Part 13

The next step was the introduction of the so-called "luminous-arc" which is a "flame-arc" with entirely different electrodes. The lower (negative) electrode consists of an iron tube packed chiefly with magnetite (an iron oxide) and titanium oxide in the approximate proportions of three to one respectively. The magnetite is a conductor of electricity which is easily vaporized. The arc-flame is large and the titanium gives it a high brilliancy. The positive electrode, usually the upper one, is a short, thick, solid cylinder of copper, which is consumed very slowly. This lamp, known as the magnetite-arc, has a luminous efficiency of about 20 lumens per watt with a clear glass globe.

The mechanisms which strike the arc and feed the carbons are ingenious devices of many designs depending upon the kind of arc and upon the character of the electric circuit to which it is connected. Late developments in electric incandescent filament lamps have usurped some of the fields in which the arc-lamp reigned supreme for years and its future does not appear as bright now as it did ten years ago. High-intensity arcs have been devised with small carbons for special purposes and considered as a whole a great amount of ingenuity has been expended in the development of arc-lamps. There will be a continued demand for arc-lamps, for scientific developments are opening new fields for them. Their value in photo-engraving, in the moving-picture production studios, in moving-picture projection, and in certain aspects of stage-lighting is firmly established, and it appears that they will find application in certain chemical industries because the arc is a powerful source of radiant energy which is very active in its effects upon chemical reactions.

The luminous efficiencies of arc-lamps depend upon so many conditions that it is difficult to present a concise comparison; however, the following may suffice to show the ranges of luminous output per watt under actual conditions of usage. These efficiencies, of course, are less than the efficiencies of the arc alone, because the losses in the mechanism, globes, etc., are included.

Lumens per watt Open carbon arc 4 to 8 Enclosed carbon arc 3 to 7 Enclosed flame-arc (yellow or white) 15 to 25 Luminous arc 10 to 25

Another lamp differing widely in appearance from the preceding arcs may be described here because it is known as the mercury-arc. In this lamp mercury is confined in a transparent tube and an arc is started by making and breaking a mercury connection between the two electrodes. The arc may be maintained of a length of several feet. Perhaps the first mercury-arc was produced in 1860 by Way, who permitted a fine jet of mercury to fall from a reservoir into a vessel, the reservoir and receiver being connected to the poles of a battery. The electric current scattered the jet and between the drops arcs were formed. He exhibited this novel light-source on the mast of a yacht and it received great attention. Later, various investigators experimented on the production of a mercury-arc and the first successful ones were made in the form of an inverted U-tube with the ends filled with mercury and the remainder of the tube exhausted.

Cooper Hewitt was a successful pioneer in the production of practicable mercury-arcs. He made them chiefly in the form of straight tubes of glass up to several feet in length, with enlarged ends to facilitate cooling. The tubes are inclined so that the mercury vapor which condenses will run back into the enlarged end, where a pool of mercury forms the negative electrode. The arc may be started by tilting the tube so that a mercury thread runs down the side and connects with the positive electrode of iron. The heat of the arc volatilizes the mercury so that an arc of considerable length is maintained. The tilting is done by electromagnets. Starting has also been accomplished by means of a heating coil and also by an electric spark. The lamps are stabilized by resistance and inductance coils.

One of the defects of the light emitted by the incandescent vapor of mercury is its paucity of spectral colors. Its visible spectrum consists chiefly of violet, blue, green, and yellow rays. It emits virtually no red rays, and, therefore, red objects appear devoid of red. The human face appears ghastly under this light and it distorts colors in general. However, it possesses the advantages of high efficiency, of reasonably low brightness, of high actinic value, and of revealing detail clearly. Various attempts have been made to improve the color of the light by adding red rays. Reflectors of a fluorescent red dye have been used with some success, but such a method reduces the luminous efficiency of the lamp considerably. The dye fluoresces red under the illumination of ultra-violet, violet, and blue rays; that is, it has the property of converting radiation of these wave-lengths into radiant energy of longer wave-lengths. By the use of electric incandescent filament lamps in conjunction with mercury-arcs, a fairly satisfactory light is obtained. Many experiments have been made by adding other substances to the mercury, such as zinc, with the hope that the spectrum of the other substance would compensate the defects in the mercury spectrum. However no success has been reached in this direction.

