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FOUNDRY IRONS
A PRACTICAL TREATISE
ON
FOUNDRY
IRONS:
COMPRISING
PIG IRON,
SCRAP IRONS
BY
EDW^ARD
KIRK,
ILLUSTRATED
PHILADELPHIA
CO.,
Walnut
1911
Street.
Copyright, 191 i
BY
EDWARD KIRK
I/-/50Z3
f:CI.A2Sl>SJ2
PREFACE.
This volume has been prepared
many
seeking
founders
Irons and
at
information
practical
FOUNDRY
on
lines of castings.
It
and
is
all
work
foundry practice.
It
the
foundries,
is
all
hoped
by both the
old and
the
as
actually
results
thus,
it
on
practiced in
all
fail to
ob-
uncertain until,
used
When
in
its
this
this
metal
will
be
may be produced
with as
PREFACE.
vl
to the
drymen's Association, The Philadelphia Foundrymen's Association, The American Society for Testing Materials from all of
to
"The
other journals.
few papers by
it
remains
o.ily to
is
their long-established custom, have caused the book to be provided with a copious Table of Contents and a very full Index,
which
will
in
the
book
eas}-
and prompt of
reference.
Edward
Philadelptiia, June, 191
1.
Kirk.
CONTENTS.
CHAPTER
I.
...
furnaces;
their principal
locations
.4
blast-furnaces
Blast-furnaces of this country in early days; Gradual decrease in charcoal
their development;
Improvement of foundry
iron;
Improvement
...
9
the elimination of sulphur and silicon from smelting fuel
Varied characteristics of coke-smelted iron as a foundry iron; Analysis
10
of Connellsville coke
Analyses of other cokes; Report of Doctor Richard Moldenke on the
coke industry as affecting the foundry, and analyses of various cokes;
.11
Coke districts of the United States; General statement
Description by states; Coke produced in Alabama and average composi.
tion of
12
it
Colorado coke and its average composition; Georgia coke; Illinois coke;
.13
Analysis of a coke made from a washed Illinois coal
Kentucky, New Mexico, and Ohio cokes; Pennsylvania cokes and their
14
range of composition
.
(vii)
CONTENTS.
Vlii
PAGE
Tennessee cokes and their range of composition; Virginia cokes and
their range of composition; Washington coke
15
Composition of Washington coke from unwashed coal; West Virginia
cokes and their range of composition; Value of a standard composi16
tion; Desirable composition for foundry coke; Solway coke
17
Preparation and constitution of Sol way coke
Average monthly analysis of Detroit Solway coke during 1907, 1908,
18
1909, and 1910
.
CHAPTER
II.
20
One
Former grading
this
of
coke
iron;
Coke
War
of the
21
.22
23
iron
grading
24
High
silicon iron
25
26
may be
-27
Melting light scrap and high silicon pig; Content of silicon in pig iron
now made for foundry work
Scotch pig; Kish
American Scotch pig, and brands of high reputation; Pig iron
30
Sand
31
28
29
32
.......
..........
.
CONTENTS.
CHAPTER
ix
PAGE
III.
Scrap Irons.
Cast iron scrap; Machinery scrap
40
45
46
47
this iron
.......
German method of
41
42
43
44
.48
49
.51
re-
52
briquetting of iron
53
Briquets for use in the cupola; Carbon percentage in the iron and
briquet combination used in the cupola
Melting borings and turnings in the cupola
Mr. Prince's patented process of melting borings
Steel turnings and mode of melting them; W. J. Keep's method of
melting borings
Melting cast iron borings in the cupola; Mr. T. Shaw's remarks on this
56
57
58
subject
Use of borings
54
55
for
.59
on this subject
CHAPTER
IV.
Mixing Irons.
Mixtures of iron; Reasons why mixtures of iron are made
.60
Mode of trying a new iron A mixture made by one founder of no value
61
to another one; Stove-plate mixtures
62
Machinery mixtures
Mixtures of pig and scrap; Mixtures for soft, strong castings, for a hard
.63
or close iron, for hard castings, and for chilled castings
Remelt iron; Locomotive cylinder mixtures recommended by Mr. Paul
64
R. Ramp
65
Making mixtures
.66
Making mixtures by fracture indications and analyses
.
knowledge of the
mixing them
Practical
67
CONTENTS.
PAGB
CHAPTER
V.
............
68
Estimate of loss upon pig and old scrap; Loss in melting machinery
scrap; Loss in melting old stove-plate scrap
69
Loss in melting plow point scrap; Loss in melting shot iron; Test to de70
termine the loss in melting this iron
71
Loss in melting burned iron
Loss and gain in melting pig and scrap iron; Gain in melting 100 net
.72
tons of pig iron bought in gross tons of 2,240 lbs.
Loss in melting 100 tons of scrap irou bought in net tons and sold as net
73
tons or pounds; Comparison of the two tables
Stove foundry melting; Tables showing statements of melting per cent,
.........
.
and Troy, N. Y
Melting done and
N.
74
results obtained at the Perry Stove
Works, Albany,
75
Determining actual
loss of iron;
is
liable to.
76
CHAPTER VL
Castings by Direct Process.
Mode
78
79
.80
Destruction of iron by rust; Hardening effect of oxide.
Decrease in the value of cast iron by rust; Oxidation of iron by heat and
81
its causes; Effect of the oxide
Nature of the 'iron obtained when remelting oxidized iron; Sandwiched
.82
hard spots, and their occurrence
Sash-weight metal; Properties required in sash weights; Materials used
83
in casting sash weights
.85
Melting the metal for sash weights; Temper in cast iron.
86
Automobile cylinder packing rings
.
..........
.
87
CHAPTER
VII.
Foundry Chemistry.
Historical data;
First experimental
Commencement
88
89
CONTENTS.
xi
PAGE
The metalloid
theory; Metalloids
to be
9U
castings;
No
.91
.........
manipulation of metalloids
Means
change
92
purposes
93
CHAPTER
VIII.
.......
'.
97
98
99
.100
Carbon
Turner
101
Amount
of carbon iron
may
absorb^in
smelting
Change
102
cast iron
in
.108
Increase in the bulk of iron by carbon; Carbon the real softener and
......
........
upon
Claims
cast iron
for
manganese
as a hardener
and strengthener
....
106
107
CONTENTS.
Xll
PAGE
ladle;
Phosphorus
iron;
....
Use of manganese in a
ladle;
in iron; Varieties of
High phosphorus
irons
in a
108
.109
Percentage of phosphorus in the better brands of soft foundry iron; Sulphur in iron; Effects of sulphur on cast iron
Curious experience with sulphur; Hardening iron with sulphur
Oxygen in iron; Tendency of iron to absorb oxygen; Drying the blast.
Oxidizing effect upon iron in melting in a cupola, and its prevention
.
Ill
113
114
CHAPTER
110
112
IX.
in the chill
.117
iron and steel Aluminum and cast iron
Attempts to combine aluminum with cast iron; Effects of aluminum;
118
Experiments with ferro-aluminum
Nickel in iron; Effect of nickel in steel; Other metals and cast iron;
119
Experiments in alloying various metals with iron in the cupola.
Untried metals in iron; Vanadium and its chief ores; Deposits of vana.
.120
dium ores.
Use of vanadium in the manufacture of steel; Dr. Moldenke's experiments in melting burned iron with vanadium; Experiments by vari121
ous founders with vanadium in castings
122
Ferro-vanadium; Effect of vanadium on iron
Cost of 10 per cent and 20 per cent, ferro-vanadium in 100 lbs. of
123
molten iron or steel
124
Content of vanadium in French automobile cylinders
.
....
CHAPTER
X.
12o
men's Association standard specifications for foundry pig iron
126
Proposed standard specification for foundry pig iron; Sampling
.127
Percentage of elements; Symbols to designate elements
The American Foundryraen's Association standard specifications for
foundry ])ig iron; Proposed standard specifications for buying pig
128iron; Percentages and variations
129
Sampling and analysis
.
CONTENTS.
xiii
13(i
Base of quoting price; Penalties; Allowance; Base table
Analysis of castings collected from various parts of the country
131
Method of calculating mixtures for the cupola; Analysis of the castings
required; Average analysis of the iron and scrap to be charged
132
Tabulation of the material to be charged and method of figuring the
mixture
138
.
CHAPTER
XI.
.......
Analyses of
chills, collars
and couplings
.......
139
machinery,
crusher jaws, cutting tools, cylinders, dies for drop hammers, diamond polishing wheels, dynamo and motor frames, bases and spiders. 140
Analyses of electrical castings, eccentric straps, engine castings, engine
frames, fans and blowers, farm implements, fire pots, fly-wheels.
141
Analyses of friction clutches, furnace castings, gas-engine cylinders,
.
...........
.....
....
142
143
144
145
146
147
.......
Anah'ses of propeller wheels, heavy and light pulleys, radiators, railroad castings, retorts, chilled rolls.
148
Analyses of unchilled rolls, scales, slag car castings, soil pipe and fit.149
tings, heavy and medium steam cylinders
Analyses of steam chests, stove plate, large and small valves, valve
bushings
.150
Analyses of water heaters, weaving machinery, large and small wheels,
wheel centers, white iron castings, wood-working machinery; Direc.
tory of pig iron brands; Classification of pig iron; Definition of terms. 151
CONTENTS.
xiv
PAGE
Basic iron; Bessemer iron; Foundry and forge irons; Classificalion and
152
atite;
Thomas
Gilchrist or
Thomas
15S
iron
16('
iron
Grading
of
Foun-
IBl
dry coke; Furnace coke; Standard foundry and furnace coke
Smelter coke; Stock coke; Soft, heating or jamb coke; Crushed coke;
162
Ferro-alloys; Ferro-aluminum
S. A. M. alloy; Ferro-chrome; Ferro-manganese; Standard ferro-man.
.........
ganese; Ferromolybdenum
Nickel; Ferro-nickel; Ferro-phosphorus; Phosphor-manganese
Silico-spiegel; vSpecial high silicon;
Bessemer
ferro-silicon
164
.165
CHAPTER
163
166
167
XII.
169
coal irons
.......
............
........
.
172
Cost of analysis
ViS
Testing laboratories
The foundry chemist; Causes of the bad repute of the chemistry of
174
foundry irons; Knowledge the foundry chemist must acquire
.
175
176
CONTENTS.
XV
PAGE
CHAPTER
XIII.
Fracture
test
Methods of making
tests;
Transverse
test;
test;
test;
.179
Impact
.
180
test;
Relative
test;
Standard
test;
Stand181
Chilled test; Test bars; Necessity of having test bars of exactly the
182
in casting test bars
.
183
.184
Strength of cast iron; The strongest part of cast iron; Attempts by civil
engineers and others to obtain an extra- strong iron by unfair tests
185
Adding strength to cast iron; Addition of steel when melting cast iron
in a cupola; Increase in the strength of cast iron by the addition of
.
wrought iron
............
186
CHAPTER
Standard
XIV.
Tests.
Trickery of inexperienced
civil
189
Association tests; Cast B, dynamo frame iron
.190
Composition of cast B
191
Tables of transverse tests of dynamo frame iron
Tables of tensile tests of dynamo frame iron
195
199
Table of compressive test of dynamo frame iron
Method of casting test-bars; Extracts from the report of Thomas D.
West; Effect of thickness and rate of cooling on cast iron; Effect of
variation in the pouring temperature on the strength of iron
200
Contradictory or at least unreliable results due to the intricate and delicate nature of cast iron; Necessity of obtaining test-bars from more
201
than one grade of iron
202
Flasks used in making the test-bars
.
.....
......
.....
..........
...
,
CHAPTER XV.
Semi-Steel.
Historical data; Early use of semi steel
into pigs
.............
iron
202
CONTENTS.
XVI
PAGE
First thing necessary in
making
.....
Mode
for
large castings
210
by James A. Murphy
.211
C. R.
McGahey;
216
Elastic limit
217
Silicon
and
tained
The wearing
218
qualities of semi-steel versus gray iron, gray iron plus
steel scrap or
without
it
is
it,
220
221
Is
semi-steel a mis-
222
Metzger
Mixture that gives a close grain that machines
silicon and manganese
Quality of piston-rings; Mixtures lor cylinders
Semi-steel gears and mixture for them
223
..........
.....
.......
easily;
Percentage of
224
225
226
CONTENTS.
CHAPTER
xvii
PAGE
XVI.
Mai,i,eable Iron.
operations collected by
....
....
227
228
229
230
purposes
231
Malleable scrap; Melting furnaces
232
Data of the various styles of furnace used for malleables; Advantages of
the air-furnace
233
234
CHAPTER
XVII.
Anneai^ing of Malleables.
Annealing ovens; Expansion and contraction of the material used in
constructing ovens; Temperature for annealing; Indications from the
...........
.............
patented
by Walter
235
S.
Vosburgh
236
Annealing boxes, and their shape and size; Material used for annealing
boxes
237
Wear and tear of annealing boxes; Remelting old boxes; Packing the
boxes
238
Methods of getting castings back to their original shapes after annealing; Packing materials; General accepted theory of the annealing
process of cast iron; Oxidizing agents generally used; Another
theory of malleables
Effect of annealing;
239
scale;
Time
..........
..........
Most
CHAPTER
XVIII.
Production of Malleables.
The making
CONTENTS.
xvni
PAGE
Cost of producing malleable castings; Expense of running a malleable
plant
Malleable plants in the United States
245
24H
CHAPTER XIX.
Foundry
Note.s.
....
...........
Hard
dope
250
Molding sand
251
their wages on the molder; Non-
....
Pickling castings.
.......
......
...........
............
....
.............
257
Mixture for sand match; Steel^or iron How browned; Process for tinuiug cast iron
258
Coppering iron castings; Cleaning foundrj' windows
259
Silvery iron; Change in the sliding scale of silvery pig iron; Table of
prices
260
....
to castings
.......
266
267
FOUNDRY
IRONS.
CHAPTER
I.
Pure
iron
as a metal
more
is
in laboratories
it
it
found
the
in
Unlike gold,
it
its
not
is
all
of
ores remains to
as
we term them,
all
fit it
plowshare and
the sword, the construction of huge vessels that plow the ocean,
of
tall
so
tiny that
they can be
eye
like
in
com-
bination with
yet
has
become
I
(I)
And
FOUNDRY
all
its
ments
IRONS.
we owe
in its
in
all
new discov-
In these
it
can be used, for our resources of this metal and of fuel are
unlimited, and
we seem
and
is
way
that
all
in a fair
is
applied to
is
do with our
and
its
all
in
these, there
it
is
hundred
million,
There
but one
is
many compounds
compounds have
of these
working, and
which
of
in
Many
the manufacture,
in
metal to suit
companies.
preponderance
of them.
formed
steel
to
is
million,
and because of
iron
necessary to do
to
many
are
preparing of the
to
it is
Of
be used.
all
of
which present
number not
characteristics,
different
than thirty-two
less
of prepa-
We
shall
its
of founding, in
in the art
such a way as
its
uses
be of value and
will
interest not only to the founder, but also to the moulder, melter
and
all
Iron Ores.
Iron
is
all
the
It is
found
in
all
the blood of
found
in
in the
ashes of plants.
Many
minerals contain
it
from
it.
in
is
as
consider-
them entirely
source from which we
the metals of
combination with
more or
etc.
oxygen
rich
in
in
iron locked
less
up with
are very
very
Iron
iron,
in
bodies, while
large
The Lake
the world.
in
in
this
some
country that
of the Pennsyl-
The poorest
ores,
the
some of which
These ores were
of
iron in early days, but since the increase of facilities for trans-
portation, the richer ores are generally smelted and the poorer
some
of
in
is
at the
Thus
it
may be
present time
civilized
to
we
are
may
is
not, or has
by imthe same
ranean Coast.
come.
said
unlimited
Besides
of greater or
rich in iron.
some
in
1870,
when the prices of pig iron went up to $45 and $50 per ton,
they predicted that it would never again sell below these figures,
giving as a reason that the iron ore deposits of Great Britain, at
that time the greatest producers of iron
in
the
world, were
FOUNDRY IRONS.
ton
in
in
this
country was
Since that time pig iron has sold as low as $12 per
limited.
in this
1870, to 25,795,471
of ore
in
sight, the
There
still
want of pig
is
iron
it
to the
and
exhausiron will
long as there
is
it
or market for
Mixing Ores.
was the custom
due
an abundance of
demand
being an abundance
it
as
it.
and
smelt only the ores from this deposit, or one quality of ore.
The
it
to
different ore
from
their furnaces as
had been
done by mixing the iron from these ores when remelted. Prior
to this furnaces were mostly located near ore deposits and we
furnaces, as they
now
are, at a distance
of
hundreds of miles
from the beds from which they receive their supply of ore.
For the production of iron of a desired quality the ores were
mixed in different proportions and the resulting iron was tested
for the purpose for which
it
was
to
By
be used.
varying the
produce a foundry,
mill,
or steel iron.
district
uced
it
an
had been
turning
out
without
of
it
been effected
in
its
quality.
This
would frequently find piles of their irons confoundry yards and the high reputation of this prodTo overcome this difficulty resort was had to vary-
a high reputation
demned
in
uct gone.
by having
it
melted
by
these changes
in
more
which
This uncertainty
in the
led
to an investigation as to
its
causes
which the iron was made. This was done by analysis of the
ores and iron and has resulted in a system of analysis of ores
that indicates accurately the quality or characteristics of iron
FOUNDRY IRONS.
6
that
may be
But
system
when
is
overcome by a
it may be used
But here again the iron is liable to change
and bad melting and while foundrymen are more
characteristics of an iron
for
This difficulty
remelted.
from poor
fuel
certain as to
its
Blast Furnaces.
the construction or
It is
management
it
it
and
is,
to
more
com-
fully under-
stand the terms or names by which the various foundry irons are
designated.
Blast furnaces are constructed
ple as the
they are
much
filled
opening
at
larger.
princi-
They
are
etc.,
supplied with air for the combustion of the fuel and smelting
by
iron
all
from them
blast iron.
Jiot
blast iron.
known as
The cold
Charcoal
is
in
a furnace with a
The
hot blast.
iron
blast charcoal iron intended to take the place of cold blast iron
has also been made, but this does not appear to have
come
into
general use, or to have been placed upon the market under this
name.
fuel
is
that
The
blast charcoal
furnaces,
some
were
cold
all
more
still
the
until the
is
number
still
forests,
as
the
the harder
source
from
of charcoal furnaces
probably be
due
is
burden of ore
which charcoal
try,
This
heavy
is
will
coal, in
Pennsylvania
in
type than
the
charcoal
some
greater, but in
foundry
iron.
furnaces,
iron,
in the
New
Jersey,
Maryland and
New
FOUNDRY IRONS.
New England
States, for
many
years
output of
time
way
its
to
small
it is
ably be
it
compared with
further decreased, as
still
many
naces are adopting coke fuel exclusively, while others are using
a
mixed
fuel of coal
The coke
and coke.
furnaces
when
first
iron
foundry
inferior quality as
iron,
manufacture of wrought
coke-making, the
in
mill
iron
in
the
come
now
be-
country,
some
of
of producing
500 tons
of iron in 24 hours.
Coke
iron
takes up
in
many
smelting
pure
and
in the
manufacture of
steel in the
in
converter or furnace, so
steel,
coke-smelted
iron answers
iron,
removed
it
is
completely
with the
all
failed,
inferior
But
is
in
this
chemistry has
for
improvement of them.
field seems in a fair way
This
to
field
be covered
is
still
open
in
will
in
fuel.
made
in
in the past
coke ovens
in
be
tirely replaced
Coke, and
The reason
is
seen
in operation.
West by
the
in
East by
this
free from sulphur and other impurities injurious to iron, and higher in carbon, and gives better results in melting than Connellsville coke.
It has not been used to any great extent in blast furnaces, ow-
for this
is
time
when
it
is
is
only a question of
re-
by the adoption of
by-product ovens or even better ones, and an improved quality
of coke be produced in abundance for both blast furnaces and
foundries.
The improvement in blast furnace smelting fuel is
what is more than anything else required for the improvement
of foundry irons, for the fuel used in smelting ores imparts to
gain
its
lost
to the
pure carbon
What
is
is
it
the elimina-
tion of sulphur and silicon, for these two elements are detri-
mental to iron
in
any proportion.
is
due
to
its
presence
in
FOUNDRY
lO
IRONS.
and producing a
soft,
from
Carbon
silicon.
is
latter
all
iron,
this fact
dry
iron,
will
be an improvement
As
is
in these irons.
may
it
found
in
to
it
scale, for
from which it is
up by the iron from the
in the ores
impurities taken
These give
smelting fuel.
on a large
it
many
is
to deal
of foundry iron.
Their
first
this,
and purchase
All foundry
know how
irons are
good
irons,
The same
work them.
if
is
the case with analysis for mixtures, and an analysis for a mix-
to
line of
in
is
of
work.
It is
it
is
variation
in
due
to
the wide
qualities of coke.
problems.
is
to
will
ever be solved
made
all
in
of the
in analysis.
coal,
which ac-
FOUNDRY
12
IRONS.
formerly considered almost too poor material for the blast furnace.
Hence,
if
wants of the foundry, and the users of coke take into account
the differences
facilities
in
its
be
little
trouble in the
It
will
be
be found
in each.
Coal from
five of the
seven great
fields of the
country
used
is
field, in
Illinois,
field, in
the east-
Kentucky
field, in
and the
Washington.
DESCRIPTION BY STATES.
is
Alabama coke
is
Prob-
the rather
similar articles.
ing composition
is
previously washed.
is
used
satis-
the follow-
From
run -of-
mine
Moisture
Volatile matter
coal.
1.34
From washed
slack.
0.75
1.03
.75
Fixed carbon
83.35
86.00
Ash
14.28
11.50
1.30
.90
Sulphur
The
coal.
Colorado.
purposes
Practically
coal
Average analysis
washed.
is
all
Average Analysis
of
about as follows:
is
Colorado Coke.
Moisture
c.44
Volatile matter
1.31
Fixed carbon
82.18
Ash
16.07
Sulphur
.44
respect to
its
high ash by
good.
corner,
Georgia.
is
market which
reaches, as a
it
easily operated.
Illinois.
In
Illinois
is
made
become standard
This coke
The
Illinois
by-pro-
in
it
can be used
qualities.
coal
is
An
analysis of a coke
as follows
made from
Analysis of a
Washed
Illinois
Moisture
Volatile
washed
Illinois
Coal.
2.78
matter
74
Fixed carbon
83.35
Ash
13-13
Sulphur
In spite of
2.49
its
Foundry men
much
like that
will
to
keep clear of
recognize
in
it
its
uses,
though probably
FOUNDRY IRONS.
14
Kentucky.
Kentucky draws
The
part.
fields.
analysis of
in the
form of
New
in
pyrite,
Mexieo.
The sulphur
much
of which
New Mexico
is
is
the coal
is
chiefly
eliminated by washing.
The
coal regions.
coal
is
its
it
still
Ohio
is
not so rapidly as
imit}' of the
coming up
it
as a
Pennsylvania
Many
fields.
lost.
Pennsylvania
is,
high.
little
that
is
geographically
is
Nearly
of the coal
mine.
As
it
will
suffice
composition.
Range
MoisUire
Volatile matter
Fixed carbon
Ash
.Sulphur
0.23 to
2910
92.53
to
0.91
2.
26
80.84
6.95 to 15.99
81 to
1.87
The upper
and
As
foundryman
the
included
coking.
or of
liable to
is
made coke
it
is
the statement.
in
Tennessee.
Tennessee
is
matter denote
volatile
is
The
washed.
Washing
In fact,
all
the slack
make coke
to
is
in
so treated before
is
The coke
analyses,
which
reflect
of
Moisture
Volatile matter
0.22 to
1.67
to
1.60
1 1
92.4410 76.87
Fixed carbon
Ash
7-23 to 19.86
61 to
Sulphur
2.45
Virginia.
The
good coke
is
to
be had.
rapidly
is
Range
Moisture
Volatile matter
Ash
Sulphur
large,
is
1.67
5.80 to
8.29
42
1.02
of Washington,
to
though not
important, not so
is
making is
treatment is shown by the following analysis
coke the coal for which had not been washed.
coal
1.52
Soto
93.24 to 88.52
Fixed carbon
Washington.
0.16 to
for coke
of a
Washington
FOUNDRY IRONS.
1.02
Volatile matter
2.10
Fixed carbon
77-53
Ash
19.35
Sulphur
.44
Everything
coke
this
in
will
IVi'st
ducer of coke
in
West
Virginia
The
the country.
State
of
is
the second
largest
pro-
coke
its
is
Hence
in
interesting
is
Moisture
Volatile matter
Fixed carbon
0.07 to
0.60
46
2.35
to
95-47 to 84.09
Ash
4.00 to 12.96
...
.Sulphur
.53 to
2.
26
man
can compare
eral States
it
really should
out
in
This function
it is
manner acceptable
hoped,
to
all
some day be
will
carried
interests concerned.
The
is
actually required
0.50
Moisture
Volatile matter
.75
Fixed carbon
89.75
.\sh
9.00
Sulphur
Solvay Coke.
70
This
is
a retort
in
Solvay
Chicago,
111.
This coke
Company
and even
made under
is
at the
of coals used.
mixed
in
is
to different kinds
at the
and mixtures
Detroit ovens
is
of the
Virginia coals
it
is
be used.
to
The
the consumer.
and again
sulphur
at
balls,
coal
is
in
mining
bone and
in
the process of
pulverizing.
cent, passes a
ture,
The
use.
coke
By
is
pushed.
at Detroit, to
other coke
bear a
made
in
made, as
beehive ovens.
The burden-bearing
qual-
ity
There
is
one
Solvay coke.
in nine
ratio
in
this
it
coke
is
runs as
air
per
FOUNDRY IRONS.
i8
pound
of coke to
combust
it.
This
is
a practical formula
and
with 9-0Z. blast the very best results can be secured with this
coke.
Much
ably less
in
less of
it
may be
used
in
the charges.
This coke
is
much
difference of approximately 75
is
19
CHAPTER
II.
used
in
of Pig Irons.
Irons
are designated
by the
from its
An
is
iron smelted
coal iron;
Charcoal Irons.
The charcoal
them
irons, cold
hot-blast iron.
and hot
in
blast, are
fuel with
which they
in
them on each
The
side
pigs are
When
No. 4 a white
iron.
first
iron ever
made
in this
country,
in the
(20)
PIG IRONS
The
foundry
many
been
in
Maryland
at
writer,
when
PIG.
visiting
an old
this iron,
i
pig had
from the work were not remelted, but were thrown into the
dump, and only pig melted to insure soft castings. A dump
was pointed out that was said to contain many tons of gates and
scrap from this foundry.
