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SPRINGER BRIEFS IN
APPLIED SCIENCES AND TECHNOLOGY

Juraj Ružbarský
Anton Panda

Plasma and
Thermal Spraying

123
SpringerBriefs in Applied Sciences
and Technology

Series editor
Janusz Kacprzyk, Systems Research Institute, Polish Academy of Sciences,
Warsaw, Poland
SpringerBriefs present concise summaries of cutting-edge research and practical
applications across a wide spectrum of fields. Featuring compact volumes of 50 to
125 pages, the series covers a range of content from professional to academic.
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On the one hand, SpringerBriefs in Applied Sciences and Technology are
devoted to the publication of fundamentals and applications within the different
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Indexed by EI-Compendex and Springerlink

More information about this series at http://www.springer.com/series/8884

Juraj Ružbarský Anton Panda
•

Plasma and Thermal

Spraying

123
Juraj Ružbarský Anton Panda
Faculty of Manufacturing Technologies Faculty of Manufacturing Technologies
Technical University of Košice Technical University of Košice
Prešov Prešov
Slovakia Slovakia

This monograph has been supported by the projects KEGA 027TUKE-4/2014 and VEGA
1/0381/15.

ISSN 2191-530X ISSN 2191-5318 (electronic)

SpringerBriefs in Applied Sciences and Technology
ISBN 978-3-319-46272-1 ISBN 978-3-319-46273-8 (eBook)
DOI 10.1007/978-3-319-46273-8
Library of Congress Control Number: 2016952880

© The Author(s) 2017

This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part
of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations,
recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission
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the relevant protective laws and regulations and therefore free for general use.
The publisher, the authors and the editors are safe to assume that the advice and information in this
book are believed to be true and accurate at the date of publication. Neither the publisher nor the
authors or the editors give a warranty, express or implied, with respect to the material contained herein or
for any errors or omissions that may have been made.

Printed on acid-free paper

This Springer imprint is published by Springer Nature

The registered company is Springer International Publishing AG
The registered company address is: Gewerbestrasse 11, 6330 Cham, Switzerland
Contents

1 Plasma Jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Characteristics of Plasma Spraying . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Temperature and Performance of Plasma Jet . . . . . . . . . . . . . . . 4
1.3 Exhaust Velocity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Plasma Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.1 Dissociation, Ionization and Enthalpy of Plasma
Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .... 9
1.5 Thermal Conductivity of Plasma. . . . . . . . . . . . . . . . . . . . . .... 11
1.6 Electric Conductivity of Plasma . . . . . . . . . . . . . . . . . . . . . .... 11
2 Formation of Plasma Sprayed Coating . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Powder Transport, Flow Trajectory and Velocity of Sprayed
Particles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2 Mutual Influence of Molten Material with Plasma Jet
and Ambient Atmosphere . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3 Impingement of Flowing Particles onto the Backplate . . . . . . . . 17
2.4 Thermic Influence upon the Backplate and Sprayed Coating . . . 20
2.5 Physical and Chemical Changes of Material in Spraying . . . . . . 22
3 Basic Properties of Plasma Coatings . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.1 Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 Density and Porosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3 Bonding, Internal Stress, Coating Thickness . . . . . . . . . . . . . . . . 26
3.4 Strength, Hardness, Deformability . . . . . . . . . . . . . . . . . . . . . . . 27
3.5 Thermal and Electric Conductivity . . . . . . . . . . . . . . . . . . . . . . . 29
4 Adhesion of Plasma Sprayed Coatings to Basic Backplate . . . . . . . . 31
4.1 Types of Bonding Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Theoretical Aspects of Optimal Adhesion Formation . . . . . . . . . 32

v
vi Contents

4.3 Principal Factors Influencing Adhesion of Coating

to Basic Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3.1 Thickness of Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.3.2 Pretreatment of Basic Material Surface . . . . . . . . . . . . . 34
4.3.3 Parameters of Spraying Process . . . . . . . . . . . . . . . . . . . 36
4.4 Experimental Assessment of Adhesion of Plasma Sprayed
Coatings to Basic Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.4.1 Testing Methods of Adhesion Detection . . . . . . . . . . . . 36
4.4.2 Adhesion Test According to DIN 50 160 Standard . . . . 37
4.4.3 Adhesion Test According to DIN 50 161 Standard . . . . 39
4.4.4 Adhesion Test by the Apex Stone Method . . . . . . . . . . 40
5 Plasma Spraying Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1 Basic Scheme of Plasma Spraying Equipment . . . . . . . . . . . . . . 43
5.2 Plasma Torches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6 Thermal Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.1 General Characteristics of Thermal Spraying . . . . . . . . . . . . . . . 50
6.2 Theoretical Bases of Thermal Spray Applications . . . . . . . . . . . . 51
6.2.1 Adhesion of Thermal Sprayed Particles to the Basic
Surface and Cohesion of Film Particles . . . . . . . . . . . . . 51
6.2.2 Methods of Regulation of Interaction
Between the Sprayed Particle Material
and the Basic Material . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.3 Technology of Thermal Spraying . . . . . . . . . . . . . . . . . . . . . . . . 54
6.3.1 Flame Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.3.2 Electric Arc Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7 Adhesion Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.1 Theoretical Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Experimental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.2.1 Plasma Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.2.2 Thermal Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8 Thermal Fatigue Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.1 Theoretical Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.2 Experimental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9 Roughness of Spray Coating Surface . . . . . . . . . . . . . . . . . . . . . . . . . 85
10 Corrosion Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
11 Assessment of Properties of Films on Cylindrical Testing Rods . . . 89
Contents vii

