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Crucible steel is
steel Steel is an alloy of iron and carbon that demonstrates improved mechanical properties compared to the pure form of iron. Due to steel's high Young's modulus, elastic modulus, Yield (engineering), yield strength, Fracture, fracture strength a ...
made by melting
pig iron Pig iron, also known as crude iron, is an intermediate good used by the iron industry in the production of steel. It is developed by smelting iron ore in a blast furnace. Pig iron has a high carbon content, typically 3.8–4.7%, along with si ...
,
cast iron Cast iron is a class of iron–carbon alloys with a carbon content of more than 2% and silicon content around 1–3%. Its usefulness derives from its relatively low melting temperature. The alloying elements determine the form in which its car ...
,
iron Iron is a chemical element; it has symbol Fe () and atomic number 26. It is a metal that belongs to the first transition series and group 8 of the periodic table. It is, by mass, the most common element on Earth, forming much of Earth's o ...
, and sometimes
steel Steel is an alloy of iron and carbon that demonstrates improved mechanical properties compared to the pure form of iron. Due to steel's high Young's modulus, elastic modulus, Yield (engineering), yield strength, Fracture, fracture strength a ...
, often along with
sand Sand is a granular material composed of finely divided mineral particles. Sand has various compositions but is usually defined by its grain size. Sand grains are smaller than gravel and coarser than silt. Sand can also refer to a textural ...
,
glass Glass is an amorphous (non-crystalline solid, non-crystalline) solid. Because it is often transparency and translucency, transparent and chemically inert, glass has found widespread practical, technological, and decorative use in window pane ...
, ashes, and other fluxes, in a crucible. Crucible steel was first developed in the middle of the 1st millennium BCE in Southern India and
Sri Lanka Sri Lanka, officially the Democratic Socialist Republic of Sri Lanka, also known historically as Ceylon, is an island country in South Asia. It lies in the Indian Ocean, southwest of the Bay of Bengal, separated from the Indian subcontinent, ...
using the wootz process. In ancient times, it was not possible to produce very high temperatures with charcoal or coal fires, which were required to melt iron or steel. However, pig iron, having a higher carbon content and thus a lower melting point, could be melted, and by soaking wrought iron or steel in the liquid pig-iron for a long time, the carbon content of the pig iron could be reduced as it slowly diffused into the iron, turning both into steel. Crucible steel of this type was produced in South and Central Asia during the medieval era. This generally produced a very hard steel, but also a composite steel that was inhomogeneous, consisting of a very high-carbon steel (formerly the pig-iron) and a lower-carbon steel (formerly the wrought iron). This often resulted in an intricate pattern when the steel was forged, filed or polished, with possibly the most well-known examples coming from the wootz steel used in Damascus swords. The steel was often much higher in carbon content (typically ranging in the area of 1.5 to 2.0%) and in quality (lacking impurities) in comparison with other methods of steel production of the time because of the use of fluxes. The steel was usually worked very little and at relatively low temperatures to avoid any decarburization, hot short crumbling, or excess diffusion of carbon. With a carbon content close to that of cast iron, it usually required no heat treatment after shaping other than air cooling to achieve the correct hardness, relying on composition alone. The higher-carbon steel provided a very hard edge, but the lower-carbon steel helped to increase the toughness, helping to decrease the chance of chipping, cracking, or breaking. In Europe, crucible steel was developed by Benjamin Huntsman in England in the 18th century. Huntsman used coke rather than coal or charcoal, achieving temperatures high enough to melt steel and dissolve iron. Huntsman's process differed from some of the wootz processes in that it used a longer time to melt the steel and to cool it down and thus allowed more time for the diffusion of carbon. Huntsman's process used iron and steel as raw materials, in the form of blister steel, rather than direct conversion from cast iron as in puddling or the later Bessemer process. The ability to fully melt the steel removed any inhomogeneities in the steel, allowing the carbon to dissolve evenly into the liquid steel and negating the prior need for extensive blacksmithing in an attempt to achieve the same result. Similarly, it allowed steel to be cast by pouring into molds. The use of fluxes allowed nearly complete extraction of impurities from the liquid, which could then simply float to the top for removal. This produced the first steel of modern quality, providing a means of efficiently changing excess wrought iron into useful steel. Huntsman's process greatly increased the European output of quality steel suitable for use in items like knives, tools, and machinery, helping to pave the way for the
Industrial Revolution The Industrial Revolution, sometimes divided into the First Industrial Revolution and Second Industrial Revolution, was a transitional period of the global economy toward more widespread, efficient and stable manufacturing processes, succee ...
.


