Non-technical chats on iron and steel, and their application to modern industrySpring, La Verne W. (La Verne Ward)
History
Non-technical chats on iron and steel, and their application to modern industry
Spring, La Verne W. (La Verne Ward)
Iron; Steel
Unlike puddling furnace and open-hearth no burning out of the silicon,
manganese and carbon is desired, though, of course, some occurs and has
to be allowed for in calculating the mixture. The intention is simply to
melt together with the least possible loss a mixture of such materials
as will give the average final composition which long experience has
shown to give the proper qualities to the finished product.
Charges usually are of certain percentages of pig iron with not too much
phosphorus, sprues from previous melts, more or less good malleable iron
scrap and small amounts of steel scrap. These are melted down as quickly
as possible. Occasionally the slag which accumulates is skimmed off and,
after rabbling, test plugs are poured from the fractures of which the
composition of the iron is judged.
When the silicon content is deemed proper or has been adjusted through
longer action of the flame if too high or addition of more silicon in
the form of a high silicon alloy if too low, the iron is tapped,
provided it is hot enough.
Malleable iron is largely used for very small castings. These require
very hot and fluid metal. So, even if it is of proper composition, the
metal must be held in the furnace until it is of a high enough
temperature to pour properly. Through prolonged and strong heating the
iron may easily become oxidized or “burnt” and much skill is necessary
for proper operation of the furnace.
After tapping, the iron must be got into the molds with the least
possible delay.
As has been mentioned with former processes the melting of iron in
contact with coke or coal results in more or less contamination with
sulphur. For this reason cupola malleable has considerably higher
sulphur than has malleable cast iron made in the air furnace. Cupola and
air furnace each has certain advantages and certain disadvantages. While
strength and elongation are somewhat greater in air furnace than in
cupola malleable, both anneal well and give materials which are
satisfactory for the purposes for which they are intended.
Cupola metal has an advantage in that the temperature and the
composition can be closely maintained the same throughout the heat,
perhaps more so than with the air furnace. With the latter the metal at
the top of the bath is hotter than that underneath, and, through action
of the flame and air, silicon is somewhat lowered before all of the heat
can be poured, especially with air furnaces of large size. The metal can
easily be “burnt” unless extreme care is taken. In the cupola we can get
very hot iron continuously so that it is unnecessary to prolong the heat
with the danger of burning that occurs with the air furnace.
Public-domain text, read in full here on John Shaqi.
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