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making tools from iron. The Iron Age began when some primitive
person noticed that a certain type of rock yielded iron when heated by
the coals of a very hot campfire. In short, we can say that
blacksmithing, the art of crafting that crude metal into a useable
implement, has been around for a long, long time.
And for a long time after that, blacksmithing remained a crude art. It
took three thousand years for man to learn the science of metallurgy.
Long after man made the first simple tools--the first spear or arrow
tips--the craft would require hundreds more years before blacksmiths
understood the magnetic properties of iron. The first compass used a
forged iron needle that floated in a round vial. This was a great
discovery. By forging the needle as perfectly as he could, the
blacksmith aligned the molecules in the iron and that is why north is
north and south is south. From that point on, sailors could travel
without need of stars nor sun to plot their courses around the globe.
As to where and when blacksmithing evolved depended on fuel and
iron ore. Early on, man discovered that small meteorites contain iron.
Iron is also present in nodules of bog ore, small lumps of iron created
by bacterial life in swampy areas. Iron ore is also present in rock strata
that have a red color, and the deeper the red hue, the higher the iron
content.
Charcoal was the primary fuel for an iron furnace. Beginning in the
18th century, ironworks began converting coal to coke. In addition to
charcoal and iron ore, a flux agent (limestone or dolomite) is also
needed to smelt iron ore.
It became a quest to find the rock strata that gave up its iron with the
least amount of work. Given the weight of the ore and the large
amounts of fuel needed to smelt the ore, the earliest ironworks were
located in areas where iron, flux, and fuel were ample and in proximity
to each other. The ironworks also had to be in an area where
transporting the finished iron ingots was practical. In early times, that
often meant being near a navigable waterway.
Early iron smelters called "bloomeries" were small furnaces built from
rocks that could withstand repeated heating. These furnaces looked
like beehives with a vent in the top and an entry portal on the side. To
create the high heat needed to smelt iron, smiths pumped air from a
bellows through the tuyere (nozzle). The furnace was filled with
charcoal and iron ore and the charcoal was then set afire. When the
temperature rises above 2,800 deg.F, the iron flows from the ore and
forms blooms.
Using large tongs, the blooms of iron were pulled from the oven and
placed on an anvil. A striker would then hammer the lumpy piece of
raw iron into a flat, rectangular bar. The bar would be folded over and
hammered again. This process would continue several more times until
most impurities had been driven from the ingot. The finished ingot,
bearing the layers of the folding process, was called "wrought iron".
Wrought Iron had a very low carbon content making it much weaker
than steel. But wrought iron was very malleable, a property that lends
itself to forging and forge welding. A forge weld is a homogenous weld
that aligns and bonds the molecules of the iron as if it were one piece;
hence, a seamless bond if done properly. The layers, or laminations, in
the wrought iron also gave it more strength than if it were only a single
layer. These qualities of wrought iron gave blacksmiths a perfect metal
for making gun barrels. A brief understanding of history should tell you
that blacksmiths have always been part of the "military-industrial
complex".
Cast Iron differs from wrought iron. Cast iron is iron that is heated to a
liquid state and then poured into a mold. The mold is lined with sand
and a small mix of clay to hold the sand in shape. A finished casting
has a rough surface because of the sand texture it was poured against.
Oftentimes, people mistake cast metal for forged metal but a quick
examination of the surface will differentiate the two. Many ornamental
iron fences, window and door grills, and other decorative ironwork
pieces are cast. Cast iron is poured at a foundry, not a blacksmith
shop. Cast iron cannot be heated and re-shaped, or (conventionally)
welded. Wrought iron can be reworked forever. Cast iron contains more
carbon than wrought iron. As it cools, the iron crystallizes and tends to
be brittle.
To fuel the smelter or the forge, wood is converted to charcoal, or coal
is converted to coke. Destructive distillation, the process name, means
burning the raw fuel with limited oxygen. The impurities are burned off
leaving nearly pure carbon which is what you know as charcoal or
coke. (The charcoal in your barbeque grill has been adulterated for
cooking purposes and will not fuel a forge.) To get the charcoal or coke
to burn even hotter, air is forced to the fire. In early times, this was
done with a bellows pumping air through a pipe into the hearth or
forge. The bellows was pumped either by hand or by a water wheel.
The result is a very hot, sustained fire.
