THE MUSKET BARREL
The fundamental, and altogether the most important operation in the manufacture of the musket, is the formation of the barrel; for it is obvious, that on the strength and perfection of the barrel, the whole value and efficiency of the weapon when completed depends. One would suppose, that the fabrication of so simple a thing as a plain and smooth hollow tube of iron, would be a very easy process; but the fact is, that so numerous are the obstacles and difficulties that are in the way, and so various are the faults, latent and open, into which the workman may allow his work to run, that the forming of the barrel is not only the most important, but by far the most difficult of the operations at the Armory – one which requires the most constant vigilance and attention on the part of the workman, during the process of fabrication, and the application of multiplied tests to prove the accuracy and correctness of the work at every step of the progress of it, from beginning to end.
The barrels are made from plates of iron, of suitable form and size, called scalps or barrel plates. These scalps are a little more than two feet long, and about three inches wide. The barrel when completed, is about three feet six inches long, the additional length being gained by the elongating of the scalp under the hammer during the process of welding. The scalps are heated, and then rolled up over an iron rod, and the edges being lapped are welded together, so as to form a tube of the requisite dimensions – the solid rod serving to preserve the cavity within of the proper form. This welding of the barrels is performed at a building among the Middle Water Shops. A range of tilt hammers extend up and down the room, with forges in the centre of the room, one opposite to each hammer, for heating the iron. The tilt hammers are driven by immense water-wheels, placed beneath the building – there being an arrangement of machinery by which each hammer may be connected with its moving power, or disconnected from it, at any moment, at the pleasure of the workman. Underneath the hammer is an anvil. This anvil contains a die, the upper surface of which, as well as the under surface of a similar die inserted in the hammer, is formed with a semi-cylindrical groove, so that when the two surfaces come together a complete cylindrical cavity is formed, which is of the proper size to receive the barrel that is to be forged. The workman heats a small portion of his work in his forge, and then standing directly before the hammer, he places the barrel in its bed upon the anvil, and sets his hammer in motion, turning the barrel round and round continually under the blows. Only a small portion of the seam is closed at one heat, eleven heats being required to complete the work. To effect by this operation a perfect junction of the iron, in the overlapping portions, so that the substance of iron shall be continuous and homogeneous throughout, the same at the junction as in every other part, without any, the least, flaw, or seam, or crevice, open or concealed, requires not only great experience and skill, but also most unremitting and constant attention during the performance of the work. Should there be any such flaw, however deeply it may be concealed, and however completely all indications of it may be smoothed over and covered up by a superficial finishing, it is sure to be exposed at last, to the mortification and loss of the workman, in the form of a great gaping rent, which is brought out from it under the inexorable severity of the test to which the work has finally to be subjected.
RESPONSIBILITY OF THE WORKMEN
We say to the loss as well as to the mortification of the workman, for it is a principle that pervades the whole administration of this establishment, though for special reasons the principle is somewhat modified in its application to the welder, as will hereafter be explained, that each workman bears the whole loss that is occasioned by the failure of his work to stand its trial, from whatever cause the failure may arise. As a general rule each workman stamps every piece of work that passes through his hands with his own mark – a mark made indelible too – so that even after the musket is finished, the history of its construction can be precisely traced, and every operation performed upon it, of whatever kind, can be carried home to the identical workman who performed it. The various parts thus marked are subject to very close inspection, and to very rigid tests, at different periods, and whenever any failure occurs, the person who is found to be responsible for it is charged with the loss. He loses not only his own pay for the work which he performed upon the piece in question, but for the whole value of the piece at the time that the defect is discovered. That is, he has not only to lose his own labor, but he must also pay for all the other labor expended upon the piece, which through the fault of his work becomes useless. For example, in the case of the barrel, there is a certain amount of labor expended upon the iron, to form it into scalps, before it comes into the welder's hands. Then after it is welded it must be bored and turned, and subjected to some other minor operations before the strength of the welding can be proved. If now, under the test that is applied to prove this strength – a test which will be explained fully in the sequel – the work gives way, and if, on examination of the rent, it proves to have been caused by imperfection in the welding, and not by any original defect in the iron, the welder, according to the general principle which governs in this respect all the operations of the establishment, would have to lose not only the value of his own labor, in welding the barrel, but that of all the other operations which had been performed upon it, and which were rendered worthless by his agency. It is immaterial whether the misfortune in such cases is occasioned by accident, or carelessness, or want of skill. In either case the workman is responsible. This rule is somewhat relaxed in the case of the welder, on whom it would, perhaps, if rigidly enforced, bear somewhat too heavily. In fact many persons might regard it as a somewhat severe and rigid rule in any case – and it would, perhaps, very properly be so considered, were it not that this responsibility is taken into the account in fixing the rate of wages; and the workmen being abundantly able to sustain such a responsibility do not complain of it. The system operates on the whole in the most salutary manner, introducing, as it does, into every department of the Armory, a spirit of attention, skill, and fidelity, which marks even the countenances and manners of the workmen, and is often noticed and spoken of by visitors. In fact none but workmen of a very high character for intelligence, capacity, and skill could gain admission to the Armory – or if admitted could long maintain a footing there.
The welders are charged one dollar for every barrel lost through the fault of their work. They earn, by welding, twelve cents for each barrel; so that by spoiling one, they lose the labor which they expend upon eight. Being thus rigidly accountable for the perfection of their work, they find that their undivided attention is required while they are performing it; and, fortunately perhaps for them, there is nothing that can well divert their attention while they are engaged at their forges, for such is the incessant and intolerable clangor and din produced by the eighteen tilt hammers, which are continually breaking out in all parts of the room, into their sudden paroxysms of activity, that every thing like conversation in the apartment is almost utterly excluded. The blows of the hammers, when the white-hot iron is first passed under them and the pull of the lever sets them in motion, are inconceivably rapid, and the deafening noise which they make, and the showers of sparks which they scatter in every direction around, produce a scene which quite appalls many a lady visitor when she first enters upon it, and makes her shrink back at the door, as if she were coming into some imminent danger. The hammers strike more than six hundred blows in a minute, that is more than ten in every