The Forging of a Japanese Blade (1)

The forging of a Japanese blade typically took hours, days, or even weeks and was considered a sacred art. As with many complex endeavors, rather than a single craftsman, several artists were involved. There was a smith to forge the rough shape, often a second smith (apprentice) to fold the metal, a specialist polisher (called a togi) as well as the various artisans that made the koshirae (the various fittings used to decorate the finished blade and Saya(sheath) including the tsuka (hilt), fuchi (collar), kashira (pommel), and tsuba (hand guard)).

The legitimate Japanese sword is made from Japanese steel "Tamahagane". The Japanese sword blade is formed from a combination of two different steels: a harder outer jacket steel wrapped around a relatively softer, inner core of steel. This creates a blade which has a unique hard, highly razor sharp cutting edge with an inner core which is resilient and able to absorb shocks in a way which reduces the possibility of the blade breaking or bending when used in combat. The hadagane, for the outer skin of the blade, is produced by heating a block of high quality raw steel, which is then hammered out into a bar, and the flexible back portion. This is then cooled and broken up into smaller blocks which are checked for further impurities and then reassembled and reforged. During this process the billet of steel is heated and hammered, split and folded back upon itself many times and re-welded to create a complex structure of many thousands of layers. Each different steel is folded a differing number of times to provide the necessary strength and flexibility to the different steels. The precise way in which the steel is folded, hammered and re-welded determines the distinctive grain pattern of the blade, the jihada, (also called jigane when referring to the actual surface of the steel blade) a feature which is indicative of the period, place of manufacture and actual maker of the blade.

The shingane (for the inner core of the blade) is of a relatively softer steel with a lower carbon content than the hadagane. For this, the block is again hammered, folded and welded in a similar fashion to the hadagane, but with fewer folds. At this point, the hadagane block is once again heated, hammered out and folded into a ‘U’ shape, into which the shingane is inserted to a point just short of the tip. The new composite steel billet is then heated and hammered out ensuring that no air or dirt is trapped between the two layers of steel. The bar increases in length during this process until it approximates the final size and shape of the finished sword blade. A triangular section is cut off from the tip of the bar and shaped to create what will be the kissaki. At this point in the process, the blank for the blade is of rectangular section. This rough shape is referred to as a sunobe.