Methods of crucible steel production

Iron
alloy An alloy is a mixture of chemical elements of which in most cases at least one is a metal, metallic element, although it is also sometimes used for mixtures of elements; herein only metallic alloys are described. Metallic alloys often have prop ...
s are most broadly divided by their
carbon Carbon () is a chemical element; it has chemical symbol, symbol C and atomic number 6. It is nonmetallic and tetravalence, tetravalent—meaning that its atoms are able to form up to four covalent bonds due to its valence shell exhibiting 4 ...
content:
cast iron Cast iron is a class of iron–carbon alloys with a carbon content of more than 2% and silicon content around 1–3%. Its usefulness derives from its relatively low melting temperature. The alloying elements determine the form in which its car ...
has 2–4% carbon impurities; wrought iron oxidizes away most of its carbon, to less than 0.1%. The much more valuable
steel Steel is an alloy of iron and carbon that demonstrates improved mechanical properties compared to the pure form of iron. Due to steel's high Young's modulus, elastic modulus, Yield (engineering), yield strength, Fracture, fracture strength a ...
has a delicately intermediate carbon fraction, and its material properties range according to the carbon percentage: high carbon steel is stronger but more
brittle A material is brittle if, when subjected to stress, it fractures with little elastic deformation and without significant plastic deformation. Brittle materials absorb relatively little energy prior to fracture, even those of high strength. ...
than low carbon steel. Crucible steel sequesters the raw input materials from the heat source, allowing precise control of carburization (raising) or decarburization (lowering carbon content). Fluxes, such as
limestone Limestone is a type of carbonate rock, carbonate sedimentary rock which is the main source of the material Lime (material), lime. It is composed mostly of the minerals calcite and aragonite, which are different Polymorphism (materials science) ...
, could be added to the crucible to remove or promote
sulfur Sulfur ( American spelling and the preferred IUPAC name) or sulphur ( Commonwealth spelling) is a chemical element; it has symbol S and atomic number 16. It is abundant, multivalent and nonmetallic. Under normal conditions, sulfur atoms ...
, silicon, and other impurities, further altering its material qualities. Various methods were used to produce crucible steel. According to Islamic texts such as al-Tarsusi and Abu Rayhan Biruni, three methods are described for indirect production of steel.Feuerbach et al. 1997, 105 The medieval Islamic historian Abu Rayhan Biruni (c. 973–1050) provides the earliest reference of the production of Damascus steel.Feuerbach et al. 1998, 38 The first, and the most common, traditional method is solid state carburization of wrought iron. This is a
diffusion Diffusion is the net movement of anything (for example, atoms, ions, molecules, energy) generally from a region of higher concentration to a region of lower concentration. Diffusion is driven by a gradient in Gibbs free energy or chemical p ...
process in which wrought iron is packed in crucibles or a
hearth A hearth () is the place in a home where a fire is or was traditionally kept for home heating and for cooking, usually constituted by a horizontal hearthstone and often enclosed to varying degrees by any combination of reredos (a low, partial ...
with charcoal, then heated to promote diffusion of carbon into the iron to produce steel.Feuerbach et al. 1995, 12 Carburization is the basis for the wootz process of steel. The second method is the decarburization of
cast iron Cast iron is a class of iron–carbon alloys with a carbon content of more than 2% and silicon content around 1–3%. Its usefulness derives from its relatively low melting temperature. The alloying elements determine the form in which its car ...
by removing carbon from the cast iron. The third method uses wrought iron and cast iron. In this process, wrought iron and cast iron may be heated together in a crucible to produce steel by fusion. In regard to this method Abu Rayhan Biruni states: "this was the method used in Hearth". It is proposed that the Indian method refers to Wootz carburization method; i.e., the
Mysore Mysore ( ), officially Mysuru (), is a city in the southern Indian state of Karnataka. It is the headquarters of Mysore district and Mysore division. As the traditional seat of the Wadiyar dynasty, the city functioned as the capital of the ...
or Tamil processes.Srinivasan 1994, 56 Variations of co-fusion process have been found primarily in
Persia Iran, officially the Islamic Republic of Iran (IRI) and also known as Persia, is a country in West Asia. It borders Iraq to the west, Turkey, Azerbaijan, and Armenia to the northwest, the Caspian Sea to the north, Turkmenistan to the nort ...
and Central Asia but have also been found in Hyderabad, IndiaFeuerbach et al. 1998, 39 called Deccani or Hyderabad process. For the carbon, a variety of organic materials are specified by the contemporary Islamic authorities, including pomegranate rinds, acorns, fruit skins like orange peel, leaves as well as the white of egg and shells. Slivers of wood are mentioned in some of the Indian sources, but significantly none of the sources mention charcoal.


