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Damascus steel is created by forge welding high carbon steel and mild steel in alternating layers. A blacksmith will often begin with five to seven layers of these steels. As each weld is completed, the billet is folded and welded again, doubling the number of layers of steel. This process is repeated until the desired number of layers is achieved.
Next the billet may be flattened, twisted, drilled, and ground to form patterns in the layers of steel. This step if followed by shaping, grinding and polishing.
The final step is to etch the piece in acid. This process causes the mild steel to turn a darker color, making the pattern in the steel visible.
Ladder patterns are created by grinding parallel lines in the billet before it is flattened, shaped, and ground. This technique results in stripes that resemble the rungs of a ladder along the knife's blade

A Star pattern is created by hammering the billet into a square bar. Next the bar is twisted, then hammered to shape. This technique results in square stars along the knife's blade.

Mosaic Damascus is created by assembling shaped metal into a picture. The assembled pieces are forge welded and drawn out into a billet. This technique is difficult to do because the first forge weld can destroy the image if the weld is not executed properly.
