.W3 rs 233 W3 o Py j TIKE Foundrymen's Primer BY WALTER H. WANGELIN, BELLEVILLE, ILL. I Treatise on the Chemical Constituents of Iron, and Methods of Calculating the Mixtures of Iron by Analysis • ,Ll6RAKY0f CC Two Copies Received : JAN 18 1905 Gopyngni tniry C^LASS «- XXc, Not / d 7 £ 5 COPY B» PREFACE. <* The object of this Primer is to give the foundrymen a good general idea of the effects of thfi varies different elements, generally contained in iron, upon each other and npon the iron, and to give the causes that produce different fractures in iron. The object is, further, to show that the fracture of iron is misleading and that the cor- rect way is to have the analysis of the iron and work by that and not by the fracture. To accomplish this several methods have also been given to calculate the mixture by analy- sis. The writer has tried to make the matter plain to all readers, and it may seem as if there was a repetition of some statements, if so, it is to be hoped that these will be well impressed upon the mind of the reader. INTRODUCTION. Gentlemen : These pages contain a valuable treatise on Iroa and Calculating the Mixture of Iron by Analysis. I have tried to make it plain to you why you should make the mixture of iron by analysis and not by the fracture. Not only that, I have gone further, and have given you several methods of how to figure the mixture by analysis. This no one, to my knowledge, has ever done, and it i3 probable that the lack of this knowledge is the reason why the use of analysis in making the mixture is not more general. It will not be necessary for you to erect a costly laboratory and employ an expert chemist. I have a complete laboratory for accurate work and make it a business to make the analysis for foundries. I have foundry experience, have the best of help associated with me, and have made the analysis and mixture for years for the largest foundries in the United States, and, if necessar3% could furnish the best of reference. I am doing the analytical work for very many foundries all over the United States, and if you are not on the list, I would be pleased to have you, whether you use one car of iron a month or one a day. I am about to publish a large treatise on iron, of which these pases will be a part. Iwould, therefore, be pleased to have you write me your opinion, good or bad, about these pages, and tell me if there is anything that is not clear or that you do not understand. I will also be pleased to have you tell me what information, not included in these pages, that you would like to see in a larger treatise. I want to publish a treatise that in as few words as possible will give just such information that is not well understood by the foundrymen. I want my laboratory to do the chemical work for most all the foundries in the United States, and want my laboratory to be known as the most accurate and rapid for all practical purposes. Send me your samples and let me hear from you. Yours truly. WAI/TEK H. WANGELIN", Belleville. III. NOMENCLATURE. Iron is a simple substance and one of the ele- ments of chemistry. In its pure state it is found only in laboratories and never in every-day life. When we speak of an article being made of iron, we do not mean that it is made of pure iron, but iron containing the impurities that it gen- erally contains. These impurities are mainly Carbon, Silicon Sulphur, Phosphorus and Man- ganese. Pure iron would not be as valuable in com- merce as the impure. These impurities, the amounts of each and their relation towards each other is what determines the value of the iron. In nature iron is found in combination with other substances and forms minerals and ores which are treated in Blast-furnaces. PIG IRON AND SOWS. Iron, when made in the blast furnace, is in the molten state, and must be cast "into molds or some shapes, so that it can be handled and remelted. In practice the iron is cast in open sand. A gutter is made from the furnace in the sand-casting bed. From the side of this gutter smaller gutters or molds are made and the iron feeds into these. It must have reminded some one of a sow nursing its little pigs and, therefore, gave the name of sow to the large gutters and pigs to the little ones; hence the name of pig iron and sow. —6— CHILLED MOLDS. As the iron runs into the sand bed some of the sand adheres to the iron, so that pig iron has more or less sand attached to it. This sand is detrimental to some processes in which iron is used, and, to overcome this, molds of iron are used and the iron from the blast furnace run into them. Iron is a good conductor of heat, and the molten iron east into these iron molds cools or chills, and hence the iron is called Iron Cast into Chilled Molds. BASIC IRON. The process in which the sand on the pig is detrimental, and for which the iron is cast into chilled molds is the Basic Open Hearth Steel process. Some persons call the iron cast into iron molds, basic iron. This is wrong. While it is true that iron for the basic process is cast into iron molds, still any iron could be cast into iron molds. The iron best adapted for the Basic steel process should contain these impurities within certain limits, and it is best to call iron within these limits Basic Iron. . BESSEMER AND OFF BESSEMER IRON. There is a process of making steel invented by a man called Bessemer, and hence the name Bessemer Process. In this process the Phospho- rus should not be above .10 per cent., and hence all iron as low as . 