Part 88

Aluminium is a white malleable metal, in colour and hardness not unlike zinc. Its colour is not so white as that of silver, as it has a marked bluish tint. It can be rolled into very thin sheets, and by rolling it becomes harder and more elastic. It can also be drawn into fine wire. It is remarkably sonorous, and a suspended bar gives out a clear musical note when struck. Perhaps no property of aluminium more strikes a person, who examines the metal for the first time, than its lightness. It is, in fact, only two and a half times as heavy as water, while zinc is seven times, silver ten and a half times, and gold more than nineteen times as heavy as water. It retains its lustre in dry or in moist air for any length of time, and at all ordinary temperatures. It is not acted upon by nitric or sulphuric acids, but is attacked by hydrochloric acids and by alkaline solutions with great energy. It has great rigidity and tenacity, and can be turned, chased, and filed with the greatest ease, and without clogging the tools. In the Paris Exhibition,[15] M. Christofle showed spoons and forks and a cup made from it; and it may be mentioned, as showing the hardness and strength of the metal, that the cup could be allowed to fall on a stone pavement without being indented. The metal gives a good impression by casting; and by striking under a die, some admirable medals have been produced in it. Aluminium has hitherto been chiefly used for ornamental articles, and for purposes where lightness and rigidity are desirable, such as in the tubes of telescopes, opera glasses, beams of balances, &c. Its unalterability and admirable working qualities have also caused it to be used for cheap trinkets and ornaments—such as watch-cases, bracelets, combs, seals, penholders, candlesticks, &c. It is, however, incapable of receiving the lustrous polish of silver, as it has a decidedly blue tint, so that it will probably never replace silver for ornamental plate; but it would be a good material for egg and mustard-spoons, as it is quite unaffected by the sulphur compounds which so readily tarnish silver. It has been suggested that if aluminium could be procured cheaply enough, “its hardness, lightness, and incapability of rusting would render it admirably adapted for the helmets and cuirasses of the cavalry; it would make splendid field-guns, as strong as the present ones, and not one-third of their weight; and, in sheets, it might serve as an incorrodible roofing, far lighter and more durable than zinc. It would admirably replace copper, if not silver, for the purpose of coinage. A crown-piece in aluminium would hardly weigh more than a shilling in silver, or a piece the size of a penny about as much as a copper farthing. The same qualities of lightness, hardness, and incorrodibility also excellently fit it for the beams of delicate balances, and for the small weights used by the analytical chemist. It would make admirable utensils for the more delicate operations of cooking—replacing the copper ones, which render pickles and soups so poisonous. It is extremely sonorous, and would make capital bells.”

Footnote 15:

Of 1867.

Some difficulty in working the metal has occurred from the want of any suitable solder. This difficulty has been overcome by electrolytically coating the metal with copper at the place where it has to be united with others, and then soldering the copper in the ordinary manner. Aluminium readily forms alloys with copper, silver, and iron. The alloys with copper vary in colour from white to golden yellow, according to the proportion of the metals. Some of these alloys are very hard and possess excellent working qualities. The alloy of copper with 10 per cent. of aluminium, which is called _aluminium bronze_, has been manufactured by Messrs. Bell in considerable quantities. It is made by melting a quantity of very pure copper in a plumbago crucible, and when the crucible has been removed from the furnace, the solid aluminium is dropped in. An extraordinary increase of temperature then occurs: the whole mass becomes white hot, and unless the crucible be made of a highly refractory material, it is fused by the heat developed in the combination of the two metals, although it may have stood the heat necessary for the fusion of copper.

The qualities of aluminium bronze have been investigated by Lieut.-Col. Strange, who finds that the alloy possesses a very high degree of tensile strength, and also great power of resisting compression, its rigidity, or power of resisting cross strains, is also very great; in other words, a bar of the alloy, fixed at one end and acted on at the other by a transverse force tending to bend it, offers great resistance,—namely, three times as much as gun-metal. An advantage attending the use of the alloy for many delicate purposes is found in its small expansibility by heat; it is therefore well adapted for all finely-graduated instruments. It is very malleable, has excellent sounding properties, and resists the action of the atmosphere. It works admirably with cutting tools, turns well in the lathe, and does not clog the files or other tools. It is readily made into tubes, or wires, or other desired forms. The elasticity it possesses is very remarkable; for wires made of it are found to answer better for Foucault’s pendulum experiment than even those of steel. These admirable qualities would seem to recommend the alloy for many applications in which it might be expected to excel other metals. It appears, however, that the demand for it has not met the expectations of the manufacturers, and the production has been somewhat diminished of late, although it is used to some extent for chains, pencil-cases, toothpicks, and other trinkets. When more than 10 per cent. of aluminium is added to the copper, the alloy produced is weaker; and if the proportion is increased beyond a certain extent, the bronze becomes so brittle that it may be pulverized in a mortar.

