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WABUKAN Journal · Weapons · 刀

The katana: steel, forging and myths

· 4 min read

The katana is probably the most recognisable sword in the world. Behind the silhouette there is a precise technology: a special steel, a forging method that combines hard and soft metal, and a clay-coated quench that gives the blade both its edge and its curve.

The katana in the WABUKAN weapons collection.
The katana in the WABUKAN weapons collection. WABUKAN illustration

From tachi to katana

The first curved Japanese swords appeared between the 10th and 12th centuries. These early blades, called tachi, were long and strongly curved, made for mounted warriors and hung from the belt with the edge facing down. From the 15th century onwards, as warfare relied more on infantry, a shorter sword worn thrust through the sash with the edge facing up became the norm. This is the katana: drawn and cut in a single movement, the basis of the arts of iaido and battodo. Paired with the shorter wakizashi, it formed the daishō, the "long and short" that marked the samurai class in the Edo period.

By convention, a katana has a blade (nagasa) longer than two shaku, about 60.6 cm; most measure between 65 and 75 cm.

The steel: tamahagane

Traditional swords start in the tatara, a large clay furnace fed for about three days and nights with iron sand (satetsu) and charcoal. At the end the furnace is broken open and a large bloom, the kera, is extracted. Its best parts are tamahagane, "jewel steel": an irregular material with varying carbon content and inclusions of slag.

Pieces of tamahagane, the steel produced in the tatara furnace.
Pieces of tamahagane, the steel produced in the tatara furnace. Author: Loulasedna · Licence: CC BY 3.0 · Wikimedia Commons

The smith sorts the pieces by hardness, flattens them, stacks them and welds them into a block. Then comes the famous folding: the block is heated, hammered out, cut and folded back on itself, usually around ten to fifteen times. The goal is not mystical: folding expels slag and evens out the carbon. Fifteen folds already produce tens of thousands of thin layers, which appear as a fine grain (hada) on the polished blade.

Hard skin, soft core

Many traditional blades combine two steels: a harder, higher-carbon jacket (kawagane) wrapped around a softer, lower-carbon core (shingane). The hard steel holds a sharp edge; the soft core absorbs shocks and reduces the risk of the blade snapping. Schools and periods used different arrangements, some more complex, with separate pieces for the edge and the sides.

The quench: curve and hamon

Once the blade is shaped, the smith covers it with a paste of clay, charcoal and stone powder, thick on the spine and thin on the edge. The blade is heated to the right colour, judged by eye in a darkened forge, and plunged into water. The thin clay lets the edge cool very quickly and become martensite, very hard; the spine cools more slowly and stays tougher.

Martensite takes up slightly more volume, so the edge expands and the blade bends backwards: a large part of the katana's curve (sori) is born in the quench. The boundary between the two structures is the hamon, the temper line, which each smith shapes with the clay: straight, wavy, like clove buds or rolling waves. Collectors study it as a signature.

Katana blade showing the groove (hi) and the temper line (hamon).
Katana blade showing the groove (hi) and the temper line (hamon). Author: Samuraiantiqueworld · Licence: CC BY-SA 3.0 · Wikimedia Commons

Polish and mounting

A finished blade is still dull and grey. A specialist polisher, the togishi, works it for days or weeks with a sequence of ever finer stones. Polishing reveals the hamon, the grain and the geometry; a bad polish can ruin a good sword. The smith's signature (mei) is chiselled on the tang (nakago), the part hidden in the hilt.

Other craftsmen make the fittings: the collar (habaki), the guard (tsuba), the hilt (tsuka) covered in ray skin and wrapped in braid, and the lacquered scabbard (saya). A small bamboo peg (mekugi) holds blade and hilt together, so that the sword can be dismantled for maintenance.

Full katana mounting (koshirae): scabbard, guard and hilt.
Full katana mounting (koshirae): scabbard, guard and hilt. Author: 国立文化財機構 · Licence: CC BY 4.0 · Wikimedia Commons

Myths worth forgetting

The katana today

In 1876 the Haitōrei edict banned the wearing of swords in public, ending the visible role of the samurai. After the Second World War, swords were confiscated by the occupation authorities, and Japan later created a registration system: traditional blades are registered as art objects by local education boards, and only licensed smiths may make them, under strict limits. In the dojo, practice is done with tools adapted to each art: the bamboo shinai in kendo, the wooden bokken in partner forms, the unsharpened iaitō in iaido, and real blades cutting rolled mats (tatami omote) only for advanced battodo practitioners.

To see the katana in the hands of history's most famous swordsman, read our article on Miyamoto Musashi.

Timeline

  1. 10th–12th c.First curved Japanese swords (tachi) appear.
  2. 14th c.Masamune works in Sagami; golden age of forging.
  3. 15th–16th c.The katana, worn edge-up, replaces the tachi.
  4. 1876Haitōrei edict bans wearing swords in public.
  5. 1958Japanese firearms and swords control law: registration required.

Related pages on Wabukan

kenjutsu iaido battodo kendo Profile: katana Profile: wakizashi Profile: tachi Profile: bokken

Sources

Original WABUKAN text, written from these cross-checked sources (facts, not sentences).

  1. Kōkan Nagayama, The Connoisseur's Book of Japanese Swords, Kodansha International, 1997
  2. Leon e Hiroko Kapp, Yoshindo Yoshihara, The Craft of the Japanese Sword, Kodansha International, 1987
  3. Tokyo National Museum — Japanese swords collection
  4. Wikipedia (EN) — Katana
  5. Wikipedia (EN) — Tamahagane

Images