Galvanized iron

“ Burning which is not accompanied by any of the appearances of ordinary burning is known as oxidation.
The tendency of iron to rust lessens its efficiency and value, and many devices have been introduced to prevent rusting. A coating of paint or varnish is sometimes applied to iron in order to prevent contact with air. The galvanizing of iron is another attempt to secure the same result; in this process iron is dipped into molten zinc, thereby acquiring a coating of zinc, and forming what is known as galvanized iron. ”

“ Ordinary galvanized iron soon loses its galvanizing cover, and the iron then is liable to rust. Attempts have been made to use sheet zinc and other alloys, which are cut or punched into nets with square or diamond-shaped holes. ”

“ Fig. 22
In placing galvanized ironwork on the sides of steel-mill buildings, it [Pg 34] is best to construct the necessary framework between the main supporting members of the building of light angles, or tees. These should be furnished punched with 3⁄8-inch or 5/16-inch holes, to which the galvanized iron may be riveted, it being best to mark the galvanized iron in the field and punch it there. This may be done without much difficulty with the usual light gauge used for this purpose. It is sometimes necessary with this construction to flash around the window and door heads with IX tin. ”

“ In reality, however, a galvanized iron rod conducts as a combination of iron and zinc, in which the zinc possesses a much higher conducting power than the iron. Zinc surpasses iron in this particular at least three times. All the statements of conductivity that have been drawn from galvanized iron conductors have hence been given much too low. The influence of a too powerful electrical discharge upon a conductor of galvanized iron is, in the first instance, to strip off its coating of zinc by melting this more readily fusible metal. ”

“ When galvanized iron is immersed in a corrosive liquid, the zinc is attacked in preference to the iron, provided both the exposed parts of the iron and the protected parts are immersed in the liquid. The zinc has not the same protective quality when the liquid is sprinkled over the surface and remains in isolated drops. Sea air, being charged with saline matters, is very destructive to galvanized surfaces, forming a soluble chloride by its action. ”

“ As zinc is one of the metals most readily attacked by acids, ordinary galvanized iron is not suitable for positions where it is to be much exposed to an atmosphere charged with acids sent into the air by some manufactories, or to the sulphuric acid fumes found in the products of combustion of rolling mills, iron, glass, and gas works, etc., and yet we see engineers of note covering-in important buildings with corrugated and other sheets of iron, and using galvanized iron tie rods, angles, and other constructive shapes in blind confidence of the protective power of the zinc coating ”

“ The steel is brighter and more silvery than the iron, but my experience is that the steel will last only two or three years; sometimes one season puts steel pipes out of commission, whereas galvanized iron will last indefinitely. ”

“ In the form of an electrically deposited coating on sheet iron it is in great demand by the building trade for cornice work, etc., under the name of galvanized iron, and is exported in enormous quantities to all new parts of the world for use as roofing and siding in those temporary structures reared for protection against the weather in lands where lumber is not available at reasonable cost. ”

“ The same principle of depositing one metal upon another in minute atoms has produced galvanized tinned-iron—iron which will not rust upon exposure to weather, and thus applicable to many purposes of building—and iron which can be applied to many objects of utility with greater advantage than tin-plate. ”

“ We know in fact the existence of iron in two states, so dissimilar, that in the one, it is to the electric chain like platinum, and in the other it is like zinc; so that powerful galvanic machines have been constructed of this one metal. ”

“ Manufactured irons differ very greatly amongst themselves. For one kind is tenacious in its nature, and this is the best; one is of medium quality: another is brittle, and this is the worst. Sometimes the iron, by reason of the excellency of the ore, is wrought into steel, as to-day in Noricum. From the finest iron, too, well wrought and purged from all dross, or by being plunged in water after heating, there issues what the Greeks call στόμωμα ”

“ The flux universally used in smelting iron is limestone. The purpose and action of this flux has been explained briefly in describing the chemical reactions which take place in the blast-furnace.
Properties of Cast Iron. The product of the blast-furnace, as already said, is cast iron. As this is the preliminary form of practically all iron for making both wrought iron and steel, its properties require a brief description. Cast iron consists of metallic iron combined with at least 11⁄2 per cent. of carbon and smaller percentages of silicon, sulphur, phosphorus, and manganese ”

“ Some kinds are broken up to be used as foundation for roads; others are granulated by being run into water, and so made into cement. Over in Germany, where the ores are rich in phosphorus, they grind up the linings of the furnace to make phosphatic fertilizers for the farmers.”
“Then,” said Dr. Crandon, “the making of iron involves the use of chemistry, doesn’t it?”
“It certainly does,” answered Mr. Prescott; “from the chemical composition of ores to the finished product. We are learning a great deal just now from the chemists about steel alloys. ”

“ On the application of heat in furnaces, constructed for the purpose, the charcoal unites with the oxygen of the oxide, reducing it to the metallic state, and escapes in the form of carbonic acid; and the lime, if the ore be argillaceous, unites with the clay, forming a kind of glass, which floats on the melted metal. When the iron is suffered to run into moulds, prepared for its reception, it usually takes the name of pig iron.
Manufacturers distinguish cast iron by its colour and other qualities. The white cast iron is hard and brittle, and can neither be filed, bored, nor bent. ”

“ That is, as soon as a vessel costing millions of dollars leaves the docks, she enters into active competition for a place on the junk pile."
The greatest improvement that can be imagined in the iron situation will be in the discovery and use of alloys or mixtures of iron with other materials. Steel, the strongest of all forms of iron, is an alloy of iron and carbon, and for various purposes these are further mixed with nickel and silicas. Many other alloys have been discovered within the last few years, and each makes possible new uses for iron requiring greater strength. ”

