THE ELECTRIC INCANDESCENT FILAMENT LAMPS

Artificial Light: Its Influence Upon Civilization by Matthew Luckiesh is part of the HackerNoon Books Series. You can jump to any chapter in this book here. THE ELECTRIC INCANDESCENT FILAMENT LAMPS

X. 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.

DIRECT CURRENT ARC
Most of the light being emitted by the positive (upper) electrode

FLAME ARC
Most of the light being emitted by the flame

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°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.

ON THE TESTING-RACKS OF THE MANUFACTURER OF INCANDESCENT FILAMENT LAMPS
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

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 [1904], 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°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°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°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.

The earlier tungsten filaments were made by three rival processes. By the first, a deposit of tungsten was "flashed" on a fine carbon filament, the latter being eliminated finally by heating in an atmosphere of hydrogen and water-vapor. By the second, colloidal tungsten was produced by operating an arc between tungsten electrodes under water. The finely divided tungsten was gathered, partially dried, and squirted through dies to form filaments. These were then sintered. The third was the "paste" process already described. These methods produced fragile filaments, but their luminous efficiency was higher than that of previous ones. However, in this country ductile tungsten was soon on its way. An ingot of tungsten is subjected to vigorous swaging until it takes the form of a rod. This is finally drawn into wire.

Much of this development work was done by the laboratories of the General Electric Company and they were destined to contribute another great improvement. The blackening of the lamp bulbs was due to the evaporation of tungsten from the filament. All filaments up to this time had been confined in evacuated bulbs and the low pressure facilitates evaporation, as is well known. It had long been known that an inert gas in the bulb would reduce the evaporation and remedy other defects; however, under these conditions, there would be a considerable loss of energy through conduction of heat by the gases. In the vacuum lamp nearly all the electrical energy is converted into radiant energy, which is emitted by the filament and any dissipation of heat is an energy loss. A high vacuum was one of the chief aims up to this time, but a radical departure was pending.

If an ordinary tungsten-lamp bulb be filled with an inert gas such as nitrogen, the filament may be operated at a very much higher temperature without any more deterioration than takes place in a vacuum at a lower temperature. This gives a more efficient light but a less efficient lamp. The greater output of light is compensated by losses by conduction of heat through the gas. In other words, a great deal more energy is required by the filament in order to remain at a given temperature in a gas than in a vacuum. However, elaborate studies of the dependence of heat-losses upon the size and shape of the filament and of the physics of conduction from a solid to a gas, established the foundation for the gas-filled tungsten lamp. The knowledge gained in these investigations indicated that a thicker filament lost a relatively less percentage of energy by conduction than a thin one for equal amounts of emitted light. However, a practical filament must have sufficient resistance to be used safely on lighting circuits already established and, therefore, the large diameter and high resistance were obtained by making a helical coil of a fine wire. In fact, the gas-filled tungsten lamp may be thought of as an ordinary lamp with its long filament made into a short helical coil and the bulb filled with nitrogen or argon gas.

This development was not accidental and from a scientific point of view it is not spectacular. It did not mark a new discovery in the same sense as the discovery of X-rays. However, it is an excellent example of the great rewards which come to systematic, thorough study of rather commonplace physical laws in respect to a given condition. Such achievements are being duplicated in various lines in the laboratories of the industries. Scientific research is no longer monopolized by educational institutions. The most elaborate and best-equipped laboratories are to be found in the industries sometimes surrounded by the smoke and noise and vigorous activity which indicate that achievements of the laboratory are on their way to mankind. The smoke-laden industrial district, pulsating with life, is the proud exhibit of the present civilization. It is the creation of those who discover, organize, and apply scientific facts. But how many appreciate the debt that mankind owes not only to the individual who dedicates his life to science but to the far-sighted manufacturer who risks his money in organized quest of new benefits for mankind? A glimpse into a vast organization of research, which, for example, has been mainly responsible for the progress of the incandescent lamp would alter the attitude of many persons toward science and toward the large industrial companies.