Learning about charcoal makingg and learning about a forced-draft fire
made the iron age possible. This was the only way to generate enough
heat to smelt iron ore.
blower for the forge greatly reduce the physical effort in modern
blacksmith shops.
Through associations such as ours, the art and the knowledge of
blacksmithing is being passed on. In large part, blacksmith associations
were started because people remembered a grandfather who had an
anvil at his farm and they wanted to learn more about the art. What
was a necessity to great-grandpa is really a leisure activity to most of
us today. The public has responded to this resurgence by buying the
wares of modern blacksmiths, but the trend has been towards artistic
work rather than common tools or goods. The new millionaires may
have their spiral staircases, but the average family is just as proud of
its garden gate, chandelier, wrought iron bed, or fireplace screen.
Another major reason for the resurgence in this art is Francis Whitaker.
He began his career at the Yellin Ironworks but left there to go into
business for himself. Despite the hard times of the 1930's, he managed
to prosper by securing commissions around the country. When he
considered retirement about 1970, he looked around and realized he
was "the last man standing." From that realization until his death in
1999, he toured the country promoting and teaching blacksmithing to
generations who knew little of the art.
I doubt that the blacksmith of olden times would ever guess that the
iron rod on my kitchen wall holds a roll of paper towels. In fact, he'd
probably have something derisive to say about paper towels since he'd
reuse every scrap of iron that he came across. But those are the ages,
his and ours. We do live in a different age and the blacksmith of old
doesn't figure into the equation anymore. After all, who buys a
magnetic compass needle when a GPS satellite can pinpoint one's
location at the touch of a button?
We do need to appreciate the man who really built our modern world,
the blacksmith. In peacetime and in wartime, the blacksmith was
called on to do many tasks. Ben Franklin, in his Poor Richard's
Almanac, wrote, "For want of a nail, the shoe was lost. For want of a
shoe, the horse was lost. For want of a horse, the rider was lost...". In
"The Village Blacksmith", Henry Wadsworth Longfellow praises the
blacksmith: " His brow is wet with honest sweat, He earns whate'er he
can, And looks the whole world in the face, For he owes not any man."
Such are the sentiments of an age gone by. For who in modern society
could qualify now for Longfellow's praise? I doubt we'll ever hear such
a romantic overture about lawyers, consultants, engineers, computer
programmers, civil servants, doctors, or for that matter, anyone else.
grilles and shackles. Unlike Europe where a city grew over time around
a Medieval castle, everything in America had to be built from scratch.
Many immigrant communities still wanted a part of their homeland,
however. After all, they traveled here with only the barest of goods.
Just as we pass down "the family silverware" from generation to
generation, the same custom held true then. However, immigrant
families left most of their heirlooms behind in the old country. This did
provide an opportunity for journeymen blacksmiths from Europe. A
blacksmith trained in, say, Cologne, Germany would seek out his
countrymen in the colonies and set up shop in their village or district.
He would prosper since he could replicate all of the old patterns that
his fellow immigrants knew so well. Though they couldn't bring their
wares on the boat, these immigrants were not denied their heritage.
1800-1860
A key date in this period is 1838. John Deere (yes, the green tractor
John Deere) invented a superior plow made from steel. His design
turned the soil better than existing plows. But what made this event
significant was the use of steel.
Deere's plows also had replaceable cutting edges and wear strips.
Unlike the hand-forged iron plow which was one piece and wore quickly
along its edges, this steel plow lasted longer and the wearing parts
could be cheaply replaced. By 1853, Deere & Co. was selling thousands
of new steel plows, a significant milestone of technological change-steel vs. iron and manufactured vs. hand-forged. The American steel
industry was underdeveloped in 1840 and produced a poor quality
product. Deere relied on imported steel from England to make his plow
successful.
In 1839, Henry Wadsworth Longfellow penned the famous poem, "The
Village Blacksmith." We can assume, then, given the poem's success,
that the blacksmith was a revered craftsman. This period may have
been the zenith in American blacksmithing. Even today, our thoughts
about a blacksmith revolve around this poet's description. But this
poem was a fading dream. Even the chestnut tree that Longfellow
wrote of later died and the people of the town had a chair made from
the wood as a gift to the poet before his death in 1882.