12 Operation Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
12.1 Material 12 060 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
12.2 Material 15 230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
12.3 Material 19 541 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
13 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Annexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Introduction

In case of all technologies of thermic application, the methods and possibilities of

improvement in diverse properties of applied coatings have been constantly sought
for, which appear logical as it represents one of the ways of enhancement of the
application of usually rather expensive material of high quality. Moreover, new
knowledge related to the sphere of applied coatings is gained that can serve for
improvement in surface properties of basic material. In the practice of mechanical
engineering, the film coatings are applied onto metal material by being dipped into
liquid metal, by thermal and plasma spraying or by other technologies.
Thermic application of films is used for the surface treatment of new products,
for the renovation of components, for the purpose of service life prolongation and
for the purpose of increase in wear resistance as well as in thermal insulation and in
corrosion resistance in different environment types. Technology of thermic spraying
allows broad scale of materials to be sprayed. Those are materials on the basis of
iron and of non-ferrous metals and their alloys, and ceramic materials and their
alloys. The materials must conform to strict requirements yet should be affordable.
The technology of plasma spraying can be regarded as the improved develop-
ment level of flame metallization. The metalizing process was invented and
patented in 1910 by Max Ulrich Schoop in Switzerland. At the same time Schoop
was the inventor of the method of arc spraying. The arc spraying was suppressed by
flame metalizing which started to develop at the beginning of the thirties in the
USA. Its usage expanded by spraying of anticorrosive coatings of zinc and alu-
minium and included was also renovation of machinery components by spraying of
steel and bronze. An effort is made to apply powder metallization the development
of which commenced in the fifties in connection with fast progress of powder
materials, thus opening new possibilities for the application of metallization. Then,
apart from hardsurfacing materials, the oxides of aluminium and zirconium become
interesting.
After the Second World War, the methods of arc spraying developed rapidly in
Central Europe. From the start, the flame and arc metallization were limited by
low-temperature oxygen and acetylene flame or electric arc which means that, for
instance, the material with melting point of 2700 °C could not be sprayed. During

ix
x Introduction

this period rather developed was thermal spraying by flame. In spraying with
auxiliary material in the form of wire, the particles are pulled by the jet of com-
pressed air out of the slag bath so the grain size depends on spraying parameters. In
spraying with auxiliary material in the form of powder, the size of particles is
determined by their grain composition. When impinging on the basic material, the
molten particle is deformed under the influence of its high kinetic energy. Elastic
deformation occurs in the particle during the impingement, and only by the effect of
impulse pressure, it is deformed on the basic material surface.
In case of thermal spraying by electric arc between two fed wires out of which
one represents the anode and the other is the cathode an electric arc is formed. The
electric arc heat melts the auxiliary material—wires in the area of the anode and
of the cathode spot. The compressed air flowing out of the nozzle at high velocity
drags the molten metal particles and casts them onto the basic material.
The development of further method of plasma spraying followed. The method
brought another advantage in the form of spraying in the environment of inert
gasses considerably decreasing oxidation of molten particles both during the flow
through the aeriform atmosphere and landing onto the basic material. The tem-
peratures reached by standard plasma torch are substantially higher contrary to the
melting temperatures of all known materials. In majority of spraying processes the
optimal temperature range is from 6500 up to 11000 °C.
Plasma spraying allows application of broad assortment of coatings—ceramic
coatings, refractory metals, combinations of alloys and plastics, etc.—with minimal
thermal influence upon the basic material. Coating material in form of powder is fed
by the flow of gas, argon, nitrogen, hydrogen, helium, or by their combination into
the plasma jet generated by electric arc burning. In plasma produced by the torch,
the ions are connected with the electrons releasing abundance of energy which heats
the gas up to over 6000 °C, causing fast expansion of gas. Plasma flame melts the
powder, and gas expansion shoots the molten drops out onto the coated surface at
velocity of even 300 m.s−1 in case of which the drops solidify rapidly.
In reference to successful usage, especially to service life of the applied coating,
the attention focuses on adhesion of the coating acquired as described afore in
dependence of its thickness on basic surface. The presented thesis analyses the issue
of adhesion as well.
Chapter 1
Plasma Jet

1.1 Characteristics of Plasma Spraying

In 1928 an American physicist Langmuir described plasma as the gas state which
besides neutral atoms and molecules contains positive and negative particles, ions and
electrons. Plasma does not follow the conventional laws of thermodynamics therefore
was regarded by a number of scientists as the fourth state of matter differing from solid,
liquid, and gas phases. Plasma state often occurs in the nature. In the Sun eruption the
ejected plasma clouds consist of nuclei of hydrogen atoms and of electrons. They
arrive at our Earth at velocity of 1500 km h−1 causing the northern lights, magnetic
storms, and ionospheric disturbances. Several natural and laboratory plasmas exist
that are characterized by number of electrons in cm3, by temperature of electrons
(K) and by induction of magnetic field (T) which can be categorized as follows:

Plasma type Number of electrons Temperature of Induction of magnetic

in 1 cm3 electrons (K) field (T)
Interstellar matter 1–103 104 10−9
Ionosphere 103–105 2 × 103 5 × 10−5
Solar corona 108 106 10–10−6
Electric arc 1016–1018 104 10−4–10−7
Electromagnetic 1015–1018 5 × 104 10−9
pulses
Thermonuclear 1016 106–108 10−7–10−9
discharge
Matter inside the 1022–1025 107 –
Sun

© The Author(s) 2017 1

J. Ružbarský and A. Panda, Plasma and Thermal Spraying,
SpringerBriefs in Applied Sciences and Technology,
DOI 10.1007/978-3-319-46273-8_1
2 1 Plasma Jet