The cold-blast iron was used in the manufacture of gear
wheels, cranks, and all parts of machinery requiring great
strength, and before the introduction of the steel
to rolling mills, and the age of steel,
Many amusing
stories
are told
One
recalled
hammer
in-
common
have been a
tation for
known
good
The founders do
shafts.
by using the
lower grades of pig, or mixing the lower with the higher grades,
in
War
the
its
proper length.
of the Rebellion
in
this country,
1861-65
show
its
This
light
quality.
iron,
work,
owing
is
at
to
its
in
In malleables
it
gives a stronger
is
FOUNDRY
22
IRONS.
grades of
it
In cylinders
grit,
it
chill of
makes
from
that polishes like steel, and does not wear rapidly or cut
cylinders,
may be
it
and good
But
results obtained.
some extent
in this
way,
it
of other iron
No
it
mixture, and
in a
large a percentage
used.
is
rule can
the resulting
quality desired.
to
malleable iron
in
oleomargarine
does
not
genuine
to
be deficient
in
some
to
have
But
no doubt
article.
Hot-blast Charcoal
Irojt.
the characteristics of
dency,
possess
said
is
be found
all
some success
which
lessened
is
Hot-blast
th,e
cold-blast except
to
considerable
chilling ten-
its
extent
by the
deep
chill
in the iron.
may be
i,
but a
chill
lower grades.
The Nos.
very
fluid
and
and
2,
when mixed
light
in
PIG IRONS
No
many
PIG.
23
much reduced
very
price
irons.
this iron
in
Ohio.
for
district,
Hanging Rock,
furnished wood
Some
still
scarcity of w^ood,
to
for the
this iron
same reason.
coke
When
in
to the
keep
sup-
to the Mississippi
of iron used
in their
castings.
who
an extra quality of iron, while the pig broken was likely the
only one that went into
being
made from
Coke Iron.
irons, for
This
it is
many
used
is
in a large
all
the foundry
The
owing
made
That
is
very strong. The No. i
from which
from some of the Lake Superior ores
to the quality of the ore
it
is
some
extent,
smelted.
FOUNDRY
24
and strong
in
IRONS.
in stove
plate
duct
light castings.
is
irons,
addition of No.
fine
A, No.
A, or No.
or No. 2 X.
This
This grading
is
silicon contained
low
silicon, a
to a large extent
in
the iron.
hard iron.
high
Silicon
is
placed
in
the iron
in
A
any
made
to
Thus, a
No.
2,
and so on.
Coke
These heavy
double
the
the
thickness of
pigs,
compared with
more
Even the
The
is
indicated to
PIG IRONS
PIG.
25
The No.
cast.
which
For
it is
to
some extent
chilled
by sudden
cooling.
may be
obtained by mix-
these proportions
light castings, in
in
and No.
or two-thirds of No.
softer
but weaker
about
in
silvery-
2.
mixture of
in light castings
than
No.
all
that runs
seldom used, except for very heavy castings; it is then generally mixed with the No. 2, and is employed in the mixture for the purpose of giving strength to the
The No.
grade
is
castings.
Anthracite Iron.
and
New
New
Jersey,
Maryland
many
years.
The
coal,
amount
anthracite fuel.
made
in-
to
its
present
time.
Valley, the
Even the
to so great
the
anthracite
an ex-
existence at the
in
anthracite furnaces
very centre of
the price
manufacture,
in
in
coal
the Lehigh
field,
have
The
pigs of the
FOUNDRY IRONS.
26
same
iron
size
it
would be
difficult,
by the
fracture.
iron, are so
iron
a similar ap-
would be
it
detail
Silver
Gray
Iron.
burned
called a
iron.
is
It
at
much
a very
re-
in
tice,
may
it
The
not be made.
appearance
in
latter
by the
distin-
from which
it
name.
its
was very
acteristics of
soft,
high
many
of the char-
iron of
It
was
very weak and unsuitable for castings when melted alone, and
was used
when melting
as softener
scrap iron.
High
into
Silicon Iron.
combination with
blast furnace.
element
large
in
been found
in
Silicon
iron.
its
is
It is
found combined
in large
may be added
pro-
to iron
proportions
this country,
accessible
have
by the
is
silicon,
it is
made from
easily
it
mined
than from
many others.
The iron i)roduced from this ore is of an inferior quality.
Rolling-mill men and the manufacturers of steel have no use
for
it,
and
it
is
PIG IRONS
The only
iron
its
2J
is
PIG.
When
rottenness.
by
is
and
softener
be found
stated,
is
It
from a finishing
tool
about as rapidly as
also reduces
but
think this
is
But
to
this
iron, as before
is
many
tons of
it
in
it
may be
of value to foun-
drymen.
The proportion
without impairing
of silicon that
its
may be
quality to any
used
in a
foundry iron
from
make; thus
^
to
is
may
require from
from
2 to 3
per
cent.
of the iron,
and prevents
to
To
when
castings
is
when
in
When
pig
is
it
all
FOUNDRY IRONS.
2S
it
may have
mix with
the opportunity to
its
in
The
iron should be melted very hot and the cupola not tapped close,
made and
body of
the cupola, when a
a considerable
bottom of
be found of advantage
to place a large ladle holding from 500 to 1,000 pounds on
trestles in front of the cupola and pour the iron from this ladle
into hand or other small ladles for light work.
iron permitted to remain in the
continuous stream
When
is
drawn.
It will also
When
recommended
to carry
should be broken
in
charging
in a
in
way
90 per
at the
as they descend,
if
on top of
was made.
a tap
all
and also
in
the
charged on the
it,
When
mix the
iron
from
5^
to 3 or
for foundry
silicon,
work
that contain
and foundrymen
will
se-
and mixing
When
it
by buying an
in silcon,
or free from
is
it.
heavy
at
in
When
in finishing
work the
is
too high.
Such
iron
gener-
pk; irons
edge
smoothly, and
rapidly, or
if
off
fig.
29
difficult to finish
is
if
Scotch Pig.
This
is
the
in this
country.
foundry
iron,
it is
brought by vessels
American foundry
The
which
iron
is
iron
is
It
is
high
in
deficient in strength
The
of Scotch
iron vary
from one
to
than
at a less price
irons.
and sold
is
open iron.
broken small
The
as ballast,
to
from the
when
fracture.
easily
brands
to the quality
Some
brands of domestic
make
and
in
in
common
Note.
Kish
soft iron
when
it
fit
Other brands
for weights or
castings.
is
castings
it is
in spots
very
work, and
difficult to
holes,
soft
been
generally
light
in
a molten state
in
is
to
a soft, dark
In thin
FOUNDRY
30
IRONS.
on the surface
collects
in spots,
Kish
due
is
is
soft
only found
is
in
it
ad-
It
off,
to
in
In heavy casting
iron.
not
It is
at the
extent
These
irons,
many
cases,
it
foundries
in
making
pig.
irons to
placed
in
as
foundry
in
light
Among
melted
many
The
writer has
them
to run as soft as
and are
still
in
in
diff-
high reputation,
was some years ago, furnacemen have generally dropped the term American-Scotch, and
the irons are known only by their local or furnace names.
demand
to the extent
is
not
is
in
it
as pig iron,
which
is
frequently desig-
nated as foundry pig, mill pig, and Bessemer pig, these terms
dicating the purpose for which the iron
is
best suited.
in-
Pig
PIG IRONS
iron
is
also designated
and sandless
pig, chill-pig
new methods
in
which
cast as sand
it is
pig.
PIG.
is
it is
Probably ever
it
become
since
in
In
manuin the
perfectly level beds of sand are made, and in these the pigs are
moulded, a
pig,
furnace.
Through
to the pig
bed
this
the
is
side of the
in-
When
is
connected with an
with clay
is
it
in
such a way
is
made
which permits iron to flow into the sow of the next pig bed.
When
this
one
is filled
the runner
is
again shut
off at
is
cast.
This
mode
all
the next
the iron
in
able labor in preparing the moulds for each cast, and to save
this
expense and obtain an iron free from sand, a cast iron pig
mould or
chill
Chilled Pig.
The molds
from
made
in a cast-iron
and of
FOUNDRY IRONS.
32
in
iron
comes
in
slight chill
On
account of the
chill this
iron never
chill entirely
of
can be found
it
Pig.
Saiidless
in
when
the iron
is
the castings.
After
the
introduction
chemistry
of
into
blast-furnace practice,
and
chill
This unevenness
in
iron smelted
from
mixed before
casting.
been thoroughly
To overcome
this difficulty
and produce
an even grade of iron a plan for mixing the iron before casting
This was done by drawing the iron from the fur-
was devised.
nace into a large ladle capable of holding the cast and to mix
From
before casting.
this ladle
is
it
poured directly
it
into the
pig moulds that are only about one-half the length of the ordi-
The moulds
wrought iron or
by the molten
metal.
The
chilling
may be
and
to
still
of thin
made
quickly heated
in
is
casting chilled
These moulds
upon which they are brought
upon
a revolving table,
filled
and removed,
to
be emptied when
They have
upon
mode
in moulding the
from the casting-house.
moving the
iron
made
for
its
PIG IRONS
PIG.
33
to a considerable extent
closer iron than sand pig, and while an analysis of the iron has
shown
this
is
more even
throughout
quality
the
cast
before casting.
of sandless pig
it
The extravagant
than to mixing
made
claims
and
pig
is
it
cast,
which
at
it
in a ladle
for superiority
produced them
in
it
The manner
in the pig.
it
of casting
is
therefore
its
quality any
more
when
Foundrymen
cast in a foundry.
shape or
mode
This
ore
in
same
it
is
This
evenness
in
the iron
the market.
when
cold,
is
same quality
to the temperature
is
working hot
is
said to be
up of the stock
in
the furnace.
made
due
is
the
it
and determining
to the
This un
its
done by breaking
due
of
its
quality
first
by the
break.
putting
it
upon
indications of the
large
crystal indi-
FOUNDRY
34
cates a soft iron.
This
designated No.
is
This
i.
IRONS.
is
graded No.
a small crystal, a
2.
still
smaller
the crystals indicates a mottled iron and one with scarcely any
i, 2, 3,
No.
4, 5, 6, 7.
indicated a soft
iron, and the iron gradually grew harder until No. 7 was reached,
to
i
this grading,
the
A, and
and No. 2 X,
and No.
and No.
X, No. 2
A, or No.
which indicated that they were very soft irons suitable for very
This mode of grading was termed fracturelight castings.
grading, and was the only means of grading employed by fur-
No.
nace
and No.
men
when
accurately indicates
It as
the grader
is
an expert, as does
by using an
new method
in iso-
PIG IRONS
new market
PIG.
.35
for them,
use
and
it
might be mixed
own
iron,
in remelting,
so universal
and No.
by
when
its
cold.
foundry
irons,
scrap, as
this
in
is
meant the
The term
ture indicates to
or
By
appearance
applies to
etc.
The
all
frac-
accurately as analysis.
The
of
large
crystal
tal
with a dark color, a No. 3 strong iron that will run hard
light castings
and
soft in
is
suitable for
in
mixing
FOUNDRY
36
IRONS.
a very small
foundries in
castings.
This iron
An
is
This iron
is
only used
in
used
ings requiring
in
No.
2 or
iron, or
iron.
chilled surface.
weak
or
patches of very
iron.
It is
used
in
mixtures as a soft-
small
crystals
an uneven
indicate
iron.
is
mond-shaped and
duller in
In
charcoal iron.
the
grades than
all
latter
in
broken apart as
in
is
never seen
in
charcoal
iron.
The breaking
of pig
iron
also
indicates to
some extent
its
characteristics.
Pig that
is
difficult to
it
runs strong
in
soft iron,
is
If
itself
may be
PIG IRONS
blast,
FIG.
37
break and presents a sharp-pointed drawnout crystal except in very hard white iron.
is
difficult to
is
now
generally sold
by
was sold
when
by fracture.
If,
however, the
founder has no knowledge of them whatever he cannot manipulate his irons after he has them in the foundry yard,
and should the irons become mixed, or there be an uncertainty as to the quality of those in various piles, he would
be liable to charge a hard iron for soft work, or soft iron
pig
iron
entirely
Fracture
indications
varies with the thickness or size of castings, and does not indi-
cate
its
is
The
principal
soft iron
and
The
iron that
may be
of the product
also not
burned
iron,
even
if
only
obtained from
from
light
it
when melted.
The
quality
be removed previous
rust
to melting.
Shape of Scrap. The shape of scrap castings and a knowledge of the quality of iron used for different lines of them is
It is only when
the most common guide in selecting scrap.
there is a doubt as to the quality of iron from which work is
cast that fracture indications are looked for, because scrap generally produces the same grade of iron when remelted as that
from which it was cast, but a shade harder, and may be brought
up to the original standard by the addition of soft pig, when
remelted.
FOUNDRY IRONS.
38
Heavy machinery
scrap
from which
it
was
cast,
much harder
in
line of
which
work.
not indi-
is
Small scrap
by
indication of fracture.
is
requires
re-
upon the
which
it
is
the
all
variations are
due
to the extent
The deception
was burned.
fected in
The
in castings.
most varied,
as the
has a hardening
cast iron
Burned
Buriied Scrap.
as well
latter
crystallization of
is
due
to the
changes
ef-
longed heating.
we may
In a grate bar,
a light bluish cast, and near the ends a large crystal with a dark
blue cast.
This
is
due
iron, presenting
burned
iron, not
burned
we
the ends.
open
to the center
in
many
find a
of the character-
And
pig iron.
we
in fact, in
find in the
in
melters
is
in
reality indicates
it.
Pieces of
PIG IRONS
PIG.
39
By
general appearance
is
meant
as
is
In burning
of
it
The same
parts of which
show
This principle
castings,
is
all
in sorting
burned, throwing
it
in
who judge
is
thrown
scrap
by
broken into
in
fracture only.
Retorts,
in a pile to rust
before being
good
scrap.
This
is
one of the
Burned
cast iron,
may be
obtained
iron,
amount
of slag.
and
in
some
The
is
slag
generally a white
may
boil in the
it
until
it
CHAPTER
III.
Scrap Irons.
classified as
cuous scrap.
This classification
is
ings were
made and
remelted.
It also
to
some exceptions,
soft iron.
for
all
Gear wheels,
are cast
from
a close fine-grained
iron and there are other lines of work, such as brick machinery,
pile,
when
remelted.
by breaking them.
Machinery scrap
castings and
Close scrap
is
is
is
if
there
is
any doubt,
this line of
(40)
SCRAP IRONS.
41
some
cases,
when very
select,
it
In
sells
when mixed with pig it produces a stronger and better casting for some lines than all pig,
and is eagerly sought for by founders doing engine work, and
Car Wheel Scrap. Car wheels, like machinery are cast from
good grade of iron, that is not changed in finishing or by the
use to which the wheels are put before being consigned to the
scrap pile.
This scrap being of the same quality of iron from
which the wheels are cast, is of value in mixtures for wheels and
is also used by founders in mixtures for castings requiring a
a
close fine-grained
surface.
iron, or chilled
most extensively used by car wheel founders, who are generby the Railroad Companies to take a certain number of old wheels in part payment for new ones. When placed
upon the market, this scrap, like machinery scrap, commands a
ally required
good
price.
This scrap
cast
is
and strength, exposing when run into thin plates, a very large
The characsurface to the chilling tendency of a damp mould.
not at all changed in finishing, but are
changed by the use to which the castings are put, some
of them being exposed to so great a degree of heat, and repeated heating and cooling, as almost entirely to destroy the
iron
others are exposed to oxidation, and when consigned to
the scrap pile such a large surface is exposed to oxidation or
radically
do not
find
quality of iron
limited
plate,
amount
and
it
is
iron
greatly deteriorated.
is
We
in
is
sells
at
principally melted
It
is
much lower
in
mix-
FOUNDRY
42
erally cast
IRONS.
at all
This scrap
is
to
which
of the
This iron
put, and
it is
same
only classified at
is
it
it
In
all
It
is
who
sort
When
scribed.
district.
Promiscuous Scrap.
scrap
not
when remelted
commands
is
is
are gen-
market
it
separately,
it is
thrown
is
is
not sufficient of
is
promiscuous scrap.
This scrap
quality, and
by founders
sells at a
ishing to be
done and
great importance.
in
is
of an
is
It is
used
is little fin-
not of any
is
all
and
is
it
designated
The founder
it
it
as
he melts
it,
using
When
of this scrap
is
purchased, and
is made at
when it is,
foundry very
little
Of
late
become
Many
their effect in
foundry mixtures
is
in
it
and for
this
mixtures.
It
to
good advantage
in
semi-
SCRAP IRONS.
Steel mixtures,
in these
and also
The per
closeness.
in
43
be used
pig used
in
Scrap of
silicon, as in semi-steel,
in
been incorporated in
machines for which they were designed, and as these machines
it is
difficult to
lot of scrap.
is
The only
practical
way
become
shape of the
such scrap
to detect steel in
may be found
is
for the
in
district.
Malleable Scrap.
This
made from
very hard when
castings
are
is
the
name given
condemned
They
to
cast,
first
from the
iron.
more than
a cast
melted.
effect
lost in melting,
it
it
to
very heavy.
its
upon
is
original state of a
iron with
said
which
it is
by founders
to
was
lost.
cupola
be burned up or
resembles a wrought
it
iron.
when melted
in
FOUNDRY
44
IRONS.
in their
pile
it is
scrap
melted
is
in
made
in their
own
it,
to
plant, such as
as
do
also the
This
it
scrap
is
may be added
in
to certain grades
increasing strength.
1846,
by Mr.
Pat-
Sterling, for
upon the quality of the latter to begin with. With 10 per cent,
of wrought iron added, the strength was increased 2 per cent;
with 20 per cent, wrought iron, 30 per cent with 30 per cent,
wrought iron, increased strengtJi 60 per cent; with 40 per cent,
wrought iron only 33 per cent. It would therefore appear that
his best results were obtained from a mixture of 30 per cent,
wrought and 70 per cent, cast iron. He states in his published
;
was able
tested.
to
attain with
Although
ling's patents
it is
the
is
in
expired, the
This
is
fact, as
stated
by Mr.
irons,
and the
be depended upon
difficulty of finding
SCRAP IRONS.
the
to
fact
that
from a mixture of
A series
very
is
it
cast
45
difficult to
and wrought
soHd
obtain
castings
iron.
by the writer
number
In
each heat, the iron was accurately weighed when charged, and
after being melted, to ascertain
was found
vary from
to
The
loss
trifle
a little less
over 20 percent., the heaviest being found with the light scrap.
We
did
The
Mr. Sterling.
high strength
ings.
in
means of strengthening
that this
foundry.
Over-Iron
slow that
is filled,
At
it
more than
it
is
is
at this
dull or melts so
becomes too
and
iron
is
dull
to
last
work
is
is
to
poured
quality as that in
the castings
in
it
upon the
if
made from
It is
of the
same
made from
scaffold, or
is
some-
FOUNDRY
46
times the case,
IRONS.
it
Shot-Iron.
be melted
There
in
gen-
numerous small
are
is
it
molten
particles of
fall
pouring, and
is
dropped.
many of them
fall
is
designated
in different
tumbling-barrel scrap,
In describing
etc.
it,
we
shall
designate
it
by
its
little
dump, gangway
entire cupola
Irofi.
Some
founders con-
at-
melted and unmelted, from the dump, and threw away the
cleanings, while others again picked out the
from the dump, threw the remainder into a tumbling barrel, from which the very small particles escaped through
the cracks between the staves, passed the gangway refuse through
larger pieces
number-two
iron.
as
it
The
riddle,
latter
is
is
That
of value.
it
this
is
this iron
remelted
is
softeners and
it
was
sometimes difficult
To prevent
pains were taken to recover all the small particles.
or reduce this hardening effect only a few bucketfuls of water
were sometimes thrown upon the dump to avoid chi}Hng the
iron, and gangway scrap was thrown upon the hot dump to
anneal over night.
It
is
doubtful
if
this
prevented
harden-
SCRAP IRONS.
ing;
any
at
rate
it
47
To
pre-
vent this iron from hardening other irons, various plans have
it,
it
tube with
device, patented a
melted
in
open
pots, tight
in
the
It
by
or
end with
inclosed
in
imbed
it
in
deteriorated,
by melting
it
iron
as to inclose or
is
pot
of
it
the pig.
It
proved but
number
by placing it
in such a way
end
at the
at the
is
not im-
end of a heat,
or
melted separately for the reason that some time and, perhaps
months,
is
During
heat.
this
time
it
it
quality, as well
for a
rust,
as the quantity,
of iron in the shot before melting; the product being an inferior quality of iron to that obtained
rust.
moderate
cost,
etc.
how
These devices
and at very
small,
little, if
any
pays to recover such iron or not, but all agree that it is not
worth the cost of the mixture from which it was made, and
founders who have given particular attention to the matter only
estimate
it
mixture
in
worth
this
FOUNDRY
48
IRONS.
lost, as
in
melted with
iron
soft
is
effect
it,
a very-
if
nor have
I been able
However, the loss
caused by burning up, and the hardening action due to the oxidizing effect of the very small shot and particles of iron thus
to learn of
it,
recovered, are no doubt greater than with the larger shot col-
In a
in
number
But
casting.
in
this
is
The
in
recently
it
was observed
amount
all
in
the
of heats
this iron
may be
entirely
declined to take
it
even
become badly
founder
per
The founder
sufificient
rusted
at three dollars
at this
is
to a sash-weight
selling at
it
when melted
and
it.
shops
in finishing castings.
new and
clean,
from which
it
is
Many
tons of
The market
when
in
many
is
SCRAP IRONS.
and was therefore a
soft iron,
Many
it
utilizing
Fine iron
it
probably
all
in
When
so great that
it
view of utilizing
future use,
pigs after
iron
it
it
is
the
obtained from
in a
is
considerable
With
iron.
ladles,
end of
at the
iron
little
is
it
it
by placing
When
is
it
for
warming the
in
is
small particles of
it
iron
this
and
a flame of a candle
left.
in
this iron
made
of which have,
all
was concerned.
way,
may be burned
filings
in this
proved
from
49
it
qualit}' of
and melting of
on the bed.
a heat with a
view of running
it
more or
less
oxidized condition
tightly
iron
in
melting,
pots, closed
in
dump.
it
has been
cover, and luted to exclude the cupola blast and melted alone,
iron.
failure, as
it
was
found the quality of iron obtained was not improved to a sufficient extent to justify the expense of the pots and labor in preparing them.
A number of
solid
it
mass
some
solid
in pots,
material to
mass.
water, etc.,
For
and also
make
this
it
in
molds without
pots, by adding to
when rammed into a
ammoniac water, molasses
stick together
purpose
sal
left
for
a few days
FOUNDRY
50
rammed
after being
into
a pig
IRONS.
to
rust
it
into a solid
Of
it
in this
way
for melting.
all
is
to place
By this
holding from lOO to
until it reaches the melting zone, when
200
lbs.
it
in tight
plan
it is
wooden boxes
held together
an entire heat
a
little
maybe
In this
in
way
the cupola
them to keep
means the oxi-
is
By
this
If
the cupola
is
may
may be poured from another.
The melting of this iron in boxes
in a
in
in ladles
to enter into combination with the soft iron in the ladle before
pouring.
But, even
casting,
it
has
unite with other iron, and to produce hard spots in the casting,
strain
The
in
parts of
it,
expected and
sometimes causing
at
which the
least
SCRAP IRONS.
51
The melting
lacies.
amount
of
it
can be melted
in
this
it
may be
the iron
carried
is
unmelted
may
This
the hand
iron with
from a shovel
m.olten iron
When
very slowly.
mass
into a solid
inch
thickness
in
in
fine iron
is
thrown
placed
in quantities,
in
it
molten
into the
When
small quantities.
in
placed
balls
in
the
up and melts
it
forms
may
when placed
in
It
molten
iron.
may be
it
floors, etc.
is
no market for
from
sal
it
being affected by
rust,
this
frost.
The
iron,
when
down
to pre-
in thickness,
before using.
inches
to
dry
When
when
difficult
and
less profitable
loose in small
quantities,
they almost or
into a solid
FOUNDRY IRONS.
52
When
melted
in
form
into a solid
penetrate except
does not
blast
in
way
in this
again be placed
In a series of tests
made
in
it
was
In fact,
it
did not
and the
make
and
good
brittle
for
We should
from our experience we think it will be found more profitable to sell it, and in localities where there is no market for it
as
to rather
in
throw
it
in
the
dump, than
to
undertake to melt
a cupola.
it
New
of years
ago,
and forming
Baden,
by mixing
it
it
in
number
results
same way
as
at
this
way
the Dayton
for
plant.
SCRAP IRONS.
Briqiietting Cast Iron Borings.
in the
53
The use of
difficulty, in
view of the
Vari-
slag.
but
tried,
it
most satisfactory
mold for these briquettes made from ordinary lumfrom 13x7 inches at the top, to 12x6 inches at the
bottom, will form briquettes weighing from 50 to 55 pounds
each.
A tapered mold is preferred, as the briquettes can more
easily be removed from the boxes. The material is mixed with
a briquetting compound, or binder, manufactured by the S.
Obermayer Co., Cincinnati, which is thoroughly mixed in a dry
state and sufficient water is added to temper the mixture, in
practically the same way that an ordinary core mixture is prepared.
The borings mixed with the compound are then compressed in the mold, by the use of either compressed air, or a
hand press, and a jarr-ramming or squeezer molding machine
can likewise be used for this work. Approximately 50. pounds
results.
ber, tapering
compound
of the briquetting
used
are
to
remain
in
should be included
in
The borings
Approximately 10
to 15
TJic
is
may be
added.
used to
Foundry.
200
turnings which
sell
steel
Some
it
can
to
to the
it
and
iron
up. as
it
it
in cast
FOUNDRY IRONS.
54
wooden
vessels, as
Briquetting the scrap was also tried, but it was found that to
do this a binding material was used which was high in cost, and
had an injurious effect on the casting.
For use in cupolas briquets of the following properties only-
can be used
They
They
They
They
1.
2.
steel chips.
4.
the
Ronay
process.
by
dumped
b)'
into
and elevators
belt conveyors
to
the magnetic separator, where dirt and scale are removed, and
last
of
blown
all
out.
