Iron foundry

“ Ordinary cast iron, while strong and hard enough for many purposes, still is brittle by reason of the large proportion of carbon and other impurities which it contains. These impurities may be burned out in the puddling process, and the nearly pure iron thus obtained, called malleable or wrought iron, has a toughness enabling it to resist far greater strains than cast iron can stand. Intermediate between the two irons, and containing one per cent of carbon, more or less, is still another product, steel, which may be made even more tenacious than wrought iron, or even harder than cast iron. ”

“ 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. ”

“ CHAPTER XI. IRON—NICKEL—COBALT—ZINC—CADMIUM. IRON.
Iron rusts or oxidises very readily, and, consequently, is rarely found in the metallic state in nature; such native iron as is found being generally of meteoric origin or imbedded in basalt and other igneous rocks. It chiefly occurs as oxide, as in magnetite, hæmatite, and in the brown iron ores and ochres. Chalybite, which is carbonate of iron, is an ore of great importance. Iron is found combined with sulphur in pyrrhotine and pyrites, and together with arsenic in mispickel. ”

“ Billy looked at him questioningly.
“That was rather technical, wasn’t it, Billy? You see, I was talking to a technical man. Just between you and me, meteoric iron comes down from the sky, from what we call shooting stars. Sometimes large pieces are found. I suppose that much of it falls into the sea. It is the purest iron that has ever been found.”
“What about magnetic iron?” asked Dr. Crandon. “Where does that come from?”
“At the present time,” answered Mr. Prescott, “most of it comes from Sweden and Norway. It makes the best kind of steel. ”

“ Primitive man could find copper and tin in their pure state but the only pure iron he could find was the little which fell from heaven in the form of meteors, and even this was not perfectly pure for meteoric iron is also mixed slightly with other metals.
The iron which lay about primitive man in such abundance was buried and locked tightly in an ore. To separate the iron from the other substances of the ore was by no means an easy thing to do. Iron can best be extracted from the ore by putting the ore in a fire and melting out the iron. ”

“ Prescott, “just remember three things: fuel, blast, and hammer—power, of course, behind the hammer. It’s the different variations that men have been making on those three things that have brought iron where it is to-day.
“Iron ore has so many things besides iron in it that the problem has always been how to get the impurities out.
“The old blacksmiths used to put it in the fire and hammer it; put it back in the fire and hammer again, until they worked most of the other things out. They made what is called forge iron. ”

“ Reaumur, who about 1722 discovered the annealing process, used iron oxide for the purpose. The white iron was packed in iron ore or mill scale. At the high temperatures employed the oxygen of the ore in some way not yet definitely known, gradually removed the greater amount of the carbon from the casting. It has always been a scientific conundrum how a solid, iron oxide, surrounding another solid, a piece of white iron, could remove from the latter its carbon when neither of them melts nor mingles with the other. ”

“ The quantity of iron in some samples falls as low as 17 per cent., but it rises with variations to as much as 50 per cent. Much of its importance arises from the fact of its occurring in beds alternating with layers of coal, limestone, and clay, so that the same pit is sometimes able to supply firebricks for building the furnace, fuel for the smelting, and limestone for the flux,—a combination of advantages that for long enabled iron to be produced in England cheaper than elsewhere. ”

“ I am not aware that there is in the arts or sciences any other than iron which is not so. Soft iron we do not bring together by fusion, but by a process which is analogous to the one that was followed in the case of platinum, namely, welding ”

“ Crandon, “from fishing ore with tongs.”
“We’ve moved along a great way since that time,” said John Bradford, “and most of our progress has been due to iron.”
“Giants don’t do all the work even now,” said Mr. Prescott. “They make short work of iron mountains and surface deposits, but most of them are too large to work underground; though we mustn’t forget that Giant Electricity works down there with the men.
“Giant Gravity helps too, for, when they work below the deposit, he caves the ore down. ”

“ 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. ”

“ For the iron is not taken possession of and allured by material effluvia, after the manner of electricks, but only by the immaterial action of its form or an incorporeal progression, which in a piece of iron as its subject acts and is conceived, as it were, in a continuous homogeneous body, and does not need more open ways. ”

“ Accordingly native iron which sui generis (as metallurgists term it) , is formed when homogenic parts of the earth grow together into a metallick lode; Loadstone being formed when they are changed into metallick stone, or a lode of the finest iron, or steel: so in other iron lodes the homogenic matter that goes together is somewhat more imperfect; just as many parts of the earth, even the high ground, is homogenic but so much more deformate. Smelted iron is fused and smelted out of homogenic stuffs, and cleaves to the earth more tenaciously than the ores themselves. ”

“ We say that the iron made by the ancients was in reality a variety of what we now term wrought iron, for it fulfilled three of the principal requirements for wrought iron, viz., it was not necessarily melted during production, it was a malleable metal, and it contained cinder or slag, but practically no carbon. ”

“ 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. ”