During this era, steam power would change the nation.[3] The first
steamboats and packets vastly improved shipping, both on rivers and
on the sea. Steam power would begin to replace water power in grist
mills and textile plants. No longer would the miller rely on seasonal
rains to grind corn meal or flour. And of course, the steam-powered
locomotive changed transportation in ways never imagined. By 1860,
the South had its Merrimac and the North had its Monitor. And both had
railroad networks.
The blacksmith shop was starting to change as well. The bellows was
replaced with a rotary fan blower and the drill press became available
for small blacksmith shops. In larger shops and some of the fledgling
factories, one might find a steam-powered trip hammer.
Americans were also moving westward. Being west of the Alleghenies
in 1790 meant you were still on the frontier. But as John Deere
invented his plow in Illinois, that alone shows how quickly the
westward movement was taking place.
For a perspective of this period, consider Salem, WV. Originally settled
in 1792 by Seventh Day Baptist families who migrated south from
Rhode Island, Salem was itself an island in the wilderness. The first
buildings were a blockhouse and fort to protect the settlers from Indian
raids.[4] From that beginning, log houses were built and the settlers
developed farms. The town grew and it did prosper as a farming
community. Six decades after its founding, Salem would find itself not
on the frontier but in mid-America--a rail stop on the Baltimore & Ohio's
mainline. And on the town's 100th anniversary, Salem was home to
Salem College and sat surrounded by oil and gas wells.
1860-1910
To understand this era, consider the lowly nail. In 1800, a blacksmith
made nails, one at a time, at a rate of perhaps one per minute. Nails
were expensive. Lumber, on the other hand, was becoming cheap. And
as lumber got cheaper, people wanted to live in houses instead of log
cabins. A way to make cheap nails had to be found and it was--the nail
factory. "Cut" nails were turned out in all sizes from spikes to brads
because the typical Victorian house and its trim needed about 400# of
nails to hold it together. Nails were so scarce and expensive prior to
1800 that some states had previously enacted arson laws, not to
criminalize arson per se, but to prevent people from burning down
sheds, barns, and houses just to sift the nails from the ashes! Factories
such as Wheeling's LaBelle Nail Co. (1852, and still operating in 2010)
met the demand for nails. And they forever removed one of the
blacksmith's product lines.
Horses, wagons, and horse-drawn implements would dominate the
blacksmith's work through this period. Factories would begin producing
many of the tools traditionally made in the village smithy. And steel,
not iron became the metal of choice. By 1910, Henry Ford had made a
farm tractor that most farmers could afford. Along with his Model T
automobile, Henry Ford would make the horse and wagon almost
obsolete. And with this change, the blacksmith that Longfellow wrote of
disappeared from the land.
In a typical American town in 1900, one would expect to find livery
stables, feed stores, wagon shops, blacksmith shops, horse corrals,
horse traders, and horse trainers in about the same ratio that we now
find auto dealers, repair shops, parts stores, driving instructors, and
fueling stations. This shows how much the blacksmith was a part of the
local economy. The change was quick and significant.
Introduced in the 1890's, it would not take long for America to begin its
love affair with the automobile. The technology of the cotton gin came
of age in the automobile assembly plant. More than anything else,
motorized vehicles and farm equipment doomed the trade of
blacksmith.
1910-1970
There was a golden age for blacksmiths who made architectural
ironwork during the early part of this period. But the Great Depression
(1930) would end this Renaissance. Still, many of America's mosttreasured iron works in iron were made during this time.
Farming with workhorses did not evaporate overnight. And even the US
Army maintained some horse cavalry and horse-drawn artillery units
into the 1930's. But by 1950, nearly all agricultural crops were tended
by machines and the Army was obviously mechanized. The farrier's
main work shifted from shoeing work horses to pleasure horses. While
many factories employed blacksmiths in their maintenance
departments in 1910, they were eventually phased out as their need
decreased.
In summary, the art of blacksmithing almost became extinct during the
latter half of this period. People would remember their grandfather's
farm and the shed where his anvil was set up. But they had no idea of
what Grandpa did in his shop. Essentially, if a job absolutely had to be
done by hand, then a blacksmith would have work. And there were
some repairs and tools that called for the blacksmith's skills. But
modern logic dictated mass-production and replacement rather than
repair. It became cheaper to throw away a broken chain rather than
have a blacksmith make the repair links! And what about those
wrought-iron railings that homeowners bought in the '50's? They aren't
hand-forged by a blacksmith; they are cold-bent in presses and welded
together, and the finials are cast iron, made a hundred at a time.
