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The Official SmithCraft Home Page
: Glassmaking

(Adapted from The Encyclopedia of Glass by Margret @ PernMUSH )


I) Glass Melting
a) Furnaces and Fuels
b) Glass Compsition
c) Structure of glass

II) Flat Glass
a) Cylinder Glass
b) Mirrors

III) Bottles

IV) The Chemistry Of Color

V) Tools
a) Small Tools
b) Larger Tools


I) Glass Melting
The temperature at which raw materials fuse to produce glass is between 1300 - 1500 Degrees Celsius, depending on the composition of the glass required and the raw materials used. Achieving such a high temperature is difficult with current Pernese technology, thus a softer sort of glass must be used, a glass with a higher proportion of alkali than Earth glass. High-alkali glasses have a lower resistance to atmospheric attack and that is why they may be covered with a white film, showing the surface symptoms of aging glass (aka glass sickness). On Pern, we must be content with solid fuel in the form of wood (highly unlikely) or Cromcoal (black rock, whatever), and we have no way of re-using the heat from waste gases of combustion. Yet.

Ia) Furnaces and Fuels
As far as I can tell, Pern has only one method of melting glass: pot melting. Pot melting is used for a smaller quantity of handmade glass (including lead crystal), and also for production of flat glass, bottles, table glass, and so on.
Pot furnaces rely on a large chamber, through which the hot waste gasses are conducted through to the atmosphere. This chamber is constructed out of refractory bricks, and has refractory or metal tubes through which air, needed for the combustion of fuel, is led into the furnace. On the outward journey the hot gases pre-heat the combustion air in the tubes and thus higher temperatures and fuel savings are achieved.
Fuel on Pern is more difficult to gauge, seeing as how we have few trees. However, the predominant fuel producer should be coal.
As an interesting note, a Glass Master usually weighs out his secret raw materials by hand, in proportions only known to him, mixing them by hand, and passing them on to his heir when he feels they're ready...mystery ;)

Ib) Glass Compositions
The main raw materials for the soda-lime-silica glass used in bottle glass, flat glass and domestic ware are: sand (silica), limestone (calcium carbonate), feldspar (alumina compounds), dolomite (calcium and magnesium) and cullet (broken glass). Other raw materials like salt cake (sodium sulfate), sodium nitrate, selenium, cobalt, chromium oxide, sulfur, carbon, iron, etc., are used in smaller quantities in colouring and decoulorizing.
Raw materials must be as pure as possible, especially when colourless glass is required; the iron impurity in sand and limestone is the glass makers greatest enemy. The sand used must have a very low iron content, and according to Anne, Keroon and Igen are good places to get some. However, much sand must still be chemically purified (to remove a natural green tinge). Decoulorizing takes advantage of the fact that green, red and blue tend to cancel each other out, leaving a colourless appearance. Green comes from iron, and is canceled by a bit of red (caused by selenium) and some blue (thanks to cobalt). The result is really a muddy-grey colour, which appears colourless to the human eye (now as for dragons...)

Ic) The Structure of Glass
Glass is a liquid, not a solid. How do we know this? Well first look at glass's transparency. The property of transparency can indicate that glass is either a single crystal, or a liquid. Because of the fact that when glass is cracked or broken, it can be seen that the fracture has no tendency to travel in one direction or another, it can bee inferred that glass is not likely to be a single crystal, but moreso a super-cooled liquid.

II) Flat Glass
Pernese glass makers have two ways of producing flat glass. They can either cast it from a crucible or pot containing molten glass on to a metal tube and then rolled it to the required thickness, or they used a method that also produces hollow glassware and crown glassware. To make crown glass, the glass-blower gathered a very large gather (A blob of molten glass attached to the end of a blow-pipe or gathering iron, prior to making the glass object. The gather is formed by dripping and twirling the pipe in the pot until a blob begins to form.) at the end of his blow-pipe, and blew a very large bubble. Then he removed the bubble from the blow-pipe, transferred it on to a rod and the spun the rod at a high speed, allowing the centrifugal force to flatten, open and spread the bubble. He was then left with a large disc, around a meter in diameter, at the end of his rod. Then he cuts the glass off the rod toughens it (by annealing it, more on this later), cools it, and cuts it into windows. Only small pieces of glass could be made in this manner...perhaps why windows are so small...

