BOOK I. NOMENCLATURE AND METHODS. CHAPTER I. TECHNOLOGY.

Previous

Confusion in Use of Terms.—Porcelain as an Instance.—Derivation of Ceramic.—Pottery.—Faience.—Majolica.—Mezza-Majolica.—Composition of Porcelain.—Origin of Word.—Where first made.—When introduced into Europe.—Hard and Soft Paste.—Soft Porcelain of Venice, Florence, England, France.—Hard Porcelain invented at Meissen by BÖttcher.—Vienna.—Discovery of Kaolin in France.—Biscuit.

enlarge-image
Fig. 20.—Blue-glazed Pottery. Egyptian.
Fig. 20.—Blue-glazed Pottery. Egyptian.

IT will be necessary as we proceed to make use of certain terms, the meaning of which should be defined with as much exactness as possible. It may be premised that considerable confusion exists in the nomenclature of the art. This has arisen partly from the want of precision in the language employed by writers, and partly from diversity of usage. As an illustration, the word “porcelain” may be adduced. The material to which the Egyptians applied a glaze, and which was very largely used in making ornaments and small images, has been called, and is constantly spoken of, as Egyptian porcelain (Fig. 20). In reality the substance is not porcelain, having neither the transparency nor the hardness of that ware, but a compound between porcelain and earthen-ware. The word was also used by the Italians in the sixteenth century, to designate their finer qualities of majolica. An equally incongruous application of it is made in the case of Lambeth faience, which is described by the manufacturers as a “kind of porcelain.” Such words as faience, hard and{49} soft porcelain, majolica, stone-ware, etc., are in continual use by writers upon ceramic art, and a few of the more important will now be defined.

Allusion has already been made to the derivation of the word “ceramic.” Viewing the subject more prosaically, the name ?e?a?? was applied by the Greeks to pottery in general, and also to a large jar; and several derivatives were used for the designation of different vessels. The potter himself was called ?e?ae??, and the pot-market ?e?ae????. Although the matter has been differently viewed, it appears probable that the root of all the above words is ?e?a?, a horn. The horn was used at a very early period as a drinking-cup, and a more decided air of probability is thus given to the above assumption, since Bacchus was the reputed parent of [Greek: keramos ?e?a??], or Ceramus. However philologists may ultimately settle this matter, the word “ceramic” is now employed to designate the potter’s art and its productions.

The word “pottery” is variously used. Its root is the Latin potum, a drinking-vessel. It is applied, according to general English usage, to all wares distinguished by their opacity from translucent porcelain. The French word poterie, on the other hand, is applied to all vessels, including those made of porcelain. The latter fact has led to a slight confusion in the use of the English word. One writer makes the assertion in one place, that the words “earthen-ware” and “pottery” have limited and distinctive meanings, the former applying only to vessels of the coarser qualities, the latter to the finest products of the fictile art, “including even porcelain.” In another place, he draws a distinction between pottery and porcelain, and in the latter course he is followed by the present writer.

Faience, fayence, or fayance, is a French word applied to every kind of glazed earthen-ware. According to the earlier French usage, the term included porcelain, but more lately it has been applied only to pottery.

The word “majolica,” as now employed, has almost the same meaning as faience. A more limited signification is attached to it by some. The writer of the article on pottery in “Appleton’s CyclopÆdia” says it is used “to signify all faience of Italian manufacture. Lately the word has been used as almost, if not quite, synonymous with faience.” A more recent writer has said, “In its now common acceptation, the word is applied to all kinds of decorated pottery made{50} in Italy, or made in colors and styles imitating the old Italian work. But when you read a book on pottery written during the present century by an expert, you will do well to remember that the word in that book means exclusively Italian decorated pottery of the fifteenth, sixteenth, seventeenth, and eighteenth centuries, in the old Italian styles. It does not include Italian vases made in imitation of German, French, Dutch, or English wares.”

The changing meaning of this word is a good illustration of the careless use of the terms employed in treating of ceramic art. Originally, majolica, or maiolica, had a meaning different from any of those given above. The name is derived from Majorca, the largest of the Balearic Islands, between which and Italy intercourse is known to have taken place in the twelfth century; and two hundred years later, the commercial transactions of Majorca were of a very extensive kind. The evidence in favor of the above derivation of the word is conclusive. Scaliger says distinctly that the Italian pottery derived its name of majolica from Majorca, where the pottery was most excellent. Ferrari believes that “the use of majolica, as well as the name, came from Majorca, which the ancient writers called Majolica.” The “Dictionary della Crusca” adds weight to these authorities. Such being the case, it seems probable that the Italians derived part of their knowledge of making majolica from the place which gives it its name. Even admitting that the Saracens who settled in Sicily, and the Moors expelled from Spain who settled in Italy, initiated the Italians in the art, nothing is thereby detracted from the importance of Majorca. The fact is left unaffected that the intercourse with the Balearic group enabled the Italians to find a name for the ware they admired so much. On trying to imitate it, the ware called “mezza-majolica” was produced. The red clay was first thinly coated with white earth, upon which the colors were laid. After a partial firing, lead glaze was applied, and lustre pigments gave the ware the iridescence characteristic of real majolica. It was after this that tin enamel was used in place of a white slip; and the lustre pigments being applied as before, fine majolica was produced. It will thus be seen that the words “mezza-majolica” and “majolica” were originally applied only to wares showing the reflet mÉtallique, or lustre. This limited use of the word was observed down to the middle of the sixteenth century. Piccolpasso,{51} writing in 1548, in no case applies the name to the painted and glazed wares of his own production. All the glazed earthen-ware of Italy was thereafter called majolica; and the application of the word has been growing wider ever since. Mr. Fortnum says, “We think, with M. Jacquemart, M. Darcel, Mr. J. C. Robinson, and others, that the word ‘maiolica’ should be again restricted to lustred wares.” Any such attempt must necessarily end in failure. The popular employment of a word is not to be controlled by its scientific application. The tendency is in the opposite direction—toward the establishment of a universal usage by which faience and majolica will become convertible terms.

The different kinds of ware, such as Lucca della Robbia, Palissy, Doulton, and Limoges, will be found described under the countries to which they belong.

Porcelain is composed of two ingredients, one of which—kaolin—is infusible, and the other—petuntse—vitrifies, and envelops the kaolin. It is translucid, and therein differs from pottery, which is opaque. As to the origin of the word, we have already seen that it was, in its Italian form, applied to majolica in the sixteenth century; and the word “pourcelaine” occurs two centuries earlier. It was used to designate Oriental china in the fifteenth century. Mr. J. F. Davis, in his work on the Chinese (1840), quotes Marsden to the effect that the word “porcelain,” or porcellana, was applied by Europeans to the ware of China, from the resemblance of its fine polished surface to that of the univalve-shell so named; while the shell itself derived its appellation from the curved or gibbous shape of its upper surface, which was thought to resemble the raised back of a porcella, or little hog. When porcelain was first invented in China is not exactly known. The combination was discovered in the province of Honan about eighteen hundred years ago; but the date cannot be more specifically fixed. From China it was introduced into Persia, Egypt, and Barbary, at a very early period, and was thence imported into Europe, where, however, it was not generally known until 1518. The first specimens of Oriental porcelain known to have reached England were given by Philip of Austria to Sir Thomas Trenchard, of Wolverton, in 1506.

To continue its history in Europe, it is necessary to observe that there are two kinds of porcelain—the natural, or pate dure, and the{52} artificial, or pate tendre. The latter cannot stand so high a temperature as the former, and can be scratched with a knife, which the hard porcelain resists. The soft-paste was the first to be discovered in Europe. Chemists, struck with the beauty of the Chinese porcelain, and impelled by a desire to imitate, began to experiment in the sixteenth century; and the first success, of which substantial evidences now exist, was gained at Florence in 1580. It is said that a Venetian potter made porcelain sixty or seventy years earlier; but no specimen known to be his is now in existence. After that of Florence, the next discovery was made by Dr. Dwight, of Fulham, England, in 1671; and in 1695 the secret was penetrated by M. Chicanneau, at St. Cloud, France. By that time the Florentine porcelain and process had been forgotten, and the English and French ceramists pursued perfectly independent investigations.

