During the eight months which were employed in the work of excavation the preparatory works of the casting had been carried on simultaneously with extreme rapidity. A stranger arriving at Stones Hill would have been surprised at the spectacle offered to his view.
At 600 yards from the well, and circularly arranged around it as a central point, rose 1,200 reverberating ovens, each six feet in diameter, and separated from each other by an interval of demi-toise. The circumference occupied by these 1,200 ovens presented a length of two miles.Being all constructed on the same plan, each with its high quadrangular chimney, they produced a most singular effect.
It will be remembered that on their third meeting the committee had decided to use cast iron for the Columbiad, and in particular the white description. This metal, in fact, is the most tenacious, the most ductile, and the most malleable, and consequently suitable for all moulding operations;and when smelted with pit coal, is of superior quality for all engineering works requiring great resisting power, such as cannon, steam boilers, hydraulic presses, and the like.
Cast iron, however, if subjected to only one single fusion, is rarely sufficiently homogeneous;and it requires a second fusion completely to refine it by dispossessing it of its last earthly deposits. So long before being forwarded to Tampa Town, the iron ore, molten in the great furnaces of Coldspring, and brought into contact with coal and silicium heated to a high temperature, was carburized and transformed into cast iron.After this first operation, the metal was sent on to Stones Hill.They had, however, to deal with 136,000,000 pounds of iron, a quantity far too costly to send by railway.The cost of transport would have been double that of material.It appeared preferable to freight vessels at New York, and to load them with the iron in bars.This, however, required not less than sixty-eight vessels of 1,000 tons, a veritable fleet, which, quitting New York on the 3rd of May, on the 10th of the same month ascended the Bay of Espiritu Santo, and discharged their cargoes, without dues, in the port at Tampa Town.Thence the iron was transported by rail to Stones Hill, and about the middle of January this enormous mass of metal was delivered at its destination.
It will easily be understood that 1,200 furnaces were not too many to melt simultaneously these 60,000 tons of iron. Each of these furnaces contained nearly 140,000 pounds weight of metal.They were all built after the model of those which served for the casting of the Rodman gun;they were trapezoidal in shape, with a high elliptical arch.These furnaces, constructed of fireproof brick, were especially adapted for burning pit coal, with a flat bottom upon which the iron bars were laid.This bottom, inclined at an angle of 25 degrees, allowed the metal to flow into the receiving troughs;and the 1,200 converging trenches carried the molten metal down to the central well.
The day following that on which the works of the masonry and boring had been completed, Barbicane set to work upon the central mould. His object now was to raise within the center of the well, and with a coincident axis, a cylinder 900 feet high, and nine feet in diameter, which should exactly fill up the space reserved for the bore of the Columbiad.This cylinder was composed of a mixture of clay and sand, with the addition of a little hay and straw.The space left between the mould and the masonry was intended to be filled up by the molten metal, which would thus form the walls six feet in thickness.This cylinder, in order to maintain its equilibrium, had to be bound by iron bands, and firmly fixed at certain intervals by cross-clamps fastened into the stone lining;after the castings these would be buried in the block of metal, leaving no external projection.
This operation was completed on the 8th of July, and the run of the metal was fixed for the following day.
“This fête of the casting will be a grand ceremony,”said J.T.Maston to his friend Barbicane.
“Undoubtedly,”said Barbicane;“but it will not be a public fête.”
“What!Will you not open the gates of the enclosure to all comers?”
“I must be very careful, J. T.Maston.The casting of the Columbiad is an extremely delicate, not to say a dangerous operation, and I should prefer its being done privately.At the discharge of the projectile, a fête if you like—till then, no!”
The president was right. The operation involved unforeseen dangers, which a great influx of spectators would have hindered him from averting.It was necessary to preserve complete freedom of movement.No one was admitted within the enclosure except a delegation of members of the Gun Club, who had made the voyage to Tampa Town.Among these was the brisk Bilsby, Tom Hunter, Colonel Blomsberry, Major Elphinstone, General Morgan, and the rest of the lot to whom the casting of the Columbiad was a matter of personal interest.J.T.Maston became their cicerone.He omitted no point of detail;he conducted them throughout the magazines, workshops, through the midst of the engines, and compelled them to visit the whole 1,200 furnaces one after the other.At the end of the twelve-hundredth visit they were pretty well knocked up.
The casting was to take place at twelve o'clock precisely. The previous evening each furnace had been charged with 114,000 pounds weight of metal in bars disposed cross-ways to each other, so as to allow the hot air to circulate freely between them.At daybreak the 1,200 chimneys vomited their torrents of flame into the air, and the ground was agitated with dull tremblings.As many pounds of metal as there were to cast, so many pounds of coal were there to burn.Thus there were 68,000 tons of coal which projected in the face of the sun a thick curtain of smoke.The heat soon became insupportable within the circle of furnaces, the rumbling of which resembled the rolling of thunder.The powerful ventilators added their continuous blasts and saturated with oxygen the glowing plates.The operation, to be successful, required to be conducted with great rapidity.On a signal given by a cannon-shot each furnace was to give vent to the molten iron and completely to empty itself.These arrangements made, foremen and workmen waited the preconcerted moment with an impatience mingled with a certain amount of emotion.Not a soul remained within the enclosure.Each superintendent took his post by the aperture of the run.