Plasma differs from common gases by the following properties:

• in plasma the chemically homogeneous gas changes into a mixture of diverse
types of particles—molecules, atoms, positive and negative ions, electrons and
photons,
• apart from elastic collisions of molecules applied are the inelastic ones which
causes the changes of quantic states of molecules (dissociation, ionization),
• plasma contains charged particles—electrons and ions which can affect the gas
through electromagnetic field; gases are conductive and send or receive energy
to/from magnetic field. The mixture as the whole is electrically quasi neutral.
The electric arc represents the most widespread source of high-pressure plasma.
In plasma spraying the fed inert gas (or water) is heated by the heat produced by
electric arc and dissociates from molar to atomic state. For instance:

N2 þ VD ! 2N ð1:1Þ

H2 þ VD ! 2H ð1:2Þ

with VD—dissociation energy

For diverse gases there exist diverse energy types and ionizations; for hydrogen
4.477 eV, or 13.5 eV, for nitrogen 9.76 eV, or 14.5 eV, for oxygen 5.08 eV, or
13.6 eV, for CO2 16.56 eV is energy of dissociation, and for argon 15.7 eV is
energy of ionization (1 eV = 1.602 × 10−19 J). To maintain a stable arc in such
state inevitable is to increase the intensity of electric field (increases with growth of
amount of fed gas) by which the temperature in the middle of a column (temper-
ature in plasma axis increases along with increasing current and voltage). In case of
these higher temperatures the gas atoms are ionized as follows:

N þ Vi ¼ N þ þ e ð1:3Þ

H þ Vi ¼ H þ þ e ð1:4Þ

Ar þ Vi ¼ Ar þ þ e ð1:5Þ

with Vi—ionization energy given for diverse gases.

A number of processes start (diffusion, transmission—conduction of heat,
chemical reactions) during formation of plasma jet in the stable electric arch. Atoms
from hotter plasma areas, in which the dissociation degree is higher along with
higher number of atoms (of dissociated molecules), diffuse to colder areas with
undissociated molecules (for instance, close to the walls of cooled tube). In these
areas the atoms are recombined and release recombining heat with recombination
energy equal to energy of dissociation of molecules and to energy of ionization of
atoms. At the same temperature enthalpy of the diatomic gases, for instance of
hydrogen, is higher contrary to monoatomic gases such as argon. Molecules again
diffuse to hotter areas and consume certain amount of heat. Plasma is thus formed in
1.1 Characteristics of Plasma Spraying 3

the environment with dissociation, ionization, and recombination processes.

Therefore plasma is referred to as a specific state of matter with concurrent
occurrence of ions, electrons, photons, atoms, and molecules of gas. Its charac-
teristic feature is quasi neutrality, i.e. concentration of positive and negative par-
ticles in plasma is identical and the final charge of space equals in fact to zero.
Thermal conductivity of such gas composes of contact and diffusion heat (in dis-
sociated and ionized gas). Two methods of formation of plasma jet are distinguished
as follows:
(a) by transferred arc (Fig. 1.1),
(b) by non-transferred arc (Fig. 1.2).
In plasma formation by transferred arc the electric arc occurs between the
wolfram (graphitic) cathode and auxiliary material (wire) as the anode. The arc is
stabilized by sulphur of ionizing gas flowing out of the torch nozzle which pulls the
formed plasma jet. This method is applied in welding and cutting of metal by
plasma.
In case of the second plasma formation the arc burns between the wolfram
cathode and the wall of water cooled nozzle included in anode. The electric arc
heats up the fed working gas by high pressure to high temperature which results in
dissociation, ionization, and recombination in plasma formation. Likewise the
plasma arc, the plasma itself flows out of the nozzle at high velocity. The system is

Fig. 1.1 Scheme of plasma

torch with transferred arc
4 1 Plasma Jet

Fig. 1.2 Scheme of plasma

torch with non-transferred arc

advantageous for plasma spraying as it allows application of auxiliary material in

form of powder or wire. Powder is usually fed into the nozzle orifice. In case of
water stabilized torches an auxiliary rotating anode is used to prevent burning of the
wall of water cooled nozzle.
Widespread application is observed in case of a plasma torch with
non-transferred arc used for melting of auxiliary material in form of powder and
being sprayed onto the basic surface. It is technology of powder metal and ceramic
material. Current development related to plasma equipment production by several
companies in Switzerland and in the USA provided in the world market sufficient
amount of plasma spray automatic machines and robots controlled by pro-
grammable regulation in assurance of diverse operations in serial large-scale
production.

1.2 Temperature and Performance of Plasma Jet

Temperature of plasma jet depends especially on the degree of ionization. Typical

temperature classification is shown in Fig. 1.3 in relation to laminar argon plasma
jet and turbulent argon jet.
Table 1.1 shows mean and maximal temperature values of argon and nitrogen
plasma.
1.2 Temperature and Performance of Plasma Jet 5

Fig. 1.3 Temperature classification for plasma jet

Table 1.1 Mean and maximal temperature values of argon and nitrogen plasma
Performance Temperature Flow rate
(kW) (K) 15 N l min−1 30 N l min−1 60 N l min−1
Argon Nitrogen Argon Nitrogen Argon Nitrogen
5 Tmax 11 400 – 11 750 – 12 000 –
Tstr 8 850 – 5 600 – 3 000 –
10 Tmax – 10 900 12 700 11 040 13 000 10 540
Tstr 10 750 7 100 9 600 6 250 6 600 5 550
15 Tmax – 12 370 14 500 11 990 14 400 12 180
Tstr 12 000 7 550 11 000 6 700 8 750 5 950
20 Tmax – 13 830 – 14 790 – 13 100
Tstr – 8 250 – 7 100 – 6 200

