The Iron Age 1899-11-09: Vol 64 Iss 19

THE IRON AGE A Review of the Hardware, Iron, Machinery --4 Metal Trades. Published every Thursday Morning by David Williams Co., 2! O € Gopamysy 5 oun suy Bi 005 EReidosy putes New York, Vol. LXIV: No. 79. New York, Thursday, November 9, 1899. $4.50 a Year, including Postage. Single Copies, Ten Cents Reading Matter Contents......... page 50 Alphabetical Index to Advertisers ** 121 Classified List of Advertisers... .. “ ~ Advertising and Subscription Rates ‘‘ 57 Dynawo a. Louis, Mo. 2DELTING New York. Republic Iron & Steel 1Co., CHICAGO. MANUFACTURERS BESSEMER STEEL BARS. DISTRICT “ALES OFFICES: Buffalo, N. Y. New York City. Cleveland, 0. St. Louis. Mo. Cincinnati, O. Birmingham, Ala. See our advertisement on inside back cover. Bristol’s Patent Steel Belt Lacing, SAVES Time, Belts, Money. Greatest Strength PIISHED JomT «with Least Me READY TO APPLY Send ter Circulars and Free Samples. THE BRISTOL CO., Waterbury, Conn. SAMSON SPOT CORD Also Massachusetts and Phenix Brands of Sash Cord. SAMSON CORDAGE WORKS, TURNBUCKLES, CH OFFICE: 11 Broadway, New York. Cleveland City Forge and iron Co., - Cleveland, O. DROP HAMMERS. MANUFACTURED BY MERRILL BROS., Brooklyn, N. Y- Low Phosphorus Pig PILLING & CRANE, Suzan’ Guizing:,Pilace Lewis Block, P ittsburgh. - Boston, Mass, We used to have to sell it —galvanized iron, Sells itself now; and can't keep up with it, Regular users don’t know that. Apollo Iron and Steel Company, Pittsburgh, THE THREE REQUISITES OF A PERFECT GUN, | BALANCE, EVEN PATTERN AND PENETRATION, Can only be obtained after years of experience. oe” THE REMINGTON HAMMERLESS is backed by nearly a century’s experience, and the success that rewards the man who shoots a Remington proves that our efforts have not been in vain. SEND FOR CATALOGUE. REMINGTON ARMS CoO., 315 S16 Broadway, N. » a Ilion, N. Y-: CAHALL BOILERS * CAPEWELL HORSE NAILS. NEW YORK, PHILADELPHIA, CHICAGO, ST. LOUIS, BOSTON, DETROIT, CINCINNATI, SAN FRANCISCO, PORTLAND, ORE., BUFFALO, BALTIMORE, NEW ORLEANS. THE CAPEWELL HORSE NAIL COPIPANY, HARTFORD, CONN. 82, BRANCHES: Compare Weights WHEN YOU ARE TOLD THAT JENKINS ’96 IS MORE EXPENSIVE THAN OTHER PACKINGS. Average weight, ¥%” “Jenkins 96,” 11 Ibs. to the square yard. %" Red Packing, 14 “ At 50c. per pound “ JENKINS °96” is not only very much cheaper, but the best joint packing manufactured. JENKINS BROS., New York, Boston, Philadelphia, Chicage. Brass Prices High, So Use Bright “Swedoh” Stamp- seg ik ing Steel Easily Brass Plated and Save Money. Pt MAGNOLIA METAL Best Anti-Friction Metal for all Machinery Bearings. Beware ot Imitations. Genuine Magnolia Metal is made up in bars of which this ig a fae-simile : The name and trade- mark appear on each words Sian ufactured “Patented June 3, "90, box and bar, and the in United States"’ and der side Of each bar. ng at A a price it has JENKING STANDARD PACKING LICE are stamped on the un- **Magnolia —- is still se always sold a if 42i9«0 MAGNOLIA METAL CO., (Sictsitectareras ) 166 & 2 U WEST ST,, NEW YORK rier, | THE IRON AGE rH} ANSONIA Brass ee” GoOPrPerR Co: MANUFACTURERS OF BRASS AND COPPER Ingot Copper. ‘LE MANUFACTURERS Tobin Bronze (TRADE-MARK REGISTERED.) Waterbury Brass Co. Established 1845. Sheet, Roll and Platers’ Brass, German Silver, Copper, Brass and Ger- man Silver Wire. Brass and Copper Tubing. COPPER RIVETS AND BURS. PERCUSSION CAPS, TAPE MEASURES, METALLIC EYELETS, Brass Kettles, Brass Tags, Powder Flasks, Shot Pouches, &c., 99 John Street, New York. AND SMALL BRASS WARES OF EVERY DESCRIPTION. PH 8 CLOWES HICK’S PRIMERS, BERDAN PRIMERS. , ANDOLP Cartridge Metal in Sheets or Shells UL LILA CONN, a Specialty. F SE 60 Centre St., New ig 126 Eddy St., Provi- on H E ETs BRASS dence, R. i. 38 Mechanic St., Newark, N. J. MILLS AT WATERBURY, CONN. NEW YACHT COLUMBIA All Her BRONZE CASTINGS are made of our... Ordnance Bronze Bridgeport Deoxidized Bronze & Metal Co., BRIDGEPORT, CONN. & COPPER. BRAZED BRASS & COPPER TUBES. SEAMLESS BRASS & COPPER TUBES’38"DIAM. 2 eTeRN DEPOT, 226 Lane = we CHICAGO, ILL. 2 " NEW YORK, AOOM 202, POSTAL TELEGRAPH 8106. 253 BAROADWAY. PHILADELPHIA, ROOM 320 PHILA BANA 8406 CINCINNATI 0. ROOM 308 WEAVE BLOG. J Matthiessen & Hegeler Zinc Co., LA SALLE, ILLINOIS, SMELTERS OF SPELTER AND MANUFACTURERS OF SHEET ZINC AND SULPHURIC ACID. Spe cial Sizes of Zinc cut to order. Rolled Battery Plates Selected Plates for Etchers’ and Lithographers’ use. Selected Sheets for Paper and Card Makers’ use Stove and Washboard Blanks, ZINCS FOR LECLANCHE BATTERY. Swiss Hide Belting HIGHEST GRADE. Runs straight, stretches but little, lasts long. MANUFACTURED BY MACHINISTS’ SUPPLY GO,, Rochester, W. ¥. HENDRICKS BROTHERS PROPRIETORS OF THE Belleville Copper Rolling Mills, MANUFACTURERS O} Braziecers’, Bolt and Sheathing COPPER, COPPER WIRE AND RIVETS. Importers and Dealers in Ingot Copper, Block Tin, Spelter, Lead, Antimony, etc. 49 CLIFF ST., NEW YORK. ~ |THE PLUME & ATWooo M6, Co.. MANUFACTURERS OF Sheet and Roll Brass WIRE PRINTERS’ BRASS, JEWELERS’ METAL, GERMAN SILVER AND GILDING METAL, COPPER RIVET! AND BURRS. Pins, Brass Butt Hinges, Jack Chain, Kere. sene Burners, Lamps, Lamp Trimmings, &c. 29 MURRAY ST., NEW YORK. 144 HIGH ST., BOSTON. 199 LAKE ST., CHICAGO ROLLING MILL : | THOMASTON, CONN. FACTORIES : WATERBURY, CONN. SCOVILL MFG. CO., Manufacturers of BRASS SHEET, WIRE, TUBES, Hinges, Buttons, Lamp Goods, Nipples, Pumps and Oilers for Bicycles, Braziers’ Solder. Factories, WATERBURY, CONN. DEPOTS : New York, Chicago, Boston. JOHN DAVOL & SONS. AGENTS FOR Brooklyn Brass & Copper Co., DEALERS IN COPPER, TIN, SPELTER, LEAD, ANTIMONY. 100 John Street, New York. WILLIAM 8S. FEARING, 256 Broadway, NEW YORK, SELLS TO THE TRADE Sheet Brass, Fancy Sheet Brass, German Silver, Copper, Brass and German Silver Wire, Brazed and Seamless Brass and Copper Tubes, Brass and Cop- per Rods, Brass Ferruleas, Pure Copper Wire, Sheet and Ingot Copper; Spelte: Tin, Antimony, Lead, &c. “dearch-Light” OIL and GAS Bicycle Lantemns: Send ter Circulars and Electrotypes. THE BRIDGEPORT BRASS CC Bridgeport, Conn. 19 Murray 8t., N. Y. 17 No. 7th 8t., Philadelph! 