ELECTROTYPING
9^^ >
ELECTROTYPING
A PRACTICAL TREATISE ON THE ART OF ELEC-
TROTYPING BY THE LATEST
KNOWN METHODS.
CONTAINING HISTORICAL REVIEW OF THE SUBJECT, FULL
DESCRIPTION OF THE TOOLS AND MACHINERY
REQUIRED, AND COMPLETE INSTRUCTIONS
FOR OPERATING AN ELECTRO-
TYPING PLANT.
BY C. S. PARTRIDGE.
SECOND EDITION.
CHICAGO:
The Inland Printer Company.
1908.
Copyright, 1899,
Copyright, 1908,
By The Inland Printer Company, Chicago.
PRESS OF THE HENRY O. SHEPARD COMPANY.
PREFACE TO FIRST EDITION.
THE art of electrotyping has within recent years made
material advancement. Labor-saving machinery
and appliances have simpHfied and at the same time
insured greater accuracy in the mechanical features of
the art, while the constant and increasing demand for
rapid work has been an incentive to invention and
research, with the result that electrotypes are now pro-
duced in much less time than was formerly required.
That the literature of electrotyping, although of great
value, is hardly up to date, is evidenced by the state-
ments of Urquhart, Wilson, Langbein and others, to the
effect that from seven to twenty hours are required to
deposit shells of practical thickness. While these state-
ments were, perhaps, correct at the time they were pub-
lished, they can hardly be considered accurate now, in
view of the fact that the plate from which this page is
printed was deposited in fifteen minutes.
In the following pages, revised from a series of arti-
cles in The Inlm%d Printer, I have endeavored to
describe, as clearly and simply as possible, the most
approved methods of producing electrotypes, with the
hope that the information may prove of value both to
the professional and the amateur,
C. S. PARTRIDGE.
Chicago, June, 1899.
PREFACE TO SECOND EDITION.
THE general favor accorded "Electrotyping-" made
several printings of the first edition necessary.
This second edition has been revised and corrected
to date and much new matter added, an important
addition being a glossary or reference list of terms,
processes and apparatus.
C. S. PARTRIDGE.
Chicago, December, 1908.
*♦
CONTENTS
CHAPTER PAGE
I. Historical Review . . ... 7
II. The Battery 18
III. The Dynamo 25
IV. The Bath . . . . ' . . 35
V. Steel, Brass and Nickel Baths ... 41
VI. Management of Baths 46
VII. Agitation of Baths 51
VIII. Measuring Instruments .... 58
IX. Preparation of Work .... 63
X. MoLniNG . '67
XI. Building ' . . . . . . . .78
XII. Metallizing 83
XIII. The Conductors 94
XIV. Depositing 99
XV. Casting 105
XVI. Finishing 119
XVII. Trimming and Routing 127
XVIII. Revising 136
XIX. Blocking 143
XX. Dr. Albert's Metal Molds . . . 150
Reference List of Terms, Processes and Appa-
ratus 161
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ELECTROTYPING.
CHAPTER I.
HISTORICAL REVIEW.
DURING the period of 1837- 1839, Professor Jacobi,
of St. Petersburg, Mr. Thomas Spencer, of Liver-
pool, and Mr. C. J. Jordan, of London, made at differ-
ent times announcement of their independent discovery
of the art of electrotyping. According to one author-
ity the rival claims of Professor Jacobi and Mr. Spencer
were presented by them in person before the Chemical
Section of the British Association for the promotion of
Science, and this august assembly after prolonged dis-
cussion decided that both had independently arrived at
the same result, but that the priority of discovery was
undoubtedly Mr. Spencer's. However, this decision of
the society with the high-sounding title did not by any
means settle the controversy, which became still further
complicated by the later claims of Mr. Jordan, In view
of the conflicting character of the evidence we are
inclined to divide the honor between the gentlemen
named; but whatever merit may attach to their respec-
tive claims as discoverers, there is probably no question
but that the credit for the first practical application of
the new art to the printing business belongs to an Amer-
8 ELECTROTYPING.
ican — Mr. J. A. Adams, of New York, who produced
successful electrotypes of wood engravings in 1841. It
is to American inxentive genius, also, that we are in-
debted for most of the labor-saving methods and machin-
ery which have brought the art to its present state of
perfection. In England, electrotyping seems to have
been first utilized chiefly for the production of metallic
art work such as engraved medals, statuary, etc.
Messrs. Elkington & Co. were so successful in this
branch of the art that in 1845 they had established a
considerable business in the duplication of cups, vases
and other articles, deposited entirely in gold, silver and
copper. While our friends over the water have perhaps
excelled in this feature of electrotyping, Americans were
quick to grasp and develop the possibilities of the art
as applied to printing purposes. In 1863, Mr. William
Filmer, an electrotyper of New York, who had much
to do with the early development of electrotyping, after
an extended trip abroad stated that electrotyping as
applied to the printing industry was generally recognized
in Europe as an American art.
The discovery of electrotyping, like many other
important discoveries, was purely accidental. Mr.
Spencer, for instance, was trying some experiments in
electro-chemistry. He had immersed a copper plate
in a solution of sulphate of copper and a zinc plate in
a solution of common salt, connecting them together
by a wire, and separating the fluids by a partition of
plaster of paris. In order that no action should take
place on the wire connecting the plates, he covered it
with sealing wax, and in so doing, spilled some of the
wax on the copper plate. After a few days he found
ELECTROTYPING. 9
that copper crystals had covered the copper electrode
except the portion protected by the drops of wax. It
at once occurred to him that by the application of wax
or other non-conducting substance, he could perfectly
control the deposition of the metal. Mr. Spencer then
coated a plate of copper with beeswax, and scratched
his name through the wax on the plate and connected it
with a zinc plate of corresponding size, immersing them
in the solutions as before. After a few hours he found,
as he expected, that the portion of the plate from which
the wax had been removed was coated with bright
metal, while the protected portions remained untouched.
The discovery of electrotyping created hardly less
interest than the nearly contemporaneous invention of
the electric telegraph. Scientists, professional men and
workmen became alike interested, and the copying of
medals, coins, etc., by electrotyping becarne a popular
amusement of the time.
The apparatus employed at this time consisted of a
single cell, as before described. The back of the coin
or medal to be copied was first coated with wax or var-
nish. Copper was then deposited on its face to form a
matrix, which, after having been removed from the coin
and properly prepared, was returned to the bath to
receive in its turn a deposit of copper in the form of
a facsimile of the original.
In 1840, Mr. Joseph Murray discovered that non-
conductive substances could be made conductive by
applying to them a film of graphite. This was a nota-
ble step in the progress of the art, for it not only made
possible the duplication of nonmetallic objects, but
opened the way for the use of gutta-percha, wax and
10 ELECTROTYPING.
similar substances for molding material in which an
impression of the coin or other object could be made,
thereby greatly expediting the work by saving the lime
required to make a matrix in copper.
The invention of the separate battery about the
same time, by Mr. Mason, marked another material
advancement in the art.
Mr. Adams made his first electrotype copies of
wood engravings by depositing copper directly on the
engraving and using the deposit for a matrix. The
process was, of course, very crude and invariably
destroyed the wood engraving, but it was of value as
an insurance against checking and because the electro-
type would stand much more wear than the wood cut.
Mr. J. W. Wilcox, of Boston, Massachusetts, an
employee of Mr. Daniel Davis, was the originator of
the methods by which electro^yping was made of prac-
tical use for the printing business. Mr. Davis had
produced a few electrotypes, but after the method laid
down by European experimenters ; and it may be that
Mr. Wilcox obtained, through his connection with Mr.
Davis, his first information of the possibility of making
duplicates by galvanoplasty, yet Mr. Davis did not
encourage, but, on the contrary, endeavored to dis-
suade Mr. Wilcox from the notion that something, in
a business way, could be gotten out of the new art.
Mr. Wilcox had so much faith in a successful result
that he resigned his position, that of foreman for Mr.
Davis, engaged a room and devoted his energies to the
work. In less than one month thereafter he produced
electrotypes from cuts and type, without injury to the
originals, by virtually the same manipulation that is
ELECTROTYPING. 11
now used. His most important discovery was of a
wax composition in which molds could be readily made
by pressure. He immediately started in the business of
making plates for printers' use, and was the first to
make a business of electrotyping. He showed speci-
mens of electrotypes in the fifth exhibition of the Mas-
sachusetts Charitable Mechanic Association (1847),
and page 42 of the report for that year reads as
follows :
2. J. W. Wilcox, Boston. Specimens of Electrotype.
These specimens are produced, as we think, in a manner
original with Mr. Wilcox. The originality, consists in making
the matrix, upon which the copper is deposited, of wax,
either coated or mingled with plumbago. Previously, matrices
were usually made of soft metal upon which, in a melted
state, the original plate was laid and subjected to a smart
blow, when the melted metal was partially hardened in the
process of cooling. Objections to this mode are: liability of
injuring molds or plates made of soft materials and, of
course, its inapplicability to wood engravings, and the diffi-
culty of obtaining perfect matrices, since even a small por-
tion of air beneath the plate might, when the blow is given,
materially injure the cast. Besides, the old mode is hardly
practicable, when the plate is of great extent. By the
method of Mr. Wilcox, matrices of any dimensions can be
made from a plate or mold of any materials without the
least injury to the original ; and the liability of failing to
obtain a good matrix is almost wholly obviated.
We hence infer that, among other benefits resulting from
this process, it will be found more economical, and will con-
tribute much to the beauty and perfection of the impression,
to use copper plates made from the blocks for wood engra-
vings, than to use the blocks themselves. Indeed, several of
the specimens exhibited were of this kind, and impressions
from them substantiate the opinion of the committee.
One of the specimens examined was a copper stereotype
12 ELECTROTYPING.
plate for common printing, accompanied by an impression
from the plate. This suggests to the committee what they
consider the most important feature of the subject, namely,
the probability that copper stereotype plates will take the
place of common type-metal plates. The circumstances to
warrant this probability are, the greater durability of copper
plates and the more perfect outline of the letters. That
copper plates will be more durable does not admit of a
doubt ; and some practical men express their belief that they
will last six times as long as type-metal plates. If so, and
if, as is almost certain, copper is soon to become much
cheaper than at present, there will be a decided economy in
using copper plates, and the use of them will contribute very
materially to the diffusion of knowledge, and, as we trust, to
the growth of virtue. In addition to this, the impression
from such a plate will be much more distinct and beautiful,
inasmuch as a mold in wax will have its lines better defined
than a similar mold in plaster. — Gold Medal.
Mr. Davis had an exhibit of magnetical apparatus
in the same class and year, for which he was awarded
a gold medal, and it is not likely that the award to Mr.
Wilcox would have passed unchallenged if not prop-
erly made.
Mr. Wilcox continued in business many years to
his profit, but did not derive as much financial benefit
from his inventions as he might had he patented them.
He died in West Roxbury, Massachusetts, February
19, 1876.
The following, from a letter recently received from
Mrs. Wilcox in reply to an inquiry regarding her hus-
band, shows that Mr. Wilcox did not confine his efforts
entirely to making printers' plates :
He perfected the art so well that the Massachusetts
Charitable Mechanic Association, in 1847, awarded him a
gold medal for specimen of electrotypes. The American
ELECTROTYPING. 13
Institute of New York awarded him a medal in 1848. He
turned his attention to making clock dials and steam-gauge
dials and all kinds of ornamental plates for decorating soda
fountains and other ornamental work. He invented a proc-
ess of electrotyping the face of rolls for dressing cloth, and
received a medal in i860 from the Massachusetts Charitable
Mechanic Association for the same.
Mr. Daniel Davis — properly Daniel Davis, Jr. —
was a prominent manufacturer of philosophical instru-
ments, in Boston. In 1842 he published " Davis' Man-
ual of Magnetism," in which the process of electro-
metallurgy was mentioned, and there appeared a cut
and an electrotype duplicate of the same. In the sixth
edition, published in 1847, there is a frontispiece —
two pages — one of which was printed from an origi-
nal engraving, on copper, and the other from an elec-
trotype duplicate made by depositing on the original
for a matrix, and by depositing on the matrix to make
the plate printed from. At the bottom of the page it
is stated that that duplicate was made by Mr. Davis.
Page 53 of that edition was printed from an electro-
type made by Mr. Wilcox. The seventh edition of
Davis' Manual, issued in 1848, contains the following
regarding the electrotype process :
An engraved copper plate may be copied by taking an
impression on clean and bright sheet lead with a powerful
press, or if the plate is small it may be pressed by hand on
the melted fusible metal. Or a mold may be made by depos-
iting copper on the plate itself, but care must be taken to
prevent adhesion both of the mold to the original and of the
copy to the mold. The duplicate thus obtained will furnish
engravings which can not be distinguished from those printed
from the original plate, however elaborate the design and
delicate the workmanship may be.
14 ELECTROTYPING.
An engraving printed from an electrotype plate by this
method is given as a frontispiece to the 1842 manual.
A medal or engraved plate is placed in the solution and
copper deposited upon it. The negative wire of the battery
should be connected with the rim of the medal, and in case
of an engraved plate it may be soldered to the corners. The
deposit is apt to adhere very firmly, sometimes so much so
that its removal is impossible. This may be avoided by
slightly greasing or oiling the mold and then brushing it
over with a little dry copper bronze.
The mold thus obtained may have a wire soldered to it
and be placed in the solution like the original one. In most
cases it will be considered safer to take a mold of a valuable
medal or plate in soft wax or by some of the other processes
to be described. An engraving printed from an electrotype
plate obtained by this process is given as a specimen in the
1847 manual.
In the same edition there is the following notice:
This book is believed to be the first ever electro-stereo-
typed throughout. A single page (the 53d) of " Davis' Man-
ual of Magnetism," published in August, 1847, was previously
electrotyped by the subscriber in the same manner. The
advantages of this process are : First, its durability, the
copper face of the type and illustrations lasting many times
longer than the type-metal; and second, the blackness of the
impression taken from copper.
I am prepared to execute any orders for printed work in
the above style, of which the present book is an example, and
to execute any number of facsimiles of engraved copper
plates and of whatever size. The face of each electrotype
copy is harder and more durable than the rolled copper.
I am also prepared to execute plates of electrotype copper
for engraving of greater purity and uniformity than can
otherwise be prepared.
I have, within two years, electrotyped a large number of
wood cuts, many of which have been in constant use and
ELECTROTYPING, 15
which have answered every expectation as to their durability
and the perfect character of the impression.^
The report of the Massachusetts Charitable Mechanic
Association, taking the lowest estimate, assigns to these a
durability six times greater than that of the type-metal stereo-
types. The slight additional expense of the electro-stereo-
types is therefore in no proportion to their comparative value.
Ornamental work and every branch of the art of electro-
typing will receive the attention of the subscriber.
J. W. Wilcox.
In 1853, an improvement in the Smee battery was
suggested by Mr. Adams, and immediately adopted by
electrotypers in America and Europe. Other improve-
ments of a more or less important nature were made
by Mr. Adams, Mr. Wilcox, Mr. Filmer and others,
and by 1858-59 the electrotyping business may be said
to have become established on a practical basis ; so
much so that the process was quite generally employed
for the reproduction of wood cuts.
In the meantime electricians had been busy with
the problem of producing a continuous current of elec-
tricity by mechanical means which could be substi-
tuted for the battery. Machines more or less useful
for this purpose were constructed by Dr. W. Siemens,
of Berlin, in 1857. Between i860 and 1870, Gramme,
Schuckert, Weston, Brush, and Wilde, brought out
improvements of more or less value. The Wilde
machines were the first to be used to any extent for
electrotyping, and were first adopted, about 1872, by
Frank Leslie and Lovejoy, Son & Co., of New York
City. They accomplished a revolution in the art by
reducing the time required to deposit a shell to about
three hours. Invaluable as these first machines were
16 ELECTROTYPING.
to the electrotyping trade, they soon gave place to
improved types, until at the present time it is possible
to produce an electrotype shell thick enough for ordi-
nary purposes in one hour or less.
Improvements in molding, blackleading and finish-
ing machinery have kept pace with the advancing
methods of electrotyping proper. In 1855, Mr. J. A.
Adams invented a blackleading machine with a vibrat-
ing brush and traveling carriage. In 1856, Mr. Filmer
patented a method of backing electrotype shells, by
means of which the shell was held down by springs
during the operation of casting. In 1858, Mr. S. P.
Knight invented an improvement in the preparation of
electrotype molds for the bath which was of great
value to the trade and is universally employed at the
present time. His invention consisted in precipitating
a thin film of copper on the mold previous to immers-
ing it in the bath. This is accomplished by flooding
the mold with a solution of sulphate of copper and then
dusting iron filings over it. The effect of the operation
is to cause the deposition of copper to begin immedi-
ately over the entire surface, instead of beginning only
at the points of contact and spreading slowly there-
from to other portions of the mold. Mr. Knight also
invented, in 1871, a process for applying blacklead to
the molds in the form of a solution, distributing it
over the face of the mold by means of a traveling rose
nozzle.
Many other improvements of a minor nature, which
we have not space to describe, have been made from
time to time, and the art of electrotyping may be said
to be now in a high state of perfection.
ELECTROTYPING. 17
In 1857, Alfred Smee made the remark that " elec-
trotyping is likely to be useful for the Bible, Shakes-
peare, ' Pilgrim's Progress,' or works that have a large
circulation." But the world has made wonderful prog-
ress in forty years, and the art of electrotyping has
kept up with the procession. Improved methods, labor-
saving machinery, cheapening material and the skill
which comes from long experience have combined to
reduce the cost and improve the quality of the product,
and to-day electrotyping has become an indispensable
auxiliary to the printing business. It is perhaps safe
to say that seventy-five per cent of the books published
during the last decade have been electrotyped, to say
nothing of innumerable engravings and jobs of all
kinds which have passed through the electrotypers'
hands. Fifty years ago there were in existence per-
haps a dozen electrotyping plants. There are in the
United States alone about two hundred and fifty estab-
lishments having an estimated annual output of over
$5,oOo,ooo. To such proportions has grown a business
that had its beginning a half a century ago in a quart
jar.
18 ELECTROTYPING.
CHAPTER II.
THE BATTERY.
ELECTROTYPING as applied to the manufacture
of printing plates may be briefly described as
follows : A mold of the object to be copied is taken in
beeswax and suspended, together with a plate of copper,
in an acidulated solution of copper sulphate. The mold
is attached to the negative pole of a battery or dynamo
and the copper plate to the positive pole. The electric
current passing through the bath decomposes the solu-
tion and sets the copper free on the wax mold, deposit-
ing it in an unbroken sheet. When the copper shell
has become of sufficient thickness it is removed from
the mold, strengthened with a backing of soft metal,
straightened, shaved, trimmed and blocked, and is then
ready for the printing press. As thus described the
process is apparently a simple one ; but it is, in fact, an
art which demands a high degree of manipulative skill
and the closest attention to detail.
The electric current which makes the electrotype
possible must be of a certain strength and tension. If
too strong or too weak, the deposited copper would be
brittle, crystalline or spongy, and unsuitable for electro-
types. It is obvious, therefore, that the source of elec-
tricity is a most important consideration. The dynamo
is now so generally employed for electrotyping that a
detailed description of the galvanic battery would seem
ELECTROTYPING. 19
to be out of place were it not for the fact that there are
possible conditions under which the battery may still be
found useful — such, for instance, as small experimental
work, the deposition of copper during the night, or
under other circumstances where power for operating
the dynamo is not available.
In discussing the galvanic battery no effort will be
made to consider the theory either of its action or the
effect of the current on the solution. It will be suffi-
cient to consider simply those facts a knowledge of
which is essential to the successful practice of electro-
typing. A plate of zinc and a plate of silver immersed
in acidulated water and connected together with a wire
will generate a current of electricity, and if this current
is passed through a copper sulphate solution under
proper conditions the solution will be decomposed.
Why this is so and how it is done are matters concern-
ing which various theories have been published in books
devoted to these subjects and to which the reader is
respectfully referred.
While a scientific education is not essential to the
successful practice of the electrotyper's art, he should
possess a sufficient knowledge of chemistry and of the
principles of electro-metallurgy to enable him to prop-
erly prepare and care for his solutions and to recognize
the cause and apply the remedy for the difficulties which
will occasionally confront him. It is essential, also, that
the student of this subject shall become familiar with
certain technical terms which are unavoidable in a dis-
cussion of the subject. The following list will be found
to contain most of the words and terms peculiar to
electrotyping :
20 ELECTROTYPING.
Positive plate, the active element (zinc) of the bat-
tery. Negative plate, the inactive (silver) element of
the battery. Positive pole, the wire attached to the
silver plate by which the current leaves the battery.
Negative pole, the wire attached to the zinc plate by
which the current returns to the battery. Electrodes,
the immersed surfaces of metal or other conductor, by
which the current enters and leaves the liquid. Anode,
the pole or plate by which the current enters the solu-
tion. Cathode, the wax mold or other surface receiving
the deposit and by which the current leaves the solu-
tion. Volt, the unit of electro-motive force. Ampere,
the unit of current strength. Watt, a current of one
ampere at the pressure of one volt.
There is hardly any limit to the number and variety
of galvanic batteries extant, but for various reasons the
one invented by Mr. Alfred Smee and bearing his name
has been found most suitable for electrotyping. When
a plate of copper and a plate of zinc are immersed in
acidulated water and connected together with a wire, a
current of electricity will at once begin to circulate,
starting at the zinc, or positive plate ; passing through
the fluid to the copper, or negative plate, and thence
through the connecting wire back to the zinc. The
current thus generated is at first powerful, but gradu-
ally decreases in strength and finally ceases altogether,
owing partly to so-called local action in the zinc plate
and partly to the adherence of hydrogen bubbles to the
copper plate, which have the effect of insulating it.
The local action referred to is caused by particles of
other metals, such as lead and tin, which are nearly
always present in zinc to a greater or less extent.
ELECTROTYPING. 21
These foreign metals form minute but independent bat-
teries in themselves, which serve to rapidly dissolve the
zinc. This local action may be minimized by amalga-
mating the zinc plate with mercury, which is done in
the following manner : After thorough cleaning with
caustic potash or dilute sulphuric acid, the zinc plate is
placed in a shallow vessel and every part of its surface
carefully coated with mercury mixed with a little sul-
phuric acid. The coating may be applied with a flan-
nel cloth tied to a stick or in any convenient manner,
and should be well rubbed in.
The adherence of hydrogen bubbles to the copper
plate may be prevented to a large extent by roughening
its surface. Mr. Smee improved upon this plan by sub-
stituting a silver plate for the copper plate and roughen-
ing the surface of the silver by platinizing. The first
cost of silver plates is considerable and platinizing is
also an expensive process, but the Smee battery is so
far superior to the zinc-copper battery for electrotyping
that the difference in first cost is a matter of small con-
sequence. Solid silver plates are seldom employed in
the battery, heavily plated copper plates having been
found to answer the purpose nearly as well. Platinizing
is effected by suspending the silver plate in a saturated
solution of bichloride of platinum and acidulated water
in the proportion of one part solution to thirty parts
water. In the same vessel opposite the silver plate is a
porous cell containing sulphuric acid and water ( i to
id) with a zinc plate suspended in it. On connecting
the zinc and silver plates with a wire the platinum in the
solution will be deposited on the silver plate in the form
of a nearly black powder, which roughens the surface
22 ELECTROTYPING.
of the plate and effectually prevents the adherence of
hydrogen bubbles.
A battery may consist of one or more sets of plates,
the number and size of plates to be determined by the
amount of work to be performed. To produce the best
results the surface of the zinc element in the battery
should equal the cathode surface in the depositing bath.
That is to say, if it is desired to deposit copper on four
molds at one time, each one square foot in area, then
the battery should contain an equal area of zinc surface;
a convenient size for the plates in a battery of this
capacity would be 12 by 12 inches. A battery made
up of four zinc and two silver plates, each twelve inches
square, would deposit a good quality of copper over
eight square feet of area.
The electro-motive force of one Smee cell is sufficient
to deposit copper on shallow molds, and there is, there-
fore, no necessity for employing more than one cell for
ordinary electrotyping, but care should be taken to make
the cell large enough to accommodate a sufficient num-
ber of zinc plates to equal the area of the molds in the
depositing bath. In this connection it may be explained
that while a strong current may be employed in electro-
typing, but very little tension or electro-motive force is
required, and it is well to remember that the size of the
battery or the number of plates it contains, have noth-
ing to do with its electro-motive force or the pushing
power of its current. A cell of one quart capacity has
the same E. M. F. as one of 100 gallons, but the
strength or quantity of current depends on the area of
zinc surface attacked. It is, therefore, essential in mak-
ing up a battery for electrotyping to connect all the zinc
ELECTROTYPING.
o.q
plates to one electrode, and all the silver plates to the
other. As before stated, the E. M. F. of one cell is
sufficient for ordinary electrotyping; but for such work
as steel or nickel facing, one cell would not have suffi-
cient power to overcome the resistance offered by the
iron or nickel solutions, and it becomes necessary to
couple two or more cells together by connecting the
zincs of one cell with the silvers of the other. In this
Fig. I.
Electrotype Battery.
way the power of the battery to overcome resistance is
increased in proportion to the number of cells employed,
but the strength of the current remains the same unless
the area of zinc surface attacked should also be increased.
In Fig. I is illustrated a single-cell battery showing
the electrode and cross-rods for supporting the zinc and
silver plates. This cell is i8 inches long, i8 inches
deep and i6 inches wide, and is designed for four zinc
24 ELECTROTYPING.
and two silver plates, each 1 2 inches square. This bat-
tery is large enough to deposit from eight to ten feet of
copper at a time. The electrodes are ^-inch copper
rods, and the cross-rods are ^ inch in diameter. The
vat is constructed of pine or vvhitewood planks, bolted
together, and is lined with asphaltum.
To obtain satisfactory shells at a minimum expense,
the battery should receive careful attention. The zinc
plates must be kept thoroughly amalgamated to prevent
waste. With this object in view the plates should be
frequently examined, and when dark spots are observed
the plate should be reamalgamated. When not in
action the zinc plates should always be removed from
the cell. The battery should be stirred as often as every
other day to equalize the solution, which becomes dense
from the addition of sulphate of zinc. A little acid and
water must also be added from time to time to keep up
the strength of the battery. In mixing acid and water
the acid should always be added to the water, and
this should be done very slowly and carefully to avoid
sudden heat and consequent danger of explosion. The
silver plates require very little attention except an occa-
sional washing, but should be platinized two or three
times a year if in constant use.
After being in action about a week the battery
usually becomes so impregnated with sulphate of zinc
that the addition of acid has little or no effect upon it.
If the quantity of sulphate becomes excessive, it will
crystallize on the positive element and entirely stop the
action of the battery. When such conditions appear,
it is better to throw away the contents of the battery
than to attempt a remedy.
ELECTROTYPING. 25
CHAPTER III.
THE DYNAMO.
AS previously stated, there are certain conditions
. under which the galvanic battery may be found
useful as a current generator for electrotyping, but it
should be understood that in every respect except the
quality of copper deposited the battery is inferior to the
dynamo. Compared with the machine the battery is
both slow and expensive. A shell which would require
twelve hours' time to deposit with the battery may be
deposited in one hour with the dynamo, and leaving the
time element out of consideration the actual cost of
deposition by the battery method is probably six times
as great as by the machine. Theoretically a pound of
copper should be obtained for each pound of zinc and
acid consumed in the battery, but in actual working the
consumption of zinc amounts to nearly two pounds.
With zinc at 7 cents per pound, a copper shell tAd of
an inch in thickness would cost for deposition about
3 cents per square foot. On the other hand, a dynamo
with a capacity of 160 square feet per day can be opera-
ted at an expense for power of not to exceed 75 cents,
or about J^ cent per square foot. The current gener-
ated by the dynamo is powerful, uniform, and easily
managed; while the machine itself requires but little
attention, is clean and always ready for business.
Dynamos of various sizes and types are now manu-
factured specially for electrotyping and plating purposes.
26
ELECTROTYPING.
and the electrotyper is offered an unlimited assortment
from which to choose. Dynamo building is no longer a
mystery, and its principles are so well understood that
there is no more excuse for building an inferior machine
than there would be for building a poor steam engine.
Fig. 2.
Electrotvping Dynamo.
There is, therefore, little danger of disappointment if
the dynamo is purchased from a reputable manufac-
turer, provided the requirements of the machine are
thoroughly understood by purchaser and seller. It
would be folly to attempt to force a ten-horse engine to
do work requiring twenty horse-power, and it is equally
ELECTROTYPING. 27
foolish to expect a dynamo to do more work than it is
designed to do. Here is where an error is often made.
To save the few dollars difference in first cost a small
machine is installed, overloaded and condemned, when
the fault is not in the machine but in the man who over-
loads it. Competition between builders of dynamos
induces them to claim for their respective machines the
utmost limit of their capacity when running under the
most favorable conditions, and as the conditions are
not always favorable, dissatisfaction results. The elec-
trotyper should himself have a definite idea of the
number of square feet he will require to deposit at one
time and the speed at which he wishes to work, for it
is true in electrotyping as in mechanics generally that
' ' we cannot get something for nothing. ' ' A dynamo
which will deposit loo feet of shells in two hours will
deposit only 50 feet in one hour, and if a rapid rate of
deposition is desired a correspondingly large machine
must be employed.
Authorities differ somewhat in their estimates as to
the maximum current density which may be employed
in electrotyping ; but it is safe to figure on about twenty-
five amperes per square foot with the solution at rest
and about fifty amperes with the solution in motion.
On this basis, a dynamo of 500 amperes, with an E. M.
F. of i)^ volts working one vat, would deposit about
twenty feet at a time. If speed were no object a some-
what larger area could be covered by reducing the volt-
age. The most economical method of utilizing the
current, and the one generally employed, is to connect
the machine to two vats in series. By this means the
current is utilized in both baths before it returns to
28
ELKCTROTVPING.
05
the machine and the capacity of the dynamo is nearly
doubled. Fig. 3 is a plan view of a double vat, show-
ing the method of con-
necting the dynamo in ^ ^^
scries. The current leav-
ing the machine traverses
the electrode a, enters the
solution in the first vat by
anode ( i ) , passes through
the solution and leaves
the vat by cathode (3)
and the dead rod c, enters
the second vat by the
anode (2), leaves it by
cathode (4) and returns
to the dynamo by elec-
trode d. By this method
the current is made to do
duty in both vats ; but
inasmuch as the resist-
ance of two solutions is
double the resistance of
one solution, the E. M.
F. of the current must be
double what would be re-
quired for a single bath.
If one volt pressure will
overcome the resistance
of one solution to an ex-
tent sufficient to accom-
plish a satisfactory rate of deposition, then two volts will
be required to effect the same rate of deposition in two
Fig. 3.
Dynamo Connkctions on Double
Vat.
ELECTROTYPING. 29
vats. It should be remembered that within certain
Hmits the rate of deposition depends on the strength of
current employed, and this fact should have due con-
sideration in estimating the capacity of a machine. A
good quality of copper may be deposited with a current
density of thirteen or fourteen amperes per square foot,
but the rate of deposition would be slow. On the other
hand, fifty or more amperes per square foot may be em-
ployed, under proper conditions, with a corresponding
increase in the rate of deposition, but at an additional
expense for power. In the first case, roughly speaking,
about four hours would be required to deposit a shell
TT)*i)5 of an inch in thickness, while in the latter case one
hour would be sufiicient to deposit the same weight of
copper. In the first case a 500-ampere machine on one
vat would deposit about thirty-five feet at one time,
while in the latter case it would deposit only one-fourth
as large an area, but would accomplish the work four
times as fast. In the long run the result would be the
same so far as the total quantity of copper deposited is
concerned, and where speed is no object the former
current density is preferable because more economical
in power.
It has been stated that fifty or more amperes per
square foot of cathode surface may be utilized in elec-
trotyping under proper conditions, and that shells of
average weight may be thus deposited in about one
hour. To effect such a rapid rate of deposition it is
essential, first, that the dynamo shall be constructed to
supply a large volume of current without dangerously
heating the machine; second, the solution should be
properly proportioned; third, the solution or the anodes
30 ELECTROTYPING.
must be kept in constant motion; and fourth, all con-
nections must be of large size, and the points of contact
clean and firmly made.
Large plants, in which more than two vats are oper-
ated, usually employ more than one machine. In other
words, it is considered good policy to employ two dyna-
mos for four vats, rather than to couple all four vats to
one dynamo. The object of such an arrangement is
that one-half the plant may be discontinued during a
dull season, and it also permits the use of low voltage
machines, such as are carried in stock by the manufac-
turers. From what has been previously said on this
subject, it will be obvious that a dynamo working four
vats in series would require to have four times the volt-
age needed for one vat, and twice the voltage needed
for two vats. If a very rapid rate of deposition is
desired, a machine working four vats would need to be
operated at a tension of eight or ten volts, whereas a
tension of four to five volts would be sufficient for two
vats. Machines of the latter capacity are of standard
make, while it is probable that a ten-volt dynamo would
have to be specially constructed.
