CHAPTER I

THE METAL AND ITS ALLOYS

Ancient bronze--The bronzes of Greece, Rome, and Eastern nations--Copper for enamels--The brass of commerce--Bell metal--The sources of copper--The making of brass--Copper as an alloy--The characteristics of metals.

The coppersmith has taken a prominent place among the craftsmen of all nations, and at all periods, and in not a few instances he has been acknowledged as an artist of no mean order. The material upon which he has worked has been copper and its alloys and compounds. From this metal have been produced many valuable antiques, and among the work of the coppersmith of more recent days there are objects of intense interest and of great beauty. In this work many collectable objects have been classified, and in the different groups of metal-work referred to attention is drawn to these beautiful and sometimes quaint reminders of past generations, and also to some of the most notable non-collectable metal-work which may be seen and admired in museums and art galleries, and to a few of the copper monuments, memorials, and historic relics which are gazed at by the curious, oftentimes without thought of the materials of which they are composed.

Ancient Bronze.

The raw material, copper, smelted and beaten or poured from a crucible into moulds, was in more ancient times used in its unalloyed purity--and it is still used in that state. It was, however, soon discovered that copper might be improved for many purposes by mixing with it other metals possessing different properties. The prehistoric peoples who lived in Britain, and in other countries within reach, soon added tin, which was found in Cornwall quite near to the surface, and was from early times sold to Phoenician traders, thereby producing bronze. It is of this metal that most of the much valued curios of the so-called Bronze Age are made. Those who fashioned them were clever manipulators of the alloyed metal, and by processes now little understood were able to temper tools and weapons and to give them keen-cutting edges. Our museums are full of spear-heads, celts, axes, and palstaves of bronze, which were cast in moulds of stone cut to the required shapes by those primitive workers in metal, who used simple crucibles in which it was melted.

The prehistoric bronzes, some examples of which are referred to in another chapter, are the earliest collectable curios formed of metal. They include implements of war and of the chase and some domestic utensils and cooking vessels. To these useful objects must be added ornaments and trinkets of bronze, so many of which have been found in the barrows and burying-places of prehistoric races.

The knowledge of bronze appears to have been widespread. It was understood by those who dwelt in this country, by the inhabitants of European countries, by Eastern nations, and by the Egyptians, who left such wonderful monuments behind them, giving evidence that they knew how to impart a knife-like edge to their tools of bronze.

Bronzes of Greece and Rome and Eastern Nations.

The ancient bronze of prehistoric days must not be confused with the metals or compounds of copper and its alloys which enabled the Greeks to produce such wonderful statues. They learned to impart hardness to copper, and wrought much delicate handiwork, much of which has perished; but enough has been spared to confirm classic history and to enable us to realize something of their conceptions of the old gods and personified hopes and aspirations. In like manner the wonderful bronzes of China and Old Japan were wrought; the metal-worker's art in those countries goes back many centuries. Some of the more delicately chiselled figures and groups were first modelled in wax upon an iron core, the mould being then formed of soft clay. When the clay was baked the wax melted, and running away through prepared outlets, left a smooth cavity into which the bronze was afterwards poured. When the metal was cold the clay would easily be broken away, and the object, at the moulding of which we often marvel, made perfect. In course of time such bronzes have been coated over with a beautiful patina of green, that natural finish which age can alone impart. It is in that state so many of the bronzes of Grecian sculptors are found, and it is covered with patina of many delightful shades that we buy the metallic curios from China and Japan.

Copper for Enamels.

In the days when so many beautiful ecclesiastical ornaments were fashioned, copper was the foundation used by mediæval artists as the base of their exquisite enamels. These beautiful objects are especially referred to in Chapter XVIII, where reference is also made to the enamels of Eastern countries, in the making of which brass was frequently used as the foundation. Copper has been found suitable as the groundwork upon which super-finishes have given that superiority and attractiveness associated with many of the fine arts. It was suitable for gilding over and for decorating with precious stones. Copper was also frequently used by painters, its smooth surface being regarded as an excellent material on which to work. As an example, some of the religious pictures, especially miniatures, were painted on copper, instead of on wood panels.