Nl stands for 1 l of gas in standard state, i.e. 0 °C and 101.3 kPa. Mean values of
exit temperature of plasma as well as of performance of plasma jet can be expressed
by the following theoretical relations:
 
I
E p  d  ak  L
Tq ¼ ð1  expÞ  ð1:6Þ
p  d  ak Cp  Q

If the relation in square brackets is denoted by letter K the plasma jet temper-
ature is expressed as

 I
E
Tq ¼ K ð1:7Þ
p  d  ak
Other documents randomly have
different content
a step, and, though most steps were failures, they made so many
that occasionally they achieved a success.
“Collect all the logs,” he said, “and get willows and bark to fasten
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They were, therefore, soon busy collecting the logs that were in
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trees for their bark or trunks. It was obvious that a raft would soon
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water), they were not wholly unprepared to see this new raft also
float.
“If one log floats why will not more?” asked Koree.
“If our bridge floated away, this also will do so,” replied another;
and they thenceforth called it the “floating bridge.”
The raft was soon finished, and a large number of men and
women at once rushed upon it, so many, indeed, that it began to
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This was looked upon as a failure, and the disappointment of the
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“The thing will not float,” observed Oko.
“It floated,” replied Duco, “until we all got upon it. If some would
get off it would float again.”
“But we must all cross over, or none,” replied Abroo, the Family-
man.
 “Let us build more rafts,” interposed Koree, “and in several of
them we can all cross.”
“Instead of this,” said Abroo, the Family-man, “let part of our hosts
cross at once, when this structure can be brought back for the
others to cross. I and my party will cross first.”
This was agreed to, except that, instead of Abroo and his clan,
Duco was chosen to take charge of the first load.
The next difficulty was in getting the raft started. It lay motionless
with its load.
“Wait till the wind rises,” said Koree.
Presently a gust struck them, but it had no effect in starting them.
“Let us push the thing with our clubs,” said Duco, at which all
applied themselves vigorously.
The raft was easily moved in this way, and continued to go as long
as they could reach bottom; but in deep water it stood still, or
floated at the mercy of the waves. Pounder tried to move it by
sitting on one log and pushing with his feet against another. Others
beat the water, which had a little effect. Duco then discovered that
by pushing in the opposite direction against the water they could
make it move; and soon they were paddling in the modern fashion.
During much of the way the water was shallow enough to permit
them to use their clubs as poles, or, to get out and push; so that
they were soon far out from land and going in the right direction.
They would now have reached the opposite shore but for Pounder,
who kept pushing in the way just described thinking he was forcing
along the raft. By reason of his vigorous efforts he snapped the
bands which held the logs together. The raft broke in pieces and he
was the first to fall through into the water. He went down between
the logs which he was pushing apart. Others fell into the water with
him, but most remained on one part or other of the raft; for it broke
into nearly equal parts. Pounder floundered awhile in the water; but,
being accustomed to that, through his previous plunges from the
log, he soon got hold of one of the rafts and lifted himself out of the
water.
“These things can’t be depended on,” he said, as he regained his
place on board.
They had now two rafts instead of one, and they pushed and
paddled on each. Pounder, instead of sitting on one log and pushing
against another, next took a seat on one log and pushed with his
feet against a knot on the same log, and believed he was rendering
the principal aid in propelling the raft.
It was easier to proceed with two small rafts than one large one,
and accordingly both were soon landed on the opposite shore, but
not till several of the passengers had fallen overboard and the craft
had been badly damaged.
This was the first water voyage made by the human race. After
repairing their vessels they returned and brought over the remaining
hosts, but not without similar mishaps. Gimbo, the grandfather of
Sosee, fell, with others, into the water, and was nearly drowned.
Only by standing on tiptoes could he keep his head above water
until he was rescued, when he made the following observation:
“The water is the only place where it is better to walk on two feet
than on four.”
Having now crossed the lake it was proposed by Oko that they
keep the rafts. “We spent too much work on them,” he said, “to
throw them away.”
“We cannot take them with us,” replied Koree.
“We may want them when we return,” interposed Duco; “so let us
fasten them where we can find them.”
“And let us leave somebody here to watch them,” said Oko,
apprehensive lest some of their property should be lost.
Like the ships of the Greeks on the coast of Troy these rafts were,
accordingly, made fast, so that they should be ready for the return
voyage of the warriors at the close of the war.
 CHAPTER XXV.
he Ammi now continued their
forward march with but little
interruption.
“I fear this expedition will end
in disaster,” said Gimbo; “our
falling into the water is a bad
sign.”
“I think so to,” added Pounder,
recalling his duckings; “but before
it ends I shall have a fight with
the Apes, and smash some of
their jaws.”
“What looks to me worst,” said
another, “is, that when I was
sharpening my flint this morning,
the Fire-monster suddenly appeared to me, starting up out of the
flint and immediately disappearing again.”
“I saw the same thing,” added another, “when Pounder struck me
in the eye. Fire flew in all directions and then disappeared.”
One of the scouts now returned breathless announcing that they
could see the Lali in the distance.
“Let me reconnoiter,” said Koree, who advanced rapidly to the
farther edge of the swamp, from which, indeed, the Apes could be
distinctly seen.
These were running up and down the trees, apparently gathering
fruit, and chasing one another over the plains without any apparent
purpose except sport. But men never knew the deep designs of
Monkeys.
“Where is Sosee, I wonder?” asked Koree, who was too much
interested in the object of his love to attend closely to the
requirements of war. He did not observe that at that moment a great
ape was stealthily approaching him from one side.
For the Apes had out their pickets as well as the men, owing to
apprehensions of an attack; while others were scattered through the
Swamp hunting food.
After a little waiting and looking he thought he descried Sosee in
the distance walking with a handsome ape who was exceedingly
attentive to her.
Jealousy now succeeded to prudence, and his rage would have at
once carried him alone into the ranks of the enemy to capture her
(and be captured instead), but, another incident prevented him from
accomplishing this disaster.
“I will have her at once,” he said, “and scatter the brains of that
monkey attendant over any one who opposes me.”
At this instant the ape who was watching him ran up and dealt
him a powerful blow, knocking his resolution, his jealousy and his
love out of him for a while.
Koree, recovering his senses, now transferred his rage to this new
quarter, and, following it up with blows, soon brought to the ground
his assailant.
This was witnessed by other scouts of the Lali who ran to the
rescue of their companion, and also by some scouts of the Ammi
who closed on the combatants, so that an immediate fight was
threatened between the pickets of the two forces.
 THE BATTLE BEGINS.