By the use of a quartz tube which can withstand a much higher temperature than glass, the current density can be greatly increased. Thus a small quartz tube of incandescent mercury vapor will emit as much light as a long glass tube. The quartz mercury-arc produces a light which is almost white, but the actual spectrum is very different from that of white sunlight. Although some red rays are emitted by the quartz arc, its spectrum is essentially the same as that of the glass-tube arc. Quartz transmits ultra-violet radiation, which is harmful to the eyes, and inasmuch as the mercury vapor emits such rays, a glass globe should be used to enclose the quartz tube when the lamp is used for ordinary lighting purposes.

It is fortunate that such radically different kinds of light-sources are available, for in the complex activities of the present time all are in demand. The quartz mercury-arc finds many isolated uses, owing to its wealth of ultra-violet radiation. It is valuable as a source of ultra-violet for exciting phosphorescence, for examining the transmission of glasses for this radiation, for sterilizing water, for medical purposes, and for photography.

THE ELECTRIC INCANDESCENT FILAMENT LAMPS

Prior to 1800 electricity was chiefly a plaything for men of scientific tendencies and it was not until Volta invented the electric pile or battery that certain scientific men gave their entire attention to the study of electricity. Volta was not merely an inventor, for he was one of the greatest scientists of his period, endowed with an imagination which marked him as a genius in creative work. By contributing the electric battery, he added the greatest impetus to research in electrical science that it has ever received. As has already been shown, there began a period of enthusiastic research in the general field of heating effects of electric current. The electric arc was born in the cradle of this enthusiasm, and in the heating of metals by electricity the future incandescent lamp had its beginning.

Between the years 1841 and 1848 several inventors attempted to make light-sources by heating metals. These crude lamps were operated by means of Grove and Bunsen electric cells, but no practicable incandescent filament lamps were brought out until the development of the electric dynamo supplied an adequate source of electric current. As electrical science progressed through the continued efforts of scientific men, it finally became evident that an adequate supply of electric current could be obtained by mechanical means; that is, by rotating conductors in such a manner that current would be generated within them as they cut through a magnetic field. Even the pioneer inventors of electric lamps made great contributions to electrical practice by developing the dynamo. Brush developed a satisfactory dynamo coincidental with his invention of the arc-lamp, and in a similar manner, Edison made a great contribution to electrical practice in devising means of generating and distributing electricity for the purpose of serving his filament lamp.

Most of the light being emitted by the positive (upper) electrode]

Most of the light being emitted by the flame]

Thousands of lamps are burned out for the sake of making improvements. The electrical energy used is equivalent to that consumed by a city of 30,000 inhabitants]

Edison in 1878 attacked the problem of producing light from a wire or filament heated electrically. He used platinum wire in his first experiments, but its volatility and low melting-point (3200 deg.F.) limited the success of the lamps. Carbon with its extremely high melting-point had long attracted attention and in 1879 Edison produced a carbon filament by carbonizing a strip of paper. He sealed this in a vessel of glass from which the air was exhausted and the electric current was led to the filament through platinum wires sealed in the glass. Platinum was used because its expansion and contraction is about the same as glass. Incidentally, many improvements were made in incandescent lamps and thirty years passed before a material was found to replace the platinum leading-in wires. The cost of platinum steadily increased and finally in the present century a substitute was made by the use of two metals whose combined expansion was the same as that of platinum or glass. In 1879 and 1880 Edison had succeeded in overcoming the many difficulties sufficiently to give to the world a practicable incandescent filament lamp. About this time Swan and Stearn in England had also produced a successful lamp.

