Iron shackles

“ Prescott, “just remember three things: fuel, blast, and hammer—power, of course, behind the hammer. It’s the different variations that men have been making on those three things that have brought iron where it is to-day.
“Iron ore has so many things besides iron in it that the problem has always been how to get the impurities out.
“The old blacksmiths used to put it in the fire and hammer it; put it back in the fire and hammer again, until they worked most of the other things out. They made what is called forge iron. ”

“ They use that for what they call a flux. That unites with the waste things, the ashes of the coke and any sand that may have stuck to the pig iron. Those things together make slag. The slag is so much lighter than the iron that it floats on top, and there are tap holes in the cupola where they draw it off. Limestone helps the iron to melt, that’s another reason why they use it.”
“I saw some scales,” said Billy.
“Those,” said Uncle John, “are to weigh the things that they put into the cupola. ”

“ Pig-iron, or, as it is sometimes called, crude iron, being saturated with carbon and oxygen, and containing also a portion of scoria, is too brittle for any other purpose than castings. Many of these, such as stoves, grates, mill-irons, plough-irons, and kitchen utensils, are commonly manufactured at blast furnaces, and in many cases nearly all the iron is used for these purposes. In such cases, the metal is taken in a liquid state, from the hearth, in ladles. ”

“ With such a volume of weakening constituents and particularly with the graphite flakes cutting through and separating the iron grains as the photomicrographs show, can one wonder that cast iron is fragile—more so than steel or wrought iron? ”

“ If enemies stand around in groups, they make the iron easy to break.
“When we want steel for chisels, for example, we invite Tungsten to come in; when we want certain parts for automobiles we call in some Vanadium pygmies.”
“So,” said Mr. Prescott, “while we need the giants to make the pig iron, the real value of the iron and steel depends on the pygmies.”
“That’s about the size of it,” said Mr. Farnsworth.
“Anything the trouble with you, young chap?” asked Dr. Crandon. “You haven’t spoken for ten minutes. Feel bad anywhere?”
“No,” answered Billy. ”

“ Why iron has been regarded as a scarer of demons has been much debated. Natives of India will tell you that it is the material out of which [12] weapons are made, and that an armed man should fear nothing. Others say that its virtues depend on its black colour, which, as we shall see, is obnoxious to evil spirits. Mr. Campbell22 thinks the explanation may be that in all cases of swooning and seizures iron is of great value, either applied in the form of the cautery or used as a lancet to let blood. The real reason is probably a very interesting survival of folk-thought. ”

“ Massy bars of hot iron are the heavy tools they handle, cylinders of the first magnitude the enormous weights they heave, vessels full of melted metal the dangerous loads they carry, streams of the same burning fluid the fiery rivers which they conduct into the deep cavities of their subterraneous moulds, and millions of flying sparks with a thousand drops of liquid, hissing iron, the horrible showers to which they are exposed. ”

“ Crandon, “from fishing ore with tongs.”
“We’ve moved along a great way since that time,” said John Bradford, “and most of our progress has been due to iron.”
“Giants don’t do all the work even now,” said Mr. Prescott. “They make short work of iron mountains and surface deposits, but most of them are too large to work underground; though we mustn’t forget that Giant Electricity works down there with the men.
“Giant Gravity helps too, for, when they work below the deposit, he caves the ore down. ”

“ But just as the chemist will tell you that there are no substances which are absolutely insoluble, just so does cast iron appear to be extremely brittle only when compared with the iron alloys of considerably less brittleness. ”

“ But the working door of a puddling furnace is the door through which the puddler does his work. It is a porthole opening upon a sea of flame. The heat of these flames would wither a man's body, and so they are enclosed in a shell of steel. Through this working door I put in the charge of “pigs” that were to be boiled. These short pieces of “mill iron” had been smelted from iron ore; they had taken the first step on their journey from wild iron to civilized iron. There isn't much use for pig-iron in this world. You've got to be better iron than that. Pig-iron has no fiber ”

