Messrs. Bell, of Newcastle, undertook the manufacture of aluminium by a system founded on this process. The first step is the preparation of pure alumina, which may be obtained by igniting ammonia alum, or by precipitating from a solution of alum free from iron, or from sodium aluminate made from the mineral called bauxite. The precipitate of hydrated alumina, mixed with charcoal and common salt, is made into balls and dried. These balls, which are about as large as an orange, are placed in upright earthenware retorts, which are heated to redness, while a current of dry chlorine is passed through them. The volatile double chloride of aluminium and sodium distils over, and is condensed in chambers lined with earthenware. This substance is mixed with powdered fluor-spar, or with cryolite (itself a compound of aluminium), which serves as a flux; and small pieces of sodium are interspersed throughout the mixture. The proportions are ten parts of the double chloride, five of fluor-spar, and two of sodium. This mixture is thrown upon the hearth of a reverberatory furnace, and the doors are shut to exclude air. A very intense action occurs: the chlorine, quitting the aluminium, seizes on the sodium, and their combination is attended by an enormous increase of temperature. The fused aluminium is run off from the furnace together with the slags which are produced by the operation. In this way, with a furnace having a hearth 16 ft. square, about 16 lbs. of aluminium can be obtained in one operation.
Rose, the eminent German metallurgist, prefers to obtain aluminium from cryolite, which is a compound of sodium, aluminium, and fluorine, found in large quantities in Greenland. It is powdered and mixed with common salt, and with the mixture a certain quantity of sodium cut into small pieces is uniformly mingled. The whole is thrown into a heated crucible, previously lined with a fused mixture of cryolite and salt, and more of the same mixture is poured upon the contents of the crucible, which is then covered and exposed to a red heat for two hours. The aluminium generally collects into buttons, which may be easily melted together by heating them in a crucible with common salt.
It will be obvious, from the preceding account of the processes of extracting aluminium, that the cost of the metal must depend upon that of sodium; and the same remark will apply to the case of magnesium. It is interesting to observe how the price of the alkaline metals has decreased as improved processes have been devised, and as the scale of production has increased with the commercial demand for the article. Prepared by Gay Lussac and Thenard’s process, these metals were produced in but small quantities, and were sold at £5 per oz. When the mode of reducing them by charcoal came into operation, the price fell to 30s. per oz.; and the researches of Deville so far improved the processes, that in 1854 sodium could be procured for 5s. per oz. Mr. Gerhard, of Battersea, subsequently manufactured sodium, so that it can now be retailed at less than 1s. per oz. The price of aluminium before Deville’s investigations was about 24s. per oz., but now the metal can be purchased at about one-eighth of that cost. [1875.]
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.”
[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.