85 to 87 Pearl St., Boston. BESSEMER Sven, mas AND Olt. TEMPERED SPRINGS. _—s ‘THE IRON AGB. THURSDAY, NOVEMBER 9%, 1899. (/ The Mahoning Iron Mine. The advent of the American Steel Hoop Company o1 the Mesaba range adds another, and nearly the last, of the large steel making combinations to the list of those con trolling, in part at least, their own ore supplies. This company, with an interest in the great Mahoning mine of the west Mesaba and with a further interest in the ex plorations under way by the Mahoning Ore & Steel Com- pany in hard ore districts, have secured ore supplies for a great many years and stand in as good position to gather in others as any of their contemporaries, and at very much less cost than some. ’ W. C. Agnew, sank a number of test pits and drill holes, 100 in all, over a portion of the north forties of Sections 1 ind 2, lying a mile er so west of the village of Hibbing. Ore was found in quantity: As the surface was light, stripping was undertaken, and in the summer of 1895 the company shipped 117,000 tons to the Mahoning Valley fur- naces that controlled their stock. The ore was found to have to some extent the usual disadvantages of Mesaba open pit mines—it was fine and liable to pack in the fur- nace; but it was of excellent chemical quality, and a large proportion was Bessemer. The presence of lumpy streaks running through the ore aided its physical composition to an extent that assisted furnace practice materially THE MAHONING The Mahoning Ore & Steel Company control under lease ore mines on the western Mesaba of such extent that the present generation can have little personal interest in the question of their ultimate exhaustion. Early in the development of this range the company secured options for the exploration of some 12,000 acres of lands lying near and to the west of Hibbing and belonging to the timber firm of Wright & Davis. A total of 360 acres were selected in one connected tract along the north line of Township 57-21, being a strip 2 miles long and 1200 feet wide. Another tract close by was also taken, together with several others lying not far off, in the same town- ship. While all of these have been explored sufficiently to determine value for mineral, only one, and but a por- tion of that, has so far been opened, and it will probably be some years before any of the rest are attacked. During 1893 and 1894 the company, under direction of Mine Shovel Working in Frozen Ore, April, 1899. ORE F & STEEL COMPANY. From the time the mine was opened till now stripping has been almost continuously under way, and there have been removed something over 1,000,000 yards of earth and bowlders, with the result that an area of ore some 1800 feet long and 800 to 900 feet wide at its greatest width has been uncovered to the sky. Stripping over this body of more than 30 acres has varied from a few feet to some 35 or 40, and the wisdom of uncovering the entire area has been amply demonstrated since, and especially this year, when labor has been scarce and high priced. For while it is one thing to add men to a proposition where they count largely in the output, it is another entirely to add a steam shovel and its crew of 50 to 70 men, that can make an added output of 3000 to 4000 tons every ten hours. To the close of the present shipping season this mine has made a total output of 2,075,000 gross tons, of which 750,000 tons have been the work of the present year. Of 2 THE IRON AGE. these shipments about 80 per cent. have been the Mahon ing grade, which is guaranteed 63 per cent. of iron and 9.05 phosphorus, and 20 per cent. of the Beaver grade, which is about the same in iron and 0.07 to 0.08 phos phorus. There is ajconsiderable amount of ore in the mine running 66 per cent. and better in iron, but no shipments higher than Mahoning are figured on. Of the 750,000 tons sent out this sedson there were about 485,000 tons Mahon ing and 265,000 tons Beaver, the higher percentage of the latter being due to salesof non-Bessemer ore to outside onsumers. It is not the policy of the owners of this mine, who ‘are all consumers of ore in quantity, to come n the market withitheir product, and next year they will require for their own furnaces something less than 1,000, - 00 tous of this ore. In opening the mine a very complete sampling system has been adopted so that the grades of ore the shovels are to encounter the following year can be determined with November 9 1899 ber of the pockets from which a vessel has loaded it is no trouble to determine the average of its cargo. So closely have these results tallied with the determinations made at the other end that but little trouble is taken to assay cargoes at the dock. For all this work a considerable and very busy laboratory is required at the mine. No. 3 mine, that now opened, seems to extend east and west for a length of nearly 2 miles, with a width of from 600 to 1200 feet, though a large part of the area has not been sufficiently tested to fully determine its ore reserves. There is, so far as ascertained, a depth of ore over much of this area of from 100 to nearly 200 feet, giving a body of truly herculean proportions. It is a peculiar and interesting fact that the north line of the ore seems to correspond very closely with the north line of this property, and that the southwestern limit is also, for a distance, quite closely analagous to the Mahon ing line. To the south and east, however, are the vast | : i FO Fiy. 2.