Steam Hammer.
These operations are conducted in a large shed, where the rollers stand like awful combinations of infernal machines and patent mangles; where a boding and vengeful tilt-hammer, worked by steam, is tended by a man, who sits like a calm fate beside its crushing bulk, and supplies it with fresh victims; where the awful boom seems to shatter the very atmosphere, and deafness reigns triumphant. In obedience to a signal, however, the monster is suddenly stopped, and we are enabled to hear that the great two-pot furnace on our left is used for making the steel from those long laths of bevel-edged iron stacked against the wall; that the furnace is constructed with wide flues on each side and under the bottom, while the fire-grate occupies the centre between the two pots; that the pots themselves are some four feet deep, and two feet and a half wide, are airtight, contain layers of charcoal and iron covered with loam sand, will remain seven days and nights in the furnace, until their contents are white hot, and that at the end of that time the iron will have been converted into steel of a slaty-blue colour. The inexorable hammer resuming its work at this point, we follow the bayonet to its completion, and once more visit the forges, to witness the “shutting on” or welding the blade to a piece of iron, which ultimately forms the socket by which the bayonet itself is fixed on to the barrel of the rifle or musket.
There is yet another operation before the blades are taken to the finishing shop, one of the most important, too, since it is no other than grinding, a process which secures an exact and uniform thickness and increases their elasticity.
We are standing at the open end of a long, vast, and gloomy shed-like building, supported by iron pillars. On each side through the entire length a series of enormous grindstones spin round amidst sand and water, and the mud from both. Seated astride the bodies of wooden horses, whose heads seem to have been transformed into these wheels, the grinders seize upon the blades, and each fearless rider rising in his stirrups, or, what looks much the same, standing tiptoe till he no longer touches his saddle, throws himself forward, and presses the sword, matchet, or bayonet on the wheel, at the same time guiding it deftly with its left hand, till its whole surface has been smoothly ground.
Along the whole line of whirling stones fly the lurid red sparks, and the grinders, with squared elbows, seem to curb the struggling and impetuous wheels.
After polishing, which is completed by wooden wheels bearing a coating of leather covered with emery, the swords and matchets go to receive handles, and the bayonets locking rings. The handles of swords are made of walnut-wood covered with the skin of the dogfish, while the hilt and guard are formed from a plain flat sheet of steel, in shape not unlike one side of a pair of bellows.
The solid socket of the bayonet is hammered into form, and afterwards stamped into shape with the rim complete, from which process it is conveyed to a shop where it is drilled by steam power. It then only remains to secure a smooth surface, by means of a revolving barrel, containing an instrument with a number of flanged blades, against which the socket of the bayonet is pressed. It is not a little remarkable to see the solid steel pared and shaved like wax, and no less wonderful to notice the simple machinery by which it is accomplished. The locking rings are stamped out by a lever and die, pierced by a punch, and afterwards “bored,” “faced,” and their shapes secured by a triple circular saw, worked by a lathe.
Mandril, with Common Musket Barrel in progress. Welding by Hand. Forging Hammer.