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How isBlade SteelManufactured

Blade steel is manufactured with one of two methods: conventional steelmaking or the more modern powder metallurgy (PM). Both methods involve combining some or all of the chemical elements we mentioned in the previous section, but the process and outcomes look different. Here’s a quick overview.

CONVENTIONAL INGOT STEEL

POWER METALLURGY (PM)

Conventional steelmaking is called conventional for a reason: It’s been around long enough to become the standard.

To make conventional ingot steel, the metallurgist melts a carefully calculated mixture of iron, carbon, and alloying elements in a furnace. They then pour the molten concoction into molds to form ingots, which are hot- or cold-rolled to flatten and elongate them into usable forms. The rolling step refines the steel’s grain structure, enhancing its strength and toughness.

The steel is then subjected to controlled heating and cooling cycles. This heat treatment alters the steel’s microstructure, manipulating its hardness, toughness, and flexibility.

The process of forging powdered metal starts much like the conventional method—by adding alloying elements to the steel and melting it down. It’s then blasted with high-pressure gas to create droplets. Because the droplets are tiny, they cool down and harden almost instantly. They’re then atomized into a fine metal powder—hence the name powdered metal.

PM has an advantage over the conventional method. The elements are evenly mixed inside the grains, preventing a problem that’s common in conventional steel: uneven gaps that appear as you use and sharpen the blade. 

That’s why powdered metal steels usually outshine their conventional counterparts, offering more wear resistance, toughness, and consistency. You’ll often find powdered metal in the steel of high-performance knives—but superior steel does come at a higher cost.

Next: Stainless vs. Non-Stainless SteelThe CRKT Blade Steel Guide