Minimizing depth of black lines between damascus layers?

[Leon Husock]

I was taught that in order to make something like twist damascus you *have* to go in on the sides and grind out all the little black lines left over between the layers from the initial welds, and that in general it's just good practice to do this. But I just ground a full 1/4" out of the side of my billet to get rid of a black line between layers, and it hurts me to waste so much (though I know that there is a lot of unavoidable wastage in damascus making). Is there anything I can do before/during the initial welding to reduce the depth of these little black lines? Would it help if at some point in my drawing out process I forged down the sides of the billet?

 

[weo]

Are you twisting round or square billets? Rounder is easier to minimize those. At least knock the corners down to an octagon before twisting.

 

[DevinT]

Those sound like welding flaws. You do need to forge on all sides. Make sure the pieces in the stack are all exactly the same size, width and length.

Hoss

 

[Stacy E. Apelt - Bladesmith]

Forge the billet solid and then forge it square.
Clean up the sides and then forge it round or hexagonal.
Clean up and twist. Twist at full welding heat.
Forge the twist down a bit and grind to a clean round billet.
Forge out flat and make a good looking knife.