This encounter, all unpremeditated, nearly defeated the schemes

of both parties. It destroyed the hope of secrecy on the part of the
Ammi, who thought to take the Lali by surprise; and destroyed the
hope of ambush on the part of the Lali who meant to entrap the
approaching enemy in the Swamp. Each party, moreover, being
ignorant of the force by which it was attacked, and fearing that it
might be larger than its own, shrank from fight.
As soon, therefore, as they got released from each other, they
flew apart, as if they had been fighting to escape, and not to
conquer. Both being afraid, and not daring to seem so, they affected
to despise each other, and so, showing their teeth and grinning a
defiance, they went in opposite directions, each hoping the other
would take the encounter for a chance meeting of strange apes
hunting for food, and not a skirmish between the advance guards of
mighty hosts prepared for battle.
It was too late, however. Both powers were now apprised of each
others’ designs, and both immediately put themselves in readiness
for action.
 Koree was much blamed by the Ammi for his rashness in
precipitating this encounter.
“It was your love,” said Abroo, “which brought us here to fight,
and it is your love which will now defeat us. O that love would take
sense along with it when it goes either to woo a woman or fight a
battle.”
“But it generally turns to foolishness before it accomplishes
anything,” added Cocoanut-Scooper.
“And were there not a fool also on the other side it would never
succeed at all,” said Oko.
“Koree’s case,” added a fourth, “makes more trouble for others
than pleasure for himself.”
“For his falling in love once,” said Pounder, “I fell in the water
twice.”
And so they went on reproaching poor Koree for having such a
strong love that it would not let them rest, and such a foolish one
that it would not let them fight.
Koree had nothing to say, but being himself most convinced of his
own foolishness, was angry that others agreed with him, and so
simply changed the subject.
“Be ready to fight at once,” he said, “as we may be attacked
before we have time to decide whether we will fight or not. Between
the lake and the Apes we have nothing left but to triumph.”
“It is either to be killed by the Apes or drowned in the water,” said
Oko, “and I don’t like either.”
“We’ll kill some apes before we are killed ourselves,” answered
Pounder; “at least, I will.”
“Their forces are more numerous than ours,” insisted Oko.
“That being so,” said Koree, who turned every objection into a
new device, “we will fight them by stealth, creeping upon them by
night, or enticing them into the woods.”
 “Let us rather,” said Duco, “attack them openly, and all at once;
though we are less numerous we are armed, and have more skill
than they.”
“I think,” said Gimbo, “that the Apes will triumph; they walk on all
fours, and people can fight better with four feet than with two;
besides, it is not right to—”
“Be still,” said Koree, “or give us your help, instead of your fears.”
It was resolved at last, as they could neither retreat nor stand still,
to go forward; and they determined to await an opportunity to make
an assault.
And now dread Terror brooded over the hosts of men, causing
hearts to flutter and visions of death to rush on the soul. Night and
Blood and Pain visited many in dreams, while to some Glory
appeared, walking over a vanquished foe. As Koree slept he thought
he saw Sosee coming to him in beauty with a branch of evergreen
oak, and promise that he should rule over a new race, while she
should sit by his side as queen to receive the admiration of all men.
The Apes also quaked, and the convulsions which had just thrown
up the Alps were trifling compared with the tremors that shook the
breasts of the embattled hosts that night. The morrow was to
witness a conflict that would decide whether the human race was to
remain on earth or go out of history in its infancy.
 CHAPTER XXVI.
urora now appeared in the east
starting the sleepers from their
dreams, and advanced so bright
that the terrified Ammi thought
the Fire-monster had seized the
sky, and was spreading his wings
over the whole world, portending
death to mortals. First she tinted
the new-born Alps with gold, then
chased the mists from the
valleys, and at last spread the
whole earth with day. The
courage of the hosts now
returned, which had left them
during the reign of the night-
monsters in their dreams.
With the coming of the light the Ammi marched boldly up to the
Lali, while the latter, thrown first into confusion, ran about in a panic,
and then, gathering themselves into a body, offered defiance to the
intruders.
As when a storm, rushing from the north, suddenly strikes the
sea, rolling the waves in mountain ridges along the main, which
again, breaking, rush back and fall like cliffs into the deep, stirring
the great cauldron of waters to its bottom, and then spread out
again into a calm, so the Apes, mightily stirred at the approach of
stern War, and driven by their fears, rushed hither and thither over
the plain, mounting the trees and scattering to places of safety, and
then, as the storm of terror passed on its way regained composure
and settled down on the field of battle ready for action.
 First advanced from the ranks of the Ammi the mighty Pounder,
impatient for battle, and, surveying the plain which lay between the
Men and the Apes, he grinned a challenge to the whole Lali.
Him seeing from afar the mighty Scratch-for-Fleas, starting up
from the hosts of the Lali and shaking himself, (at which the earth
trembled as when Jupiter shook Olympus with a nod), advanced to
him, saying:
“For what purpose come you to the shores of the Lali? Have the
cocoanuts failed beyond the Swamp, or do you come for our
women? We will defend our own, be they cocoanuts or girls. Go
back, or taste the wrath of the Monkeys.”
Him answering with a grin, the fierce Pounder showed his teeth.
His great lips parted, like the swinging gates of Babylon, bringing to
view huge rows of marble-like columns that lined, like palisades, a
deep, dark gorge.
A like mouth opened on the other side; and Scratch-for-Fleas,
