Metalworker

“ Wherever there is a stream with a fall, there is the grinding-wheel at work: and in hundreds of workshops the nicer labour of the artificer is fashioning the steel into every instrument which the art of man can devise, from the scythe of the mower to the lancet of the surgeon. The machinery that made the steel has called into action the skill that makes the file-cutter. No machine can make a file. ”

“ There is a great fascination, too, in standing near the furnace and watching the sparkling, hissing mass of metal being withdrawn by the crane, or seeing the heated bars removed from the oil forge and clapped quickly on the steel dies to be beaten into shape. No one can withstand the attraction of the steam-hammers; even those who have spent a lifetime in the shed like to stand and watch the stampers and forgers at work.
Forging and smithing are, without doubt, the most interesting of all crafts in the factory ”

“ Castings and Forgings.—There are two distinct ways of making the steel objects actually used in the arts, such as rails, gear wheels, guns, beams, &c., out of the molten steel made by the Bessemer, open hearth, or crucible process, or in an electric furnace. The first is by “steel founding,” i.e. casting the steel as a “steel casting” in a mould which has the exact shape of the object to be made, e.g. a gear wheel, and letting it solidify there. The second is by casting it into a large rough block called an “ingot,” and rolling or hammering this out into the desired shape. ”

“ To know these men you must see them at work; you must stand beside the open-hearth helper as he taps fifty tons of molten steel from his furnace, you must feel the heat of the Bessemer converters as you watch the vessel-men and the steel pourer, and above the crash and roar of the blooming mills you must talk with rollers and hookers, while five-and ten-ton steel ingots plunge madly back and forth between the rolls. ”

“ The felling of a tree would occupy a workman a month, unless helped by the destructive action of fire. Dwellings could not be built, the soil could not be tilled, clothes could not be fashioned and made, and the hewing out of a boat was so tedious a process that the wood must have been far gone in decay before it could be launched. It was a great step in advance to discover the art of working in metals, more especially in steel, one of the few metals capable of taking a sharp edge and keeping it. ”

“ Then the steam-hammer shed, in which nothing but forging is done, was a flourishing place. All the wheels for the engines and waggons, together with piston rods, driving gear, axles, and cranks, were made there. These are obtained elsewhere now, some in England and Scotland, and other parts from abroad. Steel has superseded iron in a great degree, too, being harder, tougher, stronger and cheaper. The combined skill of the chemist and scientist has simplified the manufacture of it, and it is to be obtained in large quantities. ”

“ Tools improved—from the simple metal bar through pick and shovel and candle, through drill and hammer and low explosive and acetylene, through Sullivan slugger and high explosive and electrics, through skoufer and rotary and burley and sourceless glow, to the complex gadgetry of today—but what, fundamentally, is the difference? Men still crawl, snake-like, to where the metal is. Men still, by dint of sheer brawn, jackass the precious stuff out to where our vaunted automatics can get hold of it. ”

“ Visit the iron works and see the powerful “steam hammer” moulding into form a mass of red-hot iron, many tons in weight; see the powerful and beautiful contrivances for rolling into plates, drawing into bars and wire, or cutting up this stubborn metal, and call it stubborn no more! See the powerful “locomotive” carrying along the trams hundreds of tons of goods at a rate that can hardly be equalled by the bird that flies through the air on its light pinions ”

“ There can be no doubt upon the mind of any mechanic or engineer, thoroughly acquainted with practical working in metals, that a good deal of what has been brought forward and affirmed, both by safe-makers and by burglars themselves (turned approvers) , as to the wonderfully-ingenious devices resorted to by the latter, by which, if we were to believe it all, nothing in the shape of steel or iron can possibly withstand ultimately the redoubtable powers of these people, is simply fiction—imaginary ingenuity utterly impracticable if tried. ”

“ In the steel industry the most skilled men are to be found in those trades actually engaged in the making and rolling of iron and steel—the melters, puddlers, shearmen, rollers, roughers, heaters, Bessemer blowers, etc. These men are paid upon a tonnage basis and generally receive considerably higher wages than the mechanical tradesmen—bricklayers, machinists, boilermakers, riggers, firemen, engineers, electrical workers, blacksmiths, etc., who build, maintain and generally operate the plants. It is among the favored tonnage trades that the Americans are especially intrenched. ”

“ A careful workman uses a steel die for only a short service before he returns it to the annealer, well assured that the metal, despite its seeming wholeness, has suffered severe internal strain at every blow, which, were no caution exercised, would soon reveal itself in fracture of the die, or ruined work. Facts of this kind, which every day confront the mechanic and engineer, convey a prophecy of the sensibility and memory which dawn with life. ”

“ The production of this metal by the original cause of all things, and its manufacture, are indispensable for the whole business of mankind. The blacksmith and manufacturer of iron and steel stand at the head of all other mechanics. If the productions of the former were to pass out of existence, that of the latter would inevitably become extinct and the farmer would have to abandon the cultivation of the earth, and the wheels of all the hydraulic works and manufacturing machineries whatever would cease to move. ”

“ Besides two huge furnaces for smelting the raw ore, there are upwards of thirty others for the washing, puddling, and treatment of the iron in its various stages; eighty forges, two iron founderies, and one of copper; one vast hall for the construction of boilers, another for fly-wheels, and all the portions of steam-engines, and a third for locomotives; [180] besides innumerable apartments for every other species of heavy machinery, rooms for designers and magazines of models. (The spinning, and other light machinery, is manufactured at another establishment at Liege.) ”

