October 2, 20241 yr Hi everyone, I’m working on making a katana using a high-carbon steel leaf spring, but I’ve encountered an issue. There is a hole in the leaf spring that I need to weld before proceeding. Since leaf springs are made of high-carbon steel, I know they can be tricky to weld without compromising the material’s integrity. I have an inverter-type welding machine. I am not using any forging, heating, or tempering processes. This project will be done "cold" without the use of a forge or heat treatment. What’s the best method for welding this type of steel without heat treatment to prevent the material from becoming too brittle or cracking after the weld? Should I use a specific type of filler material or electrode that works well with high-carbon steel in a cold working environment? How should I prepare the leaf spring before welding, and do I need to preheat it even if I’m not going to use a forge or do any further heating? Without heat treatment, what precautions should I take to avoid weakening the blade after welding? After welding, how should I cool the welded area? What methods are recommended for cooling high-carbon steel to minimize the risk of cracking? Is there a chance that the welded metal could become too soft after welding? If so, how can I mitigate this risk? Any tips for cold working with leaf spring steel when making a blade?
October 4, 20241 yr Welcome aboard Ihor. Where are you located, someone on the forum may live close enough for you to visit and learn how in person. What you describe won't produce a "Sword" you might as well use mild steel and polish it so it looks nice hanging from a wall. I don't believe there are any modern spring makers using high carbon for leaf springs. The ONLY thing that makes leaf spring useable for blades is heat treatment, hardening and tempering or it remains springy but too soft for a blade. To answer your original question. Don't use parts of a leaf spring in the blade, welding up the holes is a recipe for disaster without heat treatment. My best advice for making swords is, Learn to work steel to a basic level of proficiency before attempting making a blade. Your lack of knowledge of the most basic aspects of ironworking makes producing a successful blade an almost certain failure. Frosty The Lucky.
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