They
last traces
of dust are
By
this
moves the
process and the special air-removal process which relatent air out of the briquets, a
product
air,
obtained
practically no air,
is
special design.
iron,
gray iron,
will.
This
is
ways
and
get just
al-
what he
wants.
is
explained
briquets,
in the following
It is
is
way
is
The
very low.
This
structure of the
is
SCRAP IRONS.
from the furnace
5 5
to penetrate
is
burned.
As
is
When
this
iron takes
by the addition
so
little
in
is
cast,
pump
This
cylinders, etc.
fine grain
useful.
40 per
proved
machine
is
melting metal
efficient.
important, as
it
saves
money,
good
be
will
found
and
is
In
castings.
will
are easily controlled in the stock room, and the loss in convey-
is
entirely eliminated.
The
Giesserci Zeiinng.
A process
of
charging and melting borings, turnings, etc., in the cupola to insure the melting of this material with the regular pig and scrap
charges, and to prevent these same particles from being blown out
of the furnace by the blast, has been patented by Walter F. Prince,
who
is
in
FOUNDRY
56
IRONS.
Steam Pump Co., Elizabeth, N. J. The material, consisting of borings, drillings or any other small particles of iron,
is charged
in wrought iron pipes, preferably Nos. i8 to 24
gauge, and varying in length from 3 to 4 feet. The casings may
be open end cylinders, or they can be closed at one end so as to
tional
The
condition
charge.
fore,
as
drillings
added
is
as
casings
is
The
section
first
filled
of
number
of stacks
may be
used
in
the
The Foundry.
to
give better results in melting this iron than any other, as Mr.
the composition of
in
in
which borings
pipe
is
may be employed.
coke and
filled
made
The pipe
to the charging
set
is
in
around
and the
in
As
the cupola.
on, and
At
latter melts
filled
away, and
it
settles
settles with
another
the
the
it.
International
When
the pipe,
other stock
length of pipe
of
is
put
the heat.
Steam Plant
Co., Harrison, N.
J.,
SCRAP IRONS.
twelve-inch pipe
kept
filled
this
process
is
used
in their large
57
More
upon them.
from the
borings
heat
is
is
for
required to melt
the steel pipe than the borings, and hence, only the borings in
the end of the pipe
fore being melted.
come in contact with the fuel and blast beThe cost for pipe used at this plant is $i .25
small royalty
is
in
parts, etc.,
they too
soon be
will
abandoned.
Steel Turnings.
and
decidedly hardening
wrought
iron
without
chilling.
rapidly in
turnings, and
have a
iron
more
The long
requiring a
thin
close, strong
melt quickly are used, and they are dropped into the
steel that
molten iron
in
will
balling up, and thoroughly stirred into the iron with a bar that
added
to cast iron,
low
in silicon will
in silicon.
wrought
iron
little
metal be ob-
his
no doubt
W.
7.
upon the
them would
iron.
Mr.
Keep,
in
FOUNDRY
58
answer to an inquiry as
The Foundry,
writes in
IRONS.
to the best
as follows:
is
put into
or 2 inches
thick.
that
can be used."
This method
of
being
it
new
is
me, and
to
tried,
iron
upon them,
in
made
the best
T.
Shaw
the Cupola.
In answer
to the
in
method
"
says:
excellent
results
have a suggestion to
When
the past.
in
me
and on top of
of coke,
furnace
sufficient to
Some
stack.
the
in
but the speed of the blower can be regulated and the blast can
Before bedding
in the last
two charges,
is
it
advisable to re-
"
occur
at this time,
Another method
the molds
the furnace
if
have
when
all
is
good
The
entire charge of
the furnace
been poured.
loss
enough
at this
This iron
will
as
the furnace
is
hot
be suitable to run
in
The borings
SCRAP IRONS.
59
can also be thrown unto the pigs while still in a molten state,
and it will be found that a considerable quantity will be absorbed
and held
way."
in this
many
failure
times.
offers in "
"A
"
the subject:
cast or steel
came
nealed
into vogue,
The
present time.
was
first to
less to the
take up the burning effects of any stray air that might get into
a pot and thus save the sharp edges of the castings.
"A
of
all it is
it
First
;
that
them.
"
This
will
However,
if
it
is,
if
the bor-
ings cannot be sold, the supply that comes from the machine
shop can be scattered on the scale piles every day in any quantity up to the amount which will not be oxidized in the first an-
That
neal.
is, if
is
used that
amount has remained unoximore has been put in than was necessary
Reduce the amount acaccomplish the object desired.
pots a large
cordingly.
"
As
is
made
tion
is
it is
better to
If
sell
CHAPTER
IV.
Mixing Irons.
more
lines
them
of
any one
in
are
line of castings.
made
frequentl)-
furnace.
cast,
a foundr)'.
Irons
iron.
in
Two
irons than
make
used except
in
iron.
mixtures, for
all
pig.
by themselves they
are generally
too weak for castings, but they give softness and strength to
Products from three
iron that by itself is too hard for castings.
or four furnaces generally give the best grade of iron
ings, this
number enabling
the founder to
in
cast-
produce an iron of
more
irons,
and
may be
to enable
edge of
This
is
his irons
sometimes
by an
him
first
to
make
a mixture with
any
them together.
of castings
may be
the line of
work
to
lost
be
To reduce
(60)
MIXING IRONS.
mum
in
used
tained
in a
is
mixture.
a foundry,
in
at-
is
it
special lines of
made
in
is
We
In
made
all
at different
have
at
hand
iron,
and
is
number
there-
of mix-
these mixtures local brands of iron are used that are only
how mixtures
are
we shall endeavor
made for different
classes of castings.
and No.
2 plain or
No.
and No.
pig
known
as a softener
is
irons,
No.
we have known
been used
of as high
in this
mixture.
the soft,
mixed
in
In
is
increased, and
if
soft.
FOUNDRY IRONS.
62
but weak, that of No.
is
added and
this
in
If
2.
it is
way an
ob-
is
is
all
This
is
till
In this
way
by means of
test-bars,
which
in-
in these
melt
foundries
in the mixtures.
is
shrinkage.
is
seldom used
is
generally used
in
the mix-
tures.
for heavy work requiring a very strong close iron, mixtures are
made of Nos. 2 and 3 or Nos. 2, 3 and 4. In making these
is
and the
is
followed as
in
for the
work
to
be
is
melted.
these
characteristics desired,
irons are
added
to
ness, strength, or
No
them
in
to increase or decrease
chill, as
practical founder
and
maybe
hardness, soft-
would undertake
to
melt, even
by an-
MIXING IRONS.
63
alysis,
the
mixture of
all
pig,
and
it
is
the practice
it
castings.
line of
The
they desire
in
their
castings, and,
is
in
making
is
about what
mixture, only
Founders making
lines of
work
for
work, and
in this
way
which
it
to
Jobbing
to suit their
For
pig
work
in
pig, or
alone, or with No. 2 pig; for chilled castings, a hard scrap with
These mixtures are used for various classes of castthem depending upon the percent,
it contains, and varying from 15 to 50 per cent. When
of silicon
making
in
all
when
short pieces
its
mixing
melting.
be broken
in
pieces to correspond to
way
FOUNDRY
64
mixing of the irons
in
IRONS.
of the cupola.
Remelt Iron.
that
is
Remelt
be remelted
to
the term
is
;
by which
This iron
and
melted with
little
is
melted
in
it
each
in
succeeding
heats.-
this iron to
be
is
it
it
is
same
of the
is
there
melted,
known
is
it is
charge of
As
iron
all
this
it.
In
many
it
it,
but
in
is
so light that
work
50 per cent, of
the heat melted, and then becomes a matter of importance in
foundries
it
sometimes amounts
making mixtures.
Locomotive Cylinder Mixtures.
to as high
The
Ramp
in this line
as
when
of castings,
the brands of
Pounds.
I.
7
600
Hard
50o
scrap
Steel scrap
200
No.
No.
Per cent.
2.
Lake Superior
pig iron
25
Selected scrap
25
No.
3.
P^"' cent.
Cylinder scrap
35
'O
25
MIXING IRONS.
65
'^'0. 4.
Pounds.
I.
coo
I.
coo
Chilled wheels
1.500
No.
i.cco
Cylinder scrap
Shelby No.
Per cent.
5 pig iron
lO
25
25
20
20
^'0. 6.
Pounds.
200
2CO
600
No.
scrap
3C0
4C0
Steel scrap
300
It
is
districts.
The
results.
is
in
in
another
low silicon
Making
Mixtures.
way
in
a general outline
heavy machinery.
5
FOUNDRY
66
IRONS.
tirely too
in a
chill
in
iron for
all
same being
to a
of castings.
perts.
of fracture indications, but these also are deceptive, and the mixture has to be actually melted and cast before
teristics
tion
its
exact charac-
can be determined.
founders
who
still
adhere to
this
method.
met
He
of grades of iron.
also
many
requiring a
for
He was making
his
vious experience
sort his
in-
pig suitable to
it.
In this
way he had no
trouble in
filling all
the
specifications.
in
such as a
soft,
two- and
three-inch
white
chill,
and
a two-
chill, a
and three-inch
MIXING IRONS.
mottled
chill,
were melted
in the
6^
satisfactory re-
is
absolutely necessary to
and accurate
analysis, or
no analysis
mixed by a chemist
analysis,
To
at all.
curate account of the irons and proportions of each in the mixture should be kept, as well as their analysis, and after the resultant
has
iron
been
tested,
work
a note should be
cast.
new brands
is
a great help in
of iron.
of
its
up to the desired
making new mixtures and trying
standard, but
made
CHAPTER
V.
carelessness of cupola
men
in
in distributing
more than
hundred
heats, melted
from dump,
by the
writer,
in
etc.
In
different
vary from a gain of three per cent, to a loss of twenty per cent,
men and
in
others.
they were to
if
it
the system of weighing and collecting iron in castings and remelt, and trying again, that
in
melting for
per cent.
Pig and remelt scrap for light machinery and jobbing work 4
per cent.
to
6 per
cent.
The
scrap,
increase in loss
which
is
due
varied, in stove
to
in
which the
These
to from 30 to 50 per cent, of the heat.
were made from the regular foundry mixture for the class
And the loss, which is almost double in
of work indicated.
work
foundries, is due to the heavy remelt of
bench
and
stove
tests
were made,
tests
(68)
69
upon pig
of loss
of castings with
per cent.
per
cent.
These
and, as
in
irons,
This loss
will
all
cases
is
It also varies
These
ering
losses
all
as these small
probably
all
particles
burned up
that
in
same
will
loss.
heats of
all
In
number
of
foundries to
determine the
loss in melting,
it
was the actual loss in melting and does not cover the total
This scrap when piled in the yard, and
loss on this iron.
exposed to the weather oxidizes very rapidly, iron being thus
Many small pieces are lost in the yard in breaking up
lost.
the stoves, and the latter frequently contain ashes and dirt,
FOUNDRY
JO
IRONS.
iron.
thrown out,
all
purchased.
Taking
New
generally
foundrymen
cent.
are
all
plate
is
from 12
20 per
to
loss.
Plow Point
Loss in Melting
Scrap.
In a number
of heats
melted at Albany, N. Y., of scrap selected from a promiscuous pile to determine the loss on the different scraps,
This
was
it
loss in melting of
loss as indicated
by
number
'
of heats
tests to
at the
They had
The
writer has
made many
Among them
in
curious
it
become mixed
was determined
burn the
to
coal under the boilers, and in this way melt the iron and permit
to drop into the ash-pit, from which all the ashes had ^een
removed and a hole arranged in the center into which the iron
would run and form a solid ma.ss. A good hot fire was prepared under the boilers, and a thick layer of shot and coal
it
spread over
it.
The ash
pit
iron
might be seen.
When
works.
colors and
In these stars
all
in
same way,
the furnace.
it
bright
were placed
off beautiful
The
for
iron
none of
it
under the
was found
300
lbs.
the air as
much
in
as
was
to
loss
was 20 per
cent.
This shot
had been recovered from the sand heaps and was considerably
rusted.
Tiie iron obtained was very hard, although the shot
had been made from very soft stove-plate iron.
In a heat melted at a stove works in Louisville, Ky., in which
1000 pounds of shot were charged loose on the bed and the
regular heat for stove plate melted with
it,
slower
than usual, which was probably due to the slag and dirt from the
shot covering the bed and clogging the cupola.
In a heat melted at the Baldwin Locomotive Works, Philadelphia, Pa., in
put up
in
15
was
The
8 per cent.
same way;
loss
in
and
on
unfit for
this iron,
in
the
and
It
Loss
iron
ill
foundry
in
1873,
When managing
we accumulated
them
in
in a
a malleable
was decided
to
Some
from white iron, and others from grey iron. The grey iron
boxes, which were heavier than the white iron ones, were tried
We obtained from them about 40 per cent, of very hard
first.
iron, with a large amount of slag, which was so mixed with the
The
iron that it could not be separated from it until cooled.
white iron boxes produced about 50 per cent, of iron, which was
cast
also
slag
fuel to
Ware
FOUNDRY
72
used
IRONS.
in
large a per cent, of slag that the iron could not be run into the
it
was melted.
2 inches thick
been
the
in
fire
little
signs of having
been heated, the fracture indicating a soft iron, the loss in melting was 18 per cent.
slag
The
iron.
cast at
a locomotive
works from
soft
iron.
N. Y.,
of hot-blast pipe that had been used in heating blast for drying
little
indi-
The
iron obtained
is
only
fit
for weights,
purpose
is
The
The follow-
mix
it
ing tables
loss in
show the
and gain
loss
in
Gain
in melting
tons of 2,240
lbs.,
gross tons are equal to 112 net tons, and, therefore, there
gain in iron on
Iron.
all
losses
is
and sold
as net tons or
Iron.
pounds
73
in
net tons
FOUNDRY IRONS.
74
all
be taken
when founders
scrap
in
evidently
No more
been
this has
scientific
When
with
tice,
will
consideration and
into
is
founders of to-day.
time paid for
at the present
in
steel
and scrap
steel.
Metals"
in
of this country.
Stove
founders have always been noted for better cupola practice than
FIRST FOUNDRY.
Tons.
Lbs.
2,049
i>o87
Amount
Amount
of pig melted
i)300
1,860
1)344
in
total iron
melted
919
57-7
melting
15-55
SECOND FOUNDRY.
Tons.
Gross amount of iron melted
2,817
Amount
1,842
total iron
melted
9 Lbs.
1,420
1,871
62.12
1
4-51
75
THIRD FOUNDRY.
Tons.
Lbs.
3)328
84
Amount
Amount
2,118
521
2,216
The
in
melting
total iron
melted
987
56.35
16. 12
.-
foundry
in
it
was made
Tons.
Lbs.
6,695
ii97
Amount
Amount
4,276
1,042
4,433
975
This
at the
last
table
in
157
total iron
melted
melting
S^-4^
15.08
results obtained
ever produced.
his
all
of production system.
and there
is
net,
and there
is
to the
founder a gain
in iron of
157 tons
in
The
total
tons, or
FOUNDRY
76
No
IRONS.
amount
represents the remelt, which was 41.59 per cent, of the total
amount melted
6,695 tons,
in
each heat.
was 356
tons, the
The
loss
same
as
on
amount melted,
total
on the
pig, but
shows
less
This heavier loss on the pig was due to the remelt of 41.59
per cent., or 906 tons, which had to be melted twice before it
was put
These
into castings.
in
melting on a
test
and paid for is the only iron on which the loss is sustained.
These heats were all melted with anthracite coal as fuel, but
little used for the purpose at the present time, and show the per
cent, of this fuel required to melt iron sufficiently hot for light
The
stove plate.
sumed
in
fuel.
know
It
interesting
is
and of
Such
aged cupola.
from excessive
blast,
knowledge serves
to
etc.
But
is
may be
visited a
by no means
liable to.
lost
loss
recovering iron
loss in melting
in
In soft
by sinking
foundry
at
into
Hartford,
for this addition, twenty bars of pig iron were recovered, and
had the
entire yard
in
refuse.
Bad
may be found
and
Many
Iron
is
in
buried
The
in
TJ
it,
but to reduce
compare
this
on hand, because
all
is
lost,
whether
it
has gone up the cupola stack or lost in some of the many other
ways in which it may disappear from view.
CHAPTER
VI.
taken
direct
from
furnace
the
many
all
castings, light
The
heavy,
which
in
iron
and
from
of the ores smelted was not suitable for castings, and this
prevented
many
of the furnacemen
from engaging
in
the busi-
difficulty
and uncertainty
in
ob-
edge
in controlling
profitable.
work
from
to
be
cast,
and
to
own
made
at blast furnaces
This
Even with
is
now known
as
the direct
blastin
the
casting
in
mixing
ores, the
to
be broken up
latter
in
(7^)
is
into
79
its
even
soft
of
lines
steel
iron.
ingot
molds, the direct process has proven a success, and these molds
the
liability of
is
This substance
iron.
in
is
often found separating the crystals of pig iron and falling out
when
the pig
is
broken.
of soft foundry or
such
large
house.
iron
is
quantities
It
Bessemer
as
and
iron,
floats off
in
the air in
to
It
caught
than
in ladles
when
it
excess of
All the
is
it
not appear
in rare instances.
But
great annoyance.
It
in
floats
and gives
to the
that often
condemns the
in
iron as
it
fills
latter.
devised to prevent
it
number
to
when
it
enters the
For
much
kish
is
1.5
reason
iron
by the
is
direct process.
in
it
it
in
comas
may be
pouring small or
silicon
is
unfit for
of gates
collect
the latter
the mold,
made
with such
too hard for light soft castings and can only be used
Kish thrown
off
from iron
in direct casting,
in
appearance
it
resembles
it
very closely.
80
FOUNDRY IRONS.
more
experience at
many
thickness.
in
less trouble
with kish than others, and turned out satisfactory small cast-
That castings can be made cheaper by the direct process than the founder can remelt the iron and produce them
ingot-mould foundries
is undisputed, and quite a number of
have been compelled to look for other work, due to direct proingi.
cess competition.
In
sell
in
But such
course would seem to be unnecessary as owing to the uncertainty of the quality or grade of iron a furnace may from day
to
men
iron
in
suitable
are
in
for
the
may
in a
stroyed in
damp
place.
Cast iron
is
de-
or steel, but
coated with
when exposed
rust,
and
it
too
to the elements
is
in
it
becomes heavily
and when
this
and not
at
with rust
is
is
all
removed the
deteriorated.
iron
is
found to be perfectly
When
solid
it is
similar to
by placing the
latter
in
surface, in
it
tent as
is
heavy scrap.
ing
is
That the value of cast iron is decreased by rustwell known, and pig iron that has for years lain in storage
new
sold at a lower
is
and
it
at the
iron of the
foundry.
mitted to rust, for the latter not only diminishes the quantity of
this
it,
it
iron
The
from which
was
it
its
characteristics are
a heavy
changed
to
so
make
cast to
is
not at
all
homogeneous metal.
improved by running into
a
entire
decrease
in size
effected.
This oxidation
is
caused by
may
take place
when
the iron
is
enclosed
grate bars.
if
the heating
is
sufficiently prolonged.
in a fur-
open
is
upon
air as
complete
its
oxide.
The
effect of the
oxide
is
FOUNDRY
82
IRONS.
brittle.
b}'
the
strength and softness of the iron are affected varies with the ex-
which
tent to
melted.
it
its
produces a very
fluid
slag
when
action
a cupola
in
it
is
like
As
more slowly
the slag
it
will
The greater the per cent, of iron the burned iron contain.s
more readily it will separate from the slag, and when not too
badly burned may separate from it in the cupola or be skimmed
be.
the
from the ladle, the slag retaining but a very small per cent, of
iron, and the iron cannot be poured into castings if the oxide is
That an iron has been oxidized by heat is not alin excess.
ways indicated
in
nor
by
is
the outward
heat, and
it
is
can be detected.
it
and weaker iron than that from which it was cast, and
extreme cases of oxidation a very hard, brittle iron that does
a harder
in
mix
not
it
is
Such
only
fit
homogeneous
metal.
slightly oxidized,
at
make
when but
Sandwiched Hard
Spots.
Albany, N. Y.,
1876.
in
The writer
At
first
met with
this iron
that
cit}'
whatever
although
Upon
soft
to
hard
in
spots.
83
the hard iron was inside of the soft iron with a well-defined line
between the
in a thin plate
of the casting
it
in small
took
in
never
that
it
globules or ob-
was found
in
it
float
into the
when
the latter
set.
iron
When
when
and
left
to
be
in
it
it
but
in drilling,
by extending
was broken.
No.
all
No.
were using
ore was
more numerous
when
These spots were
in their
left
from the
New
iron,
and when
this
iron.
melted, although
in
some
been able
to trace
them
to the pig
body.
These spots
FOUNDRY IRONS.
84
never appeared
and either
dis-
to
when
soft iron.
is
appear when
iron of the
They may
also
be
handling.
They may be
or from any old scrap thrown into the cupola at the latter end
of a heat as
is
frequently done.
But
in
regular
sash weight
foundries, they are cast from any old metal that can be purchased at a low price, such as blast furnace scrap, pig that has
roofing,
little
in
fact,
is
more
difficult to
in
cast iron,
little
hand,
at
if
and
distributed
give
is
85
life
to
metal sets very rapidly after being drawn from the cupola and
requires to be melted
therefore
It is
mold may
so that the
This metal
may be melted
sometimes melted
dump
in
be used for
ladle
or the fol-
lowing heat.
heat to
in this
it
soft iron.
An
extra
amount of
fuel
is
is
until a
hot metal
is
in
secured.
Temper
in Cast Iron.
it is
which may be
temper by heating
cast.
The
when cold
called
broken.
This
a certain
may be
degree of
illustrated
it
this
by the
When new
elas-
light
oven plates of
if warped
these plates,
FOUNDRY
86
This
of elasticity.
is
IRONS."
all
and the
higher the temperature of the iron when cast and the more
rapidly
it
sets in the
mold up
temper and greater the elasticity, as may be seen in the deflecBut the reverse is the case with a hard or
tion of test bars.
This
chilled iron in which elasticity is increased by annealing.
temper
but
exists
is
more apparent
in a
iron than in an
This
signed.
amount
the
is
case
in
castings
all
requiring a certain
To draw
in
annealing to
remove shrinkage strain, but it may be drawn by heating in turning up a light casting in a lathe with a high speed
This has been repeatedly
tool steel, or a dull low speed tool.
shown to be the case in turning up cylinders from which small
soften or
light
In this case
cut.
the rings cut from the end of the cylinder, at which the sharp
tool
was
started,
elasticity
speed or
dull tool,
fectly useless as
become heated by
a high
packing
rings.
When
cannot be returned to
it
it
by any known
it is
imparted
sets
and cools.
The
heating of
it
produce
is
in the
One of
done
upon them,
temper or spring.
in
that for
any other
made
in
require a certain
recent years.
amount
this
of spring that
8/
light
and
procure
in
in
is
difficult to
tried,
home
product.
mixtures of them,
all
the
known elements
in
added
in
to
molten iron
One
ring.
to
in
the
of the
be tried was
to the extent of
the cost of forty dollars per ton of iron with very satisfactory
made
when containing
is
the
same
the proper
amount of silicon and carbon to insure its being soft, the required amount of elasticity and strength for the rings, provided
the temper is not drawn from the casting by heating in turning
and
finishing.
CHAPTER
VII.
Foundry Chemistry.
Historical Data
There
is
and more or
this line
made
were experimental
less of a failure.
first
work
in
of getting a
more
satisfactory chill
on
their wheels.
In
1878,
Doctor Dudley, the chemist of the Pennsylvania Railroad Company, took up the subject and
made
number
of analyses of the
steel that
engaged
irons
in blast
may be
said to date
it
was not
until
from
this year,
From
and
to
in print
was coming when pig iron would be sold by chemical analysis instead of by fracture, the method in vogue at that
time, and it was not until 1890 that this prediction was realized,
(88)
FOUNDRY CHEMISTRY.
89
and not
until 1895 that chemists were to any great extent employed by foundrymen. About 1900, the American and vari-
every
facility
istry a
was afforded
That the
success.
tunities afforded
is
to chemists to
results obtained
undisputed, for
castings
made from
to
the founder
anthracite
and coke-
and work
is
in
making mixtures of
and cast iron for car wheels, the soft-iron foundry may be
The
nothing.
smelted
in certain
The
steel
in
in
its
fuel
one having the strength and desirable characteristics of a coldblast charcoal iron for cylinders, etc., or one having the strength
and
founder were
it
little
Thus
the
interest to the
made such
in
less
New
extent
made by
these
discoveries of metal-
FOUNDRY IRONS.
90
and their effect upon cast iron are being from time to time
made, and the chemist may yet develop a means of improving
loids
first
may
to the
is
based upon a
ways or formulas for mixing iron containing a known per cent, of various metalloids to produce a
This theory,
desired quantity of iron for work to be cast.
while it may be correct, has not yet been carried far enough to
contain, and the
prove
it
is
known and
their effect
melted together
in
correct,
may be
it is
contained
upon the
If
iron
in
cast iron, has not yet been determined, and probably for this
reason,
upon
all
been
Many
but only
iron,
contradicted
of
five
known
metalloids
actual
practice.
in
and
found
importance to be considered
in
in
cast
of sufficient
free carbon
and
its
softening effect
and sulphur
to
effect;
be a deteriorator
manganese
have a
to
phosphorous
to give fluid-
in all irons.
A mixture of
coke irons for stove plate requires from 2.50 ro 3.00 per cent,
silicon to produce a soft plate, yet a softer and stronger plate
can be
per
cent, silicon,
blast charcoal
is
well
known
to
be a superior metal as regards strength to a coke iron containing a less, equal, or greater per cent, of silicon, which would
seem
and
and not
silicon,
is
.00
per
FOUNDRY CHEMISTRY.
cent, of their silicon
may
when melted
contain,
by numerous
tests
when melted
in
cupola, yet
in a
this
cent, of
actually increased
Manganese, which
way.
they
it
it
iron
in
claimed by
is
and
iron,
extensively employed
is
by
also used
soft
is
as very
little
of this element
c, for softening
/.
to
and
found
is
in
in
and
it,
Sulphur which
in
have an injurious
to
may be
it
run
any proportion
upon
effect
is
iron has
the castings.