IIa) Cylinder glass
To make larger windows, the glass blower would blow long cylinders of glass. The more glass he could get in the gather, the longer and thicker the cylinder would be. To get this, the glass maker gathered the glass from a pot, started blowing and by rolling and shaping the gather, he was able to collect more glass and again shape it and blow it gently. After a suitable sized cylinder was reached, he swung it in a pit to elongate. Both ends of the cylinder were cut off, then the cylinder was cut lengthwise and placed in a re-heating furnace. As the cylinder was heated, it softened, and by using metal rods, was opened up and flattened out. Sheets of up to two meters can be made using this method, by the quality is poor compared to Earth glass.

IIb) Mirrors
Mirrors are made of flat glass with reflective backings made with tin, lead, or a mixture of other metals. Comonly, metals are also used as a frame, but on Pern, wood and hide seem more practical. Another method is to add a metalic mixture to hot glass globes, and use the globes to coat the interior. The globes can then be cut into peices and framed. As a whole, mirrors are rare.

III) Bottles
The use of a blow-pipe enables a glass maker to gather a glob of glass at the end of a pipe and blow a bubble, which he is then able to shape into a bottle. The first shape is known as the blank or parison. The parison is much smaller and thicker than than the final shape, but looks similar in form. Then the parison is re-heated and the bottle is finnaly blown from it. Wood and iron moulds can also be used, but must be dipped in water frequently to avoid being burned.
The neck of the bottle, intended to recieve the stopper or some other form of closure, is made last. The finnaly shaped bottle is cut off from the blowing pipe, and the neck is finished up (buffed, smoothed and so on).

IV) The Chemistry of Color
By adding certain substances to raw glass, a glass maker is able to change the colour of the finished glass product. On Pern, we know /what/ happens when we add different types of chemicals, but not neccesarrily why. What follows is a basic list of what chemicals cause what colors, the most importaint thing to remeber that the exact hue is variant. It depends on the purity and oxidation of the agent. For best results, experiment.
Principal Colouring Agents

IRON...................green, blue and yellow
COBALT.................blue
GOLD...................ruby red
COPPER.................green, blue and red
IRON and COPPER........black
NICKEL.................deep blue (violet in lead glass)

V) TOOLS
This is your basic list of tools that a Glasscrafter on Pern /might/ use. The larger ones would be seen in any glassmaking shop, while a glass crafter might lug around the smaller ones in a tool belt/box.

Va) Small Tools

glass cutter...: a pen length long item, with a diamond tipped wheel on it, 
                 set in a metal holder, that cuts glass
glass pliers...: small pliers, used for gripping glass when you snap the cut
gum............: eraser for removing paint from glass
needle.........: needle on a stick for etching in painted glass
stick..........: sharp pointed stick for etching in painted glass
pen knife......: 1" blade on a wood handle. NOT diamond but hard metal
lathykin.......: looks like a dinner knife, made of hard wood and used for 
                 opening lead seals on stained glass
pallet knife...: thin blade used for spreading lead on stained glass seals
lasting nail...: finger-length long pin, looks like a fat, rounded, sharp nail.
                 Used for pinning plane glass to the work table
stopping knife.: arced blade, 2 finger-lengths long, and set in a wooden handle.
                 It's used for bending warm lead.
wire brush.....: hand sized wire brush for polishing metal attached to the glass
waxing tool....: a copper quill tip, attached to some hard wood or metal handle.
                 It's used for coating wax on glass so you don't paint certain 
                 areas
muller.........: a peice of granite or glass, flat at the base, for grinding 
                 pigment

Vb) Large Tools

blow pipe.: a hollow metal tube used to gather molten glass from the pot and 
            then to blow air through in order to shape the glass
chair.....: A bench with flat arms at eaither end, used by workers while making
            glass. The arms are for resting the blow pipe on.
mould.....: mould of wood, metal or clay, that you put the gathered molten 
            glass, using the blow pipe, and blow into, to make the glass fit the
            mould.
gadget....: a special rod with a spring clip on the end, that grips the foot of
            the just made glass. It trims off the rim and softens the edges.
marver....: an iron table on with the gather is rolled into an evenly shaped mass
partmolds.: partial moulds used to shaped the first gather
pot.......: a crucible made of fire clay in which the batch of glass ingreadients
            is heated before being transfered to the furnace.
pincers...: used to shape the cooling glass, open up the lips

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