Overview:
The “Handbook on Japanning,” originally published in 1913 by William N. Brown, provides a comprehensive guide to the art of japanning, a process that originated in Japan and involves applying a thick, brilliant varnish to surfaces like paper, wood, and metal, followed by hardening through baking. While the book acknowledges the Japanese use of natural lacquer, it primarily focuses on the English method, which is simpler and less costly.
The handbook delves into the intricacies of preparing the surface, applying japan grounds of different colours, and varnishing techniques. It explores specific pigments and varnishes suitable for each type of japan ground and explains the importance of stoving, a process of baking the coated surfaces to harden the varnish. Additionally, the book examines the various types of enamelling and japanning stoves, including those heated by direct fire and hot water pipes. It provides detailed instructions on how to japan various metals, including tin and iron, and how to enamel old work. Notably, it also introduces the modern methods of japanning with natural Japanese lacquer, outlining its benefits and limitations.
Key Findings:
- Importance of Cleanliness: The text emphasizes the crucial role of cleanliness in achieving successful japanning or enamelling.
- Durability of Undercoats: The book highlights that japan coats applied directly on the surface, without a priming coat, are more durable and less prone to cracking.
- Stoving: Stoving, a process of baking the coated surfaces, is essential for hardening the varnish and achieving a durable finish.
- Gas Stoves: Gas stoves are considered the most practical and efficient option for enamelling and japanning, offering precise temperature control and safety.
- Natural Lacquer: The book introduces the benefits of modern methods using natural Japanese lacquer, highlighting its faster drying time and superior durability compared to traditional methods.
Learning:
- Surface Preparation: The reader will learn about the importance of properly preparing the surface to be japanned, including cleaning, smoothing, and applying a priming coat if necessary.
- Japan Grounds: The reader will gain insights into the creation of different japan grounds using various pigments and varnishes, understanding the specific properties of each colour and its suitable applications.
- Stoving Techniques: The text will educate the reader about the significance of stoving and its impact on the hardness and durability of the final japan finish.
- Enamelling and Japanning Stoves: The reader will learn about the different types of stoves used for japanning and enamelling, including their advantages and disadvantages, and how to choose the most suitable stove for their needs.
- Modern Lacquer Techniques: The reader will gain knowledge about the modern methods of japanning with natural Japanese lacquer, understanding its benefits, limitations, and its applications in various materials.
Historical Context:
The book was written in 1913, a time when industrialization was rapidly changing the world. The advancement of gas heating and the development of new technologies, like the use of natural Japanese lacquer, reflected the growing importance of innovation and efficiency in manufacturing.
Facts:
- Japanning originated in Japan, where the natives use a natural varnish or lacquer that flows from a specific kind of tree.
- Japanning can be considered a process between painting and porcelain enamelling.
- The English method of japanning is simpler and less costly than the traditional Japanese method, but its coatings are less durable.
- It is advisable to use a priming coat only on coarse, uneven, rough, and porous surfaces.
- The priming coat used in japanning traditionally consists of Paris white (levigated whiting) mixed with size.
- The best japan grounds are formed with shellac varnish, with pigments added for colouring.
- For white japan grounds, special treatment is necessary due to the difficulty in achieving a hard and white finish.
- Shellac varnish is the best choice for binding and preserving pigments in japanning.
- The best quality of ivory black ground in super black japan produces a high-quality black finish after suitable stoving.
- Enamels and japans are best purchased ready-made, as attempting to make them at home is often unsuccessful.
- Enamelling must be done in a dust-free environment, as dust and dirt can mar the finish.
- All japanning or enamelling work must be thoroughly cleaned before applying enamel.
- It is recommended to use a cheaper enamel for the first coat of large jobs.
- The finer the surface is polished, the better the enamelling and finish.
- For white or light-coloured japans or enamels, lower temperatures are required for stoving than for darker colours.
- The enamel should be kept thoroughly mixed to prevent streaky work.
- Enamelling is best done by dipping large pieces of work in a trough of enamel, allowing them to drain, and then baking.
- For japanning tin, a preliminary coating of vegetable black mixed with super black japan varnish is applied before adding the final coats of super black japan.
- The electro deposition of zinc, a common method of galvanizing, was found to be costly and unreliable, giving way to the hot galvanizing process.
- Lead, despite its resistance to certain acids, is not as effective a protective coating for iron as zinc.
Statistics:
- An oven of 6 feet by 6 feet by 31/2 feet requires six rows of atmospheric burners for heating.
- Enamelling stoves require a temperature range of up to 400° F.
