Bladesmithing 2020: Session I
Sponsored by: TMS Materials Processing and Manufacturing Division, TMS: Shaping and Forming Committee
Program Organizers: Michael West, South Dakota School of Mines & Technology; Roxana Ruxanda, Copeland; David Sapiro, USNC-Tech
Wednesday 8:30 AM
February 26, 2020
Room: 2
Location: San Diego Convention Ctr
Session Chair: Michael West, South Dakota School of Mines & Technology
8:30 AM
Aluminum Bronze Cast Khopesh: Megan Burrill1; Kathy Ho1; 1Illinois Institute of Technology
In order to observe the effects of more technical casting methods and precise alloy composition on the final blade structure, stock Aluminum Bronze, C954, will be compared to a team-produced alloy. Samples of varying chemical compositions will be cast, processed using different metal-forming techniques, such as cold and hot work, and tempered afterwards. Metallographic characterization, including optical microscopy and possibly hardness or tensile tests, will be conducted on these samples to compare the material properties and determine the ideal composition for workability. An ingot with the chosen alloy composition will then be forged into an Egyptian Khopesh, a curved blade from the bronze age.
8:50 AM
Fabrication of A Historical Seax Using Historical Methods: Austin Hernandez1; Charles Meyer1; Hugo Heredia1; Stephen Stafford1; Christopher Bradley1; 1University of Texas, El Paso
The history of the Seax blade is well-known in Anglo-Saxon tales, with the Seax of Beagnoth known due to its historical significance as the only sword found with a complete inscription of the runic alphabet. A Type 410 martensitic stainless steel will be the material utilized for the blade portion for this design. We will investigate the feasibility of forming a martensitic stainless steel into a blade that resembles the Seax of Beagnoth, which has copper inlaid in grooves and runics inscribed into the length of the blade. The use of a coal-powered forge, hammer, and anvil will be used to accomplish this historical theme. The blade will be tempered using proper tempering procedures to achieve the required properties for strength and sharpness tests. We will also investigate sand and investment casting methods to form the hilt and handle designs. Characterization includes microstructural examination with mechanical testing to involve hardness.
9:10 AM Cancelled
The University of Texas at Austin’s ASME Design Team Bowie Knife Proposal Abstract: Grace Young1; 1UT ASME Design
Our blade of choice is the Bowie knife. Designed by Jim Bowie and improved upon by James Black, the Bowie knife is surrounded by countless myths that have shaped its reputation. A well-known Texas figure, Bowie’s involvement in the Battle of the Alamo was our main reason for choosing the Bowie knife. The original Bowie knife was based on a butcher’s knife. Our knife will have a 9-10 inch blade, 5 inch wooden handle, handguard, and a clip point. The blade will likely be made of 1045 carbon steel due to its price and weldability, combined with reasonable historical accuracy. This steel will need to be forged and bevelled, drilled for pin holes, and heat treated/tempered. The handguard can be milled, and the wood handle can be shaped with a sander. Members include: Grace Young, Ethan Fang, Will Hancock, and Kenna Tanaka.Affiliation: The University of Texas at Austin
9:30 AM
Forging the Future: Albert Ostlind1; 1New Mexico Institute of Mining & Technology
The process used to determine the optimum forging conditions for a novel FeNiZr nanocrystalline alloy will be presented. As this alloy is produced by ball milling, it must be consolidated into a final part. Within the modern world of manufacturing, more and more metals are being produced as powders requiring various methods of consolidation or post processing. Within this context of modern consolidation processes, such as additive manufacturing, the continued relevance of forging as a manufacturing process will be discussed.The blade produced during this work is styled after the OKC-3S, M9, and LHR combat knives used by the US Army. The blade material is an oxide dispersion strengthened (ODS) alloy of FeNiZr produced by ball milling. After ball milling the powder was extruded to form a billet, then forged to fully consolidate and shape.