The problem of making a hard-paste porcelain resembling that of the Orient still remained unsolved. No chemistry could avail the experimenters so long as the materials were wanting. To the accidental discovery of a bed of kaolin, Europe owed its first hard porcelain. This important event took place about the year 1709, and the circumstances leading to it are full of interest.

John Frederic BÖttger, or BÖttcher, was a chemist’s assistant in Berlin, and having fallen under suspicion as an alchemist, he took refuge in Saxony, which was then under the electorate of Augustus II. The elector, having questioned him as to his researches in the forbidden science, placed him in the laboratory of a chemist who was in search of the philosopher’s stone. While working to that end, BÖttcher surprised himself by producing something akin to Chinese porcelain. The course of his experiments was turned at once from the channel in which it had run. The king gave him every facility for continuing his experiments and working out his secret. He was first established at Meissen, then at KÖnigstein, and last at Dresden. The first results were comparatively rude; then came a reddish stone-ware, and afterward a dull white porcelain. How long his experiments might have been continued, or what might have been their ultimate result, cannot be estimated, had not an accidental discovery brought the object at which he was aiming suddenly within his reach. John Schnorr, a wealthy iron-founder, riding one day in the vicinity{53} of Aue, near Schneeberg, Saxony, noticed that his horse lifted his feet with difficulty. On examination he found that the clay was very white and peculiarly adhesive. Schnorr, although rich, would gladly be richer, and avarice made him ingenious. Why not use this white earth in the making of hair-powder? was the question which occurred to him. The commodity was dear, and clay was a cheap substitute. He took a quantity with him, made the new hair-powder, and was successful in his venture. In due course, the new powder reached BÖttcher, and he, in turn, found an original use for the white earth. Inquiring into the nature of the powder, he found it was earthy, and at once tried it in his laboratory. The powder was kaolin, and hard porcelain was discovered. A manufactory was established at Meissen, of which BÖttcher was director until his death, in 1719.

In 1720, the manufacture was begun at Vienna, whither the secret was carried by an escaped foreman from BÖttcher’s works at Meissen.

It is very curious to note that the first manufacture of hard porcelain in France was due to a chance discovery almost identical with that made in Germany. Kaolin had been found at AlenÇon, but the porcelain made from it was not pure in color. In 1765, the wife of a surgeon found near St. Yrieix a peculiarly soft earth of great whiteness. Being poor, Madame Darnet was also economical. Unlike Schnorr, her thoughts turned in the direction rather of keeping down household expenses than of adding to her income. The earth had a soft, oily touch, and the good lady thought that it might answer all the purposes of soap. Her husband sent a sample to a chemist, and it was soon afterward decided to be kaolin. The manufacture of hard porcelain was begun at SÈvres in 1769, the quarries of St. Yrieix supplying both the kaolin and petuntse. As illustrating the ingratitude of the world, it may be mentioned that the humble instrument by whose aid France reached its lofty eminence in the manufacture of porcelain was, for about sixty years, left unrewarded. In 1825, Madame Darnet, spending her old age in poverty, received a pension from Louis XVIII.

Biscuit is the technical term applied to both pottery and porcelain before they are enamelled or glazed. In this condition, porcelain is of a dead white, and is not very well suited to receive decoration in colors which require a glaze to bring out their full beauty.{54}

CHAPTER II.
CLASSIFICATION.

Tabulated View.—Brongniart’s Division: Its Objections.—Classification adopted.—Leading Features and Advantages.—Distinctions between Different Bodies and Different Glazes.

IN order to avoid repetitions and explanations, and for the sake of lucidity, tabulated views of the different branches of ceramics are here presented. The first is least detailed, but gives the salient points of a systematic arrangement.

POTTERY Soft Unglazed Common brick. Earthen-ware.
Lustrous Greek pottery.
Glazed Some ancient and most modern faience.
Enamelled Robbia ware.
Hard Stone-ware.
Fire-brick.
PORCELAIN Soft Naturally soft English porcelain.
Artificially soft French porcelain, pate tendre, such as old SÈvres.
Hard China.
Dresden.
SÈvres.

The following is more full, and is to be ascribed to M. Brongniart:

FIRST CLASS, SOFT-PASTE.
1st Order. Baked clay without glaze.
2d Order. Lustred wares with silico-alkaline glaze.
3d Order. Glazed pottery with plumbiferous glaze.
4th Order. Enamelled pottery, in the enamel of which tin is used.
SECOND CLASS, HARD-PASTE (OPAQUE).
5th Order. Fine faience, uncolored paste with plumbiferous glaze.
6th Order. Stone-ware without glaze, or with salt or plumbiferous glaze.
THIRD CLASS, HARD-PASTE (TRANSLUCENT).
7th Order. Hard porcelain, paste and glaze both felspathic.
8th Order. English natural soft-paste porcelain—paste, argillaceous kaolin, pegmatite, phosphate of lime, etc.; glaze, boracic.
9th Order. French artificial soft-paste porcelain—paste, a frit, marly alkaline; glaze, alkaline containing lead, alkali, and silica.

{55}

If these tables be studied carefully, it will be found that in arranging the nine orders, a gradual ascent is made from the humblest ware—baked clay left unglazed—to the finest of artificial compounds. Its only objection—and it is one very likely to confuse an inexperienced student of the art—is, that, under the head of hard-paste pottery, are classed the soft-paste porcelains of England and France. The question is, also, very likely to suggest itself, why the distinction should be drawn between the soft-pastes of England and France, and the one called natural, the other artificial. The reason is that the paste of England is naturally soft, while that of France is made soft by the chemical action of certain of its ingredients. The classification has, on the other hand, the advantage of being in general use. Terms are employed in its construction which have a peculiar but well understood significance; and even in its errors there is a modicum of truth. Thus, although the artificial porcelain of France is invariably called pate tendre, or soft porcelain, it is not improperly classed under translucent hard-pastes. The error is in the distinctive name rather than in the classification. There is, in reality, very little difference in hardness between the hard-paste and the soft-paste; and although the glaze of the latter is not so hard as the body, the appellation soft-paste has been adjudged a misnomer. The question then came to be whether it might not be better to retain the old terms, with an explanation of their technical meaning, than to supplant them with something new. The latter course has been adopted, upon the ground of obviating meaningless and misleading distinctions. Both simplicity and a clear understanding of one of the most important practical divisions of our subject point toward a revision of the old system of grouping. Pottery and porcelain differ in one essential respect, and their varieties can also be classed according to the leading features of their composition, manufacture, or appearance. These differences have been taken as the basis of the following classification, against which, at least, none of the objections to that of M. Brongniart can be brought. It has been prepared by a distinguished French artist of the present time, and is offered in the hope that it may be intelligible, although it is not claimed to be either perfectly exact or altogether complete.

