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Home / Manufacturing process

Manufacturing process

The material manufacturing process

Damascus steel is created by combining two different types of steel – one with a high carbon content and another with significantly lower carbon content. After carefully layering the “hard” and “soft” steels, the materials are joined together into what is known as a base billet. This is followed by the first heating process. The steel is heated to a very high temperature just below its melting point, approximately 1425–1540 °C. At this temperature, the structure of the steel relaxes enough for the molecules of the different steels to bond together and fuse into a single solid piece.

This process requires the use of a flux. Without it, the steel would bond very poorly or not at all. The most commonly used flux is sodium tetraborate, which melts the top layer of scale on the steel. This creates an almost liquid surface that helps achieve a high-quality forge weld. Once the steel reaches the correct temperature, the billet is forge-welded under the pressure of hammer blows. This creates a single piece of steel, which is then drawn out into a longer bar and cut roughly in the middle.

The two pieces are then folded back together, coated again with sodium tetraborate, and the entire process is repeated. This cycle continues until the blacksmith is satisfied with both the number of layers and the quality of the welds between them. From this manufacturing process it becomes clear that Damascus steel can consist of dozens, hundreds, thousands or even tens of thousands of layers. Only once such high-quality steel is achieved can the production of the final product begin.

Obtaining steel of this quality is not easy. Michal Čiliak found it in the Swedish company Damasteel, which specializes in the production of stainless Damascus steel. There are very few places in the world capable of producing it at this level – perhaps none comparable. Damasteel has even obtained an international patent for the production of patterned Damascus steel with precisely seven welds.