— General View of Openiny, Being Continuation of Fig. 3. THE MAHONING ORE & STEEL COMPANY. considerable assurance, with the result that a better mix ture can be forwarded, it is believed, and the shovels worked with more definite understanding of what they are doing than might otherwise be the case. The entire ore body is laid off in squares, and every 50 feet pits are sunk the depth‘of a level. From these pits careful sam- ples are taken and apalyses made, and the results plotted. In this way when the shovels are started at work in ore there is a general and quite close knowledge of what they will encounter.. However, as the phosphorus is not at all regular, and comes in streaks and pockets, neither this method’ nor any other can be infallible, and the final de termination by car as»ay is necessary. At Mahoning car samples are taken from each five cars, about 100 tons, which is a dock pocket full, and the result considered as the average of each car of the five. Each five-car lot thus taken is dropped into the same pocket at the ore dock, giving a sample from the mine assay of what goes from every pocket to the vessel. At the mine office is a board with receptacles numbered to correspond with the dock pockets at Duluth, and in these are kept duplicates of the car assays and the pocket average, so that given the num- deposits of the Lake Superior Consolidated Hull and Rust mines. These, with the Penobscot, appear to form a con- tinuous ore deposit from the west hmit of the Mahoning to the village of Hibbing, 144 miles, and extending from its southerly line for a distance of 4 mile or more. This ore body goes into and under a portion of the west side of the town of Hibbing, and the water works and well of the town are biilt on ore. Directly to the east and north of the town, and possibly connected with the big deposits to the west, are the Burt and Sellers mines of the Consol- idated company, together with the town site and Mc- Gregor and other properties that have been explored enough to show a large amount of ore. It is quite proba- ble that the various underground properties of the Con- solidated company at Hibbing contain more ore than Ma- honing. perhaps considera'ly more, and the gross tonnage to be mined about the town is beyond comprehension. At Mahoning, while there is not room for the running of a train in a circle into the mine and past the loading shovel, as is the case at Mountain Iron, there is room for the putting past the shovels of from 10 to 12 cars ata time. These 10 to 12 cars, handled by a powerful loco A Nn on ty at aE ey November 9 1899 motive, are loaded at the rate of 5 tons a minute by shovels whose’ dippers contain 5 tons each. The shovels work into a bank of ore about 23 feet high, each of which cor- responds to a level, and this ore is shaken up ahead of the shovels by powder. Holes are drilled the depth of the level; these are sprung with a stick of dynamite and then filled with five or six kegs of black powder, the explosion ef which loosens the ore for the shovel. At this mine some 800 kegs of powder are used monthly, with the result that shovels rarely break down and a steady output of 3000 tons or more to the shovel can be maintained. Much time is lost in switching and changing, probably not less than three hours a day on the average. A shovel crew, including trackmen, engineers, machine men, train hands, &c., varies from 50 to 70 men. THE IRON AGE. 3 is now building an ore dock 73 feet high and 65 feet wide, with 250 pockets of 250 tons capacity each, which will be ready in April, 1900. This will be by 13 feet the highest ore dock in the world, and both in width and capacity per pocket it will lead all others so far planned, It is probable that shipments from the Mahoning next year will amount to 1,000,000 tons. Some years ago the Cambria Steel Company bought a half interest in the Mahoning, and later the Republic Iron & Steel Company secured a small interest. Now the American Steel Hoop has a fourth, and the remainder is in the hands of consuming interests in the Valleys. It is a magnificent property, and has been handled with the highest skill and with thé utmost efficiency. Its annual shipments have been as follows: bey Cy 7 Re OE A Pep apne) , fi Fig. 3.—View Showing Two Ore Levels and Stripping Level. THE MAHONING ORE & STEEL COMPANY. At Mahoning the machinery equipment consists of three 65-ton shovels fitted with auxiliary engines on the booms for aiding the handiness of operation, and three 60-ton standard gauge locomotives. A portion of this equipment is maintained for a reserve in case of trouble. Mining is now done on the first and second levels. All stripping at the mine has been done under contract, Winston & Dear having had every yard of stripping since the mine was first opened. There is a charge of 271g cents a ton against every ton of ore from the mine in the shape of a royalty to the owners of the land, who originally took it for pine, and have sold that at a heavy profit on their investment. At the time these purchases were made there was no thought of what migbt lie under the surface. The Wright & Davis interests of Saginaw. Mich., have been the owners of this fee, but last year sold to the Eastern Railway of Minnesota, a subsidiary company of the Great Northern Railway. The mine is under traffic contract to the fee holders, and the rail rate to Lake Superior is 80 cents a ton. The haul is about 118 miles, heing almost a semi circle. For the expected increase of traffic another year from this mine and others on its line the Eastern Railway I ia a aa vista a bese acanseveuasseieisibadadvavasaeuinaee: 117,884 ee sonny tee tance hc etgamer ooamticaec ce conceit 167,245 MUNIN AET casters thsbanesharenecaun-ranenens coramreceecaexetees ieee MMOD ira i shen asinen ocdeicknareneneaeOeddaaneiges eagdensnacote NE ee een ae ae eer Pee 2,075,772 At no time have these shipments approximated the capacity of the mine, and it is hard to conceive what it might do if rail, dock and vessel facilities were adequate. The general aspect of the property is clearly shown in our engravings, reproduced from photographs taken by O. B Warren of the Mahoning Ore & Steel Company. The views Figs. 2 and 3 are practically a continuation of one another. —=_ The workmen employed in the Ohio Falls Iron Works, New Albany. Ind., were so overjoyed at the starting up of the long idle rolling mills on the 25th ult. that they fired 50 rounds from a cannon on the river bank near by in the evening . Press reports from Jeffersonville In4., state that last week nearly 100% men were idle at the works of the American Car & Foundry Company for lack of bar iron. The company have large contracts for such material, but their car orders seem to have been larger than anticipated. 4 THE IRON AGE. Physical Characteristics of Malleable Cast Iron.