All wares are divisible into two great classes, viz., transparent porcelain and opaque earthen-ware.{56}

  • Porcelain may be natural or artificial
    • I. Natural porcelain is made from kaolinic clay. It may have—
      • 1. A pure felspathic glaze, such as porcelain of China, Japan, Limoges, SÈvres, Dresden, Berlin; or,
      • 2. No glaze, such as the biscuit porcelain of China or France.
    • II. Artificial porcelain may be made from alkaline clay, calcareous clay, or felspathic clay.
      • 1. Alkaline clay may have an alkaline glaze, either colorless or colored, or may be biscuit.
        • a. Alkaline glaze, colorless—Persia, China, St. Cloud, Limoges, SÈvres, Tournay.
        • b. Alkaline glaze, colored—Persia, China, Limoges, Deck.
        • c. Biscuit—Old SÈvres statuettes.
      • 2. Calcareous clay has a colorless boracic glaze, as in the case of the English china of Minton, Copeland, and Worcester.
      • 3. Felspathic clay is exemplified in the parian of Copeland, Minton, and Worcester.
  • Earthen-ware is of two kinds—that showing a non-vitrified fracture, and that showing a vitrified fracture.
    • I. Earthen-ware with non-vitrified fracture may have either a transparent glaze or an opaque enamel.
      • 1. Transparent glaze may be plumbiferous or alkaline, and in either case colorless or colored.
        • a. Plumbiferous.
          Glaze, colorless—Faience d’Oiron or Henri Deux ware, Wedgwood, Meakin, Creil, Montereau.
          Glaze, colored—Palissy, Nuremberg, Minton’s majolica.
        • b. Alkaline.
          Glaze, colorless—Persian faience, Chinese and Japanese faience; Deck, of Paris.
          Glaze, colored—Haviland or Limoges faience.
      • 2. Opaque enamel is stanniferous, and may be either colorless or colored.
        Stanniferous, colorless—Della Robbia, Rouen, Moustiers, Delft, Nevers.
        Stanniferous, colored—Colinot, Parville, Longwy.{57}
    • II. Earthen-ware with vitrified fracture may be either glazed or in biscuit. Of the former, the GrÈs of Germany, Beauvais, and Doulton may be taken as examples.

For convenience of reference, the same classification may be given in tabulated form:

CLASSIFICATION OF ALL KINDS OF WARE.
Translucent
Porcelain.
Natural Kaolinic paste Glaze of felspath, pure China, Japan, Dresden, Berlin, SÈvres, Limoges.
Biscuit Biscuit porcelain of Limoges and China.
Artificial Alkaline paste Glaze alkaline, colorless Persia, China, St. Cloud, Tournay SÈvres, Haviland.
Glaze alkaline, colored Persia, China, Deck, Haviland.
Biscuit Old SÈvres statuettes.
Calcareous Glaze boracic, color English china, Minton, Worcester, Copeland.
Felspathic paste Parian Copeland, Worcester, Minton.
Opaque
Earthen
Body.
Terres.
Earthen body
with a
non-vitrified
break
Transparent glaze. Plumbiferous glaze Glaze, colorless Faience Henri II., Wedgwood, Meakin, Creil, Montereau.
Glaze, colored Palissy, Nuremberg, Minton’s majolica.
Alkaline Glaze Glaze, colorless Faience of Persia, China, and Japan; Deck.
Glaze, colored Limoges faience of Haviland, Bracquemond, and Chaplet.
Opaque Stanniferous enamel Colorless Delia Robbia, Rovigo, Fontana, Rouen, Moustiers, Nevers, Delft, Ulysses de Blois, St. Clement.
Colored Colinot, Parville, Longwy.
Earthen body
with a
vitrified
break
Biscuit Boccaro, Bizen.
Glaze GrÈs from Germany.

Under the above arrangement, it will be observed that the distinction{58} between hard and soft porcelain and pottery is done away with. The first is divided into natural and artificial, the kaolinic paste being the only one coming under the former head, and the “soft-pastes” of both England and France coming under the latter. The subdivisions are made according to the glaze employed. The division of pottery into two classes, according to the nature of the body as revealed by fracture, is the most lucid and comprehensive. The subdivisions, as in the case of porcelain, are made according to the enamel or glaze applied to the ware. It is presumed that any one can distinguish between transparent and opaque wares, and thus tell porcelain from pottery, and similarly, tell whether the fracture of a broken specimen is vitrified or otherwise, and thus distinguish stone-ware, or grÈs, from ordinary earthen-ware.

In the matter of glazes, it requires a great deal of skill and long practice to tell one from another. All are transparent, with the exception of tin or stanniferous enamel. Felspathic glaze is that most readily recognized; but in the case of the others—the alkaline, plumbiferous, and boracic—they are very often only to be distinguished by their different effects upon the colors used in decoration.{59}

CHAPTER III.
COMPOSITION OF WARES AND GLAZES.

Hard and Soft Pottery and Porcelain.—Composition of Porcelain: Kaolin—Its Derivation and Ingredients—Petuntse—How prepared in China.—The European Process.—Differences between Chinese and European Porcelains.—Chemical Analysis.—English Porcelain and its Peculiarities: Its Average Composition.—How English Clay is prepared.—French Artificial Porcelain.—Parian.—Common Earthen-ware.: Table of Ingredients of different kinds.—General Table.—Glazes: Classes.—Brongniart’s Classification.—Difference between Enamel and Glaze.—Silicious Glaze.—History.—Use of Oxides.—Egyptian Processes.—Metallic Lustre.—Stanniferous Enamel: Its History.

THE division of pottery and porcelain into two great classes, hard and soft, is based upon the difference of their composition, their hardness of surface, and their power of resisting the action of fire. The simplest test is scratching with a knife or other instrument. Hard porcelain and pottery resist the metal, while the soft is marked. The former will also stand a temperature in the kiln at which the latter would crumble or fuse.

To understand the composition of porcelain, it is necessary to bear in mind that it is a compound of kaolin and petuntse, the former of which is infusible, and the latter fusible at a high temperature. The former constitutes the body of the piece, the latter gives it its translucency. The word “kaolin” is derived from Kaoling, the name of a mountain near King-teh-chin, one of the great centres of the manufacture in China. Kaolin is simply the result of the decomposition of granitic rock, and silica and alumina are its chief ingredients. Petuntse is pure felspar. The conditions in which these materials are found in China may be briefly stated. They are either in the form of stone or sand, from which the unsuitable parts are removed by the action of water. When they are thrown into the water, the fine particles which do not sink are collected and dried. The paste, before being used, is again put into water and strained through a sieve, so that only the finest is preserved, and used in making porcelain. The{60} materials are obtained from different parts of the country, and blended according to their respective qualities, as ascertained by the most systematic investigation and experiment. The European process is similar, the kaolin being first washed clear of all argillaceous impurity, and then mixed with felspar and silicious sand. Of the further similarity between the two, MM. Ebelman and Salvetat say:

1st. The kaolin and petuntse used in making paste for Chinese porcelain are chemically identical with the materials used in Europe. The Chinese kaolin is evidently disintegrated granite. Chemically, petuntse resembles the pegmatite of Limoges; mineralogically, it is to be classed with petrosilicious felspar.

2d. The mechanical preparation of the pastes of China and Europe is based upon similar methods.

3d. The Chinese paste is the more fusible of the two.

4th. The Chinese glaze is also the more fusible, on account of the addition of lime to the petuntse, which the French use pure.

It may be added that the Dresden, SÈvres, and Limoges porcelains are baked at a higher temperature, and are harder than the Chinese.

The basis of the natural pastes of Germany and France is 46.66 parts of silex, 40 of aluminous earth, and 13.33 alkaline earth, although the proportions vary, and the following may be nearer an average: Silex, 66; alumina, 30; potash, magnesia, and lime, 4. In the glaze the proportions are different, the silica largely preponderating: Silex, 73.4; alumina, 15.7; potash, lime, and magnesia, 10.9.

