Damascus is a specific type of steel made when different kinds of metals are heated in a forge and hammered. The Damascus steel has superior mechanical properties and can be designed with specific aesthetic patterns.  The bladesmith can choose to make different patterns operating different forging processes depending on the kind of Damascus chosen.​​​​​

 

Ok, now it's time to show you how Damascus is made.  Hopefully you can understand the magic and the appeal of this kind of steel.

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Everything starts with fire.  A very powerful heat is needed.  The heat from a coal or propane forge (the coal is more appealing even if propane is more practical).   Most forgers have homemade, specific forges tailored for their specific needs. 

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To produce the first block of steel, the "the starting packet" must be prepared.  The starting packet is composed of many layers alternating two or more types of steels (fig. A).  Next, the packet is welded together (fig. B).  A handle is soldered to the packet so the packet can be easily moved and hammered without using tongs (fig. C).

 

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​At this point, the starting packet is put inside the forge and heated below the welding temperature. The borax, a flux used to prevent oxidation, is added (fig. D).

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​The starting packet is again put inside the forge. When the temperature is hundreds of degrees below ​ the melting point, the hammering begins. I start with delicate hammering (fig. E) and progress to powerful hammering when I am confident the packet has become one piece (fig. F).

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​After the starting packet has been welded and lengthened (fig. G) via hammering, it is folded and welded again.  Instead of folding the packet it can be cut into multiple pieces (fig. H). When the packet is cut into multiple pieces, a power hammer or another person hammering is helpful to weld and lengthen.

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This process is repeated, as many times as needed to reach the desired number of layers.

 

Note: it is not true that the more layers-the better the steel.

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Well, below you can see what a Damascus looks like when the processes are done. These are some examples but only imagination is a limit for the patterns of a Damascus Steel​​​.

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Enjoy.