Forge Ready Billets (Square, Round and Rough)

Flat Stock (Width × Thickness):

• 30 × 10 mm ≈ 1.18 × 0.39 in (precise: 1.1811 × 0.3937)

• 30 × 15 mm ≈ 1.18 × 0.59 in (1.1811 × 0.5906)

• 30 × 20 mm ≈ 1.18 × 0.79 in (1.1811 × 0.7874)

• 50 × 10 mm ≈ 1.97 × 0.39 in (1.9685 × 0.3937)

• 50 × 15 mm ≈ 1.97 × 0.59 in (1.9685 × 0.5906)

• 50 × 20 mm ≈ 1.97 × 0.79 in (1.9685 × 0.7874)

Round Stock (Diameter):

• 20 mm Ø ≈ 0.79 in (0.7874)

• 25 mm Ø ≈ 0.98 in (0.9843)

• 30 mm Ø ≈ 1.18 in (1.1811)

• 35 mm Ø ≈ 1.38 in (1.3780)

Square Stock:

• 25 × 25 mm ≈ 0.98 × 0.98 in (0.9843 × 0.9843)

• 30 × 30 mm ≈ 1.18 × 1.18 in (1.1811 × 1.1811)

Forging

• Carbon billets: forge at 1742–1976°F (950–1080°C).
• Stainless billets: forge at 1742–1922°F (950–1050°C).
• Cool slowly after deformation — do not quench from forging temperature.
• Soft annealing is required before further machining after any hot working.
• Note: cold working is not recommended for the stainless steel billets.

Machining All forge ready billets are delivered soft-annealed at 22–27 HRC. The weld layers will not separate during machining.

Soft Annealing (required after hot working only)

Carbon billets (1.2842 + 1.2767):

• Heat slowly to 1328°F (720°C) and hold for 2 hours. Reduce to 1202°F (650°C) and hold for a further 2 hours. Cool slowly in the furnace. Remove below 570°F (300°C).

Stainless billets (1.4034 + 19C27):

• Heat slowly to 1526°F (830°C) and hold for a minimum of 4 hours. Cool slowly in the furnace. Remove below 752°F (400°C).

Hardening

Carbon billets (1.2842 + 1.2767):

• Heat to 1544°F (840°C) and hold for 4 minutes. Quench in oil. Deep freezing is optional but recommended.

Stainless billets (1.4034 + 19C27):

• Perform under vacuum or protective gas. Heat to 1922–1976°F (1050–1080°C) and hold for 15–20 minutes. Quench in air, then immediately deep freeze.

Tempering

Carbon billets: 2 × 1 hour at 356°F (180°C) → approximately 62 HRC. Temper immediately after hardening. Cool to room temperature between cycles.

Stainless billets — knife blades: 2 × 0.75 hours at 356–374°F (180–190°C) → approximately 60–61 HRC. Decorative items: 2 hours at 572°F (300°C) → approximately 56–57 HRC. Temper immediately after hardening or deep freezing. Cool to room temperature between cycles.

Surface Preparation

• Forge ready billets are delivered with a raw scaled surface. Before etching, the scale must be fully removed. Grind or file the surface until clean bare steel is exposed across the entire face you intend to etch.
• Sand to a consistent finish — 400 grit minimum, up to 1200 grit for a finer pre-etch surface. Work through each grit cleanly before moving to the next. Scratches from lower grits will be amplified by the etch.
• Do not buff after sanding — buffing closes the surface and reduces pattern contrast.
• Wash thoroughly and dry with a clean cloth.
• Degrease with acetone or denatured alcohol immediately before etching.

Etching — Carbon Steel Billets (1.2842 + 1.2767)

• Always wear protective gloves and goggles and work in a ventilated area when handling acids.
• Use ferric chloride (FeCl₃, 15–50% solution in distilled water) or sulfuric acid (H₂SO₄, 15–30%). Gator Piss is also confirmed compatible.
• Do not use muriatic acid — it attacks both steel types equally and produces flat grey with no pattern contrast.
• Heat your chosen etchant to approximately 122°F (50°C) in a water bath.
• Suspend the billet freely in the etchant — do not let it rest on the bottom of the container.
• Etch in multiple short passes. Between each pass, neutralize in a baking-soda solution, then brush lightly with a soft toothbrush to remove smut and surface oxides. Continue until the pattern is clearly visible and the desired depth is achieved.
• Do not buff after etching.

Etching — Stainless Steel Billets (1.4034 + 19C27)

• Always wear protective gloves and goggles and work in a ventilated area when handling acids.
• Use sulfuric acid (H₂SO₄, 15–20%) heated to 122–140°F (50–60°C) in a water bath. Gator Piss is also confirmed compatible. Do not use ferric chloride or muriatic acid on stainless Damascus.
• Suspend the billet freely in the etchant — do not let it rest on the bottom of the container.
• For a deep etch (~20µm): etch in 5-minute passes — approximately 5µm depth per pass, 20 minutes total. For a lighter finish, use 20–40-second passes. Neutralize and brush between each pass.
• Do not buff after etching.

Developing Contrast — Both Steel Types

• After your final pass, neutralize thoroughly in a baking soda solution and rinse completely.
• For greater contrast, lightly sand with fine sandpaper — 2000 grit or finer for carbon, 2500 grit or finer for stainless. This polishes the raised bright layer while leaving the recessed dark layer at depth.

Final Steps

• Rinse and dry completely.
• Apply a protective oil or wax. Carbon forge billets will develop a patina over time — regular oiling after handling is recommended. Stainless billets are corrosion-resistant but benefit from occasional oiling.