Inventors at Work, with Chapters on Discovery

Properties Long Deemed Useless are Now Gainful.

If properties at first unwelcome have at last been turned to account, so also have properties which were long deemed utterly useless. A big and interesting book might be filled with the story of how by-products, long thrown away as worthless, have rewarded careful study with great profit. Thus for ages was bran discarded in flour-mills: to-day it may afford all the miller’s profit, or even more than that profit. In the Southern States until a generation ago cotton seed was regarded as valueless. At present that product, so long wasted, is the basis of a great industry, a ton of seed yielding about 1089 lbs. of meat to 20 lbs. of lint; out of this meat 800 lbs. are cake and meal; the remainder, 289 lbs., forms an oil which furnishes a substitute for olive oil and lard. Until a few years ago glycerine was thrown away as produced in candle-works and soap factories. It is now so valuable that manufacturers adopt just that method of preparing fatty acids which yields most glycerine from neutral fats. So in paper-making, the soda which formerly was sent into creeks and rivers to the pollution of sources of water-supply, is now used over and over again, largely increasing the net results of manufacture. No industry has shown of late years so large utilization of products formerly wasted as the iron and steel manufacture. Its slags are made into bricks, cement, and glassy non-conductors of heat and electricity. Its gases are used for engines developing immense motive powers, or they are in part condensed for valuable acids or other compounds. In these cases and thousands more the question has been, What are the properties of these by-products? How can they be made useful?

Separation Turns on Diversity of Properties.

Let us note how diverse substances are separated from one another by taking hold of differences in their properties. When a handful of grain which has just passed under a flail is thrown upward in a breeze, its chaff is blown much farther than the grain; the difference in breadth of surface, joined to a difference in density, enables the wind to effect a thorough separation. A common fanning mill, with its quick air current, works much better than the fitful wind, because continuously. That simple machine, like every other which takes a mixture and separates its ingredients, seizes upon a difference in properties. In Edison’s apparatus for removing iron from sand or dust, a series of powerful magnets overhang a stream of sand or powdered material, deflecting the iron particles so that they fall into a bin by themselves, while the trash goes into an adjoining larger bin. The Hungarian process of flour-milling first crushes wheat through rollers; the various products are then separated by processes which lay hold of differences in specific gravity—often but slight.

A feat more difficult than that of the Hungarian mill would seem to be the division of diamonds from other stones. It has been accomplished by Mr. Frederick Kersten of Kimberley, South Africa. He noticed one day at his elbow a rough diamond and a garnet on a board. He raised one end of this board, and while the garnet slipped off, the diamond remained undisturbed. What was the reason? He observed that the wood bore a coating of grease, which possibly had held the diamond while the garnet had slipped away. He took a wider board, greased it, and dropped upon it a handful of small stones, some of which were rough diamonds. He found that by inclining the board a little, and vibrating it carefully, all the stones but the diamonds fell off, while the diamonds stuck to the grease. He forthwith built a machine with a greasy board as its separator, and scored a success.

On quite a different plan is built the coal washer which separates coal from slate. Pulses of water are sent upward through a sieve so as to strike a broken mixture of coal and slate, making a quicksand of the mass. Because the slate is heavier than the coal it is not carried so far, and is therefore caught in a separate stream and thrown away.

Properties Newly Discovered and Produced.

Separations, such as we just considered, turn upon obvious differences in density. Properties not obvious, yet highly useful, come into view year by year as observers grow more alert and keen, as new instruments are devised for their aid, as measurements become more refined, so that matter is constantly found to be vastly richer in properties than was formerly supposed. We have long known that carbon has forms which vary as widely as coal, graphite and the diamond. Many other elements are detected in a similar masquerade. Iron, for instance, takes three forms, alpha, beta, and gamma. Alpha iron is soft, weak, ductile and strongly magnetic; beta iron is hard, brittle and feebly magnetic; gamma iron is also hard and feebly magnetic, yet ductile. Joule, the famous English experimenter, prepared an amalgam of iron with mercury; when he distilled away the mercury, the remaining iron took fire on exposure to the air, proving itself to be different from ordinary iron. Moissan has shown that similar effects follow when chromium, manganese, cobalt and nickel are released from amalgamation with mercury.