“ Like everything else in the world of iron and steel, these blast-furnaces have undergone revolutionary improvements during the past quarter of a century. From being most dangerous and destructive structures causing frightful loss of life and producing only about one ton of iron a day for every man working about them, as formerly, they have now become relatively harmless monsters, capable of turning out six times that quantity of ore for each man employed. ”

“ When this ignition has overcome the acquired polarity, and it has been now completely subdued and not awakened again, that iron is left unsettled and utterly incapable of direction. But we must further inquire how iron remains affected by verticity. It is manifest that it strongly affects and changes the nature of the iron, because the presence of a loadstone attracts the iron to itself with an altogether wonderful readiness. ”

“ That is, as soon as a vessel costing millions of dollars leaves the docks, she enters into active competition for a place on the junk pile."
The greatest improvement that can be imagined in the iron situation will be in the discovery and use of alloys or mixtures of iron with other materials. Steel, the strongest of all forms of iron, is an alloy of iron and carbon, and for various purposes these are further mixed with nickel and silicas. Many other alloys have been discovered within the last few years, and each makes possible new uses for iron requiring greater strength. ”

“ Prescott. “Heat expands iron. If we didn’t keep it cool, the screw wouldn’t be the right size when it is done.
“Cold naturally works the other way. Ever hear about the iron bridge where the parts wouldn’t quite come together, so they put ice on to do the job?” he asked, but he kept right on, without waiting for Billy to answer.
Billy saw other machines boring holes and rounding corners. It seemed as if iron could cut iron into any shape that anybody wanted. ”

“ Plunging it suddenly in cold water is apt to render the metal brittle. In the purchase of all iron fittings for either waggon work or horse equipment, about which we shall have more to say as our work proceeds, insist on seeing it, without paint or varnish, bare from the forge, as you can then see that there are no hollows, cracks, or defects in it. It is wonderful what a number of shortcomings a good thick coat of coal-tar will cover when laid on over the hot metal. Avoid malleable cast iron as you would a broken limb. It cannot be bent without the danger of nipping off short. ”

“ Amongst recent writers there are some who in cases of drought of the liver prescribe, as a much lauded and famous remedy, the electuary of iron slag, described by Rhazes in his ninth book ad Almansorem, Chap. 63, or prepared filings of steel; an evil and deadly advice: which if they do not some time understand from our philosophy, at least everyday experience, and the decline and death of their patients, will convince them, even the sluggish and lazy. Whether iron be warm or cold is variously contended by many. ”

“ For it is the sulphur and phosphorus that make the iron brittle. And brittle iron might as well not be iron at all; it might better be clay. For a good brick wall is stronger than a wall of brittle iron. Yet nature will not give us pure iron. She always gives it to us mixed with the stuff that weakens it—this dross and brimstone. Nature hands out no bonanzas, no lead-pipe cinches to mankind. Man must claw for everything he gets, and when he gets it, it is mixed with dirt. And if he wants it clean, he'll have to clean it with the labor of his hands. ”

“ In 1854 I took out a patent for puddling iron by means of steam. Many of my readers may not know that cast-iron is converted into malleable iron by the process called puddling. The iron, while in a molten state, is violently stirred and agitated by a stiff iron rod, having its end bent like a hoe or flattened hook, by which every portion of the molten metal is exposed to the oxygen of the air, and the supercharge of carbon which the cast iron contains is thus "burnt out." ”

“ If the iron has too much or too little carbon it cannot be hardened at all; if there is too little it is very soft and malleable and is called “wrought iron”. If there is too much carbon it is harder than mild steel, but is very brittle indeed ”

“ The obvious reply to such an objection is, that iron is so liable to oxidation that most of the smaller iron articles of ancient times must have perished from that cause. Many of the small masses of rust-cemented gravel and earth, found everywhere, may have originally had for their nucleus an ancient iron implement, or a fragment of one. If it be allowed that the Picts or other early inhabitants of the north used iron tools and weapons, the question at once arises,—Where and how did they procure them? ”

