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Iron and Steel An introduction to the metallurgy of by HM Boylston Hard Cover
Iron and Steel An introduction to the metallurgy of by HM Boylston
Copyright 1928 Staining on several pages
Hard Cover
571 pages Indexed
CONTENTS
CHAPTER I
THE HISTORICAL AND ECONOMIC BACKGROUND OF THE IRON
AND STEEL INDUSTRY
ANTIQUITY OF IRON
EARLY MANUFACTURE OF IRON FROM THE ORE
THE CATALAN FORGE
EARLY STEEL PROCESSES
INVENTION OF THE BESSEMER STEELMAKING PROCESS
INVENTION OF THE SIEMENS GAS PRODUCER AND THE OPEN-HEARTH FURNACE
SORBY'S EARLY METALLOGRAPHIC WORK
DEVELOPMENT OF EARLY AMERICAN BLAST FURNACES
FIRST USE OF METALLURGICAL MICROSCOPE IN THE UNITED STATES .
ECONOMIC ASPECTS OF THE IRON AND STEEL INDUSTRY
GENERAL REFERENCES
CHAPTER II
CHEMICAL AND PHYSICAL PRINCIPLES
REDUCTION AND OXIDATION 25
CHEMICAL CONSTITUENTS 26
REDUCTION OF IRON ORE27
REDUCING AGENTS 28
SOURCE OF IMPURITIES IN IRON 28
EARLY PROCESSES FOR REDUCING IRON ORE 28
ABSORPTION OF CARBON BY IRON 30
OXIDATION REACTIONS -30
DEFINITIONS 30
CHAPTER III
THE RAW MATERIALS OF THE IRON INDUSTRY
IRON ORES 36
METHODS OF MINING AND HANDLING ORES 46
THE BENEFICIATION OF IRON ORES 51
BLAST-FURNACE FUELS 52
Manufacture of Charcoal 55
Manufacture of Coke 55
The Bee-hive Oven 57
The By-product Oven 60
LIMESTONE 67
AIR 69
GENERAL REFERENCES -76
CHAPTER IV
THE BLAST FURNACE AND THE MANUFACTURE OF PIG IRON
THE BLAST FURNACE 79
BLAST-FURNACE OPERATION 101
BLAST-FURNACE REACTIONS -109
GRADES OF PIG IRON AND THEIR USES 116
U. S. PRODUCTION OF PIG IRON, BY GRADES 118
CLASSIFICATION OF IRON ACCORDING TO USE 119
REMELTING IRONS -119
PUDDLING, FORGE, OR MILL IRON 120
STEELMAKING IRONS -120
FERRO-ALLOYS 123
DIRECT CASTINGS 124
TOTAL PRODUCTION OF PIG IRON125
CHEMICAL CHARACTERISTICS OF PIG IRON 125
GENERAL REFERENCES 127.
CHAPTER V
THE FOUNDRY
THE GRAY-IRON FOUNDRY 128
THE MELTING DEPARTMENT 137
MELTING FURNACES 138
The Cupola 138
The Air Furnace 149
THE MALLEABLE IRON INDUSTRY _ 150
Historical150
The Process of Manufacturing Malleable Cast Iron 151
Physical Properties of Malleable Cast Iron159
THE STEEL FOUNDRY 161
Specifications for Steel Castings...............174
Physical Properties of Steel Castings 176
The Heat Treatment of Steel Castings...179
Physical Properties of Heat-treated Steel Castings 179
Defects in Steel Castings180
CHAPTER VI
WROUGHT IRON
PAGE
HISTORICAL -186
THE DRY PUDDLING PROCESS 187
DEFINITION OF WROUGHT IRON 187
THE MODERN PUDDLING PROCESS 188
KNOBBLED CHARCOAL IRON 193
BUSIIELED IRON 194
MECHANICAL PUDDLING FURNACES 194
CHEMICAL COMPOSITION OF WROUGHT IRON 199
PHYSICAL PROPERTIES OF WROUGHT IRON 199
CHAPTER VII
EARLY STEEL-MARING PROCESSES
THE CEMENTATION PROCESS 205
THE CRUCIBLE PROCESS 207
CHAPTER VIII
THE BESSEMER PROCESS
HISTORICAL 213 THE PROCESS IN BRIEF 214
THE CONVERTER 215
CHEMISTRY OF THE ACID BESSEMER PROCESS 223
BASIC BESSEMER PROCESS 227
THE DEVELOPMENT OF THE BESSEMER-STEEL PROCESS 228
THE DEVELOPMENT OF THE OPEN-HEARTH PROCESS 229
CHAPTER IX
THE OPEN-HEARTH PROCESS
THE FURNACE 232 FUELS.. 235
ACID OPEN-HEARTH PROCESS 243
BASIC OPEN-HEARTH PROCESS 260
STATIONARY AND TILTING FURNACES 262
TILTING FURNACES 262
THE WELLMAN FURNACE 263
THE CAMPBELL FURNACE 263
THE CAMPBELL PROCESS 263
THE BERTRAND-THIEL PROCESS 263
THE TALBOT PROCESS 263
THE MONELL PROCESS 266
RECENT IMPROVEMENTS IN OPEN-HEARTH DESIGN 266
DUPLEX PROCESS FOR STEEL MAKINGrk 275
TRIPLEX PROCESS 276
REFRACTORIES FOR THE OPEN-HEARTH FURNACE 276
GENERAL REFERENCES ON THE OPEN-HEARTH PROCESS 278
CHAPTER X
THE ELECTRIC FURNACE PROCESS
HISTORICAL 279
ELECTRIC SMELTING FURNACES 281
ELECTRIC STEELMAKING PROCESSES 282
DISTRIBUTION OF ELECTRIC STEELMAKING FURNACES 282
ELECTRIC STEELMAKING FURNACES 283
SERIES-ARC FURNACES 286
Selected References to Articles on the Series-arc Furnaces 302
ELECTRODE-HEARTH FURNACES 302
Selected References to Articles on the Electrode-hearth Furnaces305
INDEPENDENT-ARC FURNACES 307
References to Articles on the Stassano Furnace 307
INDUCTION FURNACES 309
