The history of Peate’s 62-inch mirror probably would have remained as
obscure as that of his others except for the furor which arose over
casting the disc. The Erie Conference made no attempt to publicize this
project, and both Hodge Manufacturing and Standard Plate Glass accepted
Dr. Peate’s contracts as somewhat unusual but hardly newsworthy jobs. But
when the glass trade became aware of Standard’s intention to cast this
disc, a mighty outcry arose. Instead of encouraging Standard to complete
this novel task the _National Glass Budget_, one of the leading trade
journals, reviled them as “bumpkins” for attempting something that even
the great glassmakers of Europe would not do.
It is hard to imagine why the trade journal so strenuously objected
to Standard’s attempt. It has been suggested that it derived from the
fact that Standard Plate Glass just previous to that time had refused
to join in a combination of Pittsburgh companies which had set up a
glass trust.[30] Or it is possible that the young industry was afraid
that an overly ambitious project doomed to failure might open American
glassmaking to European ridicule and so harm the entire American
industry. Whatever the reason, the _Budget_ ridiculed Standard Plate
Glass, and later Dr. Peate, for the attempt. They argued that it could
not be done, but that if it were possible Pittsburgh would be the logical
place to try it. Criticism and unfavorable comment came from other
sources also, including “university professors from Meadville” (evidently
Allegheny College).[31] Nonetheless, Standard Plate Glass started the
project.
George Howard was in charge of the casting operation. He planned to use
the glass from a pot regularly used in the routine manufacture of plate
glass. However, certain modifications were introduced in the procedure.
The glass was to be poured on the traveling casting table, upon which was
placed a circular mold made up of two semicircles of a special charcoal
iron obtained from Philadelphia. This iron was not apt to generate
bubbles of gas when in contact with the molten glass.
The iron mold was hinged at one joint of the semicircles, and the other
joint was bolted. After the cast was poured it would be allowed to cool
somewhat. When it was judged cool enough, it would be pushed into a kiln
to be annealed. After it had remained in the kiln a certain length of
time—again based simply on judgement—a quantity of pre-heated sand was
to be poured over the mold as insulation. A further innovation was the
use of a zinc sheet placed on the underside of the mold to avoid the
possibility of trouble from grease on the casting table. This was the
initial plan of operation.
Sometime early in 1895 the first attempt was made. It was an immediate
failure. The zinc sheet, intended to protect the cast from grease,
volatilized when the molten glass was poured on it, bubbled up through
the glass, and, of course, ruined the cast.
Public-domain text, read in full here on John Shaqi.
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