Early history

Crucible steel is generally attributed to production centres in
India India, officially the Republic of India, is a country in South Asia. It is the List of countries and dependencies by area, seventh-largest country by area; the List of countries by population (United Nations), most populous country since ...
and
Sri Lanka Sri Lanka, officially the Democratic Socialist Republic of Sri Lanka, also known historically as Ceylon, is an island country in South Asia. It lies in the Indian Ocean, southwest of the Bay of Bengal, separated from the Indian subcontinent, ...
where it was produced using the so-called " wootz" process, and it is assumed that its appearance in other locations was due to long-distance trade.Feuerbach 2002, 13 Only recently it has become apparent that places in Central Asia like
Merv Merv (, ', ; ), also known as the Merve Oasis, was a major Iranian peoples, Iranian city in Central Asia, on the historical Silk Road, near today's Mary, Turkmenistan. Human settlements on the site of Merv existed from the 3rd millennium& ...
in Turkmenistan and Akhsiket in Uzbekistan were important centres of production of crucible steel.Ranganathan and Srinivasan 2004, 126 The Central Asian finds are all from excavations and date from the 8th to 12th centuries CE, while the Indian/Sri Lankan material is as early as 300 BCE. India's iron ore had trace vanadium and other alloying elements leading to increased hardenability in Indian crucible steel which was famous throughout the middle east for its ability to retain an edge. While crucible steel is more attributed to the Middle East in early times, pattern welded swords, incorporating high-carbon, and likely crucible steel, have been discovered in Europe, from the 3rd century CE, particularly in
Scandinavia Scandinavia is a subregion#Europe, subregion of northern Europe, with strong historical, cultural, and linguistic ties between its constituent peoples. ''Scandinavia'' most commonly refers to Denmark, Norway, and Sweden. It can sometimes also ...
. Swords bearing the brand name Ulfberht, and dating to a 200-year period from the 9th century to the early 11th century, are prime examples of the technique. It is speculated by many that the process of making these blades originated in the Middle East and subsequently had been traded during the Volga Trade Route days. In the first centuries of the Islamic period, some scientific studies on swords and steel appeared. The best known of these are by Jabir ibn Hayyan 8th century, al-Kindi 9th century, Al-Biruni in the early 11th century, al-Tarsusi in the late 12th century, and Fakhr-i-Mudabbir 13th century. Any of these contains far more information about Indian and damascene steels than appears in the entire surviving literature of
classical Greece Classical Greece was a period of around 200 years (the 5th and 4th centuries BC) in ancient Greece,The "Classical Age" is "the modern designation of the period from about 500 B.C. to the death of Alexander the Great in 323 B.C." ( Thomas R. Mar ...
and
Rome Rome (Italian language, Italian and , ) is the capital city and most populated (municipality) of Italy. It is also the administrative centre of the Lazio Regions of Italy, region and of the Metropolitan City of Rome. A special named with 2, ...
.Bronson 1986, 19


