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Welding metal requires the use of industrial equipment of varying size and complexity,
and it is part of the wonder of welded sculpture that pieces of delicacy
and beauty come from the rugged environment of fire and brawn. A
sculptor must know how to select and operate the equipment best suited
to the media and style of his or her work.
All of Dick Kappel’s sculptures are produced using an oxy-acetylene torch, but the
methods of construction he uses depend on the type of metal, such as
steel or copper, and the thickness. Dick uses three distinct methods of
construction.
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Dick Kappel sculpting
Standing
Deer |
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Dick uses a torch to cut out two- dimensional
shapes drawn on a piece of flat metal. |
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Human figures and wildlife sculptures
Steel less than 1/16" thick
Flat shapes are cut to size and then three-dimensionally shaped by bending and heating.
Most sculptures contain two substructures for added strength. After the
figure has been rough fitted, molten steel is added to the surface to
complete the figure. The entire surface is heated to the metal’s
melting point under the oxy-acetylene flame, and the figure while in a
molten state is reformed and sculpted into its final shape.
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An oxy-acetylene torch is used to heat the
metal so the figure can be sculpted into its final shape. |
This
procedure produces a rough but continuous surface, preserved and colored
by the extreme heat and with small “blowholes” randomly appearing on
the surface. Further preservation and color are created by treating the
sculpture with a weak solution of phosphoric acid and then coating it
with a clear satin spray, highlighting the natural colors of the piece.
Prolonged outdoor display is not recommended since items created by this
method can trap moisture inside the sculpture, leading to oxidation.
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Bear
Market is an example of an open-construction sculpture. |
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Open-construction wildlife sculptures
Steel greater than 1/16" thick
Large straps, rods, and bars are cut from the steel using the oxy-acetylene torch.
The pieces are bent into shape by heating and then welded securely into the
final form. Most sculptures are finished by adding a clear satin spray
to minimize oxidation, primarily for outdoor display. These pieces are
weather resistant, though it is not recommended to leave them outdoors
for an indefinite period unless a new finish is periodically added or a
rusted appearance is desired.
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The vibrant colors in Hector the
Owl are created by brazing copper. |
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Selected human and wildlife sculptures
Copper and brazed steel
Flat shapes are cut to size and hammered into the
three dimensional shape of the sculpture. Brazing, which adds brass to
the joints and connections, is used to smooth the shape and hold the
pieces together. Heating the metal with the oxy-acetylene torch
emphasizes the natural colors, and when displayed outdoors, the
sculptures oxide adding deeper shades of color to the pieces.
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