The following table is given by M. A. Salvetat as the result of analyses made at different times by himself and others:

Pastes. Silica. Alumina. Oxide
of Iron.
Lime. Magnesia. Potash. Soda.
China, 1st quality 69.00 23.60 1.20 0.30 0.02 3.30 2.90
China, 2d quality 70.00 22.20 1.30 0.80 traces 3.60 2.70
China, 3d quality 73.80 19.30 2.00 0.60 traces 2.50 2.30
China, 4th quality 68.94 21.30 3.48 1.14 traces 3.42 1.78
Meissen 58.50 35.10 0.80 0.30 traces 5.00 ....
Vienna 59.60 34.20 0.80 1.70 1.40 2.00 ....
Berlin 64.30 29.00 0.60 0.30 0.45 3.65 ....
Limoges 70.20 24.00 0.70 0.70 0.10 4.30 ....
SÈvres 58.00 34.50 .... 4.50 .... 3.00 ....
SÈvres (sculpture) 64.10 30.24 .... 2.82 traces 2.80 ....
Worcester 82.00 9.10 ..... 1.30 7.40 .... ....
Paris 71.20 22.00 0.80 0.80 .... 4.50 ....

{61}

The English artificial porcelain differs from the natural paste of China and the European continent chiefly in one particular. At first the compound used was white clay, white sand, and glass, the latter being employed to impart the necessary transparency. More recently bone came largely into use, and is now one of the distinctive ingredients of English paste. The phosphoric acid of that material was found to produce, in combination with the other materials, a clear, translucent body, of less strength than natural paste, but less liable to sink. The following may be taken as the mean composition: Bone, 47; kaolin, 34; felspar, 19. The kaolin is found in Cornwall, where a very large tract is formed chiefly of decomposed granite. The purest rock having been selected, it is placed on an inclined plane, upon which water can be turned. It is washed down into a trench, and thence into a catch-pit, and again into lower pits, in which successively the impure ingredients are retained, the water laden with the finer particles running into tanks, and there depositing its fine silt. The clay is partially dried, and cut into blocks, and in that shape reaches the potters. The manner in which the kaolin is prepared bears a very close resemblance to that adopted by the Chinese, as previously described. The glaze is composed of felspar, carbonate of lime, borax, and white-lead. Sometimes the kaolin is mixed with the bone and felspar in the proportions above specified, and sometimes the bone is made, in combination with silex and pearlash, into a frit.

The artificial or soft porcelain of France, exemplified in the old china of SÈvres, was produced by a very intricate and ingenious process. A frit was made of saltpetre, sea-salt, burnt alum, soda-ash, gypsum, and sand. This mixture, having been purified by partial vitrification, was ground, and mixed with chalk and marl. The glaze was as follows: Litharge, 38; sand, 27; calcined flint, 11; and the carbonates of soda and potash, 15 and 9 parts respectively.

The composition called parian, in which the potters of England and America have executed much beautiful work, varies considerably. Analysis of one specimen resulted thus: Silica, 58.57; alumina, 21; oxide of iron, 1; lime, 0.14; magnesia, 0.5; potash, 11.40; soda, 5.08.

The clay from which common earthen-ware is made is composed to a great extent of silica and alumina, with admixtures of iron, lime, and magnesia. An average combination is 60 parts silex, 30 alumina,{62} 7 iron, and 2 lime. These proportions vary very widely, certain substances appearing in one place and not in another. In some, carbon is found; in others, quartz, sand, marl, or chalk, as the case may be. The work of classification, except in a very extended form, is thus rendered somewhat difficult. Possibly the following series of tables will serve our purpose most intelligibly.

Pottery. Silica. Alumina. Oxide of
Iron.
Lime. Magnesia. Water. Carbon.
German 63.90 12.76 10.24 1.04 0.52 9.98 1.02
Scandinavian 64.02 10.77 11.23 2.48 0.05 9.97 1.00
Old Gallic 62.22 18.36 5.71 1.17 0.47 10.56 0.78
Peruvian 67.04 10.83 10.17 3.24 0.28 7.07 1.00
Etruscan 64.02 12.49 8.53 3.00 1.83 8.13 2.00

In the following carbon does not appear, and the proportion of silica increases:

Pottery. Silica. Alumina. Oxide of
Iron.
Lime. Magnesia. Water.
Roman 64.00 17.77 10.23 4.86 .... 2.23
Middle Ages 72.55 20.27 2.54 1.04 .... 3.00
Egypt 81.00 13.50 1.00 3.00 .... 1.90
Egypt 92.00 4.00 .... 2.00 0.60 0.40
Persian 90.00 1.50 1.50 3.00 0.80 0.60
Jerusalem 87.16 5.50 .... 3.00 0.78 ....
Arabian 89.95 3.87 .... 2.00 0.51 3.00

The Egyptian, compounded as above, is that which has been commonly known as Egyptian porcelain. Many of the better known wares of Europe and the East have a common characteristic in the calcareous nature of their pastes. The silica decreases and the lime increases, while carbonic acid appears as a new ingredient.

Pottery. Silica. Alumina. Magnesia. Oxide of
Iron.
Carbonic Acid. Lime.
Lucca della Robbia 49.65 15.50 0.17 3.70 8.58 22.40
Majorca 48.00 17.50 1.17 3.75 9.46 20.12
Spain (old) 46.04 18.45 0.87 3.04 13.96 17.64
Valencia (modern) 51.55 20.52 1.24 2.63 10.42 13.64
Delft 49.07 16.19 0.82 2.82 13.09 18.01
Persian 48.54 12.05 0.30 3.14 16.72 19.25
Nevers 56.49 19.22 0.71 2.12 6.50 14.96
Rouen 47.96 15.02 0.44 4.07 12.27 20.24

{63}

Of the potteries which hold a place between the hard and soft wares are the Palissy and Henri Deux. The composition of the former is 67.50 silica, 28.51 alumina, 1.52 lime, 2.05 oxide of iron, with a very slight admixture of alkalies. That of the latter is 59.10 silica, and 40.24 alumina.

From what has been said, it will be seen that the difference between earthen-ware, stone-ware, and porcelain is to be attributed to a few minor ingredients, to the preparation, and to the degree of heat to which they are subjected. The following table may be studied for the sake of making comparisons:

Common earthen-ware... Silica, 60; alumina, 30; iron, 7; lime, 2.
Blue clay... Silica, 46; alumina, 38; iron, 1; lime, 1.
Staffordshire clay... Pipe-clay, 40; kaolin, 25; quartz, 20; felspar, 15.
Stone-ware... Felspar, 25; quartz or silex, 25; soda, 25; plastic clay, 15; boracic acid, 10.
Porcelain... Silica, 66; alumina, 30; potash, 3.4; magnesia and lime, 1.1.
Porcelain glaze... Silica, 73.4; alumina, 15.7; potash, 7.4; magnesia and lime, 2.2.
English porcelain... Kaolin, 34; bone, 47; felspar, 19; soda ash, 36.
Old SÈvres soft-paste... Saltpetre, 22; sea-salt, 7.2; burnt alum, 3.6;
soda ash, 3.6; gypsum, 3.6; sand, 60. This was made into a frit and mixed—75
parts frit, 17 chalk, and 8 of calcareous marl.

As to the glazes applied to clay or opaque ware, we have seen that they are broadly distinguished as translucent plumbiferous or alkaline, opaque stanniferous, and salt glaze. The distinction is also to be observed between glaze and enamel, although they are often confounded. Thus, according to M. Brongniart, there are three kinds of glaze—varnish, enamel, and couverte—all of which are vitrifiable. Varnish he describes as a transparent and plumbiferous material, melting at a lower temperature than that required for baking the paste; enamel, an opaque, generally stanniferous (containing tin) substance; couverte, a substance which melts at a temperature equal to that required for baking the paste. Birch, on the other hand, draws a distinction between glaze and enamel. In one place he speaks of “opaque glasses or enamels,” and again, “among the Egyptians and Assyrians, enamelling was used more frequently than glazing.” So, also, Fortnum, who, dividing pottery into soft and hard, subdivides the former into unglazed, lustrous, glazed, and enamelled. The glazed he again divides into silicious, or glass-glazed, and plumbeous, or lead-glazed, both of which are transparent. The word “glaze” is thus{64} more correctly applied to the covering, which does not alter the color of the body upon which it is laid, and “enamel” to that which obscures the body.