looking now to the east and now to the west, advanced, first on four
feet and then on two. Next he moved sidewise, and, at last, for a
moment, stood still, moving however in contemplation his great
features, which, following his thoughts, changed fast in shape and
color like clouds in a mountain storm.
“Do you come for the maiden of Ilo?” he said. “You will return
without her. Give back your stolen fruits and women, and we may
make peace before war begins.”
Pounder thereupon, without answering, rushed for Scratch-for-
Fleas, being better fitted for war than for diplomacy.
Scratch-for-Fleas, fearing the mighty assault, retreated to the
hosts of the Lali, unwilling to fight so great a champion; and
thereupon a loud shout went up from the Ammi at their bloodless
victory. Pounder, however, was disappointed, for he loved fighting
better than conquering.
 Then the nimble-shanked Nut-picker, he who had been reared on
the slopes of Wildcat Mountain, went out from the hosts of the Lali
bearing a cocoanut in his hand.
Him seeing, the avaricious Oko, not knowing whether it was a
weapon or a truce-signal, went forth to meet, saying, “Do you mean
war or cocoanuts? If you mean cocoanuts, produce enough and we
may give up the fight.”
Then the nimble-shanked Nut-picker, true-aiming, threw and
struck him, and the cocoanut rolled to the ground on one side, and
Oko on the other. Picking up himself and then the cocoanut, Oko
thereupon retired to the ranks of the Ammi bearing with him his
defeat and his booty.
War was now declared and begun, and the two parties, hitherto
friends, or indifferent to each other, became enemies. So great a
difference does so slight a change produce.
Then, according to the legends of the Ammi, the great spirit of
Shoozoo, looking out from the heavens at the combatants, and
fearing that his worshippers might be destroyed, called a council of
the gods. Simlee, his wife, Queen of Heaven, appeared, leaving her
mists, and the great winged Alligator came up out of the Swamp,
dripping with the flood, and the Fire-god left his place in the sky,
and the Rainbow folded up his rays, and the Wind left the earth and
sea, (so that there was a season of calms), and they all met in the
sky to take counsel on the events that were about to transpire on
earth.
“Dire war,” said Shoozoo, “is hovering over the world, and, unless
it is averted, neither Men nor Apes nor earth will long survive. Only
recently I saw the world mount up toward the sky, and to-day it
stands on tip-toe trying to reach the heavens; for the Alps have not
yet gone down. The great Swamp left its bed to march over dry
ground, and has not yet gone back. The noise of the earthquake has
hardly yet subsided, but still reverberates in distant thunders; and,
should war yet rage, things will be so mixed up that nothing will
remain for earth or sky that is certain for either.”
“I will arise as a mist,” said Simlee, “and, passing between the two
armies, prevent their collision by destroying their sight.”
“The Fire-god will soon scatter the mists,” said Night, “so that they
can fight in clear day. Let me rather settle down upon them, through
whom none can see; and, though it be but noon, I will wipe out
their day.”
And wrapping herself in thick clouds she started for the earth to
cover the battle-field with impenetrable shadows.
“Let me rather,” said the great Alligator, “empty the Swamp on
them again, and overwhelm them with a second flood.”
“They have made boats,” said the Wind, “and now defy the
waters. Let me rather start the air against them. I will give it wings
to beat their faces and call in Thunder to frighten them and Rain to
blind them, and will so mix heaven and earth and sea together
against them that they cannot proceed.”
“There is nothing,” said Shoozoo, “that will avail, but to assuage
their wrath, which crosses streams and night and outlasts weather.
An interruption to-day prolongs the war, but does not end it. Let us
not, by impeding them, add to their rage against each other and
their anger against us. For I fear that men will one day mount to
heaven and destroy the Gods.”
This advice they consented to follow, not, however, because any
of them wanted to, but because they could not agree among
themselves what to do.
It was accordingly decided that the deities, operating all together,
should descend to the combatants to work on their minds; and so,
wrapping themselves in clouds, and mists, and rain, and shadow,
and light, which were all mistaken by Mortals for forms of the
weather, they entered the battle with both Men and Apes, and
worked for peace and a mitigation of the horrors of war.
 But when Men and Gods are thus at variance, the Gods fail; and
the council of heaven having broken up, the war of earth went on.
 CHAPTER XXVII.
irst Koree, unmindful of the
counsel of the skies, moved
forward, and, fearing neither
Gods nor Monkeys, sought to
begin the battle.
He stood in the plain between
the two armies, like an oak in an
open field between two forests.
Breathing defiance to the Lali, he
called out:
“Who dares to meet me of all
your hosts, and ward off death
from his brow when I discharge
this dart, the swift avenger of my
wrong?”
Him seeing, and not fearing, the great Tree-climber of the
mountains ran to meet, he who had often pulled the tails of cats,
and grinned at larger beasts. Stopping often, and then starting
again, like a great river that now rushes with violence, and then
stops and whirls in an eddy, (showing commotion in its stop as in its
onward course), he, seeming irresolute, plunged at last at Koree,
having eluded his missiles, and seized him with hands and teeth.
Hair and blood flew from Koree, who in turn sent a blow to Tree-
climber’s ribs, which loosed his ribs and no less his fingers and teeth
from Koree’s flesh; and the great warriors, bleeding and aching, flew
apart. They stood, frowning like two mountain peaks about to fall
with a crash upon each other, but were stayed in their rage by a
return of Fear, the destroyer of battles. Both having enough, and
being uncertain what it would be to get more, went back, one to the
west like the sun, and the other to the east like a shadow; and there
was a lull in the storm.

