How Are Knives Forged?

Introduction

Bladesmiths transform a single bar of raw steel metal using heat to form a knife. First, the steel is heated. Then, it gets pounded into shape. This can be done by hand by a skilled worker or by a machine. Another way is through stamping. In this method, the blade is cut out from a big sheet of steel. After that, it’s sharpened and heat-treated to make it strong. This article will show you the deep tradition and skill of handcrafting blades. Join us and see how to shape the knives we use today.

Brief History Of Forging Knives

The ancient art of knife forging has a storied history dating back millions of years. Among the earliest known examples, humans fashioned knives around 2.5 million years ago using materials like rock, bone, and flint. These primitive blades were often fragile and prone to breaking.

As civilisation progressed, humans wanted more durable materials. Later, copper was used, followed by iron, over 6,000 years ago. During the height of the Roman Empire, iron was the preferred metal for bladesmiths because of its strength and easy availability.

Fast forward to modern times, and modern bladesmiths mostly work with steel, either forging it from scratch or shaping pre-made flat bars into knives. The traditional methods of bladesmithing saw a decline with the progress in steel production during the Industrial Revolution.

Nevertheless, the process of forging remains the same: heating metal to high temperatures and shaping it with force, typically using a hammer, to create many tools, machines, and weapons.

Forging A Blade

Hand-forged knives begin their transformation from a raw bar of steel, with no shape or purpose. Within the fiery heat of the forge, the metal is subjected to extremely high temperatures, making it pliable and easier to manipulate. Care must be taken to strike the metal at the right moment. Hitting it too soon risks irreparable cracking.

Temperature checking is a visual art, as the steel’s glow changes colour, each showing its state of readiness. Even as it cools to black heat, the steel retains a high temperature of around 900 degrees. The anvil`s purpose is to let the craftsman hammer the steel, gradually shaping it into the right look and cross-section of the knife in mind.

Typically, at this point, the next step in the process follows, moving to the handle with each calculated strike. It takes time to make unique, characterful knives that have a function too.

9 Steps To Forge A Knife

Heating to Yellow

With precision, grip the steel using tongs and put it into the forge. Apply heat until the metal changes, taking on a bright yellow colour

Assessing Mass Distribution

Using your tongs, carefully take the steel from the forge. Put the stock flat on your anvil and start hammering the corner, shaping it into the knife point. Make sure to evenly taper both sides of the steel for the best mass distribution

Blade Flattening

Using your hammer, shape the flat edge of the steel to form the bevels, defining the cutting edge of the knife. Turn the blade on the anvil and repeat on the other side until both are the same. You can also use a belt sander for a modern approach to making the bevels

Heat Cycling

With the knife shape set, begin to normalise the steel by heating it until it reaches a non-magnetic state. Allow the steel to cool naturally in the air, and make sure it returns to room temperature before reheating. Repeat this cycle three times, watching out till the red colour is gone before putting it in the forge. These steps help make the steel strong and tough

Sanding

Smooth out the edges of the blade by sanding it. This step gives a refined finish, making it look good and adding to its functionality.

Strengthening and Sharpening

Reheat the steel and quickly put it in oil until it cools to room temperature, known as quenching. This step hardens the steel, fortifying the blade. Make sure to quickly transfer from the fire to the quenching oil to stop any delay that might influence the hardening process

Reheating

Carefully reheat your quenched blade to a lower temperature, aiming to ease any brittleness and stress brought on by the quenching process. This gradual reheating is important for optimising the blade’s resilience and strength

Crafting the Handle

Attach a handle to your knife using many of the available techniques. A common method involves securing a wooden handle in place with glue and pins for added stability

Sharpening

Methodically sharpen your blade using a fine file and whetstone. This process will give the blade’s edge the correct sharpness

Choosing The Best Steel For Knife Making

When it comes to making a blade, choosing the right steel is very important. It is not the sole determinant of its performance. Heat treatment plays a huge role in the final shape of the blade. Before working with premium steels, it is important to learn your heat-treating skills.

Heat treatment is a process used to unlock the best characteristics inherent in steel. The choice of steel for your knife blade depends on what you like and your need for the blade you are making.

Knife Steel Types

In knife-making, the many options of steel types mirror the differences between iron and bronze. Steel producers follow specific recipes for each type, making sure that the quality of their products stays the same. With different proportions, these steel compositions are given names, offering customers a clear understanding of the makeup of the steel.