Glass, or silicious glaze, is formed by fusing sand with an alkali—potash or soda. When to this is added the oxide of lead, transparent plumbiferous glaze is the result; and when to both of these oxide of tin is added, we have opaque stanniferous enamel. The glass and plumbeous glazes may be colored with a variety of other oxides, without losing their transparency.

When or where glaze was first applied to clay is not known. Like many other branches of knowledge and many nations, it has its roots in the East, but whether we are indebted for it to India, Egypt, or Assyria, cannot now be decided. Upon this question Dr. Birch says:

“The desire of rendering terra-cotta less porous, and of producing vases capable of retaining liquids, gave rise to the covering it with a vitreous enamel or glaze. The invention of glass has been hitherto generally attributed to the Phoenicians; but opaque glasses or enamels, as old as the eighteenth dynasty, and enamelled objects as early as the fourth (B.C. 3000-2000), have been found in Egypt. The employment of copper to produce a brilliant blue-colored enamel was very early both in Babylonia and Assyria, but the use of tin for a white enamel, as recently discovered in the enamelled bricks and vases of Babylonia and Assyria, anticipated by many centuries the rediscovery of that process in Europe in the fifteenth century, and shows the early application of metallic oxides. This invention apparently remained for many centuries a secret among the Eastern nations only, enamelled terra-cotta and glass forming articles of commercial export from Egypt and Phoenicia to every part of the Mediterranean. Among the Egyptians and Assyrians enamelling was used more frequently than glazing, and their works are consequently a kind of faience, consisting of a loose frit or body, to which an enamel adheres after only a slight fusion. After the fall of the Roman Empire the art of enamelling terra-cotta disappeared among the Arab and Moorish races, who had retained a traditional knowledge of the process. The application of a transparent vitreous coating, or glaze, over the entire surface, like the varnish of a picture, is also referable to a high antiquity, and was universally adopted either to enhance the beauty of{65} single colors or to promote the combination of many. Innumerable fragments and remains of glazed vases, fabricated by the Greeks and Romans, not only prove the early use of glazing, but also exhibit, in the present day, many of the noblest efforts of the potter’s art.”

The use of oxides is also very ancient. The Egyptians employed that of copper for the production of their turquoise-blue, and possibly also for their green, manganese for violet, iron or silver for yellows, etc. The same processes were known in Babylon and Assyria. To the Persians and Arabians the application of metallic lustres was known at a very early period. Plumbiferous, or lead-glaze, was employed by the Babylonians, and the knowledge of its composition was in all probability imported thence among the Greeks, and by them may have been carried into Southern Italy.

The course of enamel is equally difficult of definition. Although used in Egypt, Babylon, and Assyria, it does not appear to have supplanted the lead-glaze; and for a long period all traces of it are lost, until it reappeared among the Arabs. We next meet with it as a distinctive characteristic of the potteries of Spain. It was also known to the Saracenic and Moorish potters of Sicily, and from either of these sources may have found its way into Italy.{66}

CHAPTER IV.
MANUFACTURE AND DECORATION.

Divisions of Chapter.—Japanese Method of Preparing Porcelain Clay.—Old SÈvres Soft Porcelain.—Pug-Mill.—Blunger.—Early Italian Methods.—Shaping the Clay.—Moulding among the Egyptians, Greeks, Italians, and at the Present Day.—Moulding Porcelain.—Japanese Method.—European.—Throwing.—The Potter’s Wheel in all Countries.—Baking and Firing.—Egyptian, Greek, Italian, and Japanese Kilns.—Those of Modern Europe and America.—Times of Firing.—Glazing and Painting.—Metallic-Lustre Majolica.—Japanese Methods.—Glazing Stone-ware.—Natural and Artificial Porcelain.

HAVING thus glanced at the different wares, and learned the composition of the leading kinds of paste and glaze, the attention is next attracted by the processes of preparing the materials, and the different methods of manufacture. The levigation of kaolin and making of porcelain have already been touched upon incidentally. The subject of the present chapter naturally divides itself into the following heads:

  • Preparation of the paste;
  • Forming the vessel to be made;
  • Baking or firing;
  • Preparation of the glaze or enamel;
  • Applying the glaze or enamel;
  • Laying on the color and painting.

To what has been said about the preparation of English and Chinese kaolin pastes, little need be added. There is, however, a peculiarity about the Japanese custom not unworthy of notice. In that country the raw material, whether kaolin, quartz, or felspar, is reduced to a powder by a horizontal balancing pounder of primitive construction, and worked by water-power. Two long beams are joined together at one end by an iron-cased crossbar, and a trough is attached to the other. This frame is then erected near a stream, so that the water will fall into the trough. The weight of the water carries the trough down, and the other end is raised to a corresponding height. When the trough has fallen so far that, by reason of the{67} slope, the water runs out and thus takes off the weight at that end, the iron-shod beam at the other descends, and falling into a stone mortar in which the raw material has been placed, in a very short time pulverizes it. The above is the only machine employed by the Japanese. After being pulverized, the paste is sifted, mixed with water, and decanted, and the water is finally drained off through matting and sand. The fine clay to be used in making porcelain is deposited on the mat.

For the old SÈvres soft porcelain, the frit was crushed, cleared of salts, and ground in water. The paste was then mixed with the other ingredients, as previously given in the table.

enlarge-image
Fig. 21.—Vertical Pug-Mill, in use at Union Porcelain Works, Greenpoint.
Fig. 21.—Vertical Pug-Mill, in use at Union Porcelain Works, Greenpoint.

To prepare clay for making earthen-ware or stone-ware, machines are now generally used. That for the coarser kind of wares, such as bricks or common stone-ware jars, is a pug-mill (Figs. 21 and 22). The clay, having been brought by water to a certain workable consistency, is put into the mill. This is simply a cylindrical box, with blades projecting from the inside, and having in the centre a shaft also armed with blades. By the revolving of the shaft the clay is worked into a perfect pulp, and in that condition issues from a hole in the lower end of the mill. Should any hard substance have resisted the knives, it is removed by hand.

enlarge-image
Fig. 22.—Horizontal Pug-Mill, in use at Union Porcelain Works, Greenpoint.
Fig. 22.—Horizontal Pug-Mill, in use at Union Porcelain Works, Greenpoint.

For the finer kinds of earthen-ware, into the composition of which pipe-clay, kaolin, quartz, and felspar enter, the ingredients are mixed in a “blunger.” This machine is not unlike a steam butter churn, there being a shaft passing from end to end, in exactly the same way, and{68} armed with similar paddles. Water is added to the ingredients, and, as the blunger turns, these are all thoroughly mixed into a “slip,” which is drawn off at the bottom. It is then strained and finally passed through a pug-mill, and is ready for use.

Piccolpasso, or the Cavaliere Cipriano Piccolpasso Durantino, who wrote in Italy, in 1548, gives very minute information regarding the processes of the potters of his time and country. The clay was either washed down by rivers or taken from pits. In the former case it was taken from the river-bed when the water was low, and was placed in holes in the ground, either after or without being dried in the sun. The object of keeping it was to allow all impurities to pass off. Where there were no rivers, a series of pits was dug in any convenient hollow, and connected by a channel. The earth was washed down by the rain into these pits, and purified by the passage from one to another. In some cases it was found necessary to place the earth on sieves exposed to the rain, through which the finer particles were washed into receivers placed below. Instead of using a pug-mill, the Italian potters put the earth upon a table, where it was beaten with an iron instrument, and thoroughly kneaded and cleaned by hand.