The Brass of Commerce.

Many speak of brass as a metal apart from copper, yet the brass of commerce, worked up in many forms, is only a composite metal of which copper is the basis. The popularity of pure copper as the material from which household utensils and many constructional objects of use and ornament were made in the past continued unabated until metallurgical chemists discovered how, by using an alloy of zinc, the metal we call brass could be cast, rolled, and otherwise manipulated. Among the advantages claimed for brass is that it has a harder surface and is more resisting than copper. From the days of Queen Elizabeth onward it was much favoured for domestic vessels, and even at the present time it is used to some extent; there has, however, always been a concurrent use of copper.

Bell Metal and Other Alloys.

There is yet another important alloy, which from its chief use takes the name of bell-metal; its companion alloy is gun-metal. In the mixing of these metals special alloys are aimed at according to the object in view, that is to say, the ingredients vary, but, broadly defined, the copper and its alloy tin used in bell-metal are in the proportion of three to one. The metal was in the past used for those much employed articles of commercial and domestic use, mortars, in addition to the founding of bells. Bell-metal was also the material of which weights and measures (especially the standards kept in many of the old cities) were chiefly made (see illustrations and references thereto in Chapters X and XI).

The Sources from which Copper is Derived.

Copper seems to have been very widely distributed all over the world, a fact that has contributed to its general use. At one time a local metal employed in a pure state and in conjunction with alloys, chiefly where it was mined, it is now brought to the metal-founder from other parts of the world. Although vast quantities of copper are now imported into England, it was from British mines that the supply was drawn in days gone by. The Britons understood its use, no doubt finding it out by accident, just as the natives of many other countries have done. Copper, as evidenced by the marvellous Benin bronzes, was known in Central Africa long ago. The mines at Mansfield, in Germany, are the oldest in Europe, and there workers have been digging up copper for seven centuries.

The collector of old metal objects naturally takes the greater interest in well authenticated specimens known to have been fashioned in districts once famous for their copper mines. Unfortunately, the Cornish mines produce little ore now. When the Romans worked them they obtained copper quite near to the surface; but such easily mined ores have long been cleared.

Copper smelting was carried on in Cumberland and Northumberland in days gone by. In the seventeenth and eighteenth centuries copper was smelted in Yorkshire and Lancashire. Then we read of the reopening of old Cornish mines and of furnaces being erected in Bristol. The mines of Anglesea are less known, although they were once very active. South Wales has for many years past been closely identified with copper smelting, and rolling mills were established in Swansea as early as 1720; and although the better knowledge of metallic chemistry enables manufacturers to produce copper more economically than in days gone by, the old principle of crushing, calcining, roasting, and washing the ore, although improved by modern machinery, is still adhered to.

As with many other industries, the invention of the steam-engine was a boon to the owners of copper mines in Cornwall, many being flooded towards the end of the eighteenth century. With the steam-engine to work them, pumps were put in operation, mines were cleared, and for a time at any rate ore was procured and renewed activity was visible in many British centres. In those days many of the things we now regard as curios were being made. As with many other raw materials the value of copper steadily advanced, for as trade and commerce grew, immense quantities were used up for sheathing ships' bottoms, roofing buildings, for engravers' plates, and for the rolls used in the printing of calicoes. Other sources of supply have been found, for the chain extending from Land's End to Dartmoor no longer serves. The famous Parys Mines are no more, and it is from foreign countries the supply comes. Some of our Colonies have proved rich in ores, such, for instance, as South Australia, where it is said an early settler examining the burrow of a wombat found the green mineral, that incident leading to the opening of mines yielding vast quantities of copper ore.

The Making of Brass.

The brass of commerce, rolled in sheets, drawn in rods and wire, and cast in ingots ready for the founder, is, as it has been stated, a composite metal, very well suited to many purposes. During the sixteenth century much progress was made in metal-founding. The Worshipful Company of Founders was busy. Many "battery" works were set up in England, and there brass was hammered or battered into shape. Thus brass-workers were engaged in making useful pots and pans, now in their much worn state eagerly sought after by the collector. Some worked with the ladle and crucible, others with the hammer and anvil or wood block.