The metal _magnesium_ was first prepared, in 1830, by the French chemist Bussy, by a process similar to that by which Deville obtained aluminium. Bussy heated anhydrous magnesium chloride with potassium in a porcelain crucible; and when the vessel had cooled, and the soluble residue had been dissolved out by water, the metal was found as a grey powder, which could be melted into globules. The recognition of the metal as the base of magnesia is, however, due to Davy. About a quarter of a century after Bussy’s discovery Deville having shown that sodium could be substituted for potassium in such reductions, the metal became more cheaply producible, and soon afterwards Bunsen and Roscoe pointed out its value as a source of light. Mr. Sonstadt devoted himself to the elaboration of a method of working Deville’s process on the large scale, and he succeeded in establishing a company in Manchester for the manufacture. The process as carried on at the company’s works in Salford is thus described in the “Mechanics’ Magazine,” 30th August, 1867:

“Lumps of rock magnesia (magnesium carbonate) are placed in large jars, into which hydrochloric acid in aqueous solution is poured. Chemical action at once ensues: the chlorine and the magnesium embrace, and the oxygen and carbon pass off in the form of carbonic acid. The result is magnesium in combination with chlorine, and the problem now is how to dissolve this new alliance—to get rid of the chlorine and so obtain the magnesium. First, the water must be evaporated, which would be easy enough if not attended with a peculiar danger. To get the magnesium chloride perfectly dry it is necessary to bring it to a red heat; but this would result in the metal dropping its novel acquaintance with chlorine and resuming its ancient union with oxygen. To avert this re-combination, the magnesium chloride whilst yet in solution is mixed with sodium chloride (_i.e._, common salt), and thus fortified, the aggressions of oxygen whilst drying are kept off. The mixture is exposed in broad open pans over stoves, and when sufficiently dry, the double salt is scraped together and placed in an iron crucible, in which it is heated until melted, whereby the last traces of water are driven off. It is then stowed away until required in air-tight vessels, to prevent deliquescence. Here comes in that curious metal, sodium, also discovered by Davy. Five parts of the mixed magnesium and sodium chlorides, mingled with one part of sodium, are placed in a strong iron crucible with a closely-fitting lid, which is then screwed down. The crucible is heated to redness in a furnace, and its contents being fused, the sodium takes the chlorine from the magnesium. When the crucible has been lifted from the fire and allowed to cool, the lid is removed and a solid mass is discovered, which, when tumbled out and broken up, reveals magnesium in nuggets of various sizes and shapes, bright as silver.”

The crude metal also presents itself in the crucible as small grains, and even as a black powder. The whole is carefully separated from the refuse; it is purified by distillation in a current of hydrogen gas; and it is afterwards melted and cast into ingots. Magnesium is a very light metal, its specific gravity being only 1·743; that is, it is only one and three-quarter times heavier than water. When heated in the air it takes fire, and is rapidly converted into the oxide, magnesia. In the form of wire or of narrow ribbon, it burns easily in the air, producing a light of dazzling brilliancy, which among artificial modes of illumination is rivalled only by the electric light. This is the chief use at present made of the metal. Lamps have been contrived for burning the wire in such a manner as to obtain a steady light, the wire being pushed forward at a regulated rate by clockwork. The magnesium light is rich in the rays which act upon sensitive photographic plates, and it has been successfully employed in obtaining photographs of dark interiors, such as vaults or caverns, and for the exploration of mines and other dark places. The brilliancy of the firework displays which can be produced by magnesium far surpasses that obtainable by any other material used by the pyrotechnist. In such exhibitions balloons are sent up having burning magnesium attached to them; and the metal in the state of filings is also mixed with other materials. But magnesium is still a very costly metal, and while the firework-makers find it too expensive for common use, they complain that its brilliancy in occasional displays dulls by contrast the effect of the ordinary fireworks, with which the spectators are no longer satisfied.