Selected References to Articles on Induction Furnaces 311
ELECTRIC STEEL-MELTING PROCESSES - 312
THE BASIC PROCESS 312
ACID PRACTICE 317
THE HOT-METAL BASIC PROCESS - 317
GENERAL REFERENCES 321
CHAPTER XI
THE MANUFACTURE OF COMMERCIALLY PURE IRON
A1,IERICAN INGOT IRON 322
The Development of Armco Ingot Iron 322
The Process of Making Ingot Iron 324
Physical Properties of Armco Ingot Iron 327
ELECTROLYTIC IRON 328
Physical Properties 333
CHAPTER XII
INGOTS AND INGOT MAKING
METHODS OF TEEMING 335
METHODS OF POURING 335
STRIPPING THE INGOT 343
SOAKING PITS 344
THE COOLING OF THE INGOT 347
PRINDEFECTS IN A STEEL INGOT 348
Pi g 348
Sound Ingots 352
Solidification of the Molten Steel in the Mold 352
Piping Steel 353
Open Steel 358
Blow-holes 358
Segregation 359
Ingotism 366
REFERENCES ON INGOTS AND INGOT MAKING 367
CHAPTER XIII
THE MECHANICAL TREATMENT OF STEEL
IMPORTANCE OF MECHANICAL TREATMENT 369
HOT WORK 370
Blooming Mills 371
Billet Mills 373
Reheating Furnaces 378
Finishing Mills 379
Bar Mills 380
Rod Mills 381
Slabbing Mills 385
Plate Mills 386
Manufacture of Rails 388
Structural Shapes 390
Sheet Rolling 391
Forging 393
Comparison of Rolling, Hammer-forging, and Pressing 395
Seamless Tubing 404
The Effect of Hot Work on the Structure and Physical Properties of Steel408
Importance of Finishing Temperature 409
COLD WORK 409
Cold-rolled Sheets 409
Cold-rolled Strip Steel 409
Cold Drawing of Wire 413
Effect of Cold Work on the Structure and Physical Properties of Steel416
CHAPTER XIV
THE COMPOSITION, STRUCTURE, AND PHYSICAL PROPERTIES OF
IRON AND STEEL
EARLY DEVELOPMENTS OF METALLOGRAPHY 424
THE CRITICAL POINTS IN IRON AND STEEL 424
MICROSTRUCTURE OF PURE IRON 432
FERRITE 434
PEARLITE 435
CEMENTITE, * 440
EFFECT OF CARBON CONTENT ON THE PHYSICAL PROPERTIES OF STEEL. 442
EFFECT OF CARBON ON THE SHOCK-RESISTING PROPERTIES 01' STEEL 443
IMPURITIES IN IRON AND STEEL 444
CARBON 445
SILICON 445
PHOSPHORUS 446
SULPHUR 447
MANGANESE 448
OXYGEN 452
NITROGEN. 454
HYDROGEN 454
NICKEL 455
CHROMIUM 460
NICKEL-CHROMIUM 463
VANADIUM 467
CHROME-VANADIUM 472
TUNGSTEN 475
HIGH-SPEED STEEL 478
MOLYBDENUM 485
COBALT 490
COPPER 491
CHAPTER XV
THE HEAT TREATMENT OF STEEL
ANNEALING 496
TOUGHENING TREATMENTS 523
HARDENING - 525
TEMPERING DRAWING) 531
CARBURIZING AND CASEHARDENING 541
APPENDIX
A. S. T. M. TENTATIVE DEFINITIONS OF TERMS RELATING TO HEAT TREATMENT OPERATIONS
INDEX
INTRODUCTION
IT is the author's firm conviction, that every engineer should have a basic knowledge of the metallurgy of iron and steel. Without the aid of these valuable metals civilization would indeed revert to the Stone Age. Not only the metal industry but all industries are dependent upon these metals for their existence.
A nation's industrial vitality is measured by its metal production, and the metal industry is often referred to as the pulse of American business. The production of pig iron alone is the basis for many business forecasts.
The metallurgy of iron and steel may be divided into three parts: process metallurgy, or the winning of the metal from its ores and the refining of the metal to a quality which will be of the best and most economical service to the industries that use it; mechanical metallurgy, or the processes of working steel, shaping it, and fabricating it into finished or semi-finished products; and the metallography and heat treatment of iron and steel, which deal with the properties of finished and semi-finished products and methods of improving them in order that they may be of the greatest possible service to industry.
The present treatise is an attempt to introduce all of these subjects to the reader in a concise form, and special emphasis has been placed upon the subject of ingots and ingot making, since a knowledge of this subject is necessary for an understanding of the difficulties encountered in the rolling-mill and heat-treatment departments. An endeavor has been made to bring up to date the subject of electric furnaces for the iron and steel industry and the
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