The
by a
all
and cupolas
in
generally considered
in
effect,
The
to
chill,
writer's attention
to a
mixture made
foundry
ture
made by
analysis
found
to
that a
new brand
ium
in sufficient
which
them were
An investigation showed
castings, but
for soft
in
and a mix-
of
to
It
in
casting.
and grades
of iron
is
many
by
at
failures to
produce iron
analysis alone.
Whether
necessarily
be
founder
in
shown.
The low
greater
than at
silicon
and
present,
as
will
greater transverse
warrant
and
the
tensile
92
strengths
coke
assumed
ganese
in
irons,
is
in
in
FOUNDRY IRONS.
manprobably caused by
form of carbon
is
in
in
metals.
in
change
effect this
the carbon of
in
at the
has not
It
which
it
had reached before the introduction of blast furWith our present knowledge of
limit
appears
on the
to
made
in
more metalloids
iron accurately
upon
the
must be sought for and
determined.
If this cannot be done then resort must be had to
that of the various brands and grades mixed,
their effect
it
steel,
quality desired.
Furnaces.
In
its
in
the iron
If
it
when
is
only
signed
then
the
cupola,
and
if
theory
the
results
more
this
correct
the
when the
indicated
But
is
furnace
if
by
analysis cannot be
metalloids
are
to
be
FOUNDRY CHEMISTRY.
added
to,
to the
furnace
is
molten
state
in
not at
all
inaccessible for
so
taken from
it
is
this process.
change
93
that
be
it.
elements.
added
nor
to
by charging the
re-
so great that
is
where
impossible to charge
it is
change
in
it
in
to a suffi-
it
has proved a failure and been
Another means suggested for improving the qualof iron by adding to or taking from it metalloids is the
this
abandoned.
ity
but before the desired change can be effected the molten iron
becomes too
dull to
So
voir.
that
effected during
in
if
it
change
hot or superheating
in the
the process of
that
will
moderate
the reseris
to
be
is
changes being
In the
manufacture of
accomplished
at
cost.
Steel Furnaces.
ings a
in
these
admit of
it
quality of an iron
number
steel
and
steel cast-
the iron,
in
come
under the writer's notice, the foundry has either drifted into
steel
or too expensive for cast iron, so that nothing has yet been ac-
of foundry iron.
FOUNDRY IRONS.
94
iron pipe lasts
street
steel
much
make them
lasting,
and plates are now being used for foundations and basement
work
in
etc.
steel
structural building,
exist,
in
at
many purposes
an
increased
With
for
cost,
which
steel
is
now-
and
at a less cost.
is
done with
upon
is little
is
at a
only to a
designed
moderate
prospect of a radical
steel,
CHAPTER.
VIII.
This
a non-metallic
is
silica,
is
and
too expensive to
is
it
admit of
It is,
in
in a free
or separate state
its
is
seum.
is
an example.
pure
all
it
substance which
infusible
of which quartz
Silicon
is
contained
and
claimed,
it is
alloyed with
it
to
it
less of
an excess loses
its
it
up to 20 per
and up
to
in electric
mu-
the ashes of
Therefore more or
in
it
the arts
in
laboratory or
in the
found
being used
95 per
Iron
the alloy
more the
to a
it
so brittle that
is
known
as silvery
and silver-gray
pig.
It
or combined carbon
silicon
is
necessary
if
increases or
the iron
is
to
correct only
tains only
quickly
uj) to
a certain point.
from one-half
in a ladle,
and
it
to
is
one per
only
when
is
(95)
it
can
FOUNDRY IRONS.
96
With an increase
of silicon
an iron the
in
carbon or
free
is
3 to
decrease as silicon
its life
its
strength
is
iron
and can only be run into castings when very hot. So that
theory is only correct up to a certain point, and this point
cent,
this
so unevenly distributed
is
castings
in
in
it
is
almost
number
cent,
of
same pig or
and
cast of pig,
it
is
only by making
determined.
By
may
the
iron
this
No.
White
No.
No.
No.
No.
per cent.
X
X
grades of
castings
Heavy machinery
machinery castings
bench work,
amount
etc.,
to
2.50 to
2.50
In
This
per cent.;
stove
plate,
represents the
making mixtures
test
to ob-
per cent.;
per cent.
97
The two or
in
more even
in
melting.
amount
the mixture,
the melting together of the extremely high and low silicon irons
to obtain the desired per cent, of silicon.
Charcoal Pig.
cent, of silicon
which
much
is
and coke
pigs,
The following
found
table
in
lower than
the
in
same grades
of
anthracite
is
stronger.
No.
White
No.
Soft Iron, 1.95 per cent.
These irons are graded up as far as No. 8
the higher grades varies from a mere trace
I
is
very hard,
solid,
fit
to
car wheels, chilled plows, and other chilled castings to give the
for
malleable castings to
give the desired quality of iron and per cent, of silicon for anIn making mixtures for heavy machinery castings
and 4 irons are used; for light machinery castings Nos.
2 and 3, and for stove plate, bench work, and light castings,
But these irons are so scarce at the present time
Nos. I and 2.
nealing.
Nos.
made with
to
them.
In such case
local
to
test
FOUNDRY
98
IRONS.
Silicon Lost
pola
ill
Melting.
becomes a harder
it
original
When pig
harder, this
when
iron even
size,
iron
is
in
a cu-
remelted
is
melted
becomes
it
still
it is
may contain
test in
in a
one per-cent.
silicon pig,
zone.
before melting.
But
when
this
silicon pig to
the iron
is
may be
loss
in a six per-cent.
greatly increased
by improper
melting, and the writer has known of as high as one and a-half
per cent, of silicon being lost from a three and a-half per-cent.
This heavy loss was occasilicon iron in the process of melting.
come
to a sufficient
until the
excess of fuel
The
iron
life
its
when
very
long, and was too hard for the work to be cast, although the
mixture charged should have produced a very soft iron. Analysis
showed
a loss of
corresponding
loss
of
less fuel,
to
The average
loss of silicon in
melting a
from the
The common
practice is to determine the per cent, of silicon which will give the
desired degree of hardness or softness in the casting, and make
99
melting, but
it
cent.
scrap, so
in
loss in melting.
little
made
he should use
in his
cated
in his castings.
Silicon as a Flux.
absorbed
cent.
b)-
a little
it
beyond
this point
than
its
silicon
upon
up
to
cast iron
when
make molten
more
frequently flows
to the
iron
fluid
experienced founder.
iron has no
silicon
it
more
life
be run
ings.
its
it
begins to
it
But as the
iron,
it
in
indi-
than a white
softener, but
it
in
has not
ume
in
in
In these experiments
same
some
more
little
fluid
ex-
as a cupola flux
owing
proved a
failure,
FOUNDRY IRONS.
lOO
tity of
silicon
cupola
flux,
is
such as limestone,
shells, etc.,
recommended
in
When
it
shape
by the
but
it still
It
it.
to a course
ferro-silicon
In
up
been placed
in
amount
it
of silicon has
to soften
it
give
silicon to
a sufficient
it,
powder.
silicon taken
latter
this dif-
way be added
comes too
was ground
was
it
to melt,
To overcome
it
iron,
was slow
became too
this
it
and quite
introduced
first
and before
in
for use in
frequently
in
iron.
a Softejier in Ladles.
Fcj'ro-silicon as
in
Up
ferro-silicon.
to the present
expense of the
justify the
to
good-
by the use of
to a considerable ex-
tent,
hard
iron.
method
Of course no founder
to
The
in a ladle
this
when
method
purpose.
sults
depend upon
desires to
this
results,
another
The per
pose.
iron
heat of the
iron
in
ferro-silicons
may be
taken up by the
depends
first
will
upon the
absorb more
than a dull iron, and secondly upon the tendency of the iron to
absorb
silicon, so that
stated.
Carbon
is
in nature.
kingdom and
the mineral
is
It
lOI
constitutes the
substances called
Carbon
is
without
it
iron could not be cast into desired shapes nor the degree of soft-
ness,
given to them.
free
from them.
coke-smelted irons
may
it
is
make
contain, and
into steel,
it
and
is
added
maker.
characteristics,
rolling,
steel,
it
is
effect of
surprising that
the
other elements
in cast iron
in
the
chemistry of
all
it
manufacture of
certain
first to re-
more
is
the non-metallic
all
which
must be subservient.
to
silicon
which
This was
in
the
named white
iron
would change
the
it
it
to a
now well-known
and while
it
renders
softer
is
failed to
show
and more
fluid,
up
to a certain
FOUNDRY
I02
point,
it
also impairs
IRONS.
its
is
not
for cast-
fit
and a 75 per cent, silicon iron, from which all the carbon
has been removed by the silicon, presents no more of the charac-
ing,
Our supply
of iron
is
an oxide of
is
iron and only in rare instances contains carbon to any great ex-
oxygen is
removed from the ore, and the iron it contains is left in the form
of a sponge exposing a very large surface, which is acted upon
by the gases of the furnace from which at a high temperature
In the process of smelting in a blast-furnace
tent.
carbon
is
Pure
iron
cannot be melted by the heat of a blast furnace, but by the absorption of carbon,
its
melting point
is
to
an extent
so great
is
more
fluid
lived
it
in
it
is
the
is
life
as a
absorbed the
become when melted, and the longerThe amount of carbon iron may absorb
will
The
make
cold;
is
the furnace
foundry
soft
more carbon
controlled by varying
work hot or
and
iron,
a cold
which,
in
a charcoal-smelted iron,
is
sorbs
cess
more carbon
is
in
it
When
in
an
iron ab-
out as kish during the solidification of the iron, but this only
occurs
when
a foreign
a molten state,
nation with
in
it
combined
all
element
like silicon
should
state
it
contain
when
may
is
contain
is
is
When
present.
in
it
in
combi-
can hold
IO3
the change from a molten to a solid state and held between the
iron
amount
when
white
combined carbon
of
cast
cold.
iron
reached with
is
But
of cooling.
tal
due
than
The
to the
when cooled
reverse
is
a white iron
denly.
rapidly and
it
is
always
state.
may be made
is
to a greater extent
by running
This
in
sud-
it
combination
with the molten iron, has not time to separate and assume the
is
do
to
it
we
find in
in
chill
and
How-
so.
ever, this sudden cooling only effects the iron near the
chill,
the sand
to cool
slowly.
The hardness
of cast iron
by
chilling being
due
is
to the
carbon
not rendered
removed by annealing at a
permit the combined carbon
entirely disappear
when
sufficiently
to
high
temperature
the iron
in different
parts of the same pig only being about 0.12 per cent., and
is
to
suddenly cooled
in a
mold
it is
This
state,
but remains
in
combination.
FOUNDRY
I04
IRONS.
bulk of the
latter
lbs.
lbs.
No.
soft iron
ence
weight
in
will
dif-
my
controversy with
istry in the
paper read
May
29, 1900,
Foundrymen's Association,
and a detriment
in
cast iron
trolling element.
to
it
in
chemists that carbon did not control silicon, but silicon did control
Notwithstanding
this statement and its adoption by chemhave during the past year met quite a number of foundry
chemists who have adopted the carbon theory, and do not an-
iron.
istry, I
carbon.
little
attention to
it,
and make
total
theory and
will
But
it
this
does not
making mixtures.
Foundry Irons. Kish
carbon which separates from cast
element
Kish
in
in
is
the
iron
105
tion,
never seen
It is
it.
it is
then only
the iron
in
when
filling
it
makes
its
melted, but
readily
is
cast-
cast-
ragged or streaked,
to the surface a
It is
American foundry
thrown out freely from some
grades of
is
separates from
it
It is
better
appearance and
It
on the top of
layers or streaks
iron
the
when only
the foundry
in thin
in
to differ very
sometimes found
and
in
it
seldom seen
when
irons
re-
of the brands of
English and Scotch pig, imported into this country, and foun-
drymen melting
The formation of
con
in
when
these
remelted.
irons are
is
it.
sili-
The formation
of
it,
when melting
these irons
cent,
an extent that
mixture and
will
still
It
in the
resultant
the addition of steel scrap to the mixture and a stronger casting thus be made.
But when
this scrap
is
stirred
is
irons
when remelted,
as
when
castings are
When
this
in ladles,
atmosphere.
From
made by
is
the direct
is
holding as high as 50
is
and
floats off in
FOUNDRY IRONS.
I06
the air to such
handful
in
an extent that
covered with
may be
gathered up by the
and everything
as with dust.
it
it
It
also separates
a foundry is
from the cast-
in
when melting
cent silicon.
This
is said to
be due to the iron being softer
by the direct process than when remelted, but is
probably also somewhat due to the large surface of molten iron
exposed to the atmosphere in the ladle, as kish is not seen to
when
cast
so great an extent
when
same grade of
the
iron
run direct
is
It is
gen
forms
it
five
not
is
With oxy-
acids.
It is
found
alloyed with
per cent,
in
it
up
iron),
40 per
owing
is
in
When
to
When
may be
and
to
90
combination up to 40
called " spiegel iron " (German for mirror
in
to the mirror-like
alloyed
manganese and the fresh fracture loses its mirror-like appearis more granular, softer, and is often beautifully stained
with rainbow colors due to superficial oxidation.
The effect of manganese upon cast iron is to increase combined
carbon, to decrease silicon, and eliminate graphite carbon and
ance,
sulphur.
although
Its
in
tendency
quantities
has a softening
effect.
is,
therefore, to
harden
Beyond
this point
it
forms
cast
iron,
sulphur
a
it
double
is
It
it.
is
in
to
low
in
harden
is
this
that of
all
its
With a
added
softening one due
has been accomeffect.
effect of
sulphur
It will
it.
first
other
certain point;
plished,
due
when
lO/
If
effect
the iron
is
to
is
also offset
by
its
tendency
iron,
alloyed with
it
in
iron
from coke in
manganese
effect of
up by
The strengthening
the blast
to
harden
furnace
in
it
combined
when re-
castings be-
combination
made
for
them to the iron. When thrown out of these proporby the addition of manganese when remelted,the effect of
the latter is so varying that it cannot be depended upon to give
the desired degree of hardness or strength.
It is only when
the per cent, of other elements is well known, and there is a deficiency of manganese in the alloy, that it can be added with
any degree of certainty as to results. The presence of these elements may be learned from analysis or from practical expeeither of
tions
rience, as in melting
Up
man-
FOUNDRY IRONS.
I08
the depth of
softer
chill
Beyond
iron.
Owing
iron.
and
melted
in
between
line
to these uncertainties
only
is
it
chill
the
many
when
a large per
is
it
tends to sepasoft
car-wheel founders
their
to
mix-
wheels
cent, of old
these cases a
and
chilled
manganese or ferro-manganese
refuse to add
tures,
this
with a well-defined
rate
is
is
In
generally
the cupola.
in
in
manganese
combination with the sulphur, for which it has a
entering into
iron.
Ferro-mansoftening,
for
it is
ground
to a coarse
in a forge to
the iron.
is
employed
to
results in a
it
found
to
it
in
this
way.
be very uncertain
acteristics of the
be high
have no
in
has been
cupola than
in
ladle,
prefer to apply
iron
it
effect
in
iron
In a ladle,
in action,
may harden
a
it,
and according
or soften
it,
to the char-
or should the
upon the
remove sulphur
from
and
it,
way
this
in
soften
it
to a limited extent.
09
Ferro-
And
all its
Phosphorus
liar smell.
of
it is
It
was discovered
Hamburg.
It is
is
Vv'ithout taste,
in
to protect
it
iron crystals.
this separation
weaken
is
to
Its
when
iron
effect in
cold,
consequence of
due
to the
tion
from
presence of phosphorus
it
and exists
less
to
in cooling.
in
extent found
molten
is
claimed,
state.
and
ores,
it
may be
is
its
is
separa-
phosphorus
to a greater or
alloyed with
furnaces.
it
in
is
said to be
is
iron,
it
in
in
cold,
combination with
20 per cent,
tric
As
when
brittle
it
up
in eleclittle in-
The
to impart life
effect of
and
phosphorus upon
fluidity to
to
prove
it
this
when
in
by adding
gray
iron.
grounds for
life
From
of the iron
some
that the
cent, of
FOLfNDRV IRONS.
lO
fluidity
it is
contain from
be so slight
in
to 2
effect
upon
iron,
Phos-
per cent.
this
is
by
Phosphorus also has a weakening effect upon
caused by it.
cast iron, but this weakening effect in foundry irons appears to
be given to
it
any
up
not apparent to
is
to 2 percent,
phosphorus.
Sulphur
in Iroi.
Sulphur
ver)-
is
generally disseminated
and
is
It
and
zinc,
Many
some
extent,
all
of the
the mineral
fuels with
it is
to
it,
when
cast.
of cast iron.
point,
It is
forming a
gas, which, in
its
at this
efforts to
solidifying iron, forms blow-holes, and also that the low tem-
perature at which
iron
when
it
becomes
solidifying
and
solid causes
to diffuse
it
to separate
between the
upon the
iron.
crystals, causing
It
from the
also
promotes
hardening
at
effect
temperature
globules
little
in
ening, and also a hardening, effect. This would indicate that sul-
phur
in either
form
iron as free
it
may
The
from
it
foundry
a detriment to
is
irons,
and
this
the
to obtain
as possible,
is
so that
it,
when melted.
writer a few years ago had a curious experience with sulphur when investigating the cause of hard irons in a foundry in
which only
soft irons
in a limited
number
it
of castings.
In
ladles,
upon
to
first
this
investigation
them, when
filled
with iron
a strong sulphuric
odor and
in
off
making
made from
this iron
were found
number
of times.
by heating
ladles.
thrown
off,
sulphur.
In
making an
filled
mine
and sprinkling on
it
this clay
was un-
doubtedly the cause of the hard iron, for when the use of
it
for
daubing ladles was discontinued and a loam clay used, the hardness in castings entirely disappeared.
Sulpliur.
Sulphur has
to
may
it
such a harden-
to a considerable extent
in the ladles.
This
is
fre-
iron.
The sulphur
is
upon it, or it
may be placed upon the iron and stirred in. This method of
hardening gives a very satisfactor}' casting when it is only deplaced
in
break shoes,
etc.,
is
in castings
rendered
brittle
FOUNDRY IRONS.
12
way
this
in
are
easily broken.
Oxygen
in Iron.
Oxygen
an elementary substance
is
mospheric
air,
it
uni-
being a constituent of
at-
bodies
all
and vegetable
with
less
all
extent in
to the
and
life
combustion.
to
all
found
in
combination
to a greater or
absorbed by
when exposed
is
it
and
called rust,
absorb oxygen
is
is
an oxide of iron.
The tendency
by
and
It is
high temperature
in
its
of iron to
by moisture
in
is
and cooled
is
in
almost
We
are dependent
and melting of
it
iron,
re-
cently been said and written about the effects of moist and dry
atmosphere
in these operations,
it
smelting.
The
the process of
in
in a
in a blast
in
putting in a
at the
is
only
in
is
The
foundry practice.
in blast in ordinar}'
II3
writer has not
been able
ful
any
to learn of
radical
no more
Iron
is
effect
upon
iron
it
in
the foundry.
nears
it
if
in in
hour the
three-ton charges and each of
charge
is
charge
is
so high up
when
is
the
first
one
is
The
melting that
its
third
fuel
is
in a
suflficient
extent
before melting to absorb oxygen from the blast would not ex-
ceed forty minutes, and probably not more than one-half that
length of time.
be
sufficient
in this
to
founder
in
make
iron
would
blast
oxygen the
of fuel
of
is
when too
great a quantity
is
for
is
at a
some
heat near
and be melted.
The
effect of
oxygen upon
to
cast iron
harden
it.
is
amount
the proper
8
management
of
to increase the
is in
To
FOUNDRY
114
IRONS.
The
upon
soft
irons.
Nitrogen in Iron.
ciple
Nitrogen
forming about
colorless, odorless
is
four-fifths of the
and
tasteless
atmospheric
gas.
It
It
air.
is
remarkable for
is
a
its
Nitrogen exists
as
is
he finds
it.
Hydrogen
to get
in
Hydrogen
Iron.
is
It is
an
a gas,
odorous and
tasteless.
It
little
electrolysis, in
It is
element and
is
the
air.
inflammable, but
will
not support
combustion.
to
in his iron.
which
it
is
said to
its
in
adding
make
it
to iron
except
in
in
usefulness.
CHAPTER
IX.
in Iron.
and so hard as
color
it
in iron
Titanium
resembles copper.
ore and
per cent.
is
may be
Its effect
It is
found
alloyed with
upon
cast iron
it
is
in
up
harden
to
is
said to
roll
any desired
be to absorb or
But
to shock.
car-wheel and
to almost
re-
dency
In
it is
of
more
it
its
ten-
renders iron
interest to the
wheel.
destined to
become
It
has
been used for heavy shafts of steam vessels with very satisfactory results, and may in the near future entirely replace
also
been pro-
duced
upon the
in
sufficient
quantities
to
place
it
made
it
in specially
regularly
been
fully determined.
if it is
(115)
its
place
But
this
it
FOUNDRY IRONS.
6
to
be better suited for any class of castings than the iron now
shun
in
it,
when
is
the
Ferro-titaiiiuni
is
use in
sale for
Ferro-titanium
per cent, to 25
gravity nearer
titahium
is
lump form
in
is
made
iron
cast
or
steel.
its
specific
the percentage of
If
the
and have no
effect
its
tendency being
and without
a great
loss.
is
con-
whereas
readil}',
usually
steel
won-
affinity for
The
The
more
is
to float
physical con-
becomes more
becoming harder.
iron
more in strength.
The addition of titanium can be made in the cupola, or in the
open hearth, or crucibles. The best method to introduce it,
however, is to melt it with a certain amount of the scrap in a
117
separate crucible, and add this to the bulk of the iron or steel
in a
molten condition
in
the ladle.
Titanium
may be added up
Percentage of
Pure
Titanium.
0.05 per
Percentage of
10 Per Cent. FerroTitanium to be Used.
FOUNDRY IRONS.
Humphry Davy
in
the year
in
1808, but
it
was not
it
in
fairly ob-
an impure state
that a process
everything, and
to take
its
new
all
it is
metals,
its
last
Aluminum
in
made
put
it
but owing to
its
cast iron.
and
it
is
there-
and cupola,
its
is
it
began
is
the iron ores or fuels with which they are smelted, and
to
it
but one-
is
But
it
has been
and
it is
impossible to
chill iron
taining
it,
fluidity
and strength up
point
it
results vary,
inum
is
it
a^ded.
owing
to
molten iron
Above
this
These
in
by
to the
Numerous attempts
been
con-
also increases
adding aluminum
factory,
to
It
in ladles,
latter.
extent to produce
Ferro-aluminum has also
to a sufficient
all
were obtained.
have no place
in the
At
aluminum seems
to
Nickel
It is
in
and especially
said
the
in
by
penetration
shot.
of armor-plate, in
to
manufacture of
in the
power
not found
latter.
which
it is
of the plate
to
It
may
making
to
is
it
in
found
The
same diameter.
metal,
will sustain
it
hard
a white
is
II9
to
it
but
in the ladle,
it
a cupola
in
it
and
has not
upon the
effect
these irons
the
Reports of investigations of
iron.
its
effect
its
upon
metallurgists for
American Foundrymen's Association, showed almost conmay probably be due to the grade and
effect of nickel
in steel,
it
should
in iron
increase the
cast iron
steel,
but
these
all
may be
offset
and
by
by other elements
it
in
be added
expensive a metal to
to iron
in
it
in
into
be obtained.
by the addition of
converting
it,
for
it is
far too
ordinary castings.
which
been
of
Very
little is
said or published
iron,
tin,
it,
them
is
such, that
action or effect
many
to
is
in
Iron.
years ago
upon
information
iron
made
is
not
deemed
necessary.
The
writer
FOUNDRY
I20
metals with iron
IRONS.
in
some
In
instances the
upon
beneficial effect
in the castings,
it
metals to iron.
it is
experiments
si-milar
improvement can be effected in the quality of castings by adding any of these metals to iron, either in the cupola or the ladle.
Untried
Metals in
Iron.
Tungsten,
been
steel,
tried
used
chromium,
and to
uranium,
all
in
them
in
as they are
expensive for
this
all
purpose
rare
and
likely to
be
time too
at the present
in
is
teresting element
which
it
in
or vanadate of lead.
very
difficult
It is
of
a very in-
not occur
steel,
It
is
also
and phosphorus.
Its
found
in
chief ore
is
It
does
vanadinite
in
then passes into the iron and especially into the finery cinders.
far
metal.
difficult to obtain, as
known regarding
However large deposits
little
is
its
char-
of vana-
in
S.
is
121
produced
in
now extensively
abundance
at a
moderate
price.
A use for it is now being sought and, like aluminum
when it became more plenty and cheaper, it may be recommended and tried for every purpose for which metals are used
and require, as aluminum did, twenty-five years to find its true
place among the useful metals.
Vanadium at the present time is being extensively experi-
mented with
in
desired properties
it
may
impart to
it,
some extent
tried to
accurately determine
Dr.
Moldenke
in
if it
repo.'"ts
the
all
It
sufficiently so to
experiments
in
melting
it.
The Superintendent
of the
in
Mr. Philip
their castings.
in their
foundry
at
Phillipsburg, N.
J.
it
hav-
under the
when used
of
in
vanadium used.
Wilson Bros., Easton, Pa., report that they contemplated the
use of vanadium in their ladles to increase the strength and
wearing properties of the grinding castings
in
their grinding
However, upon investigation they found that vanadium before it was taken up b\- the iron rendered. the latter too
machine.
FOUNDRY
122
and that
it
IRONS.
it,
molten iron
in
iron to
promote the
The
metallurgist of
vanadium
The
111.,
added
way
but
vanadium.
Other
tests of
vana-
dium have probably been made by founders but these are the
From these
now about
is
five dollars
in
Ferro-]^anadium. /j
to
it.
much
is
dency
to float
more
difficult to
As
much
loss, whilst
preferred, as
those of over
steel.
The
effect of the
up
to 3
per cent,
is
sufficient.
used to advantage
increases
titanium.
the
in
tensile
strength
Both prevent
can be
Vanadium
the same as
becoming
fatigued.
and
123
Percentage of
Pure
Vanadium.
FOUNDRY
124
I'anadinm
in Cast Jroti.
IRONS.
The element of
vanadium has
re-
is
in
it
American foundry
may be one
practice.
of the secrets
One
cast in America.
is
Some
in this particular.
recently
It was
found that American cast cylinders soon took a polish from the
in a
began
to
Some imported
Berliet cylinders
conditions.
These took
permanent.
were
a high polish
careful analysis
showed
tried
French
cylinIt
is
supposed, and the assumption seems reasonable, that their success was due to the presence of this element.