The next process is the formation or shaping of the vessel. This may be done either by moulding or by “throwing” upon the potter’s wheel. Both of these methods are very ancient. The Egyptians used moulds in making bricks before they resorted to the use of fire for baking them. Their lamps, etc., also give evidence of having been moulded. The Greeks used modelling tools for their ornaments, and also for pithoi, or casks. Afterward moulding was resorted to, and by that means the potter made certain parts of the vases—the handles and feet, for example, and also the ornaments. The entire vessel was sometimes produced by moulding, such as the rhyta, or drinking-cups, with terminations in the form of animals’ heads. AmphorÆ, cups, saucers, and vases of many shapes were formed by the same process.

We must refer to Piccolpasso again for the manner in which the Italian potters moulded. Like the Greeks, they appear first to have moulded the parts, such as the handles, which were fixed to the body after it was fashioned. They then, again like the Greeks, began to imitate metal vessels, and thus were brought directly to the process of moulding upon their models, or shaped pieces ornamented in relief.{69} The moulds were made of plaster of Paris, and, when ready, the clay was worked into a cylindrical shape, and sliced by drawing a wire across it. The thickness of the slice was regulated and made uniform by pieces of wood placed at either side of the lump of clay. A slice was then taken and pressed into the mould, and another for the other side into the other half of the mould. Any excess appearing over the edges was cut away. The feet were similarly moulded, and subsequently fixed to the body by means of a composition of clay and fine wool cuttings. In making vases or ewers, moulds were made for both sides, and joined at the front and back. A wire was used to cut off the superfluous clay, and the two pieces were joined together with the composition above mentioned. The handle was fastened on by the same means.

Moulds are at the present day used in every branch of the art, from the lowest to the highest. Drain-pipes are made in a cylindrical mould, with a smaller and solid cylinder inside. The clay is pressed between the two concentric cylinders. In making earthen-ware, the clay is sometimes rolled out and spread upon a block of the desired shape. In making plates, the clay is spread over a round block, and moulded by a form pressed down from above. When plaster of Paris is used, the process is very like that described by Piccolpasso. The mould is in two parts, into each of which the clay is pressed. The two pieces are then brought together, and the seams joined. Or a plaster mould may be used, into which the paste is poured in a liquid state. The absorption of the liquid by the plaster soon gives the clay sufficient consistency to take the necessary shape. Subsequent shrinkage allows its removal from the mould. After a partial drying, the ware is dressed or “shaved.” The process is a very delicate one, especially in the finer kinds of ware, in which a finely polished surface is necessary. The piece is placed on a lathe, and cut to the necessary thickness, and receives its ornamental lines, or has the mouldings applied. The handles are then attached, and, after drying, the piece is ready for the kiln.

The moulding of porcelain requires very great care, on account of the fragility of many of the pieces. In Japan, clay moulds were exclusively used until within the past three years. After being thrown or moulded, and slightly dried, the pieces are shaped by means of{70} sharp metal instruments in the same lathe on which the throwing is done. A coat of pure white clay is then laid on for the purpose of enhancing the beauty and heightening the effect of the color. This having been done, the piece is ready for the preliminary firing. When large pieces are made, the European method is to pour the necessary thickness of slip over the inside of the mould, against the side of which it is kept by means of forcing air into the interior, after covering the surface, or exhausting the air through the mould. When sufficiently dry to support its own weight, the piece is fired.

enlarge-image
Fig. 23.—A Potter in Palestine.
Fig. 23.—A Potter in Palestine.

The other method of forming the wares is technically called “throwing” upon the potter’s wheel, and is suitable for all circular{71} vessels, or those with modifications of the circular shape. The process is very simple. A piece of clay, large or small, as required, is thrown down on the revolving disk, and, as it whirls round, is formed by the potter’s hand into the requisite shape. The potter’s wheel is one of the oldest mechanical appliances in existence. Its invention was due to the desire of remedying the irregularities of handiwork, and as such was a valuable and in every way wonderful achievement. It brought symmetry and all the varieties of circular form within the potter’s reach. Its inventor is unknown. The prehistoric vases of Greece were made upon the wheel. It was used in Egypt at least four thousand years ago. In Assyria, and among the Jews, its use is attested by the frequent reference made to it in Scripture.

It is curious to find a modern traveller, Dr. W. M. Thomson, speaking thus in “The Land and the Book” of the potter of Palestine. “I have been out on the shore again examining a native manufactory of pottery, and was delighted to find the whole Biblical apparatus complete, and in full operation. There was the potter sitting at his ‘frame,’ and turning the ‘wheel’ with his foot (Fig. 23). He had a heap of prepared clay near him, and a pan of water by his side. Taking a lump in his hand, he placed it on the top of the wheel (which revolves horizontally) and smoothed it into a low cone, like the upper end of a sugar-loaf; then, thrusting his thumb into the top of it, he opened a hole down through the centre, and this he constantly widened by pressing the edges of the revolving cone between his hands. As it enlarged and became thinner, he gave it whatever shape he pleased with the utmost ease and expedition.”

enlarge-image
Fig. 24.—An Egyptian Pottery. (From a Tomb.) a, e, i, p, the wheels on which the clay was put. (Fig. 1 forms the inside and lip of the cup as it turns on the wheel a. b, c, d are cups already made. (Fig. 2 forms the outside of the cup, indenting it with the hand at the base, preparatory to its being taken off. (Fig. 3 has just taken off the cup from the clay, l. (Fig. 4 puts on a fresh piece of clay. (Fig. 5 forms a round slab of clay with his two hands. (Fig. 6 stirs and prepares the oven, q. At s is the fire, which rises through the long, narrow tube or chimney of the oven, upon the top of which the cups are placed to bake, as in v. (Fig. 7 hands the cup to the baker, 8. Fig. 9 carries away the baked cups from the oven.
Fig. 24.—An Egyptian Pottery. (From a Tomb.) a, e, i, p, the wheels on which the clay was put. (Fig. 1 forms the inside and lip of the cup as it turns on the wheel a. b, c, d are cups already made. (Fig. 2 forms the outside of the cup, indenting it with the hand at the base, preparatory to its being taken off. (Fig. 3 has just taken off the cup from the clay, l. (Fig. 4 puts on a fresh piece of clay. (Fig. 5 forms a round slab of clay with his two hands. (Fig. 6 stirs and prepares the oven, q. At s is the fire, which rises through the long, narrow tube or chimney of the oven, upon the top of which the cups are placed to bake, as in v. (Fig. 7 hands the cup to the baker, 8. Fig. 9 carries away the baked cups from the oven.

The entire process of making clay vessels in Egypt has been preserved in a scene depicted in a tomb (Fig. 24). The clay was first trampled underfoot to give it evenness of consistency and make it more perfectly plastic. It was then prepared for working by being rolled out, and was then put on the wheel. The latter was either round or polygonal and flat. It was placed upon a stand, and was turned with one hand, while with the other the potter shaped the clay, and, as he worked, sat either upon a low stool or upon the ground. Both the hollowing and external shaping were done by hand. The furnaces were hollow cylinders, about six and a half feet high, in which the wares to be baked were placed about half-way up. An{72} aperture at the bottom admitted draught sufficient to drive the flames out of the top of the furnace. Among the Greeks the wheel was also employed at a very early period, so early that its inventor or introducer is forgotten. One of the Grecian legends ascribes the honor to{73} DÆdalus, an Athenian of royal descent, and inventor of the wedge, axe, and other mechanical contrivances. Another legend ascribes it to Talos, the nephew of DÆdalus, whose murder compelled the latter to seek safety in flight. To whatever individual or city the credit may be due, the wheel was used by Grecian potters from time immemorial. They turned it with the foot—as did the Egyptians also at one period—and it appears that the turning was sometimes left to an assistant. The process was almost identical with that described above. The clay was placed upon the wheel and shaped by the hand, and when the vessel was of so large a size as to make it necessary, one hand supported and shaped the clay from the inside. In this way the body of the vessel was made, and before the clay dried, the feet, handles, and other parts were fixed to it. Before the wheel was known, the vessels were hollowed out and shaped by the hand, and the larger vessels were subsequently made in the same way.

