Forging Carbon Steel Pans

Carbon steel pans are made from an alloy, or mixture, of iron and carbon. They are first stamped into a single sheet and then bent into shape. This process involves cutting and pressing the desired shape from sheets of carbon steel. The pans are then seasoned to achieve a non-stick performance.

Carbon steel composition

Carbon steel is a hybrid of stainless steel and cast iron, combining the best properties of each. It is composed of roughly 99% iron and 1% carbon, while cast iron typically contains 2-4% carbon. The higher carbon content in cast iron makes it more brittle, as the carbon clumps into lumpy carbides or forms graphite sheets, disrupting the grain of the iron. Carbon steel, on the other hand, has a more uniform grain structure due to its lower carbon content, making it stronger and more pliable. This allows carbon steel pans to be made lighter and more ductile.

The manufacturing process of carbon steel pans involves stamping and bending a sheet of the alloy into the desired shape, which results in a tougher and more lightweight material compared to cast iron. Carbon steel pans are known for their quick and even heat distribution, long-lasting durability, natural non-stick properties, lightweight construction, and versatility for various cooking methods. They can withstand temperatures up to 1000°F and can be seasoned to enhance their non-stick performance.

The composition of carbon steel, with its high iron content, contributes to its desirable characteristics. The uniform grain structure and the ability to freeze" the grain structure through mechanical processes further enhance its strength and pliability. This composition and manufacturing process result in a material that is highly sought-after by professional chefs and home cooks for its versatility, durability, and lightweight nature.

How carbon steel is formed

Carbon steel is an alloy, or mixture, of iron and carbon. It is made by stamping the alloy into a single sheet and bending it into shape. The metal is rolled between heavy rollers while hot, and then doused with cool water or oil to "freeze" the grain structure in its best configuration. This makes the metal stronger.

Carbon steel has a smaller ratio of carbon to iron than cast iron. Carbon steel pans contain only 1% carbon, whereas cast iron contains 2-4%. This lower amount of carbon makes carbon steel tougher, more lightweight, and less brittle than cast iron.

The process of forming carbon steel pans involves cutting and pressing the desired shape from sheets of carbon steel. This is similar to cutting cookies out of rolled-out cookie dough. This method of production makes carbon steel pans lighter than cast iron pans, but with similar performance.

Carbon steel pans are also treated with surface-hardening treatments, such as blue steel or black steel, to help prevent rust. These treatments leave the surface of the pan with a blue or black colour, rather than a shiny silver.

Blue steel vs black steel

Carbon steel pans are available in blue steel and black steel varieties. These pans are made from an alloy of iron and carbon, with carbon comprising approximately 1% of the mixture. The difference between blue and black steel pans is the result of a final treatment in the manufacturing process, which protects the surface before seasoning. This treatment leaves the surface of the pan looking blue or black rather than shiny silver.

Blue steel pans undergo a heat treatment that increases their durability and helps prevent rust and oxidation. This process is called annealing, which involves heating and then slowly cooling the metal. This treatment results in a "blue" colour. Blue steel pans are more expensive than black steel pans because of their corrosion resistance and because they look nice out of the box.

Black steel pans are treated with an oil treatment called seasoning, which gives them a dark colour. This treatment is relatively stable but can wear off over time or after cooking or cleaning with acidic ingredients. Black steel pans are also used industrially, typically for pipes.

Both blue and black steel pans will eventually turn black with use, which is normal and desirable as it indicates that a 'seasoned' surface is being built up. This 'seasoning' process involves repeatedly oiling, heating, and cooling the pan, which creates an effective non-stick cooking surface.

Carbon steel maintenance

Carbon steel pans are incredibly hardy and versatile, but they do require a little extra care to keep them in top condition. Here are some tips to keep your carbon steel pans well-maintained:

• Seasoning: Seasoning your carbon steel pan is essential. Seasoning creates a natural non-stick surface, protects the pan from rust and fills in any scratches. There are two main ways to season a carbon steel pan: in the oven or on the stovetop. For oven seasoning, preheat your oven to the same temperature as your oil's smoke point. Clean and thoroughly dry your pan, then add a few drops of a neutral, high smoke point oil or seasoning wax. Use a towel to rub the oil evenly inside the pan, then place it in the oven for an hour. Turn off the heat and let the pan cool before removing it. For stovetop seasoning, follow similar steps, heating the oiled pan over a low flame for a few minutes, then letting it cool.
• Cleaning: Avoid using dish soap or steel wool on your carbon steel pan, as these can damage the seasoning. Instead, wipe out excess oil with a paper towel or cloth. For more stubborn messes, use coarse salt and oil, rubbing it around the pan's surface to dislodge stuck-on food. Another method is to bring water to a boil in the pan, using a wooden spoon or spatula to scrape away food bits. Always dry your pan thoroughly after washing to prevent rust.
• Dealing with rust: If your pan does develop rust, don't panic! Simply scrub the rust off with steel wool and a paste of baking soda and vinegar. This will remove the rust, but it will also strip the seasoning, so be sure to reseason your pan after removing rust.
• Storing: Before storing your carbon steel pan, ensure it is completely dry to prevent rust. Hanging your pan is ideal, but if you need to stack it, place a dish towel or trivet inside to protect the seasoning.
• Cooking tips: Avoid using metal utensils that could scratch the seasoning. Carbon steel pans perform best when food is tempered (close to room temperature) before cooking. Preheat your pan over medium-low heat for 2-3 minutes, then add oil or butter and let it heat for 1-2 minutes before adding food. Avoid overcrowding the pan to prevent steaming and promote a crispy Maillard reaction.

Carbon steel advantages

Carbon steel pans are a popular choice for professional chefs and home cooks alike. Here are some of the advantages of carbon steel pans:

Durability

Carbon steel is a tough and durable material that can withstand high temperatures. With proper care, carbon steel pans can last a lifetime. The pans can withstand temperatures of up to 1000°F and are heat-safe up to 1200°F. The pans can also be re-seasoned an infinite number of times to maintain their coating.

Even Heating

Carbon steel pans heat up quickly and evenly, reducing the likelihood of hot or cold spots. This makes it easier to control the temperature and ensures your food cooks evenly.

Lightweight Construction

Carbon steel pans are made from an alloy of carbon and iron, with a smaller ratio of carbon to iron than cast iron. This makes carbon steel pans lighter and easier to manoeuvre than cast iron pans. For example, a 12” carbon steel skillet weighs around 4.5 pounds, while a cast iron pan of a similar size can weigh 5.8 pounds or more.

Versatility

Carbon steel pans can be used for a wide range of cooking methods, including stovetop cooking, braising, searing, sautéing, oven broiling, and baking. They can also be used on various heat sources, such as gas, electric, induction, grill, or open flame. The high heat resistance and responsiveness of carbon steel make it a versatile option for cooking a variety of dishes.

Non-Toxic

Carbon steel is a safe and non-toxic material for cooking. There is no risk of harmful chemicals leaching into food, even at high temperatures, making it a safer choice than some non-stick coatings.

Frequently asked questions