The earlier brass was composed of copper mixed with calamine melted in a crucible, a process which continued until the more modern form of melting metallic zinc with copper was understood. Champion's process, by which this newer method was carried out, was kept secret for some time, but about the middle of the eighteenth century it was generally understood and the process of stamping brass became a common one in the Birmingham district.

Copper as an Alloy.

Copper, the base of so many alloys, has itself been found a useful alloy of most workable metals, not only in modern times but in years gone by. It is one of the best hardening agents in aluminium, the newer metal which is to some extent displacing copper and brass cooking pots and much ornamental metal-work. According to an expert, aluminium is tasteless, and possesses all the advantages of copper without its drawbacks. That being so, perhaps even vessels of brass, such as may still be seen in kitchens, may soon become obsolete and pass shortly into the rôle of the museum curio. Incidentally it may be mentioned that aluminium is not altogether a new metal, neither is its use confined to civilized countries, where metallurgists have proved its advantages; for the natives of the Philippines, Borneo, and other islands in the Pacific have long used it as an independent metal, and also for the purposes of ornamenting other materials. Many of the copper and brass curios brought into this country, the products of native smiths, working far from civilized lands, are partly made of aluminium, alloyed chiefly with native copper. The natives of Borneo melt it in fireclay crucibles over a coke fire, and are very clever at producing some remarkably fine pieces of metal-work, using different metals for the same object; thus some of their daggers have brass hilts and aluminium blades. The metal-worker has frequently introduced aluminium in the decoration of copper and brass gongs, some of the older examples from Japan being extremely decorative.

The Characteristics of the Metals.

Some collectors very wisely follow up their researches after new treasures by investigating the methods of their production, and they even visit modern works where similar methods, although more advanced, are going on. Very interesting indeed is it to watch the molten metal as it is mixed and poured into moulds and made into pigs. To see the great rolling mills through which the bars are passed, and to watch the hammering and drawing by the steam-hammer and powerful machinery, is an education which enhances the interest there is in the possession of finished goods--old and new.

It is said the brassfounder's requirements to-day are much the same as they have always been, although perhaps there are more iron moulds used and greater care is taken in their preparation. The mould must have a good surface and be composed of the right kind of iron. The best metal for the purpose appears to be one high in silica and low in combined carbon, thus securing a soft iron which will not crack when the molten metal strikes it. The science of metals is constantly being added to, and the research of chemists of recent years has done much towards improving the skill of present-day artists, most of whom, however, readily give praise to the almost intuitive skill of the artists of olden time.

The fashioning of copper and brass follows the preparation of the metal; there are many reasons why copper and its compounds and alloys have been so generally employed, one of the principal being that the ductility of copper has made it welcome wherever the hammer has been brought into play. The possibility of hammering out brass and copper, and especially the latter, is seen in the extreme fineness to which copper wire can be drawn. Hood uses the similitude when speaking of how travel improves the mind, and tells of the gradual narrowing of copper and brass as they become finer and finer, likening those who have not travelled to the narrowed metal. Collectors of curios show characteristic traits, twofold in application. There are some who get more broad-minded the farther they travel, the more museums they inspect, and the wider their knowledge of the antiquities they admire. Others, specialists for the most part, get into very narrow grooves, confining their hobbies to some one class of goods, not always the most interesting in public estimation; then they wonder how it is that their hobbies are not appreciated by their friends! Surely the greatest delight is in a representative collection, such as the hobby under review, which shows all the possibilities of copper and brass in their varied treatment. In the examples which have come down to us from the Ancients, in those schemes of decoration which mark clearly the work of the artists of some one country or period, and in those general collectable objects which have been brought together from everywhere, there is a liberal education:

"Some minds improve by travel; others, rather, Resemble copper wire, or brass, Which gets the narrower by going farther."

II

THE HUNTING GROUND