When purchasing a dynamo, consideration should
be given to the possible maximum output of the foun-
dry, as well as the rate of deposition desired. If the
plant includes but one molding press and one black-
leading machine, and rapid work is not imperative, a
dynamo of 450 amperes and two volts would take care
of all the work which could be turned out, for such a
machine working two vats in series would deposit from
forty to fifty square feet at one time, and would deposit
a sufficiently heavy shell in about three hours. In other
ELECTROTYPING. 31
words, it would deposit about fifteen feet per hour,
which would probably be the limit of the capacity of a
foundry of the indicated size. If, however, it is desired
to deposit fifteen feet every hour instead of forty-five
feet every three hours, a much larger machine would be
required, for, as has been before stated, the rate of
deposition depends principally on the strength of cur-
rent employed; and while a sufficient current density
for a limited number of shells could be obtained from
the small machine, it could be applied to only one vat
at a time, because sufficient E. M. F. could not be
generated to force the current through two solutions at
the maximum speed. The capacity of the machine in
square feet of cathodes which could be deposited at one
time would, therefore, be cut down to one-quarter of
the surface which could be covered at slow speed.
To further illustrate this point, we will suppose a
dynamo of 450 amperes and 2 ^ volts to be connected
with two baths in series. Each bath would then be
supplied with a current of i ^ volts pressure, and the
quantity of current utilized would be approximately 30
amperes per square foot of cathode. The total capacity
of the machine, 450 amperes, divided by 30, gives 15,
the number of feet which can be deposited at one time
in each bath, or a total of 30 feet. Now, if it is desired
to double the rate of deposition, it becomes neces-
sary to double the pressure of the current, which would
mean 5 volts instead of 2^. As the small machine
cannot be made to produce 5 volts, the only alternative
is to disconnect one of the vats. We now have 2^
volts applied to one bath, and are using about 60
amperes per square foot of cathode ; 450 divided by 60
32" ELECTROTYPING.
gives 7j^ as the maximum number of feet which could
be deposited at one time, and this is in theory only, for
in actual practice it is found impracticable to deposit
more than 5 feet, owing to the tendency of the machine
to heat. The economy in operating a large dynamo for
rapid deposition is thus plainly evident.
The results of a series of tests recently conducted
by the writer are given below :
Dynamo No. i Lloyd
Speed 1.350
Volts 2%
Amperes per square foot, about 51
Number of baths i
Area of cathodes, square feet 7
Time of exposure, minutes 60
Thickness of deposit, inches 003
A similar test of a No. i Eddy dynamo produced the
same result. It should be said that during the tests
these machines were both operated at higher speeds
than those mentioned, with the result that shells .007
of an inch were deposited in one hour; but owing to
heat generation only two or three square feet of cathode
surface could be exposed at one time.
A test of a larger machine resulted as follows :
Dynamo No. 2 Lloyd
Speed 1,000
Volts, per vat 2^
Amperes per square foot of cathode, about. 54
Number of baths in series 2
Area of cathodes, square feet 20
Time of exposure, minutes 60
Thickness of shell, inches 0035
These tests indicate that a dynamo of 800 amperes
and 5 volts, working two baths in series, will deposit,
ELECTROTYPING. 33
without undue heating, about twenty-eight feet of shells
per hour ; while a 450-ampere, 2^ -volt dynamo will
only deposit about seven feet per hour. It appears,
therefore, that rapid deposition is not practicable with a
small machine. However, the difference in cost of
installation is of slight moment in view of the increased
product of the large machine, and should not stand in
the way of the better service, particularly as the larger
dynamo will perform a limited volume of work equally
as well as the smaller, and at only a nominal increase in
expense for power. In later tests with larger dynamos
and an agitated solution the current strength was
increased to 125 amperes per square foot, with the
result that practical shells were produced in fifteen
minutes. The above mentioned tests are given with
the object of indicating how present facilities may
be utilized to the best advantage by electrotypers
whose machines equal or excel the capacity of the
No. 2 Lloyd.
Dynamos, as a rule, require but little attention, but
should always be kept clean and well oiled. The com-
mutator, in particular, should be occasionally cleaned
with a piece of fine sandpaper (not emery paper) and
then wiped off with a clean, damp cloth. Slow-speed
machines require no lubricant on the commutator other
than an occasional wiping with a damp cloth. On high-
speed machines a very little vaseline may be applied
every two or three hours. The brushes should fit the
commutator fairly well, otherwise there will be a ten-
dency to spark and heat. Sparking should never be
permitted, as it rapidly wears the commutator. It may
often be prevented by moving the brushes a little one
3
34 ELECTROTYPING.
way or the other from the position in which the spark-
ing occurs.
For nickel-facing electrotypes a current tension of
2^ to 3 volts is required, and for this work a separate
dynamo is usually employed ; but when the electrotyp-
ing dynamo is sufficiently powerful the nickel bath may
be operated in connection with the copper baths by pro-
viding it with a resistance coil for regulating the strength
of current supplied to it. With a dynamo operating at
2^ volts it would be possible to work the nickel bath
without a resistance coil, as in this case a sufficient vari-
ation of current strength could be obtained by varying
the distance between the cathodes and anodes. But if
the tension exceeds 23^ volts, a means must be pro-
vided for cutting down the current to the point best
suited to the conditions of the work.
ELECTROTYPING. 35
CHAPTER IV.
THE BATH.
THE depositing bath for electro typing in copper con-
sists of a solution of blue vitriol acidulated with
sulphuric acid. Copper sulphate, blue vitriol, or blue
stone, as it is variously termed, forms crystals which
when unadulterated are pure blue in color and cannot be
mistaken for any other chemical. A green tinge indi-
cates the presence of sulphate of iron and should be
rejected. While the color is a sufficient guide to the
purity of the sulphate it may be further tested by boil-
ing a small quantity of the solution with a little nitric
acid and adding spirits of ammonia in excess. The
presence of iron will be indicated by brown flakes.
Distilled water or filtered rain water should, if possible,
be used in making the solution. If rain or distilled
water cannot be conveniently obtained, well or lake
water will answer, but should always be thoroughly
boiled and filtered.
Sulphuric acid (oil of vitriol) for acidulating the
solution should be used pure and concentrated. The
crude acid contains arsenic which renders it unfit for use
in electrotyping solutions. The pure acid has a specific
gravity of 1.84. It may be recognized by mixing one
part with twenty-five parts of distilled water and com-
pounding with a few drops of barium chloride, when a
white precipitate will be formed. In diluting acid with
36 ELECTROTYPING.
water it should always be added to the water very slowly
and with constant stirring, as the heat generated by the
contact of the acid and water might otherwise be suffi-
cient to cause a dangerous explosion. Sulphuric acid
is exceedingly corrosive and should always be kept in
glass bottles or carboys.
The copper solution is the least troublesome of all
electrolytes. While some baths require accurate pro-
portionment, the use of distilled water, and even an
exact degree of temperature for their successful opera-
tion, the copper bath may be widely varied in propor-
tion and will work well under considerable variation ot
temperature. Nevertheless, there are certain limits oi
proportionment which must be observed to obtain rapid
deposition of a good quality of copper; for, while the
rate of deposition depends very largely on the strength
of current, it is essential that the solution be constituted
to work in harmony with the current. The essential
qualities of the solution are to present the least possible
resistance to the electric current and to dissolve the
anode with the same rapidity with which the copper
from the solution is deposited on the cathode. A solu-
tion of copper sulphate without the addition of acid
will conduct electricity, but its resistance is such that
a very strong current is required to overcome it. Von
Hiibl found that the minimum current density per
square foot of cathode in a fifteen-per-cent blue vitriol
solution without acidulation is 24. i amperes, while the
same solution with six per cent sulphuric acid added
required but 13.9 amperes. But while it is thus shown
that the addition of sulphuric acid lessens the resistance
ELECTROTYPING, 37
of the solution, there remains a wide difference of opin-
ion as to the maximum quantity of acid which may be
employed to advantage.
It is not difficult to prepare a solution which with a
moderate current will deposit copper of good quality at
a moderate speed. As an evidence of this fact it may
be stated that it would be difficult to find two solutions
exactly similar, the variations extending from twelve to
twenty-two per cent blue vitriol, and from two to eight
per cent acid. However, there is no question but that
a moderately rich solution is preferable and even neces-
sary for rapid work. A solution poor in copper will
deposit quickly, but the shells are apt to be porous and
granular. On the other hand, a solution too rich in
copper will deposit slowly and in crystalline form.
Deposits of this nature are specially noticeable when a
weak current is employed, and it is also noteworthy
that a poor solution is much more apt to produce gran-
ular deposits when the current is strong. From these
facts it appears that a richer solution may be employed
with a strong than with a weak current. Almost any
kind of a solution, within reasonable limits, will do good
work if the current strength is adapted to work in har-
mony with it. That is to say, by observing the quality
of copper deposited and increasing or decreasing the
current strength as the conditions demand. For in-
stance, if a pulverulent deposit is obtained it is an indi-
cation that the current is too strong or the solution too
weak, and the defect may be most easily remedied by
reducing the current strength either by means of a
switchboard or by decreasing the speed of the dynamo.
38 ELECTROTYPING.
On the other hand, a crystalline, brittle deposit indi-
cates a weak current or a rich solution, and may be
remedied by increasing the dynamo speed. However,
if rapid deposition is desired the solution must be con-
stituted to work with a strong current, and defects in
the deposit should be remedied, so far as possible, by
changing the solution rather than the dynamo, inas-
much as a reduction in the speed of the machine would
retard the rate of deposition. Of course, there are
well-defined limits to the current strength which may
be effectively employed with any solution, and it should
be the object of the operator to determine the highest
effective point of harmony between the two. With
the bath at rest, a fourteen to sixteen per cent solution
acidulated with two to three per cent sulphuric acid and
a current density of fifteen to eighteen amperes per
square foot has been found most satisfactory. An agi-
tated solution may be made somewhat richer if a
stronger current be employed, say eighteen to twenty
per cent blue vitriol and three to six per cent acid.
The depositing vat for the copper solution should be
solidly constructed of pine or whitewood planks bolted
together and lined with sheet lead united at the corners
by ' ' burning ' ' or melting the sheets together. Solder-
ing will not answer, as the acid in the solution will
attack the solder, and soon eat its way through. The
vat should preferably be partitioned into two compart-
ments, in order that the dynamo may be operated in
series, as previously described. It is essential also that
the vat shall be of ample size. The resistance presented
to the electric current by the solution is enormous,
ELECTROTYPING.
39
and only a great area will compensate for its lack of
conductivity. At least loo gallons of solution should
be provided for each twenty feet of cathode surface
exposed. A convenient size and shape of depositing
vat is shown in Fig. 4. The length is 60 inches, width
Fig. 4. — Electrotyper's Depositing Vat.
30 inches, and depth 26 inches. It will contain about
200 gallons of solution, and will accommodate about
ten cases of average size in each compartment.
In mixing the solution the vat should be about two-
thirds filled with rain, distilled or boiled water. The
blue vitriol may be conveniently dissolved by suspending
it in cheese-cloth bags just under the surface of the
water. As the water becomes saturated it will sink to
the bottom of the vat, and should be frequently stirred
and tested with a Baume hydrometer, when 14 or
40 ELECTROTYPING.
15 degrees is indicated on the instrument the bags
of vitriol may be removed and sulphuric acid added
to the solution, with constant stirring, until the reading
of the hydrometer is increased two or three degrees.
This solution will work well with a moderate current.
If the current strength is more than 20 amperes per
square foot, the solution may be enriched by the addi-
tion of blue vitriol to the extent of two or three degrees,
and if required as many degrees of acid may also be
added.
The solution should be well stirred, and may be used
at once, although it usually works better after standing
a few days.
ELECTROTYPING. 41
CHAPTER V.
STEEL, BRASS AND NICKEL BATHS.
COPPER is almost universally employed for the pro-
duction of electrotypes for printing purposes, and
generally speaking it is the most suitable of all metals
for this purpose. It is easily deposited, is tough, duc-
tile, practically non-corrosive and inexpensive. How-
ever, it is too soft to stand the wear of very large edi-
tions, and it does not print well with colors containing
mercury, which chemically attacks copper. To over-
come these defects it is customary, when the circum-
stances are such as to warrant the extra labor and
expense, to face the copper electrotype with steel, brass
or nickel. This is effected (a) by suspending the fin-
ished electrotype in the proper solution and depositing
thereon a film of harder metal, or {b) by suspending
the wax or other mold in the hard-metal solution,
obtaining thereon a preliminary deposit, and then trans-
ferring it to the copper bath where it is strengthened by
a sufficiently heavy deposit of copper. Of these meth-
ods, the former is the more readily performed and the
latter the more accurate in results. By the former
method it is obvious that only a very thin facing can
be given to the electrotype without impairing its accu-
racy, and it is doubtful if any kind of a facing could
be given to a fine-screen half-tone by this method
42 ELECTROTYPING.
without destroying something of its delicacy. How-
ever, electrotype plates of ordinary character may have
a thin facing of harder metal deposited upon them
without perceptibly affecting their accuracy.
Of the three metals employed for facing electrotypes,
nickel is the more readily deposited and its solution the
least troublesome to manage. It is malleable and duc-
tile, and nearly or quite as hard as iron. Moreover,
it is non-corrosive and altogether is an ideal metal for
the purpose. Various solutions are recommended for
the nickel-depositing bath, each of which has its ad-
vocates, but many of them are more or less compli-
cated and require special care in management. A
simple bath which has been thoroughly tested in some
of the largest electrotyping establishments in the coun-
try is made by dissolving the double sulphate of nickel
and ammonia in warm water in the proportion of ^
of a pound of the salts in each gallon of water. The
procedure is the same that has been recommended
for the copper solution, i. e. , the salts should be sus-
pended in cheese-cloth bags just under the surface ot
the water until entirely dissolved, when the solution
should be well stirred and is then ready for use. Some
operators add about ten per cent of common salt to
the solution for the purpose of increasing its conduc-
tivity.
The deposition of iron is attended with more or less
difficulty, and is not always successfully accomplished
even by experienced operators. A good bath for iron
(steel) facing may be made by dissolving two pounds
of the double sulphate of iron and ammonia in each
ELECTROTYPING. 43
gallon of water. Another bath, recommended by Urqu-
hart, is prepared by adding a solution of carbonate of
ammonia to a solution of sulphate of iron until the iron
is precipitated, when the liquid portion should be poured
off and the precipitate washed, after which it is dissolved
to saturation in a bulk of sulphuric acid equal to the
volume of solution required.
Another iron solution consists of 56 pounds of car-
bonate of ammonia dissolved in 35 gallons of water and
supplied with iron by means of a large anode and an
electric current from the dynamo.
The solution which seems to be most popular for the
production of iron electrotypes, and which is highly
recommended by M. Klein, is composed of equal parts
of sulphate of iron (green vitriol) and sulphate of mag-
nesia, kept neutral by bags of carbonate of magnesia
suspended in the bath. A sufficient quantity of the
sulphates should be dissolved in water to make the spe-
cific gravity 1.55, i. e. , about 51° Baum6. This bath
requires a current density of 18.5 amperes per square
foot. A peculiarity of all iron solutions is that the
anodes must always be of large size, preferably about
eight times as large as the cathodes.
The deposition of brass is also attended with some
difficulty, chiefly because it is composed of two metals,
one of which is positive and the other negative, hence
the current strength requires more or less regulation to
insure uniform deposition of both metals. As brass is
composed of copper and zinc, the salts of these two
metals must necessarily form the basis of the depositing
solution. A good brassing solution consists of 16
44 ELECTROTYPING.
ounces of cyanide of potassium, 5 ounces carbonate
of copper, i^ ounces carbonate of zinc, i ounce of
ammonia, and i gallon of water. The following formu-
las are recommended by Roseleur and Dr. Langbein:
Copper sulphate and zinc sulphate, each 53^ ounces,
and crystallized carbonate of soda, 15^ ounces. Crys-
tallized carbonate of soda and crystallized bisulphide
of soda, each 7 ounces ; 98 per cent potassium cyanide,
8^ ounces ; arsenious acid, 30^ grains ; water, 10
quarts. The bath is prepared by dissolving the copper
and zinc sulphates in 5 quarts of warm water, and in
the other 5 quarts, the 15^ ounces of carbonate of
soda; then mix both solutions, which will form a pre-
cipitate of the carbonates of copper and zinc. After
setting ten or twelve hours the supernatant liquor is
poured off and sufficient water added to the precipitate
to make six quarts of solution. Now add to the bath
with constant stirring the carbonate and bisulphide of
soda. Dissolve the potassium in 4 quarts of cold water
and add this solution to the first solution with the ex-
ception of one-half pint, in which the arsenious acid is
dissolved by the aid of heat, when it is also added to
the bath. This solution should be thoroughly boiled for
one or two hours and the water lost by evaporation
replaced.
Another brass solution, which is less troublesome to
prepare, contains crystallized carbonate of soda, ioj4
ounces ; crystallized bisulphate of soda, 7 ounces ;
neutral acetate of copper, 4.4 ounces ; crystallized
chloride of zinc, 4.4 ounces ; 98 per cent potassium
cyanide, 14. 11 ounces; arsenious acid, 30^ grains;
ELECTROTYPING. 45
water, lo quarts. Dissolve the carbonate and bisul-
phate of soda in 4 quarts of water, then mix the acetate
of copper and chloride of zinc with 2 quarts of water
and add this solution to the first ; retaining, however,
a small portion of it in which to dissolve the arsenious
acid with the aid of heat. Finally, add the arsenious
acid solution, when the bath becomes clear. Boiling
the bath or working it through with the current is
required.
The following solution is recommended by Watt :
Cyanide of potassium, i pound ; carbonate of ammonia,
I pound ; cyanide of copper, 2 ounces ; cyanide of zinc,
I ounce ; water, i gallon.
Another brassing solution which the writer has
found very satisfactory consists of 16 ounces cyanide
of potassium, 5 ounces carbonate of copper, i ^ ounces
carbonate of zinc, i ounce ammonia, and one gallon of
water.
Solutions containing cyanides would immediately
destroy wax or gutta-percha molds, and their use is
therefore restricted to plating or facing electrotypes or
other metallic articles.
46 ELECTROTYPING.
CHAPTER VI.
MANAGEMENT OF BATHS.
THE acid copper solution is not difficult to manage
and may be kept for years in constant use by
adding from time to time a little of one or the other of
its constituents as may be needful to make good the
loss occasioned by various causes. This loss is prin-
cipally by evaporation, and by simply adding a few pints
of distilled water the solution may generally be restored
to nearly its original proportions.
Under ordinary conditions the copper withdrawn
from the bath and deposited on the cathode is not
fully replaced by the anodes, and it is necessary, there-
fore, to enrich the solution occasionally with a little
sulphate of copper, which may be done by suspending
just under the surface of the solution a few pounds of
the crystals in a cheese-cloth bag. A reduction in the
content of copper in the bath from this cause always
produces a corresponding increase of free acid. Should
the content of acid become excessive, it may be neu-
tralized by the addition to the solution of a little car-
bonate of copper.
When the anodes are larger than the cathodes — or
when, as may happen, a number of anodes are left in
the bath, connected with the current, while molds are
ELECTROTYPING. 47
being prepared for the depositing process — the quan-
tity of copper dissolved will exceed the quantity depos-
ited, resulting in undue concentration of the solution.
This condition will be indicated by a tardy formation
of the deposit and the production of a shell of brittle
and crystalline character. Moreover, a dense solution,
unless continuously agitated, is apt to produce streaky
deposits. An excess of copper is further indicated by
the formation of crystals of sulphate of copper on the
sides of the vat and sometimes on the anodes. When
such conditions appear, the obvious remedy is to dilute
the solution with water. However, the addition of water
to make good the loss caused by evaporation is usually
sufficient to remedy any excess of copper without further
dilution.
A quiescent solution always becomes more concen-
trated at the bottom than at the top of the vat. As a
result of this condition the lower portion of the anode
will be dissolved less freely than the upper on account
of the increased resistance; but, on the other hand, the
copper will be deposited more rapidly on the lower por-
tion of the cathode where the largest quantity of metal
is in solution. For the same reason that portion of the
cathode which is suspended in the heavier strata of the
bath is apt to become covered with nodules or excres-
cences which are more or less annoying and wasteful.
This difficulty may be minimized by stirring the solution
occasionally with a wooden paddle, which will tem-
porarily equalize its density. The bath should not be
stirred while in use, particularly if old and dirty, as the
48 ELECTROTYPING.
impurities which will have settled on the bottom of the
vat would be likely to lodge on the work and cause
holes in the shells. Some electrotypers are content to
stir the solutions once a week, usually on Saturday
evening, thus giving the bath thirty-six hours in which
to settle; but, unless very dirty, it is advisable to stir
it as often as every twenty-four hours. When a bath
has become so dirty that it cannot be agitated without
danger of injuring the work it should be filtered.
The temperature of the bath should be kept between
65 and 75 degrees Fahr. At 65 degrees the best qual-
ity of copper is produced; but the quality is not seri-
ously impaired by raising the temperature ten degrees,
while the rate of deposition is materially increased.
Baths located in a room not heated at night may be
provided with a coil of lead pipe through which steam
may be circulated and the temperature increased thereby
as desired. Deposition always proceeds sluggishly on
cold mornings, unless some provision for warming the
solution is made. It is always desirable to keep the
baths in a room separate from the molding and finishing
departments in order to protect them as far as possible
from dust and flying particles of metal. It is also a
good plan to keep the vats covered when not in use.
The anodes should be removed from the solution
daily, and thoroughly cleaned from the slime which
accumulates on them and which has the eflfect of par-
tially insulating them.
What has been said regarding the general care of
the copper bath applies also to the nickel bath. An
ELECTROTYPING. 49
occasional addition of water to restore the loss occa-
sioned by evaporation is imperative, as is also the addi-
tion of a few crystals of nickel salts from time to time if
the bath becomes impoverished.
Brass and iron baths are more troublesome than
either copper or nickel. The brass bath requires fre-
quent building up, particularly if not in regular use.
As brass contains a larger proportion of copper than
zinc, the copper in the bath becomes first exhausted,
and sufficient carbonate or cyanide of copper, according
to the constitution of the bath, must be added to restore
the proper proportions. Cyanide of potassium must
also be supplied when the action of the bath becomes
sluggish and no bubbles are observed on the cathodes.
When, however, there is a vigorous evolution of gas it
is an indication of an excess of cyanide, and a slow
deposit under these circumstances would be remedied
by the addition of the metallic salts. A deposit of light
color would indicate a want of copper in the solution,
and a dark color a lack of zinc. However, the color is
not a reliable guide, as it may be caused by a variation
in the density of current employed. A weak current
would deposit more copper than zinc and would give its
color to the deposit, while a strong current deposits
both metals in their proper proportions. Constant
watchfulness is required to keep the brass bath in good
working condition.
The iron bath is even more troublesome than brass
and less certain in the production of satisfactory depos-
its. Owing to its tendency to oxidize, the bath must
i
50 ELECTROTYPING.
be frequently filtered to insure uniform deposits. For
the same reason it should be kept under cover when
possible. The surface of anodes exposed should always
be seven or eight times greater than the cathodes.
ELECTROTYPING. 51
CHAPTER VII.
AGITATION OF BATHS.
THE continuous agitation of the copper bath is of
great advantage to the electrotyper, particularly
when rapid deposition is desired. The copper is more
evenly deposited and of better quality, the formation
of gas bubbles and also of nodules and excrescences
is largely prevented, while the annoying streaks which
sometimes appear on the deposit, usually as the result
of an excess of metal in the solution, are seldom or
never seen in an agitated bath. But the principal
advantage may be found in the fact that much higher
current densities may be utilized, resulting in a corre-
sponding increased rate of deposition. With a quiescent
solution the quantity of current which may be employed
is limited to about i8 or 20 amperes per square foot ;
any excess of this quantity usually results in a deposit,
dark red or black in color, and rotten, porous or granu-
lar in texture. But in an agitated bath these defects
disappear. The copper becomes lighter in color, and
tough and ductile in character, and these conditions
will not change materially even when the current density
is increased to 100 amperes or more per square foot.
A quiescent solution is seldom of equal density
throughout. The heavier portions settle to the bottom
52 KLFXTROTYPING.
of the vat and the lighter portions rise to the top, and
while the density of the bath may be temporarily equal-
ized by occasional stirring, there is a continual tendency
to separation. The evils resulting from this lack of
homogeneity have been described in a previous chapter,
and the remedy for these evils is continuous agitation.
There are various methods by which this object may be
accomplished. A small propeller may be operated
near the bottom at one end of the vat, or, where sev-
eral vats are employed, they may be arranged in steps
and the solution permitted to flow through a connecting
pipe from the upper vat to the next lower vat, and so
on through the series.
Fig. 5 shows a depositing vat arranged for working
by the Englehard process. For electrotyping, the
anodes used are about 7 inches wide and i^ inches
thick, the length being as may be needed for the work
in hand. They are mounted on spindles as shown,
and by suitable arrangement are rotated by power
while the battery is in action, the usual rate of speed
being about fifty revolutions per minute. The agita-
tion of the solution insures thorough mixture and uni-
form density ; friction between the solution and the
moving anode clears its surface of foreign matter and
facilitates its rapid dissolution. This also permits the
employment of much greater electrical energy than
in vats as ordinarily worked — in fact, quite beyond the
capacity of nearly every plating dynamo in use. The
inventor claims a current of 6 or more volts per vat,
and 75 to 100 amperes per square foot of cathode
ELECTROTYPING.
53
Fig. 5.
54
ELFXTROTYPING.
may be used without the least indication of burning
the deposit, which is of finer quality than that usually
made in the old way, and the quantity of metal thrown
down is fully twice as much in a given time.
The Dunton* method for producing a circulation in
the solution is illustrated in Fig. 6. A small centrifu-
gal pump, with a capacity of about 40 gallons per
Fig 6.
minute, rests on the bottom of one corner of the vat.
The solution is drawn in through a strainer at a point
over the center of the wheel, near the bottom of the
vat, and discharged near the surface. In this manner
the heavier liquid is lifted, and by the force of its dis-
charge a circular motion is imparted to the whole body.
It is forced toward the end of the tub, where it glances
ELECTROTYPING. 55
across, down the other side, some of it passing between
the anodes and cathodes, across the opposite end to a
point nearly over the pump. The pvmip occupies an
area 6^ inches square by 4 inches high, and is con-
structed entirely of lead and hard rubber. Above the
solution the shaft ends in a length of hardened steel
tubing, which runs in the upper bearing and carries the
driving gear. The two lower bearings, under the solu-
tion, consist of flint glass bushings pressed into hard
rubber jackets, then forced into the sleeves provided at
the top and bottom of the pump casing.
Fig. 7 illustrates the Leetham apparatus, which is
particularly suitable for electrotyping solutions. Agita-
tion is effected by air compressed in a reservoir by a
small double-acting pump. The air is forced into the
baths through perforated lead pipes which lie on the
bottom of the vats, where they are entirely out of the
way of the work.
The perforations in the pipes are only about one inch
apart, which insures thorough circulation of the solu-
tion between the anodes and cathodes.
The pressure is regulated by valves, and the agita-
tion may therefore be made more or less violent at the
pleasure of the operator. On top of the air reservoir
and connected with it is a condensing chamber through
which the air passes before it is admitted to the vat.
The condensing chamber is provided with an inlet for
steam. When it is desired to increase the temperature
of the bath or increase its contents of water, steam is
admitted to the chamber, where it is condensed, and is
56
ELECTROTYPING.
Fig. 7.
ELECTROTYPING, 57
then conveyed to the solution through the air pipes.
This device therefore provides a means for heating the
sohition and supplying it with distilled water as well as
agitating it. Another obvious advantage of this appa-
ratus is that one machine will agitate the contents of
several vats.
r)S ELECTROTYPING.
CHAPTER VIII.
MEASURING INSTRUMENTS.
A CONVENIENT and almost indispensable measur-
ing instrument in the electrotype foundry is the
hydrometer, or, as it is popularly termed, acid gauge.
By its aid the desired quantity of salts or acid in the
bath may be conveniently measured, and the specific
gravity of any solution readily determined. The hydrom-
eter consists of a glass tube with a graduated stem of
uniform diameter, a bulb to cause it to float in the
liquid, and a weight to keep it upright as it floats.
From the reading of the scale at the point which is on a
level with the liquid in which it is floating, the density
of the fluid may be ascertained. In pure water at
a temperature of 60° Fahr., the hydrometer sinks
to the zero mark, but by the addition of salts or acid
having a greater density than water, the bulb is forced
upward, and the reading on the scale will then indicate
the increased density. In making up electrotyping
solutions, the hydrometer is floated in a vat partially
filled with water. Sulphate of copper is then dissolved
in the water until the increased density of the solution
forces the instrument upward to a reading which is
ELECTROTYPING. 59
known to indicate the desired proportions. Sulphuric
acid is then added to the solution until the desired
quantity is denoted on the scale of the instrument. To
further illustrate : a popular bath for nickel-plating is
made by dissolving three-fourths of a pound of salts in
each gallon of water ; but instead of weighing the salts
and measuring the water the same proportion may be
obtained by dissolving salts in any quantity of water
until the hydrometer scale registers 7 degrees. There
are two well-known makes of hydrometers in use,
namely : the Baum^ and the Twaddle. Every degree
on the scale of a Twaddle hydrometer represents .005
of a degree of specific gravity. Zero on the scale is
equivalent to i.ooo specific gravity. To ascertain by a
Twaddle hydrometer the specific gravity of any liquid
heavier than water, multiply the reading by .005 and
add 1.000. For example, the reading on the hydrom-
eter is 60 degrees : 60 X .005 = .300 + i.ooo = 1.300,
the actual specific gravity of the liquid. The specific
gravity of a liquid may also be easily ascertained by
means of a Baum^ hydrometer by a simple calculation
as follows : Subtract the reading from the number 144,
and divide the same number by the difference. For
example, 144 — 50 = -^ ^ i-532, the specific gravity
94
of a liquid registering 50 degrees on a Baume hydrom-
eter.
Instruments for measuring electric currents should
belong to the equipment of every well-ordered electro-
typing establishment. In the early days of the art it
fiO ELECTROTYPING.
was sufficient to know that a current of some kind was
at work and that in due course of time a shell of suf-
ficient thickness would be deposited. It might take
twelve hours at one time and eighteen at another, but a
few hours more or less was not considered of serious
moment. With the modern electrotyper, however,
every minute counts, and as a rule he employs all the
current strength which can be utilized without burning
the deposit. Having learned by experience what quan-
tity may be employed to advantage, it is of great con-
venience to be able to measure the current and by
means of proper registering instruments maintain the
pressure at the maximum point. Instruments for meas-
uring electricity are the voltmeter and the ammeter.
The former measures the tension and the latter the
density of the current. While the scientific electrotyper
would find both instruments convenient, the ammeter is
not indispensable, for the strength of a current proceed-
ing from a dynamo increases with the tension, and an
instrument which registers the tension would, so far as
the electrotyper' s necessities are concerned, also meas-
ure the volume. Assuming that one volt pressure is
sufficient to force a current of 12 amperes per square
foot of cathode through a solution of given proportions,
then with two volts pressure the current strength would
be increased to 24 amperes and three volts would mean
about 36 amperes per square foot. If, therefore, the
electrotyper is provided with a voltmeter he may
determine with sufficient accuracy for his purpose the
strength of current employed.
ELECTROTYPING. 61
The speed with which copper may be deposited
depends on certain conditions, but more especially on
the density of current employed. To reproduce such
conditions at all times it is important that the E. M. F.
existing between the anode and cathode should be
accurately measured. The ordinary galvanometer is
insufficient for this purpose because it does not give an
accurate reading of the tension. On the other hand, a
sensitive voltmeter will indicate any loss of power due
to slipping belts, short circuits or irregularities of any
kind, and when used in connection with a switchboard
will enable the electrotyper to accurately reproduce the
conditions which he has found by experience conducive
to success.
The switchboard or resistance board consists of a
number of metallic spirals, usually of German silver,
arranged on a board in such a manner that one or
more of them may be switched into the circuit,
thus presenting more or less resistance, as may be
desired, to the passage of the current. The utility
of the switchboard may be illustrated as follows : sup-
pose a tension of 2j^ volts is desired in the bath
and that by reason of slipping belts or other causes
the tension has been reduced to 2^ volts. Then by
moving the handle of the switchboard one or two but-
tons a corresponding number of spirals will be cut out
of the resistance, permitting a larger quantity of current
to enter the bath. Or suppose the load in the bath be
much smaller than usual, or for any other cause the ten-
sion increases beyond the desired limit, a movement of
62 ELECTROTYPING.
the switch handle ia the opposite direction will increase
the resistance by adding to the number of spirals in the
circuit and the tension will thus be regulated. The
wires connecting the voltmeter with the baths may be
arranged in such manner that the tension in any one of
a series may be readily determined.
ELECTROTYPING. 63
CHAPTER IX.
PREPARATION OF WORK.
SUCCESS in electrotyping depends largely on care-
ful attention to details, not the least important of
which is the preparation of cuts or type forms for mold-
ing. The finished electrotype must be perfectly flat to
insure satisfactory printing. If the original form is
defective by reason of imperfect justification, high or low
cuts or type, the defects will necessarily appear in the
electrotype and must finally be rectified at the finishing
bench. The truth of the old adage ' 'A stitch in time
saves nine ' ' is nowhere better illustrated than in electro-
typing. A few minutes' time spent in making ready the
form for molding frequently saves hours at the finishing ,
bench, particularly when a number of duplicate electro-
types are made from the same form. For instance, a
broken or mashed type, unless discovered and replaced
by a perfect one before the form is molded, will be a
defect existing in every electrotype made from that form
and must be finally corrected by punching out the
defective letter and soldering in its place a perfect type.
