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How to make a clay-tempered Samurai Sword?

Applying the differential hardening process allows a swordsmith to give the blade’s edge flexibility while maintaining hardness and sharpness.

Firstly, heat the clay-coated katana blade in the furnace and plunge the glowing red blade into a cold pool of quenching liquid (either water or oil). Because of the clay insulation, the spine cools slightly slower than the exposed edge, resulting in two distinct metal structures.

Through rapid heating and quenching, the spine and cutting-edge cool at different rates, making the cutting edge extremely hard and the spine durable and flexible.

The blade is slightly heated to relieve certain internal strains once the clay has been removed. If the blade survives,  it will become a live blade, and Swordsmith will do hand polishing.

Through polishing, you can see the difference between hard and soft metal since there is a visible temper line on the blade, also known as the Hamon. These tempered steel blades are robust enough to resist battle stress while providing improved shock absorption.