Introduction to Enamel

Intro to enamelling list:

A-1 Oil , https://yuyo.ca/a-1-klyr-fire-holding-agent-water-based-2-oz-ta01/

Counter Enamel, https://yuyo.ca/thompson-lead-free-opaque-enamel-2-oz-counter-enamel/

Copper sheet 0.8mm or thicker if you make flat piece, 0.5mm and up if you make domed piece. https://yuyo.ca/search.php?search_query=copper+sheet&section=product

Optional but better to have: Fiberglass brush for cleaning metal: https://yuyo.ca/search.php?search_query=fiberglass&section=product

Diamond Files: https://yuyo.ca/diamond-file-plate-3pc-set/

And any enamel you Like for the front, https://yuyo.ca/search.php?search_query=thompson+lead-free+enamel&section=product

Just avoid liquid if you not plan to use.

Sifter, start with Mesh 80, https://yuyo.ca/search.php?search_query=mesh+80&section=product

Tripd, If you plan to do torch enamel: https://yuyo.ca/tripod-6-with-mesh-screen-654207209140/

Materials and Preparation

Materials Needed:

• Copper Surface: A clean copper piece (flat or shaped) free from oils and contaminants.
• Enamel Powder: High-quality enamel powder (such as Thompson Enamel) in your chosen colors.
• Sifter or Fine Mesh Screen: For an even distribution of the enamel powder.
• Binder (Optional): A light adhesive or enamel slip to help the powder adhere prior to firing.
• Firing Equipment: A kiln with controlled temperature settings or a torch with an even, adjustable flame.
• Safety Gear: Heat-resistant gloves, eye protection, and proper ventilation.

Surface Preparation:

1. Clean the Copper: Use a degreaser or alcohol to thoroughly remove any oils, dirt, or residue. Rinse and allow the copper to dry completely.
2. Roughen the Surface: Gently sand or lightly etch the copper with fine-grit sandpaper. This creates a slightly textured surface that improves enamel adhesion.

The Sifting Method for Enamel Application

The sifting method involves dusting dry enamel powder onto the prepared surface. This technique offers a soft, textured appearance and allows for creative layering.

1. Optional Binder Application:
   For better adhesion, apply a thin, even layer of a clear binder or enamel slip on the copper surface. This step helps prevent clumping and ensures an even coat of powder.

2. Sift the Enamel Powder:
   Using a fine mesh screen or sifter, gently dust the enamel powder across the surface. Work in light, even layers to build up the desired intensity. Multiple passes can create depth and variation in the final color.

3. Settle the Powder:
   Lightly tap or shake the piece to help the powder settle into any textured areas. Ensure that the layer is consistent, avoiding heavy deposits that might result in uneven firing.

Counter Enamel for Flat Pieces

For flat copper pieces—such as panels, jewelry, or decorative tiles—a technique known as counter enamel can be employed. This involves applying enamel to the reverse (or “counter”) side of the piece to:

• Enhance Aesthetics: Create a visually balanced design with a complementary or contrasting color on the backside.
• Improve Structural Integrity: Even enamel coverage on both sides can help with heat distribution during firing, reducing the risk of warping or uneven fusion.
• Offer Versatility: If the piece will be displayed without a defined front and back, counter enamel ensures that every visible surface is finished beautifully.

Steps for Counter Enamel:

1. Prepare the Reverse Side:
   Just as with the front, clean and lightly roughen the reverse side of the flat copper piece.

2. Apply Binder and Enamel:
   If desired, apply a thin binder to the backside, then use the sifting method to dust an even layer of enamel powder. You can choose a single, uniform color or experiment with layered effects.

3. Ensure Even Coverage:
   Verify that both the front and back surfaces have a consistent layer of enamel. This consistency is important for uniform heat absorption during the firing process.

Firing Options

Once you’ve applied the enamel (including the counter enamel for flat pieces), you have two primary firing methods to choose from:

Kiln Firing

1. Preheat the Kiln:
   Set the kiln to the enamel’s recommended fusion temperature—often around 1400°F (760°C), though always refer to the specific guidelines provided by Thompson Enamel.

2. Controlled Heating:
   Place your piece in the kiln and use a gradual heating schedule. This slow increase in temperature minimizes thermal shock and allows for even fusion of the enamel on both the front and reverse sides.

3. Cool Down Slowly:
   After the firing cycle, let the piece cool slowly inside the kiln or in a protected area. A gradual cooldown is crucial to prevent cracks or stresses in the enamel layer.

Torch Firing

1. Prepare Your Torch:
   Ensure your torch is set up for an even, steady flame. Work in a well-ventilated area and wear your safety gear.

2. Even Heat Application:
   Move the torch steadily over the piece, taking care to apply uniform heat. Torch firing demands close attention to avoid overheating spots, which can cause bubbling or uneven fusion.

3. Monitor the Process:
   Keep a close eye on the enamel’s progress. Adjust the speed and intensity of the flame as needed to achieve an even, smooth finish on both sides.

4. Allow for Gradual Cooling:
   Once firing is complete, set the piece aside to cool gradually at room temperature.

Finishing Touches

• Inspect Your Work:
  Once the piece has cooled, examine it for any imperfections. Look for areas where the enamel might be uneven or where minor touch-ups are required.

• Touch-Up as Needed:
  If you find any issues, reapply the enamel powder using the sifting method to the affected areas and refire, following the same controlled process.

• Clean Up:
  Gently remove any loose or excess powder to reveal the final, vibrant design.

Conclusion

Using the sifting method for enameling on copper provides a versatile and creative approach to achieving unique, textured designs. By incorporating counter enamel on flat pieces, you not only enhance the visual appeal but also improve the durability and consistency of your finished work. Whether you choose kiln firing for controlled, even heat or torch firing for a more hands-on, dynamic approach, following these techniques—rooted in the expertise of Thompson Enamel—will help you create stunning, long-lasting pieces of art. Enjoy the process, experiment with colors and layers, and let your creativity shine through every enameled surface!