Hanwei Quality Swords

If you are not familiar with Hanwei swords made by Paul Chen, here is a summary. These are likely the best brand of professional swords made today. Fully functional and battle-ready, this line of swords is highly sought after by professionals who use swords.

Why are Hanwei Japanese swords so special?
Hanwei follows strict guidelines for blade geometry and surface finish to determined the correct design that will match the intended function. Heavy cutting, fast cutting and multiple use and Iaito all require different geometry in terms of length, weight, balance, curvature, procussion point and finish. The quality of Hanwei fittings are also given equal detail and craftsmanship. All of these factors are considered from forging to final polishing. Samurai swords by Hanwei are now regarded as state of the art, and offer the martial artist and collector an unparalleled opportunity to own a fine quality sword.

A Brief History

Today, the names Hanwei and its founder, Paul Chen, engender an image of fine functional swords and historical weaponry. Based in Dalian, China, Hanwei manages to combine traditional craftsmanship with modern tooling and metallurgy, in a way that enables it to supply a world–wide market while meeting or exceeding the quality of custom-made products.

Paul Chen grew up in Taiwan where, as a young man, he developed an ongoing fascination for swords and knives. Largely unable to afford antique and custom–made pieces he became a custom maker himself, enjoying success in this field in both Asia and the U.S. In 1991 he decided to become a full–time manufacturer and moved to Dalian, the "Steel City" of northern China, where he knew that he could find talented artisans capable of being trained as first–class sword and knife makers.

Early endeavors largely took the form of making knives and components for major knife companies, but by 1993 the company was ready to start trading under its own banner and Dalian Hanwei Metal Co. Ltd. (Hanwei) was formed. The early trainees became team leaders and then departmental managers as the company grew, forming a strong team at the core of operations.

Early Hanwei sword experience was with Samurai swords, which still remain the cornerstone of the product range. A little–known facet of the company's business is its Samurai sword restoration facility, where, over the years, many damaged and neglected pieces from the old masters have been restored to their former glory. The company has gained a tremendous base of knowledge in construction and metallurgical techniques from these historical pieces, and has employed this knowledge to consistently enhance the quality and authenticity of its own swords. Samurai swords by Hanwei are now regarded as state of the art, and offer the martial artist and collector an unparalleled opportunity to own a fine quality sword.

With assistance from its distribution partners, Hanwei started to introduce European–style swords into its line in the mid-1990s. These swords rapidly gained popularity with collectors, re–enactors and historical fencers throughout the world and the line expanded rapidly to cover the diverse needs of this market. At the same time Hanwei started to expand its line of knives which also have a historical flavor; as evidenced by the popular line of antique Bowie knife replicas.

A move to a large, purpose-built facility in 2002 provided much-needed space and improvements in efficiency. Today, three hundred plus Hanwei employees produce over six hundred items in the sword, knife and historical weaponry fields and are continuously developing new products involving more complex techniques and advanced metallurgy.

Today the son of Paul Chen, Ron, is carrying on the traditions and becoming very much a part of the Hanwei story. Ron, who has studied under Japanese legend Yoshindo Yoshihara, is the driving force behind the Hanwei Tamahagane and Bainite blade development. His own blades illustrate his deep appreciation for the art of the Japanese sword and are sure to become collector pieces.

SECRETS OF HANWEI STEEL:

Tamahagane Steel
Sword Samples

Paper Crane Katana (SWD5423–K)
Paper Crane Wakizashi (SWD5423–W)

Tamahagane steel is made by building and firing a Tatara, the traditional Japanese sword-steel smelter. This charcoal-fired furnace produces a very pure steel from iron sand, and this steel "Kera" or bloom can be broken and separated into high– and low–carbon pieces, which respectively form the "skin" steel and "core" steel of the blade. The skin steel is forged and folded repeatedly, to remove slag inclusions and voids and is then wrapped around the core steel before the resulting billet is forged into a blade. Careful heat treating, shaping and polishing reveals the tight "Hada" or layer pattern of the blade and the white particles of the "Hamon" or temper line. While this process results in the aesthetic qualities much admired by collectors it also produces a very functional blade, as the high carbon content of the skin steel makes a very hard edge possible while the softer core steel gives the blade its resilience and ability to absorb shock.

The steel is smelted in the traditional Tatara furnace creating a 'Kera' or bloom of raw steel. This bloom is broken into pieces by hammering and the pieces are separated visually by an accomplished smith, who can determine carbon content of each piece by its appearance.

Pieces of high carbon steel are selected for forming a billet of skin (outer layer) steel while pieces of lower carbon steel are selected for forming a core (inner layer) steel billet. The high carbon skin steel, when differentially quenched, will form a very hard edge while the lower carbon core steel will be softer, providing resilience to the blade and supporting the hard edge.

The pieces of high- and low-carbon steel are flattened and formed into separate stacks, ready for forming into billets.

Each stack is then covered in burnt straw; which aids in the forging process, and then forged into individual high- and lower- carbon billets.

The outer skin steel is folded multiple times to remove slag inclusions and voids. The repeated folding produces a fine Hada (grain pattern) when the blade is finally polished.

The folded skin steel is then wrapped around the softer core steel billet and forged into a blade. The blade is then ready to be differentially quenched, using the traditional clay method, polished, and mounted.

