boğazi̇çi̇ university

08/05/2014
BOĞAZİÇİ
UNIVERSITY
THE PROJECT IS COORDINATED BY THE SOCIETY FOR
THE HISTORY OF TURKISH SCIENCE
•  Archaeological Excavations: Kırklareli Museum (Arc. Zülküf Yılmaz)
Boğaziçi University (Prof. Günhan Danışman)
Netherlands Institute in Turkey (Assit. Prof. Fokke Gerritsen)
Boğaziçi University* (Dr. Rana Özbal-Gerritsen)
•  Architectural Documentation and Restoration: DEMİRKÖY-SAMAKOCUK IRON FOUNDRY: AN
INDUSTRIAL ARCHAEOLOGY PROJECT AT AN
OTTOMAN WORKSHOP IN TURKISH THRACE
Hadi Özbal
The objective of the archaeometallurgical studies
at Demirköy Industrial Archaeology Project is
part of a much expended project where the
metallurgy of Thrace will be studied from the
beginning mainly to understand the transfer of
metal technologies between Anatolia and Thrace
through out history.
The ultimate goal of Demirköy Industrial
Archaeological Project is to establish a
functioning Ottoman iron foundry with furnaces
and forges as an open air museum İstanbul Technical University (Prof. Atilla Bir) Boğaziçi University (Prof. Günhan Danışman) •  Ottoman Archive Studies:
İstanbul University ( Prof. Mustafa Kaçar)
İstanbul technical University (Assit. Prof. Gülsün Tanyeli)
Archaeometallurgical Studies:
Boğaziçi University (Prof. Hadi Özbal)
* Part Time
Archaeometallurgical studies at Demirköy
İstanbul Technical University (Assoc. Prof. Gülsün Tanyeli)
•  Studies in History of Technology: Bochum Mining Museum (Assoc. Prof. Ünsal Yalçın)
Diffusion of iron metallurgy
Yalçın 2006
Lewis Henry Morgan: The smelting of iron was a development on a par with
the domestication of animals . Iron proved to be cheaper and superior to bronze.
It was now possible to arm a large peasant infantry to challenge the military
superiority of LBA aristocracy armed with bronze weapons.
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Types of Iron
Types of Iron: Wrought iron by Direct Process
Iron bloom
Bloomery furnace
Fayalithic slag
Wrought iron
Steel Cast Iron
Carbon content < 0.03%
Carbon content between 0.5 - 1.5%
Carbon Content < 1.5%
FeO 60.2
SiO2 19.6
Al2O3 4.91
CaO 4.56
Composition of
Fayalithic slag
Other impurities such as Si, Mn, S, Ni, Mo, Ti, Al, and P alter the properties of steel
Forging bloom and wrought iron objects
Types of Iron: Cast Iron (Pig iron) and cast iron objects
Stückofen
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Production of wrought iron from cast iron: The Finery
Types of Iron: Steel
Steel is an alloy of iron and 0.5-1.5% carbon.
CAST IRON
Decarburization
WROUGHT IRON
Carburization
WROUGHT IRON
STEEL
Decarburization
THERMAL OPERATIONS
CAST IRON
Quenching
Tempering
Damascus steel
Ottoman cannon metallurgy
Ottoman Cannon casting
1389: Earliest record of casting bronze cannon at the siege of Kosova
1450-1474: Casting of large bronze cannons during Fatih Sultan Mehmet period.
.
Cast in 1464 Bronze
Weight: 17 tons
Wt. of cannon balls: 294 Kg
Bore: 63 cm
Wt. of Gun powder: 213 Kg
1516 : Two wrought iron cannons were produced for Yavuz Sultan Selim s Egypt campaign. Wrought Iron
Barrel: 7.40m
Bore: 25 cm
1520-1566: Reign of Kanuni Sultan Süleyman was the most active period for casting bronze cannons
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Samakocuk, Malki-Samakov
•  One of the important iron production center in
the Thrace
•  In 1696, Sultan orders to have a iron workshop
to produce morter shells.
•  In one of the documents about the construction
of Nuruosmaniye Mosque, it is mentioned that
iron from the İğne Ada was also used.
•  It is further expended in 1821
•  Cast iron in the form of ingots (Helon) was sent
to Tersane-i Amire and Tophane-i Amire from
İğne ada.
•  In 1830 foundry workers both from Samako and
Samakocuk were sent to England to learn about
the new technologies.
•  A “Salname” from Edirne mentions that the
foundry was still active in 1875 and was
commisioned to produce horse shoe, nails and
sheet iron and even machine parts
•  Before the 1st World War, operation permit was
granted to an English firm which was later
revoked when the war started.
Samakov and Samakocuk
Kırklareli, Demirköy
Location of the foundry and the environment
.
