Metal should come out of the smelter as ingots or blooms, not bars. Drawing the ingot into bars or flattening it out into a plate should be a part of the process, I think. One would probably make hammers and maces directly from ingots.
What's the difference between a "bar" and an "ingot," anyways?
For mail, the metal should first need to be drawn out into wire, then assembled. Perhaps we should even need to punch solid rings from plate, then cut the riveted rings from wire.
Would you be fine with the assumption that such processes occur during the "Forge Chain X" reaction?
Rough sword blade blanks should be able to be made from the forge on a large scale, then they go off to a grinder to be finished and sharpened. The guard and pommel would probably just be considered part of the blade blank.
See above.
What you're proposing is similar to how it works in Goblin Camp (except it uses bog iron ore)...
Is that a mod or a separate game? I'm guessing the first...
On the note of flux being a reason to keep bronze and iron around.
Well copper and bronze are melted at about 1100C, ~2000F
Wrought iron and steel though takes about 1500C, ~2800F IIRC (been a while since material science)
Steel though requires much more processing then iron.
A slightly more accurate modification to the game could be the requirement of machine power to the forge to drive billows or other air processing equipment. That machinery requiring other metals to make parts for (forcing steel to be "later tier"). Also Steel (and other metals actually), the product bars could have a quality attached to them. Flux, like used IRL, would be for trying to squeeze higher qualities out of batches of metal.
So only the highest quality steels go to your mastersmiths and make it into weapons and armor. And in turn, the better metals can lead to better gear.
Also reforging metals, attempting to get higher quality materials could be a great time sink for your dorfs. And perhaps their ability to make good metal could be tied into their furnace operator skill.
Is machinery actually required for the bellows?
...And is flux actually not required for steel?
Materials with quality levels would complicate things immensely.
I disagree. Combat calculations are fairly straightforward and so are definitions of material properties such as brittleness. I think it could add some layer of depth into the game as long as it was easy enough to macro in "elite soldiers only use high quality bronze" or things like that.
In fact, I could even get some raws for it:
[MIN_SHEAR_STRAIN_AT_YIELD:150]
[MAX_SHEAR_STRAIN_AT_YIELD:225]
And so on. The min is the STRAIN_AT_YIELD at highest quality, MAX at lowest. Or the other way around. I guess it should be able to work either way. Lower is better for strain at yield AFAIK.
Materials with quality levels would complicate things immensely.
I disagree. Combat calculations are fairly straightforward and so are definitions of material properties such as brittleness. I think it could add some layer of depth into the game as long as it was easy enough to macro in "elite soldiers only use high quality bronze" or things like that.
In fact, I could even get some raws for it:
[MIN_SHEAR_STRAIN_AT_YIELD:150]
[MAX_SHEAR_STRAIN_AT_YIELD:225]
And so on. The min is the STRAIN_AT_YIELD at highest quality, MAX at lowest. Or the other way around. I guess it should be able to work either way. Lower is better for strain at yield AFAIK.
The really complicated thing is when we start having different uses of metals, with different qualities being "good" or "bad" for them...