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Emily Yocom
Colorado School of Mines
July 1, 2005
INTRODUCTION
The hard-edged blade with its woven patterns quivers and trembles;
grasped with terrible sureness, it flashes into changing hues.
For centuries, mystery lay in the making of these beautiful swords and no
European blacksmith was able to successfully replicate the Damascene strength and style.
The art had even been lost in the land of origin, as long ago the ingot composition had
likely altered (due to the use of a new of ore deposit) and the damask pattern could no
longer be created by traditional methods. Lacking the necessary metallurgical
knowledge, ancient sword makers were unable to explain this phenomenon and
eventually, the practice died out completely. Consequently, high quality wootz
Damascus blades have not been made since somewhere around the 17th and 18th
centuries.
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Since this time a number of techniques have emerged to imitate the surface
patterns of the ancient art and the term “Damascus” has evolved to encompass not only
the genuine damascene blades forged from wootz steel, but also those produced by
various pattern welding techniques, some of which actually date back to Roman times.
Despite the fact that they share the characteristic “water marking” surface appearance,
wootz and welded blades are distinctly different in both the mechanism that causes such
markings and their fabrication. The focus of this paper will be on wootz Damascus
blades, however, a brief description of pattern welding will be included.
The method of producing wootz Damascus steel has long been contended and
many researchers have undertaken massive trial-and-error testing procedures in attempts
to match the microstructural characteristics found in the ancient blades. Recently, much
of this work has come to fruition, particularly since several museum-quality artifacts
were donated for sacrifice to scientific examination. Extensive investigation had been
difficult prior to this donation due to the destructive nature of the testing and the high
value of the rare blades. As such, a number of separate groups have been able to not only
explain the mechanisms responsible for this unique material, but make successful
reproductions as well.
It is believed that the Indian wootz steel that was traditionally sent to the
bladesmiths in Damascus was produced in small cakes or ingots (weighing around 2.3
kg) that were roughly 4” in diameter and around 2” high and contained approximately 1.5
wt% carbon1. Iron charge, to which some sort of organic material - such as wood or
green leaves - was added, was melted in a closed clay crucible and then slowly cooled.
This cooling rate would be comparable to a modern furnace cool and was crucial to
attaining the microstructure necessary to generate the famous damask pattern upon
forging. Although, the cooling rates have yet to be studied in great depth, research has
shown that slower cooling will result in a coarser dendritic microstructure and the
carbides will exist as spheroidal cementite at the prior austenite grain boundaries. A
more rapid cooling rate, however, will yield a finer dendrite spacing and Widmanstätten
cementite2. The ingots were directly forged from these cakes, as was noted by several
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18th century English observers, and depending on the technique used, a variety of patterns
could be produced3. These patterns will be discussed in further detail. It is important to
note that forging a material that was slowly cooled will cause the spheroidal carbides to
grow, whereas Widmanstätten cementite particles become increasingly fine with each
cycle2.
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Following the forging of the blades, the surface must be dressed in order to reveal
the damask pattern. This is a three-step process where (1) the decarburized and oxidized
outer layer is removed by grinding, (2) the exposed surface in cleaned and polished, and
(3) an etchant is applied. Historical and ethnographic accounts have shown that a
multitude of cleaning and polishing media was used in ancient times including: wood ash
plus water, chalk and water, as well as dry lime, water, and tobacco ash2. Modern day
etching techniques involve using dilute nitric and sulphuric acids, copper sulfate baths,
and often ferric or ferrous sulphate. These preferentially etch the blade contrasting the
ferrite as a white or light component against a dark, pearlitic background (this is what is
typically produce by etching, however, variation does occur depending on the
composition and processing of the blade, in addition to the specific etchant used)2.
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cementite/austenite boundary mobility, allowing for preferential occurrence of large
carbide particles within those regions1. Juha Perttula from the Tampere Institute of
Technology in Finland, came to a similar conclusion, however, in his investigation he
replaced the small amount of vanadium (~ 0.03 wt%) with a larger addition of chromium
(0.5 wt%) to produce the banding effect5. In addition to serving as catalysts for band
formation, impurity elements also prevent graphite formation, to which hypereutectoid
plain-carbon steels are greatly susceptible5.
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Figure 3: Thermal cycling treatment as applied directly to ingot4.
