
Scale	Oxide layer formed on hot steel
Drift	Tool used to size or shape a punched hole

Drag and Drop

Match the correct terms.	Topic
Draw out	Make the section longer and thinner
Upset	Make the section shorter and thicker
Bend	Change the direction of the bar
Punch	Start a hole through hot material
Drift a hole	Bring a punched opening to final shape

...

Crossword Puzzle

Taper	What progressive reduction in section is formed toward an end?
Anvil	What heavy support carries most hand-forging blows?
Upsetting	What operation shortens and thickens a section?
Scale	What oxide layer flakes from hot steel?
Fuller	What rounded tool helps isolate or spread material?
Pritchel	What anvil hole commonly provides clearance for punching?

LearningApps

Cloze Text

Open-Ended Tasks

Easy

Tool identification board: Create a labelled photo or drawing board showing an anvil, forging hammer, cross-peen, tongs, fuller, punch and drift; use only tools provided for observation and do not begin practical work.
Material flow sketch: Draw before-and-after cross-sections for drawing out, upsetting and bending, then add arrows showing the direction in which you think the material moves.
Safety walkaround: With an instructor, inspect an unlit forge station and produce a one-page map of the hot-work zone, emergency route, stock rack, cooling area and locations where people must not stand.
Quality comparison: Compare two cooled instructor-provided forged samples and write a short report identifying straightness, taper, surface and symmetry differences without operating any forge equipment.

Standard

Forging sequence storyboard: Produce a six-panel storyboard for a taper-and-hook exercise showing stock preparation, heating, tapering, reheating, bending and cooling, with one safety control in each panel.
Blacksmith interview: Interview a practising blacksmith, artistic metalworker or forge instructor about hammer control, tong fit and quality standards, then compare their advice with the terminology in this module.
Supervised taper practice: In an authorised workshop and only under direct competent supervision, forge an instructor-approved taper from known low-carbon steel, record each heat and stop immediately when instructed.
Process improvement review: Observe a supervised demonstration and identify two opportunities to reduce unnecessary reheating, material waste or rework without changing the required quality or safety controls.

Advanced

Repeatability study: Under direct workshop supervision, produce a small set of instructor-approved forged samples to the same template and analyse variation in length, taper, bend plane and surface quality.
Risk control briefing: Prepare and deliver a five-minute toolbox talk for classmates on hot metal, flying scale, tool condition, noise and stop-work conditions, using the local Safety Statement and risk assessment as the primary sources.
Artistic metalwork prototype: Design a simple decorative hook or scroll, prepare a dimensioned drawing and process plan, then manufacture it only if the instructor authorises the design, material, tools and supervised method.
Expert review dossier: Assemble a review pack containing the drawing, material identification, supervised process record, measurements, photographs, defect analysis, sustainability reflection and references to the current Irish official sources used in this course.

Learning Assessment

Process reasoning: Given a drawing of a tapered hook, explain why the sequence of drawing out before bending may be more controllable than bending first, and identify circumstances in which the sequence might need to change.
Hazard control analysis: Analyse a scenario with loose scale, a poor tong fit, high noise and a blocked walkway, then prioritise controls using the local Safety Statement and the principle that PPE is not the only control.
Defect diagnosis: Examine photographs or cooled samples showing a crooked taper, lap, necked transition and scale pitting, then connect each defect to a likely process cause and a preventive action.
Quality and function: Evaluate a forged part against a drawing and decide whether it is fit for use, needs rework or must be rejected, giving evidence from dimensions, geometry, surface and intended function.
Material decision: Compare known low-carbon training stock with an unknown coated scrap bar and justify which is acceptable for the supervised fundamentals exercise using safety, process reliability and traceability.
Transfer task: Plan how the same drawing-out and bending principles would be used in a different artistic-metalwork component while identifying which new risks, tools or standards would require further instruction.

Evidence of Learning

Evidence type	What demonstrates achievement
Knowledge	Accurate explanation of drawing out, upsetting, bending, tapering, punching, drifting, fullering, scale and material flow
Safety understanding	Correct use of Irish jurisdiction, HSA risk-assessment principles, stop-work reasoning and the precedence of official workplace instructions
Tool knowledge	Correct identification of anvil features, hammer types, tongs, bottom tools, punches and drifts, including pre-use checks
Planning skill	A workable process sequence linked to the drawing, stock choice, tool choice, quality checkpoints and safe cooling
Practical product	Instructor-authorised supervised sample that meets the defined dimensional, geometric and surface criteria
Quality reasoning	Measurement record and defect analysis that distinguish acceptable forging texture from cracks, laps, cold shuts or uncontrolled deformation
Sustainability	Evidence that the learner reduced unnecessary heats, selected appropriate stock and separated reusable or recyclable material correctly
Transfer	Ability to apply the same material-flow principles to a new forged form without assuming that tools, risks, standards or qualifications automatically transfer

OERs on the Topic

The English Wikipedia article on Forging provides a broad open reference on forging processes. It is not an Irish legal or vocational-authority source and must not be used to override HSA, SOLAS, QQI, NSAI or workplace instructions.