The progress in the development of electric incandescent lamps is shown in the following table, where the dates and values are more or less approximate. It should be understood that from 1880 to the present time there has been a steady progress, which occasionally has been greatly augmented by sudden steps.

Throughout the development of incandescent filament lamps many ingenious experiments were made which resulted usually in light-sources of scientific interest but not of practical value. One of the latest is the tungsten arc in an inert gas. By means of a heating coil, a small arc is started between two electrodes consisting of tungsten, but this as yet has not been shown to be practicable.

Another type of filament lamp was developed by Nernst in 1897. It was an ingenious application of the peculiar properties of rare-earth oxides. His first lamp consisted essentially of a slender rod of magnesia. This substance does not conduct electricity at ordinary temperatures, but when heated to incandescence it becomes conducting. Upon sufficient heating of this filament by external means while a proper voltage is impressed upon it, the electric current passes through it and thereafter this current will maintain its temperature. Thus such a filament becomes a conductor and will continue to glow brilliantly by virtue of the electrical energy which it converts into heat. Later lamps consisted of "glowers" about one inch long made from a mixture of zirconia and yttria, and finally a mixture of ceria, thoria, and zirconia was used. The glower is heated initially by a coil of platinum wire located near it but not in contact with it. Owing to the fact that this glower decreases rapidly in resistance as its temperature is increased, it is necessary to place in series with it a substance which increases in resistance with increasing current. This is called a "ballasting resistance" and is usually an iron wire in a glass bulb containing hydrogen. The heater is cut out by an electromagnet when the glower goes into operation. This lamp is a marvel of ingenuity and when at its zenith it was installed to a considerable extent. Its light is considerably whiter than that of the carbon filament lamps. However, its doom was sounded when metallic filament lamps appeared.

An interesting filament was developed by Parker and Clark by using as a core a small filament of carbon. This flashed in an atmosphere containing a vapor of a compound of silicon, became coated with silicon. This filament was of high specific resistance and appeared to have promise. It has not been introduced commercially and doubtless it cannot compete with the latest tungsten lamps.

Electric incandescent lamps are the present mainstay of electric illumination and, it might be stated, of progress in lighting. Wonderful achievements have been accomplished in other modes of lighting and the foregoing statement is not meant to depreciate those achievements. However, the incandescent filament lamp has many inherent advantages. The light-source is enclosed in an air-tight bulb which makes for a safe, convenient lamp. The filament is capable of subdivision, with the result that such lamps vary from the minutest spark of the smallest miniature lamp to the enormous output of the largest gas-filled tungsten lamp. The outputs of these are respectively a fraction of a lumen and twenty-five thousand lumens; that is, the luminous intensity varies from an equivalent of a small fraction of a standard candle to a single light-source emitting light equivalent to two thousand standard candles.

Statistics are cold facts and are usually uninteresting in a volume of this character, but they tell a story in a concise manner. The development of the modern incandescent lamp has increased the intensity of light available with a great decrease in cost, and this progressive development is shown easily by tables. For example, since the advent of the tungsten lamp the average candle-power and luminous efficiency of all the lamps sold in this country has steadily increased, while the average wattages of the lamps have remained virtually stationary.

It will be noted that the luminous intensity of incandescent filament lamps has steadily increased since the carbon lamp was superseded, and that in a period of ten years of organized research behind the tungsten lamp the luminous efficiency (lumens per watt) has trebled. In other words, everything else remaining unchanged, the cost of light in ten years was reduced to one third. But the reduction in cost has been more than this, as will be shown later. During the same span of years the percentage of carbon filament lamps of the total filament lamps sold decreased from 100 per cent. in 1907 to 13 per cent. in 1917. At the same time the percentage of tungsten (Mazda) lamps increased from virtually zero in 1907 to about 87 per cent. in 1917. The tantalum lamp had no opportunity to become established, because the tungsten lamp followed its appearance very closely. In 1910 the sales of the former reached their highest mark, which was only 3.5 per cent. of all the lamps sold in the United States. From a lowly beginning the number of incandescent filament lamps sold for use in this country has grown rapidly, reaching nearly two hundred million in 1919.

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