Barbicane and his colleagues, perched on a neighboring eminence, assisted at the operation. In front of them was a piece of artillery ready to give fire on the signal from the engineer.Some minutes before midday the first driblets of metal began to flow;the reservoirs filled little by little;and, by the time that the whole melting was completely accomplished, it was kept in abeyance for a few minutes in order to facilitate the separation of foreign substances.
Twelve o'clock struck!A gunshot suddenly pealed forth and shot its flame into the air. Twelve hundred melting-troughs were simultaneously opened and twelve hundred fiery serpents crept toward the central well, unrolling their incandescent curves.There, down they plunged with a terrific noise into a depth of 900 feet.It was an exciting and a magnificent spectacle.The ground trembled, while these molten waves, launching into the sky their wreaths of smoke, evaporated the moisture of the mould and hurled it upward through the vent-holes of the stone lining in the form of dense vapor-clouds.These artificial clouds unrolled their thick spirals to a height of 500 toises into the air.A savage, wandering somewhere beyond the limits of the horizon, might have believed that some new crater was forming in the bosom of Florida, although there was neither any eruption, nor typhoon, nor storm, nor struggle of the elements, nor any of those terrible phenomena which nature is capable of producing.No, it was man alone who had produced these reddish vapors, these gigantic flames worthy of a volcano itself, these tremendous vibrations resembling the shock of an earthquake, these reverberations rivaling those of hurricanes and storms;and it was his hand which precipitated into an abyss, dug by himself, a whole Niagara of molten metal!
在挖井工程進行的那八個月時間里,鑄炮的準備工作也以極快的速度同時在進行。如果一個外地來的人來到亂石崗,他會對呈現(xiàn)在眼前的景象感到十分驚訝。
在離井口六百碼的地方,圍繞中心點壘起了一千二百個反射爐,每個爐子直徑六英尺,彼此間隔半托瓦茲。這一千二百個反射爐連接起來形成一條線的話,可長達兩英里。它們?nèi)际且粋€模式,都有一個四角形的高大煙囪,景象十分壯觀。
大家記得,委員會召開第三次會議時,便決心使用鑄鐵鑄造哥倫比亞大炮,還特別指定用灰鑄鐵來造。這種金屬的確更加有韌性,有延展性,更加易于鍛壓,易于鏜孔,適應(yīng)各種模具鑄模;而且,經(jīng)泥煤處理之后,質(zhì)地上乘,適合制作各種高強度的機件,比如大炮、蒸汽壓路機、水壓機等。
不過,鑄鐵如果只經(jīng)過一次熔化的話,很難保持質(zhì)地均衡,必須通過第二次熔化,除去它最后的那些泥土雜質(zhì)之后,才能變得純凈無瑕。因此,鐵礦石在運往坦帕城之前,必須先在科爾德斯普林的高爐里加工處理,在高溫之下與炭和硅接觸,進行碳化,并轉(zhuǎn)化成鑄鐵。經(jīng)過第一道工序之后,鑄鐵被運到亂石崗。但是,一億三千六百萬磅的鑄鐵,如果通過鐵路運輸?shù)脑?,運費十分昂貴,比材料的費用多一倍??磥恚诩~約租一些船,裝上鑄鐵錠更劃算一些;但這也起碼得租六十八條載重一千噸的大船,那可真算得上一支船隊了。五月三日,這支大船隊駛離紐約,于當月十日在圣埃斯皮里圖灣靠岸,毫發(fā)未損地停泊在坦帕城港口。船上的鑄鐵被卸到碼頭,裝到通往亂石崗的火車上。一月中旬[43],這堆積如山的金屬終于運抵目的地。
不難想象,要同時熔煉這六萬噸鑄鐵,一千二百個熔爐也不算太多。每個熔爐可容納將近十四萬磅的金屬。它們都是按照當年為鑄造羅德曼大炮所需之鑄鐵的模式建造的,呈梯形,非常低矮。加熱裝置和煙囪都在熔爐兩端,因而熔爐各個部位都能均勻受熱。熔爐全都用耐火磚制成,只裝置著一個用以燃燒泥煤的鐵架,以及一張擺放鑄鐵錠的“爐床”。這張“爐床”呈二十五度角傾斜,以便熔化了的金屬得以流入承流器里;然后,一千兩百條槽溝便將金屬液引向中央基坑之中。
井壁和坑洞工程完工后的第二天,巴比凱恩便著手制造內(nèi)模:在坑洞的中心,以它的軸心為基準,立起一個九百英尺高、直徑九英尺的圓柱,它毫厘不差地填滿留給哥倫比亞大炮炮膛的空間。該圓柱由黏土和沙土混合制成,其中摻了一些干草和稻草。鑄模和井壁之間留下的空隙得灌滿金屬液,這些金屬液將成為六英尺厚的炮筒壁。為了讓這個大圓柱保持平衡,必須用一些鐵框架將它固定住,并每隔一段用橫梁插入井壁,加以支撐。炮壁鑄成之后,這些橫梁便與已凝固的金屬契合在一起,外表看不出任何痕跡了。
七月八日,鑄模工程宣告結(jié)束,第二天將開始鑄炮。
“鑄炮的開工儀式肯定很精彩?!盝.T.馬斯頓對他的朋友巴比凱恩說道。
“當然,”巴比凱恩回答道,“不過,那不會是一個公眾的節(jié)日!”
