An occasional lecturer on swords, American Bladesmith Society certified Master Bladesmith Kevin Cashen of Hubbardston, Michigan is gaining recognition with his bold pattern-welded Viking style short swords ($900-2200) and long swords ($1,200-5,000). Less expensive models feature plain AISI 5160 steel. Upwards from that (featured in right photo) are the more expensive pattern welded steel versions.

The term "pattern-welding" is in reference to the Damascus pattern that has won much endearment because of the beautiful etches and topographies created by differing alloy layers within the steel. This style in the mid-Dark Ages (600 A.D. to 1000 A.D.) came about almost by accident. Historically, the Vikings and Germanic tribes worked iron ore into smaller workable rods, then would enclose the iron billets with a carbon-bearing material (carbonization of iron creates steel) and place the rods into the forge. Whether it was for spiritual reasons or otherwise, the Vikings would use bones for the carbon-bearing material, not knowing that the high phosphorus content in bones contributed to the differing alloy layers that resulted in the high contrast in the pattern welding that we love today. After the carbonization process, the Vikings would twist the rods together and re-hammer them out into the form of a blade.

(The reason for the twisting is that earlier style Celtic blades, for example, were not twisted but were forged straight, and thus had a tendency of literally coming apart when the blades were highly impacted.)

Cashen recently won a "Best Custom Straight Knife" award at a recent knife show in Wisconsin, which is ironic, because the award-winning blade was a short sword!

Depending on the type of sword (Cashen also fashions medieval long swords and katanas) for the short swords Cashen crafts wooden scabbards wrapped with calf or kid (goat) skin. The wood used varies (bass and poplar), but nothing that is very resinous or acidic because those qualities attack the blade steel. He uses an oil-charged felt lining on the inside of the scabbard to oil it each time you insert the blade. (Oiling swords is a rust-prevention measure necessary for high carbon steel swords). "Oiling," says Cashen, "for some reason really brings out a beautiful appearance in Damascus steel. It creates a very attractive contrast."

Now equipped with a special salt-bath control system, Cashen is now able to perform extremely accurate heat treating. Says Cashen, "There are may sword manufacturers that market their swords, saying they are made of all these great kinds of steel. But despite the steel, it's really all in the heat treat." Many swords are heat treated in batches, and though made of the same 5160 steel, Cashen's attention to detail in heat treating can result in a sword that will out-perform his competitors. "AISI 5160 (.55-.60% Carbon content), by technical composition," indicates Cashen, "should not be able out-cut a AISI 1095 (.95% Carbon content)." However, Cashen's swords have cut better than factory-produced 1095 blades. All this is in virtue of the care he takes in the heat treating process.

Cashen attempts to accomplish shock resistance in his pattern-welded blades by using L6 steel, which also gives the patterns a beautiful high contrast due to its nickel content. "It's a fantastic sword steel to work with, but you have to play by its rules in the heat treat!"

Are you a Highlander fan, Kevin? Cashen chuckles. "I spend a lot of time debunking a lot of Hollywoodizing on swords and steel, especially when they go edge to edge. But it's actually my secret vice!" Cashen relates that he's a secret closet-Highlander-fan! "The show has done an excellent job at reviving an interest in swords." Often times at lectures, Cashen will dispell inaccurate illusions created by Hollywood shows. But after the lectures, he has been known to talk to his Highlander-fan friends and say, "Hey, did you catch that episode last night? Wasn't it great?"

Sword Gallery of Kevin Cashen

Viking Sword
Rapier
Broadsword