It is said that the potter’s wheel was invented in Japan, in the year 724, by a priest named Giyoki, and the event at once raised the potter’s art into very high estimation. In Arita, the wheel consists of a fly-wheel and revolving disk, the latter placed about a foot above the former, and connected with it by a hollow wooden prismatic axle. In the centre of the working disk, and between the three sides of the prism, a hollow piece of porcelain is inserted. The whole is then placed upon a pointed stick fixed firmly in the ground, in such a way that the entire weight is supported upon the point of the upright wood. As that point comes in contact with the inserted porcelain, friction is reduced to a minimum. Vessels of any size can be thrown in this way—from the huge basin three feet in diameter to the smallest work which the potter’s hand has shaped. A driving cord is employed for turning the wheel when very large pieces are being made.

The Italians of the sixteenth century used the wheel in the same way, fashioning the clay with the hands and certain tools of wood and iron (Fig. 25).

It would thus appear that the potter’s wheel improved in due course of time. At first it was merely a horizontal revolving disk turned by hand; then it consisted of a three-feet shaft with the disk on the top, and a driving-wheel below to be turned by the potter’s foot; later still, it was turned by means of a foot-board, like that of{74} a turning-lathe or printing-press; afterward the driving-wheel was separated from the disk which it turned by means of a connecting rope or band, and was worked by an assistant; more recently, steam has been brought in to the saving of labor, and in many large factories is the chief power used.

enlarge-image
Fig. 25.—Venetian Potters of the Sixteenth Century. Showing two kinds of potter’s wheels in use among them. (From engraving by V. Biringuccio.)
Fig. 25.—Venetian Potters of the Sixteenth Century. Showing two kinds of potter’s wheels in use among them. (From engraving by V. Biringuccio.)

It is almost unnecessary to add that when throwing was resorted to in place of moulding, the subsequent operations of shaving, polishing, and attaching the handles and ornaments were performed in the same manner as that described above.

We now reach the third process, that of baking or firing. Sun-dried bricks have been found in nearly every part of the world. They were introduced into Spain by the Arabs, and in the New World have been found from Mexico to Peru. In Egypt they represent the earliest works of the potter; and from that country, Assyria, and Babylonia, relics of the rudest stage of the art of working in clay have reached our own time. The climate of Egypt was such that unbaked bricks were sufficiently lasting for architectural purposes, and walls, tombs, and entire pyramids were constructed of them. The use of sun-dried clay was restricted in Assyria to bricks and small figures of an apparently religious character. In Babylon, as in Assyria, similar bricks were used as foundations for buildings. Among the Greeks sun-dried clay was widely employed. Many of their temples and the walls of some of their fortified cities were constructed of bricks dried in the sun. Even statues and models were made of unbaked clay.

The kind of furnace in use among the Egyptians at a very early period has already been described. No remnant of those used by the Greeks has been discovered, and all the information regarding them has been derived from representations on pottery or gems. A tolerably correct idea of the more ancient ones may be conveyed by describing them as tall baker’s ovens, into which the wares were pushed{75} and baked like loaves. There are several vases now in existence upon which furnaces of this kind are depicted. A kylix from Vulci, and now at Munich, is remarkable for the scene depicted on it. One of the epigrammata of Homer, entitled [Greek: ‘O Kaminos ‘? ?a???]—“The Furnace,” has been translated by Cowper. The explanatory preface is attributed to Herodotus.

“Certain potters, while they were busied in baking their ware, seeing Homer at a small distance, and having heard much said of his wisdom, called to him, and promised him a present of their commodity—and of such other things as they could afford—if he would sing to them, when he sang as follows:

“‘Pay me my price, potters! and I will sing.
Attend, O Pallas! and with lifted arm
Protect their oven: let the cups and all
The sacred vessels blacken well, and, baked
With good success, yield them both fair renown
And profit, whether in the market sold
Or streets, and let no strife ensue between us.
But, O ye potters! if with shameless front
Ye falsify your promise, then I leave
No mischief uninvoked to avenge the wrong.
Come, Syntrips, Smaragdus, Sabactes, come,
And Asbestus; nor let your direst dread
Omodamus delay! Fire seize your house!
May neither house nor vestibule escape!
May ye lament to see confusion mar
And mingle the whole labor of your hands!
And may a sound fill all your oven, such
As of a horse grinding his provender,
While all your pots and flagons bounce within.
Come hither also daughter of the Sun,
Circe, the sorceress, and with thy drugs
Poison themselves, and all that they have made!
Come also Chiron, with thy numerous troop
Of Centaurs, as well those who died beneath
The club of Hercules, as who escaped,
And stamp their crockery to dust! Down fall
Their chimney! Let them see it with their eyes,
And howl to see the ruin of their art,
While I rejoice: and if a potter stoop
To peep into his furnace, may the fire
Flash in his face and scorch it, that all men
Observe thenceforth equity and good faith.’”

The scene on the kylix at Munich is supposed to represent Homer among the potters. The furnace is on the extreme right, and has a{76} tall chimney. The fire is seen below. In front of it is a man who has apparently been placing a vase in the oven, and behind him comes another carrying what may be a large jar on his shoulder. The next figure is that of Homer, holding a staff; behind him is a vase, and a youth carrying another vessel toward the furnace. The next group shows the operation of “throwing,” a boy turning the wheel while an old man shapes the vessel. On the left is a young man sitting and holding on his knees a vase to which he seems to be attaching the handle. The entire composition is interesting, since—assuming the old man with the crook to be Homer, and not the proprietor of the pottery—it illustrates a poem which shows how widely, even at the early age in which the poet lived, the various operations in making vases were understood. For our present purpose, however, attention is chiefly directed to the furnace.

The furnaces described by Piccolpasso as in use among the Italians were of three kinds, one for oxidizing the tin and lead, a second for baking glazed ware, and a third for majolica proper, or lustred ware. In the first the furnace was rectangular, and was divided into two parts, one of which was occupied by the fire, the other by the tray for the metals. The latter was raised to such a height that the flames could play upon the metals as they passed over them to the opening at the other side. The baking furnace was also rectangular, and was built of brick. It was divided by a perforated arch into an upper and lower compartment. In the upper division the wares were placed. It had four openings on either side and nine in the roof. Under the lower chamber was the ash-pit, and each chamber had a door at one end. At Castel-Durante the usual dimensions of a furnace were six feet in height and length, and five in width. At Venice their dimensions were sometimes double those above stated. The wares were arranged according to their quality. Seggars—circular or oval cases of infusible fire-clay, bottomed, but without covers, and perforated—were used for those of fine quality. The seggars, which may be seen piled one above another in Fig. 28 and on the lower right hand of Fig. 29, were placed as in the first of these engravings, the bottom of the one above acting as a lid to that next below; and the coarser wares were arranged in rows between the piles of seggars. The openings having been partially closed, the fire was applied{77} below, and kept up for about twelve hours, when the first firing was finished. The majolica furnace will be described hereafter.

enlarge-image
Fig. 26.—Common Pottery Kiln.
Fig. 26.—Common Pottery Kiln.

