Journal of Archaeological Science 40 (2013) 439e451
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Journal of Archaeological Science
journal homepage: http://www.elsevier.com/locate/jas
Bronze production in Southwestern Iberian Peninsula: the Late Bronze Age
metallurgical workshop from Entre Águas 5 (Portugal)
Pedro Valério a, *, António M. Monge Soares a, Rui J.C. Silva b, Maria Fátima Araújo a, Paulo Rebelo c,
Nuno Neto c, Raquel Santos c, Tiago Fontes c
a
b
c
IST/ITN, Instituto Superior Técnico, Universidade Técnica de Lisboa, Estrada Nacional 10, 2686-953 Sacavém, Portugal
CENIMAT/I3N, Departamento de Ciência dos Materiais, Faculdade de Ciências e Tecnologia, FCT, Universidade Nova de Lisboa, 2829-516 Monte de Caparica, Portugal
Neoépica Arqueologia & Património Lda., Rua da Venezuela, 24, 1500-621 Lisboa, Portugal1
a r t i c l e i n f o
a b s t r a c t
Article history:
Received 5 March 2012
Received in revised form
5 July 2012
Accepted 7 July 2012
Archaeological works at Entre Águas 5 (Portugal) uncovered a seasonal LBA settlement with significant
metallurgical remains (crucibles, moulds, prills and a tuyere) related to bronze production. Radiocarbon dating ascribes an occupation period (10the9th century BC) previous to Phoenician establishment in Southwestern Iberia. In spite of the proliferation of metal artefacts during LBA, the
production of bronze alloys is still poorly understood. An integrated analytical approach (EDXRF, optical
microscopy, SEMeEDS, micro-EDXRF and Vickers microhardness) was used to characterise this
metallurgy. Crucibles show immature slags with copious copper nodules, displaying variable tin
content (c. 0e26 wt.%), low iron amount (<0.05 wt.%) and different cooling rates. Certain evidences
point to direct reduction of oxide copper ores with cassiterite. Scorched moulds with residues of copper
and tin indicate local casting of artefacts. Finished artefacts also recovered at the site have an analogous
composition (bronze with w10 wt.% Sn and low amounts of Pb, As and Fe) typical of coeval metallurgy
in SW Iberia. Some artefacts reveal a relationship between typology and composition or manufacture:
a higher tin content for a golden coloured ring or absence of the final hammering for a bracelet. An
uncommon gilded nail (gold foil c. 140 mm thick; 11.6 wt.% Ag; w1 wt.% Cu) attests the existence of
evolved prestige typologies. This LBA settlement discloses a domestic metallurgy whose main features
are typical in Iberian Peninsula. Finally, it should be emphasized that a collection as comprehensive and
representative of a single workshop has rarely been studied, enabling a deeper understanding of the
various operations involving the bronze production and manufacture of artefacts.
Ó 2012 Elsevier Ltd. All rights reserved.
Keywords:
Bronze production
Slag
Elemental composition
Manufacturing procedures
Gilding
Late Bronze Age
Iberian Peninsula
1. Introduction
During 2008, excavations to extract expansive clay for the core
of an earthen fill dam have exposed some archaeological materials
suggesting the existence of a habitat in the middle of an open valley
located at Serpa County (Southern Portugal). Archaeological excavations have revealed a protohistoric settlement nearby a small
stream (Enxoé River), a left bank tributary of the Guadiana River
(Fig. 1). The location of this settlement e Entre Águas 5 (EA5) e
suggests a seasonal occupation since the area would be partially
flooded during winter. Archaeological work has covered only the
* Corresponding author. Tel.: þ351 219946207; fax: þ351 219946185.
E-mail addresses: pvalerio@itn.pt (P. Valério), amsoares@itn.pt (A.M. Monge
Soares), rjcs@fct.unl.pt (R.J.C. Silva), faraujo@itn.pt (M.F. Araújo).
1
E-mail: neoepica@gmail.com.
0305-4403/$ e see front matter Ó 2012 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.jas.2012.07.020
areas with archaeological materials already exposed by mechanical
work for clay extraction (sectors 1, 2 and 3) and revealed several
negative structures together with a significant collection of
ceramic, lithic and metallic artefacts (Rebelo et al., 2009). These
negative structures are of two types: pits, found in sector 2, are
smaller, deeper, have a cylindrical shape (pits III, IV, V, VI, VII and IX)
and probably would be used to store agricultural products; and hut
floors (sector 1: hut II; sector 3: huts VIII and X), larger structures
composed by two circular and contiguous areas (resembling an 8),
where combustion structures were recorded.
The hut X has become particularly important due to the metallic
artefacts and, especially, the remains of metallurgical activities
recovered in it, namely crucibles, moulds, one tuyere, and tens of
small metallic prills. This structure was partially affected by
mechanical work for clay extraction, while the undisturbed stratigraphic layers contained a homogeneous set of archaeological
materials, namely ceramics identical to those found in the
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Fig. 1. Location of Entre Águas 5 (EA5) in Southern Portugal (circle equals 100 km), prehistoric copper mines given by Müller et al. (2007), photos of negative structures (pits and hut
X; scale equals 1 m) and settlement plan with excavated sectors, huts and pits.
disturbed layers. All these artefacts belong to the same cultural
period e the LBA of the SW Iberian Peninsula. The architecture of
the hut floors is also typical of LBA housing structures from this
region. Additionally, the typological features of the material culture
recovered in the remaining negative structures are characteristic of
this chronological period (Rebelo et al., 2009).
