Coppersmith

“ The Coppersmith is a bird who makes a noise exactly like the beating of a little hammer on a copper pot; and the reason he is always making it is because he is the town crier to every Indian garden, and tells all the news to everybody who cares to listen. ”

“ The easy malleability of copper allows it to be rolled into thin sheets, which can easily be hammered into any form that may be desired, and it is this operation which belongs to the trade of the Coppersmith. ”

“ Those modern artists who specialize in providing those who furnish their houses in antique style with replicas of the domestic copper-work of a century or two ago, are very careful to produce their "modern antique" by the use of tools which produce precisely similar effects to the hammered-by-hand copper-work of days gone by. In the production of such work the repoussé enrichments are wrought by hand, the anvil still holding sway in the modern coppersmith's shop. Rarely is soldering used, the parts being riveted together. ”

“ Now, we know that copper is found in the mines in a state of such comparative purity as to require very little smelting for the purpose of being brought into a state fit for use, while, on the other hand, iron in its rough state looks more like a stone than a metal, and, moreover, before it can be worked at all, must be subjected to a difficult process of smelting by means of a very powerful fire. If we look at the question only on this side, we are forced to conclude, that copper must have been found and employed before iron. ”

“ The very great variety of purposes for which the metal called copper is used, renders it one of the most valuable productions of this country, and several very important manufactures would be incomplete without it, since it is the principal material of which many large vessels are formed, and is also largely employed as an alloy for other metals. Although the metal is sometimes found in a pure or native state, its most abundant ore is that known as copper pyrites, of which there are many kinds. ”

“ Copper may be separated, in a state of great purity, from ANTIMONY, ARSENIC, BISMUTH, LEAD, IRON, TIN, ZINC, &c., as it exists in bell-metal, brass, bronze, gun-metal, mosaic gold, and other commercial alloys, by fusing it in a crucible for about half an hour, along with copper scales (black oxide) and ground bottle-glass, or other like flux. The pure metal is found at the bottom of the crucible, whilst the impurities are either volatilised or dissolved in the flux. The proportions for refining commercial copper are, metal, 10 parts ”

“ Long before iron was known utensils and weapons for the chase and war were made of copper and copper tools have been found that were made by the ancients and tempered even as steel is tempered now, but the art was lost when iron came into use.
Copper is now largely used in the arts and trades as for the sheathing and bolts of ships, the conducting parts of electrical apparatus, in making alloys, such as bronze of which tin is the other metal. Copper is easily hammered and drawn but it is so tough that it is hard to saw and drill. ”

“ As copper does not, like iron, strike fire by collision, it has on this, as well as on some other accounts, been substituted for iron in the machinery which is employed in gunpowder mills. It is also made into water pipes, and sometimes into sash frames. Under the hammer it is capable of being beaten into thin leaves like gold. Copper wire is much employed by bell-hangers and other artisans. The filings of this metal are used for giving a green colour to some kinds of artificial fire-works. ”

“ The question however suggests itself whether metallurgy did not find its natural beginning there, as elsewhere, in the easy working of the virgin copper, and so intercalate a copper age between Europe’s stone, and its true Bronze Period. On this subject Dr. Latham remarks, in his Ethnology of the British Islands, “Copper is a metal of which, in its unalloyed state, no relics have been found in England. Stone and bone first; then bronze, or copper and tin combined; but no copper alone. I cannot get over this hiatus; cannot imagine a metallurgic industry beginning with the use of alloys.” ”

“ In 1862 David Wilson, following Proclus and Tzetzes, declares the process of hardening and tempering copper so as to give it the edge of iron or steel, a ‘lost art.’ Markham [165] supposes that the old Peruvians hardened their copper with tin or silica; and he erroneously believes that tin is scarcely found in that section of South America.
Modern archæological discovery has suggested that in many parts of the world we must intercalate an age of virgin Copper between the so-called Stone and Bronze Periods. The first metal, as far as we know, was the stream-gold, washed by the Egyptians ”

“ The demand for particularly pure metal in electrical and conductivity work therefore usually necessitates a further purification of the converter-copper (unless it be an exceptionally pure brand) and the production of metal specially free from the injurious constituents which persist to a small but sometimes very appreciable extent in the metal under the ordinary oxidising conditions. The presence of silver and gold in the copper may afford in many instances sufficiently good reason for a separating process independently of the market for the pure copper itself. ”

“ Modern methods in copper smelting and refining have effected enormous economy in time, space, and labour, and have consequently increased the world’s output. With pyritic smelting a sulphuretted copper ore, fed into a cupola in the morning, can be passed directly to the converter, blown up to metal, and shipped as 99% bars by evening—an operation which formerly, with heap roasting of the ore and repeated roasting of the mattes in stalls, would have occupied not less than four months. ”

“ The alloys of copper and tin may be decomposed by dissolving them in an acid, the muriatic for instance, and immersing a sheet of iron, which will precipitate the copper. The tin may then be separated by immersing a plate of lead, or zinc, by either of which metals, it will be precipitated.
Bronze, being a mixed metal, in which the copper forms the principal ingredient, is sometimes used in fire-works, in lieu of copper or brass; for its effects are similar. By the combustion of bronze filings, we have an oxide of copper and an oxide of tin. ”

“ The collector of copper and brass takes an interest in metal-work other than that which he can collect, and admires works of art with which the architects of olden times enriched their chief buildings. It is true a considerable portion of the exterior metal-work attached to the freehold, and of the gates and palasades surrounding the more important erections, are of iron. There are enough examples of copper-work, however, to show us the skill of the old craftsmen who worked on years after the Charter granted by James II to the Braziers' Company had become a dead letter. ”