At first steel was valued for its strength and elasticity; to-day we also inquire as to its conductivity for heat or electricity, its behavior in powerful magnetic fields, its capacity to absorb or reflect rays luminous or other. As art moves onward we enter upon new powers to change the properties of matter, compassing new intensities of heat and cold, each with new effects upon tenacity, elasticity, conductivity. So also with the extreme pressures, possible only with modern hydraulic apparatus, which prove marble to be plastic, and reduce wood to a density comparable with that of coal, explaining how anthracite has been consolidated from the vegetation of long ago.

And one discovery but breaks the path for another, and so on indefinitely. Coming upon a new property, the sensitiveness of silver compounds to light, meant a new means of further discovery, the photographic plate. That plate, responsive to rays which fall without response upon the retina, reveals much to us otherwise unknown and unsuspected. Of old when an observer saw nothing, he thought there was nothing to see. We know better now. Thanks to the sensitive plate we have reason to believe that properties, once deemed exceptional, are really universal. Phosphorescence, for ages familiar in the firefly, in decaying logs and fish, now declares itself excitable in all substances whatever, although usually in but slight measure. The case is typical: the polariscope, the spectroscope, the fluoroscope, the magnetometer, the electroscope, each employing as its core a substance of extraordinary susceptibility, detects that quality in everything brought within its play. Thus from day to day matter is disclosed in new wealths of properties, and therefore in new and corresponding complexities of structure. In ages past mankind was on nodding terms with many things, and had no intimate knowledge of anything.

With materials before him richer in array than ever before, and better understood than of old, the inventor asks, What properties do I wish in a particular substance? Then, he proceeds to make, if he can, a dye of unfading permanence, an insulator resistant to high temperatures, an alloy which when subjected to heat or cold remains unaltered in dimensions. He finds materials much more under command than a century ago could have been imagined, as the glass manufacture, the alloying industry, the making of artificial dyes, abundantly prove.

Edison’s Warehouse as an Aid.

Mr. Edison, for aid in finding just the substance he needs for a new purpose, has at his laboratory in Orange, New Jersey, a large store-room filled with materials of all kinds. He may wish a particularly high degree of elasticity, hardness, abrasive power, or what not; to provide these he has gathered a wide diversity of woods, ivories, fibres, horn, glass, porcelain, metals pure and alloyed, alkalis, acids, oils, varnishes and so on. Take one example from among many which might be given from his shelves; he finds that a sapphire furnishes the best stylus wherewith to cut a channel on a phonographic cylinder. Hard, flinty particles from the air are apt to enter the wax, so as to blunt a cutting edge. Diamonds would be best as channelers, but their cost obliges him to choose sapphires as next best; they are purchasable at reasonable prices and last ten years under ordinary conditions of wear.

CHAPTER XII
PROPERTIES—Continued

Producing more and better light from both gas and electricity . . . The Drummond light . . . The Welsbach mantle . . . Many rivals of carbon filaments and pencils . . . Flaming arcs and tubes of mercury vapor.

Light Giving Properties.

Mr. Edison has achieved triumphs not only in giving sound its lasting registration, but in producing an electric light of new economy. Both exploits proceeded upon a masterly knowledge of properties. A century ago candles provided illumination both to rich and poor, the sole difference being that wax shone in the palace and tallow in the hut. The oil lamps which gleamed in the lighthouses of England and America, for all their bigness, were plainly of kin to the Eskimo saucer filled with blubber, edged with moss as wick. Yet for ages, from every hearth in Christendom, there had been the promise of better things as bituminous coals, or sticks of wood, had cheered as much by their light as by their warmth. We owe much to James Watt, who improved the steam-engine and gave it essentially the form it retains to the present hour. We owe also a weighty debt to an assistant of his, William Murdock, who, thanks to a suggestion from Lord Dundonald, attentively observed the process by which coals produce light. He saw that under stress of intense heat the solid fuel emitted streams of gas which burned with great brilliancy. Here gas-making and gas-burning went on at the same moment in the same place; might the process be separated, so that gas might be made here, and burned elsewhere at any convenient time? An experiment proved the project to be feasible, and forthwith the Soho Works, near Birmingham, in which Watt’s engines were built, were lighted by gas. Such was the beginning of an industry now important in many ways. To-day gas not only yields light, but heat and power, while, especially in metallurgy, fuels are more and more used after reduction to the gaseous form.

How the Gas Mantle was Invented.

