More layers vs thicker stock for more Damascus?

[Leon Husock]

I've noticed that a lot of people, when making an extra-large billet of Damascus, tend to go for thicker stock but stick to around 20-30 layers, rather than using thin stock and upping the layer count for a similarly sized billet (say 40-60 layers to start). Is there a reason for this? I feel like you'd want to start with as high a layer count as you can to minimize how many times you have to clean and re-weld the billet.

The only explanation I can think of is that the more layers you have, the more initial welds you have to set, the more possibilities for one of those welds to fail. Anyone have any insight on this?

 

[DevinT]

Thin layers tend to bubble up on the outside layers because they heat up faster causing problems. Can be done just have to be careful.

Hoss

 

[Stacy E. Apelt - Bladesmith]

It is also simple physics. It is simpler to weld 20 joints than to weld 40. Thicker stock does not move away from the hammer/press as much and thus welds instead of squishies out. Moving surfaces don't weld.

 

[JTknives]

The Damascus we have made for us by Salem starts a big billets of thin layers. When I made damascus in the shop here I would start with as many layers as possible and tig weld the layers together. But Salem is the expert and when I have been over there he does not seam to have issues with his layers. We start with stock that’s under .100 but I don’t think I would go crazy thin. But I have done some with my .006 1095 mixed in with other stuff and it was ok. Biggest billet I did was at Salem’s place and if I remember correctly it was 60-70 layers to start and welded up solid into crushed W’s. But he welds everything without flux.

 

[JTknives]

This had 15n20(.072)and 1075(.080) with 1095(.006) between each one.