Castings.
CHAPTER
X.
Specifications.
Materials adopted
The
American Society
for Testing
way
is
allowed.
per cent,
in
the price
not practical
No.
and No.
2 irons, for
this standard
in
were evidently
all
At any
who appointed
foundry
irons.
at
the January, 1909, meeting of the association, and the report was
they have,
in
.Specifica-
Your
The
(125)
be accurately designated by
FOUNDRY
126
IRONS.
established
upon which
which
shall
this
No.
as
grade to analyze
So
Second.
that buyers
and
sellers
character of metal they want, symbols have been put after each
analysis, the
will
express
pense
in
telegraphing.
when warehousing
iron as the
word
written into the certificate will accurately describe the iron that
is
stored.
Third.
If
which
silicon varies (0.50 per cent) the tables are so arranged that he
it
will
the
the
rvnalysis.
Sampling.
one pig
its
shall
tons of every car load, and so chosen from different parts of the
car as to represent as nearly as possible the average quality of
the iron.
Drillings shall be taken so as to fairly represent the fracture
equal quantity
ground before
of drillings
analysis.
from each
shall
pig,
consist of an
well
mixed and
12/
different elements a
Carbon,
Total carbon not less than 3.25 per cent.
Siliccn.
Per cent.
Symbol.
0.50
Ca.
2.50
,00
Cc.
3.C0
Cy.
1-50
Ci.
3.50
Ch,
2.00
Co.
0.03
Sa.
C.07
0.04
Se.
0.08
0.05
Si.
0.06
So.
Per cent.
Symbol.
Cu.
Sulphtir.
Maxima
Su.
Sy.
gravimetric method.
Phosphorus.
Pa.
1.20
Pu,
0.30
Pe.
1.50
Py.
C.60
Pi.
0.90
Po.
Mati^anese.
0.40
0.60
..
0.80
1.
Mu.
Ma.
1.20
Me.
1.60
Mi.
My.
Mo.
00
Example.
Codeword
1.50,
Whenever
they
will
1.75
cent,
silicon,
and
or, in
Thus
silicon
under.
Cix
"
means
"Cox" means
2.25
in
"
FOUNDRY IRONS.
I2S
and Eastern Pig Iron Association. This committee, after conferring with the other committees, made the following report to
the Cincinnati, Ohio, meeting of the American Foundrymen's
Association, 1909, which was adopted after
much
used
in
ratories
discussion, as
method should be
The
testing labo-
al-
making
it.
It
uniformity
in
be used.
tions shall
in
all
all
five
elements be
recommend
that
be used.)
Silicon.
Code.
Per cent.
Code.
i.oo
La.
2.50
Lo.
1.50
Le.
3.00
Lu.
Per cent.
Li.
Sulphur.
(Maximum,)
Code.
Per cent.
Code.
0.04
Sa.
0.08
Su.
0.05
Se.
0.09
Sy.
0.06
Si.
o.io
Sh.
0.07
So.
Per cent.
29
Total Carbon.
(Minimum'.)
Per cent.
Code.
3.00
Ca.
3.60
Co.
Z-ZO
Ce.
3.80
Cu.
340
Per cent.
Code.
Ci.
..
A'lattganese.
Per cent.
Code.
0.20
0.40
Ma.
Me.
C.60
Mi.
o.8o
Mo.
Per cent.
Code.
0.20
Pa.
0.40
Pe.
1.25
Py.
Pi.
1.50
Ph.
Per cent.
Code.
CO
Mil.
I.
i.?5
My.
1.50
Mh,
Pkosphortis.
0.60
0.80
Per cent.
Code.
.00 .
Pu.
. .
Po.
lower symbol.
centages
by addition of
letters
to
next
may be
used as
maximum
or
minimum
figures,
but
above given.
tions
Each
be considered as a unit
One
in
carload, or
its
equivalent,
sampling.
shall
compo-
An
made
b\'
FOUNDRY
I30
IRONS.
recommended
if
practicable at
made.
is
Gravi-
metric methods shall be used for sulphur analysis, unless otherwise specified
The
the contract.
in
cost of
resampling and
sulphur 0.05
Penalties.
(maximum)
In case the
which must be
Allowance.
shall
it
in
the above
filled
the
case
In
when
buyer
shall
iron
furnace
is
may
the purchaser
at his
made.
Base Table.
may become
The
is
due,
is
made.
any good
cannot for
filled
by the base
accompanying
table
may be
filled
out,
upon
(This table
in filling
is
is
made.
may
arise
ance, and
iron
percentages are
maximum.
Silicon Percent.
Per cent.
3.25
0.05
0.06
0.07.....
0.08
.
3.00
...
B-f-
iC
B iC
o. 10
Note.
2.50
2.75
2.00
2.25
1.75
1.50
1.25
i.oo
B iCB 2CB 3C
B
B iC B 2C B 3C B4C
B 2C B 3C B 4C B 5C
B 3C B4C B 5C B 6C
B 4C B 5C B6C B 7C
B iC B 2C B 3C B4C B 5C B 6C B 7C B 8C
B 2C B 3C B4C B 5C B 6C B 7C B 8C B9C
0.04
0.09
I3I
The
specifications of
Philadelphia
been
in
in
the buying
and selling of
irons,
but they
no doubt
will
answer the purpose, as they give a wide range for the various
elements, and cover the old and
all
Analyses of Castings.
The
collected
some
mixture.
Si. 2.80, P.
0.80, S. 0.09,
M.
0.20.
2.25,
Si.
2.00,
0.75.
P. 0.50,
M.
0.50 or
to
to 3.000 lbs.,
Thickness of
1.60, P. o.70,
less.
Bedstead Joints,
Si. 3.00, P.
i.oo,
M.
0.20, S. o.io.
M. 0.70
FOUNDRY IRONS.
132
i.oo,
Si. 3.00, P.
M.
0.05,
S. o.io.
Small Cylinders,
Si.
Chill Rolls, C. C.
1.
M. 0.21.
Mine Car Wheels,
Malleable Iron,
Chills for
1.88, P. 0.50,
0.85, S. 0.26.
M.
Si.
0.77.
M.
0.60, S. 0.04.
Si. 2.50, P.
o.io, S. 0.07.
0.75 to 1.50,
Foundry Use,
Medium Heavy
M.
Heavy
M. 0.50
to 0.75.
M.
Annealing Pots,
Si.
0.70,
0.70, S. 0.20.
composed
is
of
re-
Silicon
Phosphorus
0.70
Sulphur
less
than
o.io
Manganese
From
0.50
it is
estimated
to
be charged
should be as follows:
Per cent.
Silicon
Phosphorus
o.
Sulphur
Manganese
less
than
.85
70
0.07
0.60
133
Analysis.
Kind
of Material.
4C0 O.IO
Steel scrap
0.07
a-
t/j
If
'
O.IO
a*.
0.60
0.40 0.28
Machinery scrap
2;000
1.70?
34.00 2.00
1,600
0.70
O.IO
1.50
0.30
II.20j 1.60
1,600
3.00
0.03
0.80
1.25
No.
0.40
2.40
20.00 12.00
24.00
4.80
48.00,0.48
12.80 20.00
0.60
70.00 2.80
12.00 24.CO
0.60
28.00 0.20
No. 3 foundry
High
4,000
silicon iron
Total
1-75
800 3-50
0.07
0.30
0.025 0.07
10,400
O.56I
4.80
191.60 7-36
1.84 0.071
69.76 68.00
0.67
0.65
* Multiply the weight of each kind of material by the per cent, of the element in
it,
then divide the total weight of each element by the total weight of the materia'
which
By
in this
example
is
10,400 pounds.
the relative adjustment of the pig iron and scrap, mixtures for any desired
CHAPTER
XI.
was made
at the Detroit
of the
meeting
a committee ap-
and
interest.
The
in
number
first,
published
work; second, the private notes of the writer; third, the replies
to the inquiries sent out by your committee
Regarding this last source, which has supplied the greater
number of analyses, approximately i,ooo inquiries were sent
out to as many different foundries, selected largely at random
:
from
lows
"
At
sociation
ical
These
it
was decided
to
in
to the individual
foundryman and
to
course, be obtained
"We
by analyzing
(134)
in
giving us the
we
is
35
feel
sure that
in
names
There
is
lowing information
"Name
Comb.
To
this letter
greater
number
classification of castings,
to consider as
Nor would
more or
of which contained
Regarding the
sible
Mang.,
Phos.,
separate cases
it
less information.
is
evidently impos-
all
this
itself class
its castings into comparatively few groups which are each poured
from one kind of iron. For example, a shop doing machinetool work may make castings from several hundred patterns and
will use not to exceed four mixtures of iron for all of these,
probably dividing the work into light, medium and heavy cast-
therefore, that
necessary
is
It is
thought,
in
Thickness
a classification
is,
wherever possible.
deavored
In
this
Testing Materials,
ness as follows
known
" Castings in
has
has en-
American Society
for
(126).
thick shall be
it
to sec-
any section
less
as light castings."
which no section
is
less
Medium
nitions."
It
is
is
much
lacking
in
this
FOUNDRY IRONS.
136
many important
table,
These
analyses.
deficiencies are
ture
amount
is
to
due
may be
at
it is
is
its
manufac-
by your committee.
It
is
it
this
in
is
The most
in certain
other
limits
to this
element.
in
the use of
purifying alloys have not been taken into account here, although
specified in
Finally, in
in
some
many
carbon
cases, a very
is
per-
missible and compatible with the best results, and in such cases
first
element
to
be considered
in
Castings.
137
138
Automobile Cylinders
FOUNDRY
IRONS.
139
I40
Bases
and
Spiders, Small.
141
FOUNDRY
142
Friction Clutches.
Ref.
Silicon.
Per cent,
2.00-2.50
und.* .15
64
Sug.*
1.75-2.00
Furnace
Castings.
194
Sug.
Sulphur.
Per cent.
2.50
.08-.
10
und. .07
2.00
.085
1.85
.090
2.00-2.50
und. .c6
1-45
1.98
Sug.
0.90
1. 21
.117
1.00-1.25
.04 -.08
1.00-1.75
und. .08
Gears, Heavy.
171
1.40
.150
1.60
.080
1.50-1.75
.080
1. 00- 1.
Sug.
0.60
94
075
25
1,40-1.60
.04-.08
1. 00- 1. 50
.08-.10
Gears, Aledium.
64
171
Sug.
1.50-2.00
und. .08
1.90
.060
2.30
.060
1.90
.100
1.50-2.00
und. .09
Gears, Small.
198
3-43
2.00
Sug.
2.00-2.50
.100
und. .08
Grate Bars.
95
Sug.
2.75
low
2.00
.085
2,00.-2.50
und. .06
IRONS.
143
144
Hollow Ware.
FOUNDRY IRONS.
US
FOUNDRY IRONS.
146
Machinery
Ref.
171
Castings, Light.
Plates.
147
148
Propeller Wheels.
FOUNDRY
IRONS.
{sand cast)
149
ISO
Steam Cylinders, Medium
FOUNDRY
Continued.
IRONS.
151
FOUNDRY
152
last
it
may be
IRONS.
grades.
Basic iron
means primarily
cent.
everything
the
in
way
of
The
indicated.
CIASSIFICATION
Si /icon.
Southern Points.
IRON.
Sulphur.
53
Sulphur.
Silicon.
Buffalo Grading.
Scotch
No.
Foundry
.05
,05
2.00-2.50
"
"
,05
"
"
"
No. 2 Plain
1.50-2.00
"
"
.05
"
"
"
"
No. 3 Foundry
Gray Forge
1.50,
"
"
.05
"
"
"
"
.05
"
"
"
No. 2
Note.
If
sulphur
is in
excess of
maximum,
(under)
it is
"
(over)
of silicon.
Charcoal
but
is
is
by
sold
by
analysis,
by
tests, or by some
custom of the maker
chill
accompanied
iron
it
GRADING
PIG IRON,
Sta)idard Afialyscs of
Steel
The
Making
tJic
Irons, Ferro-alloys
and Melting
Fuels.
Addy &
furnished him by
W.
\\\
same company
Standard Bessemer. This iron is used principally for making acid Bessemer steel, this process burning out the impurities
by blowing air through the molten Bessemer metal.
As neither this, nor the acid open-hearth, process removes
any phosphorus, it must be low.
The standard specification is as follows
the
Silicon
to 2 per cent.
Phosphorus
"
Sulphur
"
pounds,
if
sand
cast, or
special purposes,
it is
2,240 pounds,
if
is
chill cast,
broken,
in
except for
which case
FOUNDRY
154
it
IRONS.
a charge of 25 cents
per ton
west (Chicago)
This
is
it
2,240 pounds.
The
Phosphorus
"
or
1.25 to 1.75
"
if
sand
cast,
Low
low
in
PJwspJiorus.
phosphorus.
This
The
still
from
steel
is
I
to 2 per cent.
"
Sulphur
''
Washed Metal.
extra
Phosphorus
It is
also
pounds.
Si'icon
as possible.
chill
few furnaces
sell
ton, 2,268
is
is
"
.25
0.75 to
the
for
Sulphur
Silicon as specified, usually
in
used
is
usual specification
silicon
is
desired as high
This
is
and also
in
making crucible
steel castings
steel.
It
is
sold
and fire-boxsteel,
by
analysis, the
Sulphur
"
Phosphorus
"
Sulphur
"
Phosphorus
"
Sulphur
"
Phosphorus
"
Sulphur
"
on an iron
cast
is
This
iron
plate,
It is
is
and comes
55
irregular pieces
in
and can
steel
com-
steel.
As
specified under
less
that
under 0.05.
Basic iron
is
by
rapidly superseded
This method
Foundry.
medium-size
larger than
of grading
is
being
large crystals.
crystals, say
and con-
the standard
is
tains
specified
is
analysis grading.
Fracture contains
No. 2 Foundry. This
considered
I
always sand-
is
The sulphur
molds.
always
it is
No.
flux,
cast in chill
is,
it
no spot
square, with
yi inch
No J.
Foundry.
Contains small
East of Altoona,
these grades are:
No.
is
the
Pa.,
fracture
crystals;
and throughout
all
is
close.
New York
of
state
2 plain.
cents a ton.
white
giving
spots,
is
the
fracture
the
in
combined
state.
carbon
all
is
in
the
com-
state.
These
last
in
in
silicon.
is
graded as
follows
No.
No.
soft (sold
2 soft (sold
same
same
price as No.
foundry).
between No.
forge).
Foundry
all
the fur-
FOUNDRY
156
IRONS.
now
sold
and
may be unbroken
or broken
is
is
by
sold
some
pounds.
by
com-
made
the
to
sell
is
POIflTS.
No.
foundry
2.75 to 3.25
0.05
No. 2 foundry
No. 3 foundry
No. 4 foundry
2.25 to 2.75
0.05
1.75102.25
0.06
1-25 to 2.00
Gray forge
1.25101.75
3.00 and over
0.07
0.05
and under
2.50 to 3.25
0.05
and under
No.
No.
2 soft
soft
.
and under
and under
and under
and up
EASTERN POINTS.
Silicon, per cent.
No. IX
No. 2X foundry
No. 2 plain
2.75
No, 3 foundry
No. 2 mill
Gray forge
Note
If
sulphur
is
0.03
and under
2.25 to 2.75
1.57102.25
0.05
1.25101.75
1.25
1.50
in excess of
and up
and under
and under
maximum,
the iron
and under
gardless of silicon.
No. I foundry
No. 2 foundry
No. 3 foundry
Gray forge
2.25 to 2.75
i-75 to 2.25
1.75
and under
re-
57
BUFFALO DISTRICT.
Silicon, per cent.
Scotch
No. I foundry
No. 2 foundry*
No. 2 plain
2.50 to 3.00
No. 3 foundry
Gray forge
2.00 to 2.50
1.50 to 2.00
1.50 (under)
0.05
and under
0.05 (over).
CHICAGO POINTS.
Silicon, per cent.
No.
foundry
2.25 to 2.50
0.02 to 0.05
No.
2 foundry
1.75 to 2.25
0.02 to 0.05
No. 3 foundry
1.35 to 1.75
Scotch
2.50 to 3.00
Silvery
2.00 to 3.50
Gray forge
The
it.
equal quantity of drillings from each pig, well mixed and ground
before analysis.
In case of disagreement between buyer and seller, an inde-
pendent analyst,
to
to
shall
be engaged
iron.
a grade.
" Scotch " indicates a
more
and sulphur.
is
to
FOUNDRY IRONS.
158
The
buyer
seller
sampHng and
cost of this
the shipment
if
if
High
otherwise.
Silicon Irons.
is
proved up
Softeners
to specifications,
are
by
sold
by the
and by the
silicon
contents
to
silicon.
Silvery irons run from about 3>4 to 5^^ per cent, of silicon.
This
last class is
sometimes divided
No.
into
Silvery,
which
is
The
still
made
in
Ferro-Manganesc
is
it is
a special
sometimes sold
as high as 75 per
an electric furnace.
This
is
is
guaranteed.
Owing
lish
to the lower
phosphorus
in
than that
made
Foreign Iron.
pounds, and
in
in
a little
lower
in
phosphorus
Germany.
All pig iron
is
sold in
England per
ton, 2,240
kilos.
In
as
Hematite.
Silicon
Sulphur
"
usually 0.035
"
Phosphorus
It
0.06
"
Thomas
Gilchrist, or
Thomas Pig
Iron.
This
is
used
in basic
Silicon
Phosphorus
2.50
"
Manganese
2.50
"
to 0.20
"
Sulphur
up
There
is
59
no open-hearth basic
practically
At Middleboro
Europe or England.
making
Phosphorus
They
"
"
.65
to 0.20
.00 to
up
Sulphur
guaranteed.
is
This
The
is
No.
I,
No.
2,
No.
3,
No.
4,
3)^
to 3^4'
to
23^
2i^
into
two
groups, with
Manganese
And Manganese.
under 0.75
say 0.75 to
Analysis
per cent.
1.
10
"
unguaranteed,
but
is
usually
shows
Phosphorus
Manganese
0.40 to 0.75
"
say 2.50
"
0.02 to 0.05
"
Sulphur
The No.
sulphur
is
extremely low.
Analysis about
as follows
Phosphorus
Sulphur
o.c6 to 0.20
"
under 0.75
"
Manganese
::
FOUNDRY
l6o
is
IRONS.
by
also sold
of No. 3 being
Phosphorus
Manganese
10 to 1.80
"
about 0.03
"
about 2 to 2.50
"
1.
Sulphur
Silicon
These
two
classes
made
is
in
Warm
which the
Blast, in
blast
air.
is
degrees Fahr.
and
is
This
iron
is
region
No.
I,
No.
and
will
chill
inch
when
No.
shows a
^-^
No. 4 a 3/H-inch
No. 5 a ^-inch
-inch chill.
to
to
^-inch
i
>2
chill.
-inch
chill,
"strongly mottled.
No. 6
is
Warm
white,
combined
all
Blast Iron.
This
iron
is
state.
No.
it
is
graded as follows
No.
No.
No. 4
No.
coke
iron.
show a
chill of
about
inch
if
plate.
No.
5,
a chill of about
'"ch to
inch.
will
show
when
mottled
to
inches and
>^
is
cast in sand.
Carbon
about
of
chill
l6l
combined.
is all
by
frac-
generally used.
Silicon, per cent.
Average.
Min.
Max.
Scotch
2.50
2.38
2.62
B Scotch
C Scotch
Low I
2.25
2.13
2.37
2.00
1.88
2.12
1.75
1.63
1.87
High
1.50
1.38
1.62
1.25
1.
1.37
Low
High
13
Chill.
12
i.oo
.88
75
.63
.87
Trace
to )/^ in.
High 3..-.
56
.50
.62
1^ to
.44
.38
.50
% to
32
20
.25
.38
.15
.25
Low
.10
.05
.15
White Mottled.
00
.00
.05
White.
Low
Low
High 4
Low
High
No. 6
Phosphorus
1.
1^ in.
Mottled.
0.15 to 0.23
>
Manganese
0.30 to 0.70
Sulphur
Coke.
to
in.
in.
Trace
This divided
This coke
is
to
0.018
is
selected from ovens which have
burned 72 hours. It is always made on Mondays and Tuesdays, as no work is done at the ovens on Sunday.
It may be
made on other days of the week by shutting down another day.
Foundry.
It is
This coke
used
is
Furnace.
This
smelting ores
is
coke that
is
in blast furnaces.
used
is
in
in
cupola
practice.
Ash
where structure
is
Sulphur
under
in ash, until
weakened.
percentage
is
per
quality
reduced
FOUNDRY IRONS.
62
Smelter coke
per cent,
in
is
While
sulphur.
this
it
does no harm
1.20
it
un-
in
the
This coke
is
when
loading,
tion that
is
it is
If
care
is
used
in selecting this
coke
good as if freshly drawn, with the excepsomewhat broken up by the double handling and
it is
as
discolored.
coke.
Crushed Coke.
This
is
The
first
^ -inch pea,
forgings, etc., the pea coke for chemical works, etc., and the
dust for packing the bottoms of soaking pits and crucible furnaces.
Ferro- Alloys.
Owing
in use for a
in
many
many
of the ferro-alloys
One compan}-
its
material
and upon
certificate of foreign
sive as to quality.
Fer^'o-aluminum
is
sold containing
and
steel,
No.
being
It is
sold
by the pound.
21
M.
Alloy.
This
One
is
an alloy of
63
aluminum, man-
silicon,
showed:
partial analysis
per cent.
"
Silicon
8.01
Aluminum
Manganese
6.80
Phosphorus
0-075
"
8.39
"
mium.
It is
carbon,
it
is
above
is
low
as follows
Chromium
64.80
66.00
Iron
33.43
21.91
Carbon
Silicon
0.29
1.40
Phosphorus
0.027
'7
Sulphur
0.02
0.22
Manganese
Copper
Aluminum
0.09
0.20
o.
....
It is
If
.2
9.90
....
Standard ferro-inanganesc
per cent, or over manganese.
is
The English
is
typical analysis,
man-
as follows:
English.
Manganese
Iron by dif
11.50
"
Silicon
1.65
"
Phosphorus
0.23
"
Carbon
6.78
Sulphur
It is
Ferro-molybdenum
240 pounds.
sold per pound of pure molybdenum
is
FOUNDRY IRONS.
64
Thus,
Molybdenum
79-
Iron
Carbon
Phosphorus
...
Sulphur
Nickel.
99 per
As
cent, nickel
Fcrro-iiickel
and
is
of nickel as specified.
per cent.
is
3.24
"
0.028
"
0.021
"
guaranteed over
by the pound.
sold
is
'
17.55
The balance
0.85
Silicon
0.25
Sulphur
0.015
"
Phosphorus
0.025
"
per cent.
"
The
foreign
is
guaranteed,
is
as follows:
Phosphorus
Iron
75.03
Manganese
0.70
"
Silicon
.63
"
Carbon
"
The domestic
is
guaranteed
Phosphorus
18 to 22 per cent.
Sulphur
under 0.05
"
Manganese
under 0.50
"
It is
Phosphor-Maiiganese
typical analysis
is
65
Manganese
Phosphorus
25.00
"
Iron
7.00
"
Carbon
2.00
"
Silicon
1.
00
"
Silico-Spicgel contains
manganese 17
The standard
to
is
Manganese
Silicon, 9 to
is
average 10
per cent
manganese and
"
silicon guar-
as follows:
Manganese
Iron by dif
68.02
"
Silicon
lO'33
"
Carbon
Phosphorus
1.26
"
0.07
"
"
Sulphur
It is
sil-
18 to 20 per cent.
1 1
anteed,
guaranteed as follows:
Special
High
40 per
cent, silicon.
It
is
typical analysis
is
Silicon
49-90
Manganese
Carbon
0.16
0.55
per cent.
"
"
Phosphorus
0.075
"
Sulphur
0.018
"
Bessemer Ferro-Silicon.
This runs
to 16 per cent, in
sili-
The "Domestic"
is
per cent.
Phosphorus
Sulphur
"
1:
FOUNDRY
l66
The
is
IRONS.
2,240 pounds.
It
is
see
silicon
'
High
Silicon Irons."
Ferto- Sodium
vs,
sodium
The standard
manganese.
is
to
40 per
guaranteed
Per cent.
Manganese,
average 20
8 to 22 per cent
Phosphorus
o.io or under.
is
as follows
Manganese
20.
Iron
73.6
Silicon
0.76
Carbon
5.18
Sulphur
0.002
Phosphorus
O-OSS
It is
Ferro-Titaniuin.
anteed only
in
by the pound
If
per cent.
150
titanium, which
is
contents
is
sold guar-
is
typical analysis
is
Titanium
Iron by
87.68
dif.
"
Carbon
0.67
"
Silicon
0.37
"
Phosphorus
0.04
"
Sulphur
0.03
"
higher
in
sold
of alloy.
titanium,
it
is
sold per
pound
of pure titanium
typical analysis
is
as follows:
S^-SO
Iron
44.18
Carbon
2.82
Manganese
0.14
Arsenic
i.io
"
"
0.04
"
0.021
"
Aluminum.
0.41
"
sold per
pound per
85.47
Iron
13-90
per cent.
"
Carbon
0.30
"
Silicon
0.13
'
Manganese
Aluminum
0.09
"
0.00
"
Phosphorus
0.019
"
Sulphur
0.025
Ferro-
Vanadium
dium contained
and
"
Phosphorus
is
selling price
is
that
is
sold per
is, if
pound
as follows:
61.20 per cent.
"
33.C2
2.97
"
0.47
"
1.88
"
0.3
^3
"
0'3
"
"
"
alloy contains
five cents
67
per cent.
"
Sulphur
Ferro-Tungstcn
per unit,
20 percent, vanadium
it
Iron
61.0
"
Carbon
0.4
"
Silicon
0.9
"
Aluminum
0.8
"
0.6
"
CHAPTER
XII.
of
Inaccuracy of Analysis.
One of the obstacles to the success
chemistry in foundry irons has been inaccuracy in the
analysis of
iron.
chemists by foundrymen,
it
employment
of
fre-
men
was right
in
To determine who
same pigs of
The
report of
from these firms as read before the Pittsburg Foundrymen's Association, by Thos. D. West, March 28th, 1898 is
analysis
given below.
TABLE
I.
TABLE
II.
169
FOUNDRY IRONS.
I/O
TABLE
IV.
Analyses.
