Damascus Steel

During the long years of the Crusades, the armies of Europe found themselves badly outnumbered. Not only were there more Saracens than Crusaders in the Holy Land, but the armies of Islam were much better equipped. They rode sleek, swift horses bred for the hot desert climate, wore a chain mail light enough to provide them mobility yet strong enough to stop European blades, and used weapons made of a steel so well-forged that it bent under pressure without breaking, yet held an edge so sharp it could cleave a man in half with only the force behind one arm. What was the secret steel of the Near East, it's forging guarded so well by the sword smiths of Syria? That steel was called Damascus steel, a term used by the Crusaders to describe the metal used by the artisans and sword smiths of Damascus, Syria.

Damascus steel is a hot-forged steel used in Middle Eastern sword making from about 1100 to 1700 AD. Damascus swords were of legendary sharpness and strength, and were apocryphally claimed to be able to cut through lesser quality swords and even rock. The technique used to create original Damascus steel in now a matter of historical conjecture. Many raw materials and the metal smiths' recipes are no longer available. The foundation for Damascus steel is Wootz steel, which originated in India and later spread to Persia.

The general term "Damascus" refers to metal with a visible grain pattern, sometimes with a texture. Modern Damascus is a lamination of folded steels selected with cosmetic qualities, with grinding and polishing specifically to expose layers. True Damascus patterns are formed when carbon trace elements form visible swirls in the steel mix. These elements change properties when the steel is work hardened (forged), creating patterns.

Damascus steel has been used to make elaborate knives and swords for centuries. Today a metal smith first layers two types of steel that are then fused at high temperatures. Mechanical hammers weighing 600 to 1000 pounds are then used along with other heavy equipment to form patterns of different types. A solid bar of material is finally produced, from which the bands are cut. While basic pattern types can be repeated, no two bands will ever be just alike.

Damascus steel can be finished to a high polished which will understate the contrast between layers of metal, or thin acid finish which when applied produces a rougher texture which dramatically displays the pattern in the metal.

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