Download - Archaeo Metallurgy
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Rough Timeline of Metallurgy
● Chalcolithic (AKA Eneolithic, Copper Age)– Poorly defined transitional period– Copper, accidental bronzes
● Bronze Age– 4000 BC – 1000 BC– Bronze = copper + tin
● Iron Age– 1000 BC onwards
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Basic Smelting Chemistry
● Very little native metal in the world– Gold, platinum, some copper, meteoric iron
● The rest is in the form of oxides, sulfides, etc.
● Smelting at its most basic:2CuO + C = 2Cu + CO2
● Need heat and a reducing atmosphere
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Timna● Earliest archaeological record of smelting● ~4000 BCE● Simple bowl furnaces with goat-skin bellows
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Backyard copper smelting
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Global source of tin
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Iron● Iron ore is everywhere● Early furnaces were nowhere near hot
enough to melt iron● Instead, a porous mass called
a bloom forms● Contains lots of chunks of
charcoal and slag● Removed from the furnace and then
hammered down to force out some of the impurities
● Very labor intensive
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http://www.bradford.ac.uk/archsci/depart/resgrp/amrg/Rievaulx02/Rievaulx.htm
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Flickr user: Stellar Muddle
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Wrought Iron
● Resulting wrought iron has banded layers of differing carbon content, making it moderately resistant to corrosion
● In modern terms, 'mild steel'● Don't confuse the name with wrought iron as a
style of metalwork● Distinctive 'grain' pattern if you know what to look
for
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Flickr user: neilalderney123
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Blacksmithing
● Two basic operations: – drawing out: making longer and narrower (easy)– upsetting: making thicker and shorter (hard)
● Welding is possible at very high temps● But riveting is easier and preferred if possible● Surprisingly easy to do in an urban setting :)
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Cast iron
● Takes very high temps, so you need good bellows or a good power source
● First achieved in China around 300 BCE● China used box-bellows● Added water power around 30 AD● Didn't spread to Europe until the 15th century● Europe stuck with accordion bellows, which suck
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Steel smelting
● Wootz● Tamahagane● Blister steel● Crucible steel (1740)● Puddling (1784)● Bessemer Process (1855) (Youtube Video)● Linz-Donawitz process (1952)
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Steel chemistry● Steel == alloy of iron + carbon● Anything beyond about 1% carbon just makes it
brittle – this is what cast iron is● Different molecular structures at different temps
– Ferrite: Pure iron, body-centered cubic lattice, low carbon solubility
– Cementite: Iron carbide, brittle cast iron– Austenite: Face-centered cubic lattice, high carbon
solubility– Martensite: Metastable result of rapidly cooled
austenite– Pearlite: Combination of ferrite and cementite
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Phase diagram
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Heat treatments● All heat treating of steel is just manipulation of the
phase diagram● Normalizing/annealing == slowly cooling from
over the critical temp to release stresses and remove all hardening
● Quenching == rapidly cooling to lock the steel into martensitic structure
● Tempering == partially degrading hard/brittle structures through the application of (much lower) heat (martensite to cementite)
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Quenching Myths● The ONLY function of the quenchant is to change
how quickly the steel cools down● The faster it cools down, the harder and more
brittle it will be● Different quenchants remove heat at different
speeds, due to bubble formation and boiling point● Oil < water < brine● Use the correct quenchant for the alloy, RTFM● USING SNOW IS BULLSHIT
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Case Hardening
● Pack the piece in carbon and heat for a long time● Much like blister steel, but non-destructive● Creates a high carbon zone maybe 1 mm deep● Good for bearing surfaces, but not blades
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Composite sword design
● The ideal blade has a very hard edge, but is still flexible over the whole length
● Can approximate this with tempering● Another way is to combine steels of different
carbon contents● This also lets you use lower carbon steel, which
traditionally was much cheaper● Classic example: the katana● (The folding 10,000 times thing? Bullshit.)
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Differential quenching and hamon
● To make the edge even more durable, you can quench different parts at different rates
● Coat the parts you want softer with a clay mixture● When quenched, those parts cool slower, thus
harden less● Forms a hamon when polished properly
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References● The Machinery's Handbook● The Craft of the Japanese Sword, Leon Kapp and Hiroko
Kapp● Out of the Fiery Furnace: The Impact of Metals on the History
of Mankind, Robert Raymond● A History of Metallurgy, R.F. Tylecote● Chalcolithic Copper Smelting: Excavations and Experiments,
Archaeo-Metallurgy IAMS monograph, Beno Rothenberg, R.F. Tylecote, P.J. Boydell
● Sources of Tin and the Beginnings of Bronze Metallurgy, James D. Muhly, American Journal of Archaeology, Vol. 89, No. 2. (Apr., 1985), pp. 275-291.
● De Re Metallica, Georgius Agricola, translated by Herbert Hoover
● http://www.archaeology-classic.com/● And, of course, Wikipedia