The research concerning the metallurgical production remains
from hut X has become a unique opportunity to understand the LBA
bronze production in this southwestern region of the Iberian
Peninsula. The study also involves a discussion concerning the
elemental and microstructural features of copper-based artefacts
recovered from the settlement, including an exceptional example of
the gilding technology, which is very uncommon in Western
Europe before contacts with the Eastern Mediterranean region.
2. Radiocarbon chronology
Radiocarbon dates were obtained from charred wood and bone
samples belonging to different contexts from EA5 (Table 1). Results
indicate that huts (II, VIII and X) and dated pits (V and VI) share
a coeval occupation that was already indicated by the recovered
material culture. The date Sac-2404 (hut II/layer 203A) must be an
outlier, perhaps due the “old wood effect”, since a second date
(Beta-313500) obtained with a short lived shrub sample, collected
in the same layer, has a value statistically not different from the
remaining dataset. Moreover, a small piece of charred wood of Erica
entrapped among the slag from one of the crucibles gave a similar
date (Beta-261318). Consequently, production remains from hut X
can be ascribed to a single metallurgical workshop coeval with
remaining huts and belonging to a moment comprised between the
10th and 9th centuries BC (Fig. 2). A metallurgical workshop with
a reliable and precise chronology like the obtained here is unique
among the LBA archaeological record from the SW Iberian
Peninsula.
3. Production remains and metallic artefacts from EA5
All traces of metallurgical production recovered at EA5 come
from the metallurgical workshop at hut X. Crucibles 1391A and
1374A have a socketed handle into which a clay covered rod or stick
could be inserted to facilitate handling during operation (Fig. 3).
The crucible 316 has a similar shape but the part that could contain
the socket is missing. Socketed handle crucibles are commonly
found among the archaeological record of the Eastern Mediterranean but are rather unusual in Iberian Peninsula (Urbina et al.,
2007). The closest example from this region can be found in the
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P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
Table 1
Radiocarbon dates obtained from wood and bone samples from EA5 (* e crucible 1374; ** e Calluna vulgaris; *** e Erica sp.; Calendar ages using IntCal09, Reimer et al., 2009
and OxCal 4.1.7, Bronk Ramsey, 2009).
Lab. Ref.
Sac-2404
Beta-313500
Sac-2411
Sac-2410
Sac-2405
Sac-2403
Sac-2409
Beta-261318
Structure/layer
Hut floor II/203A
Hut floor II/203B
Pit V/502
Pit VI/601
Hut floor VIII/809e1
Hut floor X/1012
Hut floor X/1012
Hut floor X/1374*
Sample type
Charred
Charred
Charred
Charred
Charred
Bones
Charred
Charred
wood
wood**
wood
wood
wood
wood
wood***
socketed crucible from the LBA settlement of Martes, Southern
Portugal (Calado and Mataloto, 2001) or in the socketed crucible of
Cerro de San Cristobal (Diaz et al., 2001). The crucibles 1391A and
1374A from EA5, plus two other fragments, 1374A1 and 1374A2,
have heavily slagged surfaces and evident metallic remains.
Furthermore, these crucibles exhibit thick walls (up to 2 cm) suggesting that the heating would be done from above, as it seems to
be common in pre and protohistoric metallurgical operations in the
Iberian Peninsula (Waerenborgh, 1994; Rovira, 2004). The use of
organic temper was encountered in some of the crucibles (1374A
and 1391A) being an additional indication that the heating was
done from above. The voids left from the burning of pieces of straw
or chaff increase thermal insulation and help in producing the
reducing conditions inside the crucible (Bayley and Rehren, 2007).
Fig. 2. Radiocarbon calibrated dataset generated by OxCal program (dashed lines are
suggested limits for the metallurgical workshop at EA5).
d13C (&)
25.4
25.3
25.1
25.7
20.4
21.6
21.2
23.2
14
C age (BP)
2900
2780
2660
2610
2740
2770
2650
2740
60
30
90
70
70
50
80
40
Calendar age (cal BC)
1s
2s
1210e1010
990e900
970e670
890e590
970e820
980e840
920e680
920e830
1290e920
1010e840
1040e540
920e520
1110e790
1040e810
1010e540
980e810
Another interesting example from EA5 is a somewhat deeper
crucible (1374) with a definite lip that would facilitate the pouring
of molten metal into the mould (Fig. 3). This crucible exhibits
a thinner layer of slag, as well as two other crucible fragments (1373
and 165). The study of slags in ceramic crucibles from the EBA/MBA
metallurgical site of Peñalosa (Central Spain) suggests that shallow
open examples were smelting crucibles, while deeper pots were
used as melting crucibles. Furthermore, this type of lip is more
common in the melting crucibles although being present in a few of
the smelting vases (Onorato et al., 2010).
Many metallic prills with variable sizes and irregular or
rounded shapes were also present in the metallurgical context
from EA5. A set of 20 metallic prills with sizes ranging from 0.5 cm
to 2 cm were selected for study. To avoid confusion, the smaller
metallic inclusions entrapped among crucible slags will be
designated as metallic nodules. The archaeological record from
the Iberian Peninsula indicates that Chalcolithic and Bronze Age
smelting operations did not produce true tapping slags (see, for
example, Müller et al., 2004). Commonly, the slag must be crushed
to remove the metal prills. This differs from Bronze Age metallurgy in other regions such as at the EBA site of Arisman (Iran)
showing evidences that the slag and metal would be tapped
together and worked in a semi-liquid state to improve separation
(Rehren et al., 2012).