—lI. BY ERASTUS C. WHEELER, DAYTON, 0. The advantages and necessity for uniformity in mal- leable, when the same is to be used in castings subjected to the frequent and non-equal strains incident to their locations on machines, railway cars, &c., and developed under so many dissimilar circumstances, combined with varying temperatures, make the question of physical characteristics one of great moment. Until within a few years ago the best guide, with reference to quality, has been the cold bending tests given after annealing, and if metal has proved soft and malleable under these tests the material was accepted as successful. This test is still, for a great many purposes, a most reliable one, when light castings are being considered. With heavier castings, however, when diameters are %4 inch and over, it has been rather difficult to produce satisfactory cold bending tests, the main stay being in such cases the ap- pearance of fracture after cleavage break or shear; and it is with reference to the latter class of castings that physical tests are most applicable. As all heavy cast- ings are subjected to their service requirements when cold, it will be recognized that only in rare cases have they been called upon to withstand service involving any noticeable deformity in original lines. The successful casting is one which will withstand such service and still present the same lines as before. The material need not be so high in tensile strength to accomplish this end that malleability should be sac- rificed. Malleability in heavy castings does not convey the same meaning when comparison is made with light eastings. In light castings it is a soft, pliable and con- tortionable condition. In heavier castings it is the abil- ity to receive shocks and blows without breaking or bending, and this in no degree means excessive tensile strength or excuses shortness and hardness. The ques- tions are often asked, What will your iron stand? What can be done with it? Will it bend back upon itself? All are quite natural questions, but when speaking of heavy work they do not exactly fit the case. Nor is the M. C. B. drop test for draw bars a satisfactory test for quality. There have been couplers known to stand a number of blows in excess of the prescribed specifi- cation, but in service the group represented by the tests has failed signally. There is certainly some patent cause for this, not easily explained. The perfection reached in open hearth steel casting is directly due to the lines drawn relative to chemical and physical limits. There are as yet no specifications for malleable touch- ing either, although one railroad in the East has desig- nated the tensile strength desired in its castings. It is a question whether malleable concerns are prepared at the present moment to guarantee their product fol- lowing somewhat these lines, as there has not been that liberal usage of the laboratory and its accompanying ad- vantages to warrant confidence in each succeeding heat poured. But it is believed that the near future will find all prepared to welcome specifications. There will be no greater incentive possible to any concern than the knowledge that they are working to “limits.” As it stands to-day, the make up of metal varies with every individual concern, and while thor- oughly reliable for local usages, suffers by comparisons in the interchange of parts sometimes necessary in rail- road practice. With the advent of restrictions will come the uniform shrinkage so eagerly wished for at present. A physical test for malleable iron which calls for more than 45,000 pounds does not guarantee the ideal meta! for railroad work. It will possess that doubtfully bene- ficial strength which shows to great advantage upon reports, yet has in it an element of hardness which pre- cludes the possibility of long service. Physical testing is just beginning to attract the attention due its impor- tance, and perhaps the delay in this matter has been caused by the fact that malleable, like steel in the past, has now passed through all of its experimental phases. The idea of physical specifications is very new, but it will prove a most excellent ground gainer to the careful manufacturer, whose pride in his output amounts to a question of honor. With the adoption of physical stand- ards will arise the necessity of employing chemists in all works, for the effects of the metalloids upon physical characteristics are well marked. It cannot but prove to be a source of great satisfaction to careful producers, for they will be guarded with a bulwark of safety. The malleable casting of to-day is one of the greatest offer- ings in the whole iron industry, representing as it does many long years of patience in perfecting it, and yet the real work is only begun. There are many concerns making good malleable, and not a few better than be- fore. The reason seems quite obvious. A few years November 9 1899 ago chemistry was adopted into the malleable art and was stamped a great thing, but in some localities it was not entertained with the respect due its worth. Ques- tioned and suspected at all points, it was finally dis continued, with the result that some firms have gained nothing whatever from the experience, while others are enjoying the undeniable benefits procured by judicious management. The future development of the malleable casting must be along the lines of chemical and physi- cal testing. The Influences of Heat Conditionsin Furnaces Aflect- ing the Physical Characteristics. The heat treatment of metal during melting and an- nealing has a very important bearing upon its developed tensile strength, elongation, &c. The generation of ex- cessive temperatures always promotes the chances of burning, and while metal may be burning the chemical aspect changes but little, while the molecular composi- tion is receiving a shock from which it never recovers. What is burnt iron? And why does iron become sus- ceptible of burning ? These are seasonable questions upon which there has been considerable discussion and many theories advanced, yet there are many skeptics upon the subject. Iron is burnt mainly through the generation in melting furnaces of higher temperatures than those prevailing during the initial casting at blast furnaces. Superheated metal is always to be feared re garding quality. When a heat is charged in which all the metal is “low” or high silicon pig the opportunity for burning is not as great as in heat