The Forging Process
Dynasty Forge creates blades out of two distinct processes: high-carbon
raw iron (Tamahagane) and 1095 carbon steel.
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The Raw Materials |
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1095 Carbon Steel |
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Tamahagane |
The raw iron material is hand selected to ensure an
average carbon content of 1.0-1.2%. The pebble-like material is heated
and hammered into a solid billet. To remove impurities and homogenize
the iron, the billet is folded from 12-14 times where a large amount of
material is lost and carbon content decreased. While this process is
time-consuming, it produces a blade in the traditional manner with an
active Hada (surface pattern). This process is distinctly different from
folding and forging modern steels, as the selection of raw materials and
the subsequent working of the material is much more skill and labor
intensive.
Preparing The Iron Billet
Dynasty Forge’s second line is made from 1095 carbon
steel. This modern steel, in its processed form, approximates the carbon
content the raw iron used in the Tamahagane process. However, as the
metal is not folded, since it is already homogenous, there is no Hada
evident.
Both types of blades are then hand-forged to shape.
Through the forging process, carbon loss occurs and the final carbon
content is approximately 0.7%, which is ideal for crafting a sharp yet
resilient blade. The edge is clay-tempered and water-quenched to produce
a defined and robust Hamon. All blades are then hand-polished on
Japanese stones to a mirror-finish (equivalent to 3000 grit or more).
Each blade is individually inspected by the master smith for defects and
flaws. Only blades that pass this stringent inspection are allowed to
leave the workshop.
Fittings for all Dynasty Forge blades are made of traditional materials.
The Saya and handle are hand-carved to ensure a tight fit. As well, the
Saya is lacquered (11 layers) to achieve a highly reflective polish. The
Habaki is crafted from solid brass. All other fittings are made from
iron or ox-horn. The Tsuka is covered in premium full-grain ray-skin and
wrapped with either cotton or silk Ito.