The cylinder-shaped tuyere from EA5 has a vitrified nozzle with
traces of slag and metallic remains (Fig. 3). The study of the
significant collection of tuyeres from the 8the7th century BC
Phoenician settlement of La Fonteta (SE Spain) did not identify
a clear functional distinction between round and square types,
although the last ones prevail among the iron metallurgy contexts
(Renzi et al., 2009). A similar circumstance can be found among the
coeval metallurgy of the Eastern Mediterranean, where it is
unknown whether the square cross-section replaced round tuyeres
in the bronze and iron production or if it was used only in the iron
metallurgy (Eliyahu-Behar et al., 2012).
Metallurgical remains from EA5 also comprise 13 small clay
fragments with thin walls (<1 cm), curved shapes and, in most
cases, scorched surfaces (Fig. 3). These fragments were interpreted
as moulds with inner surfaces scorched from contact with molten
metal. Macroscopically, there are no other evidences of having been
used, such as slag or metallic remains. The highly fragmented state
of these moulds lead us to believe that they could have been used in
lost-wax casting in spite of their thin walls (usually, the lost-wax
casting uses a thick clay coverage). This technique was well
known in the gold metallurgy of the Iberian Peninsula since the
MBA, but rarely applied to bronze artefacts during the LBA
(Armbruster, 2002).
Archaeological works at EA5 also uncovered several copperbased artefacts (Fig. 3), namely 1 awl, 2 beads, 1 bracelet, 2 fibula
pins, 1 needle, 2 rings and 2 fragments of unknown type. All these
objects come from the same archaeological context of the
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P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
Fig. 3. Production remains and metallic artefacts recovered from the LBA settlement of EA5 (A: sockets from crucibles 1391A and 1374A; B: diagram of socketed crucible with rod).
metallurgical production remains (hut X), with the exception of the
fibula pin 411 and the needle 491a, which belong to the hut II.
A prestige artefact was also recovered among those common
tools and ornaments e a copper-based nail with the head covered
by a gold foil (Fig. 3). Pre and protohistoric gilding is uncommon in
the European region. Recently a copper nail with a gilded head was
identified among the collection from the LBA settlement of Castro
de São Romão, Central Portugal (Figueiredo et al., 2010a). This
exceptional artefact underlines the importance of the metallic
collection from EA5 and, together with the metallurgical production remains, establishes EA5 as a unique LBA site in SW Iberian
Peninsula.
4. Materials and methods
Technical ceramics were analysed with a Kevex 771 EDXRF
spectrometer equipped with a Rh X-ray tube, secondary excitation
targets and a Si(Li) detector (FWHM 165 eV at 5.9 keV). Two excitation conditions (Ag and Gd secondary targets) were used to
optimize the detection of the elements of interest. Other details
about the equipment and analytical conditions were previously
published (Araújo et al., 1993). Preparation for further analyses
included cutting of a section and polishing with silicon carbide
papers (400e4000 grit size). Microstructural characterisation was
made with a Zeiss DSM 962 conventional tungsten filament
scanning electron microscope with secondary electron (SE) and
backscattered electron (BSE) imaging modes. Elemental semiquantifications were made with the ZAF method using an Oxford
Instruments INCAx-sight EDS spectrometer equipped with an ultrathin window to detect elements with low atomic number (Z < 5).
Experimental conditions consisted of 25 mm working distance,
20 kV accelerating voltage, approximately 3 A filament current and
70 mA emission current. Additionally, slagged samples were
observed with a Leica DMI 5000 M optical microscope (50 to
1000) under bright field illumination, dark field illumination and
polarised light.
Prior to analysis, metallic artefacts were polished in a small area
(B w3e5 mm) using a manual drill with diamond pastes (15 mme
1 mm). It was assured that the polishing depth was enough to obtain
a clean metal surface for analysis. Alternatively, a small section of
incomplete artefacts was cut with a precision saw and mounted
in epoxide resin, polished with silicon carbide papers (1000e
4000 grit size) and finished with diamond pastes (1 and 1/4 mm).
The elemental composition was determined with an ArtTAX Pro
micro-EDXRF spectrometer equipped with Mo X-ray tube and
silicon drift detector (FWHM 160 eV at 5.9 keV). Focussing polycapillary optics and accurate positioning system allow a minute
area of primary radiation at the sample (B < 100 mm, Bronk et al.,
2001). Each artefact was analysed in three independent spots with
40 kV of tube voltage, 0.5 mA of current intensity and 300 s of real
time. Experimental calibration factors were calculated with Phosphor Bronze 551 and Leaded Bronze C50.01 standard reference
materials. The accuracy is better than 2% for Cu and Sn, and better
than 10% for Fe, As and Pb. Quantification limits are 0.5 wt.% Sn,
0.05 wt.% Fe and 0.10 wt.% for As and Pb. Additional experimental
details were previously published (Valério et al., 2007). The
microstructural characterisation comprised observation of
unetched and etched samples (aqueous ferric chloride). The Vickers
microhardness was measured using a Zwick-Roell Indentec apparatus by applying 0.20 kgf load during 10 s. The hardness value
P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
considered is the average of at least 3 indentation measures, having
a relative standard deviation less than 5%.
5. Results and discussion
5.1. Bulk analyses
Elements enriched by metallurgical operations were identified
by comparison of EDXRF analyses of inner/slagged and outer/clay
surfaces of technical ceramics. The results have showed that slagged surfaces of crucibles are enriched in copper and tin, except in
the crucible with a pouring lip that is only clearly enriched in
copper (Fig. 4A and B). The presence of certain elements in these
slagged surfaces result from various components always present in
metallurgical operations e Ca, Mn and Fe from ceramics, gangue or
wood ash (Etiégni and Campbell, 1991). Other elements usually
present in copper-based alloys are more suggestive of metallurgical
operations despite presenting different tendencies to become
associated with the clay material. For example, the significant
volatility and high free energy of oxidation of Zn, in addition to
a high reactivity with clay silicates, results in a high Zn enrichment
in the crucible even when it was only present at trace levels (Kearns
et al., 2010). Thus, results established that most crucibles were used
directly in the production of bronze, while the crucible with
a pouring lip may have been used for the melting of copper nodules
or copper scrap. Indeed, the lip on this crucible suggests a well
liquefied charge, discordant with the high viscosity slag produced
by these primitive smelting operations.
