7. The melting-pots are made chiefly of the most refractory clays and sand. Much of the clay used for this purpose, in many of the glass-houses in the United States, is imported from Germany. The materials, having been sifted, and mixed with a suitable quantity of water, the homogeneous mass is formed into crucibles, by spreading it on the inside of vessels which are much in the shape of a common wash-tub. After the clay has become sufficiently solid to sustain itself, the hoops are removed from the vessel, and the several staves taken apart.
8. The crucibles are suffered to dry in the atmosphere for two or three months, after which they are applied to use as they may be needed. Before they are placed in the main furnace, they are gradually raised to an intense heat in one of smaller dimensions, built for this express purpose. The fuel employed in fusing the metal is chiefly pine wood, which, in all cases, is previously dried in a large oven. Four of the five furnaces near Philadelphia, which belonged to Doctor Dyott, were heated with rosin.
9. The materials having been mixed, in the proposed proportions, which are determined by weight, they are thrown into the melting-pots, and, by a gradually increasing heat, reduced to a paste, suitable for application by the blower. This part of the process is commonly performed at night, while the blowers are absent from the works.
10. The applications of glass are so exceedingly extensive, that it is inconvenient, if not impossible, to manufacture every species of it at one glass-house or at one establishment. Some, therefore, confine their attention to the production of window glass, and such articles of hollow ware as may be made, with profit, from the same kind of paste. Others make vials and other species of ware, employed by the druggist, apothecary, and chemist. And again, the efforts, at some factories, are confined entirely to the manufacture of flint glass, or to that of plate glass for mirrors.
11. The principal operations connected with the manufacture of different species of glass, after the paste has been prepared, may be included under the following heads; viz., blowing, casting, moulding, pressing and grinding; although all these are never performed in one and the same establishment.
12. Blowing.—The operation of blowing is nearly or quite the same in the production of every species of glass ware, in which it is employed. The manipulations, however, connected with making different articles, are considerably varied, to suit their particular conformation. This circumstance renders it impossible for us to give more than a general outline of the process of this manufacture.
13. In the formation of window glass, the workman gathers upon the end of an iron tube a sufficient amount of the metal, which he brings to a cylindrical form by rolling it upon a cast iron or stone table. He then blows through the tube with considerable force, and thus expands the glass to the form of an inflated bladder. The inflation is assisted by the heat, which causes the air and moisture of the breath to expand with great power.
14. Whenever the glass has become too stiff, by cooling, for inflation, it is again softened by holding it in the blaze of the fuel, and the blowing is repeated, until the globe has been expanded to the requisite thinness. Another workman next receives it at the other end, upon an iron rod, called a punt, or punting iron, when the blowing iron is detached. It is now opened, and spread into a smooth sheet, by the centrifugal force acquired by the rapid whirl given to it, in the manner exhibited in the preceding cut. The sheet thus produced is of a uniform thickness, except at the centre, where the iron rod had been attached.
15. An inferior kind of window glass, the materials of which are sand, kelp, and soap-boilers' waste, is made by blowing the metal into cones, about a foot in diameter at their base; and these, while hot, are touched on one side with a cold iron dipped in water. This produces a crack, which runs through the whole length of the cone. The glass then expands into a sheet somewhat resembling a fan. This is supposed to be the oldest method of manufacturing window or plate glass.
16. The window glass produced in the manner first described, is called crown glass; and the other, broad glass. But by neither of these methods can the largest panes be produced. The blowing for these differs from the methods just described, in that the material is blown into an irregular cylinder, open at its further end. When a sufficient number of these cylinders have accumulated, the end to which the blowing iron had been attached, is capped off by drawing round it a circle of melted glass, and the cylinder is divided longitudinally by touching it through its whole length with a hot iron. The cylinders, in this state, are put into the annealing oven, where, by aid of a heat which raises the glass to redness, it is expanded into sheets. These sheets are then broken into panes of several sizes by the aid of a diamond and a straight edge, as in the case of glass blown by other methods.