Damascus Feather Pattern Tutorial

The damascus feather pattern is historically very old. To make this pattern in steel the ability to forge weld a good sized billet and to make a clean hot cut in the finished billet is required. Power equipment, though not required, makes the work go faster. I use a KB-1 Kuhn power hammer and a 24-ton press.photos.

The prepared billet ready for welding showing the individual layers of contrasting steel. This billet is about 30 alternating layers of two different steels. I use carbon steels (as opposed to stainless steels) for their ability to weld readily together and for heat-treating. One steel is type 1095 (0.95 % carbon) and the other is type 15n20 (Carbon 0,78 %, Ni 2,1 %). The alternating layers are tacked welded together and a steel handle is welded on one end for putting and holding the billet in the forge to bring it up to welding temperature.

This picture shows the billet in the forge coming up to welding temperature, which is approximately 2200 degrees F (1200 degrees C).

As the billet is heating it is removed before it reaches welding temperature to apply flux. The flux is applied to prevent oxidation form occurring between the individual layers. The flux I use is anhydrous borax. When forge welding, it is extremely important to have clean metal surfaces, proper temperature, and no oxides forming from oxygen on the piece as it is welded.

Once the billet reaches temperature, it is quickly removed from the forge and brought to either a hammer or press for forging together into one piece of steel. This picture shows the billet being welded on a 24-ton press. Welding occurs from heat and compression not from power. One could also use a hand hammer to weld the billet together too. Using a power hammer and/or press speeds up the process.

Wire brushing scale off the welded billet. Scale is removed from the billet after the weld has been made. Again, clean steel is essential.

This picture shows the completed billet welded into one piece of solid steel. The billet is now ready to drawn out (i.e. hammered out) into a longer and narrow piece for cutting and refolding or stacking the pieces to increase the layer count. The number of layers in a billet can be increased to whatever number the smith wants. Different layer counts give different visual pattern effects. Layer count can go from two to two thousand. The more layers the more welding.

Billet under the hammer being drawn out. The hammer is an air German Kuhn KB-1 75 pounds US (35 Kilo)

Partially drawn piece being reheated in forge.

Billet being drawn and finished for next step in the process.

Detail of drawn billet marked for final cutting and stacking. After the billet has been drawn out to the desired size the piece is marked for cutting and re-stacking.

The cut pieces are stacked with the end grain (cut faces) in the same orientation. The stack is tacked welded to hold it together for forge welding. Notice the visible pattern of each individual piece within the stack. It is these patterns, when welded together, which will produce the basis for the final feather pattern.

Stacked billet in forge. Again the new billet is heated to welding temperature in the forge.

At welding temperature the billet is welded on the press.

After the stack has been welded, it is reheated in the forge and cut in the press with a hot cut tool

After the billet is cut in half, it is immediately refluxed and hammered back together, reheated to welding temperature and welded back into one piece.

The billet has been re-welded, hammered, drawn and shaped for blades. Note how the cutting process pulled the layers to make the feather pattern.

Using a band saw, the finished billet is cut into individual blade blanks.

The pattern is revealed in the billet.

Blade steel from different billets. Various patterns can be developed by manipulation of layer count, forging methods, steel types and other factors. The possibilities are unlimited

Finally each blade is forged to shape. In many patterns the forging is very light, as to not distort it (such as in this one). But in other patterns the distortion from the forging is intentional and part of the pattern.

This whole process requires a lot of rehandling of the billet and prep work. I do a step or so each day and have a few billets at various stages in process. You’ve got to have a bit of a different mind set with this pattern. Most other patterns you can go through pretty fast in building them to completion. Also you can blow this pattern pretty easily during the hot cut- ask me how i know 8). It’s a lot of work but it’ s a super pattern when it comes out.

Good luck and if you have any questions or need clarification on any of this email me or give me a call. Have fun and stay safe.- Kevin Casey

www.kevincaseycustomknives.com