In the case of metallic prills, EDXRF analyses have established
that the collection is entirely composed of bronzes. Similarly, the
tuyere nozzle presents high amounts of copper and tin (Fig. 4C),
443
while only some of the mould fragments were slightly enriched in
these elements (Fig. 4D). Moulds often exhibit less evidence of have
being used than crucibles because casting originates fewer residues
than smelting or melting. Nevertheless, results obtained ascertain
that moulds were used for casting of bronze alloys.
These analytical results readily establish distinct metallurgical
operations in LBA workshop from EA5. The majority of production
remains resulted from the production of bronze, while the crucible
with a pouring lip was probably used in copper melting. Furthermore, the metallurgical operation involved the use of forced air
through tuyeres, while bronze casting was also being performed in
this workshop.
5.2. Smelting crucibles
The slag in socketed handle crucible 1374A is composed of
a highly heterogeneous material with numerous metallic inclusions. Reactions between the metal and oxide melts with the
crucible fabric and charcoal ash originated a vitreous matrix of
aluminosilicates with Na, Mg, K, Ca, Mn and Fe (Fig. 5). The abundant presence of magnetite shows an iron-rich slag under local
oxidising conditions. The poor reducing atmosphere attained inside
the reaction vase is also evidenced by the numerous globules of
cuprite and malachite, most likely formed by re-oxidising metallic
copper during the operation (Hauptmann, 2007). Although, these
copper compounds can also result from oxidation during long-term
burial. The small globular CueS formations evidence the existence
of matte (molten metal sulphide). Since smelting of oxide copper
ores containing sulphide impurities resulted in slags with matte
(Hanning et al., 2010), their presence in EA5 slag can also be
understood as a natural occurrence in the copper ores. Other areas
Fig. 4. EDXRF spectra of slagged/inner versus clay/outer surface of the socketed crucible 1374A (A), triangular lip crucible 1374 (B), tuyere 1374 (C) and mould 1432B2 (D).
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P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
Fig. 5. SEM-BSE and OM-BF images of slag and metallic nodules in crucible 1374A (cross-section evidencing the slag layer and bloating of crucible ceramics).
of this slag present numerous tin oxide inclusions as globular or
euhedral needles. The latter are a secondary product resulting from
tin oxidation in molten phase. A copper nucleus inside some of
them suggests that both metals were present in an oxidising
environment, i.e. tin was oxidised leaving a metallic copper core
(Dungworth, 2000). The considerable abundance of tin oxide
inclusions, in addition to the absence of metallic tin, can be
understood as an evidence of the use of cassiterite (Rovira, 2004).
Results of microstructural analyses of slag in crucible 1374A are
summarized in Table 2.
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P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
Table 2
SEM-EDS and optical microscopy results of crucible slags from the metallurgical workshop at EA5 ( e present; e high amount; n.d. e not detected).
Crucible
Copper nodules
Bronze nodules
Cuprite
Malachite
Copper sulphide
Tin oxide
Magnetite
Other
1374A
1391A
316
1374A2
1373
1374
n.d.
n.d.
n.d.
n.d.
n.d.
n.d.
n.d.
n.d.
n.d.
n.d.
n.d.
n.d.
n.d.
n.d.
e
CueOeS relics
e
e
e
Charcoal
Metallic nodules with different sizes (from few microns up to
1 mm) are quite abundant in slag from the crucible 1374A. A high
loss of metal due to high viscosity of immature slags is a common
characteristic of primitive smelting operations. Generally,
metallic nodules show coarse granular microstructures (Fig. 5)
that evidence the slow cooling rate of slag inside the crucible.
Occasionally, the coarse microstructure enables recognition of
coring due to a slightly faster cooling, e.g. nodule N1. SEMeEDS
analyses identified CueS and Pb-rich inclusions in most
metallic nodules as well as the a þ d eutectoid in tin richer ones.
In fact, the highly variable composition of these nodules is their
more noteworthy characteristic (Table 3). This feature indicates
the reasonably heterogeneous conditions (T and pO2) inside the
reaction vase, while low iron contents (<0.05 wt.%) evidence
a poor reducing environment. All these characteristics exclude
the possibility of bronze recycling, contrary suggesting the
production of bronze with independent sources of copper and
tin. For example, recent experiments involving the co-smelting of
copper ores and cassiterite originated a slag with numerous
metallic prills of copper and bronze (up to w80 wt.% Sn) (Rovira
et al., 2009).
The slag in the second socketed handle crucible (1391A)
displays a comparable vitreous matrix with abundant copper
nodules, copper oxide and tin oxide precipitates (Fig. 6). The
numerous magnetite inclusions point to weak reducing conditions. Certainly, the most valuable information was given by relic
mineral inclusions composed of copper sulphides and malachite.
The morphology of these relics is very different from the more
abundant globules of oxidised copper, eventually formed during
the metallurgical operation or by long-term corrosion. Local
unsuitable conditions (TY and pO2[) during operation seem to
have prevented decomposition of these relics. Above all, their
presence establishes the smelting of oxide copper ores rather than
the use of metallic copper to produce bronze.