10 per cent., or lower, in Phos- phorus is called Bessemer Iron. Sometimes an iron contains a little more than this amount, say .10 per cent to .20 per cent Phosphorus. This iron is often called Off-Bessemer Iron. HOT BLAST AND COLD BLAST. In former days the blast used in the blast furnace was the ordinary air. Nowadays the blast is heated before entering the furnace. To distinguish between the two, the iron made with the unheated blast is called Cold Blast Iron. WROUGHT IRON. When Iron is treated in a puddling furnace and most of the impurities are gotten rid of, so that it can be worked and forged, it is called Wrought Iron. STEEL. When iron is treated in any other way than in the puddling process, and most of the impuri- ties are gotten rid of, it is called steel. The analysis of steel varies, as there are many kinds, depending upon the use that it is to be put to. According to the use of the steel is put to and ac* cording to the. name the maker sees fit to give it, we have any amount of steels. CAST IRON. When pig iron is melted and poured into some castings,. it is called cast iron. Some cast- ings are used for stove plate and some for ma- cfhinery castings. The quality of the iron taken for stove plate and machinery castings is differ e:it, as one is a light casting and the other heavy^ and so the two kinds of scrap iron are kept separate, one being sold as stove plate scrap and the other as machinery scrap. MALLEABLE IRON. When cast iron is treated after it has been cast so that it becomes malleable, it is called Malleable Iron. SILICA AM) SILICON. The word Silicon is used by chemists and foundrymen. Notice the spelling of the word. The last two letters are "on.*' This is an ele- ment in chemistry, a simple substance. This cle- ment can combine with other elements and form other substances. In the cupola, for instance, some of it combines with the oxygen of the air, and goes into the slag. This combination of Silicon and Oxygen forms sand, or often called Silica. Notice that the word ends in "a," and not in "on." Silicon (with an ending of "on") is the element that we speak of in iron, while the white sand and rock is called Silica (ending in the letter "a"). Many persons do not use these words correctly . -9— METALLURY OF IRON. Iron made in the blast furnace always con- \ tains impurities, the amount of each depending upon the materials used and the working of the furnace. The main impurities to be considered are Carbon, Silicon, Sulphur, Phosphorus and Manganese. These impurities mentioned are elements of chemistry, and so will be called eler ments. instead of impurities. CAEBOX AND SILICON. Iron contains, when other elements are ab- sent, about 4.5 per cent of Carbon. If Manga- nese is present then the iron can contain more Carbon, but all other elements make the iron contain less Carbon. Iron and Carbon form a white metal. The Carbon is all combined. The presence of Sul- phur, Phosphorus and Manganese helps to com- } bine the Carbon and make a white iron. Silicon is the only element (of those consid- f ered) which does not help to combine the Car- \ bon with the iron. Silicon in the iron will cause i the iron to take up less Carbon, and the more j Silicon the iron contains the less will be the Carbon. Silicon also acts in another way. It ;l not only causes the iron to take up less Carbon, but some of that which it contains is thrown I out in little flakes, while the iron is cooling, dis- tributing these flakes through the iron, partly in crystallized form and partly in an uncrystal- —10— lized form. These forms are generally called Graphite and causes the iron to look grey. Iron, when melted, contains all the Carbon in the sombined slate. Should some of the Carbon have been thrown out, on cooling, as Graphite, it would again combine as soon as remelted. No matter how much Graphite an iron contains, on melting it, this Graphite again changes over to Combined Carbon. Iron, when melted, contains all the Carbon in the combined state and may also contain some Silicon, but not enough to counteract other ele- ments and tendencies to hold the' Carbon com- bined, so that on cooling there is formed a white, hard iron, that is brittle and has no strength. Iron, when melted, may contain enough Sili- con to counteract the other elements and ten- dencies to hold the Carbon as Combined Carbon and upon cooling some of' this carbon is thrown out as Graphite, producing a strong, close- grained iron. Iron, when melted, may increase still further in Silicon, so that the greater part of the Carbon is thrown out on cooling at Graphite and form a very c oft gray iron. Iron, when melted, can. however, contain but a limited amount of Carbon and Silicon. We have seen that the amount of Carbon thrown out as Graphite upo n cooling increased as the Silicon increased. The Carbon >eemod to be dissolved in iron in presence of Silicon and held there as —11— long as the iron was melted and hot, but could not hold it however on cooling. If the Silicon is still further increased, the iron can not hold the Carbon, even in the molten state, and the Graphite is thrown out in the molten iron and rises to the surface, decreasing the amount of Carbon in the iron. This Graphite rising to the surface is called Kish. Iron containing only Carbon can contain as high as 4.5 per cent., is all combined and forms a white iron and is hard. Silicon will cause some of the Carbon to be thrown out as Graphite upon cooling to form grey iron. The Total Carbon is the same, only some being combined and the rest being present as Graphite. When the amount of Silicon increases, so that the molten iron cannot hold the Carbon in presence of this Silicon, the Total Carbon decreases, and we have 5-6 per cent. Silicon iron, looking white, on ac- count of lack of Carbon, and a 10 per cent. Sili- con contains only about 1 per cent, of Carbon. This Carbon is present almost entirely as Graph- ite, but on account of the lack of Carbon the iron is white and weak, but is soft. Iron that is white and hard on account of low Silicon and high Carbon has a different fracture and appearance than iron that is white and soft on account of high Silicon and low Carbon. Carbon makes the molten iron fluid; the same can be said of Silicon. Silicon -can combine with iron in any proportion and we have Ferro-Sil'con, containing 75 per cet of Silicon. —1-2— It can readily be seen that Silicon plays a very important part, and how necessary it is to know the amount of Silicon in iron and in the castings. SULPHUR. Sulphur makes the iron brittle and red short and makes it run very sluggish and thick. Sul- phur tends to make the