These defects are not always the fault of the electro-
typer, but it is nearly always difficult to convince the
64 ELECTROTYPING.
printer of that fact unless a proof is furnished by the
printer with the job.
Printers' forms frequently consist of both type and
cuts, and it often happens that the cuts are lower or
higher than the type. Here again a few minutes' time
spent in shaving down or underlaying the cuts, as the
case may demand, will save much valuable time in the
later operations of finishing, and will also insure a better
electrotype, for it is obvious that if the cut is low in the
plate it must be forced up to a level with the type by
punching or hammering, and it will be plain, even to
the novice, that a plate which has been subjected to
such treatment will be less perfect than one which has
been corrected in the original and which, therefore,
requires but litde attention from the finisher.
Usually better results are obtained by the molder
from metal-mounted cuts than when they are mounted
on wood, as the wood bases are liable to yield somewhat
under pressure and will thus make a shallower impres-
sion in the molding composition than the surrounding
type. Moreover there is danger of losing something of
the detail of the engraving. This is more especially
true of half-tone engravings, which should always be
mounted on metal bases.
Wood engravings, when subjected to changes of tem-
perature or atmospheric conditions, sometimes check or
crack. When it is desired to make an electrotype of
such an engraving, the checks, if not too large, may be
closed by covering them with strips of damp blotting
paper and then applying a hot building iron to the
ELECTROTYPING. 65
paper until it is wholly or partially dry. When the
check has been closed the mold should be made at once
before it has time to open again.
Forms which are to be electrotyped should be sur-
rounded by type-high beveled bearers with the beveled
side next the type. The bearers prevent the wax or
composition from spreading, and also serve to protect
the face of the electrotype from injury during the oper-
ations of shaving and finishing.
When low leads, quads and furniture are used to
justify the form, the larger blanks may be filled up to the
shoulders of the type with strips of wax. The wax will
adhere to the furniture sufficiently to hold them in place
when the form is inverted on the case ; and, on the other
hand, if the wax filling is well brushed over with black-
lead after it has been placed in the blanks, it will not
adhere to the mold. Preparing the forms in this manner
will prevent undue displacement of the molding compo-
sition and facilitate the later operations of cutting down
and building. Parts of book pages or pages of poetry
should have an inverted type placed in each corner of
the page to indicate the size of the page and serve as a
guide to the finisher, and title-pages and large blanks
of all kinds should have inverted letters so placed as
to protect isolated lines from injury during the finishing
processes.
All forms which are to be electrotyped should be
securely locked in extra strong chases and be perfectly
justified. The type should be squarely on its feet and
carefully planed. The pressure employed in molding is
5
66 ELECTROTYPING.
such that unless great care is taken to lock up the forms
securely the wax will be forced between the bodies of
the type, causing them to spread and throwing them off
their feet. This will result in an imperfect plate, and at
the same time be the cause of much trouble and annoy-
ance owing to the difficulty of removing the wax thus
firmly imbedded in the form. Moreover, unless the
form is securely locked, there is danger that some of the
types will be drawn out of the form, when it is separated
from the mold, and lost or misplaced.
ELECTROTYPING. 67
CHAPTER X.
MOLDING.
THE most important department of electrotyping,
from the workman's point of view, is the molding,
and it is here that the question of profit or loss on a job
is often determined. In some other departments of the
foundry the work may be slighted to some extent with-
out materially affecting the output, but carelessness or
inefficiency on the part of the molder always means
delay, extra expense for finishing inferior electrotypes,
and possibly a final rejection of the job. A cheap
(poor) molder is always the most expensive man in
the foundry, for unless a perfect mold is obtained the
time expended in later operations of depositing, casting
and finishing will be wasted. Until recently the mate-
rial most generally employed for molding composition
was beeswax, mixed with a little crude turpentine and
plumbago. The proportions vary somewhat, according
to the ideas of the molder. A good combination is
composed of pure beeswax eighty-five per cent, tur-
pentine ten per cent and plumbago five per cent. If
the molding room is very warm, about five per cent of
burgundy pitch may be added with advantage. A
cheaper material which is now quite generally em-
ployed is ozokerite. Ozokerite is a mineral wax, which
can hardly be distinguished from beeswax. It has a
68 ELECTROTYPING
high melting point, is non-adhesive and by most elec-
trotypers is claimed to be superior to beeswax for gen-
eral work. In some instances gutta-percha is employed
as a molding material, and under proper conditions the
results obtained are very satisfactory. The kind best
adapted for the work is what is known as the unmanu-
factured but purified sheet. Gutta-percha takes a coat-
ing of blacklead readily, and is impervious to the solu-
tion. When used for molding without pressure, as is
usually the case in duplicating steel engravings or arti-
cles of a fragile nature, it is melted and thoroughly
mixed with about forty per cent refined lard, or it may
be dissolved in bisulphide of carbon, and then moder-
ately heated until it is thin enough to pour.
A good molding composition for certain purposes
may be made by melting together one pound of lead,
^ pound of tin, and i^^ pounds of bismuth. This
alloy melts at the temperature of boiling water, and
assumes a soft but firm condition just before setting,
at which time the impression should be made. The
principal advantage of this composition is found in the
fact that it expands in cooling, and therefore takes a
very sharp impression. An elastic composition recom-
mended by Urquhart, which may be used for molding
an entire object at one time, is prepared as follows:
Eight pounds of good glue is soaked in cold water
until quite soft. It is then placed in a glue-pot and
mixed with two pounds of treacle. The whole is heated
and thoroughly incorporated by stirring; when the
mold is not likely to be roughly handled, ^ pound of
beeswax may be added to the mixture. This material
is poured around the prepared object, and when set
ELFXTROTYPING. 69
may be cut open from top to bottom and the object
removed ; the mold will now sprinj^ into its original
position and shape. The tendency of this composition
to absorb water may be prevented by immersing the
mold in a weak solution of bichromate of potash and
drying in the sun. An insoluble coating is thus secured.
A list of materials suitable for molding composition
might be extended to include nearly any inelastic sub-
stance which can be sufficiently softened to receive an
impression from type or cuts with a reasonable degree
of pressure. At this writing admirable results are
being obtained from pure lead under the name of the
Doctor Albert process, a description of which will be
found in another chapter. However, there is no mate-
rial which, for general work, equals in popularity pure
ozokerite or ozokerite mixed with a little beeswax.
Freedom from lumps, fiber or grain insures a perfect
medium for the production of the finest lines and
shades of engraving. It may be easily softened by
heat to the degree most suitable for molding and will
not perceptibly shrink in cooling or recover its form
after receiving an impression. Moreover it takes black-
lead readily, is unabsorbent and may be used over and
over innumerable times. In this age of adulterations
it is not always easy to obtain pure wax, but most
adulterations may be detected. The materials which
are most commonly mixed with wax are paraffin, resin
and tallow, and the presence of these substances may
be suspected if the fracture is smooth instead of
granular.
To prepare wax for molding it should be melted in
a steam-jacketed kettle and heated for several hours to
70 ELFXTROTYPING.
expel all the moisture. About ten per cent of crude
turpentine and five per cent blacklead should then be
added and thoroughly incorporated. Having been thus
prepared the wax is dipped out and poured through a
strainer upon some shallow trays of brass or other
metal and allowed to cool. These trays, or cases, are
sometimes made of brass plates of a convenient size
with the edges raised about one-fourth of an inch so as
to form a shallow pan. Such cases are, however, quite
expensive and entirely unnecessary, as a perfectly flat
plate made of electrotype backing metal will serve the
purpose even better than brass, for in the event of its
becoming bent or warped it may be easily straightened
by simply laying it on a flat surface and planing it
down with a hammer and block. A raised edge may be
obtained by surrounding the case with wood or metal
strips of suitable height. It is customary to place the
cases on a stone or iron table large enough to accom-
modate several at the same time and located within
convenient distance of the wax-melting pot. When a
stone table is employed for the purpose it should be
very thick, not less than five or six inches, in order
that it may quickly absorb the heat from the cases and
thereby facilitate the cooling of the wax, otherwise
much time would be consumed in waiting for the wax
to set sufficiently to stand handling. Even a heavy
stone table, unless of extraordinary size, will not cool
cases fast enough when the volume of work is consid-
erable, and under such conditions it is advisable to
employ a hollow iron table provided with water and
waste connections so that a circulation of cold water
may be maintained and the time required to cool the
ELECTROTYPING. . 71
cases reduced to the minimum. Such a table may have,
permanently secured to its surface a strip of iron,
three-eighths of an inch thick, extending entirely
around the outside edge. The flat cases, about one-
eighth of an inch thick, are then laid on the table and
wax poured on them until it reaches the height of the
^-inch strips. The cases may be separated, if desired,
by strips of wood. After the wax has set, the cases
are cut out with a knife and removed from the table,
and the residue returned to the kettle. The iron table
may be made still more effective by providing it also
with steam connections, for it often happens on a cold
morning that the table is too cold to cast perfect cases,
and considerable time is consumed in producing the
proper temperature by outside influences. In pouring
the wax on the cases it is always advisable to strain it
and thereby insure the exclusion of all dirt or foreign
matter which may have found its way into the melting
kettle. Immediately after pouring, a straight-edge or
wire should be drawn over the surface of the cases to
remove any air bubbles which may have formed. Any
bubbles which do not yield to this treatment may be
lightly touched with a gas flame. Neither wax nor com-
position material can be used for molding until some
time after it has been cast in cases, or until it has had
time to cool, and it is therefore the practice to cast
cases several hours in advance of the time they will be
required for use.
Molding presses operated by steam or hydraulic
power are usually provided with devices for indicating
the depth of impression made in the wax, or with auto-
matic stops for shifting the belt when the impression
72 ELRCTROTYPINO.
has reached a predetermined depth. Such devices are
effective only when the wax cases are all of the same
thickness and of imiform temperature. The tempera-
ture of the wax determines its degree of plasticity, and
the suitable degree is indicated when the wax will yield
under pressure of the thumb. The ability to judge the
correct temperature comes with experience, and can be
acquired in no other way.
By exercising due care to fill the cases level with
the bearers which surround them, the waxcaster may
produce cases reasonably uniform as to thickness ; but
to insure absolute accuracy they should be passed
through a wax-shaving machine, which not only in-
sures uniformity but also removes any dirt or dust
which may have become attached to the wax while in
a liquid or semi-liquid state.
When wax cases are cast several hours in advance
of their use and have become cold and brittle, it is
necessary, before molding, to restore them to a plastic
condition, as any attempt to mold in cold wax would be
not only dangerous alike to press and form, but would
inevitably result in failure. The wax is sometimes
softened by laying the cases on a steam-heated table,
such as is illustrated in Fig. 8, first placing some strips
of wood on the table to protect the back of the case
from excessive heat. Unless so protected, the wax
next the case would become much softer than the face,'
and the result of molding from a case thus unevenly
heated would almost certainly be concaved faces in the
reproduced type and cuts. Even when great care is
observed in warming the cases, it sometimes happens
that this defect occurs in the electrotype, and for this
ELECTROTYPING.
7;?
reason as well as to avoid delay it is advisable to keep
the cases in a box moderately heated by steam or hot
air where they will be gradually brought to nearly
the proper temperature for molding. They will then
require an exposure of but a few moments on the
steam table to make them sufficiently plastic. Instead
Fig. 8.
Electrotypers' Wax Kettle and Table.
of a box, a number of pigeonholes may be constructed
about two feet above the steam table in such a manner
that the cases may rest on their edges in a vertical
position, and the hot air arising from the steam table
permitted to circulate between them.
Having warmed the case until the wax will take an
74 ELECTROTYPING.
impression of the thumb, it is given a thorough coating
of molding graphite, which, when properly applied,
prevents the wax from spreading. Graphite should
also be applied to the form, rubbing it in thoroughly
with a brush in order to prevent the type or cuts from
adhering to the wax.
The form is now placed on the apron of the mold-
ing press and the case inverted upon it, or if the form
is small the operation may be reversed and the form
inverted upon the case. In either event two or three
sheets of heavy strawboard should be placed between
the back of the case and the press to prevent too sud-
den chilling of the wax. Having been thus prepared,
the form and case with its strawboard backing are slid
under the head of the molding press and pressure
applied until sufficient depth of impression has been
obtained in the wax, when the form and mold should
be carefully separated and examined.
It will sometimes be found necessary to take a sec-
ond impression in order to obtain a perfect mold, and
in such cases it is obvious that the utmost care must be
exercised to prevent a doubled impression. To provide
for such contingencies, forms which are to be electro-
typed should be imposed in such a manner as to leave
an opening between the sections of furniture at two of
the corners of the chase, that the molder, when setting
the form the second time, may accurately locate the
first impression.
When a large number of duplicates are required
from one form it is customary to prepare a sufficient
number of electrotype patterns to fill a chase and there-
after mold from the patterns instead of the original
ELECTROTYPING, 75
form. When the patterns are carefully prepared no
building- will be required on the molds, and much of
the labor of finishing will also be saved.
The operation of the molding press is sufficiently
explained by the illustrations Figs. 9 and 10. With
the exception of the hydraulic press the principle by
Fig. 9.
Electrotypers' Hand Molding Press.
which pressure is applied is the same in all molding
presses — a toggle joint operated by a screw. In the
hand press the screw terminates in a hand wheel whose
spokes extend beyond the rim of the wheel to provide
a convenient means of applying power. The screw in
a power press terminates in a large gear wheel which
is engaged by a pinion driven by steam power.
70 . Ki.iarrkoTvi'iNc.
The press illustrated in Fig. lo is provided with an
indicator consisting of a finger and graduated dial, by
means of which uniformity in depth of impression may
be obtained. The indicator is particularly useful when
two or more impressions are required, for, having
noted the location of the finger on the dial plate at the
Fig. io.
Electrotypers' Power Molding Press.
completion of the first impression, it is an easy matter
to determine the depth of the second.
In connection with the operation of the molding
press mention may be made of a fact not always recog-
nized by molders, which is, that the greatest power
exerted by a toggle joint occurs just before the toggles
ELECTROTYPING. 77
reach a perpendicular position. The amount of pack-
ing placed under the case is sometimes so excessive
that the toggles never reach the point of highest effi-
ciency, and therefore more or less power is unneces-
sarily expended in producing the impression. While
this is of no particular moment in the case of the steam
press, except as it throws a heavy strain on the yoke, a
proper adjustment of the packing would save consid-
erable hard labor to the operator of the hand press.
78 ELECTROTYPING.
CHAPTER XL
BUILDING.
MOLDING a form or pattern naturally causes more
or less displacement of wax, which is forced up
around the edges of the form and between the cuts or
type, or wherever there is an opening, however small.
Before proceeding to metallize the mold, it is necessary
that these displacements shall be cut down to a uniform
level, for it would not only be difficult to metallize, by
the usual methods, a mold whose surface consists of
knobs and protuberances of uneven heights, but it
would also be impossible to cast the electrotype plate
within the limits of the thickness usually required for
printing purposes, for every protuberance on the mold
would necessarily involve a corresponding depression in
the shell; and inasmuch as the shell must be backed
with metal and entirely covered thereby, the thickness
of the finished electrotype plate could not be less than
the highest point of the shell. As a rule, electrotypes
are made not more than one pica in thickness, and the
lowest depression in the electrotype where blank spaces
occur must obviously be somewhat less than a pica in
depth.
ELECTROTYPING. 79
For the purpose of cutting down the mold a wax
knife (Fig. ii) of special design is employed. The
mold and the knife should be warm, and the knife must
be occasionally heated over a gas jet or stove. The dis-
placed wax is removed by a shaving, outward cut of the
knife, taking care not to cut too deep into the mold.
Fig. II.— Wax Knife.
The operation requires some practice, but is easily
accomplished if the knife blade is kept warm ; other-
wise there would be danger of breaking down, or dis-
torting the walls of the cavities of the mold, in which
case the later operation of blackleading or metallizing
the mold would be rendered difficult if not impossible.
Even a sharp, warm knife will leave the edges of the
walls more or less ragged, but these edges may be ren-
dered smooth and rounded by passing rapidly over the
mold a lighted gas jet attached to a rubber hose.
After the cutting-down process, the operator should
go carefully over the mold with a sharp-pointed tool and
pick out any shavings or particles of wax which may
have become lodged in the indentations.
The mold should now present a reasonably smooth
surface, all the high places caused by displacement hav-
ing been cut down to a uniform level, which leaves the
indentations in the mold from ^^ to ^^ of an inch deep.
80 ELECTROTYPING.
If the mold has been made from a soHd type form, it
may now be metaUized and prepared for the depositing
vat; but if made from an open form, the blanks between
the printing surfaces must be raised in order to produce
a depression in the electrotype and thus eliminate all
possibility of smutting in printing. Unless the blank is
raised or built up in the mold, it would be necessary to
deepen the depression in the electrotype by routing or
chiseling, which is a much more expensive operation
than building, particularly when a number of duplicates
are required from one pattern. Building is an operation
requiring a steady hand and a quick eye as well as a
skill which comes from long practice. The tools em-
ployed are a building iron (Fig. 12), a small gas stove
Fig. 12.— Building Iron.
and a strip of wax. The building iron is a smooth,
cone-shaped block of copper, about two inches long, one
inch in diameter at one end and tapering to a sharp
point at the other, with a handle eight or ten inches in
length inserted in the side. Several of these irons
should be provided in order that while one is in use the
others may be heating. To build up a blank in the
mold, the operator takes a hot iron in one hand and a
strip of wax in the other, and, holding the point of the
iron over and close to the blank which is to be raised,
ELECTROTYPING.
81
touches the iron Hghtly with the strip of wax, which
instantly melts and runs down the iron onto the mold.
If the blank is large, the wax is held in contact with the
iron while it is moved over the space back and forth
until entirely covered and built up to the required height.
Care must be -taken not to get the iron too hot, for
in that case the wax would be made too thin and would
not chill quick enough by contact with the mold, but
would run off from the blank and into the indentations of
the mold. It is always advisable to test the heat of the
iron by running some wax onto the edges of the mold
where no damage can result. Before blackleading or
metallizing the mold it is also necessary to provide
places of contact for the electrical connections.- This
may be done in various ways. The simplest method is
to provide two pieces of copper wire, about ts of an inch
in diameter and six or seven inches longer than the case.
One end of each wire should be turned over to form
hooks by means of which the case may be suspended
from the cross rods of the depositing vat. The wires
are heated by dipping them in the metal pot or in any
convenient manner, and are then laid on the case, one
on each side of the mold, where they become embedded
by melting a channel for themselves in the wax.
Additional security is obtained by covering over the
wires with wax by means of the building iron. This
method of providing electrical connection with the mold
is simple and reasonably secure, if the case is not too
heavy ; but a better method consists in substituting for
the wires strips of thin sheet copper from one-half to one
6
82 ELECTROTYPING.
inch in width. These strips are not designed to sustain
the weight of the case, but simply to act as conductors,
and for this purpose are superior to wires, because they
assure a better contact with the cross rods. When this
connection is employed, the weight of the case is sus-
tained by S-hooks, one end of which is passed through
a hole in the case, and the other end, which should be
insulated, hooked over the cross rod.
There are several other methods of making elec-
trical connections with the molds which are valuable
chiefly as time-savers. One of them is shown in the
illustration. A piece of copper or brass is melted into
the mold near the top and makes contact with a portion
of the hook which suspends the case from the cross
rod of the bath.
ELECTROTYPING. 83
CHAPTER XII.
METALLIZING.
THE utility of electrotyping in its early days was
restricted to the reproduction of medals or other
metallic objects which were conductors of electricity,
but in 1840 Mr. Murray discovered that nonmetallic
objects could be made conductive by applying to their
surface a film of graphite (blacklead), and to this dis-
covery is largely due the successful application of elec-
trotyping to the copying and duplication of engravings
and type forms. Only the purest grades of graphite
containing from 95 to 99 per cent of carbon are used
for metallizing. For this purpose it is ground to a
seemingly impalpable powder, but under the microscope
it is found to consist of minute flakes. To metallize or
render conductive a nonmetallic object, it is essential
that these flakes shall lie flat upon it like the scales of a
fish, overlapping each other and forming a continuous
and unbroken metallic covering for the object. Such a
surface can be obtained only by brushing or otherwise
forcing the flakes into the position described, which will
incidentally give to the object a bright polish. Black-
leading is sometimes accomplished by means of a pump
84 ELECTROTYPING.
or air blast, as will be hereafter described, but the usual
method is to apply the graphite with a soft brush of
camel's or badger hair, either by hand or with a black-
leading machine. For blackleading by hand a camel' s-
hair brush is preferred. With this instrument the
graphite is brushed back and forth over the mold until a
bright polish is obtained, and until it is certain that no
spot, however small, has been neglected. If so much
as a punctuation point fails to receive the proper polish,
copper will not deposit thereon, and a hole in the shell
will result.
Blackleading by hand is a slow and disagreeable
task, and is seldom practiced in American foundries, a
blackleading machine being considered essential even
in the smallest establishments. Fig. 13 illustrates a
blackleader which is a type of the machines in general
use at the present time. While there are variations in
the mechanical movements of different machines, the
essential features are a vibrating brush or brushes, and a
reciprocating bed to carry the molds back and forth
under the brushes. The apparatus is all inclosed in a
tight box which confines and prevents waste of graph-
ite. After the mold has been built up and prepared as
previously described it is placed on the bed of the
blackleader and covered thickly over with graphite.
When the machine is started the molds travel slowly
back and forth while the rapidly vibrating brushes soon
effect the necessary polish. The time required to prop-
erly blacklead a mold depends upon the nature of the
work and the speed at which the brushes are operated.
ELECTROTYPING.
85
A mold of a type form requires considerable more
brushing than a flat engraving because of the minute
Fig. 13.— Blackleader.
indentions made by the punctuation points, etc. With
a double-brush machine running at about 600 revolu-
86 ELECTROTYPING.
tions per minute, a good polish is usually obtained in
from five to ten minutes.
A disagreeable feature of blackleading is the flying
dust, which cannot be wholly confined and which even-
tually covers everything in the molding room, including
the workmen. This annoyance is minimized by the use
of the inclosed blackleading machine but not entirely
eliminated. On this account the wet process of black-
leading is sometimes preferred. This method was
invented and patented by Mr. Silas P. Knight in 1872.
By this process the graphite is mixed with water to the
consistency of thin cream and by means of a rotary force
pump is discharged with considerable force upon the
mold through a traveling rose nozzle, the entire appara-
tus being confined in a water-tight box. In another
form of wet blackleader the emulsion of graphite is
forced over the mold by a paddle wheel which revolves
in the liquid. The blades of the wheel consist of
badger-hair brushes which come lightly in contact with
the mold and assist in producing the necessary polish.
The wet process is said to be entirely satisfactory, but
for some reason has never come into general use.
Various attempts have been made to perform the
operation of blackleading by means of a blower or air
blast, and several patents have been issued for machines
with this design. Fig. 14 illustrates a machine which
combines both the air-blast and brush features. Air
from the pressure blower (on the floor, back of the
machine) passes through tubes in the horizontal cylinder
(above the machine) and is discharged through a narrow
6
ELECTROTYPING.
87
slot extending across the table and close to the mold ;
water circulating outside the tubes reduces the tempera-
FiG. 14.— Combination Blackleading Machine.
ture of the compressed air, so the machine may be oper-
ated continuously — even in the summer — without dan-
ger of injury to wax molds. At the bottom of the
88 ELECTROTYPING.
machine there is a shallow drawer with a gauze bottom
through which the air passes to the blower ; the gauze
retains particles of wax and other substances likely to
obstruct the free passage of air through the slot. How-
ever, should the slot become clogged, by removing the
plate on the front of the machine the workman can
obtain access to the wind chest and may easily clear
away any obstruction. By a glance at the mercury
gauge, on the top of the machine, the operator can see
whether the air pressure is as it should be. The brush,
which is of badger hair, is located just back of the wind
chest and actuated from a shaft supplied with a tight
pulley, so, whenever desired, the brush may be stopped.
The distance of the brush from the table is adjustable.
In operation the workman lifts the cover, at front,
which is held raised by a hook shown at the left side,
lays the cases to be leaded on the table, which is 33 by
22 inches, lowers the cover, and starts the machine by
pulling the handle on the right until a pawl drops into a
notch in the rod ; he then adjusts the stop motion so
the table will make one, two or three trips forward and
back; when these have been completed the pawl will be
detached automatically from the rod, and the spring on
the countershaft carry the belt on the loose pulley, stop-
ping the machine. It is claimed by the manufacturers
that a tableful of molds may be metallized in one
minute.
After the mold has been blackleaded, it must be
thoroughly freed from the loose graphite which would
otherwise remain in the depressed portions, particularly
ELECTROTYPING. 89
in the smaller indentations made by punctuation points
and leaders, and cause defective shells. The removal
of the superfluous graphite may be effected by a hand
bellows, but in large establishments a rotary fan opera-
ted by power is sometimes employed. A still better
method consists in taking the air through a tube from
a reservoir in which it has been compressed by an air
pump. By this method sufficient pressure to thor-
oughly blow out the mold is assured. From such a
reservoir additional tubes may be extended to the
molding presses, and utilized to blow the loose graphite
from the molds as may be necessary during the opera-
tion of molding.
By the process of blackleading, the case is rendered
conductive over its entire surface, and should it be sus-
pended in the bath without further preparation, it would
receive a deposit of copper not only upon the mold but
upon the margin of wax surrounding the mold, and
upon the back of the case. To restrict the action of
the current to the surface upon which a deposit is
desired, the remaining portion is painted out with hot
wax or varnish, or its conducting surface is destroyed
by passing lightly over it a hot building iron. The
conductivity of graphite is only .07 of one per cent as
compared with pure copper, 100 per cent, and the
action of the electric current on a blackleaded mold is
therefore very slow until covered with a coating of cop-
per, when deposition proceeds rapidly. To give the
mold a better conducting surface than is provided by
the graphite, and thus facilitate immediate action of the
90 ELECTROTYPING.
current over its entire surface, it is customary to precipi-
tate a film of copper on the mold before placing it in
the bath. This preliminary coating of copper is pro-
duced by pouring on the mold a solution of sulphate of
copper of about i6° Baum6, and covering it with a
sprinkling of iron filings. With a badger-hair brush
the filings are lightly distributed over the mold until
thoroughly wet, when they take up the acid in the solu-
tion, and the copper thus set free is precipitated in a
bright film on the mold. If any portions of the mold
fail to take the coating the operation is repeated. Par-
ticular care is observed to avoid scratching the mold
with the iron filings.
Flat molds such as are made for the production
of copper printing plates may be readily and effectively
metallized by either of the methods previously described,
but for the production of nickel electrotypes or the
reproduction of irregular shaped objects such as stat-
uary, or art work of various kinds having undercut or
deep portions, recourse must be had to what is called
metallizing by the wet way. While this class of work
is not strictly in the line of commercial electrotyping
it is sufficiently analogous to deserve mention. The
processes to be described are recommended by such
practical writers as Langbein, Urquhart and Watt.
Gutta-percha or wax molds have their surfaces rendered
conductible by the following plan : Take equal parts
of albumen (white of egg) and a saturated solution of
common salt, and apply the mixture to the object to be
coated by means of a soft brush. Then dry the compo-
ELECTROTYPING. 91
sition thoroughly. Now make a strong solution of
nitrate of silver and dip the mold into it for a few min-
utes and dry again. Expose the mold to a strong light
until it becomes quite black. The mold is then to be
dipped into a saturated solution of sulphate of iron,
when a layer of metallic silver will be formed upon
which a deposit of copper may readily be obtained.
The mold should be rinsed when taken from the sul-
phate of iron solution and connecting wire attached to
it, when it may at once be placed in the depositing bath.
Another method of metallizing is as follows: Dis-
solve a piece of phosphorus in two drams of bisul-
phide of carbon, stir in two drams of benzine and a
drop or two of sulphuric ether; pour the whole into
half a pint of alcohol and wash the surface of the mold
with this mixture twice, allowing it to dry after each
application.
The silver solution is made by dissolving one dram
twenty grains of nitrate of silver in a mixture of half
a pint of alcohol and one dram of acetic acid. The
mold is thoroughly floated once with this solution and
allowed to dry spontaneously.
Another and simpler method of rendering the mold
conductive may be described as follows : Dissolve phos-
phorus in pure alcohol until a strong solution is
obtained and wash the mold with the mixture. The
silver solution is prepared by dissolving nitrate of
silver in aqueous ammonia to saturation. It is to be
poured evenly over the mold and allowed to float over
it for a few minutes. The solution is poured off and
92 ELFXTROTVPING.
the mold allowed to become partly dry, when it is again
floated with the mixture. Spots that do not appear to
take the solution readily should be wetted with it by
means of a soft brush.
Still another process is as follows: Apply with a
brush upon the mold a not too concentrated solution of
nitrate of silver in a mixture of equal parts of distilled
water and ninety per cent alcohol. When the coat is
dry, expose it in a closed box to an atmosphere of sul-
phureted hydrogen. The latter converts the nitrate of
silver into sulphide of silver, which is a good conductor
of the current. For the production of the sulphureted
hydrogen, place in the box, which contains the mold to
be metallized, a porcelain plate or dish filled with dilute
sulphuric acid (i acid to 8 water) and add five or six
pieces of iron pyrites the size of a hazelnut. The
development of gas begins immediately and the box
should be closed with a well-fitting cover to prevent
inhaling the poisonous gas; if possible, the work should
be done in the open air or under a well-drawing chim-
ney. The formation of the layer of sulphide of silver
requires but a few minutes, and, if not many molds
have to be successively treated, the acid is poured off
from the iron pyrites and clean water poured upon the
latter so as not to cause useless development of gas.
For coppering leaves, plants, flowers, etc., dissolve
five parts (by weight) of wax in five of warm oil of
turpentine, and add to the solution a mixture of five
parts of phosphorus, one of gutta-percha and five of
asphalt in 120 bisulphide of carbon. When both are
ELECTROTYPING. 93
thoroughly mixed, add to the whole a solution of four
parts (by weight) of guncotton in sixty of alcohol and
sixty of ether, and, after a thorough shaking, allow to
settle. The next day pour off the clear solution from
the sediment, when the solution can at once be used.
A French process for metallizing leaves, etc., con-
sists in immersing them in iodized collodion composed
of forty per cent alcohol, 40 cubic centimeters; ether,
60 cubic centimeters; potassium iodide, i gram; gun-
cotton, I gram. Allow the leaves, etc. , to dry so that
a firmly adhering layer is formed; then immerse them
in a solution of ten parts (by weight) of nitrate of sil-
ver in 100 of water, whereby a layer of iodide of silver
is formed. Now expose the article thus treated for
some time to the light, and then immerse it in the
reducing fluid consisting of water, 500 parts; green
vitriol, 25 parts, and acetic acid, 25 parts. The reduc-
tion of silver proceeds rapidly and the articles are soon
ready for coppering. Instead of the iodized collodion,
a mixture of equal parts of white of egg and solution
of common salt may be used.
94 ELECTROTYPING.
CHAPTER XIII.
THE CONDUCTORS.
THE electrodes and all connections between the
dynamo and the molds or anodes should be of
copper and should be amply large to conduct, without
heating, the strongest current practicable to use in the
depositing process. It should be remembered that the
generation of the electric current requires power, and
that a portion of the power is always expended in over-
coming resistance, and is, so far as its effect on the work
is concerned, wasted. It is obvious, therefore, in the
interest of economy, that due precaution should be
observed to provide both in the conductors and in the
bath a path of minimum resistance. A barrel of water
would run out of an inch bunghole in a very few min-
utes, while it would take a tremendous pressure to force
the same quantity of water in the same time through a
gimlet hole. In the same way a current of several
hundred amperes will flow readily through a large rod,
when the attempt to force the same current through a
small wire would result in overheating the wire and the
dynamo, with a consequent waste of power. ' ' The
development of heat in the conductors or the solution is
proportional to its resistance and is proportional to the
ELECTROTYPING. 95
square of the strength of the current. Hence, the
development of heat will be the greater, the smaller the
cross-section of the conductor and its conducting capac-
ity are, and the larger the quantity of current which
passes through it."
The size of the conducting rods required for electro-
typing depends, therefore, on the quantity of current to
be employed at one time, which may be estimated with
sufficient accuracy by multiplying the area of the cath-
odes in square feet by the number of amperes required
to deposit one square foot at the maximum practicable
rate. Curiously enough there is a wide divergence of
opinion among authorities as to the quantity of current
which may be advantageously employed. V. Hiibl
gives the maximum as 36 amperes with an agitated solu-
tion. Sprague and Watt place the maximum at 37
amperes, while other writers claim that from 75 to 100
amperes may be employed. It is probable, however,
that the latter estimates are made without considerations
of economy. It would no doubt be possible to employ
100 amperes, but at a tremendous waste of power in
overcoming the resistance due to polarization, which
increases " at a rate approaching that of the square
root of the current. " It is probable that 50 amperes
per square foot cannot be exceeded, if consideration be
given to economical working.
Depositing vats vary in dimensions, and for that
reason a conducting rod which would be of ample
capacity in one case would be too small in another.
