We may now follow briefly the process of manufacture of a fire-clay
pot or crucible. The size and shape of the crucible will depend upon
the particular purpose for which it is intended. Crucibles varying in
capacity from 4 cwt. to 2½ tons of glass are used for various kinds
of glass, but the more usual sizes lie between 30 in. and 50 in. in
diameter. For many kinds of glass the shape of the pot is simply that
of an open basin, circular or oval in plan and larger in diameter at
the brim than at the base (Fig. 1), but for the production of flint
glass, and of other glasses which are to be protected from contact with
the flame and gases of the furnace, so-called “covered” pots are used.
In these the basin--here of a more nearly cylindrical shape--is covered
over by a dome, and access is allowed only by a relatively small hooded
opening (Fig. 2). Covered pots are built up on wooden moulds, which are
made collapsible, and are removed before the drying of the pot is begun.
[Illustration: FIG. 1.--Open “pot” or crucible for glass melting.]
[Illustration: FIG. 2.--Covered pot for glass melting, as used for
flint glass and optical glass.]
The material for pot-making is first prepared with great care. The
proper variety of clay having been selected, it is ground to a fine
powder in suitable mills and carefully sieved; with this fine clay
powder is mixed, in accurately determined proportions, a quantity of
crushed burnt fire-clay. In some works this burnt material is obtained
by simply grinding up fragments of old used pots, but the better
practice is to burn specially-selected fire-clay separately for this
purpose. The quantity of such burnt material added to the mixture
depends upon the chemical nature and especially on the plasticity of
the virgin clay employed; with so-called “fat” or very plastic clays up
to 50 per cent. of burnt material is added, but with the leaner clays,
such as those of the Stourbridge district in England, very much smaller
proportions are used. The object of this addition of burnt material is
to facilitate the safe drying of the finished pots and to diminish--by
dilution--the total amount of contraction which takes place both when
plastic clay is allowed to dry, and further when the dry mass is
subsequently burnt; the burnt material or “chamotte,” having already
undergone these shrinking processes, acts both as a neutral diluent
and also as a skeleton strengthening the whole mass and reducing the
tendency to form cracks.
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