“怎么!您不把圍墻的門打開讓人們前來參觀嗎?”
“小心為佳,馬斯頓。鑄造哥倫比亞大炮盡管不能說是一種危險的試驗,但也是一種大意不得的試驗?zāi)?。我寧愿關(guān)起門來鑄造它。到發(fā)射炮彈的時候,如果愿意的話,倒是可以慶賀一番,但在這之前,慶祝是絕對不可以的?!?/p>
巴比凱恩主席說的是有道理的。這種試驗可能會出現(xiàn)一些預(yù)料不到的危險,而觀者如云的話,一旦遇到危險,場面必然一片混亂,無法控制。必須保證試驗不受任何干擾。除了前來坦帕城的大炮俱樂部會員們的一個代表團之外,任何人都不得進入圍墻內(nèi)。該代表團成員包括瀟灑倜儻的比爾斯比、湯姆·亨特、布洛姆斯貝瑞上校、埃爾菲斯通少校、摩根將軍等人,對他們來說,鑄造哥倫比亞大炮已經(jīng)變成他們個人的事情了。J.T.馬斯頓充當起他們的向?qū)?,向他們講解每一個細節(jié),帶他們四處參觀,去彈藥庫,去車間,去機器中間,還硬要讓他們一個一個地參觀那一千二百個熔爐。等參觀到第一千二百個熔爐時,他們已經(jīng)實在是累得受不了了。
鑄炮在正午時開始。前一天,每座爐子都裝滿了十一萬四千磅的鐵錠,交叉疊放著,以便熱氣得以在鐵錠中間自由流動。從早晨起,那一千二百座熔爐便開始向空中噴吐出大量的火焰,大地都在顫動著。裝填了多少磅的金屬,就得燃燒多少磅的煤。因此,六萬八千噸煤同時在陽光的照射下噴出濃煙,形成一塊厚厚的黑幕布。很快,熔爐圈內(nèi)的溫度直線上升,讓人無法忍受,再加上轟隆聲響成一片,如雷聲滾滾。大功率的鼓風機也夾雜其中,呼呼地連續(xù)地往爐內(nèi)吹風,氧氣充足,爐火很旺。要想成功,就得快速完成這項工作。號炮一響,每個熔爐就必須立即把金屬液引出,讓爐子排空。一切安排就緒之后,工頭們和工匠們都懷著一種激動而焦急的心情,等待著那決定性時刻的到來。熔爐圈內(nèi)的人全都被疏散開了,而每個熔爐爐長都守候在金屬液槽邊,堅守著自己的崗位。
巴比凱恩及其同事們站在近旁的一個高處,觀看出爐。他們前面放著一門大炮,等工程師一發(fā)信號便發(fā)炮。正午前幾分鐘,有小滴小滴的金屬液開始流出,承流器漸漸積滿。鑄鐵完全熔化之后,還得在承流器里待上片刻,以便讓金屬液里的雜質(zhì)沉淀下去。
十二點整。突然一聲炮響,一道黃褐色的光亮在空中一閃。一千二百個金屬液槽同時打開,只見一千二百條火蛇向中央基坑爬行著。到了基坑邊,只聽見一陣可怕的巨響,金屬液便嘩嘩地向九百英尺深的深淵滾滾地傾瀉著。場面十分壯觀,非常激動人心。金屬液一邊向空中噴吐著滾滾濃煙,一邊讓鑄模里的濕氣蒸騰,變成一股股的蒸汽,從井壁的通氣孔中冒出來。這時候,大地都在顫動。這些假云假霧呈螺旋狀向天穹升騰,直達五百托瓦茲的高空。如果遠方有個野人,看到這番景象的話,還以為佛羅里達州深處可能有一處火山在噴發(fā)。不過,那可不是火山爆發(fā),不是龍卷風,不是暴風雨,不是大自然在發(fā)威。不是!全都不是!是人的威力,是人在制造這些紅褐色的蒸汽,是人在制造這些可與火山媲美的巨大火焰,是人在制造這些宛如地震一般的、可怕的、震耳欲聾的聲響,是人在制造這些與狂風驟雨匹敵的轟鳴,是人的雙手在把像尼亞加拉大瀑布似的金屬液傾入自己挖出的深淵中!