Powder atomization
In a nitrogen filled atomization chamber molten steel of 1600 C is hit by the atomization jets. The solidification to powder occurs in less than a second. The solid structure is free from solidification defects.


Capsule filling
Two different grades of powder are filled into a mild steel capsule. A filling tool puts the powders in patterned layers when the capsule slowly moves downwards.

Hot Isostatic Pressing
The powder filled capsule is loaded into an extreme pressure chamber. At high temperature and pressure (1150 C and 1000 bar).
The capsule is squeezed until all porosity is gone.



Hammer forging
The capsule is forged from 400 mm down to 100 mm round billets. Afterwards, the thin capsule is removed by turning.

Rolling
The billets are rolled to a suitable dimension before the patterning. Here we have a semi finished bar with a pattern in the bar cross section. Along the bar there is a pattern of stripes.



Patterning
The patterning is made in three different ways. Twisting, coining or cutting. The intention is to turn the stripy pattern along the bar into something attractive. This part of the damascene art is sometimes performed by the bladesmiths. They can create their own patterns from damasteel laminated bars.


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Twisting - A round bar is heated and torsion twisted.



Cutting - A pattern cut bar is flat forged.



Coining
Coining is made by patterned tools in a 350 ton forging press.

Grinding
Most material delivered from Damasteel is ground in a flat grinder.



Quality control
After hardness test, etching and inspection of the pattern, the bar is ready for shipment.