Many studies have also noted the importance of avoiding hot shortness during
ingot production as it makes forging extremely difficult due to the very low temperatures
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at which it must be performed. Hypereutectoid wootz steel is highly prone to hot
shortness due to its typically high phosphorus content and the corresponding formation of
the phosphorus intermetallic phase steadite. Verhoeven et al. completed a rimming
treatment in order to create a pure iron casing around the ingot to enable the hot short
interior to be successfully forged. Evidence has suggested that makers of ancient wootz
steel performed similar treatments before forging7. Experiments have also shown that
this rimming treatment becomes unnecessary once phosphorus levels drop to the 0.02-
0.03wt% range so naturally ultra-clean steels are preferred.
PATTERN WELDING
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fashion blades such as that seen in Figure 9. After forging, as with wootz Damascus
blades, the surface is ground, cleaned and polished, and an etchant is applied9.
Figure 5: End view of a folded forge weld. This process will be performed repeatedly to
attain many fine laminations9.
(a) (b)
Figure 6: Two classic patterns, (a) the ladder and (b) butterfly, achieved by cutting grooves
into the surface of the blade and then forging it flat9.
Figure 7: Pool and eye pattern created using a combination of hole drilling and
forge/folding9.
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Figure 8: Twisting technique used in many pattern welded blades10,9.
Figure 9: Detail of a 18th or 19th century blade showing three bands of pattern-welding
between laminate layers8.
Unlike pattern-welded blades, the variety of patterns on blades made from directly
forged wootz steel are slightly more limited due to their non-laminate nature. Therefore,
cutting and drilling techniques, as discussed previously in the forging of the ladder and
pool-and-eye pattern welded blades, are the primary methods for creating complex
surface designs. This is of course in addition to simple manipulation of the blade (with
respect to the band direction) while forging. Figures 10 and 11 show two of the most
popular patterns, Muhammed’s ladder and the rose pattern.
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(a)
(b)
Figure 10: Combination of Muhammed’s ladder and rose pattern generated by (a) cutting
grooves into the surface of the nearly finished blade and (b) forging grooves into the
surface of the nearly finished blade1.
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Figure 11: Close-up showing detail of the Mohammed’s Ladder (also known as kirk
narduban) pattern on a wootz Damascus dagger from the middle to late 18th century8.
In addition to being a legendary relic of ancient times, wootz steel also qualifies
as an advanced material, one that fulfills the description by having such properties as
high impact hardness and superplasticity. These characteristics, combined with its
historical influence and reputation, have triggered a great deal of research into wootz
composition, mechanical behavior, and microstructure, and have in fact spurred a number
of developments in modern metallographic study. For example, documentation of
Damascus structure led the Swedish chemist Tobern Bergman, in 1774, to the
understanding that carbon plays a dominant role in the properties of iron and steel11.
Historians also note that wootz Damascus steel was studied in detail by Michael Faraday,
the renowned physicist.
The very recent work of scientists such as Verhoeven, and Perttula, as well as that
of master blacksmiths like Pendray, has also contributed much to the field of metallurgy.
However, despite the abundance of research available on Damascus steel there is still
much to learn, and as modern technology permits, increasingly advanced investigations
can be performed.
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REFERENCES
[1] Verhoeven, J. D., and A. H. Pendray. "The Key Role of Impurities in Ancient
Damascus Steel Blades." JOM 50.9 (1998): 58-64.
[2] Feuerbach, A. “The Production of Crucible steel and the Damascus Pattern.”
http://home.att.net/~moltenmuse/Production.htm
[6] Verhoeven, J. D., and A.H. Pendray. "The Mystery of the Damascus Sword,"
Muse, 2 (2) (April 1998), pp. 35-43.
[7] Verhoeven, J. D., et al., A.H. Pendray, and E.D. Gibson. "Wootz Damascus Steel
Blades," Mat. Char., 37 (1996): 9-22.
[10] Perret, J.J. “Method of making Steel in the style of Damascus.” L'Art du Coutelier
"The Art of the Cutler" (1771). Translation by Bernard Levine.
[11] Srinivasan, S., and S. Ranganathan. “Wootz Steel: An Advanced Material of the
Ancient World.” Department of Metallurgy, Indian Institute of Science, Bangalore.
http://www.tf.uni-kiel.de/matwis/amat/def_en/articles/wootz_advanced_material/wootz_steel.html
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APPENDIX A
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