Samples from “socketed handle” crucible 316 and fragment
1374A2 show analogous features (Table 2), namely highly
heterogeneous slags composed of an aluminosilicate matrix with
euhedral tin oxide needles, magnetite precipitates, copper and
bronze prills (Fig. 6). The similarity of these slags suggests that
crucibles were used in analogous metallurgical operations,
namely the smelting of copper ores with cassiterite to produce
bronze.
Table 3
Composition of metallic nodules in crucible 1374A from the metallurgical workshop
at EA5 (values in wt.%; n.d. e not detected).
Metallic nodule
N1
N2
N4
N7
N9
N10
SEM-EDS
Micro-EDXRF
Cu
Sn
Sn
Pb
As
Fe
94.4
93.4
75.4
95.7
88.9
74.2
3.1
e
24.6
3.8
12.0
25.8
2.4
5.8
e
3.5
9.9
e
n.d.
0.67
e
0.59
1.0
e
<0.10
n.d.
e
0.15
n.d.
e
<0.05
<0.05
e
<0.05
0.05
e
In the Iberian Peninsula, the archaeological record indicates that
copper ores were reduced in open ceramic vessels, usually designated as smelting crucibles, until the Iron Age (Rovira, 2002). For
instance, smelting crucibles with remains of copper or bronze slags
were found in several SE Iberian sites, like Los Millares (Chalcolithic), Ronda (MBA) and Peña Negra (LBA) (Ramos, 1999). On the
contrary, in Central European and Eastern Mediterranean regions
the smelting of copper ores was often made in conventional and
larger furnaces, such as the cylindrical clay furnaces from the LBA
site of Politiko-Phorades, Cyprus (Hein et al., 2007) or the LBA
copper smelting furnaces excavated near Mühlbach, Alpine Region,
Austria (Herdits, 2003). However, it must be emphasized that
crucible smelting was still utilised in the Eastern Mediterranean, as
testified by the bronze slag inside a crucible from the 10the9th
century BC site of Tell es-Safi/Gath, Southern Levant (EliyahuBehar et al., 2012).
The adoption of efficient smelting furnaces must have resulted
from the need to produce a higher amount of metal and/or to smelt
complex ores, like the fahlore deposits of the Alpine regions in
Central Europe (Orel and Drglin, 2005; Postma et al., 2011). These
motivations seem to have been absent in the Iberian metallurgy
until the Orientalizing period, since smelting crucibles were
perfectly adapted to the processing of existing high-grade oxide
copper ores (malachite and cuprite). Moreover, it seems that
metallurgical activities were usually conducted on a domestic scale
(Senna-Martinez and Pedro, 2000).
Similarly to EA5, other studies of LBA slags from the Iberian
Peninsula suggest that the co-smelting of copper and tin ores was
the preferred method to produce bronze (Rovira, 2007). Recent
experimental tests confirmed that copper ore and cassiterite can be
efficiently reduced with a simple crucible, using a couple of tuyeres
and charcoal as fuel (Rovira et al., 2009). The metal prills produced
in this way were melted in a flat-bottom crucible to obtain a bronze
ingot. An alternative process involves the cementation of metallic
copper with cassiterite, as suggested by the slag found in a LBA
socketed handle crucible from Cerro de San Cristobal, also located
in the Guadiana basin, in the southern Spanish Extremadura (Diaz
et al., 2001). Bronze can also be obtained by melting metallic
copper and tin, but the earliest evidence of this method comes from
a slag belonging to an Orientalizing context of Carmona, SW Iberian
Peninsula (Rovira, 2007). In the Portuguese territory the only
available study in this matter comprises a slag from the habitat site
of Baiões (Central Portugal) suggesting the use of a smelting
crucible to reduce copper ores with cassiterite or metallic tin
(Figueiredo et al., 2010b).
Recent studies indicate that the lead isotopic signature of copper
artefacts, prills and slags from Chalcolithic settlements in the
Portuguese Estremadura, such as Vila Nova de São Pedro (Müller
and Soares, 2008), Leceia (Müller and Cardoso, 2008) and Zambujal (Müller et al., 2007) is consistent with that of copper ores from
the Ossa Morena Zone (OMZ). In a preliminary survey Müller et al.
(2007) have identified several copper mining sites in Southern
Portugal. Some of them display evidences of having being worked
during the Chalcolithic and/or Bronze Age (i.e. stone hammers and
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P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
Fig. 6. SEM-BSE images of the slag in crucibles 1391A, 316 and 1374A2.
anvils) and are located not very far from EA5 (see Fig. 1). On the
contrary, the nearest LBA sources of tin in the Portuguese territory
are mostly located in the Central Portuguese region, probably
alluvial deposits in local rivers (Figueiredo et al., 2010b). Tin could
also be obtained from the more inland region of Caceres (Spain), as
the LBA settlement of Cerro de Logrosan presents evidences from
the exploitation of this resource (Rovira, 2002).
5.3. Melting crucibles
Slag in crucible 1373 comprises a thinner layer of a complex
vitreous matrix (aluminosilicate with Na, Mg, K, Ca, Mn and Fe)
with a few globular nodules of bronze presenting similar compositions (Fig. 7). This slag evidences a reduced interaction between
metal/oxides and crucible ceramics, while copper and tin oxide
precipitates, common in former slags, are absent (Table 2). These
features seem to indicate that crucible 1373 was used in bronze
melting rather than smelting.