:"...Bu diyâr(ın) samako denilen ateş-i
nemrud yakan körüğünü on âdem
çekemez, su değirmeni körüğü
çekerek ateş yakar, fil gövdesi kadar
demir örsler üzre akik-i Yemeni gibi
kırmızı demirleri ateşten çıkaran üstâd
haddadlar birer gunâ musannâ
dolaplar ile kızgın demirleri sendân
üzre koyup camus kellesi kadar
çekiçleri ile yine sanatlı su dolapları
vasıtasıyla kırmızı demire
urduklarında zemin ve asumanı
titredirler. Serkârda ancak iki üstâd
örsü üzre dolab ile birer ikişer kantar
demirleri çekiç altına koyub çeküb
urmakdadır, her urmakda demür
uzayup çubuk oldukda yine bir san'at
ile çark-ı dolabın suyunu keserek şebü
ruz böyle kâr-ı rüzgâr ederler. Nice
seyyâhlar bu kârı görüb engüşt
berdehân-ı hayret olurlar. Bu kârı
ancak görmekile takdir olur, yoksa
böyle yazmakla olmaz..." EVLİYA ÇELEBİ
.
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Site plan of Demirköy foundry
Excavated administration section of the foundry
Prepared by architects Erdoğan Canbaz, Murat Alaboz and Onur Karahan
Archaeological excavations at the administrative area (2002-2006)
The main foundry and the high furnace (Stückofen):
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The main foundry and the high furnace (Stückofen):
Main foundry
.
Excavations at the small workshop (2005-2006), Bloom iron furnace
Forging of the Bloom
Water canal
Anchorage holes
for forging hammer
Finery Oven?
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Ore: The bellow system
Tuyer
Magnetite: Fe3O4 (% 60-70 Fe)
Hematite: Fe2O3 (% 60 Fe)
Examples of wrought iron objects
The Furnace and the blooms
Demirköy Bloom iron samples (About 65 Kg)
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Fayalitic Slag (from the bloomery furnace)
Microstructure image of a nail made from bloom iron
a: Polished surface image of a nail made from bloom iron. Residual slags are elongated due
to extensive hammering.
Glassy Anorthide
Phase
b: Image of the same surface after etching. Darker
regions are perlite (layers of Fe & Fe3C) the
lighter regions are pure ferrite.
Fayalite (Fe2SiO4)
a
FeO
SiO2
CaO
Al2O3
MnO
MgO
% 62.7
% 9.44
%7.99
% 6.65
% 1.03
%3.23
Wüstite (FeO) Crystals
Gen. Comp.
FeO: 60.5
SiO2: 22.0
CaO: 3.75
Al2O3: 5.86 b
Nails made from Demirköy wrought iron
Forging Demirköy bloom iron
Section of bloom from Demirköy
Hot blooms is forged
Bloom is heated in an oven
Image of the polished section X50
Consolidated wrought iron
Image of the etched polished section X200
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Iron ingots
Cast iron objects
SEM image of cast iron ingot
Cast iron ingot
Graphite flakes
Typical grey cast iron
microstructure
Cannon Ball (Humbara)
Casting Humbara
Cannon Ammunition
Casting Humbara
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Casting Humbara
Glassy slag from the high furnace
An iron prill
Glassy phase
Graphite fibers
FeO 0.84%
SiO2 55.6%
CaO 10.9%
Al2O3 12.1%
Possible finery slag
2008 Excavation, the smithing workshop
Sample 05/708
FeO
%81.7
SiO2
%7.20
CaO
%12.5
Al2O3
%7.03
MnO
%1.44
Hammer scales
Furnace bottoms
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Ternary Phase diagram of slags related to iron production The composition of 43 investigated slag
samples are represented on a ternary phase
diagram that reflects the processes from
which they have formed.
Conclusions
•  Iron production in Demirköy continued until 1870 s.
•  Both cast as well as wrought iron was produced.
•  Small workshops around the main foundry must have produced only wrought iron since only fayalithic slags were observed. •  The glassy slag that form in the high furnaces was only observed around the main foundry where the high furnaces were located.
•  There were no evidence so far that steel was produced at Demirköy. •  Both hematite and magnetite sand were used as iron ores at Demirköy.
•  There are indications that iron production at Demirköy may go back to Roman Period
•  Thrace is a natural land bridge between Anatolia and Europe. Archaeometallurgical studies in the region will help us understand diffusion of metallurgy to Europe. Acknowledgement
Dedication
On behalf of a large number of scholars and students, I would
like to express my gratitude to the following institutions who
made this work possible by their generous support.
Ministry of Tourism and Culture (DÖSİMM)
National Research Council of Turkey
Society for History of Turkish Science
Boğaziçi University Research Fund
The Governance of Kırklareli
GÜNHAN DANIŞMAN 1943-2009
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