charged in which the metal is * high“ or low silicon. The first mixture has an element of contained heat to balance heat of blast while melting, but the latter has no resource in this direction whatever. If these heats were charged following each other there would be, nine out of ten times, no changes possible in the method of firing, consequently no great variance in heat of furnace, and yet there should be some counteracting agency at work in the high mixture to offset excess heat of the low mixture. Superheated metal, or metal not high enough in silicon to hold fluid- ity, is readily discernible in ladles by the rapidity with which it sets. This metal will in the physical tests show considerable tensile strength, but a small per- centage of elongation. This latter is due to the fact that the “ clinging ’’ propensity of the molecules has been injured beyond redemption. There is no tearing of the metal in testing machines previous to the break; it “goes ”’ all at once and there is that omnipresent heavy white edge to characterize it. The mixture high in sili- con should obtain its tensile strength from its silicon- carbon content and elongation from the undisturbed state of its molecular condition. The mixture low in silicon should receive its tensile strength from the den- sity of the molecules and its elongation and reduction of area from the low carbon content. When the heat of blast through the melting furnace is too strong, owing to an excess volume of air being introduced, the metal after melting will start to oxidize. This metal upon reaching its crucial stage will then be in condition to burn readily, having already exhausted considerable of its reserve qualities. It will be readily seen that this condition will affect the tensile strength most naturally. The very choicest irons thus turn out poor material, whereas if the heat had been allowed to “come up” slowly we could have anticipated the best results. A well calculated heat will (unless something unforeseen occurs) invariably produce excellent results if worked slowly. The action of the annealing ovens is also well de- fined in this direction. Whether the fuel used be coal, coke, gas or oil, the result will be the same if heat is brought to its highest point before the metal is ready to receive it. Burnt iron in the anneal is no uncom- mon feature, and, generally speaking, it is the result of carelessness. The real value of the annealing depart- ment is very often overlooked. It is often in charge of men whose compensation is low and who (to their credit must be said) do their work, as a rule, in proportion much better than their companion foremen of other departments. But here, as elsewhere, there has not been that confidence in their work which should guide them. They work by precedent and ask no questions. The theory of the anneal is sometimes a ticklish one with them. The most carefully prepared metal from melting furnaces can here be turned into worthless cast- ings by some slight inattention of detail. The highest point in temperature for the annealing should be regis- tered in each foundry, and kept there by the daily and frequent usage of a thermometer constructed for that sole purpose. The uneven workings of furnaces ac- counts for many a batch of rejected castings. These latter conditions are more likely to occur in plants where coal and coke are used in ovens, as it is simply impossi- ble to regulate heat under these prevailing circum- +g Masa ee foe ee ee Sia November 9 1899 stances. With oil and gas the danger is greatly re- moved and, barring occasional changes in pressure, the heat is uniform. Changes in the heat will at once affect the quality of iron. Steady, continued heat insures soft castings, while unequal temperatures destroy all chances for successful work, though the initial metal was of the most excellent quality. The question as to the effect for good of charging the packing with sal ammoniac is at the present mo- ment being agitated very generally, and it is with some hesitancy that the writer expresses himself. There are some concerns who never charge their packing, and claim as beneficial results as those using the prepared packing. They claim that there is nothing which an- neals but heat. However, fact is fact! The experiment was tried, and most successfully. One set of test pieces was taken and packed in “ dead ” packing and the other in “charged” packing. These bars were poured in each instance from same heats, from same Jadles and in the same molds, and were packed in furnaces with the heat conditions alike for both. With packing charged in some manner the cast- ings will be softer, having more elongation and greater reduction of area. Unprepared or “ Dead ” Packing. Per cent. Total Total elonga- earbon, carbon, Elonga- tion Number of hard soft tion, in test iron. iron. Tensile. 6inches. 6 inches. Ae 3.23 3.01 48,600 0.37 6.16 cir ease 3.39 2.92 47,400 0.80 5 ae 2.90 46,800 0.27 4.50 eee 3.10 2 90 47,400 0.31 5.16 Prepared or “ Live’’ Packing. Per cent Total Total elonga- earbon, carbon, Elonga- tion Number of hard soft tion, in test. iron. iron. Tensile. éinches. 6 inches. rr 3.23 2.90 18,900 0.43 7.16 Bisc.sace Ge 2.81 15,600 0.33 5.50 ee 2.97 2.72 18,600 0.36 6 _ Seer 3.10 2.82 15,900 0.34 5.83 These tests show unmistakably the treatment due a physical test by proper handling of annealing depart- ment. Be not deceived. It is true that without prepara- tion of the packing the annealing may be carried through, and the appearance of the castings for months may not vary, but they will not be soft. And in the case of prepared packing the identical same test bar gained from 1 to 1% per cent, in elongation in all cases. The discontinuance of charging packing is an economical move with reference to handling work cheaply, but in = instance of heavy work it is costly practice in the end. Chemical Composition Affecting the Physical Characteristics, That the chemical components exert a powerful in- fluence upon the strength of iron is an assured fact, though not as fully understood in the case of malleable as with gray iron and steel. The metalloids most injuri- ous would be singled out by the proposed specifications and limits placed thereon. Here