3 Sets.
3 Sets.
3 Sets.
3 Sets.
3 Sets.
3 Sets.
Set.
Set.
Set.
Set.
H
I
K
L
M
N
2 Sets.
'
3 Sets.
1
Set.
2 Sets,
2 Sets.
Sets.
Set.
171
in
results
unknown purity? It is this uncertainty of the accurracy of analysis, even when made under the most favorable
conditions, that has more than anything else destroyed its value
in the estimation of foundrymen.
For although chemists have
material of
endeavored
to
attribute
this
variation
in
results
to
different
this to
table.
be the case, as
And
will
even wider
Blast-Furnace Analysis.
It
has
come
to
to furnish to the
founder with
analyses are
made from
These
number of samples taken from diffrom the furnace and are supposed to
These
this
per cent, of various elements best suited for the grade of castings to be cast
from
it.
The
iron
is
sold to
show the
analysis
FOUNDRY
172
too soft, the analysis
place the
IRONS.
is
iron
There
for inaccuracy.
is
made
is
effect
by
his
own
This
chemist.
of analysis and
depend
is
entirely
upon
accurate,
if
many foundrymen
the view
take
from the
that furnished
furnace.
Cost of Analysis.
The
diffi-
said to vary
from
fifty
minimum
rate
it
analyzed
to
At
for.
the
for the per cent, of what are considered the six most important
elements
in cast
iron,
namely,
silicon,
manganese, phosphorus,
cent,
work.
by
all
is
termed contract
a higher price
minimum charge
is
charged
from one
is
$100
it
it
is
has to be built; an
apparatus, which
is
quite an item as
the breakage
it
is
considerable
supply of
73
acid and chemicals for analysis, gas for analytical purposes, and
this
employing
known
iron
in
saving to founders
As
as testing laboratories.
only a manipulation of
is
etc.-,
these
the aid of
upon
a practical
in
them
to locate
the trouble of
must give
latter
to
them the
name and per cent, of each brand of iron and scrap in his
mixture.
The information thus obtained makes it possible
for
to
ing the
trict
same brand of
As founders
in
is
it
to
melt-
any given
dis-
melt about the same brand of iron for the same class of
iron.
who
and
more
chemist
in
many
satisfactory
at their
is
cases enables
own
them
mixture than
plants,
and
in
to give to the
founders
experienced
foundry
the
one than an inexperienced chemist. But this system gives away the foundry mixture of iron, a secret many
foundries endeavor to guard very closely.
Testing laboratories
contract to do this line of work for foundries by the year at a
much less cost then they can employ a competent chemist and
maintain a laboratory.
These laboratories are also of value to
the founder, when not regularly employed by him, in settling
disputes with pig iron men as to analysis of iron, and in making
tests for tensile and transverse strengths of iron called for in
satisfactory
FOUNDRY
1/4
The
IKONS.
in
a carload of thirty
to forty tons not fairly representing the per cent, of the various
may
carload
by
it is
only
when
That the accuracy of resultant mixtures made by analysis alone can not be depended upon, is
admitted by practical foundry chemists, for in visiting foundries
value by foundrymen.
have met
many experienced
chemists
who
frankly admitted
castings,
tests,
iron or fuel
is
up
etc.,
in
gates and
to the standard, or
to
locate
some trouble
become
foundry, for
the
in
if
The
thumb
fits
fits
him
to
rule of
this training
him
enter into the composition of cast iron, and their effect in giving to this iron
its
various characteristics.
This knowledge
fits
for
irons than a
Foundry
able to attain.
is
75
not possess
in
of chemistry to them.
Fracture
in-
these
Without
irons.
when
piled
in a
if
he knew the
location of the piles from which his sample was taken, he would,
if
scaffold,
be entirely
at the
mercy
of the cupola
pile
men
and,
if
they
in
mixture.
his
He
one
they are of
little
or no value
in
at
fracture
indications, for
work
his laboratory
that
in
selecting his
in
pig, scrap
and
deter-
in
castings.
in
The
connec-
When
he has done
this
he can
importance
in
reduce
into cast-
analyses
his
number, that he
Mechanical analysis
will
is
it
have
of great
is
cast,
FOUNDRY
176
and
in
bars,
in
strengths of which in
sis
made
indicating changes to be
IRONS.
many
castings.
in
be used
of his analyses.
It
analysis, for
by
it
will
if
is
in
the mix-
in
composition of an
the chemical
made
iron
per
the mixture.
cess
less
Here
reducing the number
in
form of
contain, and
also indicate
this
may
in
the mani-
In this pro-
may be
It
to
entirely
should be the
and he
should be able to take charge of the cupola and give the cupola
men
for a
irons,
of them.
is
fitted to
details
in
When
fitted to
relieve the
his
foreman of the
little
or no value, and
turbing element
in
he frequently becomes
failure of analysis to
by
his
attempt to
in
in
foundry
"
The
prob-
iron.
Pig Iron. Replying to N. W. Shed's comthe September Foundry, regarding the " Hoodoo
Hoodoo
munication
dis-
shift the
in
Hood
in
writes as follows:
"
77
wish to take
will
"While unable
nevertheless,
ference
my
In
is
in
in different
to
number of
some quality
less
tion of a large
foundries, and
that there
in
"
is
forced to admit
unable to determine.
is
list
mistake.
black-list
is
class of
am
make
a vital dif-
ratory
is
The
making
and
so
section..
automobile cylinders.
The
storage yard
used with a
tect
was forced to
'
still
no difference
of iron tried
was
at
fall
fault.
in
satisfactory,
few days
brand
to
and
it
super-
in silicon,
'
was decided
make up
to
use
this difference.
trifle
was
low
it
FOUNDRY
1/8
IRONS.
but the usual 20 per cent, of foundry returns used were from
the heat containing this " off " iron with the result that there
tents
As
"
result of
chemistry
my
is
sc
experience compels
doing wonderful
intelligently
" Instead of
it
chemistry per
and
processes and methods.
must be used
cal
letting
is
me
things
in
do not
do
so,
and although
it
that
CHAPTER
XIII.
The term
its
to cast iron
work
its
to
it
may
tests,
it
upon it
known.
after
physical char-
acteristics
cast.
shrinkage, depth of
chill,
made by means
subjected to various
as follows
stress, etc.
Shrinkage
made by
its
when
length
when
hot.
which iron
This
test
is
the extent
it
tests, indicate
it
shrinks
was moulded.
To
This
test is of value
length or
to
179)
size,
and also
be assimilated, as
in deterin
stove
FOUNDRY
l8o
plate, will
be of a proper
size
IRONS.
cast
if
from
different brands of
iron.
Fracture Test.
By fracture
is
luster,
chilling
tendency,
This
etc.
test
large or small.
and
light luster of a
iron.
is
evidence
harder iron,
too
is
it
known
is
weight, and
is
made by supporting
it
required to break
break
in
Cross breaking
it.
and
cast iron,
this
test,
is
to the center
number
of
the most
pounds
common
iron.
is
Change of Shape.
By change
is
meant
This
is
iron
is
bend
likely to give or
in
when
subject to strain.
Tensile Test.
By
this test
is
strain
in
rately
owing
It
iron,
is
it
This
test
is
considered of
make
this
accu-
l8l
it,
it
is
broken.
is
given to this
Little attention
battered, chipped
be accurately made
in a
and by an expert.
Foundrymen
nary
hammer
weight of the
Crushing
to
make
cracked or
make
hammer
and
it
Test,
it
with an ordi-
number
of blows re-
weight upon a
sufficient
off,
test,
quired to break
of
to
This
it.
test
is
it
so great that
it
is
a casting,
and other
value
qualities
when
it
a large
is
desired to learn.
number
This
test
only of
is
pattern.
Relative Test.
All
tests
test,
it
is
only by
were able
to obtain
testing laboratory, or
self
to
it
in a
may be the best results the tester himThe latter will generally be found
be the most
in
the
test, his
only
of castings to be made.
It
all
may
include one or
in
the line
more methods
FOUNDRY
182
''
IRONS.
when
other, in
work
By
be
cast.
meant the tendency of molten iron to chill when run against a cold iron and suddenly
cooled.
This test is made by moulding a piece the thickness
and shape of the part of a casting to be chilled and forming
the side or a part of the mould with a chill the thickness of the
one to be used for chilling the casting, and filling the mould
Chilled Test.
chilled test
is
test
chill,
of value
is
making
in
chilled castings,
is
Owing
This
the extent to
fibers
This
the depth of
to the variation
in
etc.
strength of test-bars,
three or
more bars
it is
When
it
is
from one
But
ladle.
if
it
is
may
be
all
of iron throughout the entire heat, they must be cast from different parts of the heat, and
made
may be
for
is
As
very
size, for
it
It is
is
so small that
cannot be detected by
it
centre
it
first
one.
should be gated
If
the bar
at the end,
is
to
be broken
in
the
83
It is
in the same way and have the same size gate.
good practice to use a set gate. Care should be taken to not
wrap one bar in moulding more than another, and to have the
temper of the moulding sand the same for each bar. Special
care should be taken to ram each bar evenly throughout its
length, and ram all bars to give the same degree of hardness to
gated
the mould.
It is
good practice
The
moulder.
ing,
and
to
have
all
same
all
When
same temperature
as possible.
Test
bars
may be
cast of
any length
that suits the fancy of the tester, but for transverse tests, they
Twelve inches
most
common
is
the
standard
tests,
bars are generally cast twelve and a half, or thirteen inches long,
and
from the
it is
a proper bearing
upon the
its
is
is
done
to test the
no special advantage
in
to give
testing machine.
This
Cast
iron
is
may by
the
manner
bars indicate a totally different grade of iron from the one actually cast for testing.
to a large extent
under
considered
in
making
many
tons of
FOUNDRY
84
By
castings.
IRONS.
is
Hence
less.
size
It
in
same
is
the
let
The temperature
over night.
at
is
mould
poured
also
ladle of iron
ference in strength by pouring one with very hot iron and the
Some
dull, so
when
that no definite
apply to
irons,
all
But
can be stated.
as the
will
strength of the
bars are for comparison with each other and to indicate strength
of iron in castings, they should
all
moisture
in
is
to
taken
is
The
The
is
damp
iron,
is
From
according to the
hardened by boiling
in a
b)-
twenty hundredweight of
first
extent
less
size of
cast.
hot ladle
made
and Other
Test Pieces.
They,
chill,
fit
Tensile
as well as
or drilled
all
tests,
85
the same care, for they are designed to indicate the qiiaHty of
iron in the castings
conditions as possible.
The
is
casting,
This
the iron.
is
due
this
But
solid state.
this
from
more
seg-
etc.,
a molten to a
same structure or
size of crystal
at the center as
at the outer
edge, and the removal of the outer scale reduces the strength
Then
in size of
the
it
does not
beneath
it.
little effect
lie in
become
it
in
who have
its
of the iron,
Civil
to obtain
lies in
an extra-strong iron
is
iron,
it
is
made from
This
the very
to give the
FOUNDRY
86
specified
would have
was
It
to far
this
government
so
iron.
was hoped
it
ciations to take
lish a
IRONS.
parties,
to establish a
standard that
be
will
fair to
To
to estab-
By doing
both
to furnish
fairly repre-
same thickness
Adding
may be
to
when melting
it
Cast Iron.
StrengtJi to
cupola.
in
hardened by
work
to
be
it
few
strength
doing
In
of cast iron
This
is
controlled
make
it
by the per
cent, of silicon
When making
without being
steel
test bars
care must be
this,
absorb the
will
to so great an extent as to
cast.
The
mixtures of
steel
to
The
and iron
be melted
in
casting of a
the mixture.
in
this
for in a
lbs. in a
it
exceeded the
strength of cast iron, and therefore was not cast iron, as called
for in the specifications.
Wrought
melted with
In
making
controlled
by the per
as the object
sought for
is
But
when
is
soft casting,
and
in this
case, the
cent.
87
steel,
becomes dull
amount can be added.
the iron
so
rapidly
that
If
sorbed into the iron they cause blow-holes, and the least excess
of borings
way
a bar
stir
of adding
in
it
bar,
to a white heat,
a forge
with
it.
and place
it
It is
is
casting.
better
in a ladle is to
it
heat
the iron, or
in
is
withdrawn.
This insures a more even and sound casting as the bar can be
iron
is
at a
open
iron, but
iron.
a high-silicon iron.
By varying
The
to an all-pig
be added for
this
mixture invariably
About 50 per
cent, should
purpose.
home-made
machine may be
constructed in various ways at a very small cost.
But such
machines are only makeshifts at best, and require a great deal
of time and labor in manipulating, and frequently do not accuTesting Machines.
testing
the iron;
and
it
is
better to
buy
a standard testing
machine or
One
is
FOUNDRY
88
W.
that of
system of
tion,
J.
IRONS.
testing, indicates
bar.
It
is
test
For heavy work probably the best testing machines are those
manufactured by Riehle Bros. Testing Machine Co., Philadelphia, Pa.
for
all
line of testing
machines suitable
and for the one inch square transverse test. Their machine
probably the most convenient in use for a general test.
is
CHAPTER
XIV.
Standard Tests.
For many
trickery of inexperienced
civil
make
system of casting
to
in
testing that
castings,
by
this
Several series
committee
made by
one of
the committee.
test
test bars
and compression
tests of bars
made
in
is
used for
the cuts
memorandum
Cast B, Dynamo Frame
:
vertically
cations of
Iron.
This
set of
same time, in accordance with the specifithe American Foundrymen's Association committee
and
at the
(189)
FOUNDRY
(90
IRONS.
iron, furnished
262
interest
the
McDonald. Cast B
machine readily, be
thick and yet sound
scrap
cent,
is
The
trade.
to the
carried
inches
is
inch
About 45 per
reached.
mixture.
the
in
the
in
cast
illustrates
when 14
test
good transverse
The composition
so.
is
follow
Total carbon
3.82
Graphite
3.23
per cent.
Silicon
per cent.
Manganese
39 per cent.
405 per cent.
042 per cent.
Phosphorus
Sulphur
The
.95
per cent.
sizes.
The
bars
purposes of
inches apart.
ap-
is
The machined
all
12
round and
square, green sand and dry sand transverse bar was preserved,
be mounted
will
at
the
in a case,
is
From
Association, in Pittsburg.
bars
and
expected to be on exhibition
it is
much
better avail-
able for standard tests than was the case with Series A, shrink-
much
in
evidence.
However, there
is
bar cast
in
The
vertical.
But two
up nearh'
STANDARD
TESTS.
TABLE
191
I.
Transverse Test.
-DYNAMO frame IRON. BARS IN GREEN SAND AND NOT
MACHINED.
No.
0\
FOUNDRY
192
IRONS.
TABLE
series
r^
fr^
b.
III.
Transverse Test.
dynamo frame iron. bars in dry sand and not
STANDARD TESTS.
TABLE
series
Actual Size.
Depth.
Width
Diameter.
Inches. Inches
Inches.
345
346*
59
56
347
348
".58
56
349
350
1.
113
351
17
i-i5
1.69
1.74
1-73
353
354
2.15
2.26
2.26
355
356
2.82
2.6
2.84
357
358
338
3-53
3-44
3^9
360
3.95
4.01
4.01
352
361
4.61
4-51
\t2
* Defective
4.62
Shot.
TABLE
is b.
No.
V.
Transverse Test.
dynamo frame iron. bars in green sand and not
machined.
Approx.
Diameter.
No.
b.
193
dynamo
frame
lbs,
VI.
Transverse Test,
iron. bars in green sand AND MACHINED.
FOUNDRY
194
IRONS.
TABLE
series
No.
b.
VII.
Transverse Test,
dynamo frame iron. bars in dry sand and not machined.
STANDARD TESTS.
TABLE
195
IX.
Tensile Test,
-dynamo frame iron. bars in green sand and not
machined.
No.
FOUNDRY
196
IRONS.
TABLE
series
No.
b.
XI.
Tensile Test.
dynamo fkame ikon. bars in dry sand and not machined.
STANDARD TESTS.
TABLE
197
XIII.
Tensile Test,
-dynamo frame iron. bars in green sand and not
machined.
Approximate
No.
Original
Actual Area
Diameter.
in Sq. In.
Inches.
480
113
1.69
483
-^484
2.15
485
4S6
487
488
"7 489
I
490
491
.56
2.26
2.26
28,590
29,700
13,090
13.140
403
4-05
47,c<o
46,120
11,670
11,140
.26
.26
.26
.28
4.450
4,176
4.170
4.380
17,110
16,040
1 6,040
15.^50
00
15.310
14,180
15.310
14,320
30,380
32,260
13.440
'3.970
42,2CO
50,180
10.550
12,120
2.26
2-15
2.31
4.C0
4-'4
TABLE
B.
7
No.
Lbs. per
15,860
15,870
99
494
495
Square Inch.
15,220
15,870
.96
I.
1.
1.69
Pounds.
CO
.26
.28
I-I3
492
493
Strength.
16,080
17,640
1 6,000
16,430
25
.56
Ultimate
Strain.
4,020
4,410
4,280
4,600
25
476
477
478
479
Breaking
XIV.
Tensile Test.
DYNAMO frame IRON. BARS IN GREEN SAND AND MACHINED.
FOUNDRY IRONS.
198
TABLE XV.
Tensile Test.
series
b.
* Lost.
TABLE
series
No.
b.
XVI.
Tensile Test.
dynamo frame iron. bars in dry sand and machined.
STANDARD
TABLE
TESTS.
XVII.
Cross
Bar,
of
No.
Approximate
Section
Inches.
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
B.
199
FOUNDRY
200
IRONS.
Method of Casting Test Bars. A few extracts from the remade to The Pittsburg Foundrymen's Association by Thos.
D. West on methods of casting test bars for The American
Foundrymen's Association's Testing Committee maybe of value
in showing the care taken in casting these bars and the number
port
by thickness and
steel, for
body
lighter
may be
to
in
may
cause the
open-grained and
same thickness
little
in
Then
soft.
again,
we can
take the
gray
The
in its
body,
all
rate of cooling
be
will
a factor as important in
its
effect in alter-
First:
By having
Second: By
temperature of
fluidity of the
Third: By variation
melted metal
at the
in
moment
the
it
is
poured.
" Variation in the pouring temperature of metal, often greatly
affects the strength of iron
is
but
in
what
direction, according to
is
true,
in
some
others the
in
the iron.
any attempt
to obtain
made on
a plan
a position permitting
the most uniform cooling and giving the most uniform grain
STANDARD
20I
TESTS.
in
all
that can be
intended to
all
This
be comparative.
is
knowledge
practical
was
It
in
committee
at the last
is,
and what
To do
bars.
for
this properly,
one grade
what
will
cast iron
Moldenke, appointed
it
may be expected
of
it,
in
iron.
is
would show
is.
to
be tested, we have
When
it is
stated
that there are about two hundred bars in each of the grades of
iron ranging
from one
be made
in
and round,
in
sand moulds, the weight being nearly two tons for a single
or 22 tons
in all,
dry
set,
was taken
myself.
in
Designing
FOUNDRY IRONS.
202
making the
first
set
was assigned
Knowing
the
bars in any
set,
to the writer.
all
and,
if
to
advantage
is
in
McDonald
After
set.
this
is
is
to
finished, J. S.
will
sets or nearly
bars
test
is
completed.
" All having taken part in this important
full
it
work
all
the bars.
It is
mould up such
rest
men and
firms
will
present giving
will
men
of ability to
be given
will
to
do
the character of
this
work,
all
may
be as nearly attained as
is
The
flasks
iron so as to
used for
this
make them
work were
all
made
in
ramming
The
come over
in
when
tested.
ram
place.
Much
the mould.
tion of the
part of the
it
the sand
of malleable
will
care
is
also taken
in
The swab was only allowed to be used at the juncgate and pattern.
The reason for this is that if one
face of the mould is of damper sand than another,
in
will
to use the
swab anywhere
STANDARD TESTS.
203
Some
will
CHAPTER
XV.
Semi-Steel.
The
by many founders
of
Very
strength.
About
this
little
was heard of
this
commenced
using
it
for rolling mill rolls, pinions, etc., castings which require great
strength, and about the
After
this date,
these foundries.
in
their car-wheel
mix-
But
it
was not
become almost
until a
much
universal
in
getting a
homogeneous
metal which was due to the steel not mixing, or entering evenly
To overcome
resort
was had
in
this difficulty,
and
steel
to
be remelted for
cast-
semi-steel making, a
cent, of
steel
(
is
is
homogenous
204)
SEMI-STEEL.
when
205
semi-steel, the
thing to be done
first
is
In
making
ing the required per cent, of silicon to carry the desired per
cent, of
This
steel.
is
size or
cast.
to
no
silicon
still
line of
By
this
all
method
as high as
to the
it
60 per
mixture of semi-steel.
been melted
in
and a
to that
more
of semi-steel
is
When
steel.
in
low carbon
and
iron.
be preferred, for
and,
rails
like steel,
any cast
it
and
The
melts
steel
rails
are melted
in a single
give equally as
steel
charge on the
in
affect
good
But
results as
steel
rails
or
high carbon
may be
heat, without
to
is
steel,
found
the blast in
hard spots
in
castings
have been
attributed to them.
The
strength to
it,
resembling
close
steel,
up the
grain,
is
cent, of
to
upon the
which the
FOUNDRY IRONS.
206
Steel
mixed, but
is
comes
steel
it is
fair to
presume
will
As low
to steel
it
steel.
mixture of iron
claimed
is
to
test
it
500
in
the
pounds.
In the
metal
is
making of semi-steel
in a
pig containing
the
in
than
less
in
the pig
carbon
if
now made
in
almost
all
of the job-
bing and machinery and specialty foundries for castings requiring a strong iron, but
many
steel
tains at least
name
steel.
for
is
3 to 5
per cent,
50 per cent,
steel,
most
castings,
required hardness.
silicon
it
contains the
is
said to
The
at the
known
But
to
in a
in the Cupola.
It is
what degree
this
is
so,
and the
With a view
these two
of learning something
subjects,
and also
to see
more
if
it
definite in regard
were possible
total
to
to trace
carbon
in
the
SEMI-STEEL.
"
The
tensile
two, and in
a
207
some
The
For the
tensile strength
"The
me
to set
them.
it
is
to
have
amount
of
FOUNDRY
208
but
it
is
steel
more than
it
or No. 6.
as proof that
tary case,
is
IRONS.
is
which also contained 37! per cent, of steel and more carbon, was only a little stronger.
" Test No. 4 was considerably weaker than No. 5 but its higher
percentage of sulphur with its lower combined carbon would
I
I,
seem
to
poured from duller iron than were the bars from No. 5, which
may account for their being weaker than the No. 5 bars.
" In looking at
Nos. 8 to
1 1
And No.
As
expected.
Nos. 8 and
the lower
is
we
it
may be
manganese or
8, in
which
steel, gives
less strength
much lower
that their
than might be
manganese than
weakness is due either to
in
which
re-
"Nos.
of steel,
"We
13
and
show
find
cent, of steel
in
the mixture.
"The
tests
iron, ferro-silicon
" In
in
and
steel
in
order
the iron.
it
amount of
was
To see how this and the steel mixed
silicon in the charge.
with the pig iron two tests were taken from No. 13, which contained 1,000 pounds of steel, 400 pounds of ferro-silicon (8.5
The charge
per cent, silicon) and 2,600 pounds of pig iron.
necessary to use ferro-silicon to get the desired
SEMI-STEEL.
209
and the
into a ladle,
iron
taken at
tests
ladle.
The one sample contained 2.53 and the other 2.54 per cent, of
silicon.
"
Two
tests
taken
in the
1.97
pounds
steel
2,
which
v/as
made up
iron, contained
of
,000
1.50 and
"
These three cases offer pretty strong proof that the pig
and ferro-silicon mixed thoroughly.
" Although of a limited number, the tests given seem to indicate that 25 per cent, of steel will add about 50 per cent, to the
strength of the iron; and 122 per cent, of steel approximately
The tests containing 37^ per cent, of steel were
25 per cent.
hardly as much improved in strength as those with 25 per cent,
of steel, from which we may infer that the limit of the amount
of steel it is beneficial to melt with iron in a cupola, is between
25 and 372 per cent."
Melting Semi-Steel. A higher heat is required to melt steel
than cast iron, and when the two materials are melted together
in a cupola more fuel is required for the metal to be at a sufficiently high temperature when drawn from the cupola to insure
a thorough mixing and uniting of the iron and steel.
When
iron, steel,
only 2 to
is
any extra
fuel
is
required, but
when a
iron,
from two
it is
10 to
little if
greater
is
is
to three inches
cent, of steel
is
in
14
of increase
PX3UN1)RY IRONS.
2 10
The
this
is
not done, a
should be charged
steel
When
steel.
melting a
such a manner as to
may be
be melted
To
them.
to melt
If this is
all,
as has
in
number of instances.
such a manner as not
in a
in
When
melting
steel
rails
or railroad track
steel,
it is
By charging
heat,
on the coke
and
receives the
first
greatest and
For large
two metals.
castings,
it
is
is
Always melt
in
stir
it
of the
all
the
poured.
most prolonged
is
come down
it
the
in
first
and
thing to
fast.
When
be done
is
to
Very
The
be melted
in a ladle of
added
to the
them
balling
up or adhering
to the
way
bottom
of the ladle.
is
objection, and a
long as
in
lining,
melting iron.
been found
to
be any great
lasts
almost as
SEMI-STEEL.
Semi-Steel Mixtures.
With
211
from
may be
used.
per cent,
silicon,
pinions, etc., this mixture gives a strong, close metal that wears
and
well
is
thick,
For the
15 per cent,
is
lighter castings
tures prove too hard, or the metal uneven, a less per cent, of
steel
foundry pig
to 2
is
To make
silicon.
in
in silicon
than No.
a 50
or
2
i
furnish
The
of
all
it.
maximum
Below
made by
are
all
such work.
the
semi-steel and
class of work.
in
about 30 per
spectors
was
in-
phosphorus,
No.
i.
Silicon,
sulphur, .065;
.70.
ganese, .85
transverse
test,
4,400
lbs.
tensile test,
37,300
lbs.
steel.
phos-
steel.
Silicon, 1.70;
sulphur, .075;
phos-
FOUNDRY
2 12
IRONS.
,300
lbs.
steel.
The
latter
mixture
as the analysis
is
is
The percentage
pig iron
may be
from 2.50
what
The
used.
somewhat harder
and the
often better, a
is
total
A simple way
cent.
