How Are Damascus Steel Knives Forged?

In the Near East, Damascus Steel was used to make sword blades with Wootz steel. Swords with this pattern have distinctive bands of banding and mottling that resemble flowing water. Those blades were known to be tough, resistant to shattering, and capable of being honed to a sharp, resilient edge.

Damascus Steel Knives: Their Origin

The origins of Damascus steel are shrouded in mystery. It has been speculated that the production process was introduced to the Middle East by traders from India, but there is no scholarly consensus on this theory. Whilst there is evidence of similar steel being made in India, some scholars insist that the Indian version did not contain true Damascus steel's signature wootz steel recipe that includes finely ground recycled iron filings and charcoal dust.

There are records of Damascus steel knives being imported into the Middle East for ceremonial purposes as early as 1347 CE, but it remains unclear whether these blades were made with or without knowledge of Damascus steel's secret formula.

The Demand For Damascus Steel Knives

It is known that the swords of Damascus were in great demand across Europe, Arabia and Persia. For example, between 1760 and 1780, nearly 2 million swords were imported by the Sultan to stock the armouries at Istanbul.

The first documented use of the term "Damascus steel" dates back to 1486. The first half of the nineteenth century saw a tremendous increase in demand for Damascus steel blades as a result of the Napoleonic Wars. It was widely believed that a sword forged from Damascus steel could not be broken, but there were those who knew better.

In 1838, an English warlock named George Clarke published "In Mechanics and Trade", a book which contained fascinating accounts of Damascus steel knives being made and used as weapons by warriors from all over Europe during the Crusades and other historical conflicts.

Process Of Making Damascus Steel Knives

Bladesmiths have been making forged-damascus for centuries, it’s tougher than ever to find someone who still does it. You can tell a forged damascus steel knife by its distinctive grain pattern—different layers show up as different colors when the light reflects off the blade. This is known as "pattern welding.”

The three basic kinds are laminated patterns, interlocked patterns, and two-layer patterns. There are many variations on these three basic styles. No definitive guidelines exist for the production of damascus steel knives.

The complex pattern is created when several different steels are all heated at the same time, rolled together in one forging operation. As the steel is cooled, it shrinks in certain places more than others—thereby creating different shapes in the final product. The result is a damascus steel knife with an organic grain pattern, like the scales on a fish. The pattern does not exist in the steel itself, but rather is created by forging and differential cooling.

• Two-Layer Pattern

The layers of different types of steel are randomly arranged as the forging starts. In the early days, the smiths would hammer out each layer separately so they would form a random pattern. Today's smiths have access to powerful blowers and cutting torches, which allow them to shape each layer as it comes out of the forge. This reduces the time required to make a damascus steel knife.

• Laminated Pattern

Laminated patterns are created by combining two or more layers of steel. Each layer is heated and then forced into a die that forms a double thickness. After the layers cool, they are welded together.

• Interlocked Patterns

Interlocked patterns use two different types of steel with different characteristics, such as high hardness and low toughness, so the ends will not bind each other during forging or when they’re being cut from the metal.

Damascus Blades Today

No matter what type of Damascus steel knife you desire, whether that's something decorative, a handmade collector's item, a high quality kitchen knife, or a more utilitarian fixed blade or pocket knife, there is something out there for everyone. Make sure you pay careful attention to fakes, poor-quality construction in some Damascus and poor heat treatment.