In 1782 Mr. Cort, after many years of experiments, discovered the means
of converting cast or pig-iron into malleable iron by a process which
was at once sure, rapid, and economical. The iron is remelted in a
puddling furnace, as it is called, which is heated with raw coal, and
there, by a series of operations, the object of which is to give the
iron malleability and toughness by expelling the carbon, it is
manipulated until it acquires the consistency of a solid white-hot ball.
In this shape it is subjected to the action of an enormous hammer, by
which the coarser parts are beaten from it, and it is formed into the
shape of thick short bars, called blooms or slabs. While still red-hot
it is passed through a series of grooved rollers, till it is drawn out
into a long bar, the exact dimensions of which are regulated by the
requirements of the manufacture for which it is destined. The bars thus
made are technically called puddled bars, and considered as _half-
manufactured_ iron. To refine them into _merchant_-iron, they are again
submitted to the action of fire, and, when hot enough, are welded
together and formed into the various denominations of bars, rods, hoops,
sheets, or plates. Mr. Cort’s discovery, though of immense importance,
would yet have proved of comparatively small value without the aid of
the double-power steam-engine, which was about the same time invented by
James Watt, and supplied the power which was needed to give our iron-
works their full development.
Hitherto the ‘top measures’ only of the mineral had been worked, and
generally on ‘the rise of the mine,’ where the water would not lie, or
those strata favourably situated on the side of a hill where levels
could be driven in and the water released. Water was the great enemy in
the pits, and even in shallow workings it often accumulated faster than
a gin turned by horse-power could bring it to the surface. By the new
agency of steam the deepest pits were drained, and materials were drawn
up from the bowels of the earth in a quantity and with a rapidity and
security hitherto unknown. By the same means that prodigious blast was
obtained for the furnaces to which all subsequent improvements of the
manufacture owe their origin. Instead of the rude machinery of
waterwheels and bellows, huge engines of enormous power forced an
immense volume of air through several small _tuyeres_ or tubes so
disposed at the lower part of the furnaces that in each portion of the
ignited mass an equally diffused blast might raise an equal intensity of
heat. Furnaces of greater height and much larger capacity than any
hitherto known were erected, and in its general aspect the iron
manufacture assumed very much the appearance which it maintains at the
present day.
[Illustration:
BLAST FURNACE.
_a._ Tuyeres.
]
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