This is tamahagane. It is produced in Japan using satestu (iron bearing sand) and charcoal in a  tatara which is a very old and basic smelting technique. The charcoal combines with the iron to produce a very pure form of steel that is ideal for producing the Japanese sword.

    The tamahagane is forged into wafers and sorted according to carbon content.

   The wafers are arranged on a plate and forged into a rough block.

   After the billet is consolidated, it is drawn out, folded and cut. This is repeated until I feel the steel has reached a level of refinement that I am happy with.

   If the blade is to be kobuse style, the kawagane or jacket steel is formed in such a way as to fill it with shingane, a soft iron core. This process will leave the final sword with an outer wrap  of very hard steel capable of retaining a razors edge and a soft core to give the sword resilience in battle.