those wavy lines in san mai....

timos-

Knifemaker / Craftsman / Service Provider
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Oct 22, 2012
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Ive got some san mai I plan on using soon. I have come to really prefer using it for kitchen blades, so I guess I should learn how to work it. I am strictly stock removal and am just wondering what is the bare minimum of equipment I need to manipulate the layers.

I am hoping its just a torch and a hammer....no?
 
I have some of the v-toku 2 core with stainless cladding. there is a thin layer of nickel between layers too.
I also have some of Aldos 410SS with 52100 core.
 
Based on my limited experience making stainless clad san mai it takes more than I thought to get a desirable level of randomness at the parting line. I was heating in a forge and striking with both a ball peen and cross peen hammer and while there was some activity from this, it wasn't very dramatic. The mild steel cladding will likely move easier. Also, the closer your billet is to the finished blade width you're going for, the better, so you have more control over where your bevel intersects the parting line and you keep it rather close to the edge, as the closer it is to the edge the easier it is to work those indentations in.

Doing it with a hammer and torch is possible but you'll need something like an anvil/use as an anvil and the torch needs to be capable of getting the work to forging heat.
 
I have been wanting to buy an atlas mini forge so maybe this could be some justification...
 
You can carefully use a cutoff wheel to grind through part if the cladding in a ladder pattern, but you have to forge it flat again after.
 
2 brick forge, plumbers torch, and a block of steel will be the minimum. Depending on the torch, you might need acetylene to get hot enough. I haven't used that type of setup in a while, but I remember it gets well above heat treat temps, and with acetaline, I got to welding temps in a 2 brick forge.
 
If just wanting to manipulate the line between the core and cladding, you can grind the bevels to about 50%, then manipulate. The edge should be about .030-.050" at this point. Depending on the core thickness, the core may not even be showing yet. Once the bevels are basically shaped, use a drawing peen on a blacksmith's hammer to work the edge and cladding with the blade at a full red-orange color. A small forge would be best, but a presto-lite plumbers torch or welding torch would work. I don't think a cheap propane bottle torch for soldering pipes would do the job. You don't have to have a real anvil for this either. A small HF anvil, or even a big block of steel will work. You don't need the whole blade red-orange, but the 1" or so you are working on should be fully hot. Work the blade from ricasso to tip to make it wavy in rolling ridges and valleys. After the manipulation is done, grind it back flat again. Test the look with a dip in FC, and grind some more. As you sneak up on the proper edge thickness, the boundary between the metals should start to show as a wavy line. Again, depending on the core thickness, it may barely show at this point.

Note:
The blade will likely start to curve up as you work the edge. Get the whole blade evenly full red, place on your "anvil", and straighten the spine by gently striking the edge. Straighten any warps and twists after you grind or file down the waves the same way. When the blade is done being ground/filed it should be straight and flat. At tis point it is ready for the rest of the sanding to prepare for HT. The final edge pre-HT for a san-mai blade is about .020".

After HT, start working the bevels down until the blade becomes almost sharp. This should show the wavy san-mai boundary.
 
Thanks for the tutorial! Ill be getting an Atlas Mini or maybe the slightly larger one. I am currently working on sourcing an anvil shaped object. A friend of mine has access to all sorts of end cuts at a very large mold making cnc plant. Looks like I could score some 1/2" thick plates of pre hardened RAMAX steel. I think it is mid 40s RC and I can get that bolted on top of some 4140 or something. I am shooting for an anvil around 80 lbs and a couple 2 lb hammers.
 
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