“ Though many trials have been made in working extra-terrestrial metal, all have hitherto failed; the phosphorus, nickel and its alter ego, cobalt, render the forgings, in our present state of technology, too brittle for use. Terrestrial or telluric iron is again divided into two classes—the nearly pure ore and the native steel. According to the schedule of Rosset:
100
Iron is a metal not cast and malleable. ”

“ During the melting of the charge the heat is kept as high as possible and the molten iron is “puddled,” i. e., stirred, by the “puddler” or his helper with a “rabbler” or iron bar. In order to take out the phosphorus and sulphur, which for best results should be removed before the carbon is eliminated, the heat of the furnace is lowered somewhat as soon as all of the pig has melted, and some iron oxide is mixed into the “bath” of molten iron and cinder. Most of the phosphorus and sulphur are chemically acted upon and pass into the cinder which covers the iron. ”

“ But since modern methods of manufacturing have been adopted, tons of metal, which would have been classed as iron if judged by the cooling test, are at present known as mild or soft steel.
Steel may properly be defined as an alloy of iron with carbon, the latter not exceeding 1.8 per cent; the materials are completely fused and poured into molds, allowed to cool, and then rolled into shape. In the processes of making wrought iron the materials are only partly fused and are not cast into molds, but are taken out of the furnace in a soft, pasty condition suitable for immediate working. ”

“ Open-hearth iron is practically pure iron, having no constituents or slag inclusions which materially affect its properties.
2. Wrought iron, for all practical purposes, is pure iron 86except for its content of slag. It is the only one of the iron family which does normally contain slag.
3. Neither open-hearth iron nor wrought iron contains carbon in appreciable quantities.
4. The distinguishing and active element of the steel family is carbon. With increase of carbon the hardness of the alloy increases as does its tensile strength, but the ductility (elongation or stretch) decreases. ”

“ It is so highly 75refined that it can hardly be called steel at all but is often called “open-hearth iron” or “ingot iron.” It is probably the purest iron on the market in commercial quantities to-day. While in the chemical laboratory iron of considerably greater purity can be made, for a commercial product this is remarkably pure, seldom containing more than 1⁄4 per cent of elements other than the metal, iron. ”

“ No one knows just when, with increase of carbon, steel ceases to be steel and becomes white cast iron. There is no definite dividing line either in chemical or physical properties. The changes are extremely gradual throughout the scale. Aided by the microscope, modern physical chemistry has disclosed the fact that alloys of iron with carbon “freeze” from molten to solid condition according to two different laws. ”

“ It was only after the next great advance that we found man utilizing iron for his purposes of civilization. This metal, which with us is so common, was in those days very expensive, so much so that it could be used only for purposes of war and as the gifts of kings.
But the world was traveling fast and it was not long before the iron-carbon alloy, steel, was produced. Even so, many hundreds of years elapsed before the present wonderful age was ushered in through the great inventions of Henry Bessemer and the Siemens brothers. ”

“ The rusting of iron is almost entirely checked, in pure air, by galvanising or coating with zinc. It is used for nearly every other purpose in connection with building, and it is difficult to understand why it should be discarded on account of its liability to decay for this particular purpose, where it is always under supervision. ”

“ As a commercial product, such as is used in the arts and manufactures and by the smith, it is always combined with other substances, such as carbon, silicon, and phosphorus.
Iron is distributed through the earth very widely, but not always in sufficient quantities to make its extraction from the ore profitable; consequently the ores used for the extraction of iron are somewhat limited. There are four general grades of iron ore, which are known by the following names: magnetite, red hematite, limonite, and ferrous carbonate. ”

“ An important feature in the process is, that by stopping it at a particular stage, immediately following the boil, before the whole of the carbon has been abstracted by the oxygen, the crude iron will be found to have passed into the condition of cast-steel of ordinary quality. By continuing the process, the metal losing its carbon, it passes from hard to soft steel, thence to steely iron, and last of all to very soft iron ”

“ The defect of breaking when cold, has been attributed to the presence of phosphorus by high authority. There are, however, ores in this country, containing a phosphate of lime, which yield iron of excellent quality.
A mixture of sulphur and carbon deprives iron of its property of welding, and in the highest proportion gives the opposite defects of being both red and cold short.
Ores of iron contain the earths, silex, alumina, lime, and magnesia. With the bases of these earths the metal is capable of forming alloys ”

“ One has no difficulty in realizing that these flakes, which cut in every direction through the metal, make it structurally weak, especially toward a sudden blow.
No. 1d shows a typical section of wrought iron cut lengthwise of the rolled bar. It will be noted that, as in photomicrograph No. 99b, there are no graphite flakes.
In the process of wrought iron manufacture practically all of the carbon of the original pig iron is burned out, leaving little besides the iron itself and some viscous cinder or slag. ”

“ When the metal thus prepared is exposed to humidity, the zinc is said to oxidize slowly by a galvanic action, and to protect the iron from rusting within it, whereby the outer tinned surface remains for a long period perfectly white, in circumstances under which iron tinned in the usual way would have been superficially browned and corroded with rust. ”

“ There is, however, a tendency on the part of some owners to return to iron as less liable to the pitting caused by the galvanic action arising from want of homogeneity in the steel; a vessel’s bottom, unless well guarded by protective compositions, being frequently severely corroded, generally in small pits the size of a pea, but often extending to large patches. ”

“ Thus it is capable of the widest variety of uses, being soft when ductility, fibrous when tenacity, and crystalline when hardness is required. Its variety of transformations is something wonderful. Meeting iron, or even iron at its best in the form of steel, in the same field, it easily vanquishes it at every point. It melts at 1,300 degrees F., or at least 600 degrees below the melting point of iron, and it neither oxidizes in the atmosphere nor tarnishes in contact with gases. The enumeration of the properties of aluminum is as enchanting as the scenes of a fairy tale. ”