Inasmuch as the difference in the cost between a small
96 ELECTROTYPING.
rod and a large one is inconsiderable, it is always wise
to err on the side of safety. The text-books recom-
mend a cross-sectional area in the conductor of one
square inch for each 500 amperes, and in practice, rods
of this size have been found to be of ample capacity.
The resistance of a conductor is proportional to its
length as well as to its cross-sectional area, and this rule
applied to electrotyping means that the dynamo should
be located in the immediate neighborhood of the depos-
iting vats. For the purpose of conducting the current,
the cross rods, i. e., the rods from which the anodes and
molds are suspended, do not usually require to be more
than one-fifth the size of the main conductors, but inas-
much as it is their province to sustain the weight of the
heavy anodes they should not be less than one-half inch
in diameter.
Less trouble will be found in making good connec-
tions if the main conducting rods are rectangular in
shape, as in that case the cross rods which rest upon
them will have a larger area of contact surface, particu-
larly if the ends are slightly flattened. If the main
conductors are round, the ends of the cross rods should
be not only flattened but curved to fit over the larger
rods, and thus insure a good contact. The anodes are
usually suspended in the solution by two copper hooks,
which should be large enough to transmit the current
without becoming sensibly heated — say three-eighths of
an inch in diameter. These hooks, like the cross rods,
should be flattened and curved in order to insure ample
contact surface. Undoubtedly the best method of
ELECTROTYPING. 97
suspending the anodes is to drill and tap holes in the
ends and screw the suspending hooks into them. This
makes a perfect connection, and will remain as long as
the anodes last.
It has been frequently noted that electrotypers do
not always appreciate the importance of making good
connections. It is of no avail to provide large conduct-
ing rods and cross rods if the conducting capacity of
the rods is to be choked off at the point of connection,
which is what occurs when one round rod is laid across
another round rod. It should be plainly obvious that
unless one or both of the rods are flattened where they
come in contact, the area of the contact will be extremely
limited compared with the area of the conductors on
both sides of the contact. It is hardly necessary to say
that all contact points should be kept clean and bright.
A neglected rod will soon become corroded, and corro-
sion increases resistance and is a frequent cause of heat.
It should not be forgotten that the solution is a con-
ductor of the current in the same sense that the rods
are, and should be considered in that capacity as well
as a dissolving medium. Pure sulphate of copper solu-
tion is an extremely poor conductor. The addition of
sulphuric acid improves its conductivity, but under the
most favorable conditions its resistance is several million
times greater than copper. To reduce this resistance
to a point where the solution will not become appreci-
ably heated by the passage of a strong current it' is
necessary to provide an exceedingly large area of con-
ducting fluid and to suspend the anodes and cathodes
7
98 ELECTROTYPING.
as near together as possible, say two to three inches
apart. According to Joule's law, previously quoted,
the development of the heat will be the greater the
smaller the cross-section of the conductor and its con-
ducting capacity are, and the larger the quantity of
current which passes through it. If, therefore, it is
desired to employ a very strong current, the vats must
be larger in proportion to the size of the anodes than
would be necessary with a moderate current. It is safe
to say that the cross-sectional area of the solution should
be at least double the area of the anodes.
ELECTROTYPING. 99
CHAPTER XIV.
DEPOSITING.
WHEN a mold has been metallized by the dry
graphite method, and before proceeding to
strike it (i. e., precipitate on its surface a preliminary
coating of copper to render it more conductive), it is
essential that the air shall be expelled from its surface
by thoroughly wetting it, otherwise the mold when first
immersed in the bath will be apt to repel the liquid, and
the film of air retained on its surface will partially insu-
late the mold and cause holes in the shell. Wetting
may be accomplished by pouring over the mold a small
quantity of alcohol or wood spirits. A more economical
method consists in placing the mold face up on a shelf
in a tank partially filled with water in such a manner
that it will rest an inch or two under the surface, and
then by means of a rotary pump and a rose nozzle
direct a stream of water upon it. In some foundries
graphite is mixed with the water, in which case the
apparatus becomes an auxiliary blackleader and aids
in the metallization of the mold.
After wetting and striking the mold it should be
immediately suspended in the bath from one of the rods
connected with the negative pole of the dynamo or bat-
100 ELECTROTYPING.
tery. It will be recalled that the current enters the
bath through the positive electrode and leaves it
through the negative. It is obvious, therefore, that
were the mold suspended from the positive rod no
action would result.
The anodes are solid plates of rolled copper of any
convenient thickness, but they should have as nearly as
possible the same area of exposure as the cathodes. If
the anode be much smaller than the cathode the deposit
will be brittle and the solution become impoverished.
If the anode should be much larger than the cathodes
copper will be dissolved faster than it is deposited,
increasing the density of the solution and resulting in
streaks on the back of the electrotype and the forma-
tion of uneven deposits.
Holes in the shell are usually due to defective black-
leading or failure to expel the air from the mold by
thorough wetting. In some instances, however, they
are caused by hydrogen bubbles. The remedy for the
latter evil is to decrease the current strength or pass a
camel' s-hair brush lightly over the mold several times
during the time it is in the bath, or, better yet, agitate
the solution.
The mold should be examined after it has been in
the bath a few minutes, and if any dark spots are
observed it should be at once removed and a solution
of graphite and water, or, better yet, graphite and alco-
hol, should be thoroughly rubbed into the defective
spots. The mold should then be rinsed under a strong
head of water applied through a spray nozzle and
ELECTROTYPING. 101
returned to the bath. On no account should the mold
be allowed to dry while out of the bath.
The anodes should, of course, be suspended from
the positive pole of the dynamo, and it is evident that
only one anode need be provided for each pair of
cathodes, for, to maintain an equal area of exposure,
a mold should be placed on each side of the anode.
If the baths are arranged in series, which is the most
economical method of working, the total number of
molds should be divided as evenly as possible between
the vats to insure an equal rate of deposition.
The copper sulphate solution requires little attention
as a rule, because the proportions of its ingredients may
be quite widely varied without materially affecting the
quality of the deposited copper, and, on the other hand,
the current strength may also be varied and the quality
of the production still remain satisfactory; but, notwith-
standing these facts, it is possible to make the solution
too rich or too poor in metal, or too weak or too strong
with acid, and the current density may be too great to
work in harmony with the solution. Very often a
defective shell may result from one of two or three
causes. It is, therefore, sometimes necessary to experi-
ment a little in order to determine the exact cause of
the trouble. For instance, a sandy, pulverulent deposit
may be caused by an excess of current, or it may be
caused by an excess of metal in the solution, or both.
A brittle deposit will be caused by a weak current, or a
solution poor in metal, or both. But if the electro-
typer be provided with an accurate voltmeter it is a
102
ELECTROTYPING.
comparatively easy matter to locate the cause of the
trouble, for if the instrument indicates a current of suit-
able tension for a properly proportioned solution, it may
be assumed that the cause of the defective deposits will
be found in the bath and may be removed by enriching
or diluting the solution as may be indicated by the char-
acter of the deposited copper.
Under ordinary conditions of current and solution,
the molds should be separated from the anodes by a
distance of about two inches; but if it is found that the
deposit is very dark in color or granulated in texture,
this distance may be increased, thereby increasing the
resistance of the solution, which is equivalent in its
effect to cutting down the current strength.
After working a few hours the anodes become more
or less coated with slime, consisting of impurities and
small quantities of foreign metals, which are always
present to a greater or less extent in rolled copper. To
remove the slime, which has the effect of partially insu-
lating the anodes, they should be removed from the
bath once every day and thoroughly scrubbed and
rinsed with clean water.
When molds are removed from the bath the anodes
should always be disconnected from the dynamo, as
otherwise copper would be dissolved into the solution,
thereby unduly increasing its density.
The length of time required to deposit a shell of
given thickness depends on the current - strength em-
ployed and the condition of the solution and connec-
tions. According to Gore, a current density of 17.94
ELECTROTYPING. 103
amperes per square foot will deposit .001 inch of copper
per hour; 35.88 amperes will deposit .002 per hour, and
so on. Having ascertained the current-strength avail-
able there would be no difficulty in calculating the time
necessary to obtain a deposit of any required thickness
provided it were certain that no variation in the current
would occur, and that the connections would remain
clean and in perfect contact, for having once ascertained
the time required to deposit a satisfactory shell, it would
be safe to assume that the same results would be obtained
thereafter; but carelessness in the preparation of molds,
as well as dirty rods or connections, sometimes delays
the action of the current, and the electrotyper, after the
calculated time, usually separates one corner of the shell
from the mold with a sharp-pointed tool, and tests its
thickness by bending it back and forth. This would
seem to be a " rule-of-thumb ' ' method of working, but
constant practice makes the workman so expert that he
seldom makes a mistake. In establishments where the
volume of work is large, it is customary to provide time
tags which may be attached by clothes pins or other
devices to the molds or cross-rods. When the mold is
suspended in the bath, a tag is attached on which is
written the hour it is due to come out. In this way the
electrotyper is enabled to keep tab on his work and
avoids waste of time in testing work which has been
insufficiently exposed; for while it sometimes happens
that a longer time is required to deposit a shell than
would be indicated by the voltmeter or ammeter, it never
takes less than the time so indicated.
104 ELECTROTYPING.
The electrotypers' sink should be of ample dimensions
and should be provided with an unlimited supply of hot
and cold water. The cold water faucet should be a hose
bib, to which should be attached a short piece of hose
terminating in an adjustable nozzle, to provide either a
spray or a strong stream of water as circumstances may
demand. The hot water should be kept in a tank at
one end of the sink, from which it may be dipped as
needed. One end of the sink should be provided with
a hinged apron to protect the operator and the floor
from the spray when using a strong head of water such
as is necessary in washing out molds.
ELECTROTYPING.
105
CHAPTER XV.
CASTING,
ELECTROTYPERS' furnaces were formerly con-
structed of brick with an iron kettle and face
plate. These furnaces are, however, seldom seen now,
the modern furnace (Fig. 15) being constructed of iron,
lined with fire brick. It occupies less room than the old
style furnace, is set up several inches from the floor to
provide an air space underneath and thus minimize the
Fig. 15.— ELECTROTYPERS' Furnace.
106 ELECTROTYPING.
danger from fire, and it may be moved from one place
to another when desired without tearing it to pieces.
The kettle is square or oblong in shape, for convenience
in floating the backing pans, and is about six inches
Fig. i6.— Leveling Stand.
deep, A wide flange or shelf extends around the top
of the furnace to provide a convenient resting place for
the backing pans and body molds. The floor vmder
the furnace and for some distance in every direction
should be covered with heavy sheet iron, about No. i6
gauge.
The leveling stand (Fig, i6), upon which the back-
ing pans rest while the cast is poured, is a light but
substantial framework of iron, whose upper rails are
provided with T-screws which may be so adjusted as to
ELECTROTYPING.
107
keep the pan always in a level position and thus insure
a cast of uniform thickness.
The backing pan (Fig. 17) is a plate of iron or steel,
planed perfectly true and surrounded with a raised edge
whose height determines the thickness of the cast. The
pan is provided with handles to facilitate handling.
Where the pans are large it is customary to handle
them by means of a crane with an arm of sufficient
length to swing them from the furnace to the leveling
Fig. 17.— Backing Pan.
stand. Backing pans should always be kept perfectly
clean, and to that end should be scoured after each cast.
Unless they receive proper attention in this respect they
will soon become rusted and totally unfit for the purpose
for which they are designed ; for to assure a perfect cast
it is essential that the shell shall lie perfectly flat upon a
smooth and level surface.
Backing metal is composed of lead, tin and anti-
mony. A popular mixture is lead 90 pounds, tin 5
pounds, antimony 5 pounds. However, the proportions
of tin and antimony are sometimes varied. Some elec-
trotypers prefer 4 pounds of tin and 6 of antimony,
and others 6 pounds of tin and 4 of antimony. The
108 ELECTROTYPING.
requirements are that the metal shall be soft enough to
straighten easily under the hammer and punch, yet not
so soft as to crush down on the press, and it must
contain tin in sufficient quantity to insure perfect adhe-
sion of the metal to the copper shell.
Having deposited a shell of satisfactory weight, the
mold is removed from the bath and placed in the sink
in a slanting position. After cutting the connections, a
small quantity of hot water is poured over the mold,
beginning at the upper end and allowing it to flow
down over every portion of its surface. The heat
softens the wax and releases the shell, which should be
carefully handled to prevent buckling or bending.
After rinsing the shell in cold water it should be washed
with hot potash to remove the film of wax which will
still adhere to the copper. The shell may be placed on
a slanting board over the lye kettle and scrubbed lightly
with a soft brush, and then rinsed with potash and after-
ward with clean water. Unless the shells are to be
immediately backed up with metal, they should be
placed in a shallow, lead-lined box partially filled with
water slightly acidulated with sulphuric acid. If the
shells are permitted to become dry they will tarnish and
will not readily amalgamate with the backing metal.
In order to effectually unite the backing metal to
the shells it is essential that the back of the shell shall
be perfectly clean, and that it shall be first covered with
a coating of solder or with tin foil, which becomes
solder when mixed with the lead in the backing metal.
Tin foil may be purchased in rolls of any desired width
ELECTROTYPING. 109
and thickness. A convenient size is five or six inches
in width and about .002 inch in thickness.
To thoroughly clean the shell it should be brushed
over with a solution of chloride of zinc, which may be
prepared by dissolving scraps of sheet zinc in muriatic
acid to saturation and adding twenty-five per cent pure
water. The zinc should be dissolved in a wide-mouthed
bottle in the open air, as the fumes given oflf are disa-
greeable and poisonous. The zinc solution may be
applied with a bristle brush, and the operation may
preferably be performed on a glass-topped table or on
a sheet of heavy plate glass placed on the workbench.
Glass is preferred because it is not affected by acid and
may be easily kept clean.
After cleaning with the tinning solution the shell is
covered with tin foil and placed face down in the back-
ing pan, which has been previously heated by floating
it in the molten metal, whose temperature should be
sufficiently high to scorch a piece of white paper with-
out burning it. The tin will almost immediately melt
and cover the shell with a thin coating. If preferred,
the shell may be placed on an iron plate heated by gas
instead of in the backing pan, the object being to melt
the tin foil on the shell. After the tin is melted the
backing pan should be immediately transferred to the
leveling stand and the shells covered with molten metal,
pouring it on slowly from a small ladle and holding the
shell down with a stick or any convenient instrument if
it shows any inclination to rise to the surface of the
metal.
no ELECTROTYPING.
To expedite cooling of the cast a small blower may
be placed on the floor under the leveling stand in such
a manner that a stream of air may be directed against
the bottom of the pans.
A device which is sometimes employed in connection
with the backing-up process and which is claimed to
Fig. 19.
accomplish a material saving of time and labor is illus-
trated in Fig. 19. The description is taken from the
circular of the manufacturer.
The apparatus is designed to flatten the plates by
pressure after the metal has been poured and before it
has set and hardened. The process differs but little
ELECTROTYPING. • 111
from that hitherto employed, the new feature being
the application of pressure, whereby much of the ham-
mering and finishing is obviated.
The press has been so designed as to make it thor-
oughly efficient and convenient, many suggestions from
experienced electrotypers being embodied in its con-
struction. Its operation is very simple, presenting no
difficulties.
When the pan is lifted out of the metal pot the
metal that adheres to the bottom of the pan is scraped
off by a steel scraper attached to the front end of the
press. On the inner sides of the frame of the press
are rollers, seven on each side, upon which the pans
move easily and quickly. The pan is set on the rollers
on the front of the press and the shell backea as usual.
Air is blown on the bottom of the pan from a pipe
underneath, and on the metal from a pipe above, the
object being to cool the cast evenly as well as quickly.
When the metal has commenced to set, a sheet of thick
asbestos, covered with powdered chalk or blacklead, is
laid on top of it and the pan rolled under the platen.
The blast is then turned on the bottom of the pan
under the platen. The rollers under the platen are on
springs, and depressed by the pressure on the pan until
the pan rests on supports underneath. The asbestos
and the rollers being elastic, the pressure is gradual and
easy. The pan remains under pressure till the next
one is ready, and is then pushed out to the back of the
press and taken off. The blast pipes underneath are
supplied with the press and provided with dampers.
112
ELECTROTYPING.
They are so arranged that connection can be made with
the pipe from the blower on either side of the press.
Electrotypes are usually mounted on wooden blocks
to make them "type high," but for certain purposes it
Fig. 20.
is desirable to mount them on metal bases, as, for
instance, half-tone cuts and matter which is to be
stereotyped, such as advertising cuts for daily news-
papers. For the latter purpose electrotypes are made
in standard widths, i. e. , single, double or triple column.
The electrotype, after it has been backed up and
straightened, may be tacked or soldered to metal bases
which have been previously trimmed and shaved to the
proper dimensions, but better results are obtained both
in appearance and security by casting the base directly
ELECTROTYPING.
113
on to the plate by placing the electrotype face down in
an iron mold and pouring molten metal on the back.
The cover of the mold is provided with corrugations
which form depressions in the metal, thus effecting a
saving in material and at the same time producing a
cast both light and strong and more easily handled
than a solid metal cast.
Figs. 20 and 21 illustrate respectively a body mold
and a section of a cast made therein. The bottom
plate of the mold on which the electrotype rests is not
shown.
Before making a cast all parts of the mold are
floated in the metal pot until they are of uniform tem-
perature with the metal. With a pair of pincers or
tongs the bottom plate is then withdrawn from the metal
and placed on two supporting blocks, one under either
end, one of which is slightly higher than the other, so
that the plate will have a pitch of about one-half inch.
The frame of the mold is then laid on the bottom plate,
the electrotype placed inside, the cover adjusted and the
8
114 ELECTROTYPING.
different parts clamped together with two iron haind
clamps. The cover is somewhat shorter than the frame,
which leaves an opening at the upper end to receive the
metal. The temperature of the mold is sufficient to
soften the backing of the electrotype, so that the new
metal, which is poured slowly and cautiously, readily
amalgamates with it. Having filled the mold, the cast
may be cooled by swabbing the mold with cold water.
As the metal cools it shrinks and more metal must be
continually added until the cast is set.
Electrotype body molds are made in several standard
sizes, from 6 to 41 picas in width and about 14 inches
long. Electrotypes wider than 41 picas are cast in
adjustable molds, an illustration of which is shown in
Fig. 22. In such a mold electrotypes from one-half to
four columns in width may be cast solid or cored.
Eight cores of different sizes are usually provided,
suitable for different kinds of work.
In some foundries the mold is cooled after the cast
has been poured by partially immersing it in a tank of
water. When employing this method it is important
that the cooling shall be effected gradually, otherwise
uneven shrinkage would result and the electrotype be
injured or destroyed. A convenient means of handling
the molds is by means of a small derrick which may be
locked in any desired position and thus permit the grad-
ual immersion of the mold in the water.
After the shell has been backed up, the cast is taken
to the scrubbing trough and thoroughly cleaned with
kerosene and powdered pumice stone applied with a
ELECTROTYPING.
115
moderately stiff brush, and finally polished and dried
with soft sawdust. Great care should be observed in
cleaning half-tones, as a slight scratch is sufficient to
ruin them.
The backing pan will usually accommodate several
shells, and after they have been cast and cleaned the
next operation is to saw the different jobs apart that
that they may be separately straightened and finished.
For this purpose an iron saw table is employed, of which
Fig. 23 is an illustration. The mandrel is driven by a
countershaft and pulleys which are furnished with the
116
ELECTROTYPING.
machine. The rear end of the table is hinged to the
frame of the machine; the front rests on the end of
a screw, terminating in a hand wheel, by means of
which the top may be adjusted to any desired height for
sawing mortices, etc. An adjustable side gauge and a
sliding end gauge are necessary features if the saw is to
Fig. 23.
ELECTROTYPING. 117
be used for general work, and a glass saw guard for
protecting the eyes of the operator from flying chips
and sawdust is also essential.
Saw blades for cutting electrotype metal should have
about the same temper as for sawing wood, and should
not be of greater diameter than the nature of the work
demands. A large saw is liable to wind and warp, while,
on the other hand, if it projects but slightly through
the work this tendency will be minimized. The diam-
eter of the saw must depend, of course, upon the dis-
tance between the saw mandrel and the table top. For
instance, if the saw mandrel is three inches below the
top of the table, a nine-inch saw would be required to
give sufficient cutting surface above the table and allow
for a reasonable amount of wear. In most machines,
however, the mandrel is located within two and one-half
inches from the top, or even less, thus permitting the
use of smaller blades. For general use a cross-cut saw,
eight inches in diameter. No. i8 or 19 gauge, and with
about five points to the inch, is found most practical and
convenient. Such a saw should be driven about 4,000
revolutions a minute.
To cut freely without sticking or filling up, saws
should be kept sharp, round, evenly set, and the teeth
should be filed all with the same angle and without
hook. To keep the saw round, it should be jointed
occasionally by elevating the table top until only the
longer teeth of the saw project through the slot in the
top, when they may be ground down with a piece of
emery stone to uniform length. If the saw mandrel fits
1 18 ELECTROTYPING.
perfectly the hole in the saw and no more filing is done
than is necessary to bring the teeth to a point, a perfect
circle will by this method be obtained.
The saw may be set by laying it on a block of hare-
wood and striking every alternate tooth with a hammer
or punch, and then turning it over and repeating the
operation with the remaining teeth. It requires consid-
erable skill, however, to set a saw evenly in this way,
and it is preferable, particularly for the novice, to use a
carpenter's saw set which may be purchased at any
hardware store.
To file a saw properly it should be clamped between
two round blocks, about one inch thick and one inch
less in diameter than the saw. The blocks may be
clamped together on the saw by placing them in a vise.
The saw should be filed straight across and should not
hook or lean forward of a line drawn from the center of
the saw to its periphery.
ELECTROTYPING. 119
CHAPTER XVI.
FINISHING,
THE duties of the electrotype finisher are to make
the face of the electrotype perfectly flat and level,
to repair defective letters, or cut them out and replace
them with type; to repair defective rules, etc., and
finally to bevel the edges of the plates if they are to
be worked on patent blocks, or to mount them upon
wooden or metal bases.
The tools required to properly straighten an electro-
type are a light hammer, with one round face, Fig. 24;
a set of punches, Fig. 25; a pair of calipers. Fig. 26,
and a rubber, Fig. 27.
The first operation is to beat down the edges of the
bearers surrounding the page or engraving with the
hammer, after which the plate is laid face down on a
smooth, steel-faced finishing block, and planed down
with a block of wood and hammer to make it lie flat
and solid. If any bad sinks are observed in the electro-
type their exact location is marked on the back of the
plate by means of the calipers. The plate is then again
laid on its face on the finishing block, and with a suit-
able punch the marked spot is driven down until it is
flush with the surrounding matter. After the plate has
been rough-finished and straightened it is taken to the
rougher. Fig. 28, and a cut taken off the back, which
reduces it to an approximately uniform thickness.
120
ELECTROTYPING.
As its name implies, the rougher was designed to
take the first or rough cut ofT from the electrotype cast.
Its chief utility consists in the fact that a large quan-
tity of "metal may be removed at one operation. The
electrotype rests face down upon a traveling bed, and
Fig. 24.
Fig. 25.
is held down during the operation of planing by two
spring rolls located one on either side of the track of a
reciprocating cutter. The cutter is secured in a tool
post which is arranged to slide on an arm extending
over the bed and at right angles thereto. The cutter is
actuated by a pitman, one end of which is connected
with a stud on the cutter head and the other with a stud
ELECTROTYPING.
121
on the drive pulley. The bed is operated in one direc-
tion by a worm, which is driven by a belt from a pulley
on the drive shaft, and is reversed by hand.
Fig. 26.
While the machine was originally intended for rough
work, yet if carefully constructed it can be made to per-
form its duty so accurately that no further planing or
shaving is necessary, and in many foundries it takes the
place of the shaving machine.
An improved type of rougher has an adjustable
shaving knife located just back of the reciprocating
cutter, which frees the plate from the metal chips which
Fig. 27.
become imbedded in the plate by passing under the
spring roller, and which would otherwise have to be
removed with a file or scraper. The shaver knife also
removes the tool marks left by the rougher, and gives
the plate a finished appearance.
122
ELECTROTYPING.
After the electrotype has been roughed it is taken
back to the finishing block and carefully examined.
Every minor defect is then remedied and necessary
corrections made.
To more readily detect the low spots in the plate,
the face of the electrotype is lightly rubbed over with a
rubber ink eraser, mounted on a block of wood, or with
a piece of fine emery paper stretched over a block.
Those portions of the electrotype which do not receive
a polish from this treatment are obviously low, and after
locating them on the back of the plate with the aid of
Fig. 28.
ELECTROTYPING. 128
the calipers, they are hammered or punched up to a
uniform level. After each operation of hammering or
punching, the electrotype is planed down and straight-
ened, and again tested with the rubber, and these treat-
ments are repeated until all the dark spots have been
brightened.
While the process of straightening an electrotype as
thus described is very simple, it really calls for a high
degree of mechanical skill, which can be acquired only
by long practice.
The electrotype having been straightened and re-
paired, it is taken to the shaving machine for a final cut,
which should reduce its thickness, if a book plate, to
exactly ii points (small pica), this thickness having been
adopted by the electrotypers' associations of America as
a national standard for bookwork. If the plate is to be
mounted on a wooden base it may be shaved somewhat
thinner.
Shaving machines are of various patterns and sizes,
some operated by steam power and some by hand. The
hand shaver consists of an iron table planed perfectly
true upon its upper surface, and provided with a stop at
one end to hold the plate in position. The side edges
of the table are planed true, both top and bottom, and
serve as guides for a sliding head to which the knife is
bolted. Secured to the rear of the head and traversing
the entire length of the machine are steel racks, one on
either side, which are engaged by two pinions located
on a shaft which is at right angles with the racks. To
one end of the shaft a cast-iron spider is keyed, and to
the spider long wooden spokes are bolted, which afford
the means of operating the head. The head is provided
124
ELECTROTYPING.
with brass gibs, and the wear on the gibs may be taken
up by means of set screws.
In large establishments shaving machines are usually
driven by steam power. There are various devices for
applying the power, one of which is illustrated in
Fig. 29,
Fig. 29. The shaft and pinions acting on the racks
are the same as in the hand machine. A large gear
wheel is substituted for the spoke wheel on the main
shaft and is driven by a pinion to whose shaft power
is communicated through intermediate gearing by means
of band wheels shown at the left of the machine.
ELECTROTYPING.
125
Nearly all shaving machines are provided with a
spring roller located in front of and attached by brack-
ets to the head. The purpose of the roller is to press
the plate flat down on the bed of the machine just
before the knife begins its cut. A plate which is slightly
uneven or warped is thus secured against the danger of
' ' go"gii^g> ' ' ^nd the necessity for planing or filing a
bevel on the end of the plate is also obviated.
Another type of shaving machine has a bed resting
on steel wedges which are made adjustable by a screw
Fig. 30
126 ELECTROTYPING.
passing through the front of the machine and terminat-
ing in an indexed hand wheel. By means of this wheel
the bed may be raised or lowered to any desired height
within the range of the machine.
Fig. 30 illustrates a machine which is of compara-
tively new design and differs in many respects from
other makes. The following description is given by
the manufacturer: "The knife remains stationary, the
plate to be shaved being placed on a table and passed
under the knife. Power is applied to move the table
in one direction only, the power being thrown on
and off by a lever handle, not shown, convenient to
the right hand of the operator. The backward move-
ment is obtained by means of a hand wheel. The table
is extended beyond the head toward the front of the
machine, affording increased bearing surface and equaliz-
ing the wear over all parts of its length ; the extended
portion, is made slightly concave, on which plates may
be bent so that they shall rest properly on the shaving
table. At the front of the machine, on the left side, is
an inverted plane, by which the plates may be beveled
as is usual to prevent the too abrupt commencement of
the shaving operation. ' '
ELECTROTYPING.
127
CHAPTER XVII.
TRIMMING AND ROUTING.
ALL electrotype plates, whether job or book work,
require to be trimmed on sides and ends. In
the case of wood-mounted plates the trimming is done
after they have been mounted on blocks, when plate
and block may be finished at one operation. The cir-
cular saw is unsuited for such work because of its
tendency to spring away from the job, and because its
cut is more or less ragged and uneven.
Fig. 31.
Various machines have been designed for the finish-
ing of electrotypes, the simplest and least expensive of
which is the shootboard, Fig. 31, which consists of an
128 ELECTROTYPING.
iron plate with a gutter or chute along one side in which
a plane, furnished with an adjustable cutter blade, freely
slides. A stop extending across the bed at right angles
with the gutter serves as a rest for the electrotype and
also as a guide for squaring the plate. The plane is
Fig. 32.
provided with two blades, one for making a square edge
and one for producing a beveled edge such as is required
on book plates.
Fig. 32 illustrates a very convenient and efficient
trimming machine, specially designed for finishing type-
high or ' ' body ' ' work. A rapidly rotating arbor carry-
ing a cutter head, in which are secured two or more
ELECTROTYPING. * 129
cutting tools, is journaled in a substantial iron frame.
The work is carried past the cutters on a reciprocating
carriage which slides on ways parallel with the cutter
head. The carriage is furnished with a right-angled
adjustable gauge against which the work rests, which is
adjusted by a finely threaded feed-screw, admitting of
close and accurate work. The trimmer head should
travel at a speed of about 3,500 revolutions per minute.
To prevent the work from being drawn into the
cutters and mangled it must be held securely on the
carriage. Large and heavy pieces may be held by the
fingers without danger, but the very small pieces, such
as one, two or three line electrotypes, should be held
by a lineholder, Fig. 33. The lineholder is an oblong
Fig. 33.
block of iron ten or twelve inches in length, two inches
in width, and one inch high. A dove-tailed groove,
extending the full length of the side face of the block,
admits two thin serrated clamps, one of which is secured
by means of a set screw at any desired distance from
the end of the block, and the other is pivoted to the
end of a lever which is operated by a handle on the
top of the block. The under side of the block is
recessed to receive a spiral spring which is attached to
130 ELECTROTYPING.
the lever and serves to hold the clamps firmly together
upon the work. In operation the block is placed upon
the carriage of the trimmer, the clamp jaws separated
by means of the handle and the work inserted between
them. On releasing the handle, the spring acting on
the lever draws the clamps together. The work is thus
securely held and may be trimmed without danger to
the eyes or fingers of the operator, provided the line-
holder itself be held firmly against the side gauge of
the machine during the operation of trimming. It
should be impressed upon the workman that whether
trimming large or small pieces it is important that the
carriage be kept free from chips. More accidents have
been caused by carelessness in this regard than from all
other causes combined. A chip or a small piece of
metal under the work will cause it to chatter or rock
when it encounters the cutters, with the result that the
workman often loses control of it; and even if he
is not injured by flying fragments his work will be
destroyed.
Two kinds of cutters are used in trimming machines,
one for trimming metal and the other for wood, or wood
and metal combined, such as job or book plates mounted
on cherry or mahogany blocks. The cutters should be
made of Stubs' tool steel, hardened, and the temper
drawn to a purple color. The holes in the cutter head
are usually made round, in which case round steel of a
size which will accurately fit the holes should be used
for tools. The cutting ends of the metal cutters must
be squared for at least a half inch back from the end —
that is to say, there must be one right-angled corner to
do the cutting. Fig. 34 is a side and end view of a
ELECTROTYPING.
131
metal cutter, and Fig. 35 illustrates a wood cutter or
"goose-bill."
It sometimes becomes necessary to deepen the relief
in an electrotype to prevent blacking or smutting the
paper in printing. While this operation may be per-
FlG. 35.
formed with a mallet and chisel, it is always preferable
to employ a router. Fig. 36. In this machine a rapidly
revolving vertical spindle carries on its lower end a
chuck in which may be secured cutting tools of various
sizes suited to the nature of the work to be performed.
The box in which the spindle turns is bolted to a handle-
bar, one end of which serves as a handle for guiding the
tool over the work, while the other end is pivoted to
another handle-bar which is again pivoted to the frame
of the machine. The double joints thus formed permit
the tool to be moved freely in any direction over the
bed of the machine. The second handle-bar is sup-
ported at the elbow formed by pivoting together the
two bars, by a steel segment, and the first handle-bar
132
ELECTROTYPING.
rests on a straightedge of hard wood extending the
entire length of the machine. The ends of the hard-
wood slide are supported by spring studs, which hold
Fig. 36.
the handle-bar carrying the spindle high enough from
the table so that the cutting tool clears the work when
not in operation. A pedal attached to a lever under-
neath the machine affords a means of compressing the
springs, thereby permitting the tool to enter the work.
ELECTROTYPING. 133
The tool spindle is adjustable in a vertical direction f:o
provide for plates of different thicknesses, as when a
change from type-high to plate work, or vice versa, is
desired. This adjustment is obtained by means of a
hand wheel attached to a threaded sleeve in which the
spindle turns. The sleeve is provided with a feather to
prevent its turning, so that a movement of the hand
wheel in either direction raises or lowers the spindle.
The work is held in screw clamps, which slide freely in
dovetailed grooves planed in the bed of the machine.