Carbon Steel

Carbon steel is a go-to for strong, sharp blades, perfect for tough tools like machetes and Bowie knives. The ‘C10_’ series, such as C1045, C1075, C1090, and C1095, are widely used. The ‘C’ indicates carbon steel, while ’10’ means plain carbon steel with up to 1% manganese.

The last two digits show the carbon percentage; for example, C1045 has 0.45% carbon. For the best balance of hardness and durability, opt for steel with 0.30%–0.60% carbon. Among these, 1095 is a popular choice for its many uses in knife-making.

Stainless Steel

Stainless Steel specifications are often represented by three-digit codes, with each digit showing a specific side of the makeup. Popular for many knife-makers, the 400 series

420:

420 is classified as cutlery grade, containing approximately 0.38% carbon and a minimum of 12% chromium. Its lower carbon content makes it relatively soft, resulting in less edge retention. Knives made from 420 steel require frequent sharpening and are susceptible to chipping. However, its high corrosion resistance makes it ideal for wet environments, like diving knives.

440:

440 is a higher-grade cutlery steel known for its superior hardness and edge retention. It comprises three main types:

440A: This type features a carbon content range of 0.65% to 0.75%, offering excellent rust resistance.
440B: With a higher carbon content, typically ranging from 0.75% to 0.95%, 440B steel maintains sharp edges more effectively.
440C: Considered premium, 440C steel boasts a carbon content range of 0.95% to 1.20%, providing exceptional durability and edge retention.

Aus Series

Japanese knife-making steel is often fortified with vanadium, adding to its toughness, wear resistance, and durability.

Commonly used grades in knife making include:

AUS-6: With 0.65% carbon content, AUS-6 holds an edge reasonably well
AUS-8: This steel, containing 0.75% carbon and increased vanadium, is preferred for its superior edge retention compared to AUS-6
AUS-10: Featuring 1.1% carbon and higher vanadium content, AUS-10 offers even better edge retention than AUS-8

ATS Series

Among the steels in the ATS series, ATS 34 stands out as the premier choice for knife-making. With a carbon content of 1.05%, it is highly favoured for crafting higher-end knives.

Sxxv Series

This steel series is increasingly used because of its robustness, resistance to corrosion, and

ability to maintain a sharp edge. Notably, variants labelled 30, 60, and 90 are often used in knife-making, denoting their vanadium content of 3%, 6%, and 9% in the alloy. It is worth mentioning that while these steels offer impressive qualities, they can be very difficult when it comes to sharpening.

Tool Steel

Tool steel is prized for its hardness and durability and has many alloys to enhance crucial properties such as heat resistance. Its ability to withstand high temperatures and pressure while still being functional and shape makes it indispensable for industrial tools.

Common tool steels used in knife-making include:

A2: Known for exceptional toughness despite being less hard, typically containing 1% carbon and 5% chromium.
D2: Offers corrosion resistance and excellent edge retention, though less tough, with higher percentages of carbon and chromium.
M2: is renowned for retaining a sharp edge, yet its hardness can lead to brittleness, making it unsuitable for certain applications. Primarily molybdenum-based.

However, tool steel lacks a smooth finish and is less corrosion-resistant than Stainless Steel, making it less suitable for uses such as kitchen knives.

Damascus Steel

Damascus Steel is forged by combining two different steel grades and then undergoing an acid-etching process, giving pretty patterns. While often liked for their beauty, Damascus Steel knives are also known for strength and durability, depending on the materials used and the expertise of the forging technique.

Learn how to forge a knife from the Experts

Seeing how tricky it is to make a knife, choose a specialised course! Learn from great bladesmiths. You will learn forging techniques important for making high-carbon steel tools with razor-sharp edges. Yes, commonly known as knives!

You will have the opportunity to be part of a knife-making community.

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https://www.andreknives.co.za/index.htm

https://www.sdknives.co.za/

https://zeesknifesupplies.co.za/

https://zeesknifesupplies.co.za/product-category/tools-consumables/forging-tools/

In the ancient craft of forging knives, fire, and steel combined to craft enduring tools. From primitive origins millions of years ago to today’s bladesmiths shaping steel, the tradition has evolved.

Using heat and force, craftsmen shape steel into knives, merging tradition with modern methods. Each blade reflects dedication and skill, connecting us to our past and the enduring craftsmanship that defines us.