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Ajou University Industrial and Information Systems Engineering

Materials & Manufacturing Processes Spring 2012

Report Title: Japanese Samurai Sword Making Process

Submitted by: Hassam Ahmed

Date: 20/04/2012

I’ll discuss the following steps one by one in detail.Japanese Samurai Sword Making Process In this report I am going to discuss that how to make famous Japanese Samurai Sword. In the making of Samurai Sword high level of skills are required and making a single sword like KATANA requires a month of time period to make it in use. Its popularity is due to its making process which takes a month of time period and its wide use in Japanese wars. The Samurai Sword was widely use by Japanese warriors in their wars and battles in their early ages. And I’m going to cover following Areas. there are many steps including making of steel etc. Introduction 2. But now Japanese use their Samurai Sword for sword fighting and for their culture heritage. etc. Summary & findings  Introduction Samurai sword is one of the famous sword. 1. Analysis 3. Step 2 : Forging the Steel Step 3: Polishing the steel.  Analysis Discussing about the process of making of a Samurai Sword . Step 1 : Making of the UNIQUE STELL. .

The sand is now added in the furnace and the furnace is maintained at a very high temperature. each piece of the steel is carefully observed by experienced persons and good pieces of the steel are send to the Samurai sword maker. carbon charcoal is added in the furnace which then mixed melted iron sand and forms unique steel. After making of this specific steel. First step include in the making of Samurai sword is to find the perfect type of steel. The hammering process weights down the steel to about 50% of its actual weight. The heat from the forge and constant hammering is used to make the surface of steel flatten.  Step 2 : Forging the steel The process of forging the unique steel known as KATANA which takes a very long time of forging for about 3 months. The expert sword makers guess the concentration of carbon by the colour of the steel. After this the steel is wrapped in paper and then covered by the clay and ash in order to prevent the steel from oxidation. And it requires a lot of care and observations in order to make it perfect for the making of Samurai sword. This process must be complete quickly before the temperature of the steel drops making it impossible to work with it. In Japanese these steel is known as TAMAHAGANI. Step 1 : Making Of The UNIQUE STELL. The process of making the steel goes on for three days and three nights without any break. Now the experts makes the folds of the steel by hammering to the point where there are 5000 folds/cm. When the sand start melting. This process combines all pieces of steel together. Iron sand is used for the making of this steel because it has very less impurities as compared to ordinary iron sand. This steel is made in traditional Japanese furnace which is usually known as TATARA. . These impurities causes iron and sand brittle. Again it is heated to 1300o C and then hammered. And the main reason of choosing this iron is that it does not contain any sulphur and phosphorus impurities.

This process is very carefully controlled by sword maker and it is known as HAMON. Metallurgical speaking. If it stays low. Because if the temperature goes up to the range then the sword will break. then the proper hardening never comes. After the process is finished. This rapid cooling of sword causes the blade to get more sharpen. mean coating is finished a line appears on the blade. When the blade gets red hot . Now a very secrete mixture of clay and charcoal powder is used to protect the blade during further hardening process. . it is a line distinguish between martinsite and the paralite. it is then quickly quenched in water which causes the sword to become very hard.The steel is moulded in such a way that the hard material is on the edge and the ductile material is on the back of the blade which makes the sword shock resistance. The structural changes appears during the rapid cooling process gives the sword its unique shape. Now again the sword is heated to 800oC and this time temperature is carefully maintained and controlled.

Now a days samurai is manufactured not for wars and battles but for its traditional and cultural need. Step 3 : Polishing The KATANA The step in the manufacturing of JAPANESE Samurai sword is polishing the KATANA. The design that the sword maker makes during forging get more prominent during polishing. In short this sword is not easy to manufacture although it requires a lot of time and experience for just making a single sword. During polishing the blade get more sharpened. During polishing two things are carefully look after one is its sharpness and the other its shinning. The process of polishing also requires a lot of time. Different types of katana sword requires different types of polishing styles based on their look. Although the use of Samurai sword is almost finished but its beautiful look and its sharpness still attract people towards it from all-around the world. But it’s the actual thing which gives the perfect look to katana the famous Japanese Samurai sword. .  Summary & Findings : In this report we discuss how the famous Japanese Samurai sword is manufactured and what are the different secrete techniques used in the manufacturing of this famous Samurai sword.

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