Sho Aoyagi stars as Gosuke, who has to choose between becoming a master blacksmith of samurai sword steel like his father or becoming a samurai himself to protect his village. ©2017 Tatara Samurai Production Partnership
An introduction guide to the process and materials used in forging a Samurai sword.
The katana, a traditional Japanese sword, is renowned for its craftsmanship, sharpness, and distinctive design. The process of making a katana is a highly skilled and intricate art that has been passed down through generations. It involves multiple stages of forging, folding, and heat-treating steel, as well as precise attention to detail in shaping the blade, handle, and other components.
The katana is typically made from tamahagane steel, which is created by smelting iron sand in a traditional Japanese furnace called a tatara. The steel is then folded multiple times during the forging process to improve its strength and flexibility. This process also creates the distinctive layered appearance of the blade, giving it both beauty and functionality. The blade is carefully shaped, sharpened, and hardened using a method known as differential hardening, which results in the katana’s signature curve.
In addition to the blade, the katana’s handle (tsuka) and guard (tsuba) are meticulously crafted, often featuring intricate designs or symbols. The katana’s creation is a harmonious blend of artistry and functionality, where each step is performed with precision to ensure the sword is not only a weapon but also a symbol of Japanese culture and tradition.
The entire process of katana making, from forging the blade to its final polishing, takes months to complete and requires an exceptional level of skill and patience, making each katana a unique masterpiece.
How big is a Samurai sword?
The size of a katana varies depending on the blade length, hilt, sword guard, and scabbard:
Blade length
The blade of a katana is typically between 23.62 and 31.50 inches long. However, the length can vary depending on the type of sword, such as the longer tachi used by mounted samurai and the shorter kodachi used for close-quarters combat.
Hilt
The hilt, or handle, of a katana is another component that contributes to the sword’s overall length.
Sword guard
The sword guard, or tsuba, is a circular or squared guard that is another component of the katana.
Scabbard
The scabbard, or saya, is typically as long as the blade, but is sometimes slightly longer to accommodate the blade tip and prevent damage. A traditional sheath is made of wood and varnished to prevent rotting.
The ideal dimensions of a katana depend on a number of factors, including personal body proportions, style of training, and purpose of use. The goal is to choose a well-balanced katana that provides optimal performance.
What processes are involved in making the katana?
- Smelting: The steel for a katana is traditionally made using a tatara, a clay furnace that heats iron-rich sand and charcoal to produce tamahagane, or “jewel steel”. The process takes three days and nights, and can yield about two tons of steel.
- Forging: The steel is heated and shaped into a U-shaped channel, and a strip of low-carbon steel is hammered into the channel. The two metals are then forged together.
- Folding: The steel is folded in half multiple times using a hammer and chisel. Each fold increases the number of layers in the steel, and after 15 folds, the steel can have over 30,000 layers.
- Coating: The blade is coated with a mixture of clay and charcoal powder to protect it and give it its wavy design.
- Curving: The blade is plunged into water to bend it.
- Polishing: The blade is polished with grinding and polishing stones to sharpen the edge.
Video: Forging a Samurai sword
The process of making a katana is an art form that has developed over centuries. The Japanese government limits the number of swords a swordsmith can make in a year to maintain the quality of Japanese swords.
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