- A 1-inch diameter wrought-iron tube filled with water can be heated to 300° or 400° F.
- Thin layers of urushiol (Japanese lacquer) harden within 5 hours at 100° C, 30 minutes at 150° C, and 10 minutes at 180° C.
- A hot galvanizing bath with dimensions of 10 feet by 4 feet by 41/2 feet can hold 28 tons of zinc.
- A zinc-iron alloy used to cast art ornaments contains 6% iron.
- A portion of a zinc coating applied by the hot process, with an average thickness of 0.015 inch, was found to contain 2.20% tin, 3.78% iron, and a trace of arsenic, with the remaining percentage being zinc.
- Zinc coating applied by the cold process requires less zinc to provide the same resistance to corrosion as the hot process.
- Hot galvanizing can increase the weight of a 16-inch plate by 1.76 ounces, a 2-inch plate by 2.04 ounces, a 7/8-inch cut nail by 2.19 ounces, and a 7/8-inch die bolt and nut by approximately 1.206 ounces.
- The increase in weight due to hot galvanizing ranges from 1.00% to 6.72% for various articles.
- The addition of aluminium to the molten zinc bath for hot galvanizing reduces the thickness of the coating applied.
- Adding tin to the hot bath for hot galvanizing can shorten the life of the protective coating.
- The dross formed during the hot galvanizing process can amount to 25% of the total zinc used.
Terms:
- Japanning: The art of applying a thick, brilliant varnish to surfaces like paper, wood, and metal, followed by hardening through baking.
- Lacquer: A natural varnish derived from a specific kind of tree, traditionally used in Japan for japanning.
- Stoving: The process of baking coated surfaces to harden the varnish.
- Japan Ground: A base layer of varnish and pigment used as a foundation for decoration in japanning.
- Pigment: A substance used to give colour to paint or varnish.
- Varnish: A protective and decorative coating applied to surfaces.
- Shellac Varnish: A type of varnish made from shellac, commonly used in japanning.
- Priming Coat: A first layer of paint or varnish applied to a surface to prepare it for further coatings.
- Enamel: A type of paint or varnish known for its glossy finish and durability.
- Galvanizing: A process of coating iron or steel with zinc to prevent rust.
Examples:
- Tortoise-Shell Ground: This ground is created by applying a thin layer of vermilion followed by a coat of black varnish, then subjected to intense heat for a prolonged period, resulting in a beautiful, hard surface that resembles tortoise-shell.
- Enamelling Bedstead Frames: Large pieces like bedstead frames are dipped in a trough of enamel, allowed to drain, and baked to harden the finish.
- Japanning Tin: Tin goods like tea-trays are first coated with vegetable black, followed by two or more coats of super black japan, and baked between each coat to achieve a durable finish.
- Modern Lacquer Techniques: Natural Japanese lacquer can be applied to a variety of materials like metal, glass, and porcelain and dried at high temperatures, resulting in a hard and durable coating.
- Bronzing Compositions: Polished brass objects can be immersed in boiling solutions containing various salts to achieve different colours, including shades of green, brown, violet, and blue.
- Black Stain for Iron: Iron and steel can be coloured a dead black using a mixture of bismuth chloride, mercury bi-chloride, copper chloride, hydrochloric acid, alcohol, and lamp-black, followed by heating in boiling water and oil.
- Black Varnish for Sewing Machines: A black varnish for repairing scratched or damaged japan surfaces can be made by mixing fine lamp-black or ivory-black with copal varnish.
- Tarring Sheet-Iron Pipes: Sheet-iron pipes can be coated with coal tar and set alight with wood shavings to create a rust-resistant coating.
- Hot Galvanizing: Large articles like bridge structures and roofs are often galvanized by dipping them in a bath of molten zinc.
- Cold Galvanizing: Applying a zinc coating using an electrolytic process, while less common than hot galvanizing, offers some advantages, including more uniform coverage and less brittleness.
Conclusion:
This 1913 “Handbook on Japanning” provides a fascinating glimpse into the art and science of japanning, a process with a rich history and enduring relevance. The book highlights the importance of careful preparation, the variety of techniques used for achieving different finishes, and the continuous evolution of japanning methods. While modern methods have introduced new techniques and materials, the core principles outlined in this handbook remain essential for understanding and mastering the art of japanning. The text emphasizes the importance of cleanliness, stoving, and using appropriate materials to achieve a durable and aesthetically pleasing finish. Whether you are a seasoned craftsman or a curious learner, this handbook offers a valuable resource for exploring the world of japanning and its enduring legacy.