iron take up less Car- bon, it combines the Carbon in the iron and makes it white. In melting iron with coke the iron takes up the Sulphur in the coke to a great extent, so that the castings will contain more Sulphur on this account. MANGANESE'. Manganese causes the iron to take up more Carbon. It combines this Carbon and makes the iron white. An iron containing 80 per cent of Manganese contains about 8 per cent of Carbon. Manganese 'has, however, more attraction for the Sulphur than iron has, and combines with it and neutralizes the effect of the Sulphur. The Sulphur and the Manganese unite and often rise to the surface of the molten metal, decreasing the amount of each thereby and purifying the metal. For this reason molten iron high in Sul- phur is dirtv, the combination rising to the sur- face. It can, therefore, occur that by taking an iron, that is bar;! and white on account of Sul- phur, and melting it with an iron, hard on ac- —13— count of Manganese, that a good grey iron is produced. Iron that contains Manganese is white and it looks like the white of a mirror, and hence some German gave it that name. The German name for a mirror is Spiegel, and hence it is called Spiegel Eisen. Lately an iron is made that con- tains more Manganese — in fact, more Manga- nese than iron. To designate this, and because eveiything must have a name, all iron contain- ing a smaller amount of Manganese, say up to 30 per cent of Manganese, is called Spiegel Iron, and if it contains more it is called Ferro-Man- ganese, the word Ferro meaning iron. Spiegel Eisen is generally made to contain about 20 per cent and Ferro Manganese about 80 per cent Manganese. In buying either, the analysis should always be checked up. Ferro-Manganese can be bought broken into small pieces or ground. It is a good article to have around the foundry, for reasons explained above, namely: It combines with the Sulphur and rises to the surface, thus decreasing the amount of Sulphur and purifying the iron. It combines with the Sulphur that does not rise to the surface and neutralizes its bad effect. The Sulphur being thus reduced, the Silicon which was required to counteract the bad effects of the Sulphur is free to act upon the Carbon, and thus clirectlv and indirectly the addition of Man- —14— ganese when Sulphur is present makes an iron softer, more grey, etc., etc. When Sulphur is not present to a great ex- tent, and the iron is too open, Manganese will combine the Carbon and make it a closed grain and stronger iron. Manganese, therefore, softens the iron in one case, and under different condition hardens it. By knowing the analysis of the iron, the foun- drymen can tell whether the addition of Man- ganese will be beneficial or not and the amount required. It must not be supposed, however, like the Indian who took some medicine that little does good, that more would do heap good. The amount of Manganese added, or whether any should be added, depends, of course, upon the amount of Sulphur, and this can and should always be ascertained by analysis. Most of the irons in the United States con- tain between .50 per cent and 1.00 per cent of Manganese, which is about the amount required for the general run of castings. If the iron con- tains less, then Manganese should be added. Some irons now made contain between 2.00 per cent and 3.00 per cent of Manganese, and can be ust 1 to mix with low Manganese irons or irons thai contain Sulphur. It is necessary, of course, to have these irons analyzed to know just what ilicv contain. —15— PHOSPHOKUS. Phosphorus combines the Carbon and makes makes the iron sensitive to sudden strains, A pillar of a house, for instance, that is high in Phosphorus will carry the load easily, but it apt to break when a heavy wagon runs along the street. Phosphorus combines the Carbon and makes the iron white, and the Combined Carbon again makes the Phosphorus act stronger. Silicon counteracts the action of the Phosphorus indi- rectly by decreasing the combined Carbon. Phos- phorus makes the iron very fluid, and for that reason it is well liked, provided that it does not contain too much. For stove plate the Phospho- rus runs as high as .90 per cent to 1.00 per cent, while in good machine castings it is never so high. It is, therefore, very important to know the Phosphor-is of the iron, and every car should be analyzed. Amounts of Different Elements May Vary in Good Castings The action of* any one element depends not only upon the amount present, but whether J some other elements are present, and the | amount of these. For instance, as explained^ a casting may be high in Sulphur, but still be a good casting, because it contains Manganese, while the same castings without Manganese would be worth nothing. Silicon in iron can be —16— increased or decreased, as the presence of other elements may require, so that it can readily be seen that there are a nnjmber of combinations that can be made and have good results. This of course, can only be done intelligently and correctly by knowing the analysis of the iron. FRACTURE OF IRON. Take a ladle of iron and pour several castings. One in a dry sand mold ; another in a green sand mold, making the casting rather large in all di- mensions, and gradually decreasing to a thin stove plate and one cast against a chill. The molten iron is alike and has the same in- gredients. Still, upon breaking the cold cast- ings, we find a vast difference in the fracture. The large and dry sand casting? are open grain and look like a number one iron, but as the castings decrease in size the fracture be- comes closer and the iron is harder, and stove plate is probably white and cannot be drilled, and the casting against the chill is white and hard. Xnw. if what has been said above about the chemical constituents of iron is true, then these castings should all be alike, or else there is some other action that we have not taken into ac- count. We analyze these castings and find the total Carbon. Silicon. Sulphur, "Phosphorus and Manganese are the same, but the state of the 1 —33— of