9:50 AM
Boridized AISI 1045 Carbon Steel for "MortuarySsword" Bladesmithing: David Flores1; Karen Miroslava1; Orlando Castro1; Gerardo Salinas1; Enrique Duque1; Simon De La Rosa1; José Mariano Flores Herrera1; 1Universidad Autónoma de Nuevo León
In this work, we propose the manufacture of a "Mortuary sword" with a boridized AISI 1045 carbon steel. The history of this sword goes back to the 17th century, during the archbishops and the civil wars, where these swords were characterized by its lightness, excellent quality and balance. Its approximate weight was 2 pounds and 6 ounces, and a broad one-edged blade of 31.9 inches. Manufacturing a sword’s blade requires forging and treating, in this case boriding is explored. Boriding consists of a heat treatment at high temperatures (700 - 1000°C); the boron content on the steel surface will promote the formation of interstitial compounds to improve the strength of the base material. Finally, an AISI 1045 carbon steel will be used, although it is a medium carbon steel, it presents the optimal properties for the sword manufacturing processes.9
10:10 AM Break
10:30 AM
Titanium Bonding to High Carbon Steel through Vanadium for Bladesmithing: Ryan Mier1; 1Los Alamos National Laboratory
Many bladesmiths have been interested in bonding titanium alloys to high carbon steel in a San Mai style for decades for aesthetic and performance reasons. However, getting a reliable bond proves quite challenging because of formation of brittle intermetallics at the steel/titanium interface. In this talk, two methods of bonding Ti6-4 to a simple high carbon steel utilizing vanadium as an interlayer are explored. Diffusion bonding in a high vacuum furnace and canned roll bonding were used as methods to achieve a 3 layer blade material with adequate mechanical properties to use in knives. Differences in these two bonding methods are looked at from the perspective of bond reliability, complexity of processing and practicality for bladesmiths. -LANL and New Mexico Tech (member of 2019 2nd Heat team)
10:50 AM Cancelled
Comparing Mechanical and Microstructural Properties of a Damascus Steel Forge Welded with and without Flux: Al Medrano1; Fernando Robledo1; Jason Lin1; Sam Lee1; Jordan Tran1; Natalie Wu-Woods1; Calvin Belcher1; Tucker Parris1; 1University of California, Irvine
Flux is a substance applied to metal while forge welding in order to protect the metal from reacting with impurities. However, there is debate in the bladesmithing community regarding whether it has any significant effects on the weld. This work will compare the mechanical and microstructural properties of two processes for forge welding carbon steel damascus. 15N20 and 1084 Carbon steels will be stacked and forge welded together into a preliminary Damascus billet. A second billet of Damascus steel will be produced without the use of flux during the forge welding process. Both billets will undergo microstructural characterization using SEM and EDS. The billets will also be mechanically tested through hardness indentation. This investigation will provide a fundamental understanding of the role of flux when producing forge welded damascus.
11:10 AM
Decapigator: Devin Ritter1; Brandon Capellini1; 1University of Florida
Decapigator is a 100-layer forge welded Damascus sword composed of W2, 1084, and 15N20 steel with a raindrop pattern. The sword features a cast silicon bronze cross-guard, pommel, and a cedar wood handle. The billet was started with 10 layers welded together and was heated in a coal forge and then hammered, folded, rolled, cut, and then reforged to ultimately create the 100 layers. The sword was heat treated inside a gas forge, quenched into canola oil, and differentially tempered to obtain martensitic edges and a tough spine with an average Rockwell Hardness of 35. The hilt was assembled with stainless steel pins and joined to the blade with epoxy. The inspiration for the hilt design and sword comes from “Oathkeeper,” a famous sword in Game of Thrones. The UF bladesmithing team worked with artisan Jordan Borstelmann at his home forge shop, “Crooked Path Forge.”
11:30 AM
Investigating Chemical and Mechanical Inhomogeneity in Pattern Welded Steel: Cullen Pearson1; 1University of Tennessee Knoxville
Modern pattern welded steel and historical Damascus steel have seen research attention in both academic and knife making communities. The bulk of fundamental academic research occurred in the 90s, focusing on microstructures of historical Damascus steel. Processing and properties of pattern welded steel are of more interest to the knife making community. While knifemakers theorize with metallurgical knowledge, they rarely have access to advanced characterization techniques. This paper investigates common theories of chemical and mechanical inhomogeneity through pattern welded steel. Characterization techniques such as scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and microhardness mapping are used in conjunction with CALPHAD software to predict and measure chemical diffusion and mechanical properties of pattern welded steel.