KOREE’S CHALLENGE.

Then Kimpoo, the skunk-scented, rising among the Lali, went

forth, breathing war from his extended nostrils, and, scratching first
his thigh and then his ribs, said in defiant tones:
 “Invaders of our homes! go back to disgrace, or come forth to
death.”
So saying he threw a cocoanut which grazed the ear of Duco,
calling forth a little blood and a big howl, and then passed on and
struck the stomach of Pounder, producing only a grunt.
Then High-tail, the Wood-pecker hunter, ran forth, he who knew
all the holes in Possum Grove, and smelt at many and was sad.
Aiming at Kimpoo a marrow bone, he threw it with such force, that,
whistling through the air, it was heard but not seen. It entered his
head where a flea had left a bite at early dawn; and as the bone
went in his soul went out. Down he fell with a crash, as when a
mountain fir is broken in the storm.
Then Ilko, a friend of the slain ape and lover of huckle berries,
rushed forth to avenge his death, and, aiming a stone at the head of
High-tail, threw it with such precision that death entered where he
struck, and the losses between the two forces were equal.
Then seeing that Death was to be the companion of this War, and
uncertain which army would survive, Koree invoked the aid of
Shoozoo.
“Great spirit of the skies and Swamp, God and Alligator,” he said,
“teach us to conquer on this field or to run away in time. May our
arms be stronger than the enemy, or our feet swifter than Death.”
And then rushing out he called on any of the Lali to come forth to
meet him in battle, and particularly Ilo, the robber of his pleasures.
But Ilo was sitting afar off with Sosee, guarding her against
escape and the seductions of Oboo his rival, and he heard not the
challenge to battle.
But Owl-catcher heard, and, fired with anger and a desire for
glory, went forth to meet him. On all fours he went, looking up at
times as he ran and rising on his feet to survey the field.
Koree, advancing, threw a sharpened flint at him, aiming at where
the hair is parted on the brow, and there it entered. The distant Alps
disappeared from the eyes of Owl-catcher, and, as all things faded
from his sight, he knew not whether the world or a monkey was
collapsing.
Now Ilo, hearing that he was challenged, came to the fight; but
not willingly. Sosee had demanded that he play not the coward; for
love cannot follow the timorous. But whether she deeply designed
that he should die or be victor, none could fathom. He came to the
front and met the proud Koree who said:
“I have a plentiful supply of death for the Lali, and for you I will
send it on this bone;” and he discharged a split marrow-bone at his
breast. It was one that Sosee had sharpened while they talked
together of love and acted out their conversation, and she had
graved on it, with a bear’s tooth, the wing of a dragon fly.
This marrow-bone pierced the flesh of Ilo, but not his love-tickled
heart; and he ran away screaming and bleeding, not wishing to die
while in the joys of his first love.
He sought out Sosee in the distance, who showered her
compassion, if not her affection, upon him; and she drew the bone
from his breast, when, seeing it was the weapon of Koree which her
own hands had fashioned, she was thrown into consternation.
“Is my lover fighting my lover?” she asked, “and do I make the
weapons that slay them?” and she rushed to the scene of battle and
came between the lines.
At the sight of Sosee a shout arose from the Ammi, who thought
that she had escaped, or else that the Lali, fearing their defeat, were
surrendering her. Koree ran to meet her, forgetful that the battle was
raging, when, being about to grasp her in his arms, he was struck by
a cocoanut in the ear, which had been thrown by Tree-jumper, an
ape from the Bamboo plains, who had started in her pursuit. Koree
fell to the ground, stunned by the stroke of the ape and the sight of
his beloved, for the double blow on his eye and ear exhausted him,
being already weary from strife. But he fell unhurt, and was picked
up by friends and carried to a place of safety.
 Sosee, however, was seized by Tree-jumper, and taken back to the
Lali, who placed her far from the front, where she was safe from
both death and rescue.
 CHAPTER XXVIII.
ow the battle raged on all sides.
Not one but many went forth
from each army, and were
engaged in groups fighting hand
to hand, or throwing missiles.
The sudden appearance of Sosee,
which revived the hopes of the
Ammi, who thought the girl and
the end of the war were both
within their grasp, increased their
fury when they saw her followed
by a captor, and a general rush
was made to take the field and
the girl by storm.
First Pounder entered the
combat, and was met by an ape
from the north country. This ape was descended from a long line of
heroes; Sookaloo was his father, who had fought bumble-bees in the
meadows about the great springs, and there the bones of his
kindred repose. This ape, advancing to meet Pounder, drew the
battle toward him. Both clenched and opened their jaws, and soon
both were in each other’s arms and teeth. Anger and strength met in
Pounder, and were united for the death of his antagonist. But this
was delayed awhile, and struggles, growls and blood were yielded
instead. Then weakness followed, and at last darkness gathered
about the eyes of the ape; his thoughts took flight, and quiet settled
over him even in battle.
Striding over his body Pounder now rushed on to new conquests,
impatient for more strife. A great gorilla-like monster next met him,
approaching from afar. With thoughts of death in his eye, he came
walking on his hands, swinging his great body between them, like a