course, is nonsensical talk. Did a foundry ever make $-±00 worth of castings and not have them examined? Every casting is examined, and when it does not suit the party, they will, reject the casting. Foundrymen should always have each car of iron checked up for Silicon and Phosphorous, and ,if the occasion requires, for Sulphur and Manganese. GOKE. a Every foundry should use good coke. As to the analysis, this is deceiving. The cokes that have -the least ash and most Carbon are not necessa- rily the best. The coke should not have too much ash, but the most important part of coke, to get a hot iron is the density and structure. >An open, porous coke does not give the heat jof a dense coke. An open coke requires less P blast. The Sulphur in the coke is important, ! and it is well to analyze the coke for Sulphur, as I most of it goes into the iron, and a high Sulphur I coke will, of course, raise the Sulphur in the pasting. — 34— Calculating the Mixture by Analysis. One great drawback in making the mixture by analysis was not only the lack of knowledge of the effects the different elements had upon the iron, but the lack of information as to how to calculate the amounts of the different irons when the analysis had been made. The following methods of calculating will show the foundrymen how-to mix the irons, and it • is hoped will cause many foundrymen to change over from the old way of making the mixture by fracture to the only correct way of having each car analysed and working by this analysis : When one figures that a car of iron contains, as a rule, twenty-five tons, and then divides the cost of analysis by this to see the cost per ton, it can easily be seen that it pays well to have an- alysis made. The proofs of this are so numer- ous that when a foundry once starts to have an- alyses made, the advantages will be so many that they will be surprised that they did not start long ago. The saving to a foundry using analysis over the time when they did not have the iron checked up and analyzed is often aston- ishingly great. Aside from the money question, it has been clearly shown that the only correct way to make the mixture of iron is by analysis. —35— Calculating the Mixture of Iron for Silicon, When Two Irons are Used. When iron is melted in a cupola it loses some of its Silicon by oxidation. The amount differs in different cupolas, depending upon the mix- ture, the size of the cupola, the blasts etc. Knowing the average Silicon of the mixture and the Silicon of the molten iron, the difference will be the loss in melting. It is an easy matter to ascertain this. This loss must always be added to the amount of Silicon the casting is to ' 'contain, which will give us the amount of Sili— :-on the mixture should contain. Let us suppose that this is .30 per cent and the casting is to be a machine casting containing L.80 per cent Silicon, then the mixture must contain 1.80 plus .3, equaling 2.10 per cent Sil- con. * Let us suppose that we have two irons in the rard containing 1.50 per cent Silicon and 2.40 per cent Silicon and we want to make a mixture of 2.10 per cent Silicon. I If the mixture should contain 2.10 per cent aind the low Silicon iron contains 1.50 per cent Silicon, then, by subtracting 1.50 per cent from 2.10 per cent, we have .60 per cent, the amount that the low Silicon iron requires to bring it up to the mix. If the mixture should contain 2.10 per cent and the high Silicon iron contains 2.40 per cent, —36— then, by subtracting 2.10 per cent from 2.40 per cent, we have .30 per cent, the amount that the high Silicon iron has too much. For every part of low Silicon iron used, we have .60 per cent too little, and must add so much of the high Silicon iron to make up this .60' per cent. If we use one part of the high, we have only .30 per cent too much, so that it re- quires as many parts of the high as it takes to make .60 per cent. Now, .60 per cent divided by .30 per cent is equal to 2, so that it takes 2 parts of the high to one part of the low. Proof : 1 part of 1.50 per cent equals 1.50 per cent. 2 " " 2.40 " " u 4.80 " " 3 " mix (or 2.10 per cent) " 6.30 " " One part of the mix would contain 2.10 jpei cent Silicon. J Again, if for every part of high Silicon iroi we have .30 per cent too much, then we must use as many parts of a low Silicon iron, so that the amount too little is equal to .30 per cent. 'Now, if we use one part of low, we have .60 per cent too little. We see then that we must use less. We must use so many parts so that multi- plied by .60 per cent it makes .30 per cent. Di- viding .30 per cent by .60 per cent, we have .50 —37— times, so that we take .50 parts of the low to every part of the high. Proof: 1 part of 2 40 per cent equals 2.40 per cent. .50 " " 1.50 " " " .75 " " 1 50 "mix 2.10 " " " 3.15 # " Again, if it takes 1 part of the low and 2 parts of the high to make 3 parts of the mix- ture, thn to make 1 part of the mixture, it would take 1 divided by 3 of the low Silicon iron and 2-3 of 1 of the high, so that we have .333 parts of the low and .666 parts of the high. Thus we have our mixture given in how many parts of the high to one part of the low. How many of the low to one part of the high, and how many of each to mak one part? We can take as many parts as we like. Suppose we call a part a pound; then we multiply the number of parts by whatever number of pounds we want to take. For instance: If we want to make a mix of 500 pounds, we see that we must take 500 times .333 of the low Silicon and 50i0 times .666 of the high Silicon iron, which would be 166 pounds of low and 333 pounds of high. Or, if it takes 3 parts to make the mix, then in 500 pounds, 1 part would be 500 divided by 3, which is 166, an the other would be 2 times 166, or 500 pounds, less 166, which would be 333 pounds. In practice we would (as we do not weigh closer —38— than 50 pounds) call this 150 of the low and 35C of the high. This would make the Silicon a lit- tle higher, but it would be as close as we gener- ally weigh. We have then all we need in a little calculat- ing of subtraction and division. Looking ovei our figures, we find that we have the following rule: RULE. Subtract the Lower Silicon Iron Froi the Amount of the Mixture, and the Amount of the Mixture From the High Silicon Iron 1 Divide one Difference by the Other and thi Answer Will be the Number of Parts of th< Divisor to One Part of the Dividend. Above example the Mixture 2.10 per cent. High 2.40 per cent. Low Mix Si. 1.50 " " Mix. 2.10 " " .60 " " .30 " " .30). 