South India and Sri Lanka

There are many ethnographic accounts of Indian crucible steel production; however, scientific investigations of the remains of crucible steel production have only been published for four regions: three in India and one in Sri Lanka.Feuerbach 2002, 164 Indian/Sri Lankan crucible steel is commonly referred to as wootz, which is generally agreed to be an English corruption of the word ''ukko'' (in the Canarese language) or ''hookoo'' (in the
Telugu language Telugu (; , ) is a Dravidian languages, Dravidian language native to the Indian states of Andhra Pradesh and Telangana, where it is also the official language. Spoken by about 96 million people (2022), Telugu is the most widely spoken member of ...
).Feuerbach 2002, 163 European accounts from the 17th century onwards have referred to the repute and manufacture of "wootz", a traditional crucible steel made specially in parts of southern India in the former provinces of Golconda, Mysore and Salem. As yet the scale of excavations and surface surveys is too limited to link the literary accounts to archaeometallurgical evidence.Griffiths and Srinivasan 1997, 111 The proven sites of crucible steel production in south India, e.g. at Konasamudram and Gatihosahalli, date from at least the late medieval period, 16th century.Srinivasan 1994, 52 One of the earliest known potential sites, which shows some promising preliminary evidence that may be linked to
ferrous In chemistry, iron(II) refers to the chemical element, element iron in its +2 oxidation number, oxidation state. The adjective ''ferrous'' or the prefix ''ferro-'' is often used to specify such compounds, as in ''ferrous chloride'' for iron(II ...
crucible processes in Kodumanal, near Coimbatore in
Tamil Nadu Tamil Nadu (; , TN) is the southernmost States and union territories of India, state of India. The List of states and union territories of India by area, tenth largest Indian state by area and the List of states and union territories of Indi ...
.Ranganathan and Srinivasan 2004, 117 The site is dated between the third century BCE and the third century CE.Craddock 2003, 245 By the seventeenth century the main centre of crucible steel production seems to have been in Hyderabad. The process was apparently quite different from that recorded elsewhere.Craddock 1995, 281 Wootz from Hyderabad or the Deccani process for making watered blades involved a co-fusion of two different kinds of iron: one was low in carbon and the other was a high-carbon steel or cast iron.Moshtagh Khorasani 2006, 108 Wootz steel was widely exported and traded throughout ancient Europe, China, the
Arab world The Arab world ( '), formally the Arab homeland ( '), also known as the Arab nation ( '), the Arabsphere, or the Arab states, comprises a large group of countries, mainly located in West Asia and North Africa. While the majority of people in ...
, and became particularly famous in the Middle East, where it became known as Damascus steel.Srinivasan 1994Srinivasan & Griffiths Recent archaeological investigations have suggested that Sri Lanka also supported innovative technologies for iron and steel production in antiquity.Ranganathan and Srinivasan 2004, 125 The Sri Lankan system of crucible steel making was partially independent of the various Indian and Middle Eastern systems.Bronson 1986, 43 Their method was something similar to the method of carburization of wrought iron. The earliest confirmed crucible steel site is located in the Knuckles range in the northern area of the Central Highlands of Sri Lanka dated to 6th–10th centuries CE.Feuerbach 2002, 168 In the twelfth century the land of Serendib (Sri Lanka) seems to have been the main supplier of crucible steel, but over the centuries production slipped back, and by the nineteenth century just a small industry survived in the Balangoda district of the central southern highlands.Craddock 1995, 279 A series of excavations at Samanalawewa indicated the unexpected and previously unknown technology of west-facing
smelting Smelting is a process of applying heat and a chemical reducing agent to an ore to extract a desired base metal product. It is a form of extractive metallurgy that is used to obtain many metals such as iron-making, iron, copper extraction, copper ...
sites, which are different types of steel production.Juleff 1998, 51 These furnaces were used for direct smelting to steel.Juleff 1998, 222 These are named "west facing" because they were located on the western sides of hilltops to use the prevailing wind in the smelting process.Juleff 1998, 80 Sri Lankan furnace steels were known and traded between the 9th and 11th centuries and earlier, but apparently not later.Juleff 1998, 221 These sites were dated to the 7th–11th centuries. The coincidence of this dating with the 9th century Islamic reference to Sarandib is of great importance. The crucible process existed in India at the same time that the west- facing technology was operating in Sri Lanka.Juleff 1998, 220 Excavations of the Yodhawewa (near Mannar) site (in 2018) have uncovered a lower half of a bottom spherical furnace and crucible fragments used to make crucible steel in Sri Lanka during the 7th-8th centuries AD. The crucible fragments uncovered at the site were similar to the elongated tube-shaped crucibles of Samanalawewa.


Central Asia

Central Asia has a rich history of crucible steel production, beginning during the late 1st millennium CE.Papakhristu and Rehren 2002, 69 From the sites in modern Uzbekistan and Merv in Turkmenistan, there is good archaeological evidence for the large scale production of crucible steel.Rehren and Papakhristu 2000, 55 They all belong in broad terms to the same early
medieval In the history of Europe, the Middle Ages or medieval period lasted approximately from the 5th to the late 15th centuries, similarly to the post-classical period of World history (field), global history. It began with the fall of the West ...
period between the late 8th or early 9th and the late 12th century CE,Rehren and Papachristou 2003, 396 contemporary with the early
crusades The Crusades were a series of religious wars initiated, supported, and at times directed by the Papacy during the Middle Ages. The most prominent of these were the campaigns to the Holy Land aimed at reclaiming Jerusalem and its surrounding t ...
. The two most prominent crucible steel sites in eastern Uzbekistan carrying the Ferghana Process are Akhsiket and Pap in the Ferghana Valley, whose position within the Great
Silk Road The Silk Road was a network of Asian trade routes active from the second century BCE until the mid-15th century. Spanning over , it played a central role in facilitating economic, cultural, political, and religious interactions between the ...
has been historically and archaeologically proved.Rehren and Papakhristu 2000, 58 The material evidence consists of large number of archaeological finds relating to steel making from 9th–12th centuries CE in the form of hundreds of thousands of fragments of crucibles, often with massive slag cakes. Archaeological work at Akhsiket, has identified that the crucible steel process was of the carburization of iron metal.Rehren and Papakhristu 2000 This process appears to be typical of and restricted to the Ferghana Valley in eastern Uzbekistan, and it is therefore called the Ferghana Process.Rehren and Papakhristu 2000, 67 This process lasted in that region for roughly four centuries.. Evidence of the production of crucible steel have been found in Merv, Turkmenistan, a major city on the 'Silk Road'. The Islamic scholar al-Kindi (801–866 CE) mentions that during the ninth century CE the region of Khorasan, the area to which the cities
Nishapur Nishapur or Neyshabur (, also ) is a city in the Central District (Nishapur County), Central District of Nishapur County, Razavi Khorasan province, Razavi Khorasan province, Iran, serving as capital of both the county and the district. Ni ...
, Merv, Herat and Balkh belong, was a steel manufacturing centre.Feuerbach 2003, 258 Evidence from a metallurgical workshop at Merv, dated to the ninth- early tenth century CE, provides an illustration of the co-fusion method of steel production in crucibles, about 1000 years earlier than the distinctly different wootz process.Feuerbach 1997, 109 The crucible steel process at Merv might be seen as technologically related to what Bronson (1986, 43) calls Hyderabad process, a variation of the wootz process, after the location of the process documented by Voysey in the 1820s.Feuerbach 2003, 264


