By the next post he sent a sketch to the company, who approved his design heartily, but were unable to use it, since the need for the paddle-shaft had already been nullified by the substitution of a screw as the motive power of their ship. Poor Nasmyth knew that he had discovered a "good thing," but British forge-masters, with a want of originality that amounted to sheer blind stupidity, refused to look at the innovation. "We have not orders enough to keep in work the forge-hammers we have," they wrote, "and we don't want any new ones, however improved they may be."
His invention, therefore, appeared doomed to failure. Help, however, came from France in the person of Mr. Schneider, founder of the famous Creusot Iron Works, notorious afterwards as the birthplace of the Boer "Long Toms." Mr. Nasmyth happened to be away when Mr. Schneider and a friend called at the Manchester works, but his partner, Mr. Gaskell, showed the French visitors round the works, and also told them of the proposed steam hammer. The designs were brought out, so that its details might be clearly explained.
Years afterwards Nasmyth returned the visit, and saw in the Creusot Works a crank-shaft so large that he asked how it had been forged. "By means of your steam hammer," came the reply. You may imagine Nasmyth's surprise on finding the very machine at work in France which his own countrymen had so despised, and his delight over its obvious success.
On returning home he at once raised money enough to secure a patent, protected his invention, and began to manufacture what has been described as "one of the most perfect of artificial machines and noblest triumphs of mind over matter that modern English engineers have developed." A few weeks saw the first—a 30-cwt.—hammer at work. People flocked to watch its precision, its beauty of action, and the completeness of control which could arrest it at any point of its descent so instantaneously as to crack without smashing a nut laid on the anvil. "Its advantages were so obvious that its adoption soon became general, and in the course of a few years Nasmyth steam hammers were to be found in every well-appointed workshop both at home and abroad."[7]
Nasmyth's invention was improved upon in 1853 by Mr. Robert Wilson, his partner and successor. He added an automatic arrangement which raised the "tup," or head, automatically from the metal it struck, so that time was saved and loss of heat to the ingot was also avoided. The beauty of the "balance valve," as it was called, will be more clearly understood if we remember that the travel of the hammer is constantly increasing as the piece on the anvil becomes thinner under successive blows. Under the influence of this very ingenious valve every variety of blow could be dealt. By simply altering the position of a tappet lever by means of two screws, a blow of the exact force required could be repeated an indefinite number of times. "It became a favourite amusement to place a wine-glass containing an egg upon the anvil, and let the block descend upon it with its quick motion; and so nice was its adjustment, and so delicate its mechanism, that the great block, weighing perhaps several tons, could be heard playing tap, tap upon the egg without even cracking the shell, when, at a signal given to the man in charge, down would come the great mass, and the egg and glass would be apparently, as Walter Savage Landor has it, 'blasted into space.'"[8]
Later on Mr. Wilson added an equally important feature in the shape of a double-action hand-gear, which caused the steam to act on the top as well as the bottom of the piston, thus more than doubling the effect of the hammer.
The largest hammer ever made was that erected by the Bethlehem Iron Company of Pennsylvania. The "tup" weighed 125 tons. After being in use for three years the owners consigned it to the scrap-heap, as inferior to the hydraulic press for the manufacture of armour-plate, though it had cost them £50,000. They then erected in its stead, for an equal sum of money, a 14,000-ton pressure hydraulic press, which fitly succeeds it as the most powerful of its kind in the world.
The change was made for three reasons. First, that the impact of so huge a block of metal necessitates the anvil being many times as heavy, and even then the shock to surrounding machinery may be very severe. Secondly, the larger the forging to be hammered, the less is the reaction of the anvil, so that all the force of the blow tends to be absorbed by the side facing the hammer; whereas with a small bar the anvil's inertia would have almost as much effect as the actual blow. Thirdly, the blow of the hammer is so instantaneous that the metal has not time to "flow" properly, and this leads to imperfect forgings, the surface of which may have been cracked. For very large work, therefore, the hammer is going out of fashion and the press coming in, though for lighter jobs it is still widely used.
Before leaving the subject we may glance at the double-headed horizontal hammer, such as is to be found in the forge-shop of the Horwich Railway Works. Two hammers, carried on rails and rollers, advance in unison from each side and pound work laid on a support between them. Each acts as anvil to the other, while doing its full share of the work. So that not only is a great deal of weight saved, but shocks are almost entirely absorbed; while the fact that each hammer need make a blow of only half the length of what would be required from a single hammer, enables twice as many blows to be delivered in a given time.