60 (2 .60). 300 (.5 60 300 The low difference is .50 per cent and thi high difference is .30 per cent. When we divid .60 per cent, we get amount of high to 1 of low which is 2, and when we divide the .30' pr cen we get the amount of low to 1 of high, which 1 .50. The number you divide is the number yo, get one part of. —39— This rule is very simple. In the example taken the figures divided evenly. This was done to explain easier. In practice this does not al- ways come out that way. To further illustrate the method of making the mixture, let us take another example. We have two irons, one of 3.40 per cent Silicon and the other 2.00 per cent Silicon, and the mixture ic to contain 2.50 per cent Silicon. Applying the rule and, for simplicity sake, dropping the per cent Silicon, we have the fol- lowing calculations: High 3.40 Mix 2.50 Mix 2.50 Low 3.00 .50). 90(1. 8 50 90). 50 (.555 450 .90 .50 400 400 500 450 1 part of 3.40 equals 3.40 1.8 ;t " 2.00 " 3.60 1 part of .55 " " 2.00 3.40 equals 2.00 " 1.88 2.8 •' " 2 50 " 7.00 1.55 " " 2.50 " 3.88 If it takes 1 part of 3.40 per cent iron and 1.8 part of 2.00 per cent iron, or a total of 2.8 parts to make the mix, then, if we want to make a mix of say 560 pounds, 1 part would be equal to 560 pounds, divided by 2,.8, which would be 200 pounds; the amount of the 3.40 per cent iron, and the difference of 560 and 200, which is 360 pounds, would be the amount of the 2.00 per cent iron. The amount of 2.00' per cent iron could also be obtained by taking 1.8 times 1 —40— part or 1.8 times 200 pounds, which is 360 pounds. If, instead of having the mix be equal to 560 pounds, it might have been say 1000, or any other number. Whatever the amount, the calculation would be similar by dividing the amount by the total number of parts, which in this instance is 2.8, and subtracting the result from 1000 to obtain the amount of the other iron. Calculating the Mixture of Iron for Silicon When More Than Two Irons are to be Used. When we have two irons we can make but one mix. When we have three irons, so that one is higher than the mix, or vice versa, then any amount of mixtures can be made. For two of them can be taken as above and iform a mix. Then one of these two irons and the third can form a mix, and the proportion of these mixes that can be taken to make the mixture is indefi- nite. Hence, in making a mixture with more than two irons," one must assume a given amount of some of them. Calculating the Mixture of Irou for Silicon, When More Than Two Irons are to be Used, and the Amount of Iron Assumed Does Not Equal to the Total Weight of the Mixture. If the mixture is to contain, say 1000 pounds at 2.50 per cent Silicon, then the 1000 pounds • would contain 1000 times 2.50 per cent Silicon, which is equal to 2500 per cent Silicon. If the mixture was to contain 600 pounds, then the total mix would contain 600 times 2.50 per cent Silicon, which is equal to 1500 per cent Silicon. The total amount of Silicon a mixture con- tains is obtained by multiplying the average amount of Silicon the mixture contains "by the number of pounds in the mixture. Let us suppose that we have a mixture of 1000 pounds of 2.50 per cent Silicon, using 300 pounds of gates at 2.20 per cent Silicon, 20O pounds of 2.00 per cent Silicon iron, 300 pounds of 3.40 pr cent Silicon iron, and the balance of scrap iron, containing 1.75 per cent Silicon, and as much more of the above-named irons as is necessary to make the correct mixture. For simplicity sake, we will omit the per cent Silicon in calculating, assuming for instance, that when we say 2.50 we mean 2.50 per cent Silicon. —42— We then have: 300 of 2. 20 equals 660 200 of 2.00 equals 400 300 of 3.40 equals 1020 \ 800 2080 1000 of 2. 50 equals 2500 200 420 Average of 2.10. If the mix is to be lOOOi pounds at 2.50, then the total amount will "be 1000 times 2.50, equal to 2500. We have in the assumed mix 800 pounds | of iron, the total Silicon of which is equal to 2080, so hat we must add 200 pounds that will have a total Silicon of 420. Dividing 420 by 200,1 we have 2.10, which is the average amount of} Silicon the 420 pounds must contain. We now have the problem of making a mix- ture of 420 pounds at 2.10 per cent Silicon, using the 1.75 per cent iron and 3.40 per cent iron. U>ing the rule for making the mixture of two! irons we have the following : High 3.40 Mix 2.10 .35)1.30(3.714 Low 2.10 Low 1.75 1.05 1.30 .35 250 245 1 part of 3.40 equals 3 40 3.714 " " 1.75 " 6.4995 4.714 " " 2.10 " 9.8995 —43— Or one part of 3.40 and 3.714 parts of 1.75 makes 4.714 parts of the 2.10 mixture. If the amount of the mixture is to be 200 pounds, then one part will be 200, divided by 4.714 equals to 42.44 pounds, the amount of the 3.40 iron re- quired, and 200 pounds, less 43.44 pounls, equals to 157.56 pounds, equals the amount of 1.75 iron required. Adding the 42.44 pounds of 3.40 iron to the originally assumed 300 pounds, we have the following for our mixture: 300 pounds gates @ 2.20 equals . . 660 200i pounds of iron @ 2.00 equals. . 400 157.56 pounds or iron @ 1.75 equals. . 276.85 342.44 pounds of iron @ 3.40 equals. .1162.23 1000.00 2499.07 This would give us a mixture of 2.50, but as we do not weigh, as a rule, closer than 50 pounds, we change the 157.56 to 150 and the 342,44 to 350. Calculating the Mixture of Iron For Silicon, When More Than Two Irons are to be Used, and the Amount of Iron Assumed Equals to the Total Weight of the Mixture, but the Total Silicon is Either Greater or Less Than the Total Mixture Should Contain. Suppose that we take the same iron as in the previous example, but, instead of not taking the full amount of iron, we make our mix the full —44— weight and see how near we would get at the cor- rect total Silicon. For simplicity sake, we drop the per cent Silicon, rembering that when we say the iron contains, for instance, 2.50, we mean 2.50 per cent Silicon. Let us assume the following mixture: 30(0 pounds gates at 2.20 .... 