6. Combining Soft and Hard Steel

Katanas are made from tamahagane steel. It is produced by traditional Japanese smelting processes that result in layered steels with varying carbon concentrations, that are welded, folded, and hammered out to reduce impurities. A katana needs a sharp and hard edge. However, steel that is hard enough for a sharp edge is brittle, while softer steel that is not brittle will not take and retain a sharp edge.
Katana makers solved the dilemma by using four metal bars: a soft iron bar to guard against breaking, sandwiched by two hard iron bars to prevent bending, and rounded off with a steel bar to take the cutting edge. The result was a sword that had a hard enough blade with a sharp cutting edge. However, contra many a WWII tall tale, no katana was ever hard enough, or sharp enough, to cut through machine gun barrels.