again will that ever prominent feature of heat conditions assert itself. The metalloids occurring mostly in pig iron may be grouped with reference to their peculiar effects upon the phys- ical showing of tests, and thus we would have in the finished metal silicon, manganese and graphitic car- bon working together for the strength, and sulphur, phosphorus and combined carbon affecting the tensile strength. With silicon and manganese in their certain and relative proportions there can be no doubt of their beneficial action toward strengthening the product, and almost, it may be said, when in excess to the point of “shortness.” Very often the metal has shown in tests and finished castings a steely fracture, and almost in- variably has the same been explained by the presence of too much silicon. Chemical research has also demon- strated it. When the silicon is about 0.75 in finished metal it will show higher tensile strength and less elon- gation, for the reason that had the same mixture been properly worked the silicon would have been reduced, but now it resembles, after a manner, gray cast iron, with its correspondingly high silicon content. With this high silicon comes a resulting condition—namely, higher carbon in the graphitic state. There cannot be a high silicon and low carbon in material, as these two ele- ments must act jointly in eliminating each other. The low silicon-carbon content must be maintained when calculating heats in which strength is desired. Silicon holds the carbon in certain ratios, as in the making of steels. That low total carbon is the secret of attaining reduction of area and elongation is demonstrated beyond & possible doubt. In the following tests there will be found some of these facts demonstrated—namely, with THE LRON AGE. 5 low silicon and carbon comes the reduction of area and elongation: Reduction Elongation Number of Total of in test Silicon. carbon. Tensile. area. 6 inches, 219.. —_ 0.62 2.20 17,350 3.24 5.33 Sib eccenccca ODN 2.40 418,950 3.42 6.50 . a Y 2 32 15,370 1.333 5.83 Wl. cccccce 0.47 2.07 42,050 1.83 7.83 Manganese in the latest practice is kept high, mainly with reference to the combining of carbon in the hard iron, with that easing off of liquid shrinkage so preva- lent in the older working. In the anneal manganese stands practically unaffected by the heat generated there, and so is an element of strength all through. The reduction of area and elongation are the direct results of low carbon. It is simply a metallurgical imposs!- bility to have the reductions, &c., with a-high carbon content. With sulphur and phosphorus comes a weak- ening of malleable. Their action and effects are clearly drawn, both having a hardening tendency, making metal stiff. Often in malleable foundries castings containing carbon in the graphitic condition are passed through the hard iron inspection to anneal, and these castings show high tensile figures, but with small reductions. To obtain an iron which will work under the hammer while hot and without caking (this is a very trying oper- ation) there must be this low silicon-carbon-phosphorus feature. Malleable iron with high carbon will not bend back upon itself. The following figures are from heats in which these negative features have been prominent: Per Reduc- Eionga- Number Per cent. tion tion of cent phos- Total of in test. sulphur. phorus. carbon. Tensile. area. 6 inches. 220....-. 0.052 0.272 4.46 49,500 7 3 , ee 0.197 3.01 49,000 1.3 2.33 , 0.047 0.216 2.42 47,620 2.@ 1.88 248...... 0.058 0.172 2.67 51,000 0.82 1.50 The most destructive features of high sulphur and phosphorus are the small cracks, like incisions, over the surface of castings. In physical testing these cracks play a considerable part in the question of elongation, too small at times to be seen, yet the stretch of the metal taking place in these apertures leaves no great elonga- tion in the metal. The combined carbon in annealed castings, which is, in most cases, very low, still has a hardening effect. Though not prominent, it still con- tributes. A very beneficial move was made some time since by a blast furnace management in Ohio, when they put a burden of selected ores in stack and cast the iron into iron chills. This iron was ideal for malleable, hav- ing a low silicon-carbon content, with phosphorus and sulphur in reasonable limits, and was a great step for- ward toward the end hoped for in coke iron. But at the time of its initial appearance it was not taken up witn the favor it should have received, and was therefore not appreciated, being thought premature. A heat o* this pig metal under the writer’s observation developed the following somewhat remarkable results: Forty-seven thousand pounds tensile strength, 4.33 per cent. reduc- tion of area and 8 per cent. elongation. Stiffness with malleability. It was a distinct move in the right direc- tion toward uniformity of material. Physical Characteristics of Malleable Iron Before Annealing. In considering this topic we will call the heat test— i. e., the test made at the furnace to determine whether carbon is in combination—a physical one, and the en- deavor will be made to demonstrate that this test, while carrying great weight as to the condition at the point of pouring the metal in the furnace, does not possess the necessary reliability and does not, strictly speaking, furnish a fair criterion of the metal. Here again is en- countered a heat condition. A furnace charged with 10 or 12 tons of metal, and taking from one-half to three-quarters of an hour to run out, according to the size of the tap hole, cannot produce metal which may be called uniform. As soon as metal has been brought up to its highest heat, carbon being in combination, the quicker it is gotten out of the furnace the better will be the ensuing product. After the highest heat point has been reached the continued blast necessary to maintain the heat in the metal to a suitable point for pouring works havoe with those chemical metalloids which affect fluidity, but, on the other hand, enhances the chance of a better iron physically by serving to reduce the carbon and silicon. Thus it will be seen at a glance how im- possible it is to rival open hearth steel regarding unl- formity, or