I made... something.

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May 23, 2013
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I went over to a friend's house(BF member SinePari) for a little hammer-in today. Had a blast forging out my first blade. I'm hoping to do a little grinding on it later tonight at another friend's house(BF member esnyx). It started life as a leaf spring, assumed to be 5160. I hand forged the edge to shape and then had some help from SinePari with cutting out the handle profile. It's still a bit rough right now but I think it will clean up nicely. I plan to do a convex grind and wood handles.

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On the anvil

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Before & after with another piece of leaf spring


Big thanks to SinePari for his guidance and use of his forge and materials. And big thanks to esnyx for his future help in finishing this bad boy.
 
Looks like you had a lot of fun and it will be awesome to see what the end results are. So far it looks like a cross between a machete and a cutlass :D looking forward to the progression to completion. Keep the pictures rolling.
 
Philllll thats freekin awesome! Love that shape too. Im putting my forge together now and want to do my first soon too. Its got to be a great feeling to get no 1 shaped! Have you tempered it yet?
 
I can't wait to see what it does to a row of innocent wata-bottles of the 5 gallon persuasion... :D
 
Awesome. :thumbup: UB would have said you should start working for HI!

Question: I've ground out some blades using a slack belt grinder, but have never forged anything. When using a forge, after shaping the blade how did you quench the steel, or are you just going for the basic shape at first?

If you quenched it, how did you know how hot to get it before tempering it? Did you differentially harden it? Looking forward to seeing the finished product. (Looks like maybe 15-16" or so? What do you think the finished weight will be?)

Thanks for any info. (Now the hard part, you have to give it a name! :D)
 
Thanks for the encouragement, everyone. Here is another photo after some preliminary convex grinding, pre-heat treat.

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Svashtar, I don't really know enough to fully answer your question. I know we did a triple normalization and quench before putting the preliminary grind on, and then it will go back into the forge and get quenched again in oil, then tempered in the oven (I think). I want to try a differential heat treatment for this one.

As far as a name goes, I was thinking "De-Limber" has a nice ring to it...
 
There are two basic methods of preparing the steel usually found on the internet:

Triple normalizing - heat and cool in air several times, usually at 1650F,1450F,1250F - accomplishes the stress removal very well, but does nothing to refine the grain. This is a common practice, and does no harm to any steel. On stock removal blades, it is enough to prepare the steel for final hardening. In a forged blade, there may be more severe grain and internal condition issues that are better dealt with by Thermal Cycling.

Triple austenitization accomplishes grain refinement to various degrees, depending on the temps and hold times. It does nothing to reduce stress, and may even add some. There are those who use this method, largely based on one makers procedures, but I can find no metallurgical reason for it making the blade harder or superiorly finer grained.
Those who want to use this method should refer to other people for advice on temperatures and procedures, as I don't do it or recommend it.

Here is more detail on my opinion:
I call the process that can gain the finest grain and hardest blade - Thermal Cycling.
It starts with grain refinement, proceeds with normalization and stress relief, and ends with hardening and tempering.
Start with a high end austenitization at around 1650F, a soak ( if needed and your equipment allows), and air cooling to black from 1650F (in some cases, a quench is used instead of air cooling, but is normally not needed)
Next, a cycle at low end austenitization, about 1450F, to re-refine the grain as small as possible...followed by a quench. Cool in the quenchant to room temp.
Then, a sub-critical soak at 1250-1350F and air cooling to below 900F to remove all stress and prepare the blade for the final hardening quench. You can water cool once the steel cools to black.
The final step is the actual austenitization and quench to harden the blade...followed by a double temper.


My normal procedure is:
1) Heat to well above non-magnetic (1550-1650F) and let cool to room temp (I water quench to speed the cooling once the steel is black/900F, or you can let it air cool )
2) Heat to just slightly ABOVE non-magnetic (1425-1450F) and quench. Cool to room temperature in the quenchant.
3) Heat to just BELOW non-magnetic (1250-1350F), hold here for a few minutes, and cool to room temp. (the blade may be water cooled after it turns black, or allowed to air cool)
4) Heat to the target temperature ( normally between 1450F and 1525F) and hold for sufficient time to allow the alloying to go into solution ( varies by steel type), then quench in the proper quenchant for the steel type. Allow to cool in the quenchant, or air cool after 5-10 seconds of quench. This step is the actual hardening step.
5) Temper twice for 1 hour each, with a water cooling between tempers. ( 400-425F is my normal temper)

^
We're following Stacy's "Thermal Cycling" and we are @ step #3... And I see that I screwed it up as well... no harm no foul though it wasn't at critical when we quenched it in oil... Worst comes to worse, we'll just repeat step 3, unless stacy wants to chime in on a different contingency...
 
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.... As far as a name goes, I was thinking "De-Limber" has a nice ring to it...

Very nice work. It could become addictive.

If you reshape the end of the handle a bit, you could call it a Philllll-Suga Knife. :)
 
Great work. I think that is the natural shape a bar of steel will take as one side is pounded down towards a thin edge. Fortunately, it's a very useful shape.
 
Apocalypso blade!

Now....i know why your sharking has been excellent!
(hint: on the top left corner, Sharking juice!)

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Great work. I think that is the natural shape a bar of steel will take as one side is pounded down towards a thin edge. Fortunately, it's a very useful shape.

Haha you've got that right, Howard. Not a whole lot of shaping went into it besides the natural curve it took from pounding out the edge.

Now....i know why your sharking has been excellent!
(hint: on the top left corner, Sharking juice!)

:D:thumbup:
 
I think the triple austenitization produces an edge that's a little easier to sharpen for a given hardness. That has been my experience. Only works with 5160, 52100 and maybe 80CrV2 (i haven't tried it with this steel).
 
Made lots of progress yesterday! The blade is heat treated (with differential edge quench), convex ground, and sharpened. The Brazilian Cherry handle slabs are epoxied on and curing. Only thing left to do is to shape the handle!

We tested it out and it chops like a beast, with no chipping or rolling to the edge!

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Thanks, J. I am amazed by the chopping power of this thing. I can't wait to finish it up!!!
 
Thats cool phillll! I havent tried differentially hardening yet but I have tried differentially tempering. Either way I guess you have to make sure you get the straw color to the edge. Fine job and handle will be cool too. Kinda has a parang look to it.
 
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