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pansion of the iron trade in Scotland by his preparation of steel from bar-iron by a direct process, combining the iron with carbon, and by his discovery of the effect of manganese on steel.
Steel is the material of which the instruments of labour[Pg 16] are essentially made. Upon the quality of the material, that of the instrument naturally depends, and upon the quality of the instrument, that, in great measure, of the work. Watt's marvellous invention ran great risk, at one time, of being abandoned, for the simple reason that the mechanical capacities of the age were not 'up' to its embodiment. Even after Watt had secured the aid of Boulton's best workmen, Smeaton gave it as his opinion that the steam-engine could never be brought into general use, because of the difficulty of getting its various parts made with the requisite precision.
The execution by machinery of work ordinarily executed by hand-tools has been a gigantic stride in the path of material civilisation. The earliest phase of the great modern movement in this direction is represented, probably, by the sawmill. A sawmill was erected near London as long ago as 1663--by a foreigner--but was shortly abandoned in consequence of the determined hostility of the sawyers; and more than a century elapsed before another mill was put up. But the sawmill is comparatively a rude structure, and
the material it operates upon is easily treated, even by the hand. When we come to deal, however, with such substances as iron and steel, the benefit of machinery becomes incalculable. Without our recent machine-tools, indeed, the stupendous iron creations of the present day would have been impossible at any cost; for no amount of hand-labour could ever attain that perfect exactitude of construction without which it would be idle to attempt fitting the component parts of these colossal structures together.
The first impulse, however, to the improvement of machine-tools for ironwork was given by a difficulty born not of mass but of minuteness.
Up to the end of the last century, the locks in common[Pg 17] use among us were of the rudest description, and afforded scarcely any security against thieves. To meet this universal want, Joseph Bramah set his remarkable inventive faculties to work, and speedily contrived a lock so perfect, that it held its ground for many a day. But Bramah's locks are machines of the most delicate kind, depending for their efficiency upon the precision with which their component parts are finished; and, at that time, the attainment of this precision, at such a price as to render the lock an article of extensive commerce, seemed an insuperable difficulty. In his
dilemma, Bramah's attention was directed to a youngster in the Woolwich Arsenal smithy, named Henry Maudsley, whose reputation for ingenuity was already great among his fellows. Bramah was at first almost ashamed to take such a mere lad into his counsels; but a preliminary conversation convinced him that his confidence would not be misplaced. He persuaded Maudsley to enter his employment, and the result was the invention, between them, of the planing-machine, applicable either to wood or metal, as also of certain improvements in the old lathe, more particularly of that known as the 'slide-rest.'
In the old-fashioned lathe, the workman guided his cutting-tool by sheer muscular strength, and the slightest variation in the pressure necessarily led to an irregularity of surface. The rest for the hand is in this case fixed, and the tool held by the workman travels along it. Now, the principle of the slide-rest is the opposite of this. The rest itself holds the tool firmly fixed in it, and slides along the bench in a direction parallel with the axis of the work. All that the workman has to do, therefore, is to turn a screw-handle, by means of which the cutter is carried along with the smallest possible expenditure of strength; and even this trifling labour has been since
got rid of, by making the rest self-acting.[Pg 18]
Simple and obvious as this improvement seems, its importance cannot be overrated. The accuracy it insured was precisely the desideratum of the day! By means of the slide-rest, the most delicate as well as the most ponderous pieces of machinery can be turned with mathematical precision; and from this invention must date that extraordinary development of mechanical power and production which is a characteristic of the age we live in. 'Without the aid of the vast accession to our power of producing perfect mechanism which it at once supplied,' says a first-class judge in matters of the kind, 'we could never have worked out into practical and profitable forms the conceptions of those master-minds who, during the past half-century, have so successfully pioneered the way for mankind. The steam-engine itself, which supplies us with such unbounded power, owes its present perfection to this most admirable means of giving to metallic objects the most precise and perfect geometrical forms. How could we, for instance, have good steam-engines if we had not the means of boring out a true cylinder, or turning a true piston-rod, or planing a valve-face?'
It would perhaps be impossible to cite any more authoritative estimate of Maudsley's invention than the above. The words placed between inverted commas are the words of James Nasmyth, the inventor of that wonderful steam-hammer which Professor Tomlin-son characterises as 'one of the most perfect of artificial machines and noblest triumphs of mind over matter that modern English engineers have yet developed.'[Pg 19]
Nasmyth's Steam-hammer.
This machine enlarged at one bound the whole scale of working in iron, and permitted Maudsley's lathe to develop its entire range of capacity. The old 'tilt-hammer' was so constructed that the more voluminous the material submitted to it, the less was the power attainable; so that as soon as certain dimensions had been [Pg 20] exceeded, the hammer became utterly useless. When the Great
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Western steamship was in course of construction, tenders were invited from the leading mechanical firms for the supply of the enormous paddle-shaft required for her engines. But a forging of the size in question had never been executed, and no firm in England would undertake the contract. In this dilemma, Mr Nasmyth was applied to, and the result of his study of the problem was this marvellous steam-hammer--so powerful that it will forge an Armstrong hundred-pounder as easily as a farrier forges a horse-shoe, and so delicately manageable that it will crack a nut without bruising its kernel!
BESSEMER STEEL.
In 1722, Reaumur produced steel by melting three parts of cast-iron with one part of wrought iron (probably in a crucible) in a com-mon forge; he, however, failed to produce steel in this manner on a working scale. This process has many points in common with the Indian Wootz-steel manufacture.
As we have seen, to Benjamin Huntsman, a Doncaster artisan, belongs the credit of first producing cast-steel upon a working scale, as he was the first to accomplish the entire fusion of converted bar-iron (that is, blister-steel) of the required degree of hardness, in crucibles or clay pots, placed among the coke of an air-furnace. This process is still carried on at Sheffield and elsewhere, and is what is generally known as the crucible or pot-steel process. It was mainly supplementary to the cementation process, as formerly blister-steel was alone melted in the crucibles; but latterly, and at the present time, the crucible mode of manufacture embraces the fusion of[Pg 21] other varieties and combinations of metal, producing accordingly different classes and qualities of steel.
In 1839, Josiah Marshall Heath patented the important application of carburet of manganese to steel in the crucible, which application imparted to the resulting product the properties of varying temper and increased forgeability. He subsequently found out that a separate operation was not necessary to form the carburet--which is produced by heating peroxide of manganese and carbon to a high temperature--but that the same result could be attained by simply in the first instance adding the carbon and oxide of manganese direct to the metal in the crucible. He unsuspectingly communicated this after-discovery to his agent--by name Unwin--who took advantage of the fact that it was not incorporated in the wording of the patent, and so was unprotected, to make use of it for his own advantage. The result was one of the most remarkable patent trials on record, extending over twelve years, and terminating in 1855 against the patentee--a remarkable instance of the triumph of legal technicalities over the moral sense of right.
A very important development of the manufacture of steel followed the introduction of the 'Bessemer process,' by means of which a low carbon or mild cast-steel can be produced at about one-tenth of the cost of crucible steel.