660 200 pounds gates at 2.00 400 200 pounds gates at 1.75 350 300 pounds gates at 3.40i 1020 1000 2430 We see that our total weight is 1000' pounds, but the total Silicon is not 2500, but 2430, or it is 70 short. The mixture is too low in Silicon, and we must take more of the 3.40 and less of the 1.75. Now, if we take one pound more of the 3.40 and one pound less of the 1.75, we do not change th'e weight, but we increase the Silicon. One pound more of 3.40 and one pound less of 1.75 would increase the mix 3.40 — 1.75, equals 1.65. We want to increase the mix 70i; so that if one pound changes the mix 1.65, then, to change it to 70. we must change as many pounds as it re- quires to make 70, or 70 divided by 1.65 equals 42.424. We will then have to increase the 3.40 iron 42.43 pounds and decrease the 1.75 the same amount, and we^ have the same results as we have calculating the amounts the last method. —45— . Had our assumed mix been greater than the required amount, we would decrease the higher Silicon iron and take more of the low Silicon iron. Let us suppose the Phosphorus of the iron to be as follows: '2.2.0 Gates 93 3.40 per cent Silicon iron to be 1.40 per ct. Phos 2.00 per cent Silicon iron to be .80 per ct. Phos 1 . 75 per cent Silicon iron to be . 50 per ct. Phos Then the mixture would be as follows: 300 pounds gates @ . 93 equals ..2.79 200 pounds 2.00 @ 1.60 equals. .1.20 150 pounds 1 . 75 @ .50 equals . . .75 350 pounds 3.40 @ 1.30 equals. .4.55 1000 9.29 Or an average of .93 per cent Phosphorus. If the mixture was to have been lower in Phos- phorus, then less of the high Phosphorus iron would have to be used, and in case the Phosphor- us was to have been higher more of the high Phosphorus iron would have to be used. Another example: To make a mixture of 1500 pounds at 3 per cent Silicon. —46— The total Silicon of this mixture would be 1500- times 3 per cent, which is equal to 4500 per cent. We will assume the following mixture as a trial, and see how near we come to the correct -amounts to be used. Per Ct. Per Ct. 400 pounds of gates @ 2.70 equals. . .1080 200" pounds of iron @ 1.82 equals. ... 364 150 pounds of iron @ 2.00 equals 300 200 pounds of iron @ 2.43 equals 486 100 pounds of iron @ 3.10 equals... . 310 150 pounds of iron @ 3.20 equals 480 300 pounds of iron @ 4.50 equals 1350 1500 4370 15 pounds at 3.00 equals... .450*0 130 The total weight of the mixture is correct, but the total Silicon, instead of being 4500 per cent, is only 4370 per cent, or it is 130 per cent too low. The mixture must be increased in Silicon. One pound more of the 4.50 per cent and one pound less of the 3.20 per cent would increase the Silicon 4.50 per cent less 3.20 per cent, equals 1.30 per cent. To increase the mixture 130 per cent it would take as many pounds as 1.30 per cent is contained in 130 per cent, which. is 100. One hundred pounds more of the 4.50 —47— per cent iron and 100 pounds less of the 3.20 per cent iron would make the mix correct. Again. One pound more of the 4.50 per cent iron and one pound less of the 1.82- per cent would increase the Silicon 4.50 per cent less 1.82 per cent, equals to 2.68 per cent. To increase the mixture 130 per cent it would take as many pounds as 2.68 per cent is con- tained in 130 per cent, which is 48.4 — practically 50 pounds. We have made the change in each case by increasing one iron and taking the same amount less of another iron, changing the amounts in but two irons. We do not have to confine ourselves to two irons, but can take sev- eral irons. One pound more of the 4.50 per cent iron and one pound less of the 3.20 per cent iron woulcl increase the mixture 4.50' per cent less 3.20 per cent, equals to 1.30 per cent. Taking 50 pounds we would increase the mixture 50 times 1.30 per cent, equals to 65 per cent. The total as- sumed mixture is 130 per cent too low, so that by this change we would still be 130 per cent less 65 per cent, equals to 65 per cent, too low. One pound more of 2.43 per cent iron and one pound less of 1.82 per cent iron would increase the mixture 2.43 per cent less 1.82 per cent, equals to .61 per cent. Taking 100 pounds, we would increase the mixture 100 times, .61 per cent, equals to 61 per cent. We would then be —48— 65 per cent less 61 per cent, equals to 4 per cent, too low on the total mixture. This is calculating about as close as possible within 50 pounds. We have, however, two irons very near alike, namely, 3.20' per cent and 3.10 per cent. One more of 3.20 per cent and one pound less of 3.10 per cent would increase the mixture 3.20 per cent lesi* 3.10 per cent, equals to 10 per cent. Fifty pounds more would increase the amount 50 times 10 per cent, equals to 5 per cent. The total Silicon of the mix would then be 5 per cent less 4 per cent, equals to 1 per cent too high. Notice that we took 50 pounds less of 3.20 per cent iron with the 4.50 per cent iron, and now take 50 pounds more of the 3.20' per cent iron with the 3.10 per cent iron, so that we might have taken the 4.50 per cent iron and the 3.10 per cent. But we did not suppose to know this. This example illustrates very well how the method can be used. In assuming the amounts of iron, the total Phosphorus should be figured the same way as the total Silicon. As the Phos- phorus is too. high or too low, that will decide what changes had best be made. In the example given many more changes could have been made. Some irons might have been discarded alto- gether. The Phosphorus would determine that to a great extent. —49— Calculating the Mixture of Iron for Silicon, When More Than Two Irons are to be Used, by Making Separate Mixtures of Two Irons, and Combining These Separate Mixtures. We have had the method of calculating the mixture of iron for Silicon where two irons are to be used. The method is here used, and then the different mixtures are combined to make a grand total mixture. . Z "" To illustrate the method, let us suppose that we have three kinds of iron in the yard that analyzes 3.40 per cent, 2.00 per cent and 1.75 per cent Silicon, and we want to make a casting that will contain 2.20 Silicon. Suppose that the loss in the cupola is .30 per cent; then the mix- ture would have to be 2.50» per cent Silicon. Now, by applying our rule for two cars at a time, we have the following calculation: Taking 3.40. and 2.00 we have High 3.40 Mix 2.50 .50). 