Iron shields and armor are made through a series of processes that involve extracting, refining, and shaping iron to create protective gear. Here’s an overview of how iron shields and armor are traditionally made:
- Mining and Refining Iron:
Ore Extraction: Iron ore is extracted from the earth through mining.
Smelting: The iron ore is heated in a furnace to extract pure iron. This is done by removing impurities (slag) from the ore using a heat source, such as charcoal or coke, in a process known as smelting.
Refining: The extracted iron is refined into wrought iron or steel, depending on the desired properties. Wrought iron is more malleable, while steel, which contains more carbon, is harder and more durable.
- Shaping the Iron:
Heating: The iron or steel is heated in a forge until it becomes red-hot and malleable.
Hammering: Blacksmiths use hammers and anvils to shape the heated iron into desired forms. For armor, they would use large hammers to beat sheets of iron into curved or flat pieces, depending on the type of armor (such as breastplates, helmets, or gauntlets). Shields are typically made from flat sheets, sometimes with a curved boss in the center for deflecting blows.
Quenching and Tempering: The shaped iron is quenched (rapidly cooled) in water or oil to harden it. To avoid brittleness, the armor is then tempered by reheating it to a moderate temperature and allowing it to cool slowly, improving toughness.
- Joining and Finishing:
Riveting: Many pieces of armor, such as chainmail or plate armor, are held together by rivets. Small metal rings or plates are hammered and riveted together to create flexible or articulated joints.
Polishing and Decoration: Once the armor or shield is shaped and assembled, it may be polished to remove oxidation and make it resistant to rust. In some cases, armorers would decorate the armor with engravings or paint, especially for high-ranking individuals.
- Additional Materials:
Lining: Armor often had padding or leather lining on the inside to improve comfort and absorb impacts. Shields were commonly reinforced with wood, leather, or additional metals.
Straps and Handles: For shields, a handle or straps would be attached to the back so the user could carry it effectively. Armor might include leather straps for fastening different pieces to the body.
This process evolved over time, with improvements in metallurgy and craftsmanship, allowing for more durable, lighter, and intricate designs, especially in the medieval period.