China

The production of crucible steel in China began around the first century BC, or possibly earlier. The Chinese developed a method of producing pig iron around 1200 BC, which they used to make
cast iron Cast iron is a class of iron–carbon alloys with a carbon content of more than 2% and silicon content around 1–3%. Its usefulness derives from its relatively low melting temperature. The alloying elements determine the form in which its car ...
. By the first century BC, they had developed puddling to produce mild steel and a process of rapidly decarburizing molten cast-iron to make wrought iron by stirring it atop beds of saltpeter (called the Heaton process, it was independently discovered by John Heaton in the 1860s). Around this time, the Chinese began producing crucible steel to convert excess quantities of cast iron and wrought iron into steel suitable for swords and weapons. In 1064,
Shen Kuo Shen Kuo (; 1031–1095) or Shen Gua, courtesy name Cunzhong (存中) and Art name#China, pseudonym Mengqi (now usually given as Mengxi) Weng (夢溪翁),Yao (2003), 544. was a Chinese polymath, scientist, and statesman of the Song dynasty (960� ...
, in his book '' Dream Pool Essays'', gave the earliest written description of the patterns in the steel, the methods of sword production, and some of the reasoning behind it:
Ancient people use ''chi kang'', (combined steel), for the edge, and ''jou thieh'' (soft iron) for the back, otherwise it would often break. Too strong a weapon will cut and destroy its own edge; that is why it is advisable to use nothing but combined steel. As for the ''yu-chhang'' (fish intestines) effect, it is what is now called the 'snake-coiling' steel sword, or alternatively, the 'pine tree design'. If you cook a fish fully and remove its bones, the shape of its guts will be seen to be like the lines on a 'snake-coiling sword'.


Modern history


Early modern accounts

The first European references to crucible steel seem to be no earlier than the Post Medieval period.Craddock 2003, 251 European experiments with "
Damascus Damascus ( , ; ) is the capital and List of largest cities in the Levant region by population, largest city of Syria. It is the oldest capital in the world and, according to some, the fourth Holiest sites in Islam, holiest city in Islam. Kno ...
" steels go back to at least the sixteenth century, but it was not until the 1790s that laboratory researchers began to work with steels that were specifically known to be Indian/wootz.Needham 1958, 128 At this time, Europeans knew of India's ability to make crucible steel from reports brought back by travellers who had observed the process at several places in southern India. From the mid-17th century onwards, European travellers to the Indian subcontinent wrote numerous vivid eyewitness accounts of the production of steel there. These include accounts by Jean-Baptiste Tavernier in 1679, Francis Buchanan in 1807, and H.W. Voysey in 1832.Ranganathan and Srinivasan 2004, 60 The 18th, 19th and early 20th century saw a heady period of European interest in trying to understand the nature and properties of wootz steel. Indian wootz engaged the attention of some of the best-known scientists.Ranganathan and Srinivasan 2004, 78 One was
Michael Faraday Michael Faraday (; 22 September 1791 – 25 August 1867) was an English chemist and physicist who contributed to the study of electrochemistry and electromagnetism. His main discoveries include the principles underlying electromagnetic inducti ...
who was fascinated by wootz steel. It was probably the investigations of George Pearson, reported at the Royal Society in 1795, which had the most far-reaching impact in terms of kindling interest in wootz amongst European scientists.Ranganathan and Srinivasan 2004, 79 He was the first of these scientists to publish his results and, incidentally, the first to use the word "wootz" in print.Bronson 1986, 30 Another investigator, David Mushet, was able to infer that wootz was made by fusion.Bronson 1986, 31 David Mushet patented his process in 1800.Needham 1958, 132 He made his report in 1805. As it happens, however, the first successful European process had been developed by Benjamin Huntsman some 50 years previously in the 1740s.Craddock 1995, 283