Calculating Mixtures.
steel
mixtures
is
as follows
Per Cent, of
Silicon in iMix-
Scrap.
ture.
3.10X0.40
1.24
2.30X0.20
2.00X0.15
o.04Xo.25
0.46
0.30
o.oi
2.01
phorus
in
Pig Iron
Per Cent, of
Phosphorus
and Scrap.
40 per
0.65x0.40
1.50x0.20
0.30
0.60x0.15
0.09
0.08x0.25
0.02
When making
in
Mixture.
0.26
0.67
care should be taken not to use too high a per cent, of steel
in
and boring.
Good mixtures
are
made
cupola semi-steel,
it is
silicon,
SEMI-STEEL.
the semi-steel
ments
to
show than
to
it
semi-steel
to
is
213
mixture
and
hot,
pour
is
insure a sound
hot to
it
ele-
Melt a
melted.
casting.
Test-bars
The
Senii-Stcel.-
cast
light castings,
upon heavy
etc.,
Steel
to
from 12
cent, of steel
be made for
is
due
is
shrinkage
in
steel
castings
to
this
amounts
This
be used for
X24.
is
have to be used'for
to be placed
reduced.
is
Shrinkage in
when being
to the chilling
it
used
this
to
40 per
When
a large per
castings than for iron, as well as for sink heads through which
On
is
account of this
chunky and
light ones,
The shrinkage
in
such cast-
ings has also been found to be uneven, and in this case they are
if
they do not
warp.
Semi-Steel Malleables.
known
A new
after casting
it
is
cast
is
soft, malleable,
and
FOUNDRY IRONS.
214
strong.
It is
used
when
mixture, they
in the
much
stronger
may be
way been
drawn from the
The
made.
is
cupola into very small hand ladles and cast into the lightest of
and
Founding.
Steel
Many
iron founders
who have
an
occasional call or order for steel castings have an idea that they
can put
in a
foundry.
is
is
very
little in
steel
common
blacking
is
be made.
Its
The metal
By
conclude there
will
is
all
it is
required.
these things, he
and
steel
iron founder
iron
and
be
lost,
steel
many
Before
they learn
SEMI-STEEL.
21$
to this
must be kept
its
it
trained
if
by the
eye,
in
ily
to
It will
make
ing
if
customers.
thus read-
to
undertake
may engage
found-
steel
in
in
and employ a
to
be
steel
expert to
make
work
cast.
Steel.
Cast
iron
strength-
is
flake,
crease in hardness.
it
First,
weak or
erratic.
The amount
which
little in-
the iron
it
make
not to any extent affect the per cent, of carbon present in the
iron, as the steel in
by the use
For example,
carbon
is
ture
2. 00
But
this
is
not
the case, for the melted metal takes up carbon from the fuel
until
it
verts
The
iron.
it
carbon
back
is
amount
introduction of steel into cast iron in a cupola coninto iron, but with this difference, that the graphite
broken up
carbon taken up by
FOUNDRY IRONS.
2l6
than that
in
in
The
the iron.
it
carbon
when
in cast iron
This
this control
is
The
many
writers illustrate
may
it.
BY
The foundryman
C. R.
of to-day
is
MCGAHEV.
ordinary
more
My
tests ran
not
all
kinds of iron
satisfactory,
in the
as a
to 2,400, with a
coupon.
to 0.55-inch.
The
deflections
is
not at
and
selected to which
in
work.
Elastic Limit.
Presented
tion.
To best
at the Cincinnati
resist
SEMI-STEEL.
heavy work,
as possible
is
it
217
we would
strength and elastic limit in cast iron are not far apart,
naturally try to get our transverse test quite high, and for the
bar
in
This
is
like are
may be
made.
obviated as
where
much
minimum,
as possible.
and the
aid in this, and the addition of steel to the mixture, thus reduc-
way
In this
it
Semi-Steel
and
Ferro-Cai'bon.
The
terms semi-steel
and
thing like
we do
steel,
iron mixture,
making
it
steel scrap
added
of higher strength.
It
the coke.
is
in the
the same.
In using steel scrap,
have
reverse.
the peculiar results are doubtless due to the composition, structure and behavior of the coke in the cupola, causing the iron to
melt more or
less
rapidly,
and remain
Thus
in
in
other words high fixed carbon, gave a very hot iron, but with a
much lower
The
to the other
is
It is
further
FOUNDRY IRONS.
2I
manganese, as
to carry high
as a manganese-sulphide.
much sulphur
this tends
is
present,
and hence
it
Mixing
the
of the charge to
heavy enough
it
(from
five
to
strengths than
time
is
well
when allowing
best results
ing
mix
six
is
to use
ounces only).
when
To
very desirable.
me
higher
If
given for the steel to melt and mix with the cast iron,
be lower than
will
if
ture flows rapidly past the steel and has no chance to unite.
For
this reason
low
in
it
is
This allows
it
The reduction
as
it
much
by
steel
denser.
If
makes
additions
the sulphur
steel,
is
con-
and Sulphur.
Another point
scrap melting
shows wide
variation.
and
better
The
if
the temperature
when
the sulphur
following arc
is
in
The
Silicon,
is
in
rises
rapidly.
The
deflection
is
low.
some
results
chill
that
may be
of
interest
SEMI-STEEL.
219
had siHcon, 0.82 per
The percentage
of steel carried
Another
cent.
The
test
gave
silicon,
was
test
sulphur, 0.08
per
cent.;
7.
at
find that to
close
to these
analyses, and
steel scrap.
my
have made
strongest bar at
The
iron
had
a fine
grain,
was low
may be
FOUNDRY IRONS.
2 20
from
taining
superior
to
15
25
common
wearing qualities to
in
the mixture
in
iron?
When
the steel
is
as
it
cupola.
Semi-steel
when
is
the
such thing
in natur'."
The term
semi-steel
is
a trade
name having
Semi-steel
some percentage
it is
meant
this will
and
Air-fiiniace Iron.
Semi-steel
no better,
is
if
On
charcoal iron.
in
this
For strength
wearing
fine
qualities,
made from
is
it
all
it
is
gray iron
far
in
right
Steel
becomes such
in the
when reduced
in
it
first
inal
production
No
steel.
being
Steel in
in
it.
tributed,
in its orig-
There
is
no
steel
place by
again returns to
it
is
by
its
it
in
semi-
SEMI-STEEL.
Semi-steel, to use
among
cipally
its
those
Neither
how
mix
to
scrap
steel
failures in
foundries nor
all
in
enemies, prinproduction,
its
foundrymen
all
desired result.
for attaining a
it
many
221
It
is
know
to these
many
dismal failures
" It
does not
not keep
it
mix"
in
from running
attributed.
Many
to holes.
chilling.
may be
is
it
can-
from
all
of which,
in
after being
machined, would be
if
it
the metal
would wear
in all
gray-
is
show up on the
finished sur-
Failures
builders
who aim
for the
Some even
in their cylinders.
chill
last
iron
is
much -debated
semi-steel or air-furnace
is
many
of
in
The melancholy
ers'
in their
Club on the
vancement
know
almost en-
employ.
in
steel proposition.
Praetical Requirements.
to
is
dryman
failures that
It is
still
FOUNDRY
222
perfect alloy.
often
When wrought
true, but
IRONS.
neither of these
is
fit
is
some
on the subject
notwithstanding.
practice
to the contrary
They
is
metallurgical authorities
used, this
steel
In
and
my
owii
would not
will
them properly,
and for machine or finished work they are unfit for use.
Rc/ics on Steel Scrap.
After a long and varied experience in
the engine and heavy jobbing business. I have nothing but the
efficiency,
ills
to
heir.
in its
to
It
it
what
it
in
vantage
in
wearing
in
every way to
that there
is
qualities.
common
but very
IS
On
the whole
it
latter
is
is
an ad-
so far superior
little
SEMI-STEEL A MISNOMER?
BY DAVID MCLAIN.
made from
steel
as semi-steel.
Many foundrymen
still
filled
steel
that there
is
no mixture which
They claim
metals do not mix; that the steel does not unite with the iron
steel
have
many
hard spots.
Never-
castings, such
as small
SEMI-STEEL.
cylinder heads, cylinders, piston
223
ammonia
rings,
dry
many fancy
at a
letter
30 per
as high as
my
in
castings of
containing
etc.,
be made
in
iron mixtures.
the founI
have a
1,
However,
from 30
ing from
to
40 per
you on
some good returns from it.
others should be
made
to
later
"I can
said:
Nevertheless,
lose
wrote as follows:
practice of using
money
eminent
"
it
all
seems
have found
it
may
reap
a pity that
electrical engineer a
few
steel
say that
only, there-
this
An
of producing this
fore, congratulate
months
my method
my
Referring to
possible to
way between
work both
motors, would
in
density and
and cast
iron.
In
100
steel
50 of
speed
steel.
is
It is
from 10
which the
types."
and
Now
steel, to consider.
some
cases there
Would you
call
it
is
he has
iron, steel
and
In
semi-steel?
According
to analysis
no two are
Therefore,
it
is
may
fail
in
tear.
The
follow-
FOUNDRY
224
No.
IRONS.
I.
300 pounds.
Remelt,
silicon, 2
1,200 pounds.
per cent
500 pounds.
3Jrt pounds.
9 pounds.
pound.
coke; charge the pig, then the remelt; place the silicon and
aluminum in the ladle. Use ground ferro-manganese and pour
it
in the
Do
running.
is
you
will
needed
Machines Easily.
The
large
amount
it is
mixture;
it
is
above mixture
better than a
is
machines very
easily.
Do
This mixture
manganese.
Use 72-hour
to deoxidize the
under any
the cupola or
in
The aluminum
ture.
not,
in
exceptionally good
The
steel is
2.
500 pounds.
1.3CO pounds.
200 pounds.
2 p9unds.
8 pounds.
Pure aluminum
Mix No.
Silicon
pound.
and Manganese.
cent.,
The
and
in
No.
No.
silicon
2
about
in
No.
i.
should run
casting.
The manganese
in
in
SEMI-STEEL.
225
Be accurate
in
3.
800 pounds.
1,100 pounds.
100 pounds.
Boiler steel
Pure aluminum
No.
The
I.
Charge
It
silicon
silicon should
this
pound.
This mixture
casting.
in
is
very
The
seems
to
it
is
Note.
There
as well as
ists
is
foundrymen
The
among chemmanganese
1.60.
weak one.
Semi-steel properly mixed and melted requires no aluminum
to
all
its
Per cent.
50 Coke iron,
10 Car Wheel,
Per Cent.
2.20 Silicon
i.io
0.60
"
0.06
.80
"
0.54
10 Steel Scrap,
30 Cast Scrap,
Total Silicon
.70
Per Cent.
40 Coke Iron,
10 Car Wheel,
Per Cent.
2.20 Silicon
0.88
0.60
"
0.06
.80
"
0.54
20 Steel Scrap,
30 Cast Scrap,
Total Silicon
1.48
FOUNDRY
226
If
fail
IRONS.
it is
unknown
Semi-Steel Gears.
about 25 per cent, steel scrap. This can be made of pig iron,
machinery scrap and steel scrap. The pig iron should have
3.25
Sulphur
0.C4
Phosphorus
0.50
Manganese
0.75
scrap,
in
2.00
Sulphur
CIO
Phosphorus
0.50
Manganese
0.60
Graphitic carbon
2.40
Combined carbon
i.oo
CHAPTER
XVI.
Malleable Iron.
History.
The discovery of
the process of
numerous founders
to soften
many
making malleable
In
1722,
Reaumur
in
collected
making malleable
principles of
knowledge does
So
little
in
no
is
But
foreign countries.
it
is
telling
when
practised
first
and even
at this
time the
output of malleables
History
first
in
started
this
in
this
is
Country.
Malleable
iron
founding
in
It v/as
J.
was
the year
there
that he began casting and annealing buckles and bits for harness
makers, and
it
all
things were
of
wrought
forged prior
to
this
date.
from which
In
1828, the
is
Premium No.
awarded
to
J.,
iron,
(227)
FOUNDRY
228
IRONS.
attempt
This
is
the
in this
come under
it
maker
to a silver
medal."
in
which
moulders
was
quite
one
large
for
those
days.
at
managed by
into
number
of firms, but
little
is
still
in
existence at the
remains.
which
cast in
is
"
Inventor
Soon
after Seth
which he
failed to patent,
Newark became
In 1837,
of Seth
Boyden,
was operated
in Cincinnati,
Newark
all
Ohio, and
in
in this
way
the business
at
MALLEABLE IRON.
2 29
time that Mr. Morris had gotten hold of the writer's first
work, " The Founding of Metals," in which he was very much
this
first
up between
us.
same
salt, saltpetre,
alum, various
settling
down,
Boyden did, to
known for packing
as Selh
and
etc.,
also to certain
perience
results, the
done before
annealing malleables,
have proved
to
castings.
In Seth Boyden's
first
experiments
all
his iron
was melted
in
number
heat desired.
in air-
furnace melting.
made
attached to gates.
Flasks were
made
so that there might not be any spring to them, and castings were
cleaned
in a
wooden tumbling
from the
FOUNDRY
230
IRONS.
barrel.
day very
little, if
in the
it,
it
remains
and better
facili-
is
in the
mak-
is
The
num-
local
brands used
Of
equally good.
country are
castings be-
Good
malleables can be
made from
in
several grades of
any one
At malleable
Eriar Hill
2500
15CO
Hinckley
loco
"
Ella
1750
"
Sprews
3250
"
mixture
irons be
in
made about
is
lbs.
"
as follows
Mabel
2000
Briar Hill
1000
"
Hinckley
Ella
500
2000
"
Sprews
3250
"
Malleable Scrap
250
"
lbs.
"
MALLEABLE IRON.
mixture to which
steel scrap
23
added
is
is
made about
as
follows
^Tabel
2COO
Briar Hill
icco
"
linckley
Ella
500
15C0
"
Sprews
3250
Malleable Scrap
Steel Scrap
lbs.
250
500
"
"
"
"
all
The
life
and
following analysis
is
recommended
for
malleables
0.75 to 1.50 per cent.
"
3.00
Silicon
Carbon
c.04
"
c.6o
"
0.200
Malleable Scrap,
0.45
Sil
in
made
melting
"
"
making mix-
The
cent.
Steel
when used
in
age
in the casting.
Coke Iron.
Coke and
with
late
many
After
many heavy
making coke
known
iron
suitable
as coke-malleable
is
for malleable
now
regularly
purposes, and
made
at
many
iron
fur-
FOUNDRY IRONS.
232
For
naces.
of coke
used
is
iron certain
this
amount
limited
of mill cinder
is
if
to charcoal iron.
It is
is
made from
larly
to the mixture.
Plenty
ture,
by many
added
in
and appear
this iron
to give
good
gen-
is
doubted
now
regu-
satisfaction.
All coke irons, however, are not suitable for this purpose and
This pig
whose reputation
for
is
used
in
Malleable Scrap.
Malleable
The
it
by
make
late
purpose.
It
is
an
all
this
is
it
is
junk dealer
and
who was
in
it,
and
it
it.
for cast-
also to
is
it
said to
it
it.
a competitor
it,
mixture
effect
was a
mixture.
years
his
But of
many
it,
an imaginary customer
lot to
One foundry,
rails in their
scrap for
mixtures.
in
is
it
and more
is
steel,
fuel to melt
In
requiring a
it.
But
its
cent, of
steel.
castings
do not present
Melting Fitrnaces.
At
the
first
first
malleable
plant
in
this
MALLEABLE IRON.
done, was melted
in
233
found
to
more rapidly
with,
at less cost
and,
when
But with
as the air-furnace.
now
country 369
According
cupolas.
doomed
continued
and
it
to
in
may
use
this
in
its
becomes
of malleable pig
more
in
air-furnaces,
difficult
it
before pouring.
The
is
less
air-fur-
The
iron
iron, as
may be
it is
From
long as desired.
this
may be
may be
Should the
frac-
may be
may be added by
is
tapped
at
thus the work can be more rapidly poured than from a cupola.
FOUNDRY IRONS.
234
do not pour well or produce a strong malleable when anis no doubt due to unknown or
may
the latter
its
is
more
controlled
easily
it is
and,
Shrinkage.
iron
is
about one-eighth
However,
is
made
in
in
is
in
is
con-
made from
the
same
pattern.
But
in
is
is
than that of gray iron, the tendency to shrink and draw apart
far greater,
to
is
be resorted to to pre-
this.
checking
as
in
chills,
etc., to
prevent
the casting.
and
it is
more
by anneal-
CHAPTER
XVII.
Annealing of Malleables.
Annealing Ovens.
Annealing
capacity to suit the size of the plant and character of the work.
In large plants they are generally about seven feet high, twelve
feet long,
in
Flues constructed
the oven.
to
and open
roof,
at
in
them hot
after
It is
boxes,
when
hot, can
which
is
become
and the
fires
is
During
temperature
is
Natural
cold.
is
from four
to
brought up to
a bright
When bricking
up the ends
of the oven, sight holes are provided for observation, and the
experienced annealer depends more upon the color of the heat
and other indications than on thermometers, which are
quently unreliable.
fre-
(235)
scale,
and he
FOUNDRY
236
IRONS.
process
is
completed, the
down
mitted to cool
firing
for a
is
day or
The ends
so.
then removed and the boxes drawn out while hot and permitted
to cool in the
The furnace
air.
once
at
is
refilled
with boxes,
which have been packed for annealing, and in this way the oven
is kept hot, and annealing goes on continuously.
Ovens are
sometimes constructed with the
latter
this
is
on an incline to
floor
being pushed
in
common
not the
at
facilitate
provided for removing the hot boxes and replacing them with
others for annealing.
cleaned
in
tumbling barrels or
To make
re-
sufficient scale,
have another
is
set of
ovens of a
port, Pa.
This oven
is
manner
that
may
it
a small crane
in the
door
is
placed
the
claimed for
arranged
in
such
in
cooling
light
is
is
oven
this
to
it
maybe
annealed
in
it
at the
same time,
without danger of burning the light ones by too prolongied annealing, or injuring the heav)- ones
ANNEALING OF MALLEABLES.
oven
removing the
in
light
237
Before the malleable plant at Deposit, N. Y., went out of business, this
and during
this
in
and no bad
effects
This oven,
for
it,
if it
in
many
plants
weight to
fill
making
any one
a va-
size or
malleable scrap, but they are generally cast at the end of a heat
from white
iron, to
which
is
frequently added a
little
condemned
iron
is
But
if
a fairly
if
not de-
good quality of
is
first
heat,
FOUNDRY
238
may
very badly
scrap
said
is
IRONS.
to
make
packed
them.
in
Malleable
itself,
and
its
last-
melted with
to give
it
and
life
it
Even
fluidity.
the best of
come warped
are no longer
The
is
cast, be-
fit
old boxes
by new ones.
may be
the iron in
wrought iron or
steel
The
it.
this
purpose,
tried.
box or
the Boxes.
plate
in lifting
to place
it
in
it
the oven.
between them.
When
this
and
box
filled- in
the
height which
is
same way,
about
more time
is
until
in
one
set of
number
of large castings to
the
same way,
The
fill
in
When
in
in
is filled.
there
is
packing, the
light
ones
in
not a sufficient
attempt
is
made
but this
is
to give
and frequently
fails
to
ANNEALING OF MALLEABLES.
produce a good malleable.
In packing, care
is
239
result,
minimum, but
done by hammering, hydraulic pressure, drop hammeretc., and in some cases steel forms have to be made to get
This
is
ing,
being
in
at
way
this
Nothing
incurred.
is
gained by heating a
malleable
in
straightening
it,
the boxes have been packed, the joints are carefully luted with
clay,
placed
in
the
covered
is
oven
in
the
in
same way.
They
are then
suffi-
around them.
The ends
temporary brick
wall,
of the oven
which
after
firing
begun.
Packing Material.
The
generally accepted
to the
carbon
in
by
that
is
will yield a
is
portion of
decarbonized
Red hematite
pose.
employed
in rolling,
iron ore
is
is
theory of the
off.
its
in
oxygen
conse-
The
and
also to
oxi-
when an
iron
is
used, the castings are porous and the surface has the appearance
of being full of small pin holes.
too high
in
When
this
is
change may by a prolonged heat be effected without packor with a packing of sand or clay.
This theory was ex-
ploded
in
FOUNDRY
240
may be made
in
way,
this
IRONS.
it
nealed with
mill
heavy malleables
carbon
is
scale
way.
this
in
practically
is
it
In
to those an-
impossible to
make
carbon
sult.
this
It is
therefore
contain.
lasts indefinitely.
The burned
scale falling
from the annealing boxes can also be used for packing, and the
amount of this material obtained from the boxes after each annealing heat
is
is
and to
scale.
but
iron,
This
it
and
is
this
The
in
and permitting
it
to rust
scale out
upon the
floor,
To
is
added
wetting
increase the
to the
salt, salt-
effect in the
in rusting
monly used,
as
it
ANNEALING OF MALLEABLES.
and when business
241
is
it
is
is
of value.
in a thin
comes dry
it is
is
determined by experience.
scale that
ally
it
be-
this
is
This
is
is
As
it.
it
should be occasion-
from
it,
as
may by
themselves
annealing.
in scale
for anneal-
upon the
and thick-
size
ness of the castings, the size of the packing boxes, the quick or
More time
etc.
for annealing
is
required
to
this point in
The time
it
flues.
may
duce a stronger
iron.
by the
is
generally done
managed by supposed
However,
in large plants
noticed that
if
the}' are
it
it
has been
any good.
malleableized
in
Any
made
white iron
may be
so short a time.
it
annealed
in this
all
proved
fail-
FOUNDRY
242
IRONS.
commercial scale
is
The
in
they
is
are
generally effected
is
very
in
hard
run
are
Cleaning
annealing, the
all
this material
wood
Before
light
ver}-
put
at a
in
and
castings
Heavier
time.
and
light
brush or sand
blast.
steel
may be tum-
bled to any extent, and are gencralh- tumbled until they shine
as
if
Castings that
polished.
become
But
this
is
lime-water bath to
in a
kill
erly arranged
stars,
barrels,
if
prop-
welded
in the
common
But
good
lbs. to
malleable bar,
is
is
therefore
much
The
is.
It is
jar,
about 4,000
lbs.,
but
this strength
is
not con-
ANNEALING OF MALLEABLES,
The
strain.
sorted
This
test
is
monkey wrench.
little
it
over on
is
itself
good malleable
placing a
flat
bar of
The
test
subjected to but
good malleable
ling
is
re-
and any
it
commonly
made by
but
the one
a large
is
243
will
in
little
itself
into a circle
to
strain in twisting
Another
or indication of fracture.
amounts
and doubIt
requires
CHAPTER
XVIII.
many hours
arid
may be
upon which
frequently
for, are
week for
condemned, and in this way heavy
But these are nothing as comlosses are frequently sustained.
pared with the chances taken by the malleable iron founder, for
while the gray-iron founder may in a few hours or days turn
If perfect,
lost.
the iron
out and deliver a perfect casting, from two to four weeks are
required to mold, anneal, and turn out a batch or large ovenful
of malleables, and at the end of this time part or
all
them
of
may
ing,
underheating,
etc.
plies required
in
The expense
producing
this
Two
falls
to
four weeks are required to reproduce the castings, and the cus-
tomer,
his patterns
more
smale
waiting
away or cancel
trying business
scale, a malleable
all
this
his order.
may
Altogether, there
to
take
not
is
On
pay unless
same
size
ovens
b}'
in
permitting ovens to
heating.
Very small
become
light castings
(244)
is
incurred
and fuel
in
245
'
same box or oven with large ones, although they are frequently put in to fill up the holes, and different grades of iron
are required for various classes of castings.
For these reasons,
malleable founding tends towards large plants with numerous
in
the
A small
malleable plant
in
may
connection
many
made
is
in
it
having a resemblance to
The
knew
about
tons,
to pay,
in fact,
this business
With a
the molding
to four-fifths
of this amount.
specialty covered
one or more of
fill
this line,
many
is
dull
frequently
in
The
running.
is
per pound more than that for gray iron castings of the same
The
grade.
iron, with
etc.,
their size
and the
sold, varies as
difficulty of
lb.
in
gray
molding, annealing,
In
castings and jobbing work, while in dull times they have sold as
lb.,
duced
at
any such
leable pig.
which of course
in this
price,
is
malleable plant
is
more expensive
to construct
and manage than a gray iron one and, owing to the greater
length of time required to turn out an order of castings, from
three to four times the working capital
is
business.
But
that there
is
room
246
ing would
dry, which
FOUNDRY
IRONS.
seem to be indicated by data collected by The Founshow that in 1907 there were in the United States
tons,
and that
to 168.
in
19 10 the
CHAPTER
XIX.
Foundry Notes.
All white irons or low-silicon irons do not chill to an extent
The
chill test
should be used on
Pack
in
Heat
all
to a bright red,
an oven.
this
some
is
way
sufficiently
Hard
nary
Castings
may be
annealed
extent.
in this
im-,
fire,
Any
to
hard casting
even a half-inch
prolonged.
may
castings
be softened
by heating
forge or ordi-
in a
is
so short and,
when
phorus
in
Owing
to the
low content of
malleable scrap,
it
silicon,
Only
it
a very small
is
high
amount
in
in soft castings.
to car-wheel
it is
it
can be used.
hardening or spotting
Malleable scrap
and
being seen
in
in
is
effect
sometimes added
producing
chill.
(247)
FOUNDRY IRONS.
248
Blow
holes
may
venting,
sense.
It
to
is
more
from
it
is
lose a
to
hundredweight of coke
hundredweight of castings
dull iron.
results
at
low-silicon iron
iron.
in
strength when
The lower the
Vanadium
is
in a
no increase
in
semi-steel.
At
it
is
cheaper
to
make
it
Use
tail
is
also
due
to
rolls
over
in filling
Any
into
the
The
iron
it
unite to
rat tail.
to a jet of
be punched
FOUNDRY NOTES.
When
ings the
loam
bind
to
is
added
enough
it
in
etc.,
iron,
249
3 to
it.
the mixture.
in
Test bars one inch square, twelve inches between centers, have
shown 2,800
air
lbs.
lbs.
lbs.,
lbs.,
The average
in
lbs.,
for
medium,
strength
lbs.
same
iron,
ladle
is
about
6 per cent.