Magnesium wire is not produced by drawing, as the metal is not ductile. The wire is formed by a method identical with that used in the fabrication of the leaden rope for making bullets (p. 330); that is to say, the metal is forced in a heated and softened state through a small opening in an iron cylinder. The intensity of the magnesium light has been measured by Bunsen and Roscoe. They say that 72 grains of magnesium, when properly burnt, evolve as much light as 74 stearine candles burning for ten hours, and consuming 20 lbs. of stearine. Lamps in which magnesium may be steadily burnt are made by Mr. F. W. Hart, of London. In the more elaborate forms of these lamps, there are springs and wheels for pushing forward the magnesium ribbon, or a strand of magnesium wire, into the flame of a spirit-lamp; while at the same time the magnesium wire is made to revolve on its axis, in order to overcome its tendency to bend down, which would be a great disadvantage when the light is used for optical apparatus. But for ordinary purposes a much simpler arrangement suffices: the magnesium ribbon or wire is coiled on a drum, from which it is drawn off by passing between two little rollers, which are turned by hand. The wire or ribbon is drawn off the drum by the rollers, and pushed forward through a guiding tube, which brings it into the apex of the flame of a spirit-lamp. In this simpler form of lamp the rate is, of course, directly dependent on the person who turns the winch of the feeding-rollers; but in the automatic lamp there are appliances for adjusting the rate; the suitable speed must be first found by trial, and then the apparatus is to be regulated accordingly. By means of these lamps photographs can be taken as quickly as with sunlight, on account of the abundance of chemically-active rays given out by the burning magnesium. It has been found that an equivalent of magnesium, in combining with oxygen, liberates a larger amount of heat than the equivalent quantity of any other metal, not excluding even potassium. Magnesium forms alloys with several other metals, such as lead, tin, mercury, gold, silver, platinum. All these alloys are brittle, and have a granular or crystalline fracture. They are too readily acted on by air and moisture to be of any service in the arts. The alloy of 85 parts of tin with 15 of magnesium is hard and brittle; its colour is lavender, although both constituents are white, or nearly so; and it decomposes water at ordinary temperatures. Both metallic magnesium and aluminium furnish useful re-agents to the scientific chemist. The latter metal, when fused, dissolves boron, silicon, and titanium, and on cooling deposits these elements in the crystalline form, this being the only known process for artificially preparing them in the crystalline state.

Since the above paragraphs were written, the price of sodium has been further greatly reduced, and it can now (1890) be purchased in bulk at about 4_s._ per lb. This cheapness has brought the substance into use for the reduction of other metals and one consequence has been a great fall in the price of aluminium. At Salindres, in France, the process of obtaining this metal that has been described on page 587, has been in use for many years, during which considerable quantities of aluminium have been produced, the output for 1882 being stated as 5,280 lbs. Aluminium has lately been prepared by a company at Wallsend-on-Tyne from _cryolite_, a mineral which is found only in Greenland, but occurs there in great abundance. Cryolite is a double fluoride of aluminium and sodium, and the processes for its reduction consist in fusing it with common salt in a reverberatory furnace, drawing off the mixture into an iron vessel, and stirring into the fused mass a certain quantity of sodium. This produces a violent action, on the cessation of which the slag is poured off, and the metallic aluminium is found as a “button” at the bottom of the converter. For obtaining a purer metal, the fusion is made in crucibles, and the sodium is added in two operations without removing the crucible. The yield of aluminium is about 8 per cent. of the weight of cryolite, and three parts of sodium are required to furnish one part of aluminium. Another large manufactory of aluminium is in operation at Oldbury, near Birmingham. There is a special difficulty in the metallurgy of aluminium, arising from the fact of the qualities of the metal being much deteriorated by the presence of a very small amount of foreign matters such as iron, silicon, &c., at the same time that no process has been found for purifying the product from these substances. If the aluminium is to be pure it must be so prepared at the first. Electrolysis has been proposed as a means of reducing the compounds, and obtaining the metal free from admixtures. Experiments seem to show that the dynamo-electric machine may be applied to this purpose, as well as to the reduction of sodium compounds, when certain practical difficulties arising from the chemical energies of the liberated substances have been overcome. What is called the “electric” furnace has been successfully used in the production of aluminium bronze. It is a rectangular iron box, 5 feet long, 1 foot deep, and 15 inches wide, with electrodes formed of rods of carbon 30 inches long and 3 inches in diameter. It is charged with a mixture of 25 parts of corundum (native crystallized oxide of aluminium), 12 parts of carbon, and 50 parts of granulated copper. This is covered at the top by lumps of charcoal, and a lid is fastened over the whole. The current from a powerful dynamo is sent through the carbons, and in about ten minutes the copper is melted, when the electrodes, at first only a few inches apart, are moved to an increased distance, and the strength of current increased. The corundum is reduced, the aluminium alloying itself with copper, and the oxygen combining with the carbon to form carbon monoxide, which is driven off. The resulting alloy is cast into ingots, its percentage of aluminium ascertained, and then it is melted with enough copper to produce aluminium bronze (page 719). The price of aluminium, which was as already stated about 3_s._ per ounce in 1875, has been so much reduced that the metal may now (1890) be purchased for 11_s._ or 12_s._ per lb. We may therefore expect to see wider applications of its excellent qualities. Though the price per lb. is still much higher than that of copper-–22 or more times as much—the metal is so much lighter that a lb. of aluminium occupies nearly 3⅓ times the space of a lb. of copper, so that, taking bulk for bulk, aluminium is only about seven times as dear as copper. [1890.]

