History of Iron Casting
Cast iron has been used in metal work since the Bronze Age. The process has been refined over time to develop castings that were both strong and resilient, with less susceptibility to breakage. Castings were formed by pouring molten metal into a sand or clay mold. Since each component could be easily accounted for and cast separately, this method was ideal for mass-producing a limited number of products. This blog will map the history of casting iron and how it has developed through the ages from its use in ancient civilizations to the innovations brought about by the Industrial Revolution.
Iron Casting in Early Days
Ancient Egypt: The Hittites of ancient Egypt are credited with discovering the metal iron between 5000 and 3000 BCE. In this period, tools and weapons were made by pounding or hammering metal. The Hittites refined the method of smelting iron between 2000 and 1200 BCE, heating the ore to remove impurities and thus increasing the metal’s utility.
Iron Age: Much of Europe, Asia, and Africa entered the Iron Age when they began to produce iron and steel tools and weapons. Though iron may have been smelted occasionally during the Bronze Age as a primitive sheet metal fabrication technique, it was likely viewed as subpar at the time. As a result, iron tools and weapons weren’t as robust or durable as their bronze equivalents.
Persian Empire: Once mankind had mastered steel, it led to the Persians developing their weaponry and this was significant towards building of their empire. Compared to their bronze or stone counterparts, steel swords were sharper and more durable; however there were more safety hazards attached to metal fabrication during this period.
Casting in China: Cast components made from bronze and copper by Chinese metallurgists were once employed extensively in China’s agriculture sector. The introduction of the iron plough greatly facilitated the process of ploughing in agricultural settings. In 645 BCE, China began utilizing sand molding and this made a substantial impact on the iron casting process.
Later Developments
Blast Furnace: The blast furnace was another technological breakthrough invented in China where iron was refined before being utilized to create steel. In Europe, the blast furnace was originally used in Sweden, then spread to France and Belgium in the 1300s and finally to England in 1491.
America Iron Works: The Virginia Company of London built North America’s first iron foundries in 1619. The Saugus Iron Works, located in what is now Lynn, Massachusetts, was the first iron foundry in the Americas in 1642. The first iron casting in the United States, the Saugus pot, was created in this area as well and was used to develop mining plant and equipment.
Britain: The 1700s saw a flurry of innovations, the first of which was in 1709 when Abraham Darby used a coke-fired furnace to process iron instead of charcoal – thus playing a pivotal role in the development of the iron casting industry. James Watt created the steam engine in the late 1700s that could be used to power machines, locomotives, and ships. This improved the speed and efficiency with which raw materials and finished commodities could be transported using tanks throughout the iron casting industry.
Closing Remarks
As can be observed, the iron casting industry came a long way since its introduction in the ancient civilizations of China and Mesopotamia. War played a part in boosting the industry in recent times, with iron production in Britain increased between 1793 – 1815 in response to rising demand from the military. As of recently, Britain had the highest rate of iron and steel production in Europe. The innovation of iron casting techniques had a profound impact on the country’s economy and way of life – and was one of the major factors behind the rise and rise of the British Empire!