huge kettle between two posts. He appeared to be walking and
sitting at once.
“Come you to bring new honor to these arms?” said Pounder. “I
will soon bear your death about me as a trophy, and those that I
send out of the world will not be lonely beyond the Swamp.”
As when Day and Night meet at dawn, and, in hot contest redden
the whole sky with blood, and, Night being slain, Day moves on over
the sky in undisputed and undivided sway, so these mighty heroes
met, and in the battle the ape was overcome and sank from the
contest, while Pounder, rising like the sun from the death of Night,
marched on victorious over the scene, and was lord of the field.
On again rushed Pounder, like Hector at Troy; and the Apes,
seeing their warriors fall at his strokes, feared to engage him in
single combat.
“Let us attack him together,” they said; and two great apes stood
up to meet him, like twin mountain peaks approached by a storm.
One met his fist with his eye and saw no more that day; the other
seized his arm and in that grasp laid hold of Death, whom none
survive; and as he fell the dull earth reëchoed the crash to the
mountains, which he alone did not hear.
Terror now took hold of all that beheld the mighty Pounder, and
they fled from his advance as peasants working in a field flee from
an approaching flood, some to be overtaken and destroyed, and
others to escape to a safe place in the highlands. Pounder now
chased, instead of fought, the Apes, hunting for a foe with whom to
measure his strength and with difficulty finding one.
At last Ilo, recovering from his wound, but not his rage, rushed
again to the field, (impelled also by Sosee), and, seeing the advance
of Pounder, which drove the Apes before him, met him with a stone,
(which reaches further than an ape’s arm). Forth into the air, like Iris
from the command of Jove, rushed this messenger of wrath, and,
singing a battle cry as it went, it struck Pounder in the breast; when
out went his breath and up went his feet—but only for awhile.
Pounder arose again, but, being unable to fight, was carried back by
his comrades; and again the fight went on without him, to his great
disappointment.
The Apes, encouraged by the arrest of the flood of death, now
returned to the field, and everywhere were single fights. Stones,
cocoanuts, gourds and bones flew through the air. Cries and groans
mingled with growls, and which was man and which was monkey
could not be discerned in the battle.
Finger-at-his-nose, an ape from the shores lying to the south,
where his ancestors fished for crabs with their tails, and made
mighty grimaces while waiting for a bite, scraped the face of Stretch-
mouth with a shell, and was put to flight with a club in hands of
Abroo; and, as he ran a shower of stones followed him, and he
thought the crabs of all the Swamp were pulling at him.
Then High-climber, who was quick to look around and unfriendly
to mosquitos, advanced from among the Apes with a cocoanut in his
hand. This cocoanut he had pulled in a dense grove at sunset and
hid at the foot of a palm, where a buzzard was feeding on an
aurochs. The buzzard dug it up and carried it to a mountain crag,
where Imko, finding it, brought it to the camp of the Lali. There
High-climber, seeing it, again took possession of it and slew Imko
the supposed thief. With this cocoanut, High-climber, aiming at the
head of Frog-catcher, struck him where the nose separates the eyes,
like the mountains of Caucasus between two great seas. Frog-
catcher fell and one less Ammi was left to propagate the new race.
Then Watch-the-Girls, furious with rage, rushed forth, and, with a
sharp stone and loud shout, mixed in the fight. Ape after ape fell
before her, wounded or scared. Like a she-wolf tearing the fold she
ran about dealing destruction, while the timid flock fled on all sides,
or gathered in groups too frightened to flee. One, Bushy-face
thought to resist her, and, turning, aimed a dart at her bright eye.
But, too dazzled or too terrified to aim, he missed his mark, when,
from the same eye, she sent a dart of defiance and from her hand a
stone. Both struck the eye which aimed the first blow, and back
went retribution on the wrong intended. Down sank Bushy-face in
darkness, and away went all things from his view. To the world the
monkey was no more, and to the monkey the world was no more;
and which was destroyed has never been settled between them.
Then off in the distance was heard a great chorus of screams,
while a rush of all the Apes to that quarter drew the battle with it.
The girls, who had been led to the war by Watch-the-Girls, then
thought to enter the fight. They had been restrained by their leader;
but now, impetuous, they rushed against the enemy; whom seeing,
the salacious Apes, enamoured of the daughters of Men, and
forgetting their anger in their lust, gave up the battle for a rape, and
rushed upon the girls to make them prisoners. The girls, scorning to
be carried away instead of attacked, (having come to fight and not
to be wooed), struggled hard with their captors, but more from pride
than desire.
Then all the Ammi, seeing that their girls were about to be taken,
transferred the war to that quarter, and fought for their own, instead
of against the enemy. Inspired by jealousy as well as rage, the battle
now waxed fiercer, as when to a raging fire is added the wind, and
the conflagration spreads into a forest. Death moved about rapidly
over the field, visiting now a man and now an ape, and calling him
to the Walhalla beyond the Swamp; and the plain was scattered with
his victims.
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