The slag in the crucible with a pouring lip (1374) displays
a different feature since it is composed of an oxide copper matrix
with copper sulphide inclusions (Table 2 and Fig. 7). A charred
wood inclusion entrapped among this slag was morphologically
identified as Erica sp. (heather). This species is very common in
southern Portuguese territory and has one of the highest calorific
powers among the woods known to be used as fuel in ancient times
(Martínez and Sala, 2010). Furthermore, charcoal inclusions are
more commonly found amongst completely liquefied slags
(Hauptmann, 2007). Considering these characteristics together
with the typology of the crucible e somewhat deeper and with
a pouring lip e it seems that it may have been used to melt copper.
However, the high amount of matte suggests a primary copper
source rich in sulphur rather than remelting of scrap copper.
5.4. Metallic prills
Some of metallic prills were analysed by micro-EDXRF to
establish their compositions (Table 4). The bronze prills show
a variable tin content (6.0e16.5 wt.%), comparable to the obtained
in smaller bronze nodules entrapped in crucible slags. Moreover,
the impurity pattern is very similar (Pb > As > Fe), which
together with the very low amount of iron (<0.05 wt.%) points to
the poorly reducing environment attained during smelting. Some
Fig. 7. SEM-BSE images of the slag in crucibles 1374 and 1373.
P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
Table 4
Composition of metallic prills from the metallurgical workshop at EA5 (values in
wt.%; n.d. e not detected; * e twin prills).
Prill
Reference
Shape and size
Cu
Sn
Pb
As
Fe
P1
P2a*
P2b*
P3
P4
P5
P6
1386a
1386f
1386f
1389a
1390
1426a
1699a
Irregular (1.8 cm)
Rounded (0.5 cm)
Rounded (0.5 cm)
Rounded (0.6 cm)
Irregular (1.2 cm)
Irregular (0.9 cm)
Rounded (0.7 cm)
93.8
85.9
84.1
93.4
86.9
83.2
83.2
6.0
13.3
14.9
6.2
12.6
16.5
15.6
0.12
0.46
0.68
0.24
0.33
0.30
0.82
<0.10
0.29
0.27
0.10
0.13
n.d.
0.38
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
of the prills show coarse microstructures (P2a, P2b, P3 and P6,
Fig. 8) that are compatible with the slow cooling rates inside
a crucible. These prills tend to be rounded (see Table 4) due to liquid
immiscibility, thus suggesting its formation inside a partially liquefied slag. Others have irregular shapes and cored dendritic
structures (P1, P4 and P5, Fig. 8 and Table 4) showing relatively
faster cooling rates.
5.5. Bronze artefacts
The results of micro-EDXRF analyses show that the collection of
copper-based artefacts has a variable content of tin (1.6e15.5 wt.%)
plus minor amounts of lead, arsenic and iron (Table 5). These
copper-based artefacts can be considered rather pure since the sum
of metallic impurities is below 1 wt.%. The iron content is very low
and comparable to the metallic prills. Low amounts of iron are very
common in Iberian bronzes before Orientalizing influences
(Craddock and Meeks, 1987). LBA geographically closer examples
can be found in habitat sites and hoards from Central Portugal,
namely Baiões, Viseu (Figueiredo et al., 2010b), Canedotes, Viseu
(Valério et al., 2007) and Freixianda, Ourém (Neira et al., 2011). In
Southern Portugal, the 9the8th century BC (Soares and Martins,
2010) fortified settlement of Castro dos Ratinhos (Moura) presents a bronze collection with low iron contents, suggesting that
the smelting technology remained unchanged despite some
447
Orientalizing influences, such as rectangular habitat structures,
wheel-turned pottery, red slip ware, amphorae, iron and ivory
artefacts (Valério et al., 2010).
The nearly exclusive usage of binary bronzes with suitable tin
contents is another feature of this LBA metallurgical tradition.
Actually, most artefacts from EA5 are composed of binary bronze
alloys with an average tin content of 9.7 3.2 wt.%, whereas only
the bead 1127a has a tin content below 2 wt.%. The similarity with
bronze alloys from Castro dos Ratinhos (10.1 2.5 wt.% Sn) is
remarkable evidencing that this LBA metallurgy lasted until later in
this inland region of the Portuguese territory. However, a new
metallurgical tradition was already present in this west end of the
Iberian Peninsula, as established by the copper, leaded bronze and
low-tin bronze (5.4 2.0 wt.% Sn) artefacts from the 9the7th
century BC Phoenician seaboard settlement of Quinta do Almaraz
(Valério et al., 2012).
Similarly to the Portuguese territory, LBA copper-based artefacts from the remaining regions of Iberia are commonly manufactured with binary bronze alloys. The exception can be found in
the NW region, where leaded bronzes are common following the
Atlantic tradition of the British Isles and of the Western France.
Metallic artefacts from the SW Iberian region are well depicted by
the hoard from Ria de Huelva (Huelva). Despite the controversy
about its origin (ritual deposit, ship wreck or other), it is noteworthy to realize that this 11the9th century BC collection of
about 400 artefacts comprises bronze alloys with homogeneous
content of tin (w8e14 wt.%) and low amount of impurities
(Rovira, 1995).
The relatively standardized composition of LBA bronzes shows
the expertise of ancient metallurgists even using primitive
smelting crucibles. Furthermore, it provides some hints about the
copper ores used, probably high-grade carbonate ores, as complex
sources will certainly originate more variable compositions and
higher amounts of impurities. A good example of this relation
comes from the copper-based artefacts with 6e16 wt.% of Sb, As,
Ag and Ni due to the smelting of complex Alpine fahlore deposits
(Postma et al., 2011).
Fig. 8. OM-BF images of metallic prills recovered from the metallurgical workshop at EA5.