Power is transmitted to the tool spindle by a belt passing
over idle pulleys at the corner of the machine. The
pulleys at the pivotal points of the radial arms enable
the operator to move the spindle freely in any direction
without changing the tension of the belt. To perform
smooth and rapid work router tools require to be driven
at a high speed. For electrotype metal the speed
should be about 12,000 revolutions per minute. A
machine running so rapidly should, of course, receive
careful attention. The bearings should be kept clean
Fig. 37.
and well oiled, and must not be permitted to become
overheated. Router tools for general work are about
the size of a lead pencil. For special work they
may be made as small as one-sixteenth of an inch
in diameter, and when large quantities of metal are to
be removed, the size of the tool may be increased to
one-half inch. The cutting end of the tool is made in
134
ELECTROTYPING.
the shape of a half moon, as shown in Fig. 37, the
leading point being slightly longer than the heel, to pre-
vent clogging. This tool is sharpened by grinding the
end only, and may, therefore, be easily kept in order.
Book plates, when finished ready for the press, are
usually mounted on patent blocks, and are secured to
Fig. 38.
ELECTROTYPING. 135
their bases by bevel clamps which lap over the edges of
the plates. It is, therefore, necessary to provide a bev-
eled edge for the plates. This work may be performed
on a shootboard by using a suitable plane; but when a
large number of plates are to be prepared, it is cus-
tomary to employ a beveling machine — Fig. 38. This
machine resembles a trimmer, but has an adjustable
vertical shaft. It has a reciprocating carriage to carry
the work past the cutters, is provided with gauges for
the alignment of the work, and may be adjusted so as
to produce either a rabbet or bevel, as may be desired.
136 ELECTROTYPING.
CHAPTER XVIII.
REVISING.
AFTER book plates have been straightened, shaved
. and beveled, a proof is taken, and it sometimes
happens that errors or omissions are then discovered
which make changes and corrections necessary. Such
changes may consist in some cases of only a single let-
ter, while in others an entire line or paragraph may be
involved. In the former case, the defective letters are
punched out and type inserted in their places, and in the
latter, the line or paragraph is set up and electrotyped,
and after cutting out the defective portion of the plate
the new piece is set in and soldered. The special tools
required for this work consist of a set of punches and
chisels and a pair of calipers, such as have been pre-
viously described; a revising stick (Fig. 39), a blow
pipe, a pair of cutting pliers, a soldering iron, some small
flat files, and a light hammer. A complete set of chisels
and punches consists of eight sizes, and corresponds
with the different sizes of type in general use, namely:
pica, small pica, long primer, bourgeois, brevier, minion,
nonpareil and agate. The thickness of the tools corre-
sponds with that of the letter i in the respective fonts.
The revising stick may be made of a piece of print-
ers' brass rule, six or more inches in length. To one
edge and one end of the rule a strip of brass one-eighth
ELECTROTYPING.
137
of an inch square should be soldered, as shown in Fig.
39. This makes a convenient, and in fact indispensable
tool for holding a line of type while fitting it to the slot
in the plate in which it is to be soldered.
Fig. 39.
A line gauge, Fig. 40, is employed for detecting
errors of alignment between the inserted type and the
remainder of the line, and is also employed for the
alignment of newspaper headings or other jobs com-
posed of capitals and lower-case letters. In trimming
a line composed of a capital letter followed by several
lower-case letters, the width of the block, of course,
Fig. 40.
must correspond with the width of the capital, and it is
obvious that without a guide it would be difficult to
trim the block so that the lower-case letters would all
be at an equal distance from the top and bottom of the
block. The same difficulty would occur in trimming
138
ELECTROTYPING.
any kind of a job requiring a margin above and below
the matter. The Une gauge enables the operator to
trim the edges of such jobs exactly parallel with the
printing face, and is, therefore, an important and almost
indispensable tool. When used in revising, the edge of
the gauge is set in alignment with the line in which a
correction is to be made. After the type has been
inserted, and before it has been permanently secured by
soldering, an application of the gauge will determine
whether the alignment is perfect.
The blowpipe is used for soldering in places which
cannot be conveniently reached with a soldering iron.
It consists of a Y of brass tubing, one of whose arms is
connected by a rubber tube with the gas supply. By
blowing in the other arm of the Y a stream of air is
mixed with the gas. The point of flame may be
directed and focused on any desired point, however
small.
Referring to Fig. 41, it will be observed that the
cutting ends of the revising punches are provided with
V grooves, which give to the tools two cutting edges,
Fig. 41.
thus admitting of a sharp, clean cut through the plate
of just the size of the type which is to be inserted. In
correcting a typographical error in a plate, the workman
first marks with his caliper the exact location of the
ELECTROTYPING. 139
letter upon the back of the plate. With a small chisel
a groove is then planed at the point marked by the
caliper to the depth of about one-half the thickness of
the plate, A punch of the proper size having been
selected, the plate is turned over, face up, upon a block
of wood, and with a sharp blow with the hammer the
letter is punched out. Turning the plate over again,
face down upon the finishing block, the type is inserted
in the hole, and the contiguous metal crowded against
it with a chisel until it is secured against dropping out,
when the face is examined to see that the inserted type
is in alignment with the remainder of the line and level
with the surface of the plate. Care must also be
observed to keep the type on its feet — that is to say, it
must not lean from the perpendicular. The body of the
type which has been left projecting through the hole is
now cut off with the pliers level with the back of the
plate, and the type secured in its position with a drop
of solder. It is of course necessary to observe some
care, otherwise there would be danger of melting the
surrounding metal or the type itself After the type is
secured the superfluous solder is removed with a chisel
or file.
When several consecutive letters are to be mserted
in the plate, the hole made with the punch is enlarged
with chisel and file to the size of the correction, and the
type which has been previously set up in the revising
stick is inserted and temporarily secured as before.
Somewhat more skill is required to make a correction
of this kind than to insert a single letter, as the slot
must be kept parallel and in exact alignment with the
remainder of the line, and this is a more difficult matter
140 ELECTROTYPING.
than to punch a single hole in the plate. When the
slot has been made too large, as sometimes occurs, the
type is aligned by crowding the contiguous metal against
that side of the type which is above or below the
line. When the type has been properly placed it is
usually partially secured by soldering before cutting
off the body; otherwise there would be danger of dis-
turbing it.
When the correction consists of several words or
parts of lines, the matter is set up and electrotyped in
the usual manner. The corrected piece so made is laid
on the plate in the position it is to occupy, and with a
graver or other sharp-pointed tool its exact outline is
transferred to the plate. A hole is drilled in one corner
and the defective portion of the plate cut out with a jig
saw — Fig. 42. The correction is then inserted, the
plate turned face down and a drop of solder applied to
each of the four corners. During the operation of sol-
dering, the plate and correction should be firmly held
against the finishing block to prevent warping or spring-
ing of the pieces, which might otherwise be caused by
the heat of the iron. For this purpose the cutting pliers
may be reversed, the end of one handle being used to
hold the plate and the other the correction.
A necessary part of the equipment of an electrotype
foundry is a set of brass standards based upon the print-
er's universal unit of measurement, the pica. These
standards should be twenty-six in number, ranging from
one to twenty-six picas in length. The convenience of
such standards will be apparent when it is remembered
that all large type, such as is employed for newspaper
headings, etc. , is made to occupy the space of a certain
ELECTROTYPING.
141
Fig. 42.
142 ELECTROTYPING.
number of lines of pica and is called 6-line type, 7-line
type, etc.
In addition to the pica standards, the electrotyper
should have a type-high standard, preferably made of
steel, about 2 by 3 inches in size and .919 of an inch
thick. Such a standard is useful not only for testing
finished work, but also for setting the knife of the shav-
ing machine, for which purpose it is placed on the bed
of the shaver and the knife screwed down until it will
just touch it.
Book plates are usually worked on patent blocks and
should be shaved to exactly eleven points (small pica)
in thickness. For testing this class of work a standard
should also be provided.
ELECTROTYPING. 143
CHAPTER XIX.
BLOCKING.
"DOOK plates are usually worked on patent blocks,
^-^ with which every large publishing house is sup-
plied. These blocks are made in some cases of wood,
but preferably of iron, accurately finished and provided
with clamping devices for securing the plate to the base.
The best blocks are made in sections, and may be
arranged and adjusted to fit various sizes of plates.
The clamps are beveled and made adjustable so that
they will fit snugly over the beveled edge of the plates.
Plates which cannot be worked on patent blocks are
secured by screws, tacks or anchors to wooden blocks.
Mahogany makes the best blocking wood, but is rather
expensive for general work. Cherry comes next, and is
the wood most generally employed for blocks ; birch and
maple are also used to some extent. Blocking wood
may be procured ready for use, kiln dried, and surfaced
to proper thickness; but most electrotypers prefer to
purchase lumber in the rough and dress it to thickness
as it is required for blocking, thus avoiding danger of
warping, which is likely to occur when the wood is
dressed several days in advance of its use.
Lumber which has been thoroughly dried in the
yard is superior to kiln dried lumber because it is less
susceptible to changes of atmosphere. When sufficient
space is available it is always advisable to carry a stock
144
ELECTROTYPING.
in the foundry, where it soon becomes seasoned. It
often happens, however, that well-seasoned lumber can-
not be procured and kiln drying then becomes neces-
sary. By whatever process the wood is dried it should
Fig. 43-
be thoroughly done, otherwise the block will warp after
the electrotype has been secured to it, probably after it
has been delivered to the printer, in which case much
annoyance and expense will inevitably result.
ELECTROTYPING. 145
Blocking wood must be surfaced on both sides and
with perfect accuracy to insure good printing. For this
purpose a rotary planer, Fig. 43, is almost indispensa-
ble. The peculiar advantage of this machine consists
in the fact that it dresses the wood perfectly flat and
level, no matter how badly it may have been warped or
sprung before planing. In this respect it is far supe-
rior to the ordinary wood planer, for, while the wood is
flattened by the pressure rollers during the operation of
planing, it springs back to its original shape on being
released.
Referring to Fig. 43, it will be observed that the cut-
ting tools of the rotary planer are secured in a revolving
disk which is made vertically adjustable by means of the
crank shown at the top of the machine. Power is com-
municated to the disk by a belt passing over idlers at the
rear of the upright frame to the pulley on the disk shaft.
One of these idlers is secured to a shaft which carries
on its outer end a grooved pulley which provides a
means of transmitting power to the worm shaft shown at
the side of the machine. The worm wheel driven by
this shaft is secured to a shaft passing under the travel-
ing bed, and is provided on its inner end with a small
pinion which engages the rack attached to the under
side of the bed. By a simple mechanism which is at all
times in control of the operator, the worm is thrown
out of gear at the termination of the cut and the bed
returned to its first position by hand. The lumber is
held during the operation of planing between the jaws
of two clamps, one of which is stationary and the other
connected with a screw which terminates in the crank
handle shown at the front of the machine. In opera-
10
146 ELECTROTYPING.
tion, the board is placed between the jaws of the clamps
and locked by means of the crank mentioned. The
board is thus secured against springing or rocking while
its upper surface is dressed perfectly true and level.
The board is then turned over with its flat surface
against the bed of the machine, and again passed under
the cutters, which reduce it to the required thickness.
The disk is raised and lowered by a graduated adjust-
ing screw operated by the crank shown at the top of the
machine, and may, therefore, always be returned to the
proper height for the finishing cut without going to the
trouble of comparing each board with a standard. Ow-
ing to the large size of the disk and the fact that the
tools are located near its periphery, the machine should
be driven at a speed not exceeding 1,500 revolutions
per minute.
After planing, the boards are cut into convenient
lengths for handling, and the plates secured to them
by means of wire brads or screws, or both. Brads
may be driven through the thin places (spaces) in the
plates, but for the screws holes should be drilled and
countersunk in order that the heads may be sufficiently
depressed to avoid danger of blacking or smutting in
printing. Where a plate has no spaces or blanks where
brads or screws may be driven, it is customary to
"anchor" the plate to the block. For this purpose
holes about one-fourth of an inch in diameter are bored
through the block and deeply countersunk on both
sides. If the plate has been finished long enough to
have become oxidized, the back should be brightened
by filing, and is then laid on the block and temporarily
secured thereto by hand clamps. It is then turned over
ELECTROTYPING. 147
on its face, and, after a very small quantity of soldering
fluid has been applied to the plate through the holes,
melted solder is poured in until the holes are full. It is
important, of course, not to get the solder too hot, as
in that case there would be danger of its melting
through the plate. There is always an element of
uncertainty in securing electrotypes to blocks by this
method, and, when possible, it is best as an additional
safeguard to rabbet the edges of the plate and drive in
a few brads. When the plate is small, it may some-
times be fastened securely in this way without the use
of anchors.
When several small cuts are to be blocked at one
time, it is customary to tack them on to a board as
large as may be conveniently planed, leaving sufficient
room between the cuts to saw them apart. Should it
be necessary to take a final shaving off the bottom of
the cuts after they have been blocked, it may be done
more economically if several are shaved at a time than
if each one were to be handled separately.
Very large blocks are liable to warp in time, in spite
of any precautions which may be taken to prevent it,
and to reduce this tendency to a minimum each block
should be strengthened by end strips crossing the grain
of the block. The strips may be secured to the blocks
by countersunk screws, but a more satisfactory method
is to dovetail them together. A machine specially
designed for this work is illustrated in Fig. 44. The
cutting tools are a thick gouge saw of about No. 3
gauge, which cuts a slot in the board or strip, and a
vertical revolving cutter, which follows in the slot and
changes it into a dovetail groove. The mechanism for
148
ELECTROTYPING.
driving the tools is sufficiently explained by the engrav-
ing. The parallel side gauge, against which the board
is pressed during the cutting of the dovetail, can be
instantly changed by means of the small lever at the
Fig. 44.
ELECTROTYPING. 149
right of the machine so that either the center or the
edge of the strip may be thrown in alignment with the
cutters, thus providing a means of cutting a dovetail in
one board and a tenon on the other. The mechanism
for changing the side gauge from one position to the
other is such that there can be no variation in the dis-
tance it is moved, and whatever position it occupies it
is automatically locked therein, thus insuring absolute
uniformity of work. The machine may be readily
adjusted to operate on lumber of different thicknesses.
150 ELECTROTYPING,
CHAPTER XX.
DR. Albert's metal molds.
THE subject of metal molds is one in which all
progressive electrotypers are interested, and we
have therefore translated from the German Dr.
Albert's description of his process, which is sufficiently
in detail to enable the skilled electrotyper to compre-
hend how it is possible to mold in lead. Dr. Albert
does not explain the nature of the mechanism by which
he is able to obtain " successive partial pressures " on
" any press," nor does he describe fully the character
of the alloy which he employs in loosening the shell
from the matrix. The American patents concerning
Dr. Albert's process have been purchased by an Ameri-
can manufacturer of electrotyping machinery, who has
already installed several plants in this country which
are in more or less successful operation. The follow-
ing is a translation from " Theory and Practice of the
Metal Matrix," by Dr. E. Albert :
" Jacobi, the inventor of the art of electrotyping,
has for more than half a century experimented in pro-
ducing lead matrices for engraved steel and copper
plates, and with the greatest success. Nevertheless,
the wax and gutta-percha matrix has been the popular
method of electrotyping until recently, although the
defects of the electrotypes made from it urgently called
for a change in the method.
ELECTROTYPING. 151
" The origin of these defects is to be found princi-
pally in the fact that the non-conducting material must
first be made conductive by brushing with black lead,
whereby it is impossible to avoid an essential deterio-
ration in quality as compared with the original ; and
that in consequence of the necessary heating of the
material before the impression is taken, and the
changes in its dimensions after cooling, an exact regis-
ter of electrotypes for multi-colored prints can not be
guaranteed. With the possibility of using conducting
and cold-molded metal matrices, all this inferiority of
the electrotypes, as compared with the original, is at
once removed.
" But modern printing forms, such as photoengra-
vings, woodcuts, type forms, heliogravure, can not be
impressed in soft metal in the same manner as in wax
and gutta-percha. The requisite pressure would be
so great that the soft printing material would be
destroyed.
" Some attempts to avoid the high pressure in pro-
ducing metal matrices by using very thin lead foils
and putting on them layers of thoroughly saturated
pasteboard, or wax, have never had any practical
results, although they date back to the forties in the
last century, and for the following reasons :
" Every electrotyper knows that in molding from
mixed type and cut forms the type is impressed long
before the shading of the woodcut or a photoengraving
is molded. The above-mentioned thoroughly satu-
rated pasteboard affects the impression just as wax or
gutta-percha made soft by heating, i. e., the lead foil
must first be pressed into the large and then into the
152 RLECTROTYPING.
smallest depressions of the printing form by the satu-
rated pasteboard. In spite of the enormous ductility
of lead, it will not, of course, satisfy this demand for
expansion.
" It must be considered that in the square milli-
meter of a photoengraving there are thirty-six depres-
sions into which the lead foil must be pressed, and
that it applies itself to 144 side walls per qmm. In
underetched printing-plates considerable force is nec-
essary to separate the matrix from the plate, and,
therefore, it is impossible in larger forms, ""without dis-
torting the mold, to separate the plate from the lead
foil, which, in the interest of lessening the pressure,
must be very thin.
" The pressure necessary for forcing any molding
material into the smallest depressions of a form can
not be produced as long as an opportunity remains for
it to make its way into open spaces. In consequence
of this characteristic, all wax matrices must be sub-
jected to a shaving process to remove the large angu-
lar protuberances, which correspond to the depressions
in the printing form. This necessary manipulation
would, of course, be impossible in matrices consisting
of thin lead foil, and also for these reasons the use of
this method for rule etching, woodcuts and type mat-
ter is excluded.
" It has been pointed out as a characteristic of the
materials hitherto used for the production of matrices
that the molding of the largest depressions is done
before that of the smallest. With soft metals, espe-
cially lead, the contrary is the case, as this material
first shifts in the direction of the pressure and fills the
ELECTROTYPING. 153
small depressions. With increased pressure, which is
necessary in order also to press the lead down in the
large depressions of the form, the lead also begins to
shift like wax to the sides in the neighborhood of the
first-molded parts.
"Apart from the fact that the already molded little
points, which correspond to the smallest depressions in
the form, will be shaved off, this shifting of the lead
has another disadvantage, namely, that the lead lodges
in these smallest depressions and the original will be
made unfit for use through this filling up with lead.
Besides, neither type matter nor cuts will withstand
the enormous pressure that must be used to impress a
lead plate of at least five millimeters (about one-fifth
of an inch) thickness into the large depressions.
" But such a thickness in the lead plate would be
just as necessary as in the wax or gutta-percha, as the
difference in height between the face of the type and
that of the spacing is about one pica.
" With the present means, therefore, matrices can
not be produced in metal plates, and it has been neces-
sary to use wax or gutta-percha for this purpose, until,
in the year 1903, Dr. Albert succeeded in establishing
a method for the rational production of metal matrices.
This method is based on a number of inventions and
is patented in all civilized countries.
" The knowledge that depressions in the electro-
types in the blank spaces are required only to prevent
smearing in the subsequent printing of the electro-
types, led to the course of pressing or bending a lead
plate of about two millimeters (about seventy-eight
one-thousandths of an inch) thickness into said depres-
154
ELECTROTYPING.
sions only so far as the technical necessities of printing
demanded, by means of a backlayer of some soft
material.
" This method is accordingly based upon a com-
bination of impression and bending. The bending of
the lead will be greater the larger and wider the
depressed surface is, and the blank places will there-
fore be of such a depth that they will not smear in
printing. The process is illustrated by Figs, i and 2.
" Fig. I shows the arrangement of the press platen,
the lead plate and the soft, elastic intermediate layer
Fig. I.
before the impression is taken. The material used for
this purpose must originally, or in its arrangement, be
of certain qualities, and must be softer than the mold-
ing material. It must be compressible without giving
way sideward under the pressure ; but it must also
give a certain resistance to the compression in order to
be able by this power of resistance to bend the lead
plate where it lies over the hollow. This material,
however, should not be so soft as, for example, heated
wax, but should be porously soft, either in its nature
or in its arrangement. A certain degree of elasticity
is useful in the interest of the bending of the molding
plate into the depressions in the form.
ELECTROTYPING,
155
" Such intermediate layer can suitably consist of a
number of layers of paper, and such a one is, through
the nature of the fiber of the paper, as well as through
the air inclosed between, soft and elastic in itself in
respect to the vertical direction toward the surface of
impression ; while, on the other hand, through the
texture of the paper, the necessary check will be given
to prevent the paper from gliding sideways at the
beginning of the pressure. In earlier experiments the
latter tendency was prevented by saturating the paper.
" In Fig. 2 the platen is lowered so that the inter-
mediate layer between the points o o', from which the
first counterpressure comes, is compressed to half its
original volume. In the moment when, through com-
FlG. 2.
pression, the intermediate layer has reached the same
degree of hardness as the molding material, the next,
increase in pressure will press this material into the
smallest depressions of the surface o o'. The lead
lying perfectly free between the points u u', and there-
fore exerting no counterpressure, will simultaneously
be pressed down in the hollow space u u' as an effect
of the resisting power of the intermediate layer.
" The same will be the case between the points
m m', although in a lesser degree, just as a board that
156 ELECTROTYPING.
is supported at intervals of two meters will sag more
than one whose supports are only one meter apart,
with the same weight on it.
" By the use of this bending i)rocess, the requisite
molding pressure is reduced to one-tenth of what
would otherwise be necessary, and the use of metal
molds is made possible.
" The question of producing the metal matrix was
thus solved only for moderate sizes, for, even if the
pressure was considerably lessened by the correct selec-
tion of the thickness of the lead plate and by the back-
layer of a soft, elastic matter, still an essentially greater
pressure than is required for wax or gutta-percha is
necessary. The usual hydraulic presses with about
one hundred atmospheres were consequently not usable
for the impression of larger sizes.
" By using a successive partial pressure and at the
same time introducing a secondary pressure, Dr.
Albert has succeeded in changing any press to a twenty
times higher capacity at very small cost. This gradual
progress of a limited pressure over the whole form
affords an opportunity for the air to escape and pre-
vents troubles arising from this cause. As the shifting
proceeds automatically, there is no loss of time worth
mentioning in this method. For example : The mold-
ing of a form of Woche (the Week) requires only a
period of fifty-five seconds, and for a form of Berliner
Illustrirte Zeitting (Berlin Illustrated Gazette) not
quite two minutes. For molding of cut forms of the
same size only half of the time mentioned is required.
With this method there is no difficulty whatever in
producing molds of any size.
ELECTROTYPING. 157
" It is self-evident that a copper shell deposited on
a lead matrix can not be loosened directly, as is the
case with a wax matrix. It would not be possible to
melt the lead away from the copper without injury to
the electrotype. But by letting the matrix and copper
deposit float on a very easily fusible metal alloy with
many free calorics, this loosening succeeds so well that
the same matrix can be used five times for the produc-
tion of new electrotypes without affecting the quality
of the electrotypes. Thus the problem of the metal
matrix is perfectly solved in all respects.
" These inventions have made a revolution in elec-
trotyping technics. The word revolution, however, has
more reference to the clearness, rapidity, cheapness
and quality of the production than to the change of
the working methods and arrangements of already
established electrotype foundries.
"Of great importance is the discarding or doing
away with the blackleading of the mold matrix,
whereby in soft printing elements of photoengravings,
etc., a shifting of the tone values in respect to the
original occurs. The metal matrix in itself conducts
the electricity and needs no blackleading.
" The Albert electrotype is identical with the origi-
nal. A difference in the print of both can not be
detected. This identity of the Albert electrotype and
the original, in respect to the tone values, is based on
the nature of the metal matrix and is not dependent
on the skill of the workman.
" The molding process itself can be done on any
hydraulic press in use. The machinery for successive
partial pressure can be set up in a few hours at a small
158 ELECTROTYPING.
expense. The increase of the capacity of the press is
enormous ; with 120 atmospheres (1,800 pounds to the
square inch), with 40 centimeters piston diameter
(about 16 inches) photoengravings, 40 by 50 centi-
meters ( 16 by 20 inches) large, can be molded. Faulty
moldings, as in wax, which are occasioned by inclosed
air, do not generally occur, as the air always has a
chance to escape during the successive partial pressure.
" It has already been mentioned how little time is
necessary for successive partial pressure when suitable
arrangements are made. Wax and gutta-percha have
not only to be blackleaded after molding, but by heat-
ing be brought to a certain degree of softness before
molding. In this way changes in the dimensions arise
when the molds cool off, and exact register can there-
fore not be guaranteed in electrotypes for multi-
colored prints. The metal matrix is perfectly cold-
molded, and therefore an exact register in multi-
colored prints is always assured.
" Thus the metal matrix is cleaner and more rapid
than wax or gutta-percha, and, besides, is of a quality
that guarantees the identity of the electrotypes with
the original. The financial advantages of the Albert
electrotype will be seen in the further manipulation of
the matrix.
"After the lifting off of the form, the matrix will,
without any afterwork whatever, be fastened with four
nails to a board, whose suspending bow touches the
matrix by contact, and the latter will at once be coated
over the whole surface with copper in the same
moment it is suspended in the bath. Owing to the
high melting-point of the matrix, the copper bath can,
ELECTROTYPING. 159
without any danger to the matrix, be heated to 50° to
60° Celsius (which will allow an increase in the cur-
rent tension of eight to twelve volts), and the forma-
tion of a sufficiently thick copper deposit will follow in
a hitherto-considered impossible short time ; for
medium sizes only one-half to one hour for producing
the deposit is needed.
" Besides this shortening of the time for producing
the deposit, the high temperature will act favorably
on the physical character of the electrically deposited
copper, as well in respect to its hardness as to its elas-
ticity, which also is evident in the fact that the electro-
types need only a minimum straightening.
" The loosening of the copper shell from the metal
matrix is done so easily, rapidly and surely that no
damage to or change in the metal matrix or copper
shell results. The matrix can therefore at once be
suspended in the bath again for a second copper
deposit, and this second electrotype, as well as the
third and fourth, is in no way inferior to the first elec-
trotype.
" When the matrix is not to be used any more, it
can be converted into backing metal. The loosened
copper shell can, of course, be backed in any way
desirable, and the electrotype be made ready for print
in the usual way. Only one hour and a half is needed
(inclusive of the molding and copper deposit) for put-
ting the electrotype in shape for the press."
REFERENCE LIST
OF TERMS, PROCESSES AN-D APPARATUS.
ACID, TO ASCERTAIN PERCENTAGE OF, IN
SOLUTION. — Dilute lo grams of the solution with an equal
quantity of distilled water. Add normal soda solution until
Congo paper is no longer colored blue. The number of grams
of soda solution consumed multiplied by 4.9 gives the number
of grams of acid per liter. One liter equals 1,000 grams.
ACID, EFFECT OF, ON NICKEL BATH.— The pres-
ence of a small quantity of free acid in the nickel bath effects
the reduction of a whiter nickel than in the case with a neutral
or alkaline solution. Hence a slightly acid reaction of the bath
due to the presence of citric acid, with the exclusion of the
strong acids of the metalloids, can be highly recommended.
The quantity of free acid must, however, not be too large, as
this would cause the deposit to pull off.
ACID, EFFECT OF, IN SOLUTION.— According to
Von Hubl, the minimum current density per square foot of
cathode in a fifteen per cent blue vitriol solution without acidu-
lation is 24.1 amperes, while the same solution with six per
cent sulphuric acid added required but 13.9 amperes.
ACID, HYDROCHLORIC— The pure acid is a colorless
fluid which emits abundant fumes in contact with the air and
has a pungent odor by which it is readily distinguished from
other acids. The specific gravity of the strongest hydrochloric
acid is 1.2; the crude acid of commerce has a ycllowi.sh color,
due to iron, and contains arsenic.
ACID, MURIATIC— See hydrochloric acid.
ACID, SULPHURIC— Ordinary sulphuric acid has a spe-
cific gravity of 1.84. It is used in the preparation of the
11 161
162 ELECTROTYPING.
depositing solution. In diluting the acid with water, it should
in all cases be added to the water in a gentle stream and with
constant stirring, as otherwise a dangerous explosion might
result. While it is known that sulphuric acid aids in making
the bath conductive, there is, of course, a limit to the quantity
which may be advantageously employed, and it is doubtful if
this point has ever been exactly determined. The writer has
been to some trouble to ascertain the views of certain practical
electrotypers on the subject and compared them with the
recommendations of numerous scientific writers. From these
various sources of information we learn that the solution of
copper should show a specific gravity of from 14° to 18° B.,
and that to the solution should be added sulphuric acid in suf-
ficient quantity to increase the density of the mixture from
J4° to 9°. This wide divergence of opinion is probably due in
some cases to the effort of the electrotyper to adapt his solu-
tion to the current strength which his dynamo may happen
to be generating.
ACID, SOLDERING. — Prepared by dissolving scrap zinc
in hydrochloric acid (muriatic acid) to saturation, and adding
from 25 to 50 per cent of water. The operation should be con-
ducted in the open air, as the fumes produced are both dis-
agreeable and dangerous.
AGITATION, BENEFITS OF.— The continuous agita-
tion of the copper bath is of great advantage to the electro-
type, particularly when rapid deposition is desired. The copper
is more evenly deposited and of better quality, the formation of
gas bubbles, nodules and excrescences is largely prevented,
while the annoying streaks which sometimes appear on the
deposit, usually as a result of an excess of metal in the solu-
tion, are seldom or never seen in an agitated bath. But the
principal advantage may be found in the fact that much higher
current densities may be utilized, resulting in a corresponding
increased rate of deposition.
AGITATION, DOES IT ELIMINATE RESISTANCE?
— While agitation is a practical and useful aid to deposition of
metals, and is recognized as such by all electrotypers who have
ELECTROTYPING. 163
given it a trial, as well as by all the great copper refiners of
Europe and America, its chief value consists in the fact that
it promotes uniformity in the composition of the solution, aids
in the diffusion of metal in the solution, and, when a strong
current is employed, prevents to a certain extent the forma-
tion of nodules, excrescences and streaks on the cathode. It
also minimizes the tendency to polarization and promotes
purity in the character of the copper deposited. If inequality
in the composition of the solution tends to increase the resist-
ance of the solution, then agitation, by promoting uniformity,
would diminish the resistance to just that extent. It is doubt-
ful, however, whether the mere fact of giving motion to a
solution adds to its conductivity. In other words, if an agi-
tator should be introduced into a depositing solution which
had previously been employed for electrotyping without agita-
tion, and if no change were made in the content of acid or
metal in the solution or in the speed of the dynamo, the
increase in the rate of deposition would probably be inappre-
ciable. It should be understood that some motion always takes
place in the solution whenever deposition is going on. With-
out motion there could be no diffusion, and without diffusion
there could be no deposition, for it is obvious that there must
be constant renewal of metal in the solution next the cathode,
as otherwise it would soon become exhausted. This motion
is caused by the sinking of the heavy liquid next the anode
and the constant rising of the liquid next the cathode, where
it is deprived of its metal, and consequently becomes lighter
than the surrounding liquid. This motion, together with the
stirring of the solution occasioned by the immersion and
removal of the cathodes, is sufficient for the diffusion of the
metal when a current of low density is employed. It is true
that a solution undisturbed for some time will become more
acid at the top than at the bottom and, therefore, more con-
ductive at the top than at the bottom. Yet it is doubtful if
the total resistance of the solution is very much affected by
this condition. Granting that agitation would diminish the
resistance of the solution to a slight extent by promoting uni-
164 ELECTROTYPING.
formity, it is certain that it does not influence the resistance
beyond this point, for frequent tests have demonstrated that
the current strength measured at the electrodes remains
unchanged whether the agitator be in operation or not. But
if the agitator does not in itself increase the rate of deposition,
it enables the operator to increase his current and thereby
accomplish practically the same purpose. Von Hubl found by
careful laboratory tests that the current strength could be
increased about fifty per cent when the bath is kept in gentle
motion. This statement is very conservative and probably
means that the current strength may be increased fifty per
cent without changing the character of the copper or causing
waste of power by polarization. If no consideration be given
to economical working, there is no doubt but the current may
be increased far beyond the fifty-seven amperes per square
foot which he gives as a maximum.
AGITATION, METHODS OF.— One of the main objects
of agitation is to remove the exhausted stratum of solution
next to the cathode and replace it with a saturated solution in
order that deposition may proceed with the greatest possible
rapidity. Various mechanical means are employed to effect
this object. The most popular method is that of forcing air
through the solution from perforated lead or rubber pipes laid
on the bottom of the vats. Another method consists in pump-
ing the solution from the bottom of one end of the vat and
discharging it in such a manner as to create a circular motion.
Another method consists in mounting the anodes on spindles
and revolving them slowly in the solution between the cathodes.
By another and very effective method a horizontal rod is made
to travel up and down between the anode and cathode. The
latest and, it is claimed, the best method is briefly described
as follows : A large perpendicular cylinder is made to revolve
slowly in the solution. The cylinder is surrounded by anodes
and to the periphery of the cylinder the cathodes arc attached.
In operation the cathodes are constantly passing the anodes
and the disturbance is so effectual that 200 or more amperes
per square foot may be utilized without burning the deposit.
ELECTROTYPING. 165
ALKALINITY AND ACIDITY.— An excess of acid or
alkali in a nickel solution may be instantly detected by dip-
ping simultaneously into the solution strips of blue and red
litmus paper. If the blue litmus paper becomes red, it indi-
cates an excess of acid, while on the other hand the test shows
that when red litmus paper becomes blue an excess of alkali
is indicated.