History of production in England

Benjamin Huntsman was a clockmaker in search of a better steel for clock springs. In Handsworth near
Sheffield Sheffield is a city in South Yorkshire, England, situated south of Leeds and east of Manchester. The city is the administrative centre of the City of Sheffield. It is historically part of the West Riding of Yorkshire and some of its so ...
, he began producing steel in 1740 after years of experimenting in secret. Huntsman's system used a coke-fired furnace capable of reaching 1,600 °C, into which up to twelve clay crucibles, each capable of holding about 15 kg of iron, were placed. When the crucibles or "pots" were white-hot, they were charged with lumps of blister steel, an
alloy An alloy is a mixture of chemical elements of which in most cases at least one is a metal, metallic element, although it is also sometimes used for mixtures of elements; herein only metallic alloys are described. Metallic alloys often have prop ...
of iron and
carbon Carbon () is a chemical element; it has chemical symbol, symbol C and atomic number 6. It is nonmetallic and tetravalence, tetravalent—meaning that its atoms are able to form up to four covalent bonds due to its valence shell exhibiting 4 ...
produced by the cementation process, and a flux to help remove impurities. The pots were removed after about 3 hours in the furnace, impurities in the form of slag skimmed off, and the molten steel poured into moulds to end up as cast
ingot An ingot is a piece of relatively pure material, usually metal, that is Casting, cast into a shape suitable for further processing. In steelmaking, it is the first step among semi-finished casting products. Ingots usually require a second procedu ...
s.Juleff 1998, 11 Complete melting of the steel produced a highly uniform crystal structure upon cooling, which gave the metal increased
tensile strength Ultimate tensile strength (also called UTS, tensile strength, TS, ultimate strength or F_\text in notation) is the maximum stress that a material can withstand while being stretched or pulled before breaking. In brittle materials, the ultimate ...
and hardness in comparison with other steels being made at the time. Before the introduction of Huntsman's technique, Sheffield produced about 200 tonnes of steel per year from Swedish wrought iron (see Oregrounds iron). The introduction of Huntsman's technique changed this radically: one hundred years later the amount had risen to over 80,000 tonnes per year, or almost half of Europe's total production. Sheffield developed from a small township into one of Europe's leading industrial cities. The steel was produced in specialised workshops called 'crucible furnaces', which consisted of a workshop at ground level and a subterranean cellar. The furnace buildings varied in size and architectural style, growing in size towards the latter part of the 19th century as technological developments enabled multiple pots to be "fired" at once, using gas as a heating fuel. Each workshop had a series of standard features, such as rows of melting holes, teaming pits, roof vents, rows of shelving for the crucible pots and annealing furnaces to prepare each pot before firing. Ancillary rooms for weighing each charge and for the manufacture of the clay crucibles were either attached to the workshop, or located within the cellar complex. The steel, originally intended for making clock springs, was later used in other applications such as scissors, axes and swords. Sheffield's Abbeydale Industrial Hamlet operates for the public a
scythe A scythe (, rhyming with ''writhe'') is an agriculture, agricultural hand-tool for mowing grass or Harvest, harvesting Crop, crops. It was historically used to cut down or reaping, reap edible grain, grains before they underwent the process of ...
-making works, which dates from Huntsman's times and is powered by a
water wheel A water wheel is a machine for converting the kinetic energy of flowing or falling water into useful forms of power, often in a watermill. A water wheel consists of a large wheel (usually constructed from wood or metal), with numerous b ...
, using crucible steel made at the site.