Part 3
Ages of Technology
If you study the civilizations of history, you will read that a particular
society lived in one of three technological ages--the Stone Age, Bronze
Age, or Iron Age. And you will notice that certain dates are often
attached to the these ages. You may fall into the trap of believing that
all of the world's peoples threw down their stone tools in 6,500 BC and
ordered new, bronze tools. In truth, societies progressed at different
rates and throughout much of the last few millennia, the Stone Age,
Bronze Age, and Iron Age were all in place at the same time. This was
evident when European sailors landed in the Americas.
Even as astronauts blasted off for the first moon landing, some tribes
of rain forest Indians in the Amazon and elsewhere were still living as
people did in the Stone Age. They hunted and fished with sharpened
sticks, ground food roots to a pulp with a round rock, and, in some
locales, did not know how to build a fire with human-made tools or
implements.
Strange as this may seem that they did not know how to "make" fire,
one does have to ask the burning question: What need did they have
of fire? After all, the tropical rain forest is balmy the year round. And
fresh fruits and berries are always in season. Even if these tribes
wanted to cook a meal over a campfire, then they would have a hard
time finding enough dry wood to build the fire.
Without need of fire (primarily for warmth), these tribes were almost
guaranteed to live in the Stone Age. Why? Because it was the heat of a
campfire that led humans to discover that metals were contained in
rocks and that the intense heat of a fire could smelt the metal from the
ore rock.
If you were a Stone Age person, you would be acutely aware of your
surroundings. Living off the land, you would know every square inch of
the many square miles of your range. You would have discovered that
a tree limb with a knot made for a durable mallet. Of the rocks you saw
in the gravel bed of a stream, you would have quickly learned not to
step on a flint rock because of its sharp edges. You'd also see that
animal bones could be dried and splintered. With just these three
discoveries, you would be on your way to building a shelter, making
tools, and cutting and sewing animal hides for clothes or shoes.
Even though your life would be better than before you discovered how
to make tools, you would still want to make improvements to your
situation. One day, you would poke through the ashes of your campfire
Iron came into use because the scarcity of copper, etc. pushed up the
prices of metals and alloys. It takes much more energy to melt iron
than it does copper. But as copper went up in price, iron smelting
became feasible. Iron is well-distributed throughout the world--a red
rock is an indication of iron. But the first iron source that people used
were meteorites that they found laying on the ground. Iron nodules are
also found in bogs and clay banks.
Copper melts at 1,981 degF. Iron melts at 2,802 degF. To achieve this
temperature, wood had to be converted to charcoal (nearly pure
carbon) and then burned with an air blast, which was supplied by a
bellows (a simple air pump.) While iron is harder and more durable
than the Bronze Age metals and alloys, it is not so simple as to say the
difference in Ages is the difference in the properties of the metals.
Making iron required a new way of thinking. Making iron was an
industrial process.
The first civilization credited with making 'wrought iron' from blooms is
the Hittite Empire which controlled present-day Syria and Iraq from
1700-1200 BC. While it took over 3,000 years from that first bloom of
smelted iron to the building of the first iron bridge at Ironbridge,
England, the thought process changed little. Iron making showed man
that he could make everything bigger, better, stronger, and faster. The
Industrial Revolution, the capstone of the Iron Age, could not have
happened without wrought iron and the blacksmith.
In today's world, the cruise ship is built from tens of thousands of tons
of steel. The jet airliner has nary and ounce of steel. Though dissimilar
in the metals that they are built from, they both represent the thinking
process of Iron Age technology.
Some futurists say that we have entered a new age of technology
based on computers. Call it the Silicon Age if you will. If that is true,
then our computer age began in 1801 when Joseph Jacquard invented
a loom that operated by punch cards. However basic, it was a
computer-controlled device. Whether we are starting this new age is
debatable. What is probably true is that it will not take 3,000 years to
develop the next age of technology.
In the 21st Century, man will develop a way to supply 90% of the
world's energy power from the sun and the cost will be minimal. And it
would not surprise me at all to see man-made rainstorms in the Sahara
Desert. But when this century ends--and I predict this with certainty-mankind will still not have found a cure for the common cold.