About Aluminum Blades
1) Why Aluminum Blades?
Aluminum Blades have long been used as an alternative to steel in theaters martial arts training, and stunt performance - live and on film.
Aluminum's lighter weight allows performers to safely perform for longer periods of time with greater control and less fatigue. This not only improves performance, but safety as well.
Aluminum blades also provide greater safety through light weight as it allows their edges to be thicker and blunter while still weighing less. In the event something does go wrong and a blade makes contact with a performer, less weight spread over a larger area greatly reduces the chance of injury.
There are occasions where Steel might be preferable to aluminum. Steel is more durable and can be tempered so it remains strong while flexible (ideal for fencing for example). While aluminum can be made to flex safely it will yield and fatigue before steel.
2) How tough is Aluminum?
Aluminum (like steel) is not indestructible, and though our blades are designed for blade on blade contact, they are only intended to do so in a controlled manner: through choreographed sequences performed by individuals with specific stage combat training, or by martial artists with appropriate safety gear operating under controlled circumstances. These tools are not meant for hard, or uncontrolled impact or free sparring where impact force cannot be regulated.
Being softer than steel, Aluminum blades should never be used in contact with steel or any other material besides Aluminum. Any harder material, like steel, will dig into the aluminum and create a weak point which can lead to potentially dangerous failure.
The same damage can occur with repeated forceful impacts against aluminum as well. If an aluminum blade has received visible damage, you must have it inspected and potentially repaired by a professional. Damage to any metal blade can propagate underneath the surface undetected until sudden failure.
3) About Our Aluminum
We use 7075-T6 Aluminum - This is one of the strongest aluminum alloys available and is the industry standard for theatrical blades.
Many vendors, mainly in the martial arts, market their aluminum blades as "high strength" or "aircraft grade" aluminum. These terms imply that the material is particularly strong, however these are often used to refer to 6061 Aluminum. Not only is it one of the most common aluminum alloys, but it has half the strength of 7075.
This is what one of our blades does to a typical bar of "aircraft aluminum." Which would you rather have your sword made of?
Over time with normal use Aluminum Blades will show signs of wear.
This is an Elite Performance Katana, our thinnest katana, after seeing use in several filmed fight sequences:
On a properly ground edge of 7075 aluminum that has not been abused, there should only be small round dents, and not sharp jagged burrs as on the bar of 6061 above.
4) Care for your Aluminum Blade
Aluminum does not rust like steel, so does not need to be oiled. However, certain chemicals (and enough plain old water) can cause it to corrode. In all but the most extreme of situations aluminum corrosion should never be as harmful as to risk the integrity of an aluminum sword, but it may cause undesirable discoloration and texture.
Even when using proper technique and control the edges may wear over time. If the wear becomes too uneven or rough, peaks and edges that can catch against skin or fabric may form. In this case the edges may be simply burnished, or rubbed, against another blade (aluminum or even rounded steel) until these spots are removed or rounded. If more extreme action is required they can be sanded, or filed, likely requiring a progression of grits to get back to its original finish. - CAUTION Do not use traditional "grinding" wheels on aluminum as this could cause injury! - If you are unsure whether to use a particular tool on aluminum or not, please consult a professional.