[Geoff Freeman]

How does one go about putting inlay on the blade of a sword? Is it as simple as etching the pattern into the blade and soldering or otherwise adhering the inlay meterial (gold, bronze, etc.) into the etchings?

Thanks.

[Dan Crowther]

Most valleys left by etching aren't deep enough nor 'sharp' enough to take an inlay.

True inlays use a keyway cut formed with chisels so that when the softer metal is hammered into the valley it deforms and locks in place. The keyway looks something like this: (gotta love ascii art )

\ /
/__\

Now, you can also 'flow' the metal to achieve an 'inlay'. But this also requires a clean chiseled cut. Though the critical aspect here is the 'lip' material so the soft metal doesn't merely flow all over the place. Something like this:

__^ ^__
\ /
V

Flux the groove, place the inlay metal into it, and melt the inlay metal. Then you simply file the lip and any excess metal away.

Edited to try to correct ascii art

[Blaz Berlec]

It's not about inlaying a sword, but this article shows the basics. I don't think they messed with molten metal around a heat treated blade, that's why all the inlays are made with softer metals.

http://www.anvilfire.com/21centbs/armor/Norma..._index.htm