even, in many cases, a well managed cupola on gray iron. In open hearth steel practice, when car- bon and silicon have been reduced to a certain specified point, the “ heat ” is drawn in bulk and there is no fur- ther chance for a chemical or molecular change. In gray iron cupola practice new raw material is con- stantly comipg in contact with fuel, and insuring, in a way, the continued grade of metal at point desired. In eee ame TF RT a ee SE ee ee re Fe ee PE ent ne RE 6 THE IRON AGE. the air furnace, on account of the length of time the liquid is kept in contact with the flame incident to pour- ing, it of necessity affects the molecular conditions, and in the case of pouring heavy castings (and this is the class of work being considered under this heading) the last iron out is better than the first. There cannot be a doubt but this fact accounts in a measure for the vari- ations met with in material after the anneal. In heavy work mixtures the first metal poured from the furnace will be “softer,” or higher in total carbon, consequently inclined to be of an open grain, and the last metal is denser. being lower in total carbon, &c. That there is a marked and influencing difference be- tween extremes of heat (from the moment the metal is tapped until run out), which explains many breakages, is clearly demonstrated by vests here submitted, taken in each instance from same heat at extremes: First Iron. Elongation Total in carbon, Silicon. Tensile 6 inches. Sees 3,52 0.91 46,500 4.33 RE 3.37 0.72 52,000 3.37 See 0.68 49,000 2.93 __, MISA 3.29 0.89 13,000 3 3 Last Iron, Elongation Total in carbon. Silicon. Tensile, 6 inches, a > a 0.62 42,700 6.16 _ Sees | 0.68 $6,000 5.28 _ eee Ys 0.62 12,000 4.27 Ee 3.07 0 72 12.000 3.33 In keeping this idea of desired uniformity ever be- fore us, the question naturally arises, How can the re- sult be otherwise, using the present reverbatory fur- nace ? With light work mixtures the differences are not marked to any great extent. In heavier work there is a remedy, and one tending toward a possible solution of the question. It has been the writer’s privilege for two years to have charge of several Siemens-Martin acid open hearth furnaces producing malleable iron, and during that period he had great opportunity to study the problem in hand, and believes that thorough uni- formity is possible and necessary. Owing to a peculiar foundry construction it was not possible for the molders to catch the metal at furnace spout, and it was not practicable to carry metal to them in “bull” ladles. Therefore the whole heat of 8 tons was tapped into a previously heated ladle and conveyed by electric crane to a suitable place in the foundry for pouring. The tests at the furnace were made until just the point desired was reached and then the furnace was tapped. In less than one minute the contents were in the ladle away from any possible further chemical or molec- ular change. This metal was uniform! The results of this peculiar practice gave the castings thus pro- duced a great prestige over the ordinary air furnace metal. The physical tests were most encouraging. The adoption of this style of furnace in malleable works would be a most radical change in founding, though not practical in present erections. But with the neces- sity of a better and more thorough refining of coke iron this idea is brought forward as possibly an outcome of the situation. The most satisfying feature about it is that it is no experiment. Here we have at this early day a thoroughly advanced material claiming the atten- tion of more thoughtful producers. Some of the physical tests are remarkable and show to great advantage the points mostly desired in rail- road castings: Number Reduction Elongation of of in test. Tensile. area. 6 inches Dicieanch ba dusensees neaetens 52,000 6.42 7.33 Seer 10.12 6.50 cca eaheseun ab sdsenedcnad 18,000 11,12 7.00 The appearance of hard iron tests are forerunners of the quality of iron after annealing. Seen under the magnifying glass are many peculiar phases, all of which have directly traceable bearings upon the result- ant product. In the light work mixtures the tests show a distinctly rough and disjointed condition of the par- ticles, owing to the fibrous nature of the metal when in hard iron, and, having a high carbon content, break with the toughness of original pig metal, there being in such instances but a small loss in carbon. After an- nealing, this metal, which in the hard iron was so tough, is now lamentably weak, owing to this excessively high carbon. In the tests for heavy work mixtures the microscope reveals an entirely different aspect. There is that crys- talline glacial formation, converging toward the center, owing its formation to the intensity of cooling strains, and which in many cases when iron is run too “ high” causes castings to crack. Then, again, is found a test, with crystals as large as in a No. 3 iron, having a black circle around its edge. This almost invariably comes from a higher percentage of sulphur which has com- November 4%, 1899 bined carbon higher, relieving somewhat the internal strains. A test piece 1 inch in diameter will show a complete combination of the carbon, but one 2% inches in diameter, poured at the same moment from same ladle, will show graphitic carbon in bulk. In cooling tests in hard iron, preparatory to tapping out, the test will, if the carbon is combined, crack with a distinct ring, whereas if there was graphitic carbon present the latter would assemble in small groupings, holding the metal together and resisting the action of water. The most satisfying test in hard iron is the “ wedge,” giv- ing, as it does, an early criterion of the capabilities of the heat. This test acts not only as a physical test, but also serves as a fluidity gnide. When carbon is only about one-half combined with the iron, and two large tests should be poured, one of which will be cooled with water and the other allowed to cool by itself, the former will show small and regular clusters of graphitic carbon remaining, while the latter will resemble very closely a light colored gray iron, the crystal groupings being very dense. This latter condition arises entirely with the heat