In Edison's early experiments with filaments he used platinum wire coated with carbon but without much success. He also made thin rods of a mixture of finely divided metals such as platinum and iridium mixed with such oxides as magnesia, zirconia, and lime. He even coiled platinum wire around a piece of one of these oxides, with the aim of obtaining light from the wire and from the heated oxide. However, these experiments served little purpose besides indicating that the filament was best if it consisted solely of carbon and that it should be contained in an evacuated vessel.

One of the chief difficulties was to make the carbon filaments. Some of the pioneers, such as Sawyer and Mann, attempted to cut these from a piece of carbon. However, Edison and also Swan turned their attention to forming them by carbonizing a fiber of organic matter. Filaments cut from paper and threads of cotton and silk were carbonized for this purpose. Edison scoured the earth for better materials. He tried a fibrous grass from South America and various kinds of bamboo from other parts of the world. Thin filaments of split bamboo eventually proved the best material up to that time. He made many lamps containing filaments of this material, and even until 1910 bamboo was used to some extent in certain lamps.

Of these early days, Edison said:

It occurred to me that perhaps a filament of carbon could be made to stand in sealed glass vessels, or bulbs, which we were using, exhausted to a high vacuum. Separate lamps were made in this way independent of the air-pump, and, in October, 1879, we made lamps of paper carbon, and with carbons of common sewing thread, placed in a receiver or bulb made entirely of glass, with the leading-in wires sealed in by fusion. The whole thing was exhausted by the Sprengel pump to nearly one-millionth of an atmosphere. The filaments of carbon, although naturally quite fragile owing to their length and small mass, had a smaller radiating surface and higher resistance than we had dared hope. We had virtually reached the position and condition where the carbons were stable. In other words, the incandescent lamp as we still know it to-day , in essentially all its particulars unchanged, had been born.

After Edison's later success with bamboo, Swan invented a process of squirting filaments of nitrocellulose into a coagulating liquid, after which they are carbonized. Very fine uniform filaments can be made by this process and although improvements have been made from time to time, this method has been employed ever since its invention. In these later years cotton is dissolved in a suitable solvent such as a solution of zinc chloride and this material is forced through a small diamond die. This thread when hardened appears similar to cat-gut. It is cut into proper lengths and bent upon a form. It is then immersed in plumbago and heated to a high temperature in order to destroy the organic matter. A carbon filament is the result. From this point to the finished lamp many operations are performed, but a discussion of these would lead far afield. The production of a high vacuum is one of the most important processes and manufacturers of incandescent lamps have mastered the art perhaps more thoroughly than any other manufacturers. At least, their experience in this field made it possible for them to produce quickly and on a large scale such devices as X-ray tubes during the recent war.

During the early years of incandescent lamps, improvements were made from time to time which increased the life and the luminous efficiency of the carbon filaments, but it was not until 1906 that any radical improvement was achieved. In that year in this country a process was devised whereby the carbon filament was made more compact. In fact, from its appearance it received the name "metallized filament." These carbon filaments are prepared in the same manner as the earlier ones but are finally "treated" by heating in an atmosphere of hydrocarbons such as coal-gas. The filament is heated by electric current and the heat breaks down the hydrocarbons, with the result that carbon is deposited upon the filament. This "treated" filament has a coating of hard carbon and its electrical resistance is greater than that of the untreated filament.

The luminous efficiency of a carbon filament is a function of its temperature and it increases very rapidly with increasing temperature. For this reason it is a constant aim to reach high filament temperatures. Of all the materials used in filaments up to the present time, carbon possesses the highest melting-point (perhaps as high as 7000 deg.F.), but the carbon filament as operated in practice has a lower efficiency than any other filament. This is because the highest temperature at which it can be operated and still have a reasonable life is much lower than that of metallic filaments. The incandescent carbon in the evacuated bulb sublimes or volatilizes and deposits upon the bulb. This decreases the size of the filament eventually to the breaking-point and the blackening of the bulb decreases the output of light. The treated filament was found to be a harder form of carbon that did not volatilize as rapidly as the untreated filament. It immediately became possible to operate it at a higher temperature with a resulting increase of luminous efficiency. This "graphitized" carbon filament lamp became known as the gem lamp in this country and many persons have wondered over the word "gem." The first two letters stand for "General Electric" and the last for "metallized." This lamp was welcomed with enthusiasm in its day, but the day for carbon filaments has passed. The advent of incandescent lamps of higher efficiency has made it uneconomical to use carbon lamps for general lighting purposes. Although the treated carbon filament was a great improvement, its reign was cut short by the appearance of metal filaments.