90 (1.8 .90). 50 (.555 Mix 2.50 Low 2 00 50 450 .90 .50 400 500 450 500 450 1. part of 3.40 equals 3.40 1.8 it " 2.03 (C 3 60 2.8 " " 2.50 " 7.00 —50— 1. part of 2.00 equals 2.00 1.55 " " 3.40 " 1.88 1.55 " " 2.50 »« 3.88 1 divided by 2.8 equals .357, or .357 parts of 3.40 per cent and .643 parts 2.00. Taking the 3.40 and the 1.75 we have High 3 40 Mix 2.50 .90) .750 ( .833 .75). 90(1. 2 Mix 2.50 Low 1.75 720 75 .90 .75 300 150 270 150 300 270 300 1 part of 3.40 equals 3.40 1.2 " " 1.75 " 210 2.2 2 50 5 50 1 part of 1.75 equals 1.75 .833 " " 3.40 " 2.83 1.833 " " 250 " 4.58 Dividing 1 by 2.2 equals .4546, hence .4546 parts of 3.40 and .5454 parts of 1.75. If the cast-, ing is to be 2.50 per cent Silicon, then the gates or return scrap will be 2.20 per cent Silicon, which will require a higher Silicon iron to bring, it to 2.50 per cent. Taking, then, the gates witl the 3.40 per cent iron, we have —51— High 3.40 Mix 2.50 .90) .300 ( .333 Mix 2.50 Gates 2.20 270 .90 .30 300 270 30 1 part of gates 2 20 equals 2.20 .33 " " 3.40 " 1.13 133 parts 2.50 " 3.38 Dividing 1 by 1.333 equals .75, or .25 parts of 3.40 and .75 parts of Gates. Taking one part to mean one pound we hare from the above: 100' pounds of G-ates require 33.33 pounds of 3.40 per cent Silicon iron. 100 pounds of 2.00 per cent requires 55.55 pounds of 3.40 per cent Silicon iron. 100 pounds of 1.75 per cent requires 83.33 pounds of 3.40 per cent Silicon iron. With two kinds of iron only one mixture can be made, but with two or more, and figuring for but one element, any amount of mixtures can be made. This is evident, for it is taken as granted that the first and second will make a mix and the first and third will make a mix. Now the amounts taken of these two mix to make a mix can vary almost inefinitely. Hence, in making a mix we must decide upon the amounts of some —52— of the irons and let the balance be taken as re quired to make the mix. To illustrate, let us suppose that we make i mix of 1000 pounds. We desire to use up o§ gates, which amount to 300 pounds a charge also want to use 300 pounds of the 2.00 per cen iron and the rest of 1.75 per cent and 3.40 pe: cent iron. From the above table we see that 300 lbs. of gates require 1C0 lbs. of 3.40 per cent. 200 lbs. of 2.00 per cent. Ill lbs. of 3.40 per cent. 500 lbs. of iron require 211 lbs. of 3.40 per cen Or making a total of 711.11 pounds of iron. Th mixture is to contain 1000 pounds, so that w have 1000, minus 711.11 pounds, equals 288.8 gates, to make with the 3.40 per cent iron an the 1.75 per cent. Looking up the 1.75 iron, we find that it r( quires .4546 of the 3.40 per cent and .5454 c the 1.75 per cent iron to make one part. Thei to make 288.90 parts, it will take 288.89 tinn this amount, or 131.33 of the 3.40 per cent au 157.56 of the 1.75 per cent iron. Adding the three different amounts of 3.4 per cent iron to be used, we have 341.83 pound The mixture, as calculated, will then be as fc lows : 300 lb£. of gates at 2.20 660. 200 " " iron " 2.00 400. 157.56 175 27685 342.44 3.40 1162.22 1000 pounds of mix 2.50 2499.07 —53— This is practically 2500, or average of 2.50 per cent. We find above that we use 157.56 of 1.75 per cent iron and 342.44 of 3.40i per cent iron. Now in practice we do not weigh so close, but only within an even 50 ponnds. Of course, every one can weigh as close as they see fit. It is always better to have the iron a little higher in Silicon than lower (chilled iron excepted); so we round off the mix above and call it 150 pounds of 1.75 per cent and 3.50 of 3.40 per cent iron. The -mix will then be 300 pounds of 2.20 per cent iron 200 pounds of 2.00 per cent iron 150 pounds of 1.75 per cent iron 350 pounds of 3.40 per cent iron 1000 This will make the average about 2.51 per cent. If there had been another kind of iron that was above the mixture in Silicon, then this could have also been used. The main idea is to get the amount that is required with 100 pounds of iron and the amounts of each to make 100 pound?, and we have all that is required to make any mix. Calculating For Two Elements. It is impossible to calculate for more than one element at a time. If it is desired to figure the mixture for two elements, for instance, , Silicon —54— and Phosphorus, then two or more mixtures must first be figured for Silicon and these mix- tures taken and figured for Phosphorus. For Silicon it requires but two kinds of iron, but to figure for Silicon and Phosphorus it re- quires three or more kinds of iron, and the Phos- phorous in these irons must be so that when two of these irons are taken together the Phospho- rus of two of them will be above the require^ Phosphorus of the mix and the second two will be below the required Phosphorus of the mix. In the example for Silicon we had three kinds of iron. Let me take these same irons and give the Phosphorous: 3.40 Silicon 1.40 per cent Phosphorus 2.00 Silicon .80 per cent Phosphorus 1.75 Silicon .50 per cent Phosphorus Taking the 3.40 per cent and 2.00) per cent, we see in the Silicon table that it takes .357 parts o' 3.40 and .643 parts of 2.00. The Phosphorus in 100 pounds would then be 3577 times 1.40 equals 49.98 64.3 times .80 equals 51.44 100 1101.42 Mix would then be 2.50 Si.; 1.01 Phos. Call this "A." Taking 3.40 per cent and_1.75 per cent, we see from the Silicon table that it takes .4546 parts oj 3.. 