remaining in test for a considerable period, thereby holding that proportion of graphitic carbon re- maining in suspension. In the test cooled with water the graphitic carbon, being in excess of the absorbing qualities of the iron at that particular point in heat, has been driven into the small group, as before de- scribed. These above mentioned phenomena occur mostly when the silicon content is high, particularly in light work mixtures, and show to great advantage the altering phases of carbon. Carbon is never thoroughly combined with iron until the silicon has been greatly diminished. A high percentage of silicon will hold car- bon in suspension, preventing the combination so essen- tial in heavy castings. In light work with its high silli- con and carbon, metal is chilled and carbon is combined by contact with damp sand. In malleable cupola prac- tice this is about the only method of affecting carbon, there being practically no molecular change possible in cupola while melting. A low total carbon and silicon— a certain percentage of sulphur being present—has the effect of giving test pieces their very close fracture, re- sembling the high state of glacial crystallization found in a No. 6 or No. 7 iron. Higher carbon and silicon and lower sulphur keeps the test pieces gray for a continued period, necessitating higher heat in furnace, while at the same moment affecting the life of fire brick in no small manner. The malleable casting, when cast, is subject to both internal and external strains, according to section. The malleable draw bar with surface chills and hard cores has been relieved of many detrimental features. But with the lighter castings and patterns of unequal diameters there is always the likelihood of cracking under casting strain. There are several safe- guards against this trouble; one of the best is the usage of small quantities of aluminum in ladles. There have been many shapes under personal ob- servation which, when molded, presented a great ques- tion regarding best method for saving same when cast, the only resource in some cases being a cooling down in a previously heated furnace over night. Physical Test Bars. If there is to be any possibility in the future for uni- formity in malleable castings there must be adopted some general method of testing, which will be broad enough to cover the inequalities of comparative work- ings. To sell malleable under chemical and physical clasifications is; at the present moment, an impossibility. This also was the history in steel castings for many years, but with far sighted experiment the point has been reached when producers may guarantee their metal with safety. The adoption of a test bar for general use could be decided by some discussion. We believe, how- ever, that it should be exactly 1 foot long, and when molding a chill should be placed upon either end, to thus attain the greatest shrinkage. A micrometer reading should then be made of bar before annealing and shrink- age for shop practice established. Malleable concerns making agricultural shapes, &c., cannot afford to de- viate in their founding practices, as castings which are supposed to fit snugly over other shapes must be made of metal in which the correct amount of shrink- age is assured. When metal is said to shrink \ or 3-16 inch to the foot it is understood that this is hard iron shrinkage in all cases. The metal in annealing expands, and finished product shows rarely over 1-10 inch shrink- age from original measurements, bringing it finally close to gray iron shrinkage. To illustrate above statements the following figures will prove interesting, one set showing hard iron shrink- age and the other set the shrinkage found after anneal, the test bar being exactly 1 foot long: Hard. Soft. 0.225... ..-0.090 DP cndennenpccnnes #o0Abs phatohndens nithassnwbineed>s ineseseae 0.100 a Ri ae November 9, 1899 The above figures represent a very fair working, no freak heats being considered in figures given by writer. A very convenient form for the bar is a round section which tigures about 1-3 square inch. The square bar is absolutely without one redeeming feature when consid- ering for malleable work. The pattern should have 6 inches in the clear in center and be enlarged toward ends for the grips of the testing machines. In molding bars the gates should be cut upon the side of the bar near the ends, but not on the ends. The pattern should be well proportioned, bringing the larger end sections to meet the smaller middle section by an easy gradation, thus avoiding the shrinkage in bars which causes them to break in the grips of the machines. With the present air furnace practice test bars should be poured as near the middle of the heat as is possible. The number of each heat being molded upon the end of the test bar will, while following the physical results, also furnish a reliable guide in determining the chemical composition of any heat desired. The test bar is the surest method of following a heat’s working through the process. The matter of having bars tested brings the matter down to a question of local coloring. Many concerns will argue that the physical test is not of enough importance to them to warrant purchasing a machine for their use. Physical testing is a recognized necessity with all the larger concerns producing railroad castings and these works will have their own apparatus. A very good plan for smaller works to pursue would be to make some ar- rangement with parties having machines for a test at least once per week. Riehlé Bros., Philadelphia, manufacture a small ma- chine, 50,000 pounds capacity, which is ideal for malle- able works. Since the test bars are 1-3 or % inch diame- ter the capacity is far beyond any possibility in the metal. This machine, when connected with a 1 horse- power motor, is very convenient. Advantages Anticipated Physically of a Basic Malleable. There is not one branch of the iron and steel indus- try, with the exception of malleable cast iron, which has not undergone some very radical changes in mode of production during recent years, and all have proved to be benefits physically. With the tightening of the iron market and loss in choice of buying iron, the producer finds an awkwar