Material properties

Previous to Huntsman, the most common method of producing steel was the manufacture of shear steel. In this method, blister steel produced by cementation was used, which consisted of a core of wrought iron surrounded by a shell of very high-carbon steel, typically ranging from 1.5 to 2.0% carbon. To help homogenize the steel, it was pounded into flat plates, which were stacked and forge welded together. This produced steel with alternating layers of steel and iron. The resulting billet could then be hammered flat, cut into plates, which were stacked and welded again, thinning and compounding the layers, and evening out the carbon more as it slowly diffused out of the high-carbon steel into the lower-carbon iron. However, the more the steel was heated and worked, the more it tended to decarburize, and this outward
diffusion Diffusion is the net movement of anything (for example, atoms, ions, molecules, energy) generally from a region of higher concentration to a region of lower concentration. Diffusion is driven by a gradient in Gibbs free energy or chemical p ...
occurs much faster than the inward diffusion between layers. Thus, further attempts to homogenize the steel resulted in a carbon content too low for use in items like springs, cutlery, swords, or tools. Therefore, steel intended for use in such items, especially tools, was still being made primarily by the slow and arduous
bloomery A bloomery is a type of metallurgical furnace once used widely for smelting iron from its iron oxides, oxides. The bloomery was the earliest form of smelter capable of smelting iron. Bloomeries produce a porous mass of iron and slag called ...
process in very small amounts and at high cost, which, albeit better, had to be manually separated from the wrought iron and was still impossible to fully homogenize in the solid state. Huntsman's process was the first to produce a fully homogeneous steel. Unlike previous methods of steel production, the Huntsman process was the first to fully melt the steel, allowing the full diffusion of carbon throughout the liquid. With the use of fluxes it also allowed the removal of most impurities, producing the first steel of modern quality. Due to carbon's high
melting point The melting point (or, rarely, liquefaction point) of a substance is the temperature at which it changes state of matter, state from solid to liquid. At the melting point the solid and liquid phase (matter), phase exist in Thermodynamic equilib ...
(nearly triple that of steel) and its tendency to oxidize (burn) at high temperatures, it cannot usually be added directly to molten steel. However, by adding wrought iron or pig iron, allowing it to dissolve into the liquid, the carbon content could be carefully regulated (in a way similar to Asian crucible-steels but without the stark inhomogeneities indicative of those steels). Another benefit was that it allowed other elements to be alloyed with the steel. Huntsman was one of the first to begin experimenting with the addition of alloying agents like
manganese Manganese is a chemical element; it has Symbol (chemistry), symbol Mn and atomic number 25. It is a hard, brittle, silvery metal, often found in minerals in combination with iron. Manganese was first isolated in the 1770s. It is a transition m ...
to help remove impurities such as oxygen from the steel. His process was later used by many others, such as Robert Hadfield and Robert Forester Mushet, to produce the first alloy steels like mangalloy, high-speed steel, and
stainless steel Stainless steel, also known as inox, corrosion-resistant steel (CRES), or rustless steel, is an iron-based alloy that contains chromium, making it resistant to rust and corrosion. Stainless steel's resistance to corrosion comes from its chromi ...
. Due to variations in the carbon content of the blister steel, the carbon steel produced could vary in carbon content between crucibles by as much as 0.18%, but on average produced a eutectoid steel containing ~ 0.79% carbon. Due to the quality and high hardenability of the steel, it was quickly adopted for the manufacture of tool steel, machine tools, cutlery, and many other items. Because no oxygen was blown through the steel, it exceeded Bessemer steel in both quality and hardenability, so Huntsman's process was used for manufacturing tool steel until better methods, utilizing an
electric arc An electric arc (or arc discharge) is an electrical breakdown of a gas that produces a prolonged electrical discharge. The electric current, current through a normally Electrical conductance, nonconductive medium such as air produces a plasma ( ...
, were developed in the early 20th century.''Tool Steels, 5th Edition'' By George Adam Roberts, Richard Kennedy, G. Krauss. ASM International, 1998, p. 4


19th and 20th century production

In another method, developed in the United States in the 1880s, iron and carbon were melted together directly to produce crucible steel. Throughout the 19th century and into the 1920s a large amount of crucible steel was directed into the production of cutting tools, where it was called ''tool steel''. The crucible process continued to be used for specialty steels, but is today obsolete. Similar quality steels are now made with an electric arc furnace. Some uses of ''tool steel'' were displaced, first by high-speed steel and later by materials such as tungsten carbide.


Crucible steel elsewhere

Another form of crucible steel was developed in 1837 by the Russian engineer Pavel Anosov. His technique relied less on the heating and cooling, and more on the quenching process of rapidly cooling the molten steel when the right crystal structure had formed within. He called his steel bulat; its secret died with him. In the United States crucible steel was pioneered by William Metcalf.