ALLOY, FUSIBLE.— Melt i pound of lead in a clean
vessel, and stir in % pound of tin and, finally, iJ/S pounds of
bismuth. Stir well, and thoroughly incorporate the mixture;
pour out gradually into water ; collect, and repeat until a com-
plete admixture is obtained. It melts at 212° F., the tem-
perature of boiling water.
AMALGAMATION OF ZINC— To amalgamate zinc
plates it is necessary, first, if the plates be new, to wash them
in hot caustic soda solution, so as to remove the greasy film
imparted to them at the rolling mills. A flat vessel is then
partially filled with dilute sulphuric acid and upon it is also
poured a little of the best quality of mercury procurable. The
plate is dipped in the liquid and the mercury rubbed on with
a pad of tow or other suitable substance. The workman should
take particular care to cover every portion of the surface.
When the plates present a uniform silvery appearance they
may be set upon edge to drain, after which they are ready to
be placed in the battery.
AMMETER? WHAT IS AN.— Without going into
technicalities, it may be said that the ammeter is an instru-
ment for measuring the amount or quantity of electric current
employed in performing work. The ammeter measures quan-
tity, while the voltmeter measures pressure, and the product
of quantity multiplied by pressure, as measured by these instru-
ments, is called watts and is what we who buy electric power
have to pay for at the end of each month.
AMMETER VARIATION.— The ammeter reading may
vary from two causes on a constant surface (cathode) load
without the voltmeter varying. The resistance of the solution
166 KLF.CTROTYPING.
may vary or the resistance between the supporting or case
rods and the tank rods may vary. Another reason, probably
the best, is that a new case when immersed presents a large
resistance, due to the lack of copper on the surface. A new
case will not use full current density for some minutes after
it is immersed. In fact, the current for the first few seconds
is almost nothing. If you have a large number of fresh cases,
and a few that are nearly done, your current will perhaps
be fifty per cent low with no voltmeter change. Bad brush
contact would vary voltmeter and ammeter together.
AMMONIA. — Is water saturated with ammonia gas.
Must be stored in closely stoppered bottles. It is employed
for neutralizing nickel solutions when too acid and is some-
times added to soldering fluid.
AMPERE. — The unit of current strength is produced when
an electromotive force of one volt acts through a resistance
' of one ohm and conveys one coulomb per second. An ampere
is that strength of current which will deposit .00508 grain of
copper per second from a blue vitriol solution.
ANCHORING ELECTROTYPES AND HALF-TONES.
— Bore several holes through the base and countersink both
sides. If the plate has been finished long enough to have
become oxidized, brighten the back by filing and tlicn lay it
on the block and secure it temporarily by hand clamps. Apply
a small quantity of soldering fluid to the plate through the
holes and then pour in melted solder until the holes are full.
It is important, of course, not to get the solder too hot, as in
that case there would be danger of melting through the plate.
There is always an element of uncertainty in securing plates
by anchoring, but in some cases there is no other way to
accomplish the object.
ANODE. — The pole or plate by which an electric current
enters a depositing solution. In electrotyping a solid plate of
copper of any convenient thickness and about the same area
as the cathode or mold, it should be connected with the posi-
tive pole of the battery or dynamo and kept clean by occa-
sional scouring and washing.
ELECTROTYPING. 167
ANODE CONNECTIONS.— A new anode connection
recently introduced consists of a broad strap of copper about
three inches wide and one-eighth of an inch thick, accurately
milled where it hooks over the rod so as to make a perfect
connection. The strap is secured to the anode by a casting of
electrotype metal which covers and protects the connection
from the action of the solution. The anode may, therefore,
be suspended entirely under the solution without danger of
destroying the connection, which is practically everlasting. In
addition to the advantage of having a perfect connection, the
anodes wear away evenly, leaving no stub ends to go in the
junk pile or be worked off in the baskets.
ANODE HOOKS.— Anode hooks should be of ample
dimensions to carry a large volume of current without heating.
Copper wire of three-eighths of an inch in diameter is recom-
mended. The hooks should be kept clean where contact is
made with anodes and cross rods, to insure minimum resist-
ance.
ANODE PLATES, SIZE OF.— The anode and cathode
should each present an equal surface to the solution. The
anode has two sides, but the back, when facing flat work,
should be left out of account. Hence an electrotype a foot
square should be faced by an anode a foot square. If there
be any difference in size, the anode should be the larger.
ANTIMONY. — Antimony is hard and brittle and melts
at 842° F. It is not attacked by cold sulphuric acid. It is
employed with lead and tin in the manufacture of electrotype
and stereotype metal to harden the mixture.
" BACKER-UP," THE.— Next to the molder, the backer-
up is the most valuable man in a first-class foundry — that is,
a good one that knows his business in regard to having his
metal right and how to pour it on his shell with the least
injury to the plate and to avoid shrinks. The responsibility of
the backer-up is very great, and, if he does his work properly,
he can save a great deal of time and labor in the finishing
room.
168 ELECTROTYPlNC.
BACKING-UP PRESS FOR ELECTROTYPES.— A
patented device for backing up and straightening electrotypes
consists of a bed frame supported by suitable legs and made
long enough to provide room at its middle part for a yoke and
vertically adjustable platen. At one side of the platen suffi-
cient space is provided for the backing pan to set during the
process of backing up the shell, and on the other side there is
room for moving the finished plate out so that another pan
may be placed in position at the left hand of the platen. The
yoke and platen are somewhat similar to the yoke and platen
of a stereotyper's drying press, except that the platen is pro-
vided on its under side with a layer of felt about one-fourth
of an inch in thickness, and a press plate having projections
or teats on its surface called a " hurdy-gurdy " plate. The
hurdy-gurdy plate, with the intermediate layer of felt, is
attached by bolts to the platen. The bed frame is provided
with rollers to facilitate the passage of the backing pan from
one end of the bed to its position under the platen, and from
thence to the other end of the bed. In operation, the shell is
placed in the backing pan on one end of the press, where it
is backed up and cooled in the usual manner. The backing
pan is then rolled under the platen and pressure applied by
means of a hand wheel and screw, which has the alleged effect
of straightening the face of the electrotype and bringing all
parts of the same, by means of the hurdy-gurdy, into one
plane, removing all unevenness and irregularities. It is
claimed the intermediate layer of yielding material permits the
hurdy-gurdy to give and adapt itself so it will not press any
harder on the ends or sides of the electrotype than on the
intermediate points. The inventor asserts that a great saving
of time is accomplished by this method of straightening plates,
as very little finishing is required.
BLACKLEADING BY HAND.— Blackleading by hand is
a slow and laborious process and is seldom practiced, a machine
being considered essential even in small foundries. For black-
leading by hand, a camel's-hair brush is employed. The
graphite should be brushed back and forth over the mold until
ELECTROTYPING. 169
a bright polish is obtained and until it is certain that no spot,
however small, has been neglected. If so much as a punctua-
tion point fails to receive the proper polish, copper will not
deposit thereon, and a hole in the shell will result. In the
days before blackleading machines were invented, it was the
custom to place the mold in a box provided at the front with a
curtain. Then, by inserting the hand through a hole in the
curtain, the polishing could be effected without filling the air
of the room with dust.
BLACKLEADING MACHINE, WET.— The only wet
leading machine is the one patented about twenty-six years
ago by Mr. S. P. Knight, foreman of the electrotyping depart-
ment of Harper Brothers. The machine consisted of a tank
with a centrifugal pump, to which there was attached a hose
and syringe. The tank contained a mixture of plumbago and
water, of about the consistency of cream, which by means of
the pump, was forced through the syringe, which was arranged
to move to and fro across the tank and thus coat the molds,
which were laid on a rack placed just below the surface of the
solution in the tank. On moving the cases from the machine,
the surplus mixture was scraped oflf with the hand, the cases
being afterward thoroughly washed in another tank. The
plumbago in the second tank was allowed to settle before the
water was drawn off. This process gave promise of obviating
much dust in the foundry, but never came into extensive use
owing to the inability of workmen to operate it successfully,
notwithstanding that Mr. Knight used it and no other method
for coating his molds. In use it was found that, from the drip-
pings from the cases after the water had dried out, there was
nearly as much dust in the room as with the dry process.
BLISTER ON SHELLS.— Blister is sometimes caused by
an excess of crocus on the mold ; it will cause shrinks in the
plates, making trouble for the finisher. Crocus should be used
very sparingly, if at all, and should be carefully brushed off
the mold before it goes into the vat. Instead of crocus, brush
a small quantity of sulphate of zinc on the case before molding.
170 ELECTROTYPING.
BOOK-PLATES, DEVICE FOR HOLDING.— When
molding from beveled book-plates, make four wooden blocks
exact size of the book-plates which arc to be duplicated. Place
them in chase, with wooden furniture at one end and one side,
next to the chase. Place inverted brass rules around each
block and a pica slug between the rules which are at the ends
of the block where they meet in the middle. Lock up with
Hempel quoins at one side and one end. Only one rule is
necessary between the blocks the long way. The brass rules
should have teats or lugs soldered on to catch the plates at
the bevel to prevent them from lifting when wax mold is
being lifted.
BRASSPLATING HALF-TONES.— Plating with brass
is not an easy proposition for an amateur and is rendered
unnecessarily difficult by the complicated solutions recom-
mended by most writers. The following formula is simple and
less troublesome to keep in order than those generally advo-
cated: i6 ounces cyanid of potassium, 5 ounces carbonate of
copper, iJ/2 ounces carbonate of zinc, i ounce ammonia and i
gallon of water. The deposition of brass is usually attended
with some difficulty because it is composed of two metals, one
of which is positive and the other negative ; hence the current
strength requires more or less regulation to insure uniform
deposition of both metals. As brass contains a larger pro-
portion of copper than of zinc, the copper in the bath becomes
first exhausted, and sufficient carbonate of copper must be
added to restore the proper proportions. Cyanid of potassium
must be supplied when the action of the bath becomes slug-
gish. A strong current is required. Constant watchfulness is
necessary to keep the bath in good working condition. To
increase the wearing qualities of zinc half-tones, the " Process
Photogram" suggests facing the half-tone with brass, and
recommends the following bath formula : Zinc carbonate, lo
parts ; copper carbonate, lo parts ; soda carbonate, 20 parts ;
soda bisulphite, 20 parts ; potassium cyanid, 20 parts ; arsen-
ious acid, 1-5 part; water, 1,000 parts. To make up the solu-
tion, proceed as follows : Take 12 parts sulphate of copper
ELECTROTYPINC;. 171
and 12 parts sulphate of zinc, and dissolve them in water;
then add carbonate of soda, already dissolved, to the solution.
This precipitates the copper and zinc in the form of carbonates,
a greenish-colored powder. Allow the precipitate to settle and
pour off the supernatant liquor. Wash the precipitate and
then mix in with the carbonate and bisulphite of soda in 900
parts water. Next dissolve the cyanid and arsenic in the
remaining 100 parts of water and pour this into the first solu-
tion. This bath should be used cold.
BRITTLE DEPOSIT. — A weak current always and under
all conditions causes the deposition of a harder and more
brittle nickel than a current of medium strength.
BRONZING SOLUTION.— One gallon of water, Yi ounce
sulphate of potash, ^ pint of ammonia. This mixture should
be well heated. After the electrotype has been immersed, take
it out and apply a wet scratch brush until the surface assumes
a dark cherry hue, which is a favorite color with art lovers. A
very beautiful bronze color may be imparted to copper arti-
cles, such as medals for instance, by boiling them in a solution
composed of verdigris, S ounces ; muriate of ammonia, 5
ounces ; strong vinegar, ^/^ ounce. Mix the verdigris and the
sal ammoniac by pulverizing in a mortar and then add a suf-
ficient quantity of vinegar to form a paste. Now pour this
into a copper vessel with a pint of water and boil for about
half an hour. When cold, stand the mixture aside until the
sediment has subsided, when the clear liquor may be poured
off and bottled until required. The articles to be bronzed
should be boiled in this liquor for ten minutes or longer, tak-
ing care that they do not come in contact during the opera-
tion. The fumes of hydrochloric acid or of chlorid of lime
will produce a very good green bronze upon electrotypes, giv-
ing them the appearance of ancient bronze. The following
process is recommended by Watt : " Electrotypes may be
bronzed by suspending them in a wide-mouthed bottle (or
other vessel) at the bottom of which a small quantity of sul-
phid of ammonium has been placed. The sulphid of hydrogen
which escapes will give a good bronze tint to the copper in a
172 ELECTROTYPING.
few moments, the depth of tone being regulated by the time
of exposure."
BURNING. — An error is frequently committed in nickeling
with too strong a current, the consequence being that the
deposit on the lower portions of the objects soon becomes dull
and gray-black, while the upper portions are not sufficiently
nickeled. This phenomenon, which is due to the reduction of
the nickel with a coarse grain in consequence of a too powerful
current, is called burning or overnickeling. A further conse-
quence of nickeling with too strong a current is that the
deposit readily peels off after it reaches a certain thickness.
This phenomenon is due to the hydrogen being condensed and
retained by the deposit, which prevents thick deposition.
CASES. — Cases made of electrotype metal, cast in the
backing pan and shaved down to about three-sixteenths of an
inch in thickness, are superior in every respect to the expen-
sive brass pans sold by manufacturers of electrotyping machin-
ery. The soft metal may be easily kept in shape by planing
down with a block of wood after each use.
CASES, WARMING OF.— Warming cases by laying them
on the steam table, although quite generally practiced, is not a
good plan, for it softens the wax next the case more than on
the surface, and often results in concaved work. Cases should
always be kept in a " hot box," the temperature of which
should be so regulated as to keep the cases in proper condition
for molding without additional warming.
CASTING HARD SHELLS.— It will be found that there
is a great deal of difference in copper shells about the solder
flowing readily. When a shell is extra hard the solder is
invariably obstinate about flowing.
CATHODE. — Cathode is the pole or plate by which an
electric current leaves a depositing solution. In electrotyping,
the wax or composition mold which receives the deposit of
copper. It is suspended from the negative pole of the dynamo.
CIRCUIT. — A circuit is the entire path of an electric cur-
rent
ELECTROTYPING. 173
CLEANING BRUSHES, HALF-TONE.— Mr. E. R.
Rodd, superintendent of the electrotyping department of the
Butterick Publishing Company, is the inventor of certain half-
tone brushes which are rapidly becoming popular with electro-
type molders. Although these brushes are made of metal, the
material is such that they may safely be applied to the most
delicate half-tone without fear of injury. By the aid of these
brushes, dirty half-tones may be thoroughly cleaned and all
the original detail restored. Two brushes are employed. The
ink or dirt in the half-tone is first softened with wood alcohol
and then brushed out with the No. i brush. The cut is then
covered with a soft rag and patted gently with the hand.
After the cut is dry it is rubbed gently with the No. 2 brush,
and again after the form has been blackleaded until all the
black lead has been removed.
CLEANING CUTS. — The molder will often receive forms
containing dirty woodcuts, though not so many now as for-
merly, since the zinc line cuts and half-tones have to such an
extent taken the place of the woodcut, but it will be well to
know a liquid that will clean the woodcut nicely and which
may be made as follows : To i quart of alcohol, add J/2 ounce
of bisulphid of carbon and lYz ounces of strong liquid ammo-
nia; thoroughly mix and apply with a brush as you would
bezin. This wash will be found efficient in removing ink from
a woodcut, or, in fact, from a half-tone. A good cleansing
fluid, according to Dunton, is composed of alcohol, 16 ounces ;
carbon disulphid, i ounce, and strong fluid ammonia, 2 ounces.
This may be used in the same way as benzin and will be found
very effectual.
CLEANING ELECTROTYPE CASTS.— Scrub the casts
while hot with kerosene oil and powdered pumice stone. Then
lay the cast in a shallow sink with inclined bottom, and steam
it out, using a steam hose without a nozzle. Then take the
cast to a sawdust box and brush it thoroughly with clean, dry
sawdust or lay it on a heated steam-table until dry.
CLEANING MACHINE, PLATE.— The Raisbeck Elec-
trotype Company, of New York, has devised a machine for
174 ELECTROTYPING.
cleaning electrotype plates, which is said to be superior to hand
scouring and much more rapid. The machine " subjects the
face of the plate to a current of benzin or other solvent or
detergent simultaneously with gentle friction. We accom-
plish this by an apparatus which moves the plate to be cleaned
backward and forward several times in contact with a moving
brush of the proper soft material, adjusted sufficiently near to
act in all the interstices. In the most complete form of the
invention the brush is caused to reverse its motion on the
plate and thereby to act more effectively in the recesses." The
apparatus is the subject of letters patent No. 621,539.
BLACK ELECTROTYPES.— Seven pennyweights sul-
phate of barium, i quart of water. After the article has been
immersed in the solution a light brown color is produced,
which gradually deepens until it assumes an intense black. The
object must be rinsed in hot water and then allowed to dry.
To secure a brilliant polish, all that is necessary to do is to
rub it with chamois.
COLOR-PLATES, REGISTERING.— Fasten the plates
to the blocks by driving the nails only part way in. Then draw
your nails, cut out the portions of the plates not wanted, and
reblock the electros, using the same tack holes. This will
insure a perfect register, provided your blocks have first been
accurately finished to the same size.
COLORING ELECTROTYPE MEDALLIONS.— A very
pleasing effect may be produced thus: Having well cleaned
the electrotype, apply varnish with a soft brush to the base
or flat surface, carefully avoiding the figure ; when the varnish
has become hard, attach a wire to the electrotype and place
it in a gold or silver^ bath for a short time until sufficiently
coated. Now remove the varnish and apply the bronzing
material to the copper surface, and thus the figure will stand
out in relief, cither in gold or silver as the case may be.
CONCAVE. — This is almost invariably caused by over-
heating the backs of the cases, which softens the wax next
the case more than on the surface. • The temperature should
ELECTROTYPING. 175
be uniform throughout. For this reason it is advisable to
employ a "hot box," i. e., a box or cabinet heated by steam
or gas and so arranged that the cases may be kept at just the
right temperature for molding.
CONDUCTIVITY OF LIQUIDS.— The following is a
list of the conductivity of a few liquids as compared with that
of pure silver :
Pure Silver 100,000,000,000
Nitrate of copper, saturated solution 8,990
Sulphate of copper, saturated solution 5,420
Chlorid of sodium, saturated solution 31,520
Sulphate of zinc, saturated solution 5,77o
Sulphuric acid, i.io specific gravity 99,070
Sulphuric acid, 1.24 specific gravity 132,750
Sulphuric acid, 1.40 specific gravity 90,750
Nitric acid, commercial 88,680
Distilled water 7
CONDUCTIVITY, INCREASING.— To increase the
conductivity of a blackleaded wax mold, it is customary to
precipitate a film of copper on its surface by the well-known
method of first floating the mold with a solution of sulphate
of copper and then sprinkling iron filings thereon. Another
method consists in immersing the mold for a few moments
in a solution of wood alcohol and phosphorus, afterward par-
tially drying, then rinsing in running water and immediately
suspending in the bath. This method is specially desirable for
nickeltyping. The phosphorus solution is made by placing a
few small pieces of phosphorus in a bath of wood alcohol and
allowing it to stand for three or four days. Phosphorus is
only soluble in alcohol, and the portion dissolved will be hardly
perceptible, but will be sufficient for the purpose. While phos-
phorus is a dangerous substance to handle, on account of its
inflammability when exposed to the air, it is perfectly safe
if kept under water or alcohol, and the quantity employed is so
very minute that no danger whatever need be apprehended
from its use in the manner described.
CONNECTIONS, GOOD.— It has been frequently noted
that electrotypers do not always appreciate the importance of
making good connections. It is of no avail to provide large
conducting rods and cross rods if the conducting capacity of
176 ELECTROTYPING.
the rods is to be choked off at the points of contact, which is
what occurs when one round rod is laid across another round
rod. It is obvious that unless one or both of the rods is flat-
tened where they come in contact, the area of the contact will
be extremely limited compared with the area of the conductors
on both sides of the contact.
COPPER DISSOLVED BY SOLUTION.— An electric
current passing through a solution of sulphate of copper will
dissolve copper suspended in the solution, whether it is in the
circuit or not. This fact may be readily tested by weighing
a small piece of copper and hanging it in the solution, without
electric connection, and after a few hours weighing it again.
It is because of this fact that extra anodes not in use, if left
in the solution, will make it dense and heavy at the bottom
and frequently cause the deposit to be spongy and granular.
COPPER SCRAPS UTILIZED.— Copper clippings and
scraps may be utilized as an anode by packing them in a per-
forated lead box and suspending the box from an anode rod.
The box may be constructed of plates of electrotype metal
joined at the corners by soldering. It should be somewhat
longer and deeper than your cases and about four inches wide.
The perforations should be as near together as possible.
COPPER, TO SEPARATE FROM WATER.— There is
a method called the " Cementation Process," which was
employed a great many years, " for separating copper from the
drainage water from mines containing copper in solution
derived from the oxidation of mineral sulphids in the earth."
By this process the water is brought into contact with scrap
iron and its copper deposited by simple immersion. Under
such circumstances the copper separates in little loose crystals
termed " cementation copper," which contains nearly all the
impurities of the iron u.sed to precipitate it, and requires to
be purified. Spain and Portugal export about half a million
tons annually of iron pyrites containing several per cent of
copper, the whole of which is extracted by this process.
ELECTROTYPING. 177
COPPER, WEIGHT OF.— A copper shell .005 of an inch
thick weighs about 3.71 ounces per square foot. One cubic
inch of copper weighs 5.1585 ounces.
CORROSION OF COPPER-FACED TYPE.— In a dry
atmosphere and under ordinary conditions, copper will not
corrode to an extent sufficient to injure printing-plates, or
type faced with copper, but there are certain colored inks
which attack copper by reason of the mercury contained in
them, and certain cleaning compounds containing ammonia
which would be likely to produce corrosion if allowed to
remain on the type. Verdigris may be removed from copper
by brushing with very dilute nitric acid or ammonia and thor-
oughly rinsing with clear water.
CORROSION, TO PREVENT.— Copper soon loses its
luster when exposed to the atmosphere, but the printing quality
of the electrotype is not impaired thereby. When electrotypes
are stored in a d^mp vault or exposed to the action of acid
fumes or gases which cause excessive corrosion, damage will
of course result. The remedy is to remove the plates to a
dry place. If such a place is not available, a coat of hot
paraffin will protect them to some extent, or they may be
given a coat of lacquer such as is used to preserve the luster
on certain kinds of metal artwork. Most electrotypers would
ridicule the idea of spending any time or money in an attempt
to preserve the color of an electrotype, and if they are care-
fully cleaned and stored in a dry place there is really no
necessity for further protection.
COST OF ELECTROTYPE SHELLS.— The material in
a tinned shell costs about .05 of a cent per square inch. The
cost of molding and the various other operations involved in
producing a shell are estimated to be about one-half the cost
of the finished electrotype. It is customary, therefore, to
charge half price for shells. From the seller's standpoint this
is a satisfactory method of estimating, but as a matter of fact
the cost of the shells is considerably less than one-half the
cost of finislicd book-plates. That is to say, the value of the
metal in the plates, together with the labor of backing up and
12
178 ELECTROTYPJNG.
finishing, is actually about two-thirds of the total cost cf the
electrotypes.
COULOMB. — A coulomb is the amount of current which
passes through a conductor in one second when the strength
of current is one ampere.
CROCUS. — Crocus is sometimes used to prevent the form
from " sliding " and also to prevent the wax from sticking
to solid cuts and causing them to be rough. If used at all,
it should be carefully brushed off the mold before it goes into
the vat, otherwise it is a frequent cause of " blisters " and
" sinks."
CURRENT, HIGH TENSION.— The incandescent light
current will not answer for electrotyping or plating, because
the tension is too high. The voltage of an electric light machine
is no or more, while one to three volts is amply sufficient for
electrotyping. There are other reasons, not necessary to
explain, why the electric light current would be unsuitable for
electrotyping.
CURRENT STRENGTH.— Current strength is the quan-
tity of electricity which flows through any cross section of a
circuit in one second of time; it depends on the electromotive
force and the* total resistance. The unit of measurement is
called ampere (see Ampere). According to Ohm's law, the
strength of current is equal to electromotive force divided by
resistance. Current strength is measured by means of an
ammeter.
CURRENTS, MEASURING ELECTRIC— The ammeter
is employed to measure electric currents, and the voltmeter, to
measure the electromotive force or pressure. Speaking of
water flowing through a pipe, we would say that it is delivered
at the rate of so many gallons per minute. The quantity would
depend upon the pressure behind it and the friction of the
pipe. So with the electric current ; the number of amperes
delivered depends on the pressure (E. M. F.) and the resist-
ance of the conductors. If the pressure is one volt and the
resistance one ohm, the current delivered will be one ampere
ELECTROTYl'lNG. 179
per second. If the resistance is only .01 of an ohm, the cur-
rent will be 100 amperes per second. The current always
equals the E. M. F. divided by the resistance. Inasmuch as
the current depends on the resistance as well as the pressure,
it is obvious that the voltmeter will not always accurately
measure the current, for, while one volt pressure may produce
100 amperes under certain conditions of resistance, under
different conditions the product may be more or less than 100
amperes ; and, while one volt may produce 100 amperes, it
does not always follow that two volts will produce 200 amperes,
for increasing the pressure may increase the resistance by
heating or polarization. A current of one ampere will deposit
18. 1 16 grains of copper per hour, and as the ammeter is
employed to measure the current after resistance has been
overcome, its working value is always uniform. On the other
hand, a current of one volt E. M. F. may deposit more or less
copper at different times as the conditions of resistance vary.
It is, therefore, evident that the true working value of the
current can be measured only by the ammeter and can not be
accurately measured by the voltmeter.
CURVED ELECTROTYPES, CASTING.— Many of the
pages (all of the colorwork) of the Chicago Blade and
Chicago Ledger are printed from curved electrotype plates
which are cast by pouring the stereo metal directly into the
tinned shell, in the same manner that a stereotype plate is
cast from a paper matrix.
CURVED PLATES, EXPANSION OF.— The only way
to prevent expansion in curved plates is to curve the shell and
cast it in a curved box. Most electrotypers consider this an
impractical method, although the writer knows of one large
publication whose color pages are all printed from plates made
in this manner. While it is obviously impossible to curve an
electrotype without stretching it, the expansion may be mini-
mized by surrounding the form with wide bearers and cutting
down spaces so as to niake the plate as nearly solid as possible.
A form of open type matter will always stretch more than a
solid tint or half-tone.
180 ELECTROTYPING
DEPOSITION, ECONOMICAL.— It is a waste oi power
to run the dynamo at a high voUage and prevent " burning "
by cutting down the conductivity of the solution or increasing
its resistance. It would obviously be in the interest of economy
to make the solution as conductive as possible and adapt the
current strength to the solution.
DEPOSITION, RATE OF.— One ampere deposits 18.116
grains of copper per hour; 10 amperes deposit 9.84 ounces in
24 hours ; 386.4 ampSres deposit i pound in i hour ; 746
amperes deposit 1.93 pounds of copper in i hour; 17.94
amperes per square foot deposit .001 inch thickness of copper
per hour.
DURABILITY OF ELECTROTYPE PLATES.— Accord-
ing to the New York Times, the greatest achievement in
connection with the printing of " David Harum " was the part
played by the plates from which the book was printed. Only
one set has been used to print 425,000 copies. When certain
signs indicated that " David Harum " was fast winning an
extraordinary popularity, a second set of electrotype plates
was made, to be used in case of emergency, but so well has
the electrotyper done his work that this set has not as yet
been pressed into service.
DYNAMO, CHOOSING A.— When making choice of a
dynamo, it should be remembered that a certain volume of
current is required to produce certain results. According to
Gore, 17.94 amperes will deposit .001 of an inch thickness per
hour on a square foot of cathode. A dynamo whose capacity
is 360 amperes, or twenty times 17.94, will, therefore, deposit 20
square feet at a time at the rate of .001 of an inch per hour,
or, to put it in another way, it will deposit 6,480 grains of
copper per hour. By increasing the E. M. F. of the dynamo
this weight of copper may be deposited .002 of an inch thick
on 10 square feet of copper, or .004 of an inch thick on 5
square feet, or even .008 of an inch thick on 2J/S square feet,
but the limit of the capacity of the dynamo in weight of
copper deposited per hour is 6,480 grains, and this limit can
not be exceeded. It is obvious, therefore, that to perform a
ELECTROTYPING. 181
large amount of work in a limited time requires a large
dynamo. The best results which the writer has ever seen
produced in an electrotype foundry were obtained from a
lo-volt, i,ooo'-ampere dynamo coupled to three baths in series,
and arranged in such a way that one of the baths may be
disconnected when it is desired to hurry the work in the other
two. Ordinarily the E. M. F. is sYs volts per bath and the
time required to deposit a satisfactory shell is from forty-five
to sixty minutes, but this time may be reduced to thirty minutes
or less by utilizing the entire pressure in two vats. This
machine will deposit thirty feet of good shells per hour or
about one hundred pounds of copper per day, and will take
care of the product of four molding presses.
ELECTROMOTIVE FORCE.— The electromotive force
of a current means that power by virtue of which it can sur-
mount resistance. A current of low electromotive force may
be entirely stopped or absorbed by a moderate resistance. A
current of high electromotive force can overcome a high
resistance or accomplish work in such a circuit.
ELECTROTYPES, NEW METHOD OF MAKING.—
A sheet of thin metal, copper or an alloy of copper and some
other metal, is laid on the type-form, which is then covered
with a blanket and passed through a machine similar to a
matrix-rolling machine. The blanket is then removed and a
sheet of softened gutta-percha substituted therefor, after which
the form is passed through the machine again. This gives a
deep and sharp impression of the type in the sheet metal, which
is now stripped from the form and backed up with electrotype
metal. It is claimed that the plates obtained by this process
are satisfactory except possibly in the case of very fine-screen
half-tones.
ELECTROTYPING IN AMERICA.— According to the
" Typothetae and Platemaker," there are 372 firms in the
United States and Canada who make electrotyping their sole
business, and New York city has about ten per cent of them.
FINISHING HALF-TONES.— If half-tone shells are
made extra heavy, there will be no necessity for using a
182 ELECTROTYPING.
smasher in finishing the plate ; in fact, little or no finishing
should be required other than straightening. If punching is
unavoidable, it is a good plan to employ a sheet of soft paper
to protect the face of the plate.
FINISHING VIGNETTED HALF-TONES.— Before
straightening the electro, take a punch of suitable shape and
go around just outside the edge of the vignetting. This will
have the effect of sinking the edge a little below the level.
When straightening the plate do not bring up the edges of
the vignetting, but leave it a little lower than the half-tone.
The result will be that the print will shade off to nothing
and give the soft effect of the original.
FOREMAN'S SALARY, THE.— There is a vast differ-
ence in foremen, just as there is among workmen. The ideal
foreman possesses large executive ability, has a thorough
knowledge of his business and has his employer's interests
always at heart. He keeps his machinery in first-class work-
ing order and is as careful in expenditures as if the business
were his own. He secures and retains the respect of his men
and obtains from them their best efforts. He is prompt, accu-
rate, energetic and courteous, and always a hustler. There
are only a few of him. His services are in demand at good
wages, and he is worth more than he gets.
GUTTA-PERCHA MOLDS.— If the character of the
work is such that black lead is not objectionable, it may be
used, in preparing for the bath, the same as on a wax mold.
On molds of half-tones or steel engravings, the molds may
be coated with silver. The following is an extract from a shop
talk by Mr. G. J. Kelly, of London, England : " Gutta-percha
is a product of the earth, and, in its natural state, is of a white
color ; it is gritty usually, and wants careful washing before
manipulating. There are three kinds of gutta-percha in the
market ; the purest is white, the next brown, and the last or
commercial article is black. The third-class article, for pur-
poses in the trade, is the best. Of course there are various
grades of black percha, and the choice is a difficult matter,
known best to those who have had to try inferior material
ELECTROTYPING. . 183
through economizing. The pcrcha should be about one-eighth
inch in thickness and carefully rolled out in sheet. It should
be hard and without any patches of ' brown ' in its composi-
tion, because a good percha is always black and shiny as
ebony after pouring. Now the next thing is its touch ; it
should be free from clamminess and dry to the finger. If
there is a tendency to stick, you may reckon at once that the
tar, or whatever foreign substance it contains, means trouble
in store. When you have chosen your percha, it will suit
your purpose best to cut it up into strips and then into squares
of about four inches. It will not run down as wax when
steam or heat is applied, and here begins the addition of fat.
If you get English mutton fat, you have the very best article
for mixing with gutta-percha. We now have selected our two
principal materials, and we place in the same pan say four
pounds percha and one pound fat. Then mix and stir the
percha and fat together with a painter's knife say ten inches
long. You mix and stir for some time, the longer the better,
because all the air must be exuded. The plate to be duplicated
must be absolutely free from dirt. The temperature of the
plate should be hot enough to enable one to touch the plate
with the fingers, and no more. You plunge the knife in and
then take a portion of the percha on the blade from out of the
pan, and pour exactly in the center of the plate, and this must
be done to prevent airholes. We have now poured a mold,
and we immediately remove the same from the heat to a cold
slab for cooling. After the mold has set and cooled, I take it,
press the edge of the mold gently down, the original upward,
and, if I find the mold loosen from the corners, I gently lift
the original off by means of a paring knife. If I find the
slightest tendency in the percha to cling to the original, I give
the mold another half hour. You may find that the mold
may never come off; in other words, it will stick for all it is
worth. Well, that is caused by pouring your material too hot
or on a dirty original. If your mold has creases or airholes,
it is cold material, and all this can be overcome only by expe-
rience. I face the mold by pouring and drying on the face a
184 ELECTROTYPING.
solution of phosphorus and silver nitrate, which immediately
gives it sufficient conductibility to cover the mold by an ordi-
nary Smee battery in thirty seconds."