448
P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
Table 5
Results of micro-EDXRF, optical microscopy, SEM-EDS and Vickers microhardness testing of copper-based artefacts from EA5 (composition in wt.%; n.d. e not detected;
C: Casting; A: Annealing; F: Forging; FF: Final Forging; [: high amount; Y: low amount; hardness in HV).
Artefact
Reference
Cu
Sn
Pb
As
Fe
Phases
Inclusions
Manufacture
Hardness
Awl
Bead
Bead
Bracelet
Fibula (pin)
Fibula (pin)
Fragment
Fragment
Needle
Ring
Ring
1554
1037
1127a
314a
1384a
411
314
1250
491a
1388
1425
88.3
88.8
97.6
94.6
91.5
89.6
90.1
92.2
93.1
84.3
87.1
11.6
11.1
1.6
5.0
8.3
10.3
9.5
7.7
5.9
15.5
12.7
n.d.
n.d.
0.49
0.27
0.10
n.d.
0.20
n.d.
0.69
0.20
0.12
n.d.
<0.10
0.33
<0.10
<0.10
n.d.
<0.10
<0.10
0.20
<0.10
<0.10
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
a
a
a
a
a
a
a
a
a
a, d[
a
CueS[
CueS[
CueS[
CueS[
CueS
CueS[
CueS[
CueS[
CueS[
CueS[
CueS[
C
C
C
C
C
C
C
C
C
C
C
e
148 8
e
79 1
146 7
166 8
e
139 4
154 3
163 6
126 5
The microstructural characterisation of metallic artefacts from
EA5 evidenced that the ring 1388 has a significant amount of a þ d
eutectoid (Fig. 9). This agrees with the high tin content of the ring
(above the solubility limit in the a phase, i.e. w14 wt.% Sn, Hanson
and Pell-Walpole, 1951). The significant presence of the harder
d phase originates an alloy with a lower ductility, but this typology
probably does not require a high toughness or a significant
metalworking. These circumstances suggest that those ancient
metallurgists were conscious that bronzes richer in tin were more
difficult to work. Consequently, alloys with higher tin amounts
could be retained for specific typologies. A recent study described
the colour of copper alloys using the CIELAB colour space, establishing that the addition of up to 15 wt.% Sn reduces the redness of
the alloy thus approaching of a golden hue (Fang and McDonnell,
2011). A golden colour allows recognizing the raw materials
(prills or ingots) richer in tin and would certainly be appreciated in
prestige artefacts.
The optical microscopy observations identify a-Cu deformed
equiaxial structures with annealing twins and slip bands (Fig. 9).
These characteristics evidence a common manufacturing process,
which would be finished with hammering after cycles of forging
þ
þ
þ
þ
þ
þ
þ
þ
þ
þ
þ
(F
(F
(F
(F
(F
(F
(F
(F
(F
(F
(F
þ
þ
þ
þ
þ
þ
þ
þ
þ
þ
þ
A)
A)
A)
A)
A)
A)
A)
A)
A)
A)
A)
þ FF
þ FF
þ FFY
þ
þ
þ
þ
þ
þ
þ
FF
FF
FF
FF
FF[
FFY
FF
and annealing (Table 5). The occurrence of small CueS inclusions is
another common feature among these artefacts. For instance, the
SEMeEDS analysis of ring 1388 shows a high amount of CueS
inclusions, together with the a þ d eutectoid displaying an interdendritic morphology. CueS inclusions are common in LBA artefacts from the Iberian Peninsula (e.g. Baiões, Figueiredo et al.,
2010b; and Ria de Huelva, Rovira, 1995) indicating that the same
type of ore was being processed. Similarly, metallurgical remains
from EA5 point to the smelting of copper ores with significant
amounts of sulphur.
The bracelet (314a) is the single artefact without the characteristic slip bands, originated by a final hammering (Fig. 9). The
absence of this finishing operation in a well recrystallized microstructure resulted in a rather soft material (79 HV, Table 5), which,
interestingly, is not detrimental to this specific typology. The final
hammering was always applied to remaining artefacts regardless of
their type, but the intensity of deformation differs. For instance, the
needle 491a has a much higher density of slip bands than the ring
1388 (Fig. 9). Overall, the Vickers testing shows that final
hammering actually produced a harder material, but other factors
like the tin content, recrystallized a-Cu grain size and secondary
Fig. 9. OM-BF and SEM-BSE images of bronze artefacts recovered from the LBA settlement of EA5.
P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
449
Fig. 10. Image of gilded nail 1495b showing the gold foil over a totally corroded bronze head (OM-BF and SEM-BSE images of contact area between foil and bronze substrate).
phases present also influence the final hardness. The high hardness
of ring 1388 (163 HV) is a clear example of the effect of higher tin
contents, in this case resulting from a-Cu phase super-saturation
and precipitation of harder d phase. Nevertheless, the equally
high hardness of the needle 491a (154 HV) proofs that low-tin
bronzes can be effectively strain hardened by a strong final
hammering.
5.6. Gilded nail
Preliminary micro-EDXRF analyses made over corroded surface
of the nail have established that the head and pin are made of
bronze. The advanced state of corrosion of the artefact advised
against any attempt to obtain a clean surface for analysis, but
a small fragment previously detached was prepared for additional
studies. This fragment is constituted by the base metal and gilding
layer (Fig. 10). Optical microscopy and SEMeEDS analyses established that gold layer has a thickness of c. 140 mm and is composed
of a gold alloy with 11.6 wt.% Ag and about 1 wt.% Cu. The method
used can be classified as foil gilding, as opposed to leaf gilding that
evidences an enhanced technique e the leaf can reach thicknesses
of less than 1 mm e commonly applied to refined gold (DraymanWeisser, 2000).