It is
very
difficult to
and you
scrap,
To
men
dump, weighing
in
in
weighing
over-iron etc.
at
strike
in steel
Aluminium
The cupola
and
of
is
fast melting,
moving or adding
A
a
but the
air
good healthy
to
be doctored, give
Always melt
The
heat
it
air furnace,
cupola
is
is
when
if
the iron
you have
is
sickly,
to so high a temperature.
iron in a cupola
for re-
in a
it
metalloids.
and has
in
little
by melting
It
it
is
is
not heated
hot.
FOUNDRY IRONS.
250
The
When
high
in
in
between the
test
it
if
good
and chilled
chill
when
iron, the
silicon
is
too
spots in castings
falls into
damp
soft
the sun
Hard
cast iron
should be used
To
shows a
fined line
by melting
cupola.
in a
may be
in
by the
Such hard
chilled
and
in clusters.
in
To
a
prevent
this,
sputter.
in a
mold, and to
this
two.
is lost.
This iron
sets
in
more
rapidly than
To
avoid dirt
inin
generally due
is
to
uneven
thing.
High
soft foundr\-
make
even when
iron
the chill
is
right.
old
are
Regular car
is
If
the chemist's
dope
for
all
the
ills
of foundry irons.
FOUNDRY NOTES.
25
Grate bars are generally cast from any old iron that can be
thrown
makes
cupola
into the
the
at
last
menting.
W.
J.
Keep recommends
a 2.75
iron
silicon
grate bars.
for
this iron
well.
Iron does not absorb carbon or silicon from the melting fuel
in
a cupola, but to
Hence
ments.
than
is
a limited
iron
is
hardened
actually required
in
in
will
it
be
it is
in a
Heat removes
them.
in
the cleaner
has to be melted
the castings
in castings.
not be
made
that give
the castings.
P^or sash
steel,
that
plate,
may be
is
melted, for
scrap, wire or
steel
it
is
When
iron
is
way
to
add
in
this
element
tin-
is
to
not fluid
fluidity.
mixtures of sluggish
in
when
The
phos-
iron.
Molding sand is a porous substance that admits of gas generated in a mold by molten iron coming in contact with its surface to escape from the mold.
The troweling or slicking of the
surface of a mold closes the pores and causes a blow or kick of
the iron in the mold, due to explosion of gas under
vent
this,
leave the
mold
as the pattern
left
it.
it
little
of
some
of the core
in
To
pre-
Dust on black-
it.
necessary.
with
FOUNDRY
252
ladle
lining;
IRONS.
ladle clean
compound by bulk
life
of the
recom-
is
mended.
water of combination
the clay.
in
in
this
If
it
is
in
is.
and a loam clay and sharp sand mixture the best for large ladles.
A molder should never be permitted to build up a hand ladle
with daubing to make it hold more iron.
Such daubing frequently gives way and iron
It
is
is
output of castings.
to
time spent
molder
at
a high-priced
is
gangway.
man and
should
more
profitable to
employ
out castings, temper sand, and put the pattern and flask
work
in
if
for the
b}'
man.
molder
to
go
to
he
is
it
is
in place
to
have
does the laborer's work for nothing, because relieving the molder
of this
in
him more
in a
foundry,
all
The
other employees
profits
on the castings
employed
in a
certain
amount
of non-productive labor
is
necessary
in
to
the
number
of molders
is
em-
ployed.
falls
FOUNDRY NOTES.
253
practice for years to pick out the larger pieces of this coke and
put
it
back
The very
next heat.
small
pieces are shoveled into the tumbling barrel together with the
dump, ground up
in
This coke
used
what
to
do with
blacksmiths'
It
it.
It
fires.
in
these purposes
for domestic
it
is
the very
too small to be
in
all
When
may be
use, as
it
sold
of
all
at a
it
nominal price
makes an excellent
fuel
employees
to
for
cooking
To be
tumbling box, which also tends to close the surface grain and
The
placed
in a
hot pickle of
from one
hours, or until the recesses are free from scale and sand.
may be removed by
then washed
to dip.
in
in clean
P^or
then
articles are
The
to
two
Spots
castings are
composed
of 4 parts of
1
part of
the castings to
the tin or a
surface and
little
tin.
sprink-
the
in a
sal-ammoniac
ling of pulverized
tallow
make
tin,
oil
or tallow at a tem-
FOUNDRY IRONS.
2 54
As soon
the castings.
as the tin
be washed
in
in
sawdust.
number
Ginis.
The
of old cannon,
Government
among
recenth-
ing these heavy pieces of cast iron into marketable shape as scrap
iron,
weight.
method
the
in
of drilling a
driving steel wedges into these holes until the gun split open.
To
way
into suitable
sections
when
the\-
is
process
in
Alnminum
having large
castings
Blow-Holes
run,
fired
Castings.
The
in use.
repair of
aluminum
blow-holes, or
is
practiced.
exam-
used, having a hole cut in the center exactly the size of the
hole
in
carry
the casting.
off
from the
to
set,
flow-off
is
prevent
lifting.
the surplus
is
aluminum
held firmh'
aluminum
is
in
in
is
being poured
FOUNDRY NOTES.
Hardening
the
Face of Castings.
255
process for hardening
by Morgan A.
Perrigo,
of Wilkesbarre, Pa.
come
in
The
harden.
is
it
in
will
desired to
method pro-
53
used
in
tween the
On
silica contracts at
this account,
if
temperatures
a high-silica brick
in
At
make an
order to
a recent
elastic lining.
from a chemical
analysis, the
amount
of chill an iron
would show have not proven successful, and the speaker stated
that the chilling qualities of an iron were
At
like chill.
will
somewhat
difficult to
employed
contains from 3.25 to 3.60 per cent, of total carbon, about 0.75
per cent,
silicon,
0.50 per cent, manganese, 0.50 percent, phosto 0.15 per cent, of sulphur., of
The
cent.
total
The depth
of chill
carbon
5
is
which the
limit
lowered to the
produced by
this
mixture
is
about
inch.
Cupola Daubing.
material used in
For
mending the
from 20
to
25 per cent, of
the joints
silica
should be
being dipped
made
in a thin clay
as
in posi-
FOUNDRY IRONS.
256
The
tion.
surface
may be washed
dum
to
fit
is in
two pounds of
finely
to
<S
made
ground carborun-
carborundum can
Welding Cast
Iro7i to Steel.
The
ganese.
it
is
silicate will
This keeps
Coat
all air
joint,
rust.
If
and
if
no oxygen
Welding Cast
off,
One
Iron.
bedded
in cast iron
in
this
One
man-
The
flux,
aid of a blowpipe.
is
fluoride.
to the
first
may
require
it.
Punched
Castings.
cast-iron plates
The
Russell
&
Will, foundry
The
castings were
firm
in
tiuestion
in
making
foreman of
made from
in
by the
Company
their
engines, harvesting
FOUNDRY NOTES.
No
257
alloys of
in
any way.
was
Sg inch
Nos.
14 y^ inch thick.
punchings were
No.
thick, while
was
10 and
7, 9,
}^
12
Some
inches in diameter.
of these
Pickling Castings.
of the solution
w^ater,
in
For
some
generally
is
left
in the
10 parts
to
may
is
not
sufificient
be stronger and
where the
accommodate
to
proportion of
in the
The
castings
are
when they
is
When
the scale
Mr.
J.
method
is
to
it,
the
produced.
so firmly
is
it
The
pump
plan
the acid
castings in the form of a fine spray, this also taking place from
several sides so that
all
The
pumped up
17
it
may be
neces-
FOUNDRY
258
sary, until the sand
when
would
way ahead
work
the
left
will
is
off easily
is
washed
moved and
comes
IRONS.
of the
all
air,
In this
machine shop.
re-
when they
country we
foundry
ing.
figures given to
The
unfortunately, not
the
process
is,
barrel.
Parts.
gangway sand
Finely sifted
89
Pulverized
litharge
Boiled linseed
oil
Mix
keep out
all
bottom board
screws
in
is
preference to
nails.
match made
in this
manner
Steel or Iron
a
brown
tint
as possible),
gallic
acid in four
desired shade of
it,
and
finally
rub
brown
it
dr}-
oil.
M. Bertrand
He
dissolves salts
iron.
FOUNDRY NOTES.
rate of
per cent, of
tin salt
and
acid.
dipped, and
is
at
259
is
previously cleaned,
is
in
is
tin,
wire and
" Brannt's
from
is
Metal Workers'
Handy Book": To
con-
and a
of 15 degrees B.
80 parts of
subsequent polishing
nitric
articles in clean
is
In this
acid
manner ground
is
of
or rough objects
mendable on account of
bility of the
coppering.
its
simplicity, cheapness,
To
An
A handful
of oxalic acid to a
over the glass with a woolen rag or soft skin and give
which
will
would.
if
left
in this
way
it
it
is
to
go
a polish,
otherwise
will stay
clean
unpolished.
a mixture of fine sand and soft soap for cleaning foundry win-
dows.
presentable
success
in this
way.
this a positive
FOUNDRY IRONS.
26o
The windows
of a foundry
may
fectly
Brush
then
this
finish
with
more
of the
it
is
brushed
the cast-
off
same mixture.
have used
this
Compressed
air is
are not coated with oxide of iron, the air alone doing the
when
method
is
work;
it.
Be-
securely
Silvery Iron.
An
There
will
be an advance
in contracts, the
the
hereafter
Up
be 25
50 cents per ton for each
clearly
in price
one-half of
made in the
by the Jackson County,
To
following table
more
be understood
presented, which
is
this
illustrate
silicon content to
is
based on
silicon
Silicon will range
Per cent.
per cent.
Price.
3-75 to
425
^16.50
4)^
4-2Sto
4.75
16.75
4.75 to
5.25
17.00
S%
5-25 to
5.75
17.25
5-75 to
6.25
17.50
6>^
6.25 to
6.75
17.75
6.75 to
7.25
18.00
1%
7-25to
7.75
7-75 to
8.25
18.25
,
18.50
8>^
8.25 to
8.75
18.75
8.7510
9.25
19.00
FOUNDRY NOTES.
261
per cent.
Per cent.
10
..
Price.
9.25 to
9.75 to 10.25..
9.75..
19-50
10.25 * "o-TS*
20.00
20.50
II
10.75 to 11.25..
ii>^..
11.25 to
12
11.75 to 12.35..
19.25
1.75'
2 1. CO
21.50
FOUNDRY
262
limited.
F'or
it
IRONS.
Now
is
who
at
pound and
castings
is no more reason why the price of castupon the price of pig iron, than that of a
piece of furniture upon the price of lumber consumed in mak-*
ing it, or that of a packing box on the cost of the few boards
founder.
there
used
in its
thinks of objecting to the price, for the reason that that of lum-
sumed
in
producing an
It
is
article
that determines
its
it.
piece of
made
from lumber of the same price or grade. The cost for labor in
making a complicated piece of core work may be three or four
times greater than that of a plain piece cast from the same
ladle of iron.
It is
The
price per
may be
casting.
is
wood
pattern before
no reason
why
castings
should not be sold by the piece at a price based upon the cost
of labor required to
by the pound.
In Indiana a founder
was making
a small
which he received
FOUNDRY NOTES.
263
him about
fifteen
Baltimore,
Md. foundry,
Had
was shown a
iron,
even
he knew
if
nothing about the price of pig iron per ton, he would no doubt
have objected to it, but when asked a given price he paid it the
same as he would have done for any other manufactured article,
and was satisfied with it.
But the piece price cannot be adopted by a founder at an
advance price for anything but a speciality so long as his com-
by
met
To
the pound.
illustrate this;
recently
a founder in a Massachusetts
The
made from
motor boat.
was
five cents
per pound or
pay
When
the founder's
cents was
attention
was
called
to
this,
he said
five
and he could
but
failed to see
why
This
down
by
and he
to vv^eight,
soft
is
not at
all
and castings
proper pouring.
The consumer
and
if
the casting
is
is
FOUNDRY
264
ditional cost
The
until
is
IRONS.
incurred for
result
is
it
never
know what
With
machine cost
until
to
is
it
pound
would be a
is
actually finished.
in
weight
castings.
Contract Castings.
tract or
agreement
to
at
into a con-
all the castings for a machine shop or other consumer of castings. This price is always below that of core work
and above that of plain work, and the founder figures on making
up his loss on the core work from the profits on the plain work,
and thus realize a profit on the contract. This theory figures
out very well when the plain and core work are of proper pro-
core work,
'
But the
and sends
all
them
is
paying more
other foundry at a lower price leaving only the core and light
plain castings to be
made on
loss
and
As
it
is
is
compelled
to
In this
his contract.
making
way
the con-
castings at a
and bound
With
may
find himself
to continue to
a piece price
it
do
all
making them
Unfair Practice.
at a
heavy
loss
so.
if
etc. for
producing
at a price
based
it.
unfair practice
is
that of
FOUNbRY
NOtiiS.
26^
for
machine shop.
in their
This practice
is
to
both the machine shop and the foundry of the concern where
carried on.
shop.
who undertakes
penses of a foundry
The
piece price
will
may
by foundries making
readily be adopted
it is
now
sold
by
more labor
is
by many founders.
the piece
required to figure
to
be considered
in
In the opinion
all
by
kinds
of castings.
file
so
many
to
may
adhere to
brush,
improved
them
we have
the
tumbling barrels of
acid
sizes
all
is
bath,
steel
wire
last
but not
least,
but also of cutting away the iron of the casting, and we find even
sash weights polished
in
FOUNDRY IRONS.
266
it is
many Hnes
of castings
upon which
a coating of
than
in
a coating of
use. in a
damp
sand upon
coming heavily coated with rust and eaten away by it, while the
latter remain as good as new for years under the same condiIn castings placed in the ground the sand-coating protec-
tion.
may be
tion
seen to a
present time,
all
still
From
surface.
is
are
many more
castings, such
is
used.
as foundation
plates, grate-bars,
This
is
man, for
injured
for facing
by every foundry-
That the
purposes
is
much
by the adoption
and
lasting
many
its
lost prestige.
NDEX.
ACID-resisting castings, 137
Agricultural machinerv castings,
137
Air cylinders, 137
-furnace for melting malleabies,
233, 234
iron and semi-steel, 220
superiority of the cupola
over, 249
Alabama coke, 12, 13
All Mine pig iron, 159
Alloys, pig iron and coke, grading
of, 153-167
Aluminum and cast iron, 117, 118
castings, blow holes in, 254
American charcoal irons, 160, 161
foundry and forge iron by analysis, 156, 157
Foundrymen's Association, report
chemical
on
standards
iron
made
inaccuracy
of, 168
of castings, 131, 132
samples for, 126
sampling for, 157, 158
Annealing boxes, 237, 238
pots and pans, 137
cast iron, 247
indications of, 235
malleabies, 235-243
ovens, 236-237
pots, anal)'sis of, 132
scale, use of borings for, 59
time required for, 241, 242
coke iron, 7
foundry pig, silicon
for
castings
to, 134-
167
second series of
tests, 189-199
standard specifications f o r
.
foundry
pig
iron, 128-131
Scotch pig, 30
Society for Testing Materials,
analysis for foundry irons as a
standard adopted by, 125
Analyses, comparative, of Bessemer
of, 7
in grades of,
96
iron, 7, 25, 26
crystals in, 36
Antimony, effect of, on cast iron, 119,
120
86, 87
cylinders, 138
analysis of, 131
French, 124
fly-wheels, 138
iron, 169
charco a 1
iron, 169
foun
dry
iron, 168
of coke, 10-19
standard, of the various grades of
foundry and
steel-making
irons, ferro-alloys
and melting
fuels, 153-167
BADEN,
Bench work,
Bertrand's
(267)
of,
131
268
INDEX.
Bessemer
Carbonates of iron, 3
comparative analysis
of,
Carborundum
169
malleable, 154
standard, 153, 154
Binders, 138
Bituminous iron, 7
Black band, 3
Blast, drying the, 112
furnace analysis, 171, 172
location of, in early days, 4
furnaces, 6-8
locations of, 7, 8
hot, 112
oxidizing action of, 49
Blow holes, causes of, 248
in aluminum castings, 254
Blowers and fans, 141
Boiler castings, 139
Borings, cast iron, briquetting of, 53
melting of, 48-51
Keep's method of melting, 57, 58
melting of, in the cupola, 55-57
new methods of melting, 52
use of, for annealing scale, 59
wrought iron and steel, melting
of, 51, 52
Boyden, Seth, award of medal to,
227, 228
malleable
iron
founding
started by, 227
monument of, 228
Brake shoes, 139
Briquetting cast iron borings, 53
iron and metal turnings and
chips, German method of, 5355
Bronze, effect of, on cast iron, 119,
120
Brown hematite, 3
Burned cast iron, 39
iron, crystals in, 37
loss in melting, 71, 72
scrap, 38, 39
Car wheels,
effect of
and aluminum,
annealing
of, 247
best results in melting, 250
borings, briquetting of, 53
burned, 39
carbon the real softener and
hardener of, 104
cause of hardness of, by
chilling, 103
cutting tools, chilled, 140
decrease in value
81
effect of
of,
manganese
by
rust,
on, 106-
108
metals
on,
119, 120
by wrought
iron,
44,
45
CANNON
INDEX.
Castings, coppering of, 259
distribution of silicon throughout, 27, 28
early production of, 4
hard, softening of, 247
hardening the face of, 255
heavy, change of structure in,
185
in the early days of founding, 78
light, transverse strength for, 249
malleable, cost of producing, 245
methods of selling, 261-264
of,
169
97
silicon in, 97
Chemical standards
134-167
31,32
182
Chills, 140
for foundry use, analysis of, 132
Chips, briquetting
of,
53-55
iron,
1-10
on cast
iron, 119,
coke, 12
of,
12
16
desirable
212
Cornwall ores, 3
Cotton machinery, 146
Crushed coke, 162
Crusher jaws, 140, 249
Crushing test, 181
Cupola bricks, behavior of, 255
calculating mixtures for, 132
districts of the
6, 7
means
foundry,
crystals in, 36
for malleables, 231, 232
-smelted iron, characteristics of,
10
for, 211'.
iron, 7, 23-25
irons, 20-23
grading
furnaces, 8
industry, report on, 11-16
120
for mixtures, 97
of,
Coke
Copper, effect
fi
comparative analyses
hot Ijlast, 7
use
269
composition
for, 16
change
in the
93
melting borings and turnings in,
55-57
semi steel in, 206
mixing materials for semi-steel
in, 218
superiority of, over an air furnace, 249
use of steel scrap in, 216-219
Cutting tools, chilled cast iron, 140
Cylinder bushing, locomotive, 140
Cylinders, 140
hydraulic, 144
jacketed, semi-steel mixture for,
quality of iron
211
in,
70
INDEX.
li25
Founders, trick
of, 23
unfair practice of, 264, 265
Founding, iron and steel, 214, 215
Foundry and forge iron, American,
by
140
Dies for drop hammers, 140
Diller, H. E.. on semi-steel, 206-209
Direct process, casting by, 78-87
Directory of pig iron brands, 151, 152
Drop hammers, dies for, 140
weights, 249
Dudley, Chas. B., on iron for car
wheels, 255
Dynamo and motor frames, bases and
spiders, 140, 141
iron, tests of, 189-199
frame
chemist, 174-176
chemistry, 88-94
of, to improve the
quality of foundry iron, 8
chemists and analysis, 168-177
coke. 161
desirable composition for, 16
iron, 152, 155
classification of grades of, 152,
153
comparative analyses of, 168
English, 159
failure
improvement
ECCENTRIC
Eckfelt,
straps, 141
J. L.,
on pickling
cast-
8-10
125
fracture indications in, 35-37
history and sources of, 1-19
of,
227
FANS
test,
37
scrap iron, 37
iron graded bv, 155, 156
test, 180
French automobile cylinders, 124
Friction clutches, 142
Furnace castings, 142
coke, 161
hot or cold working, 33
Furnaces, 92, 93
for anthracite iron, location of, 25
melting, for malleables, 232-234
INDEX.
Georgia coke, 13
German method
of briquetting iron
and metal turnings and chips, 53-
up
of,
254
143
Hard
sandwiched, 82-84
b}-, 81,
88-90
History and sources of foundry irons,
1-19
Hollow ware; 144
Hood, H., on the hoodoo in pig iron,
176-178
Hot blast charcoal iron, 22, 23
best
known
brands
of,
23
iron, 0, 7
Housings for rolling mills, 144
ILLINOIS
vanadium by,
of. 5,
compounds
of,
vanadium
Iron,
sulphur on, 9
coke, 13
Steel Co., use of
122
Impact test, 180, 181
for,
High
Hydrogen
vanadium, 121
loss in melting, 71, 72
Grate bars,
271
on, 123
of,
152, 153
graded by fracture, 155, 156
2/2
INDEX.
MCCLAIN, DAVID,
Middlesboro, 159
mixtures of, 60, 61
steel a
McGahey,
ores, 8
supply of, o
oxidation of, by heat,
oxidized, 80-82
for, 96
mixtures, 62
scrap, 40, 41
Magnetic
81, 82
239
remelt, 64
silver gray, 26
sulphide, 110
246
production of, 244-246
tensile strength of, 242
transverse strength of, 242
scrap, 43, 44, 232
iron produced from, 247
Malleables and castings, cleaning of,
cliarcoal, 20-23
commercial,
high
of, 6, 7
silicon, 158
mixing
of,
60-67
scrap, 40-59
silvery, 158
242
KEBLER,
Keep, W.
J.,
method
ings
Kentucky
of melting bor-
of, 57,
58
testing machines
by. 188
coke, 14
made
ABORATORIES,
testing, 173
Lv
Lead,
Kil
ores, 3
effect of, on cast iron, 119, 120
Loam
sand, 252
Low
phosphorus
pyrites, 3
designation
loss in melting, 69
ores, 3
Irons,
C. R., on
in the cupola, production of semisteel castings, etc., 216-219
Machine tool castings, 146
Machinery castings, 145, 146
silicon
in
mixtures
mottled, 155
Mountain
on.
Is semi222, 223
use of steel scrap
misnomer
iron, 154
in a
ladle, 1( 8, 109
iron, 106-108
eflfect of, on cast iron, 106-108
metallic, discovery
sulphide, 110, 111
of,
106
and borings,
INDEX.
Melting
furnaces
232-234
iron,
malleables,
for
in,
76, 77
and gain
in,
154, 155
223-225
Mine
Mowers, 146
Murphy, James
A.,
68-77
washed,
spiders, 146
loss
273
of,
132
ores, 4-6
Mixture, tabulation of material to be
charged, and method of figuring,
133
locomotive cylinder,
machinery, 62, 63
making
of, 65-67
of iron, 60, 61
pig and scrap, 63, 64
semi steel, 211, 212
stove plate, 61, 62
Mold
ties
characteristics of
semi-steel, 219-
222
semi-steel mixtures
for steam cylinders published by
211, 212
MEXICO coke,
NEWNickel,
164
14
in iron, 119
Niter pots, 146
Nitrogen, affinity of titanium
in iron, 114
OHIO
for,
110
coke, 14
Open-hearth basic
iron, 159
4-6
Ornamental work, castings for, 146
Ovens, annealing, 235-237
Over-iron, 45, 46
Oxidation of iron by heat, 81, 82
Oxidized iron, 80-82
Oxygen in iron, 112-114
Ores, mixing
PACKING
of,
Physical
Pig,
American Scotch, 30
and scrap mixtures, 63, 64
chilled, 31, 32
iron, 30, 31
153-167
INDEX.
274
grades
of,
34
M. alloy, 163
SA.Sampling
and analysis,
.
of, 3,
129,130
mixture
Punched
for, 21
RAILROAD
castings, 148
track steel, melting of, 210
Ramp, Paul R., locomotive cylinder
mixtures given by, ()4, 65
Rat tail, cause and prevention of, 248
Red hematite, 3, 240
phosphorus, 109
Relative test, 181
Remelt iron, 64
Retorts, 148
Revolving annealing ovens, 236, 237
Riehl^ Bros Testing Machine Co.,
testing machines made by, 188
Rolling mill scale, 240
mills, housings for, 144
melting
mixing
in a cupola, 206
materials for, in the
221
cupola, 218
rings, 225
no
practical
221, 222
requirements
for^
INDEX.
275
dry work, 28
controlling element in semi-steel
making, 204
distribution of, throughout the
castintis, 27,
effect of, 251
2<S
dium, 121
Smokestacks, 149
Soft,
heating or
Soil pipe
and
Solway coke,
Spar ores, 3
jamb
coke, 162
fittings, 149
9,
16-19
making
melting
fuel,
153-167
and
iron in the
cupola, effect of, 206-209
punchings,
plate
melting of, 205
rails, melting of 205, 210
scrap, content of sulphur in melting. 218
efficiency of, for semi-steel,
222
reduction of silicon in melting, 218
use of, in the cupola, production of semi-steel castings,
etc., 216-219
strengthening cast iron with, 215,
216
superiority of cast iron to, for
many purposes, 93, 94
turnings and borings, melting of
51, 52
melting of 57, 210
use of nickel in the manufacture
of 119
vanadium in, 121
welding cast iron to, 256
Sterling. Mr., patent of 44
Stock coke, 162
Stove foundry melting, results of, 74-
76
plate, 15(
70
silicon in
mixtures
for,
96
INDEX.
276
on iron, 9
hardening iron with,
Turnings, melting
55-57
steel, melting
of, in
of,
the cupola,
57
effect of,
UNITED
111, 112
STATES,
malleable
first
in iron, 110-112
So, 86
output of malleables
in, 228
Use of steel scrap in the cupola, production of semi-steel castings, etc.,
216-219
frame iron, 195-
Tennessee coke, 15
199
Test bars, 182, 183
care in casting, 183, 184
length of, 183
method of casting, 200-203
required by civil engineers,
185. 186
chilled, 182
crushing, 181
foundry standard,
181, 182
blast
and
187,
Washington coke,
Water heaters, 151
pipes,
Wilson Bros
castings,
151
Wrought
52
scrap, 44, 45
and
of,
121, 122
ing, 52
melting
16
Wheels, 151
51,52
151
to steel, 256
iron, 189-199
steel,
266
of,
wrought iron
wear
15, 16
188
dynamo frame
154, 155
standard, 181
Tests,
150
Valves, 150
Vanadinite, 120
Vanadium, 120-123
effect of, 123, 248
experiments with, 121, 122
in cast iron, 124
use of, in making steel, 121
Virginia coke, 15
Vosburgh, Walter S., revolving annealing oven designed by, 236, 2.37
charcoal
WARM
Washed metal,
fracture, 180
machines,
VALVE bushings,
ZINC,
120
effect of,
on cast
iron,
119,
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