The Romance of Industry and Invention. Various
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years later, and the Sussex iron-furnaces were blown out altogether. Farnhurst in Western, and Ashburnham in Eastern Sussex, witnessed the total extinction of the manufacture. The din of the iron hammer was hushed, the glare of the furnace faded, the last blast of the bellows was blown, and the district returned to its original rural solitude. Some of the furnace-ponds were drained and planted with hops or willows; others formed beautiful lakes in retired pleasure-grounds; while the remainder were used to drive flour-mills, as the streams in North Kent, instead of driving fulling-mills, were employed to work paper-mills.' The plentifulness of timber in the Scottish Highlands explains the establishment of smelting-furnaces, in 1753, by an English company at Bunawe in Argyllshire, whither the iron was brought from Furness in Lancashire.
Few of our readers can be unacquainted with the fact that iron-smelting at the present day is performed not with wood but with coal. It will readily, then, be understood that the substitution of the one description of fuel for the other must have formed the turning-point in the history of the British iron manufacture. This substitution, however, was brought about very slowly. The prejudice against coal was for a long period extreme; its use for domestic purposes was pronounced detrimental to health; and, even for purposes of manufacture, it was generally condemned. Nevertheless, as wood became scarcer and dearer, a closer examination into the capabilities of coal came naturally to be made; and here, as in almost every other industrial path, we find a foreigner acting as our pioneer. The Germans had long been experienced in mining and metallurgy; and it was a German, Simon Sturtevant, who first took out a patent for smelting iron with coal. But his process proved a failure, and the patent was cancelled. Other Germans, naturalised here, followed in Sturtevant's footsteps, but with no better results; until at last an Englishman, Dud Dudley (1599–1684), took up the idea, and gave it practical success. The town of Dudley was even then a centre of the iron manufacture, and Dud's noble father, Lord Dudley, owned several furnaces. But here, also, the forest-wealth of the district was fast melting away, and the trade already languished under the dread of impending dissolution. In the immediate neighbourhood, meanwhile, coal was abundant, with ironstone and limestone in close proximity to it. Dud, who, as a child, had haunted and scrutinised his father's ironworks with wondering delight, was placed just at this juncture in charge of a furnace and a couple of forges, and immediately turned his energetic mind to the question of smelting with coal. Some careful experiments succeeded so well that he wrote to his father, requesting him to take out a patent for the process; and this patent, registered in Lord Dudley's name, and dated the 22d February 1620, properly inaugurated the great metallurgic revolution which had made the English iron trade what it now is. Andrew Yarranton was another pioneer in the iron and tin-plate industry, and wrote a remarkable work on England's Improvement by Sea and Land (1677–81).
Nevertheless, even with this positive success on record, the inert insular mind long refused to follow the path cleared for it. Dud's discovery 'was neither appreciated by the iron-masters nor by the workmen;' and all schemes for smelting ore with any other fuel than wood-charcoal were regarded with incredulity. His secret seems to have been bequeathed to no one, and for many years after his death the old, much-abused, forest-devouring system went tottering on. Stern necessity, however, taught its hard lesson at last, and a period insensibly arrived when the employment of coal in smelting processes became the rule rather than the exception, and might be seen here and there on an unusually large scale—especially at the celebrated Coalbrookdale works, in the valley of the Severn, Shropshire.
The founder of the Coalbrookdale industries was a Quaker—Abraham Darby (1677–1717). A small furnace had existed on the spot ever since the days of the Tudors, and this small furnace formed the nucleus of that industrial activity which the visitor of Coalbrookdale surveys with such wonder at the present day.
In Darby's time, the principal cooking utensils of the poorer classes were pots and kettles made of cast-iron. But even this primitive ware was beyond native skill, and most of the utensils in question were imported from Holland. Exercising an effort of judgment, which, moderate as it was, seems to have been hitherto unexampled, Darby resolved to pay that country a visit, and ascertain in person why it was that Dutch castings were so good and English so bad. The use of dry sand instead of clay for the moulds comprised, he found, the whole secret.
On returning to England, Darby took out a patent for the new process, and his castings soon acquired repute. The use of pit-coal in the Coalbrookdale furnaces is not supposed, however, to have become general until the worthy Abraham had been succeeded by his son; but when it once did become so, the impetus thereby given to the iron trade and to coal-mining was immense. It is the latter industry which may pre-eminently claim to have called the steam-engine into existence. The demand for pumping-power adequate to the drainage of deep mines set Newcomen's brain to work; and the engine rough-sketched by his ingenuity, and perfected by the genius of Watt, soon increased enormously the production of iron by rendering coal more accessible and the blast-furnace more efficient.
A son-in-law of Abraham Darby's, Richard Reynolds by name, made a great stride towards the modern railway by substituting iron for wood on the tramways which connected the different works at Coalbrookdale; and it was a grandson of the same Abraham who designed and erected the first iron bridge.
England, we have seen, borrowed the idea of her smelting processes and iron-castings from Germany and Holland; but the discovery of that important material, cast-steel, belongs, at least, to one of her own sons. Yet even here the relationship is a merely conventional one, for Benjamin Huntsman (1704–1776) was the child of German parents who had settled in Lincolnshire.
Huntsman's original calling was that of a clock-maker; but his remarkable mechanical skill, his shrewdness, and his practical sense, soon gave him the repute of the 'wise man' of the district, and brought neighbours to consult him not only as to the repair of every ordinary sort of machinery, but also of the human frame—the most complex of all machines! It was his daily experience of the inferior quality of the tools at his command that led him to make experiments in the manufacture of steel. What his experiments were we have no record to show; but that they must have been conducted with Teutonic patience and thoroughness there can be no doubt, from the formidable nature of the difficulties overcome.
England, however, long refused to make use of Huntsman's precious material, although produced in her very midst. The Sheffield cutlers would have nothing to do with a substance so much harder than anything they were accustomed to, and Huntsman was actually compelled to look for his market abroad! All the cast-steel he could manufacture was sent over to France, and the merit of employing this material for general purposes belongs originally to that country. The inventions of Henry Cort (1740–1800) for refining and rolling iron (1785) were the mainspring of the malleable iron trade, and made Great Britain independent of Russia and Sweden for supplies of manufactured iron. One authority has stated that since 1790, when Cort's improvements were entirely established, the value of landed property in England had doubled. But he was unfortunate in business life, and in 1811 upwards of forty iron firms subscribed towards a fund for the assistance of his widow and nine orphan children. David Mushet (1772–1847) did much for the expansion of the iron trade in Scotland by his preparation of steel from bar-iron by a direct process, combining the iron with carbon, and by his discovery of the effect of manganese on steel.
Steel is the material of which the instruments of labour are essentially made. Upon the quality of the material, that of the instrument naturally depends, and upon the quality of the instrument, that, in great measure, of the work. Watt's marvellous invention ran great risk, at one time, of being abandoned, for the simple reason that the mechanical capacities of the age were not 'up' to its embodiment. Even after Watt had secured the aid of Boulton's best workmen, Smeaton gave it as his opinion that the steam-engine could never be brought into general use, because of the difficulty of getting its various parts made with the requisite precision.
The execution by machinery of work ordinarily executed by hand-tools has been a gigantic stride in the path of material civilisation. The earliest phase of the great modern movement in this direction is represented, probably, by the sawmill. A sawmill was erected near London as long ago as 1663—by a foreigner—but was shortly abandoned in consequence of the determined hostility of the sawyers; and more than a century elapsed before another mill was put up. But the sawmill is comparatively a rude structure, and the material