Among the Japanese the kilns are arranged in a peculiar manner. That in which the first firing is done is a small furnace, used only previous to the painting. The oxide of cobalt, which is more extensively employed than any other, is laid upon the white clay coating, and the piece is then glazed, usually in a compound of felspath and wood-ashes. The second firing then takes place. The kilns are built in terraced rows of from four to twenty, and rise about three feet above each other, growing larger in size as they extend up the hill. The ground-plan is trapezoidal, and the walls rise vertically for a few feet, and are then rounded off into an arch. The front wall, looking toward the lower end of the row, is pierced with holes near the ground, and others are made in the back wall at about three feet above the ground, so as to open directly upon the floor of the next kiln above. The draught in this way rushes through the entire row toward the chimneys behind the largest and uppermost kiln. The fuel is thrown directly into the kiln, and not into a fireplace. It is arranged along the lower side in a narrow space divided from the rest of the kiln by fire-clay slabs set upright. The fire begins in a furnace attached to the lowest kiln. The hot air rushes through the air-holes into the next kiln, which is thus heated before its own firing begins, and so on throughout the entire range, the kilns furthest up the line having thus to stand the highest temperature. Each one has the benefit of the heat of all the lower ones. The Japanese do not make any extensive use of seggars. To keep the pieces free from dust or falling particles of the vault, the inside of each kiln is glazed before the firing begins. The pieces are placed one above another upon fire-clay stands. The small kilns for the preliminary firing are in the potter’s yard, but the kilns above described belong to the community, and are rented to the manufacturers.{78}

enlarge-image
Fig. 27.—Hard Pottery Kiln.
Fig. 27.—Hard Pottery Kiln.

enlarge-image
Fig. 28.—Porcelain Kiln.
Fig. 28.—Porcelain Kiln.

The kilns in use in America and Europe vary very much in shape. M. Brongniart gives representations of three—that for common pottery (Fig. 26), that for hard pottery (Fig. 27), and that for porcelain (Fig. 28). Those used in England often take the shape of a low, vaulted chamber, with the fire at one end, the chimney at the other, and the firing chamber between. In the United States, the usual shape for both earthen-ware and stone-ware is conical, not unlike a ball-cartridge. The common pottery kiln is divided, by means of baked plates, into cells, in which the wares are placed. The length of time during which they are kept in the furnace varies according to the nature of the ware. It may be twenty-four hours or, as in the case of fine stone-ware, several days. For some wares, seggars are used in place of the open cells; and the arrangement of{79} the seggars may be seen in the porcelain kiln. When, in the case of non-vitrifying earthen-ware, a combination of firing and glazing in one operation is not practicable, the ware is kept at a white-heat for about thirty-six hours; and on the kiln cooling, the pieces then known as “biscuit” are removed for glazing. This operation consists of dipping it into the glaze, composed as previously mentioned, ground to a powder, and mixed with water until of the right consistency. The second firing melts the glaze, and covers the surface with a thin, transparent coating. The Italian potters gradually increased the heat for four hours, and allowed the ware to remain at a white-heat for twelve hours, and then to cool. Porcelain is fired according to its composition. For English porcelain, the first firing lasts about fifty hours; the second firing, after the glaze is applied, lasts about twenty hours or less, at a lower temperature. Soft-paste or artificial French porcelain takes from eighty to a hundred hours for the first, and thirty for the second, firing. The greatest caution is demanded in placing the pieces in the seggars and in regulating the heat. The chief peculiarity about the making of porcelain is that the glaze fluxes with the paste, and forms, with it, a translucent whole.

enlarge-image
Fig. 29.—Broome’s Improved Porcelain or Parian Kiln. A, ash-pit; G, grate; F F, flues; B B, bags for the flames; D, door for filling the kiln; E, damper, or draught regulator; S S S, spy-holes for watching, or trials while burning.
Fig. 29.—Broome’s Improved Porcelain or Parian Kiln. A, ash-pit; G, grate; F F, flues; B B, bags for the flames; D, door for filling the kiln; E, damper, or draught regulator; S S S, spy-holes for watching, or trials while burning.

Mr. Isaac Broome, of Trenton, has invented a new kiln, of which an engraving is here given (Fig. 29). An equal distribution and perfect regulation of the heat are the features which commend it to attention.

Very little more need be said here about the preparation and application{80} of the glaze, and that little can be included in what requires to be added about the laying on of the colors. The Italians worked in the following manner: The biscuit having been dipped in the enamel bath, was allowed to dry, and was then painted and again dried. The piece was then dipped in the transparent glaze, and, having been for a third time dried, was ready for the final firing. Piccolpasso gives much minute instruction regarding the preparation of the colors and manner of painting, which must here be omitted. What he says about painting majolica, or lustred ware, is, however, interesting. The parts to receive the metallic-lustre pigment were sketched in outline, and left white when the other colors were applied. After the piece was fired the lustre pigments were laid on, and the piece was again placed in the kiln. For this purpose a special kiln was necessary. It was built with a square fire chamber intersected by two arches, on which was placed a circular chamber large enough to touch the four sides of the square kiln, but necessarily leaving the four corners uncovered. This chamber was perforated in all directions, in order to admit the flames to direct contact with the wares. Dry willow branches were used for the first three hours, and then dry broom was thrown on the fire, which was kept up for another hour. The kiln having cooled, the pieces were removed, soaked in soap-and-water, washed, rubbed dry with flannel, and then polished with wood-ash and flannel. The object of the process is obvious. The flames being allowed to play directly upon the wares, the carbon in the smoke decomposed the salts contained in the metallic oxide, and the metal was left glittering and iridescent upon the surface.

The Japanese porcelain painted under the glaze with the oxide of cobalt has been already described. Other qualities are painted over the glaze with colored enamels made from glass (or silica, litharge, and nitre) and white-lead. The coloring oxides are gold for carmine, copper, antimony, manganese, red oxide of iron, and oxide of cobalt. These are mixed and applied directly by the painter without any previous preparation, so that the colors do not show themselves until brought out by the fire. The method of decoration is peculiar. The design is first sketched in black lines, with strokes for the shades. When the enamel colors are opaque, they are laid on thinly; when translucent or resembling colored glass, so that the design appears{81} under, they are laid on more thickly. Occasionally a white opaque enamel—but containing no admixture of tin—is first applied, and the colors are laid upon it.

Stone-ware is very seldom glazed by a “dip.” The usual method is to combine the firing and glazing. When the ware has been exposed to the maximum heat for the necessary time, salt is thrown into the kiln. The heat vaporizes the salt, and of its constituent parts one, the chlorine, escapes; while the other, the soda, is, on coming in contact with the silex in the red-hot ware, formed into a silicate of soda, a perfectly transparent and intensely hard glaze.

In regard to the colors, the only ones now known which will bear the first firing—couleurs de grand feu—and are therefore put on before glazing, are blue from cobalt, browns from iron, manganese, and chromate of iron, green from chrome, and yellows from titanium and uranium. Between these and the more delicate couleurs de moufle, or enamel colors, are violets, reds, and browns from manganese, copper, and iron, which are designated as couleurs au demi grand feu. Beyond these, the colors used in decorating hard or natural porcelain are laid on the glaze, to which they adhere without incorporating themselves.

The great difficulties attending the manufacture of porcelain may now be estimated. The piece must pass through the kiln as many times as there are colors requiring different temperatures. Too much heat will blot out the delicate colors, too little will leave them dull. Those on artificial or soft porcelain sink into the glaze, and thus present a softness and creamy delicacy never seen on any other kind of ware.

The results are generally a sufficient reward for the difficulty of the process. This is altogether exceptional in the case of pate tendre. As its alkaline ingredients volatilize at a certain heat, the fire must be stopped before that temperature is reached. The glaze, also alkaline, is then applied in the form of dust, and not, as with hard porcelain, in the form of a dip. The second firing melts the glaze. If the heat be too strong, the alkalies will fly off; if too weak, the surface will be uneven. For a third time the same danger is incurred, when the firing for fixing the colors takes place.{82}

                                                                                                                                                                                                                                                                                                           

Clyx.com


Top of Page
Top of Page