Forging a Custom Buoy Blade with Damascus Steel

🔥The blade is made using the technique of forge welding, where tiles are heated and hammered together to create a solid piece of steel.

⚒️The process of shaping the blade involves carefully heating and hammering the steel and using a round bar to forge out the tang.

🔪The tip of the blade is forged to add a slight curve and stretch the Damascus pattern, creating a unique look.

🔨After the forging process, the blade is normalized through multiple heating and cooling stages to reduce warping and prepare for heat treating.

⚙️Next comes the surface grinding step, where excess material is removed and the blade is shaped and flattened to the desired thickness.

What is forge welding?

—Forge welding is a process where heated metal pieces are hammered together to create a solid weld. In this video, multiple tiles of steel are forge welded to create the blade.

Why is the tang forged separately?

—The tang is forged separately to ensure it aligns properly with the handle and pommel nut. By using a round bar, the metal is pushed into the desired shape without deforming the rest of the blade.

What is the purpose of forging the tip?

—Forging the tip adds a slight curve to the blade and stretches the Damascus pattern, giving it a unique and visually appealing look.

What is the purpose of normalization?

—Normalization is a heat treatment process that helps reduce warping and prepares the steel for further heat treating steps. It also helps reset the grain structure, resulting in a more consistent and reliable blade.

Why is surface grinding necessary?

—Surface grinding is necessary to remove excess material, shape the blade, and achieve the desired thickness. It also helps create a flat and smooth surface for the blade to be finished.

00:00Introducing the process of forging a custom buoy blade using Damascus steel, lapis lazuli, and 24 karat gold inlays.

02:39Demonstrating the delicate process of forge welding tiles together to create a solid piece of steel for the blade.

09:59Shaping the blade by carefully heating and hammering the steel and forging out the tang with a round bar.

11:50Forging the tip of the blade to add a curve and stretch the Damascus pattern, giving it a unique look.

12:43Normalization process to reduce warping and prepare the blade for heat treating.

13:58Surface grinding to remove excess material, shape the blade, and achieve the desired thickness.