See also

* Damascus steel * Noric steel * Pattern welding


Notes


References

* Bronson, B., 1986. "The Making and Selling of Wootz, a Crucible Steel of India". ''Archeomaterials'' 1.1, 13–51. * Craddock, P.T., 1995. ''Early Metal Mining and Production''. Cambridge: Edinburgh University Press. * Craddock, P.T, 2003. "Cast Iron, Fined Iron, Crucible Steel: Liquid Iron in the Ancient World". In: P.T., Craddock, and J., Lang. (eds) ''Mining and Metal Production through the ages''. London: The British Museum Press, 231–257. * Feuerbach, A.M., 2002. "Crucible Steel in Central Asia: Production, Use, and Origins": a dissertation presented to the University of London. * Feuerbach, A., Griffiths, D. R. and Merkel, J.F., 1997. "Production of crucible steel by co-fusion: Archaeometallurgical evidence from the ninth- early tenth century at the site of Merv, Turkmenistan". In: J.R., Druzik, J.F., Merkel, J., Stewart and P.B., Vandiver (eds) ''Materials issues in art and archaeology V: symposium held 3–5 December 1996'', Boston, Massachusetts; Pittsburgh, Pa: Materials Research Society, 105–109. * Feuerbach, A., Griffiths, D., and Merkel, J.F., 1995. ''Analytical Investigation of Crucible Steel Production at Merv, Turkmenistan''. IAMS 19, 12–14. * Feuerbach, A.M., Griffiths, D.R. and Merkel, J.F., 1998. "An examination of crucible steel in the manufacture of Damascus steel, including evidence from Merv", Turkmenistan. ''Metallurgica Antiqua'' 8, 37–44. * Feuerbach, A.M., Griffiths, D.R., and Merkel, J.F., 2003. "Early Islamic Crucible Steel Production at Merv, Turkmenistan", In: P.T., Craddock, J., Lang (eds). ''Mining and Metal Production through the ages''. London: The British Museum Press, 258–266. * Freestone, I.C. and Tite, M. S. (eds) 1986. "Refractories in the Ancient and Preindustrial World", In: W.D., Kingery (ed.) and E., Lense (associated editor) ''High technology ceramics : past, present, and future ; the nature of innovation and change in ceramic technology''. Westerville, OH: American Ceramic Society, 35–63. * Juleff, G., 1998. ''Early Iron and Steel in Sri Lanka: a study of the Samanalawewa area''. Mainz am Rhein: von Zabern. * Moshtagh Khorasani, M., 2006. Arms and ''Armor from Iran, the Bronze Age to the End of the Qajar Period''. Tübingen: Legat. * Needham, J. 1958. "The development of iron and steel technology in China": second biennial Dickinson Memorial Lecture to the Newcomen Society, 1900–1995. Newcomen Society. * Papakhristu, O.A., and Rehren, Th., 2002. "Techniques and Technology of Ceramic Vessel Manufacture Crucibles for Wootz Smelting in Centural Asia". In: V., Kilikoglou, A., Hein, and Y., Maniatis (eds) ''Modern Trends in Scientific Studies on Ancient Ceramics, papers presented at the 5th European Meeting on Ancient Ceramics'', Athens 1999/ Oxford : Archaeopress, 69–74. * Ranganathan, S. and Srinivasan, Sh., 2004. ''India's Legendary Wootz steel, and advanced material of the ancient world''. Bangalore: National Institute of Advanced Studies: Indian Institute of Science. * Rehren, Th. and Papachristou, O., 2003. "Similar like White and Black: a Comparison of Steel-making Crucibles from Central Asia and the Indian subcontinent". In: Th., Stöllner et al. (eds) ''Man and mining : Mensch und Bergbau : studies in honour of Gerd Weisgerber on occasion of his 65th birthday''. Bochum : Deutsches Bergbau-Museum, 393–404. * Rehren, Th. and Papakhristu, O. 2000. "Cutting Edge Technology – the Ferghana Process of medieval crucible steel smelting". ''Metalla'' 7.2, 55–69 Srinivasan, Sh., 1994. "woots crucible steel: a newly discovered production site in south India". Institute of Archaeology, University College London, 5, 49–61. * Srinivasan, Sh., and Griffiths, D., 1997. Crucible Steel in South India-Preliminary Investigations on Crucibles from some newly identified sites. In: J.R., Druzik, J.F., Merkel, J., Stewart and P.B., Vandiver (eds) Materials issues in art and archaeology V: symposium held 3–5 December 1996, Boston, Massachusetts; Pittsburgh, Pa: Materials Research Society, 111–125. * Srinivasan, S. and Griffiths, D. ''South Indian wootz: evidence for high-carbon steel from crucibles from a newly identified site and preliminary comparisons with related finds''. Material Issues in Art and Archaeology-V, Materials Research Society Symposium Proceedings Series Vol. 462. * Srinivasan, S. & Ranganathan, S
''Wootz Steel: An Advanced Material of the Ancient World''. Bangalore: Indian Institute of Science.
* Wayman Michael L. ''The Ferrous Metallurgy of Early Clocks and Watches''. The British Museum 2000 *


External links


Merv, Turkmenistan





Making Steel by Hand: A 1949 British Pathe newsreel showing the production of crucible steel in Sheffield

Metalworking History Detailed from 9000 BC
{{DEFAULTSORT:Crucible Steel Steels Steelmaking Indian inventions Firing techniques