L6 / Bainite Steel
Sword Samples

Praying Mantis Katana (SWD5429)

Bainite is a structure of high-carbon steel that combines great strength with excellent flexibility and shock absorption characteristics. It has been known as an exemplary Katana blade component for a number of years but its use has been restricted to a few top-class master smiths, due to the difficulties involved in performing the exacting heat treatment procedures necessary for the production of a Bainite blade body in combination with the very hard Martensite Yakiba (edge section) required for Katana blades.

Performance Series Katana

Click below to view our selection of Performance Series swords:

Iaito
Elite
XL
XL Light

Our Performance Series Katana are the culmination of years of study, trial, and error into the optimum blade designs for today's martial artists. Four distinct variations are available, each optimized for a particular discipline or cutting application. The Iaito is an unedged training blade, available in three different lengths, for use in drawing practice and Kata. Its correctly-weighted and balanced steel blade prepares the student for advanced work with live blades. The blade geometry and physical characteristics of each of the Tameshigiri (cutting practice) blades are tailored towards different targets. The Elite Katana's blade is a little wider and a little thicker than its traditional counterpart, allowing for easier cuts on normal targets, while that of the Katana XL is significantly wider , for use in cutting heavy targets. The Katana XL Light has the XL profile but is provided with Bo-hi, reducing the weight to the point where double cuts are possible but clean cuts on heavier targets may still be made.

Iaito: Frequent Drawing Practice
— These unedged training blades provide for safe drawing for the beginning practitioner of the 450 year old art of Iaido. Forged from stainless steel the tempered blades are not only maintenance-free but more importantly provide the correct weight and balance needed for the rigors of repetitve drawing and sword motion practice. Each blade has a deeply cut groove (bo-hi) to provide audible feedback when swung properly.

Elite Katana: Frequent Cutting / Advanced Drawing Practice
— Our Katana Blades embody the classical design elements of the most prolific sword design in history. With their strong Shinogi Zukuri shape that accentuates the differential heat treatment, these blades are traditionally proportioned to appeal to the collector but they will also perform well in general cutting of hard or soft targets.

XL: Heavy Competitive Cutting
— Designed strictly for competitive cutting, our XL Katana blades incorporate the geometry, strength, weight and profile needed for successful cuts on substantial targets. Featuring differential heat treatment and a narrow edge angle, these wide blades will reward good technique with clean cuts and excellent durability.

XL Light: Competitive Cutting / Light Weight
— The XL Light blades feature the same geometry as those of the XL but incorporate deeply cut grooves (bo-hi) to reduce the weight of the blade while retaining most of it's strength and cutting ability. This weight reduction makes for a quicker sword, well adapted for multiple cuts in lighter targets.

Monosteel Katana Construction
This is a quick outline of the many steps involved in creating a high quality monosteel (non-folded) Katana blade construction:

Rough Forging: The blade is formed by hot forging a billet of high-carbon steel. The repeated hammering provides an even dispersion of carbon throughout the steel for uniform strength of the finished blade.

Rough Shaping: The scale is removed and the blade is shaped roughly to the required dimensions. At this stage, the steel is still in the annealed (soft) state and the blade is straight.

Clay Covering: A special clay is applied to the blade by hand, using a thin covering near the edge and a thicker layer over the rest of the blade. This results in a relatively quicker cooling of the edge during quenching, producing a hard edge and softer back.

Quenching: This is a critical part of the operation. The blade, with its clay covering, is heated to a predetermined temperature and quenched in a water bath. The shape and continuity of the hamon, the sori (blade curvature), and blade straightness are all determined by the care and skill exercised in quenching.

Sizing: The sori is adjusted if necessary, to set the point of balance and point of percussion, and the blade is de-scaled. Rough polishing is carried out to size the blade accurately. The habaki (blade collar) is fitted.

Finishing: Careful final polishing and fine finish work are carried out on the various surfaces to define ridgelines and bring out the beauty of the hamon.

Furniture Construction:

Saya: The saya is carved from two pieces of wood to match the length, width, thickness and curvature of the finished blade. The two halves are then wrapped in cambric and lacquered numerous times. Final polishing gives the saya finish a high gloss.

Tsuka: The handle core is comprised of two pieces of hardwood carved to tightly fit onto the tang. Channels are carved into the sides to facilitate the fitting of two panels of ray skin. The entire handle is then wrapped with high quality woven cotton or silk, depending on the sword being fitted, while small paper triangles are used to help shape the wrap correctly. The Menuki and Kashira are added during this process.

Sageo: The sageo is typically woven of high quality cotton or silk to match the handle wrap. In some cases, the sageo is still woven by hand (see Paper Crane). This process requires many hours of skilled hand labor but allows thematic designs to be worked into the sageo.

Assembly: Finally all the pieces can be assembled and the handle securely fastened to the tang. This is accomplished by drilling the handle and the tang together in two places and inserting bamboo pegs (mekugi) to pin the handle to the tang.

The Parts of a Katana:

Note: Real Armor of God.com is a Preferred Partner and authorized dealer for all Hanwei (Paul Chen) rapier swords, katanas, medieval swords and all other Hanwei-Paul Chen products. The images and text used herein are copyrighted and trademarked by CAS Iberia, Inc. Used by permission. All rights reserved.

If you have any questions about our products or would like to have us carry something you did not see here today, contact us and we will see what we can locate for you.

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