“ Copper is used in small quantities as an alloy for gold and silver both in coinage and in plate, to give the requisite degree of hardness. Gold used for coins, or what is called standard gold, is formed of eleven parts of pure gold and one part of copper. Being a better conductor of electricity than any other metal, it is largely employed in the formation [299] of telegraphic wires; and, as it is not hard enough to strike fire with flint or grit, it is used in gunpowder mills and magazines instead of iron. ”

“ The copper was, no doubt, recognised as a malleable rock, differing from all others in its ductility, so that it could be fashioned, with the aid of a hammer-stone, to any desired form. By this means the ancient miners of Lake Superior provided themselves with the most suitable tools for their mining operations, and were probably the manufacturers of most of the widely diffused copper implements. But for general purposes, both of industry and war, American man had to be content with the more abundant chert, hornstone, and quartzite. ”

“ The poling of copper is an operation, the theory of which is involved in a great deal of mystery. Copper, when taken from the smelting furnace, is what is termed dry, that is, it is brittle, has an open grain and crystalline structure, and is of a purplish red colour. The following is the process by which it is refined, or toughened, by the process of poling. The surface of the melted metal in the furnace is, in the first place, covered with charcoal. ”

“ Best Select Copper.—For the production of copper alloys, such as best brass, etc., it is essential that the copper should be pure. The impurities which are present in ordinary tough copper, and which may be valuable for imparting strength to the material, have a very harmful effect when present in alloys. In the older Welsh process of manufacturing copper, a special method was employed for obtaining metal free from these impurities, especially arsenic and antimony. ”

“ A small United-States coin is termed a “nickel.”
Fig. 411.—Native copper.
Copper is the next metal we have to notice. It has been known for centuries. It is encountered native in many places. The Cornish copper ore is the copper pyrites. The fumes of the smelting works are very injurious, containing, as they do, arsenic and sulphur. The ground near the mines is usually bare of vegetation in consequence of the “smoke.” Sheet copper is worked into many domestic utensils, and the alloy with zinc, termed Brass, is both useful and ornamental. ”

“ A large furnace and a Bessemer converter, the pair capable of making a million pounds of copper a month from a low-grade sulphuretted ore, will not occupy a space of more than 25ft. by 100ft.; and whereas, in making metallic copper out of a low-grade sulphuretted ore, one day’s labour used to be expended on every ton of ore treated, to-day one day’s labour will carry at least four tons of ore through the different mechanical and metallurgical processes necessary to reduce them to metal. ”

“ The electrical industry is the largest consumer of copper. The manufacture of brass, bronze, and other copper alloys constitutes another chief use for the metal. Considerable quantities of copper sheets, tubes, and other wares are used outside of the electrical industry, as for instance in roofing, plumbing, and ship bottoms. Copper is also used in coinage, particularly in China, where it is the money standard of the working population.
The average grade of all copper ores mined in the United States in recent years has been about 1.7 per cent metallic copper. ”

“ If the copper be varnished, or covered with a coat of wax, they will not deposit themselves or go together at all; but where they find the clean surface of the metal, they at once not only settle, but fix and adjust themselves in their proper forms, building up as it were a metal structure, not eccentric or uneven, but forming a correct plate of new metal, so pure, so hard, and so free from defect or extraneous matter, that engravers prefer copper plates thus formed to any other for working upon. ”

“ THE SECOND CHALCITIC AGE OF ALLOYS [242] —BRONZE, BRASS, ETC.: THE AXE AND THE SWORD. The use of copper, I have said, would be essentially transitional; and the discovery of smelting one kind of metal would lead immediately to that of others and to their commixture. Moreover, when casting and moulding began to be a general practice, unalloyed copper difficult to smelt, and when melted thick, sluggish, and pasty, would not readily run without some mixture into all the sinuosities of the mould. ”

“ This alloy is very hard, and possesses qualities which make it more valuable for weapons and tools than the relatively soft metal copper. But we can hardly suppose that the first metal-workers discovered, immediately after they had learnt how to smelt metals, that a mixture of metals was more useful than a pure one. In point of fact, it is clear that in some places, at least, the age of bronze was preceded by a period when developing man used pure copper for his implements.
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Our word copper is derived from the name of the island of Cyprus, which is particularly rich in copper ores. ”

“ The uses of copper are numerous and important. When rolled into sheets, betwixt large iron cylinders, it is employed for the covering of houses, sheathing the bottoms of ships, and other purposes. As a covering for houses, copper is lighter than slate, but whether it be more durable has not been yet ascertained. The coppering of ships tends to facilitate their progress through the water, by presenting a smoother surface than that of wood, and not permitting shell animals to fasten to it as they do to wood. ”

“ The Nicholls and James Process.—Nicholls and James have applied, very ingeniously, well-known reactions to the refining of copper, raised to the grade of white metal. This process is practised by the Cape Copper and Elliot Metal Company. A portion of the white metal is calcined to such a degree of oxidation that when fused with the unroasted portion, the reaction between the oxygen in the roasted matte and the sulphur in the raw material liberates the metallic copper. The metal is so pure that it can be refined by a continuous operation in the same furnace. ”

“ The ordinary uses of copper are well known. In medicine, 3 or 4 gr. of the filings or powder were formerly given in rheumatism, and to prevent hydrophobia. Some of its salts are still used as astringents, emetics, and caustics. Its alloys are of great value. With zinc it forms BRASS; with tin, BRONZE, BELL-METAL, Gun-metal, and SPECULUM-METAL. White copper is formed by the addition of metallic arsenic, and German silver is a mixture of nickel, zinc, and copper. ”