“ Again, iron which has been excited by a loadstone, * if that iron on account of obstacles should not be able to turn round immediately in accordance with its nature, as happens with a versorium, is laid hold of, when a loadstone approaches, on either side or at either end. Because, just as it can implant, so it can suddenly change the polarity and turn about the formal energies to any part whatever. So variously can iron be transformed when its form is adventitious and has not yet been long resident in the metal. ”

“ Naber and Bérard, unlike Cauer and Helbig, give the obvious explanation that when iron came in, but its manufacture and the sharpening of it were ill understood, men would make heavy axes and other rural implements of iron, but would not trust their lives to iron weapons which were brittle or which "doubled up." ”

“ The famed ordeal by red-hot iron, also, has been a palpable swindle in the hands of the authorities. In India and Arabia the test is to lick the iron, which will burn the guilty tongue but not the innocent. ”

“ Billy looked at him questioningly.
“That was rather technical, wasn’t it, Billy? You see, I was talking to a technical man. Just between you and me, meteoric iron comes down from the sky, from what we call shooting stars. Sometimes large pieces are found. I suppose that much of it falls into the sea. It is the purest iron that has ever been found.”
“What about magnetic iron?” asked Dr. Crandon. “Where does that come from?”
“At the present time,” answered Mr. Prescott, “most of it comes from Sweden and Norway. It makes the best kind of steel. ”

“ The forge-blast was also worked for the most part by water-power. Where the furnaces were small, the blast was produced by leather bellows worked by hand, or by a horse walking in a gin. The foot-blasts of the earlier iron-smelters were so imperfect that but a small proportion of the ore was reduced, so that the iron-makers of later times, more particularly in the Forest of Dean, instead of digging for ironstone, resorted to the beds of ancient scoriae for their principal supply of the mineral. ”

“ Wrought iron is softer than cast iron, and, being pure iron, is more liable to be corroded by the action of the atmosphere and products of combustion of the powder; it possesses also considerable ductility. The tensile strength of wrought iron, which under the most favorable circumstances is double that of the best cast iron, depends on the character of the crystalline structure, and the manner of applying the tensile force, or in other words, wrought iron offers the greatest resistance to a force of extension when the structure is fibrous, and the force acts in the direction of the fibres. ”

“ First it must be mentioned that iron frequently contains injurious contaminations, sulphur, phosphorus, etc., and that it must have been very difficult for these primitive metallurgists to remove these contaminations, and to introduce the proper quantity of carbon into the iron. We must also consider that even a good, pure steel would be a useless product unless it was worked by a skillful and experienced smith. Finally, iron is much more rapidly destroyed by oxidation than bronze. ”

“ Crandon.
“He roars!” added John Bradford.
“And,” said Mr. Prescott, “even if he could be moved, he’s rather too valuable for a circus manager to buy, for he cost a million dollars. I really think he’s the most fearful thing ever made by man. The Germans, though, did a great thing for iron when they evolved the blast furnace.”
“Makes our cupola,” said John Bradford, as they stopped before the tall iron stack, “look very small.”
“Ours,” said Mr. Prescott, “is only a dwarf, but he does something like the same work; only here they put in iron ore instead of pig iron. Blast furnaces make pig iron.” ”

“ Primitive furnace for smelting iron ore.
Not many of us have ever seen iron, the pure metal, soft, ductile and white like silver. As soon as it is exposed to the air it veils itself with a thin film of rust and becomes black and then red. For that reason there is practically no iron in the world except what man has made. It is rarer than gold, than diamonds; we find in the earth no nuggets or crystals of it the size of the fist as we find of these. But occasionally there fall down upon us out of the clear sky great chunks of it weighing tons. These meteorites are the mavericks of the universe. ”