Early in the day of gas-making it was noticed that gases of various kinds differed much in light-giving quality. It was presently shown that their light depended on the carbon brought to incandescence in a flame; in the absence of that carbon, as when a jet of pure hydrogen was consumed, extreme heat was accompanied by no light whatever. Then came a capital discovery, namely, that lime introduced within a burning jet of hydrogen became intensely luminous while itself but slowly consumed. Adopting lime for the core of his apparatus, Captain Thomas Drummond, of the Royal Engineers, in 1835 devised the lime light. Upon a block of pure, compressed quick lime, he directed a jet of burning gas, obtaining a beam of great vividness still employed in stereopticons and in theatres. For modern types of the Drummond lamp a twin jet of hydrogen and oxygen is used. Lime has many sister substances having light-giving quality when highly heated, and among them are many rare earths, oxides of uncommon elements. These strange substances were destined to play a prominent part in the battle between gas and electricity as illuminants. When Edison in 1878 perfected his incandescent bulb, it seemed as if electricity were soon to be the sole illuminator of houses. But the gas engineers were to be rejoiced by the invention of a mantle which quadrupled the brillancy of a gas flame, withstanding the rivalry of electricity in a notable degree. This mantle was invented by Dr. Auer von Welsbach, a chemist of Vienna, who virtually adopted the principle of the Drummond light. His efforts give us an admirable example of an inventor passing from a hint to a test, day after day meeting new difficulties with unfailing courage and resourcefulness.

In 1880 Dr. von Welsbach took up the study of rare earths, mainly with a view to ascertaining their value as illuminants. As he brought one specimen after another to melting heat on bits of platinum wire, he found that the little beads formed were unfavorable in shape to the production of light. Then came into his mind an idea of that golden quality which occurs only to the man who earns it: Why not soak cotton with solutions of salts of rare earths, burn the cotton and leave behind an earthy skeleton of slight thickness and much surface? Experiment proved that the idea had promise, but the skeletons crumbled to dust with the least tremor. For success a fair degree of cohesion was imperative, but to secure that cohesion demanded skill, resource, and patience. After a long series of trials a mantle was made with lanthanum oxide; immersed in flame its beam was particularly bright, now for the first time suggesting that the rare earths might yield light on a large scale. But trouble was at hand, to be overcome only at the end of much toil.

During an absence of several days, the inventor left a mantle of lanthanum oxide locked up in his laboratory. When he returned it had fallen to powder, having attracted from the atmosphere both moisture and carbon dioxide. Evidently this harmful attraction must be avoided by adding an ingredient to keep the mantle dry and preserve it from union with carbon dioxide. For this purpose magnesia was chosen; the resulting compound proved to be durable, and gave an agreeable light of moderate intensity. But, alas, after glowing about seventy hours, the mantle failed in its radiance, becoming of glassy and translucent texture. Thus impeded, the untiring inventor turned to mixtures having zirconium as a basis; these not only gave a steady beam, but extended to hundreds of hours the life of a mantle. Still bent on getting more light if he could, Dr. von Welsbach tested thorium oxide with gratifying results; yet, strange to say, when he had purified this material to the utmost, his light fell off in an unaccountable fashion. What could be the matter? Surely in the purifying process some invaluable element had been cast aside. This element, in the researches of an associate, Mr. Ludwig Haitinger, proved to be cerium in minute quantity. Here was a discovery of the highest moment; at the end of many experiments it was determined that one per cent. of cerium and ninety-nine per cent. of thorium oxide are the best proportions for a mantle such as we use to-day. Why these proportions are best nobody knows, any more than why one per cent. of carbon added to iron gives us a steel incomparably better than iron for many uses. A Welsbach mantle has good points apart from its economy of gas. Its combustion is thorough, so that it throws into the air a much lower percentage of injurious products than does an ordinary gas flame. It never smokes, and its light is so steady as to be available for work with the microscope and other exacting demands. It has one defect which may yet be removed: its light has a somewhat unpleasant tinge of green. In another chapter of this book, producer gas, much cheaper than common illuminating gas, is described. Dowson producer gas, with a Welsbach mantle, yields a light of 8 to 10 candle-power with a consumption of 4.5 to 4.8 cubic feet per hour.

