Henley's Twentieth Century Formulas, Recipes and Processes. Various

quantities of aluminum now, both for spinning and stamping, are paying their men by the piece the same amount that they formerly paid on brass and tin work, and it is stated that the men working on this basis make anywhere from 10 to 20 per cent more wages by working aluminum.

      After aluminum has been manufactured into the shape of an article, the next process is the finishing of it. The best polish can be obtained by first cutting down the metal with an ordinary rag buff on which use tripoli, and then finish it with a dry red rouge which comes in the lump form, or that which is known as “White Diamond Rouge.” One point, however, that it is necessary to observe carefully is that both the tripoli and the rouge should be procured ground as fine as it is possible to grind them; for, if this is not done, the metal will have little fine scratches all over it, and will not appear as bright and as handsome as it otherwise would.

      If it is desired to put on a frosted appearance, this can either be done by scratch brushing or sand blasting. A brass wire scratch brush, made of crimped wire of No. 32 to No. 36 B. & S. gage, with three or four rows of bristles, will probably give the best results. This work of scratch brushing can be somewhat lessened, however, if, before applying the scratch brush to the surface of the aluminum, the article is first cut down by the use of a porpoise-hide wheel and fine Connecticut sand, placing the sand between the surface of the aluminum and the wheel, so that the skin and the irregularities on the surface are removed, and then putting the article on a buffing wheel before attempting to scratch brush it. This method, however, is probably more advantageous in the treating of aluminum castings than for articles manufactured out of the sheet metal, as in the majority of cases it is simply necessary before scratch brushing to cut down the article with tripoli, and then polish it with rouge as already described, before putting on the scratch brush; in this way the brush seems to take hold quicker and better, and to produce a more uniform polish.

      An effect similar to the scratch-brush finish can be got by sand blasting, and by first sand blasting and then scratch brushing the sheets, a good finish is obtained with very much less labor than by scratch brushing alone. Another very pretty frosted effect is procured by first sand blasting and then treated as hereinafter described by “dipping” and “frosting,” and many variations in the finish of aluminum can be got by varying the treatment, either by cutting down with tripoli and polishing, scratch brushing, sand blasting, dipping, and frosting, and by combinations of those treatments. A very pretty mottled effect is secured on aluminum by first polishing and then scratch brushing and then holding the aluminum against a soft pine wheel, run at a high rate of speed on a lathe, and by careful manipulation, quite regular forms of a mottled appearance can be obtained.

      The dipping and frosting of aluminum sheet is probably the cheapest way of producing a nice finish. First remove all grease and dirt from the article by dipping in benzine, then dip into water in order that the benzine adhering to the article may be removed, so as not to affect the strength of the solution into which it is next dipped. After they have been taken out of the water and well shaken, the articles should be plunged in a strong solution of caustic soda or caustic potash, and left there a sufficient length of time until the aluminum starts to turn black. Then they should be removed, dipped in water again, and then into a solution of concentrated nitric and sulphuric acid, composed of 24 parts of nitric acid to 1 part of sulphuric acid. After being removed, the article should be washed thoroughly in water and dried in hot sawdust in the usual way. This finish can also be varied somewhat by making the solution of caustic soda of varying degrees of strength, or by adding a small amount of common salt to the solution.

      In burnishing the metal use a bloodstone or a steel burnisher. In burnishing use a mixture of melted vaseline and coal oil, or a solution composed of 2 ta­ble­spoon­fuls of ground borax dissolved in about a quart of hot water, with a few {85} drops of ammonia added. In engraving, which adds materially to the appearance of finished castings, book covers, picture frames, and similar articles made of sheet, probably the best lubricant to use on an engraver’s tool in order to obtain a clean cut, which is bright, is naphtha or coal oil, or a mixture of coal oil and vaseline. The naphtha, however, is preferred, owing to the fact that it does not destroy the satin finish in the neighborhood of the cut, as the other lubricants are very apt to do. There is, however, as much skill required in using and making a tool in order to give a bright, clean cut as there is in the choice of the lubricant to be used. The tool should be made somewhat on the same plan as the lathe tools already outlined. That is, they should be brought to a sharp point and be “cut back” rather far, so as to give plenty of clearance.

      There has been one class of work in aluminum that has been developed lately and only to a certain extent, in which there are great possibilities, and that is in drop forging the metal. Some very superior bicycle parts have been manufactured by drop forging. This can be accomplished probably more readily with aluminum than with other metals, for the reason that it is not necessary with all the alloys to work them hot; consequently, they can be worked and handled more rapidly.

      ALUMINUM, TO CLEAN: See Cleaning Preparations and Methods.

      ALUMINUM ALLOYS: See Alloys.

      ALUMINUM BRONZE: See Alloys under Bronzes.

      ALUMINUM CASTINGS: See Casting.

      ALUMINUM PAPER: See Paper.

      ALUMINUM PLATING: See Plating.

      ALUMINUM POLISHES: See Polishes.

AMALGAMS

       Table of Contents

      See also Easily Fusible Alloys under Alloys.

      The name amalgam is given to alloys of metals containing mercury. The term comes to us from the alchemists. It signifies softening, because an excess of mercury dissolves a large number of metals.

      Preparation Of Amalgams.

      —Mercury forms amalgams with most metals. It unites directly and readily, either cold or hot, with potassium, sodium, barium, strontium, calcium, magnesium, zinc, cadmium, tin, antimony, lead, bismuth, silver, and gold; directly, but more difficultly, with aluminum, copper, and palladium. This combination takes place oftenest at the ordinary temperature; certain metals, however, like aluminum and antimony, combine only when heated in presence of quicksilver.

      Quicksilver has no direct action on metals of high fusing points: manganese, iron, nickel, cobalt, uranium, platinum, and their congeners. Still, amalgams of these metals can be obtained of butyrous consistency, either by electrolysis of their saline solutions, employing quicksilver as the negative electrode, or by the action of an alkaline amalgam (potassium or sodium), on their concentrated and neutral saline solutions. These same refractory metals are also amalgamated superficially when immersed in the amalgam of sodium or of ammonium in presence of water.

      Processes for preparing amalgams by double decomposition between an alkaline amalgam and a metallic salt, or by electrolysis of saline solutions, with employment of mercury as the negative electrode, apply a fortiori to metals capable of combining directly with the quicksilver. The latter of these methods is especially utilized for the preparation of alkaline earthy metals by electrolytic decomposition of the solutions of their salts or hydrated oxides with quicksilver as a cathode.

      General Properties Of Amalgams.

      —Amalgams are liquid when the quicksilver is in great excess; solid, but readily fusible, when the alloyed metal predominates.

      They have a metallic luster, and a metallic structure which renders them brittle. They even form crystallized metallic combinations of constant proportions, dissolved in an excess of quicksilver, when the excess is separated by compression in a chamois skin, or by filtration in a glass funnel of slender stem, terminating with an orifice almost capillary.

      According as the fusing heat of a metal is less or greater than its combination heat with quicksilver, the amalgamation of this metal produces an elevation or a lowering of temperature. Thus {86} potassium, sodium, and cadmium, in alloy with