In 1803 a new element was discovered and named tantalum. It is a dark, lustrous, hard metal. Pure tantalum is harder than steel; it may be drawn into fine wire; and its melting-point is very high (about 5100 deg.F.). It is seen to possess properties desirable for filaments, but for some reason it did not attract attention for a long time. A century elapsed after its discovery before von Bolton produced the first tantalum filament lamp. Owing to the low electrical resistance of tantalum, a filament in order to operate satisfactorily on a standard voltage must be long and thin. This necessitates storing away a considerable length of wire in the bulb without permitting the loops to come into contact with each other. After the filaments have been in operation for a few hundred hours they become brittle and faults develop. When examined under a microscope, parts of the filament operated on alternating current appear to be offset. The explanation of this defect goes deeply into crystalline structure. The tantalum filament was quickly followed by osmium and by tungsten in this country.

The osmium filament appeared in 1905 and its invention is due to Welsbach, who had produced the marvelous gas-mantle. Owing to its extreme brittleness, osmium was finely divided and made into a paste of organic material. The filaments were squirted through dies and, after being formed and dried, they were heated to a high temperature. The organic matter disappeared and the fine metallic particles were sintered. This made a very brittle lamp, but its high efficiency served to introduce it.

In 1870 when Scheele discovered a new element, known in this country as tungsten, no one realized that it was to revolutionize artificial lighting and to alter the course of some of the byways of civilization. This metal--which is known as "wolfram" in Germany, and to some extent in English-speaking countries--is one of the heaviest of elements, having a specific gravity of 19.1. It is 50 per cent. heavier than mercury and nearly twice as heavy as lead. It was early used in German silver to the extent of 1 or 2 per cent. to make platinoid, an alloy possessing a high resistance which varies only slightly as the temperature changes. This made an excellent material for electrical resistors. The melting-point of tungsten is about 5350 deg.F., which makes it desirable for filaments, but it was very brittle as prepared in the early experiments. It unites very readily with oxygen and with carbon at high temperatures.

The first tungsten lamps appeared on the market in 1906, but these contained fragile filaments made by the squirting process. When the squirted filament of tungsten powder and organic matter was heated in an atmosphere of steam and hydrogen to remove the binding material, a brittle filament of tungsten was obtained. The first lamps were costly and fragile. After years of organized research tungsten is now drawn into the finest wires, possessing a tensile strength perhaps greater than any other material. Filaments are now made into many shapes and the greatest strides in artificial lighting have been due to scientific research on a huge scale.

The achievements which combined to perfect the tungsten lamp to the point where it has become the mainstay of electric lighting are not attached to names in the Hall of Fame. Organization of scientific research in the industrial laboratories is such that often many persons contribute to the development of an improvement. Furthermore, time is usually required for a full perspective of applications of scientific knowledge. In the early days organized research was not practised and the great developments of those days were the works of individuals. To-day, even in pure science, some of the greatest contributions are made by industrial laboratories; but sometimes these do not become known to the public for many years. The whole scheme of scientific development has changed materially. For example, the story of the development of ductile tungsten, which has revolutionized lighting, is complex and more or less shrouded in secrecy at the present time. Many men have contributed toward this accomplishment and the public at the present time knows little more than the fact that tungsten filaments, which were brittle yesterday, are now made of ductile tungsten wire drawn into the finest filaments.