HALF-TONES AND ELECTROTYPES.— Half-tone
shells should be made extra heavy, so that the pressure or
weight of the metal will not distort them or force to the
surface those portions of the shell corresponding to the high
lights in the picture and which are a trifle low in the engraving.
The same caution applies to the vignette. It is too much to
expect that electros will be absolutely perfect. There is prob-
ably always some loss in reproduction, notwithstanding the
claim of some electrotypers to the contrary. Sometimes the
loss is hardly perceptible, but an expert will usually detect a
difference.
HALF-TONES INSERTED IN ELECTROTYPE
PLATES. — The method most commonly employed is to back
up the etching to the thickness of the book-plate, then fit it
into the plate and secure it by soldering. Mr. P. M. Furlong's
process, which is patented, is described as follows : A base
or blank block is fitted under the etching to make it type-high,
and, having been properly trimmed to fit into the type-form,
the etching is removed and the base alone is locked up in the
form with the type. The removal of the etching is necessary
in order that the type may be blackleaded to cause it to freely
release from the molding composition in the operation of mold-
ing, and it being preferable that the face of the etching should
not be blackleaded. After blackleading the type-form, the
etching, having had its back thoroughly cleaned, is replaced
face upward on the base within the form, with its face flush
with the type, and then the surface of the molding composi-
tion having been coated with plumbago, the form is molded
in the usual way. When the mold thus obtained is lifted from
the form, the etching will be found imbedded in and adhering
to the molding composition, face inward. The mold contain-
ing the etching is then blackleaded in the usual way prepara-
tory to being placed in the electrotyping bath ; but, before
being placed in the bath, the exposed back of the etching
ELECTROTYPING. 185
should be freed from black lead and scraped bright to insure
the incorporation of the electro-deposited metal with the back
and edges of the etching and in order that the metal may be
deposited in a continuous and unbroken sheet over the edges
of the etching to the back thereof and thereby form a perfect
union between the electrotype and the etching, so that when
the shell is removed from the mold it brings the etching with
it, the two forming practically one plate, which, after having
been freed from adhering wax or molding composition, may
be backed with composition metal and finished in the same
manner as ordinary electrotype plates. By this simple, direct
and economical process, an absolutely perfect incorporation of
an etching plate with an electrotype of reading matter is
obtained.
HALF-TONES, MOLDING.— Molding half-tones requires
considerable skill and careful attention to every detail of the
process. The molding composition must be of a certain tem-
perature, which can not be described but must be learned by
experience; the blackleading, washing and coating should be
performed with the utmost care, to avoid filling up the minute
hatches of the engraving; and, lastly, you should not attempt
to mold half-tones in connection with type. Mold them sepa-
rately, and, after the plates are finished, insert the engraving in
the page. It is impossible to learn electrotype molding from
written instructions. Skill comes only from long practice
under the tutelage of an expert workman.
HOLES IN SHELLS.— Holes in the shells are due either
to defective blackleading, failure to remove the air from the
mold by thorough wetting before placing in the bath, or the
use of a current so strong that it causes the formation of
hydrogen gas on the cathode. Defective blackleading may be
caused by a poor quality of graphite or insufficient brushing.
The best way to wet the surface of the mold is to place it
face up in a tank partially filled with water in such a man-
ner that the mold will be an inch or two under the surface,
and then direct a stream of water from a rotary force pump
on to the mold. If trouble is due to the third cause, the
186 ELECTROTYPING.
remedy is to reduce the speed of your dynamo or use an
agitator. The latter is by far the best plan, as the agitator
will not only dissipate the gas bubbles but will enable you to
employ a current twice as strong as would be practicable with
your solution test, and thus double the rate of deposition.
HORSE-POWER. — One horse-power equals 746 watts.
The unit of electric output: 1,000 watts equals 1.34 horse-
power; I horse-power equals 746 amperes — with i-volt pres-
sure causes 1.93 pounds of copper to be deposited per hour.
HOT BOX, DUNTON'S.— The cabinet consists of two
boxes, one built inside of the other and having an air space
between them. The outer box should be constructed of heavy
material, or, better still, of two thicknesses of board, with a
lining of thick asbestos board between the wooden walls.
This keeps all the heat on the inside. Both boxes should be
built practically tight; that is, do not bore any holes through
the walls of the inner box to communicate with the heat space
between the boxes. This is unnecessary and a detriment to
the satisfactory working of the cabinet. The radiating space
between the outer and inner boxes should be at least six
inches; that is, the walls of the inner box should be placed
six inches from those of the outer, on the top, ends and sides,
while on the under side there should be at least eight inches,
and the floor of the inner box should be made of two thick-
nesses, with a layer of asbestos paper between them. The heat-
ing coils, consisting of six lengths of ^-inch steam pipe, should
run lengthwise of the cabinet and be placed under the floor
or bottom of the inner box. There should be at least six inches
between the top of the pipes and the floor of the inner box,
and they should be supported on iron rods going through the
walls of the outer box. The doors and their casings need spe-
cial attention ; they must not be made of a single thickness
of wood, for this might spoil the satisfactory working of the
whole affair. They should be constructed of two thicknesses
of wood, with an air space between, similar to those on a
refrigerator, and closed in on the sides, top and bottom, having
holes of at least an inch in diameter bored at intervals on the
ELECTROTYPING. 187
four sides, corresponding to the same holes bored in the cas-
ings, to connect the air spaces with the heat chamber of the
cabinet. Both doors should be provided with springs, so that
they will not be left open after molds have been taken out of
or placed in the cabinet. The volume of heat can be regulated
perfectly satisfactory by the manipulation of the valve in the
steam pipe. The cabinet should stand up off the floor at least
six inches, and be located handy to the wax shaver and filling
tables.
INVENTIONS. — It is gratifying to note that inventors
are taking up the subject of electrotyping and striving to
produce more economical or more convenient methods of
manufacture. The invention or discovery of a compound to
satisfactorily anneal ozokerite may be mentioned as an indica-
tion of what may be expected in the way of improvement. A
firm of Brooklyn chemists has just put on the market a solder-
ing fluid, ready for use, which does away with the use of
muriatic acid and the disagreeable and unhealthy process of
" killing " it with zinc. Another inventor claims to have dis-
covered a material which acts as a precipitant of copper to be
used in the place of iron filings, thus eliminating all danger of
scratching the molds. The electrotyping business is suscepti-
ble of much improvement.
IRON DEPOSITION OF.— Deposition of iron, except for
the purpose of " steel facing," is seldom practiced in this
country, and there are probably not half a dozen establish-
ments which are equipped for such work. In St. Petersburg,
however, M. Klein has been very successful in producing elec-
trotypes in iron, which are largely, if not exclusively, employed
in the printing of state papers, documents, labels, etc. Some
of these electrotypes, which were on exhibition at the Colum-
bian Exposition, were very heavy and would indicate that there
is no limit to the thickness which may be deposited with proper
facilities.
LEVELING ELECTROTYPES.— In a recent patented
process for leveling electrotypes, the method consists in intro-
ducing the backing pan and its contents into an air-tight
188 ELECTROTYPING.
chamber and of forcing artificially cooled air into the chamber
at a high pressure in order to cool and level the electrotype.
LITMUS PAPER. — Blue litmus paper is colored red by
acid fluids, and red litmus paper blue, by alkaline fluids. By
simultaneously dipping one-half a strip of blue and of red
litmus paper in a solution, the reaction of the fluid can be
judged from the change in color and the rapidity and intensity
of its appearance.
MEASURING INSTRUMENTS.— Instruments for meas-
uring electric currents should be included in the equipment of
every well-ordered electrotyping establishment. In the early
days of the art, it was sufficient to know that a current of some
kind was at work and that in the course of time a shell of the
desired thickness would be deposited. It might take twelve
hours at one time and eighteen at another, but a few hours
more or less was not considered of serious moment. With
the modern electrotyper, however, every minute counts, and,
as a rule, he employs all the current which can be utilized
without " burning " the deposit. Having learned by experience
what quantity may be employed to advantage, it is of great
convenience to be able to measure the current and by means of
the proper registering instruments maintain the pressure at
the maximum point. The voltmeter and ammeter are also
useful indicators of the condition of the solution. For instance,
with the solution properly proportioned and the tanks con-
nected in multiple, a pressure of 2^^ volts should produce a
current strength of about seventy-five amperes per square foot
of cathode. If the ammeter registers less, it is an indication
that the solution is deficient in acid.
METALS USED IN ELECTROTYPING, MELTING
POINT OF.— Antimony, 840° F.; copper, 1,196° F.; lead,
617° F.; tin, 773° F.
METAL ELECTROTYPE.— Electrotype backing metal
is composed of lead, tin and antimony. The proportions may
vary somewhat. The most popular formula is : Lead, 90
pounds; tin, 5 pounds, and antimony, 5 pounds. However, 6
ELECTROTYPING. 189
pounds of tin and 4 pounds of antimony, or 6 pounds of anti-
mony and 4 pounds of tin, may be employed with good results.
Electrotype metal fuses at about 600° F.
METAL-POTS, CAPACITY OF.— To calculate the con-
tents of a round pot, multiply the cube of the diameter by the
decimal .5236 and divide by 2, to find the number of cubic
inches. To calculate the contents of a square pot in cubic
inches, multiply the length, breadth and depth together. On
account of the slope in the walls of the pot, the length and
breadth measurements should be taken at a point equally
distant from the top and bottom of the pot. A cubic inch of
stereo metal weighs 6.15 ounces. A cubic inch of electro metal
weighs 6.28 ounces.
METALS USED IN ELECTROTYPING, SPECIFIC
GRAVITY OF.— Antimony, 6.70; copper, 8.889; lead, 8.01;
tin, T.z.
MOLDING COMPOSITION.— Most molders have their
own opinion as to what constitutes the best molding composi-
tion. Possibly no two of them use exactly the same com-
bination of ingredients, and yet all produce excellent results.
Some of the best molders still use beeswax and decline to
accept a substitute ; others use ozokerite ; others " crask "
wax, which has ozokerite for a base ; others a combination
of ozokerite and beeswax, or " crask " wax and beeswax.
All molding compositions are subject to changes, caused by
repeated meltings and coolings, changes of temperature, etc.
The skilled molder watches his wax and adds from time to
time the material necessary to preserve its virtue. A good
molding composition may be made by mixing together pure
beeswax, 85 per cent ; crude turpentine, 10 per cent ; plum-
bago, 5 per cent. In summer add 5 per cent burgundy pitch.
Ozokerite may be substituted for beeswax and is becoming
popular as a molding composition. The following mixture is
specially recommended by Mr. George E. Dunton : 10 pounds
ozokerite, Y^ pound vaseline and % to y2 pounds of white-
pine pitcli. If by long use the composition becomes hardened.
190 ELECTROTYPING.
it may be annealed by adding from time to time a small quan-
tity of vaseline.
MOLDING COMPOSITION, ELASTIC— Dissolve 32
parts (by weight) of gelatin in 24 parts of water, over a slow
fire ; when dissolved, add i part beeswax cut up in small
pieces. The mixture should be warm but not hot when used.
Before applying the composition, the plaster casts should be
well brushed with oil. The following composition is recom-
mended by Mr. George E. Dunton : " Select 10 pounds of the
best cabinetmaker's glue and put it to soak over night in S
pints water. The semi-plastic mass should be heated over a
water bath until it becomes of the consistency of thick syrup.
To this mass should be added 2J/2 pounds of a good quality
of molasses and i pound of pure glycerin, and thoroughly
incorporated by stirring. The molasses and glycerin must not
be added until within one-half hour from the time the compo-
sition is to be poured. Never try to make up this composition
in a kettle sitting directly over the blaze of a fire." This
composition is suitable for obtaining a reverse mold of objects
which may not themselves be suspended in the bath. When
the mold has been obtained, a duplicate of the original should
be made by pouring wax into the elastic mold. This wax cast
may be suspended in the bath and deposited upon, thus secur-
ing a metallic reverse upon which a duplicate of the original
may be deposited.
MOLDING PRESSES, HYDRAULIC.— The hydraulic
molding presses in one of the larger electrotyping establish-
ments in New York are operated by accumulators, in which a
pressure of 1,000 pounds to the square inch is maintained by a
suitable pump. When the pressure in the accumulators reaches
one thousand pounds an automatic governor stops the pump,
which starts again when the pressure is diminished by reason
of the operation of the presses. Pressure is applied to the
presses by simply turning a valve, and, as the pressure is con-
tinuous, the travel of tiie press bed is much more rapid than is
the case when the pump is attached to the press. The plant
would be considered very expensive by most electrotypers, and
ELECTROTYPING. ' 191
for that reason this method of molding is not likely to become
popular.
MOLDING WAX, TO SOFTEN.— A new composition
for softening wax which has become dry and brittle has
recently been put on the market and is sold by dealers in elec-
trotyping supplies. It is called Ozo Compound, and is highly
recommended by many electrotype molders.
MOLDS, BLISTERED.— Blisters are sometimes due to
moisture in the wax. It may be due to adulteration. The
trouble may be partially remedied by burning down the case
before molding. Skimming the case with a hot wire will also
help to remove the moisture.
MOLDS, COATING.— When spots appear on the molds
which do not coat readily, the difficulty may be due to the fact
that the mold has not been thoroughly wetted, and may be
remedied by using stronger alcohol or a more powerful stream
of water. Greasy iron filings might also cause the trouble.
NICKEL ELECTROTYPES.— To deposit nickel on wax
molds, blacklead the mold in the usual manner and increase
the conductivity by floating the surface of the mold with a
solution made by dissolving phosphorus in wood alcohol to
saturation. After floating the mold with the phosphorus solu-
tion, rinse in running water and repeat the operation. Mold
will cover in five minutes, and, after ten minutes, may be
removed from the bath, rinsed and immediately placed in the
copper bath. An interesting invention comes from Louis
Boudreaux, of Paris, France. In order to produde electrotypes
in nickel, he covers the wax (before taking the impression)
with powdered bronze, the coating with graphite being omitted.
In this way he secures a surface of wax that, when placed in
the bath, will permit the adhesion of the nickel and result in
the quick building up of a shell. As is well known, if electro-
plating is undertaken with nickel, after the manner of copper,
the small amount of adhesion of the nickel to the graphite
often causes a failure. The inventor further claims that a
1 92 ELECTROT Y PING.
metallic surface, as of bronze, on the wax is much better for
electroplating with any metal than is the plumbago surface.
NICKEL-PLATING ELECTROTYPES.— In printing
from electrotypes with colored inks, more especially with inks
which are prepared from a mercurial pigment, such as red,
brown or vermilion, not only is the surface of the electrotype
injuriously affected by the mercury forming an amalgam with
the copper, but the brilliant colors are also seriously impaired
by the decomposition which occurs. To avoid this, it is best
to give electrotypes to be used for such purposes a coating of
nickel, which effectually protects the copper from wear and
the action of the mercury, and seemingly brightens the color
of the ink. It is absolutely necessary that the face of the
electrotype should be chemically clean, in order that the nickel
deposit may adhere to the copper. After printing-plates have
been nickeled, they should be rinsed in clear water, then
plunged in hot water and dried in sawdust. It is claimed that
nickeled plates will take ink better if they are also brushed with
fine whiting.
NICKEL-PLATING HALF-TONES.— There appear to
be conflicting opinions regarding the nickel-plating of half-
tones, the usual impression being that the cut becomes filled
up. While this may be true to a certain extent, the effect so
produced is far less than is generally supposed. This may be
determined by depositing a good plating of nickel on one por-
tion of a first-class electrotype and comparing the plated and
unloaded portions under the microscope. Some nickel-plated
electrotypes, made for the purpose of determining this point,
appeared to be equally as sharp as nickeltypes from the same
originals, the amount of nickel on the plated cuts being con-
siderable, .001 inch or more, as judged by the time and current.
The reason of this may be found in the fact that nickel deposits
in a very smooth condition, and that the current densities
during plating being greater at points nearest the anode, more
metal would be deposited upon the printing surface than in
the depth of the dots, thus, if anything, increasing the depth
of the half-tone plate. Deterioration, if any occurs, would
ELECTROTYPING. 193
seem to be due to a decrease in the diameter of the dots in
the half-tones and the accumulation of nickel on the high-
light points, causing the impression in printing to be darker.
In practice, it is doubtful if such an effect could be noticed.
NICKEL SOLUTION.— The following formula is recom-
mended by Dunton : To make a solution in which nickel will
be deposited as near faultlessly as it is possible in an alkaline
bath, the proportion of the nickel-ammonium sulphate should
be J/2 pound to the gallon of boiling water, and make this
volume of water slightly less than the bulk of the desired
solution is to be. If the solution is to be 12 gallons, dissolve
5 pounds of the sulphate in 10 gallons of boiling water, stir-
ring until the sulphate is all dissolved ; then strain off into
the tub, and add 2 gallons of cold water. Allow it to stand
until the temperature has fallen to 70°, and test with the
hydrometer. If it registers 5°, or even a half degree less,
it is in condition to work; but if more than that, it must be
reduced with cold water to that point, to obtain the best
results. Outside of the advised addition of certain organic
acids, certain theorists have recommended the addition of all
kinds of nitrates, sulphates, carbonates, citrates, sodium, mag-
nesium, potassium and calcium chlorids ; but, as the result of
my personal experiment, I would advise the reader to leave
them all entirely out of his prospective nickel baths. The
results without their addition will be far more satisfactory.
The nickel bath will be found quite a troublesome customer
to keep in sorts, as it is supposed to be kept at a state of
neutrality that is neither alkaline nor acid ; if either, I believe
it should show a very slight acid reaction. This state may be
tested for, and proved, by the ordinary " litmus paper," which
should be always kept handy to the tub. Either the blue or
red will answer the purpose equally well. If the red is used,
first dip in strong ammonia, which will turn it a deep blue,
proving that the ammonia is strongly alkaline. Allow the
paper to dry (it will retain the blue color) ; now dip it in the
solution and allow to dry. If, upon drying, the color has
.changed to a reddish purple, between the red and the blue,
13
194 ELECTROTYPING.
in which neither predominates, the sohition will yield the best
results. If it should turn a reddish tint as soon as drawn
from the liquid, rest assured there is too much acid in the
solution, and the deposit will peel. If the paper retains its
blue, the solution is too alkaline and will yield a deposit which
will prove too brittle or hard. A very slight reaction toward
the red is prolific of the best results. If the solution becomes
too acid, the addition of a small quantity of ammonium sulphate
will correct the fault ; if too alkaline, the nickel sulphate.
Consequently, it is an easy matter to keep the contents of the
solution constant. A simple bath, which has been thoroughly
tested in some of the largest electrotype foundries in the
country, is made by dissolving the double sulphate of nickel
and ammonia in warm water, in the proportion of three-
quarters of a pound of the salts in each gallon of water. The
procedure is the same that has been recommended for the
copper solution, i. e., the salts should be suspended in cheese-
cloth bags just under the surface of the water until entirely
dissolved, when the solution should be thoroughly stirred, and
is then ready for use.
NICKELTYPES. — Nickeltypes possess three principal
advantages over electrotypes for half-tone reproduction : First,
they are much more durable ; second, they take ink better,
particularly colored inks, and, third, the method of their manu-
facture is such that there is less danger of scratching or
injuring the mold than in the ordinary methods of electrotyp-
ing. Probably the chief advantage of the nickeltype is found
in the fact that it is not affected by colored inks, although due
consideration should be given to the other points mentioned.
NICKELTYPING. — The proper anodes for the purpose
are so hard that they are subjected to 4,000 degrees of heat
in casting, and, when coming in contact with the sand, a thin
scale or coating is formed on the outside, which causes irregu-
lar deposit and gives the anode the appearance of being
veneered or plated. This outer covering also contains an
indefinite quantity of iron (carbon), which, if liberated in the
solution to an excessive degree, will stratify the latter to an
ELECTROTYPING. 19/5
extent of causing endless trouble. Where this iron oxid comes
in contact with the cathode before the shell is perfectly formed,
further development is checked, and the next deposit, or back-
ing, comes through to the face, giving a faulty plate, the sur-
face either being rough or copper specks and spots showing
through. If this same oxid is allowed to dry or adhere to the
nickel shell after it is perfectly formed, the copper or tinfoil
will not unite perfectly, and the shell will be lost and blister
or peel oflf. These are the genuine blisters, and should not be
confounded with the so-called globular and irregular blisters
that arise when depositing the nickel shell. These are not
blisters, but, more properly, gas-blows, caused by the current,
solution, anode and cathode surface exposed not harmonizing.
A certain amount of effervescence during deposition is neces-
sary to insure quick, bright and perfect deposit; too little
retards the work; too much produces the defects mentioned,
which are next to impossible to eradicate after the shell is
backed up, especially in half-tones.
NICKELTYPING, CONNECTIONS FOR.— In deposit-
ing nickel on wax molds, it is desirable that the mold shall be
covered as quickly as possible. To promote this end, it is
well to extend a loop of wire entirely around the mold, sinking
it into the wax and having it long enough so that the ends
may be bent into hooks for suspending the mold in the bath.
By observing this method, deposition will begin on all sides
of the molds at once, instead of beginning at the top and
spreading down over the entire length of the mold, as is the
case when the ordinary electrotyping connection is employed.
With the loop-wire method, the mold will cover in from two
to three minutes.
NICKELTYPES, DEFECTIVE.— Depressions in the face
of nickeltype plates are due to gas bubbles, caused usually by
too strong a current. Nickeltyping is not an easy proposition,
and, to be successful, all the conditions must be just right. The
current and solution must harmonize. To ascertain the proper
strength of current is a matter of experiment, and for this
196 ELECTROTYPING.
purpose depositing apparatus should include a rheostat, by
means of which the current may be varied at will.
OZO COMPOUND.— The quantity of ozo compound to
be added to the molding wax or ozokerite varies with the
season of the year and the condition (or quality) of the wax.
Start with from one pint to one quart to each fifty pounds of
wax, adding more until the wax is soft enough. Most of the
ozokerite in use is of inferior grades. The less pure ozokerite
is the more crude oil it contains and the lower its melting
point, requiring less ozo compound. Beware of an overdose,
as it takes some time to get the wax into shape in case of an
overdose. The best molds are made with pure ozokerite
reduced with ozo compound. Never heat the forms, and use
cold cases or molds. In lifting forms out of the mold, give a
steady, strong pull. The form will not release quite so easily
from a cold case as from a heated case, but the results will be
better from the cold case.
OZOKERITE, TO SOFTEN.— When ozokerite molding
composition becomes hard and brittle, add vaseline, or ozo
compound, a little at a time, until it becomes sufficiently soft
and plastic.
OZOKERITE, TO HARDEN.— In hot weather, if the
composition becomes too soft, add a very little of pine tur-
pentine.
PATINA, IMITATION OF GENUINE.— Repeatedly
brush the objects with solution of sal ammoniac in vinegar,
the action of the solution being accelerated by the addition of
verdigris. A solution of 9 drams of sal ammoniac and 2J4
drams of potassium binoxalate, in i quart of vinegar, acts still
better. When the first coat is dry, wash the object and repeat
the manipulation, drying and washing after each application,
until a green patina is formed. It is best to bring the article,
after being brushed over, into a hermetically sealed box, upon
the bottom of which a few shallow dishes containing very
dilute sulphuric acid and a few pieces of marble are placed.
ELECTROTYPING. 197
PEELING, TO PREVENT.— The great difficulty in nick-
eltyping is peeling of the deposit before a sufficient thickness
has been attained. To prevent peeling, the solution and the
current must be of just the right strength. To enable the
operator to work intelligently, a voltmeter and a rheostat
should be included in the circuit. The current may then be
suited to existing conditions and varied at the will of the
workman. Nickel is a somewhat obstinate metal to deposit,
and requires careful attention. It will not adhere to surfaces
which are not absolutely clean, and even then will peel if left
in the bath too long, or if deposited with too strong a current.
The printing surfaces which are to be nickeled should be
scrubbed with hot lye or brushed with lime paste, and then
thoroughly washed in running water, after which they should
be immediately suspended in the bath. They should not be
allowed to dry or be touched with the hands ; with a current
of two to three volts tension, fifteen or twenty minutes in the
bath will be sufficient. The plates should be separated from
the anode by a distance of six or seven inches.
PINHOLES. — Shells which are defective by reason of
" pinholes " are very annoying. The usual cause is insufficient
blackleading, or failure to blow out the lead thoroughly after
the mold has come out of the machine. There are other
causes, however, among which may be mentioned the forma-
tion of gas bubbles in the depressions of the mold, and an
insufficiency of acid in the solution when working with a very
strong current. The second cause may be remedied by employ-
ing an agitator. The remedy for the first and third causes is
self-evident.
PLATING WITHOUT A BATTERY.— Simple immer-
sion of an iron article in an ordinary solution of copper sul-
phate, such as is employed in electrotyping, will produce
sufficient action, chemical or electrotlytic, or both, to form a
very thin coating of copper on the iron. Steel pens, needles,
etc., are coppered by revolving them in a tumbling-box with
sawdust moistened with a solution made by dissolving i^
ounces of blue vitriol in lo quarts of water, and adding i^
198 ELECTROTYPING.
ounces of pure sulphuric acid. Brush coppering is executed
as follows : The utensils required are two vessels of sufficient
size, each provided with a brush. One vessel contains a
strongly saturated solution of caustic soda, and the other a
strongly saturated solution of blue vitriol. The well-cleansed
object is first uniformly coated with the caustic soda and then
with the blue vitriol. A quite thick film of copper is immedi-
ately deposited. Care must be taken not to take the brush too
full, and not to touch a second time the place once gone over,
as otherwise the copper will not adhere firmly.
POSTAGE STAMP PLATES.— The United States post-
age stamps are printed on a steam press, from steel plates, and
not from electrotypes. The original is engraved on soft steel
and then casehardened, and this hardened die or original is
pressed into the rim of a soft steel roller, which is also case-
hardened, and from this hardened roller any number of dupli-
cates are made on soft steel, which are again hardened before
printing.
RAPID ELECTROTYPING.— Mr. J. A. Corey, manager
of the electrotyping department of His Majesty's printing-
office, claims to have invented a depositing apparatus which
enables him to successfully employ 220 amperes per square
foot. No more time is required to prepare the mold for the
bath than is usually necessary. He hopes soon to be able to
give the trade full particulars of this depositor. The full sig-
nificance of Mr. Corey's announcement may be realized when
it is remembered that the average electrotyper employs from
forty to seventy-five amperes per foot. Mr. Corey's invention,
if practical, would reduce about two-thirds the time at present
required ior depositing.
RESISTANCE. — Resistance is that quality in an object
which prevents more than a certain amount of current passing
through it in a given time, when impelled by a given electro-
motive force. The resistance of a conductor is equal to the
time required for a unit quantity of electricity (i. e., a
coulomb) to pass through it, while its two ends are maintained
at a unit diflference of potential, i. e., at one volt. The unit
ELECTROTYPING. 199
of resistance is termed an ohm. The resistance of liquids as
compared with metals is enormous, the resistance of a satu-
rated solution of blue vitriol being 16,885,520 times greater
than copper. The resistance of a wire is directly proportional
to its length, and inversely to its sectional area or weight, per
unit of length. Conductivity is the reverse of resistance. By
rise of temperature, the conductive resistance of metals is
increased, and of electrolytes is decreased; thus warm solu-
tions facilitate deposition.
RESISTANCE BOARD.— The switchboard, or resistance
board, consists of a number of metallic spirals, usually of Ger-
man silver, arranged on a board in such a manner that one
or more of them may be switched into the circuit, thus pre-
senting more or less resistance, as may be desired, to the
passage of the current.
REVERSE ELECTROTYPING.— To prevent the deposit
from adhering to a metallic matrix, clean the matrix thor-
oughly and then flow over it a very weak solution of potas-
sium sulphuret. An impalpable film will effectually prevent
adhesion of the deposit. This process is found very useful in
the production of reverses and in the manufacture of embos-
sing dies.
SAWS, CARE OF. — Royle says: If new saws do not
run true sideways, get the manufacturers of them to remedy
the trouble. The eye of the saw should always fit the mandrel
nicely. Never use a hammer on the spindle nut — a wrench is
provided especially for this nut. A piece of emery wheel or
grindstone is good for truing up a saw. Do not use a saw
that is out of round. See that every tooth in the saw cuts.
To set a saw truly, much care is needed. Avoid too much set.
Set over only the points of the teeth. Use as little set as
possible. Never use a nail punch for setting. Work with a
sharp saw. Don't be stingy with saws; keep an assortment.
Specially good workmen should have saws for their special
use. Change saws to suit the work required — remember that
this can be readily done. The smaller saw that is suitable is
the preferable one to use. A sharp, true saw is required for
200 ELECTROTYPING.
good work. A dull saw is a dangerous one. Avoid a high
ripping gauge, or fence, when a low one will answer. Before
ripping stuff, try the ripping gauge to see if it is parallel with
the saw. A good test of this is to rip a short piece to a
width, and see if, as it passes through, it just glides along the
edge of the saw-blade, touching it lightly. Adjust the table
top so that the saw will just reach through the stuff. While
sawing, keep your eyes on your work. Use great caution, but
avoid timidity. A smoking saw needs sharpening. Flying
smoke means trouble for the saw. Burnt and buckled saws
indicate carelessness. A buckled saw is a bad one. Screech-
ing saws have long teeth. Avoid high or long teeth. Joint
off the saw frequently, and, when you do so, remove it to the
clamps for filing. File straight across. In filing, first sharpen
the face or front of the tooth, then file off the back of the
same tooth. Save time by filing from one side. Different
persons should not file the same saw. Why use a fleam-toothed
saw for crosscutting when a fine-tooth rip will answer? Try
it. Fleam teeth are unnecessary except for special work. Too
thin saws will screech and run. A good sawyer is known by
the saws that he keeps. Avoid a worn throat-piece — renew it
frequently. Most accidents arise from carelessness. Have the
belt-shifter work freely; control it with the foot. It is essen-
tial that the belts be even in thickness throughout their entire
length. The spindle belt, at least, should have no rivets or
lacings; all joints should be lap-glued or cemented.
SERIES, ELECTROTYPING IN.— There is no object in
connecting two tanks in series unless you use twice the E. M.
F. you would on one tank. The primary advantage in con-
necting tanks in series is found in the general principle of
electric distribution — that a given amount of power or energy
is conveyed more cheaply at a high pressure than at a low
pressure. Next, it is easier to build a machine of a given
capacity for high pressure and low current than for low pres-
sure and high current. The current capacity of a dynamo is
determined by the cross-section of the armature conductors.
A four-pole armature wound with J<2-inch copper rods has a
ELECTROTYPING. 201
capacity of 1,500 amperes. It will get too hot on a high cur-
rent. Suppose you are working quiet solutions : i volt is
enough E. M. F. per tank, and 20 amperes per square foot
of cathode, we will say, is the current required. If this 1,500-
ampere armature is revolved in such a field and such a speed as
to develop or generate i volt, it is evident that tanks in parallel
only can be used — or one big tank. The surface that can be
covered at a maximum rate is 1,500 divided by 20, or 75 square
feet. If, however, this same armature be revolved in such a
field and at such a speed as to generate 2 volts, its current
capacity will in no wise be affected, and you can use the cur-
rent twice over, consuming i volt in its first passage through
the solution, and the remaining i volt in its second passage,
and so on. If a 1,500-ampere armature be revolved in a field
which will produce 10 volts, a corresponding number of tanks
can be operated, each depositing for a maximum on 75 square
feet of surface. A water-power may, perhaps, give a simple
analogy. Suppose 1,000 cubic feet per minute is flowing in a
given stream. It is evident that, with 20-foot fall or head,
twice the work can be accomplished that can be with a lo-foot
head. From the fact that the E. M. F. of an armature is
dependent on three things, namely, turns of armature, strength
of field, and velocity, it follows that an armature built for
1,500 amperes and i volt can not be used for 1,500 amperes
and 5 volts, without making an enormously large field and
running it at a prohibitory speed. Therefore, a change in E.
M. F. above 25 per cent, on small, slow-speed machines,
demands a rearrangement of parts and different windings.
There is no object in taking a dynamo of 3 volts or less and
putting it on two tanks either in series or in parallel, for, if
the solution be agitated, the entire 3 volts may be used in
one tank.