40 per cent and 5454 parts of 1.75 per cent. —55— The Phosphorus in 100 pounds would then be: 45.46 times 1.40 equals 53.64 54.54 times .50 equals 27.2? 100. 80.91 Mix would then be 2.50 per cent Silicon; .8091 Phosphorus. Call this "B." Let us suppose the castings should be .93 per cent Phosphorus. Then, figuring the same way as in Silicon, we have : .014 .93 .93 .809 .084) 121 (.144 84 .121) 0840 (.694 726 .084 .121 370 336 1140 1089 1 part of .809 equals .809 1.44 ; - ■« 1.469 " 1.460 2.44 2 269 1 part of 1.014 equals 1 014 .694 " " .809 " .5614 1 694 1.5764 Dividing 1 by 2.44, we have .4098, hence .4098 of .809 Phosphorus and .5902 of 1.014 Phospho- rus would make the mix. The mix would then be 40.98 of "A" and 59.02 of "B." 40.98A. .357 of 3 40 per cent equals 14.62986 .643 of 2.00 " " " 26.35014 —56— 59,02B. .4546 of 3 40 per cent equals 26.830492 .5454 u 1.75 '• " •' 32.189508 lOO.OOOuOO Adding the two amountts of 3.40 per cent Sili- con, we have: 41.460 of 3 40 per cent Silicon 1 40 per cent Phof 26.350 of 2 00 " " " 80 " " " 32 190 of 175 " " '« .50 " " " 1000 000 of 2.00 " " " .93 " " " This is calculated to 100 pounds. Of course any amount could be taken by multiplying the above. If another iron was on hand, this coulc be figured like above and another mixture made This is all very easy, it being only a matter of , few figures. Any of the methods for calculating the Silicor can be used to make a mixture with the correc Silicon. The Phosphorus that these mixture contain must be calculated. Two or more mix tures are made and the Silicon item not consi( ered. The Phosphorus is then calculated th same manner as the Silicon has been. -^ Facts Worth Thinking About. By having analysis made you can tell whether the furnace sent you the iron ordered. By having each car checked the furnace will be more particular as to what they send you. Otherwise they are apt to think that you will not know any better. By analysis you can use the iron to the best advantage and save money. By analysis you can have the same mixture day after day and have better castings, changing your irons as you please. By analysis you are not dependent upon any particular brand, but can buy from whoever sells the cheapest. A ear of iron generally contains 25 tons of iron and costs between $400 and $500. Would not any one be willing to pay a dollar or two more to know that the iron is all right, and have the correct analysis so that the iron, can be used to the best advantage? Any foundryman that cannot save many, many times the cost of analysis ,in making the mixture, have better castings and less loss, had better give up his position. —58— SAMPLING IRON. Take three to six pieces (the more the better) of iron from different parts of the ear. If the iron is broken and the fracture can be seen, then se- lect different-looking pieces. Take borings of these pieces, throwing away the first cut, so that you get clean borings. Mix these borings well, and put about an ounce in a small envelope. On this envelope put the car number, name of iron or casting, or place any number or mark on it, so that you will know what it contains. Mark tne elements that you want analyzed on this en- velope. The same for any casting. I furnish a special printed envelope to my customers. Place this envelope or several envelopes in a large one and mail to WAUTEH H. WANGELIN, Chemist. Belleville, 111. — 59— tjsiei S. OBERMAYER CO. Cincinniti. Chicago- Pittsburg. MANUFACTURES "Everything Yoi Need in Yoir Foundry." HIGH GRADE PLUMBAGO AND BLACKINGS, *Moderntf oundry* Equipment. * iff. LOUIS OFFICE, 305 Roe Building. 0. M BARKER, Representative. Telephones Bell, Main 2410. Kinloch, B 570. —GO— The Modern" Molding Machine Especially Adapted for Making Small, Light Gast/ng. The "MODERN" is a Match Plate Machine designed to handle successfully a great variety of snap work. It has many features superior to other molding machines. In our own foundry we have developed a saving in the cost of our castings of 15 per cent to 40 per cent, according to the class of work, and get much more perfect and satisfactory castings. DIMENSIONS when set up all complete ready for operation are as follows ' Height, 34 inches; length, 49 inches; width, outside wheels, 42 inches. iW*wi weight, 1050 lbs.'*^ • The "MODERN" will take in flasks varying in size from a 10 x to to a P"*# 14 x 22 inches. ^> , Write for our Catalog and further information. AflOADE MFdrBb.. Freetttrt. til. -61- S3 Blower Talk . To any foundry man needing a blower for curaola use we would recommend that, before buying else- where, you communicate with the COXXEKSYILLE BLOWEE CO., Connersville 3 Indiana, They are the manufacturers of a Eotary Positive Pressure Blow- er, which is being used very exten- sively in foundries and is giving ex- cellent satisfaction. A postal will bring you their cata" logue and prices will be quoted up- on application. They have also an Eastern office at 95 Liberty street, New York City, in charge of Mr. Horace G. Cooke. S3 —62— De Camp Bros. & Yul IRON, GOAL X GOKE GO; PIG IRON, FOUNDRY COKE, SMITHING COAL. Sole agents for The St. Louis Blast Furnace Co.'s Basic (Chill Mold) Malleable and Car Wheel Irons. Also high grade foundry iron for castings requiring great strength. 1103 Fischer Bldg., Missouri Trust Bldg., CHICAGO. ST. LOUIS. —63— F. H. Cha.mberlin, President. J. D. Smith, Sec. and Treas THE J. D. Smitb Foundry SupDly Co PROPRIETORS Cleveland Facing Mill -MANUFACTURERS OF— foundry Facing, Blacking and Foundry Supplies, Importers and Refiners of Plumbago . —AND— Silver Lead CLEVELAND, OHIO.. LIBRARY OF CONGRESS WiUBnkr 003 275 863 © 11 b 111 M MISSISSIPPI GLASS COMPANY, FIRE BRICK DEPARTMENT GENERAL OFFICES! W0RKS \ST. LOUIS, MO. MAIN & ANGELICA STS., ST. LOUIS. } VANDALIA, MO. CUPOLA LININGS, CUPOLA BLOCKS, FIRE BRICK, FIRE CLAYS. We make and carry in stock a large assortment of high grade Cupola Blocks, Fire Brick and Clays. Avail yourself of this oppartunity, save time and worry, and always specify and insist on getting WALSH BRANDS. Gold Medal awarded us at the Louisiana Purchase Exposition.