When first introduced by Deville, in 1854, aluminium cost £20 per lb.; but its prospective value for application in the arts was recognised, and in two or three years afterwards it was put on the market at 40_s._ per lb. It was then, as already remarked, applied to many purposes where lightness is desirable, such as for the tubes of telescopes, opera-glasses, the mounting of photographic lenses, &c. And in 1888, when the production of sodium had been cheapened and applied to the separation of aluminium, the price of the latter metal fell to 18_s._ per lb. In the meantime, the cheap electricity of the dynamo caused attention to be again directed to the original electrolytic method; but many difficulties in detail had to be overcome in applying this process on the commercial scale. At length the sodium process was superseded; and by the beginning of 1890, a Swiss company was producing aluminium at 11_s._ per lb. In the course of the following year they succeeded in bringing the price down to 2_s._ per lb.; and again three years later, namely at the beginning of 1894, they could offer the metal at 1_s._ 7_d._ per lb. The conditions required for effecting this great reduction were found in driving the dynamo machinery by water-power, and in an abundant supply of cryolite at moderate cost. This cheapness of production at once placed the Swiss company in the position of being the largest and most successful aluminium manufacturers in the world, so that in 1892 they had realised a net profit of £21,563, paying their shareholders 8 per cent., and, further, in 1893, the net profit was half as much again, and the dividend was increased to 10 per cent. A British aluminium company has recently been formed in London for acquiring the rights of working all the processes of the successful Swiss company, purchasing outstanding English patents, amalgamating with certain existing companies, and for working the _bauxite_ deposits in Ireland, &c., &c. There is every reason to believe that an important result of this enterprise will be a still further reduction in the price of this metal, and consequently a great extension of its applications. And now (September, 1895) we have already heard of a further reduction in the price of this metal, which, at the present time, can be purchased in bulk for about 1_s._ 6_d._ per lb.

INDIAN-RUBBER AND GUTTA-PERCHA.

_INDIAN-RUBBER._

Researches into the history of the human race in remote ages have revealed the fact, that before man knew how to extract metals from their ores, his only implements were formed of stone; and before he became acquainted with iron, there was an intermediate period in which the more easily obtained metal, copper, had to serve as the material for all tools and weapons. Hence archæologists speak of the stone age, the bronze age, and the age of iron. If we were obliged to name the nineteenth century after the material which distinctively serves in it for the most extensive and varied uses, surely we should call it the Age of Indian-rubber!

The industrial application of Indian-rubber is entirely modern. The substance itself appears, however, to have been known to the natives of Peru from time immemorial, and to have been used for the preparation of some kind of garments. Although the first specimens were sent to Europe so long ago as 1736, and the substance was from that time submitted to many investigations, no other use was found for it up to the year 1820 than to efface from paper the marks made by pencils. From this it derives the name by which it is commonly known. It has also been called “gum elastic,” and _caoutchouc_ from the Indian name. Crude caoutchouc is the product obtained by the spontaneous solidifying of the milky juice of certain tropical plants—such as the _Hævea elastica_, _Jatropha elastica_, and the _Siphonia cautshu_. The first grows chiefly in South America, and in the basin of the Amazon forms immense forests. At a certain season each year bands of persons, called “_seringarios_,” armed with hatchets, visit these forests for the purpose of extracting the caoutchouc. They make incisions into the trunk, and the milky juice immediately runs out, and drops into a vessel placed to receive it, and attached to the tree by means of a lump of clay. In about three hours the juice ceases to flow, and the _seringario_ collects the products of the incisions in one large vessel. By dipping a board into this vessel, it becomes covered with the juice; and when this is allowed to dry, the caoutchouc remains as a thin brownish yellow layer. The caoutchouc is not dissolved in the juice, but is merely suspended in it; and to hasten the drying and coagulation of the liquid, the board is warmed over a smoky fire made with green wood. When alternate immersions and drying have covered the board with a sufficient thickness of caoutchouc, the layer is slit open with a knife, and the board is withdrawn. This is the best kind of crude caoutchouc, because it is free from all admixture of foreign bodies except the carbon derived from the smoky flame. The _bottle_ Indian-rubber is moulded on pear-shaped lumps of clay, which are covered with successive layers of the milky juice; when a sufficient thickness has been attained, the clay is removed by soaking in water.