Sheet iron

“ 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. ”

“ These three forms of iron differ in hardness, strength, elasticity, malleability, etc., according to the amounts of carbon, sulphur, phosphorus, manganese and other elements.
Ochers and metallic paints are iron oxides. Prussian blue and copperas are iron compounds.
The United States manufactures more iron and steel than any other country. Almost half of the production is in Pennsylvania. Cast iron appears in many articles but is weaker than other forms of iron. Wrought iron contains less impurity and is used for bars, plates, wire, structural material and parts of machinery. ”

“ The strength of iron is at its maximum in the smallest mechanical structures.
2. The quality of the metal is improved as it is subjected to greater pressure and condensation.
The extent to which this improvement may be carried has never yet been ascertained; every fresh manipulation improves its quality. The tenacity of wrought iron is best displayed in a wire, drawn out until it is not thicker than a human hair. Large masses of wrought iron are weak and spongy in geometrical progression with the mass, and the crystalline or molecular form increases with the mass. ”

“ With such a volume of weakening constituents and particularly with the graphite flakes cutting through and separating the iron grains as the photomicrographs show, can one wonder that cast iron is fragile—more so than steel or wrought iron? ”

“ 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 ”

“ Wrought iron is softer than cast iron, and, being pure iron, is more liable to be corroded by the action of the atmosphere and products of combustion of the powder; it possesses also considerable ductility. The tensile strength of wrought iron, which under the most favorable circumstances is double that of the best cast iron, depends on the character of the crystalline structure, and the manner of applying the tensile force, or in other words, wrought iron offers the greatest resistance to a force of extension when the structure is fibrous, and the force acts in the direction of the fibres. ”

“ 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. ”

“ With us iron is employed in three states, of cast iron, wrought iron, and steel.
Cast iron is distinguishable, by its properties of being, in general, so hard as to resist both the hammer and the file; being extremely brittle, and for the most part, of a dark grey or blackish colour.
A great number of useful and important articles are formed of cast iron, such as grates, chimney backs, pots, boilers, pipes, and cannon shot. These are made by casting ladles full of the liquid metal into moulds that are shaped, for the purpose, in sifted sand. ”

“ 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. ”

“ 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. ”

“ 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. ”

“ Its glare lights up the countryside for miles around, and the hissing and roaring of the molten iron, or rather of the steel groaning in its birth throes, forms a fitting accompaniment. It is a sight that once seen will never be forgotten. ”

“ 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. ”

“ 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. ”

“ 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. ”

“ The principal iron ores are the oxides and carbonates, and these readily yield the metal by smelting with carbon. The metal so obtained invariably contains a certain amount of carbon, free or combined, and the proportion and condition regulate the properties of the metal, giving origin to the three important varieties: cast iron, steel, wrought iron. The perfectly pure metal may be prepared by heating the oxide or oxalate in a current of hydrogen; when obtained at a low temperature it is a black powder which oxidizes in air with incandescence ”

“ 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. ”

“ The toughness of malleable iron renders it applicable to purposes, where great strength is required, while its difficult fusibility, and property of softening by heat, so as to admit of forging and welding, cause it to be easily wrought.
2. Cast iron, from its cheapness, and from the facility with which its form may be changed, is made the material of numerous structures. Steel, which is the most important compound of iron, exceeds all other metals in hardness and tenacity; and hence it is particularly adapted to the fabrication of cutting instruments. ”

“ My own experience leads me to think that a cast iron having about 3 per cent. of carbon, a small per centage of phosphorus, say about 1⁄2 of 1 per cent., and very small quantities of silicium, the less the better, and traces of manganese (the two latter substances slagging out almost entirely during the process of remelting for casting) , makes a metal best adapted to the general use of the founder. Such proportions will make a soft, even grained, dark gray iron, whose crystals are small and bright, and whose fracture will be uneven and sharp to the touch. ”

“ Symbol Fe (Latin Ferrum) . Atomic weight 55.9. Specific gravity, pure iron, 7.86; cast iron, 7.1. In magnetic properties, it is superior to all other substances.
The value of iron is largely due to the facility with which it can be worked. Thus, when heated it is malleable and ductile, and can be easily welded and forged at a high temperature. As cast iron, it is easily fusible; as steel, is very tough, and (when tempered) very hard and elastic. Chemically, iron is grouped with cobalt and nickel. Steel is a variety of iron containing more carbon than wrought iron, but less that cast iron. ”

“ 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. ”

“ 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. ”

“ It is impossible to assign the limits between these three forms of iron, or their relative proportions of carbon, with ultimate precision; for bar iron passes into steel by insensible gradations, and steel and cast iron make such mutual transitions as to render it difficult to define where the former commences, and the latter ceases, to exist. In fact, some steels may be called crude iron, and some cast irons may be reckoned among steels. ”

“ 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 ”

“ From the above it is seen that all sorts of cast iron can be produced ranging from the extremely hard, high cementite, white irons with low silicon content down to the very soft gray irons which result mainly because of higher silicon content and slower cooling.
The white irons are more or less unstable as is shown by the decomposition through which the hard, white iron castings become “malleable” by annealing as was told in Chapter XII which discussed Malleable Cast Iron. ”

“ Cast iron or crude iron is the metal when first extracted from the ore; it usually contains carbone, oxygen, phosphorus and silica, in small proportions, with perhaps other earths occasionally. It cannot be considered as having these elements united in definite proportions; for they vary much, and probably give to crude iron its several modifications. Cast iron contains about 80 per cent. of its weight of iron in a state capable of solution in dilute sulphuric acid, and yielding a corresponding quantity of hydrogen gas. ”