"Masters on the Cutting Edge" article in Topeka Capital Journal On Master Smiths Steve Culver and Dan Petersen

Area residents create forge welded blades

By Carolyn Kaberline The Topeka Capital Journal December 11, 2010 - 3:06pm

Meriden resident Steve Culver deftly wipes the oil from the dagger's blade before immersing it in a ferric chloride solution. After placing the dagger in a vice on his work table, he and fellow knife maker Dan Petersen, of Auburn, watch the design on the Damascus steel blade begin to emerge.

"Damascus steel is named such because hundreds of years ago forge-welded blades were traded in Damascus," Culver explained. "In this time period, the steel smelting process was too crude to make good-quality high-carbon steel in large quantities. Knife makers of that era learned to forge weld together layers of high carbon and low carbon steel for knife blades."

In doing so, the early knife makers discovered that patterns could be created in the layers and soon began to do that solely for artistic effect, Culver said, adding that today's patterns welded on Damascus steel are made in much the same way.

"Modern pattern welded steel is made by forge welding together at least two steels that are chemically different," Culver said, noting that one steel will usually have chrome or nickel in it.

After the differing steels are stacked together in alternating layers, the entire stack is then heated to an almost molten state, removed from the forge and folded over on itself numerous times creating as many as 400 layers. Finally, the blade is heat-treated, then sanded to a smooth surface before the etching solution is applied.

"Since the materials used to make the blade are chemically different, the etchant erodes the steels at different rates and a pattern emerges. The blade is cleaned and then returned to the etchant. The process is repeated several times until it is ready for final finishing," he said.

As two of fewer than 140 practicing master knife makers in the world, Culver and Petersen have created patterns on Damascus steel many times. Culver, a full-time knife maker, has been making knives since 1989, while Petersen, who teaches at Washburn University, has been making them part time since 1978.

"I've liked making things ever since I was a kid," Culver said. "When I picked up a knife magazine and saw people making them, I was hooked." When Culver decided to make knives, he decided to work with a blacksmith and applied for a grant from the Kansas State Historical Society and Kansas Arts Commission. After receiving the grant, Culver worked under Valley Falls knife maker Jim Bevan. He also took a few classes at the Bill Moran School of Bladesmithing in Texarkana, Texas, to supplement what he already knew.

Petersen's interest in knife making came with a gift from his father. "My father and grandfather emigrated from Denmark," Petersen said.

"My grandfather was a blacksmith there, but it wasn't something he could make a living at in the late '30s. When I was 12, my dad gave me a knife he and my grandfather made. It was my first knife from a forge. After I went to school and earned a doctorate in psychology, I bought a forge and tools."

Both Culver, who primarily makes bowie knives, daggers and a few swords, and Petersen, who makes "pretty much the same thing," have knives they made scattered around the world. "These are basically art pieces that go to collectors," Culver said, adding that the knives are fully functional. "It's not uncommon to make a hunting knife, get $2,000 for it, and then have it used. Even if I make it for art, it must work." Petersen agreed: "I take most blades I make and use them before I finish them off."

Becoming a master knife maker recognized by the American Bladesmith Society is no easy task. The applicant first must be a member of the society for at least two years, then successfully complete a performance test administered by a master knife maker to become a journeyman smith. The performance test consists of rope cutting, wood chopping, shaving and bending. In addition, five more completed forged knives made of plain carbon steel must be submitted for judging. After successful completion of these tests and two years as a journeyman, an applicant can try for the title of master smith. Similar tests must be successfully completed using a pattern welded Damascus steel of at least 300 layers.

"Lots of people fail," Petersen said. "You can be off on one blade and be out. There can be no gaps between the handle and blade. The material and guard must be perfect."

While watching the pattern form on the blade in Culver's shop, the two discuss their current projects and the pros and cons of certain designs. "This is what happens when knife makers get together," Culver said. "We're always discussing ideas."

To make those discussions easier, the two are part of the Kansas Custom Knifemakers Association, founded in 2008 to promote the art of knife making and provide a forum for exchanging ideas and techniques. "We knew there were others out there making knives, but didn't know how many," Culver said.

Currently, membership is at 39 and includes one other master knife maker. "We get together every three months to have shop tours, seminars and to sit around and pick each other's brains," he added. "It's been a fun experience."

Carolyn Kaberline is a freelance writer in Topeka. She can be reached at [email protected].

Click for the Online article which has 6 photos: http://cjonline.com/...he_cutting_edge