“ Again, iron which has been excited by a loadstone, * if that iron on account of obstacles should not be able to turn round immediately in accordance with its nature, as happens with a versorium, is laid hold of, when a loadstone approaches, on either side or at either end. Because, just as it can implant, so it can suddenly change the polarity and turn about the formal energies to any part whatever. So variously can iron be transformed when its form is adventitious and has not yet been long resident in the metal. ”

“ If, then, extra iron is required for ship-building, the first effect is to withdraw part of the iron habitually consumed for other purposes, and to raise the price of iron. Presently, the iron-makers feel this change and their stocks dwindle. ”

“ We know that iron is a chemical element—the chemists write it Fe for short, after the Latin word "ferrum," meaning iron—it is one of those substances which cannot be separated into anything else but itself. It can be made to join with other elements; for instance, it joins with the oxygen in the air and forms scale or rust, substances known to the chemist as iron oxide. But the same metal iron can be recovered from that rust by abstracting the oxygen; having recovered the iron nothing else can be extracted but iron; iron is elemental. ”

“ It was only when iron had become thus plentiful that it could be productive of any effective change on the characteristics of the races by whom it was used. But though iron is the most abundant of all the metals, and was the latest to be introduced into use, it is at the same time the most perishable, rapidly oxidizing, unless preserved by the most favourable circumstances. ”

“ Pure iron like pure gold is homogeneous, but unlike gold it is rarely pure. If gold be kept in a melted condition a sufficiently long time, all extraneous matters may be burnt away, but if iron be kept in a hot state too long it will be burnt away itself. Pure iron appears to be ductile, but pure iron will not melt. To form cast-iron, a quantity of carbon must be mixed with the pure iron. If the quantity of carbon be less in amount, steel is the result. ”

“ Primitive furnace for smelting iron ore.
Not many of us have ever seen iron, the pure metal, soft, ductile and white like silver. As soon as it is exposed to the air it veils itself with a thin film of rust and becomes black and then red. For that reason there is practically no iron in the world except what man has made. It is rarer than gold, than diamonds; we find in the earth no nuggets or crystals of it the size of the fist as we find of these. But occasionally there fall down upon us out of the clear sky great chunks of it weighing tons. These meteorites are the mavericks of the universe. ”

“ Thus, when combined with carbon, in varying proportions, substances are produced, so different, but each so valuable, that they might almost be regarded in the light of distinct metals,—such, for example, as cast-iron, and cast and bar steel; the various qualities of iron enabling it to be used for purposes so opposite as a steel pen and a railroad, the needle of a mariner's compass and an Armstrong gun, a surgeon's lancet and a steam engine, the mainspring of a watch and an iron ship, a pair of scissors and a Nasmyth hammer, a lady's earrings and a tubular bridge. ”

“ Upon a close examination of the specimen that I had brought away with me in my bag, home to the Hermitage, and by consultation with my book, I felt convinced that I had discovered what is called magnetic iron; that is, iron ore that is most universally dispersed over the earth. The action of the compass added to this belief, and the limestone formation was exactly fitted to this kind of ore, which is the same as is generally called the Swedish iron ore, one of the best-known irons in the world. ”

“ In fact, even though an ounce of gold is worth twice as much as a ton of iron, the value of the iron we dig out of the earth each year is far greater than that of gold. When that rough ore is converted into iron and steel and then into thousands of useful articles, its value mounts so high that it cannot be estimated. The qualities of iron and its alloys are so excellent and so varied under different treatment that this metal may truly be said to form the foundation of all our mechanical progress. ”

“ It is so, and that is one of its worst properties. Every liquor, and even a moist air corrode it. But the rust of iron is not pernicious: on the contrary, it is a very useful medicine.
Geo. I have heard of steel drops and steel filings given for medicine.
Tut. Yes; iron is given in a variety of forms, and the property of them all is to strengthen the constitution. Many springs are made medicinal by the iron that they dissolve in the bowels of the earth. These are called chalybeate waters, and they may be known by their inky taste, and the rust-coloured sediment they leave in their course. ”

“ If enemies stand around in groups, they make the iron easy to break.
“When we want steel for chisels, for example, we invite Tungsten to come in; when we want certain parts for automobiles we call in some Vanadium pygmies.”
“So,” said Mr. Prescott, “while we need the giants to make the pig iron, the real value of the iron and steel depends on the pygmies.”
“That’s about the size of it,” said Mr. Farnsworth.
“Anything the trouble with you, young chap?” asked Dr. Crandon. “You haven’t spoken for ten minutes. Feel bad anywhere?”
“No,” answered Billy. ”

“ Iron we need, and iron we must have. We cannot well do without it, and have it we must, if we have to send to England for it. We have an abundance of the best quality of iron ore. A trial furnace was made, and kept hot for sixteen days, and produced as good pig metal as can be found in the world ”

“ Prescott. “Heat expands iron. If we didn’t keep it cool, the screw wouldn’t be the right size when it is done.
“Cold naturally works the other way. Ever hear about the iron bridge where the parts wouldn’t quite come together, so they put ice on to do the job?” he asked, but he kept right on, without waiting for Billy to answer.
Billy saw other machines boring holes and rounding corners. It seemed as if iron could cut iron into any shape that anybody wanted. ”