SILVER ELECTROTYPING.— Silver is occasionally
used in special cases for copying works of art or even valuable
engraved steel plates. Ordinary wax and gutta-percha molds,
such as are used for copper electrotyping, are not admissible
for silvering, because they are to some extent attacked by the
202 ELECTROTYPING.
cyanid solutions. The simplest method of obtaining replicas of
works of art in silver is to obtain, first, a thin electrotype shell
of copper from the intaglio mold, and then to deposit silver
upon this in the cyanid bath. The copper protecting film may
be of the thinnest, so that it shall not destroy the sharpness
of the lines, but it must, of course, be subsequently removed,
after the required thickness of silver has been deposited, and
the whole electro separated from the mold. This solution of
the copper may be effected by treatment with warm hydro-
chloric acid, or, better, with a warm solution of iron per-
chlorid, either of which will attack the copper but leave the
silver untouched. On the removal of the copper, the pure
silver surface has the required form in practically undimin-
ished sharpness and brilliancy. The silver may be built up
to a thickness of one-eighth of an inch or more. It is seldom,
however, that this process is required, and practically the sole
application of electro-silvering is -to be found in the coating
of other metals to endow them with properties which they do
not themselves possess.
SILVERING SOLUTION FOR GLASS.— (i) Nitrate of
silver, i ounce; water, lo ounces; add liquid ammonia until
the brown precipitate is redissolved ; then add 90 ounces
water. (2) A i per cent solution of formaldehyde. Mix two
parts of I with one part of 2. Flood the surface to be silvered.
In fifteen to twenty minutes wash in running water.
SOLUTION, CONDUCTIVITY OR— It should be
remembered that the solution is a conductor of the current in
the same sense that the rods are, and should be considered in
that capacity as well as a dissolving medium. Pure sulphate
of copper solution is an extremely poor conductor. The addi-
tion of sulphuric acid improves its conductivity, but under the
most favorable conditions its resistance is several milKons of
times greater than copper. To reduce this resistance to a point
where the liquid will not become appreciably heated by the
passage of a strong current, it is necessary to provide an
exceedingly large area of conducting fluid and to suspend the
anodes and cathodes as near together as possible, say two or
ELECTROTYPING 203
three inches apart. According to Joule's law, the develop-
ment of heat will be greater the smaller the cross section of
the conductor and conducting capacity are, and the larger the
quantity of current which passes through it. If, therefore,
it is desired to employ a very strong current, the vat must be
larger in proportion to the size of the anodes than would be
necessary with a moderate current.
SOLUTION, COPPER, HOW TO ASSAY.— There are
two ways of measuring the content of copper in a solution,
both of which require accurate instruments and the facilities
of a laboratory. The simplest and best method is that of
electrolysis. A very delicate and accurate scale is required,
capable of measuring i-ioo of a grain. The process is
described by McMillan as follows : " A platinum dish about
three-quarters of an inch to an inch in height, and about three
inches in diameter, forms a convenient cathode, at once hold-
ing the solution and receiving the deposited metal. The anode
consists of a circular plate of stout platinum foil about 2^
inches in diameter, with several perforations to allow gas to
escape from beneath it. The platinum sheet is fastened hori-
zontally, without solder, to the end of a vertical platinum wire,
attached to the positive pole of the battery, the platinum dish
making contact externally with a copper wire attached to the
negative pole. Instead of this, a cylinder of platinum foil
may be used as a cathode, being suspended with its main axis
vertical within a small beaker, the anode consisting of a coil
of platinum wire placed within the cathode. The object of
the electrolysis method is to continue the action of the current
until every trace of copper is precipitated on the platinum
cathode, and, as the latter should have been weighed pre-
viously, the increase of weight shown after deposition gives
the number of grains of metal in the quantity of solution taken.
It is possible to separate every trace of copper from the solu-
tion, so this method rhay be made to give absolutely accurate
results. Half an ounce of the liquid may be employed, and
electrolysis is continued until the liquid is decolorized and a
204 KLECTROTYPING.
drop removed from it strikes no blue color with an excess of
ammonia."
SOLUTION, HOT, REMEDY FOR.— Heating of the
solution is caused by resistance. This is always the cause of
heat, and the way to minimize resistance is to increase the
capacity of the conductors. The solution is a conductor of
the current from the anode to the cathode. It is a very poor
conductor, however, as all solutions are, and must, therefore,
have a large area to compensate for what it lacks in quality.
Under ordinary conditions the cross-sectional area of the solu-
tion should be at least twice as great as the area of the anode ;
with a very strong current, the cross-sectional area of the solu-
tion should be at least three times that of the anode. In other
words, if the anode is 15 by 20 inches, the vat should be 32
inches wide and the solution 28 inches deep. A current of
sufficient strength to deposit good shells in one hour requires
large conductors, and this applies not only to the copper rods
but to the solution, which is also a conductor. Moreover, the
solution is a very poor conductor, and what it lacks in respect
of quality must be made up so far as possible in quantity. The
cross-sectional area of the solution should be from two to
three times the area of the case.
ELECTROTYPING.
205
SOLUTIONS, SPECIFIC GRAVITY OF, CORRESPONDING TO
THE DEGREES OF THE BAUME HYDROMETER.
Degree
Specific
Degree
Specific
Degree
Specific
Degree
Specific
Baume.
Gravity.
Baume.
Gravity.
Baume.
Gravity.
Baume.
Gravity.
o
I.OOO
19
1. 147
37
1-337
55
1.596
I
1.007
20
I 157
38
1-349
56
1. 615
2
1. 014
21
1. 166
39
1. 361
57
1-634
3
1.020
22
1. 176
40
1-375
58
1.653
4
1.028
23
1. 185
41
1.388
59
1. 671
5
1.034
24
1. 195
42
1. 401
60
1.690
6
1. 041
25
1.205
43
1. 414
61
1.709
7
1.049
26
1. 215
44
1.428
62
1.729
8
I 057
27
1.225
45
1.442
63
1-750
9
1.064
28
1-235
46
1-456
64
1. 771
lO
1.072
29
1.245
47
1.470
65
1-793
II
1.080
30
1.256
48
1.485
66
1. 815
12
1.088
31
1.267
49
1.500
67
1.839
13
1.096
32
1.278
50
1. 515
68
1.864
14
1. 104
33
1.289
51
1. 531
69
1.885
15
1. 113
34
1.300
52
1.546
70
1.909
i6
1. 121
35
1. 312
53
1.562
71
I 935
17
I. 130
36
1.324
54
1.578
72
1.960
i8
1. 138
Note. — The specific gravity of a solution is rapidly ascertained by
floating a hydrometer in it. This instrument sinks deeper in solutions
of low density than in those of high gravity, and the actual gravity is
found by the level at which the liquid stands on the graduated portion
when the apparatus is floating freely in it. Hydrometers of this kind
are sometimes graduated so that the specific gravity is read off direct
from the scale, others are graduated by Baume's method, and the reading
may then be converted into the number representing the true density, by
reference to the above table.
STATISTICS. — A London writer states that there are
fourteen electrotype foundries in that city, whose total output
is £80,000 (approximately $400,000) yearly. In Chicago there
are twenty foundries, having an estimated output of over
$500,000. Prices in the two cities do not differ materially,
while the population of London is probably three times that of
Chicago. On the basis of population, as compared with Chi-
cago, London should support sixty electrotype foundries and
should produce $1,500,000 worth of electrotypes annually. It
is evident that English printers do not employ electrotypes
as extensively as the Americans, and one reason for this may
206 ELECTROTYPING.
be found in the popularity of stereotyping. Nearly every large
printing establishment operates a stereotyping plant, and it is,
to a certain extent, independent of the electrotypers. In Chi-
cago, very little job-printing is done from stereotypes. Few
printers have facilities for doing their own stereotyping, and,
when purchasing plates, most of them prefer to pay the extra
cost for electrotypes.
SWEATING. — Shave the top of the base and the back of
the plate so as to have clean, smooth surfaces. Do not shave
the bottom of the base. Brush over the shaved surface of the
base with soldering fluid, made by dissolving scraps of zinc
in muriatic acid to saturation, and diluting with an equal bulk
of water. After covering the surface of the base with a sheet
of tinfoil, place it on an iron plate and float it in your metal-
pot. When the tin begins to melt, remove the base from the
metal-pot, place the electro upon it, and immediately clamp
them together. The back of the electro should have been pre-
viously brushed over with the soldering fluid. The plate and
base may be clamped together with an ordinary hand clamp, or
more than one if the plate is large, first protecting the face
of the plate by laying upon it a piece of smooth board. In
this method of blocking, advantage is taken of the fact that
tin fuses at a much lower temperature than stereotype or
electrotype metal, and also that clean, bright metal fuses much
more readily than old metal, or, strictly speaking, metal which
has become oxidized. Because of this latter fact, it is impor-
tant that the bottom of the base should not be shaved, as the
film of oxid protects it to a considerable extent and insures the
fusing of the tin before the base metal is attacked.
THREE-COLOR BLOCKS, ELECTROTYPES OR—
Mr. J. S. Sunderland, in " Penrose's Pictorial Annual," advises
that in making electrotypes of fine-screen plates no brush
should be allowed to come in contact with the molded surface.
He produces a conducting surface by polishing the wax sur-
face before molding, not merely brushing over the case with
molding lead, but giving it a real polish. Dixon's and Mor-
gan's polishing lead in equal proportions is recommended.
ELECTROTYPING. 207
Cover the wax mold with a sheet of paper while trimming, and
only blacklead the parts cut with the trimming knife. The
result will be electrotypes equal in every respect to the origi-
nals.
VATS, GLASS RAILS FOR.— Electrotypers' depositing
vats are usually lined with lead, which is turned over the top
edges of the tank to guard against any possibility of leakage.
To insulate the rods from the metal lining, a wooden rail is
fitted over the top edges of the vat on top of the lead. So
long as the wood remains dry, the insulation is effectual, but
eventually it becomes saturated with the solution and must be
removed. With an agitated solution, the life of the wood is
shorter than when a quiescent solution is employed, but in
either case it is only a question of time when the wooden rail
will become saturated and rotten, and in this condition it
becomes a conductor of the current and creates a short circuit
which absorbs more or less of the energy of the current. The
life of the rail may be prolonged by giving it several coats of
waterproof paint, but a more cleanly and altogether more
satisfactory plan is to substitute for the wooden rails strips of
heavy glass about one inch in thickness. Such strips may be
procured from glass dealers at small expense, and, with a
couple of holes drilled and countersunk in each, to provide a
means of securing them to the vat, they furnish a neat and
serviceable finish for the vat and provide a reliable insulation
for the rods.
VERDIGRIS, TO REMOVE FROM ELECTROTYPES.
— Acetic acid and table salt will aid in removing the objection-
able spots. First dissolve the salt thoroughly in the acid. It
is then ready for use. Use a nail-brush or tooth-brush to apply
the wash. Do this carefully to avoid scratching the face of the
plates. This wash will not remove the enamel from original
copper engravings. After cleaning the plates, rub a little
kerosene over them before and after use. Creosote will also
be found a good remover of verdigris from copper surfaces.
WASHING ELECTRO SHELLS.— Backing up electro
shells without washing is a very objectionable practice. Even
208 ELECTROTYPING.
when washed with hot lye there is likely to be some wax
remaining, which will be burned to the backing pan, rendering
it uneven and making lots of trouble in finishing plates.
WRINKLES IN SHELLS.— Wrinkles in shells are
caused by wrinkles in the molds. Unless the molds are care-
fully examined, they would not be noticed, but close inspection
in a strong light will detect them.
WATT. — A watt is a current of one ampere, at a pressure
of one volt; equal to 1-746 of a horse-power.
WAX ENGRAVING. — The term wax engraving is, in one
sense, misleading, for, while wood, zinc, copper and steel
engravings and etchings may be printed direct from the origi-
nals, the wax engraving, like the chalk-plate engraving, can
not be utilized direct. The wax engraving is, in fact, a mold
into or upon which copper or other metal must be deposited
by the electrotyping process in order to obtain a printing sur-
face. To make a wax engraving, a plate of copper or other
metal is thinly coated with wax. The design which is to be
reproduced as a printing-plate is then drawn through the wax
upon the plate beneath. In the reproduction of wood engra-
vings, zinc etchings, etc., by the electrotype process, a mold of
the object is made by impressing it in a bed of wax. The wax
mold is then suspended in the depositing bath, and the deposit
formed upon it will obviously be an exact duplicate of the
original. But we do not want a duplicate of the wax engra-
ving. What we do want is a reverse. So, instead of making
a mold, we hang the engraving in the solution, and deposit
directly upon it. The process of making an electrotype of wax
engraving from this point on is just the same as making an
electrotype of any other printing surface. Previous to immer-
sion in the bath, the spaces between the engraved lines are
built up with wax. The engraving is then blackleaded, a film
of copper is precipitated upon it by the iron-filings process, to
increase the conductivity of the mold, and the connections
adjusted. When a shell of sufficient thickness has been
deposited, it is removed in the usual manner, backed up with
ELECTROTYPING. 209
metal, straightened, mounted on a wood or metal base, and is
then ready for the press. '
WAX-KETTLES. — For melting beeswax or ozokerite,
a steam- jacketed kettle should always be employed. Never
heat by gas or fire, as there would be great danger of over-
heating and spoiling the composition.
WAX MOLDS, METALIZING.— The following methods
of making the surface of wax molds conductive are recom-
mended by Langbein, Urquhart and Watt. Take equal parts of
albumen (white of egg) and a saturated solution of common
salt, and apply the mixture to the mold by means of a soft
brush. Then dry the surface thoroughly. Now make a strong
solution of nitrate of silver and dip the mold into it for a few
minutes, and dry again. Expose the mold to a strong light
until it becomes quite black. The mold is then to be dipped
into a saturated solution of sulphate of iron, when a layer of
metallic silver will be formed, upon which a deposit of copper
may be readily obtained. The mold should be rinsed when
taken from the sulphate of iron solution, and connecting wire
attached to it, when it may at once be placed in the depositing
bath. Another method is as follows : Dissolve a piece of
phosphorus in a small quantity of bisulphid of carbon. Stir
in two drams of benzin and a drop or two of sulphuric ether ;
pour the whole into half a pint of alcohol and wash the sur-
face of the mold with this mixture twice, allowing it to dry
after each application. The silver solution is made by dissolv-
ing one dram twenty grains of nitrate of silver in a mixture of
half a pint of alcohol and one dram of acetic acid. The mold
is floated once with this solution and allowed to dry spon-
taneously. Another and simpler method of rendering the
mold conductive is described as follows : Dissolve phosphorus
in pure alcohol until a strong solution is obtained, and wash
the mold with this mixture. The silver solution is prepared
by dissolving nitrate of silver in ammonia to saturation. It
is to be poured evenly over the mold and allowed to float over
it for a few minutes. The solution is then poured off and
the mold allowed to become partly dry, when the operation is
210 ELECTROTYPING.
repeated. Spots which do not appear to take the solution
readily should be wetted with it by means of a soft brush.
WAX SHAVERS, VALUE OF.— Most large electrotype
foundries are equipped with wax-shaving machines. They are
chiefly valuable when used in connection with power molding
presses which are provided with indicators to register the
depth of impression. The shaved case being of uniform thick-
ness, and the proper depth of impression having been estab-
lished and noted on the indicator, the operator may thereafter
be guided entirely by the indicator, for, if the press is stopped
each time at the same reading, the impressions will obviously
be all of the same depth. A shaved case is also preferable,
because the " skin " is thereby removed from the case, and,
with it, all dust or dirt which may have collected thereon, or
which, being in the wax, may have risen to the surface when
poured in the case.
WOODCUTS, TO PRESERVE.— If wood is wet, oil can
not enter it ; if wood is oiled, water can not get in. As it is
alternate cold or dampness and heat or dryness that swell and
warp cuts and blocks, let every cut you care anything about
be soaked in oil at the bottom — the place most affected — and
the trouble will be overcome. You can then lay the cuts on
cold stones or presses, or in moderately warm places, with
little or no risk of injury.
WOOD ENGRAVINGS, CLOSING CHECKS IN.—
Wood engravings, when subject to changes of temperature or
atmospheric conditions, sometimes check or crack. When it is
desired to make an electrotype of such an engraving, the
checks, if not too large, may be closed by covering them with
strips of damp blotting paper and then applying a hot building
iron to the paper until it is wholly or partially dry. When the
check has been closed, the mold should be made at once, before
it has time to open again.
INDEX.
Acid, to ascertain percentage in solu-
tion, i6i; effect of, on nickel bath,
i6i; effect of acid in solution, i6i;
hydrochloric, i6i; muriatic, i6i;
sulphuric, i6i; soldering, 162; acid
gauge, 58
Adams, J. A., 8, 16
Agitation of bath advisable, 51 ; bene-
fits of, 162; methods of, 164
Alkalinity and acidity, 165
Alloy, fusible, 165
Amalgamation of zinc, 165
Ammeter, 60, 165
Ammonia, 166
Ampere, 166
Air blast for blackleading, 86
Albert, Doctor, 69
Anchoring plates, 146, 166
Anode, 166; connections, 167; hooks,
167; plates, 167
Antimony, 167
Backer-up, the, 167; backing up
press, 168
Backing metal, 107
Backing pan, 107
Baths, constituents of, 35; size of
depositing vat, 39; testing the
solution, 40; steel, brass and nickel
baths, 41, 44; brassing solution,
43; management of bath, 46; holes
in shells, 48; temperature of bath,
48; cyanide, 49; agitation of bath,
51; Englehard process, 52; Dun-
ton method, 54; Leetham appa-
ratus, 55
Battery, Smee, 15, 20; strength of,
18; scientific knowledge not essen-
tial, 19; positive and negative
plates, 20; positive and negative
poles, 20; electrode, anode, cath-
ode, volt, ampere, watt, 20; platin-
izing, 22; care of battery, 24
Beginning a job, 63
Beveling machine, 134
Black electrotypes, 174
Blackleading, 16, 84, 168, 169
Blister on shells, 169
Blistered molds, 191
Blocking, sectional and wood blocks,
143; rotary planer, 145; anchor-
ing and nailing, 146, 166; warp-
ing, 147; dovetailing, 147
Blowpipe, 138
Blue vitriol, 35
Body mold, 113
Book plates, 135, 136; device for
holding, 170
Brass bath, 41, 44
Brassplating, 170
Brittle deposit, 171
Bronzing solution, 171
Brushes, cleaning, 173
Building, wax knife and how to use
it> 79 i how to use building iron,
80; making electrical connection
with mold, 8i
Burning, 172
Cases, warming of, 172; handling the
case, 81; thickness of, 72.
Casting, the furnace, 105; leveling
stand, 1 06; backing pan, 107; com-
position of backing metal, 107;
preparing the shell for backing,
108; flattening plates, no; electro-
typer's press, no; casting hard
shells, 172; mounting, 112; metal
bases, 11.2; body mold, 113; cool-
ing the cast, 114; saw table, 116
Cathode, 172
Circuit, 172
Cleaning, brushes, 173; cuts, 173;
electrotype casts, 173; plate ma-
chine, 173
211
212
INDEX.
Coating molds, 191; coating of cop-
per, preliminary, 90
Coloring electrotype medallions, 174
Color plates, registering, 174
Combination blacklcading machine, 87
Composition, molding, 67
Concave, 174
Conductors, quantity of current, 95;
size of rods, 96; importance of
good connections, 97
Conductivity, 175; of mold, 90, 91,
92; of solution, 202
Connections, 175; importance of good
connections, 97
Copper, dissolved by solution, 176;
scraps utilized, 176; to separate
copper from water, 176; weight of
copper, 177; how to assay copper
solution, 203; copper sulphate, 35;
copper vat, 38
Coppering foliage and plants, 92
Corrections, see Rezising
Corrosion of copper-faced type, 177;
to prevent corrosion, 177
Coulomb, 178
Cost of shells, 177
Crocus, 178
Current, high tension, 178; strength,
178; measuring, 178; restricting
action of, 89
Curved electrotypes, casting, 179; ex-
pansion of curved plates, 179
Cutters, 130
Cyanide of potassium, 49
Davis, Daniel, 10, 13
Davis' Manual of Magnetism, 13
Deposition, rate of, 28, 180; econom-
ical deposition, 180
Deposit, cost per foot, 25
Depositing, vat, 38, 39; striking the
mold, 99; holes in shell, 48, 100;
causes of imperfections, loi; time
required to deposit, 102
Discovery of electrotyping, 7, 8
Doctor Albert process, 69
Dovetailing, 147
Dunton's hot box, 186
Dunton method, 54
Durability of electrotype plates, 180
Dynamo, choosing a, 30, 180; superior
to battery, 25 ; capacity of, '27; con-
nections, 28; rate of deposition, 28,
29; care of, 33; current for nickel-
facing, 34
Electrical connections with molds, 82
Electrical terms, meaning of, 20
Electromotive force, 181
Electrotyping in America, 181
Elkington & Company, 8
Englehard process, 52
Filtner, William, 8, :6
Finishing, tools required, 119; rough
finishing, 119; low spots in plate,
122; straightening, 123; finishing
half-tones, 181, 182; standard thick-
ness of plate, 123; shaving machine,
123
Forms, preparation of, 64
Furnace, 105
Glass rails for vats, 207; Silvering
solution for glass, 202
Goose-bill, see Cutters
Graphite in metallizing, 83
Gutta-percha molds, 182
Hard shells, casting, 172
Half-tones, and electrotypes, 184; in-
serted in electrotype plates, 184;
molding of, 185
Holes in shells, 48, 100, 185
Horse-power, 186
Hot box, Dunton's, 186
Hot solution, remedy for, 204
Hydrometer, 58
Impression, depth of, 71, 72; taking
the impression, 74
Instruments, measuring, 58, 188; acid
gauge, 58; voltmeter and amme-
ter, 60; switchboard, 61
Inventions in electrotyping, 187
Iron, deposition of, 187
Irregular shaped objects, electrotyp-
ing of, 90
Jacobi, Professor, 7
Jordan, C. J., 7
Knight, Silas P., 16, 86
Leetham apparatus, 55
Leveling stand, 106; leveling, 187
Line gauge, 137
Lineholder, 129
Litmus paper, 188
Low spots in plate, how to detect, 122
Massachusetts Charitable Mechanic
Association, 1 1
Measuring instruments, see Instru-
ments
Medallions, coloring, 174
Melting point of metals, 188
Metal bases, 112; metal molds. Dr.
Albert's, 150; electrotype metal,
188; capacity of metal pots, 189;
specific gravity of metals, 189
Metallizing, use of graphite, 83 ; black-
leading, 84; wet process, 86; air
blast, 86; restricting action of cur-
rent, 89; preliminary coating of
INDEX.
213
copper, 90; irregular shaped ob-
jects, 91; conductivity of mold,
90, 91, 92; coppering flowers and
leaves, 92
Molding, press, 71, 75, 76, 190; im-
provements in, 16; composition, 67,
189, 190; blistered molds, 191;
metallizing molds, 209; striking the
mold, 99; gutta-percha molds, 182;
Dr. Albert process, 69; preparation
of mold, 69, 70; cooling cases, 70;
depth of impression, 72; even
thickness of cases, 72; warming
cases, 73 ; wax kettle and table, 73 ;
taking the impression, 74
Molding wax, to soften, 191
Mounting, 112, 146
Murray, Joseph, 9
New method of making electrotypes,
181
Nickel-facing, 34, 192
Nickel electrotypes, 191
Nickel solution, 193
Nickeltypes, 194
Nickel bath, 41
Ozo compound, 196
Ozokerite, 67; to soften or harden, 196
Patina, imitation of, 196
Peeling, to prevent, 197
Pinholes, 197
Planer, rotary, for blocks, 145
Plants and flowers, coppering, 92
Plates, apparatus for flattening, 1 10
Plating without a battery, 197
Platinizing, 21
Postage stamp plates, 198
Preparation of work, 63 ; shaving and
underlaying cuts, 64; wood cuts,
64; forms to have bearers, 65
Press, electrotyper's, no
Punches, revising, 138
Rapid electrotyping, 198
Reference list of terms, etc., 161
Resistance, 198; resistance board, 61,
199
Reverse electrotyping, 199
Revising, tools, 136; revising stick,
'37; punch, 138; line gauge, 1^7;
blowpipe, 138; method of inserting
corrections, 138, 139, 140; brass
standards, 140; type high stand-
ards, 142
Rough finishing, 119
Router, 131
Routing, see Trimming and Routing
Salary, foreman's, 182
Sawing, etc., 115, 118
Saws, care of, 199
Sectional blocks, 143
Series, electrotyping in, 200
Shaving machines, 123
Shavers, wax, 210
Shell, preparing for backing, 108;
holes in, 48, 100, 185; time re-
quired to deposit, 102; washing
shells, 207; wrinkles in, 208; cost
of shells, 177
Shootboard, 127
Silver electrotyping, 201
Silvering solution for glass, 202
Sink, 104
Smee battery, 15, 21
Solution, hot, remedy for, 204; sil-
vering, for glass, 202; specific
gravity of, 205; how to assay cop-
per solution, 203; conductivity of
solution, 202; testing the solution,
40.
Specific gravity, of solutions, 205;
how to find, 59
Spencer, Thomas, 7
Standards, brass, 140
Statistics, 205
Steel bath, 41
Stick, revising, 137
Sulphuric acid, 35, 161
Sweating, 206
Switchboard, 61
Temperature of bath, 48
Thickness of plate, 123
Three-color blocks, electrotypes of,
206
Tools for finishing, 119; revising, 136
Trimming and routing, 127; shoot-
board, 127; the lineholder, 129;
cutters, 130; the router, 131; book
plates, 134; beveling machine, 134
Type high standards, 142
Vats, glass rails for, 207
Verdigris, to remove, 207
Voltmeter and ammeter, 60, 165
Warping blocks, 147
Washing shells, 207
Watt, 208
Wax shavers, 210; wax kettles, 73,
209; wax molds, metallizing, 200;
wax engraving, 208; wax knife, its
use, 79; wax table, 73
Wet process of blackleading, 86
Wilcox, J. W., 10
Woodcuts, 64; to preserve, 210
Wrinkles in shells, 208
BOOKS AND
UTILITIES
Published or For Sale by
The Inland Printer Company
120-130 Sherman Street, Chicago
116 Nassau Street, New York
BOOKBINDING
Bookbinding — Paul N. Hasluck $0.54
Bookbinding and the Care or Books — Douglas Cockerell 1.35
Bookbinding for Amateurs — W. J. E. Crane 1.10
ManuaIi of the Art of Bookbinding — J. B. Nicholson 2.35
The Art op Bookbinding — J. W. Zaehnsaorf 1 . 60
COMPOSING-ROOM
Concerning Type — A. S. Camell $ .50
Correct Composition — Theodore Low De Vlnne 2.10
Covers and Title Pages in Various Color Combinations on Differ-
ent Stocks — An Interesting Showing of Artistic Designs —
Full of Sug:gestions 75
Imposition, a Handbook for Printers — F. J. Trezise 1.00
Impressions of Modern Type Designs 25
Modern Book Composition — Theodore Low De Vinne 2 . 10
Plain Printing Types — Theodore Low De Vinne 2.10
The Practical Printer — H. G. Bishop 1.00
Printing — Charles Thomas Jacobi 2.00
Printing and Writing Materials — Adeie Millicent Smith 1 . 60
Specimen Books:
Bill-heads 25
Envelope Comer-cards 25
Letter-heads 50
Professional Cards and Tickets 25
Programs and Menus 50
Covers and Title Pages 75
The Stoneman — Charles W. Lee 1.00
Title-pages — Theodore Low De Vinne 2 . 10
Vest-pocket Manual of Printing 50
DRAWING AND ILLUSTRATION
A Handbook of Ornament — Franz Sales Meyer $3.75
A Handbook op Plant Form 2 . 60
Alphabets — A Handbook of Lettering — Kdward F. Strange 1.00
Alphabets Old and New — Lewis F. Day 1.35
Decorative Designs — Paul N. Hasluck 54
Drawing for Printers — Ernest Knaufft 2.00
Drawing for Reproduction — Charles G. Harper 2.35
Human Figure — J. H. Vanderpoel 2.00
Lessons on Decorative Design — Frank G. Jackson 2.10
Lessons on Form — A. Blunck 3.15
Letters and Lettering — Frank Chouteau Brown 2.10
Lettering for Printers and Designers — Thomas Wood Stevens 1.00
Line and Form — Walter Crane 2.10
The Principles of Design — E. A. Batchelder 3.00
Theory and Practice of Design — Frank G. Jackson 2.60
ELECTROTYPING AND STEREOTYPING
Electrotypinq — C. S. Partridge. Being revised.
Partridge's Reference Handbook of Electrotypinq and Stereotyp-
ing— C. S. Partridge $1.50
Stereotyping — C. S. Partridge. Being revised.
ESTIMATING AND ACCOUNTING
A Money-making System foe the EmpIiOying Printer — Eden B.
Stuart $1.00
Actual Costs in Printing — Isaac H. Blanchard 5.00
Style 2. Annual Tables for Printers and Binders. Every practical
printer insists on revising his cost figures each year, and for that
purpose the cost-figfuring tables, together with the blank sheets for
use in annual inventory, have been bound togetlier in convenient
book form 2.00
Campsie's Pocket Estimate Book — John W. Campsie 75
Challen's Labor-saving Records — Advertising, Subscription, Job Print-
ers. 50 pages, flexible binding, $1 ; 100 pages, half roan, cloth sides,
$2, and $1 extra for each additional 100 pages.
Cost of Printing — F. W. Baltes 1.50
Employing Printer's Price-list — David Rainaley 1.25
Fundamental Principles of Ascertaining Cost of Manufacturing —
J. Cliff Dando 10.00
Hint for Young Printers Under Eighty — W. A. Willard 50
How to Make Money in the Printing Business — Paul Nathan 3.20
Nichols' Perfect Order and Record Book 3.00
Order Book and Record of Cost — H. G. Bishop 3.00
Printer's Insurance Protective Inventory System — Charles S.
Brown 10 . 00
Starting a Printing-office — R. C. Mallette 1.60
LITHOGRAPHY
Album Lithographique (specimens) $1.50
Handbook of Lithography — David Cumming 2.10
Lithographic Specimens 3.50
Photo-lithography — George Fritz 1.85
Practical Lithography • — Alfred Seymour 2.60
The Grammar of Lithography — W. D. Richmond 2.10
MACHINE COMPOSITION
A Pocket Companion for Linotype Operators and Machinists — S.
Sandison $1 . 00
Correct Keyboard Fingbeino — John S. Thompson 25
Facsimile Linotype Keyboards 25
History of Composing Machines — John S. Thompson 2.00
Thaler Linotype Kbyboaed 4 . 00
The Linotype Operator's Companion — E. J. Barclay 1 .00
Thb Mechanism of this Linotype — John S. Thompson 2.00
MISCELLANEOUS
A Treatise on Photooravuhb — Herbert Deniston $2.25
The Art of Engraving 1 . 60
Author and Printer — F. Howard Collins 2.35
The Building of a Book — Frederick H. Hitchcock 2.20
Eight-hour-day Wage Scale ^ Arthur Duff 3.00
The Graphic Arts and Crafts Year-book, $5.00; foreign 5.80
Inks, Their Composition and Manufacture — C. Ainsworth Mitchell
and T. C. Hepworth 2.60
Manufacture ok Ink — Siginund Lehner 2.10
Miller's Guide — John T. Miller 1 . 00
Oil Colors and Printing Inks — L. E. Endes 2.60
Practical Papermaking — George Clapperton 2.60
Printer's Handbook of Trade Recipes — Charles Thomas Jacobi.... 1.85
Writing for the Press — Robert Luce 1.10
NEWSPAPER WORK
Establishing a Newspaper — O. F. Byxbee $ .50
Gaining a Circulation — Charles M. Krebs 50
Perfection Advertising Records 3.50
Practical Journalism — Edwin L. Shuman 1.35
PRESSWORK
A Concise Manual of Platen Presswork — F. \V. Thomas $ .25
Color Printer — • John F. Earhart.
The Harmonizer — John F. Earhart 3.50
Tympan Gauge Square 25
Overlay Knife 25
Practical Guide to Embossing and Die Stamping 1.50
Stewart's Embossing Board, per dozen 1.00
PROCESS ENGRAVING
Penrose's Process Year-book, 1906-7 $2.85
Photoengraving — H. Jenkins; revised and enlarged by N. S. Amstutz 3.00
Photoengraving — Carl Schraubstadter, Jr 3 . 00
Photo-mechanical Processes — W. T. Wilkinson 2.10
Photo-trichromatic Printing — C. G. Zander 1.50
Prior's Automatic Photo Scale 2.00
Reducing Glasses 35
Three-color Photography — Arthur Freiherrn von Hubl 3.50
PROOFREADING
BiGELow's Handbook of Punctuation — Marshall T. Bigelow $ .55
Culinary French 35
English Compound Words and Phrases — F. Horace Teall 2.60
Grammar Without a Master — William Cobbett 1.10
The Orthoepist — Alfred Ayres 1 . 35
Webster's Pocket Dictionary 50
Pens and Types — • Benjamin Drew 1.35
Proofreading and Punctuation — Adele Millicent Smith 1.10
Punctuation — F. Horace Teall 1.10
Stylebook op the Chicago Society of Proofreaders 30
The Art op Writing English — J. M. D. Meiklejohn, M.A 1.60
The Verbalist — Alfred Ayres 1.35
Typographic Stylebook — W. B. McDerniutt 50
AVilson's Treatise on Punctuation — • John Wilson 1.10
PAMPHLET GIVING CONTENTS OF EACH BOOK
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405 Hiigard Avenue, Los Angeles, CA 90024-1388
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