A systematic study (Soares et al., 1996), gathering about 100
analyses from the SAM project of prehistoric gold artefacts from the
Portuguese territory (Hartmann, 1982), showed that the majority of
Bronze Age artefacts has a silver content between 10 and 15 wt.%.
Additionally, LBA gold artefacts show a high range of copper
contents, whereas most artefacts from previous periods presents
values bellow 0.5 wt.% Cu. Consequently, the gold alloy applied to
this bronze nail is typical of the LBA metallurgy in Portuguese
territory.
The next stage involved determining the process used to attach
the foil in the base metal. A close observation indicates that the foil is
bended over the edges of the bronze head (Fig. 10). Furthermore, the
SEMeEDS analyses established that no gold was diffused to the base
metal, which is completely corroded suggesting an initial weak
cohesion between components. The expansion originated by bronze
corrosion originated fissures in the foil and some gold fragments
were detached to the oxidised layer of the base metal. These
features indicate that the gilding involved mechanical work e the
gold foil was burnished over the bronze head and the edges were
bended to secure it e but no evidences were found of the application of heat to promote interdiffusion bonding between components. An intermediate layer, more friable and enriched in Si and Ca
(in addition to Cu) should result from alteration processes. Alternatively, it might suggest the use of an adhesive to improve bonding.
Although this technique is not usually associated with metalworking, it has been used occasionally for leaf gilding, such as in an
Egyptian figurine gilded over a layer of finely ground dolomitic
limestone (Oddy, 1981).
In Iberian Peninsula, earlier gildings involve thick gold foils over
non-metallic hilts of swords and daggers from the Bronze Age
(Perea et al., 2008). Gold foils were commonly applied with rivets or
by bending the edges over the base material. Up to now, gilding
over metal before the Orientalizing period was unknown since the
earlier examples involve iron artefacts. Moreover, the gilded copper
nail from the LBA settlement of Crasto de São Romão involved
diffusion gilding, a method that suggests earlier contacts with
Eastern Mediterranean societies (Figueiredo et al., 2010a). Consequently, considering that EA5 precedes the establishment of
Phoenician settlements in the coastal region (i.e. during the late 9th
and early 8th centuries BC) the gilded nail found in this settlement
is probably the earlier evidence of gilding over metal in Iberia.
6. Conclusions
The elemental and microstructural study of material culture
from EA5 opened a window into the LBA metallurgy in SW Iberian
Peninsula. The remains of the metallurgical workshop found at EA5
are particularly important because of multiple evidences of
different stages of the metallurgical process. The first operation
consisted in smelting inside ceramic crucibles and some evidences
point to co-smelting of oxide copper ores and cassiterite. The
bronze prills formed in the high viscosity slag produced by this
primitive smelting would be gathered to be melted later. This
implies that crushing the slag to hand-pick metal prills was
a common process among early metallurgists on the Iberian
Peninsula, as well as in other European and Mediterranean regions
in general. The slow cooling evidenced by many of metal prills is
consistent with this hypothesis. A crucible with thinner slag layer
and bronze nodules was probably used to melt these prills. The
molten charge could have been poured directly into moulds to
obtain artefacts, which would explain the almost absence of ingots
in the archaeological record. Anyway, some of the fast cooling prills
from EA5 could be casting spills. Apart from these metallurgical
steps, there is another crucible at EA5 that suggests a second
method of bronze production. The copper slag in this deeper
crucible with a definite lip for pouring, suggests the production of
metallic copper prior to alloying.
450
P. Valério et al. / Journal of Archaeological Science 40 (2013) 439e451
The impurity pattern of most finished artefacts recovered in this
settlement is comparable to that of metallic prills locally produced
(Pb > As > Fe) which suggests a possible local production of the
artefacts. Additionally, the low iron content of bronzes indicates
mild reduction conditions during smelting, which are common
among primitive operations conducted in open crucibles. The set of
copper-based artefacts from EA5 is mostly composed of binary
bronzes with about 10 wt.% Sn. Some examples suggest that
manufacture would be adjusted to the artefact functionality e
a ring with a higher amount of tin has a more attractive golden
colour, while a bracelet could exempt the hardening effect of final
hammering.
The area excavated shows that the metallurgical activities
(smelting, casting and, probably the manufacture of artefacts) were
all done in the same area of the settlement suggesting a domestic
metallurgy. Regional copper sources precluded the need for
exchange networks, but perhaps a different matter was the probable importation of tin ores from more distant sources, such as the
Central Portuguese region or the Caceres area in Spain. The
exceptional gilded nail indicates circulation of quite evolved artefacts in addition to simple tools, ornaments and weapons,
commonly found in LBA sites. Finally, the features evidenced by
a comprehensive and significant set of archaeological remains from
this metallurgical workshop (i.e. small scale production, crucible
smelting, poor reducing atmosphere, co-smelting and absence of
ingots), in addition to characteristics of the metal artefacts (bronze
alloys with suitable tin contents), reveal similarities with the
known LBA metallurgy from the SW Iberian Peninsula.
Acknowledgements
This work was carried out in the framework of the project “Early
Metallurgy in the Portuguese Territory, EarlyMetal” (PTDC/HIS/
ARQ/110442/2008) financed by the Portuguese Science Foundation.
CENIMAT/I3N gratefully acknowledges the funding through the
Strategic Project PEst-C/CTM/LA0025/2011. The taxonomic identification of the charcoal was made by Paula Queiroz (Terra Scenica).
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