“ We have given these particulars of the advance in man’s knowledge of the metallurgy of steel and its results by way of illustration. A parallel story could be told of the metallurgy of copper and tin, and of a multitude of metals, nickel and aluminium to name but two, unknown before the nineteenth century dawned. It is in this great and growing mastery over substances, over different sorts of glass, over rocks and plasters and the like, over colours and textures, that the main triumphs of the mechanical revolution have thus far been achieved. ”

“ The even whirr of the power house increased it, and the shrieks of machinery gave it a streaky quality. There were staccato punctuations, of course, by the whistles, [Pg 119] and when a distant "blaw" came to me, I thought how loudly it drove into the ears of the hot-blast man, turning his wheel by a stove. But it was mostly the summed-up roar that occupied your head—an insistent thing, that made you excited and weary at the same time. The mills had been running for ten years; they always had a night-shift in Bouton.
It is easy to get excited about a steel-mill sky at night. ”

“ These, with the primitive hammer, formed the principal stock-in-trade of the early mechanics, who were handicraftsmen in the literal sense of the word. But the work which the early craftsmen in wood, stone, brass, and iron, contrived to execute, sufficed to show how much expertness in the handling of tools will serve to compensate for their mechanical imperfections. Workmen then sought rather to aid muscular strength than to supersede it, and mainly to facilitate the efforts of manual skill. ”

“ Thousands of tons of metal must pass through his hands in the course of a year, and the work is very hot and laborious. By the age of fifty the shinglers and forgemen are usually worn out and superseded at the forge. When they can no longer perform their duties at the steam-hammer they are removed from the manufacturing circle and presented with a broom, shovel, and wheel-barrow. Their wages are cut down to that of a common labourer, and thus they spend their few remaining years of service. ”

“ Railways were stretching their lines into the golden regions of the West; manufacturers of farm implements were calling for steel to be fashioned into tools to reap the rich crops of the wide prairie lands; inventors were each day evolving some new use for the metal. Was it any wonder then that steel became a world necessity and that the blast furnace became a philosopher’s stone that transmuted dull ore into precious gold? ”

“ And even this labour has now been got rid of; for, by an arrangement of the gearing, the slide itself has been made self-acting, and advances with the revolution of the work in the lathe, which thus supplies the place of the workman's hand. The accuracy of the turning done by this beautiful yet simple arrangement is as mechanically perfect as work can be. The pair of steel fingers which hold the cutting tool firmly in their grasp never tire, and it moves along the metal to be cut with an accuracy and precision which the human hand, however skilled, could never equal. ”

“ The vanner, as well as the jigger, will become an instrument of precision; and in combination with rushing appliances operated by cheap power in almost unlimited quantities it will materially assist in multiplying the world's supply of metals. This again will aid in promoting the further extension of machinery. Gold will be produced in greater abundance for what is called the machinery of commerce; and the base metals, particularly the new alloys of steel and also copper and aluminium, will be more largely produced for engineering and electrical purposes. ”

“ The artisans may be divided into two great [Pg 410] classes—the workers in metal, and those in wood; the former being employed in making locomotives' wheels, axles, springs, &c., and the latter in constructing the carriages. By far the greatest number of hands are employed in the former.
That our hasty inspection may begin at the beginning, let us peep at the foundry. Both brass and iron are east here, but to-day it is iron. The sandy floor is covered with moulds of all descriptions, and swarthy workmen are preparing them to receive the melted iron. ”

“ Some are spinning round swiftly, others sluggishly, some edgewise, some flatwise; but all are in motion, and all seem to be deliriously devouring great cakes of red-hot metal, with which they are being fed by some forty or fifty grimy workmen. Close to us are two great iron rollers revolving one over the other, and on either side of them are half-a-dozen workmen, who are passing and repassing an immense sheet of red-hot metal from one to the other through the wheels. The moment the metal is through, bang! ”

“ On the day he left, he went out the usual gate at the tempered after-work pace, walked the gravel path to the railroad embankment, and stopped for a moment to look back at the mill. He stood like a stone-pile on the embankment for a quarter of an hour, looking at the cluster of steel buildings and stacks. He had spent a life in them, making pipe, and I haven't a doubt this was the first time it came to him in perspective. From my own brief memories, I could guess at those fifteen minutes: pain, struggle, monotony, rough-house, laughter, endurance, but principally toil without imagination. ”

“ The story of railroading leads naturally to that of progress in iron and steel work generally, which has been extraordinary during the century. Of inventions in this direction perhaps the most notable is the Bessemer steel-making process, which converts iron into steel by the direct addition of the necessary quantity of carbon, and has had the important result of making steel cheaper to-day than iron was not very many years ago. In iron-working machinery the progress has been very great, and in no other field has the genius of the American inventor been more conspicuously displayed. ”

“ Some collectors very wisely follow up their researches after new treasures by investigating the methods of their production, and they even visit modern works where similar methods, although more advanced, are going on. Very interesting indeed is it to watch the molten metal as it is mixed and poured into moulds and made into pigs. To see the great rolling mills through which the bars [48] are passed, and to watch the hammering and drawing by the steam-hammer and powerful machinery, is an education which enhances the interest there is in the possession of finished goods—old and new. ”

“ Some manufacture nothing but axes; others make plane-irons and chisels, augers, saws, or carvers' tools. Others, again, make smaller instruments, such as table-knives, forks, pen-knives, scissors, and razors. There are also cutlers who manufacture nothing but surgical instruments.
2. The coarser kinds of cutlery are made of blistered steel welded to iron. Tools of a better quality are made of shear steel, while the sharpest and most delicate instruments are formed of cast steel. The several processes constituting this business may be comprised in forging, tempering, and polishing ”