Thus far no successful mantle for a petroleum lamp has been devised. With alcohol a mantle yields a brilliant flame. A lamp with a Boivin burner and a Welsbach mantle has given a light of 30.35 candle-power for 57 hours and 5 minutes in consuming one gallon of alcohol, almost twice as much light as given by a Miller lamp with a round wick and a central draft, burning a gallon of kerosene. In the United States on January 1, 1907, there will cease to be an excise tax on alcohol used in the arts, a denaturalizing process rendering the liquid unfit to drink. As this alcohol may be easily produced from grain or potatoes at 20 to 25 cents a gallon, a capital illuminant will be available for the public, as well as an excellent fuel and a substitute for gas or gasoline in motors.

As first manufactured, gas-mantles were woven, they are now knitted,—a change for the better in closeness and firmness of texture. Nearly all the thorium used for mantles is found in the monazite sands of the provinces of Bahia and Espirito Santo, along the coast of Brazil. These sands were for a long time valuable only for the zinc they contained. To-day the thorium they carry is of vastly more account; for chemical treatment this is sent to Germany whence the manufactured product is borne to every quarter of the globe.

Improvements in Electric Lighting: Incandescent Lamps.

While the Welsbach mantles have been constantly improved in quality, and given new and inverted forms of special value, the inventors in the field of electric lighting have not stood still. For interior illumination the Edison incandescent bulb still holds its own despite many a threat of dispossession. Since 1881 its details of manufacture have been steadily bettered and its price much reduced, while its consumption of current has fallen from 5.8 watts per candle to 3.1. This advance, marked as it is, leaves a long path ahead of the inventor whose estimate is that were the whole of an electric current transformed into light, a candle would cost us but .11 of a watt, that is, but one twenty-eighth part as much as when we set a carbon filament aglow. In electrical terms a horse-power yields 748 watts, representing, were there no waste in conversion, no less than 425 lamps each of 16 candle-power.

It is this immense margin for improvement that has spurred ingenuity to attack the problem of electric lighting from many new sides. The General Electric Company produces a carbon filament of one fifth greater efficiency than an ordinary untreated filament. Fibers of the usual cellulose kind are enclosed in a carbon box, placed in a carbon-tube resistance furnace heated to between 3,000° and 3,700° C. This converts the filament into a graphite of increased luminosity which, furthermore, blackens its enclosing glass much less than a common filament does.

In the early days of electric lighting a good many experiments were tried with threads of platinum, but without success. That metal remains unmelted at a very high temperature, but as a light-giver its quality is poor. Of late years investigators have turned to other metals, of high melting points, and with results so remarkable that we may expect some of them to be in general use in the near future. Tantalum, a rare and costly metal, has been found to give a candle-power with as little as two watts and, in specially favorable circumstances, with only 1.85 watts. Osmium, in the hands of Dr. Auer von Welsbach, reduces this figure to 1.5 watts. Dr. Hans Kuzel, of Baden, Austria, has employed filaments of tungsten in lamps which he claims demanded only one watt per candle. From among these new lamps it seems highly probable that as soon as methods of manufacture are settled and standardized the world will be given an electric light, in small units, much cheaper than ever before.

New Arc Lamps.

For large spaces indoors and for out of doors the arc-lamp maintains its popularity in much the form originally devised by Mr. Charles F. Brush of Cleveland. But, as in the case of the incandescent bulb, many a rival is now disputing the field, so that supersedure may be close at hand. In what are known as flaming or luminous arcs the carbon pencils are impregnated with salts of the calcium group of elements, of extreme luminosity. In these lamps the electric arc itself is the chief source of light, instead of the glowing end of the positive carbon as in a common arc lamp. As the calcium salts volatilize into gases they provide a path of less resistance than air for the passage of the current, so that the electrodes may be drawn apart to a distance which may be as much as 2¹⁄₂ inches. These lamps require free ventilation, so that they must be open. Their economy is extraordinary, a candle-power being afforded for .353 watt, as against 1.78 watts for an enclosed arc lamp, a five-fold gain in effectiveness. To renew the carbons, which waste rapidly, a new device provides fresh pencils, cartridge fashion, as required. Without this aid, trimming is often necessary, and this fact joined to the high cost of the carbons lessens the net gain in their use. On another line of experiment noteworthy results have been reached with metallic oxides. Magnetite, an oxide of iron, has developed a candle-power with but one half of one watt. Ferro-titanium, a compound of iron and titanium, has given a candle-power with only one third of a watt, and it is expected that still higher efficiencies will soon be attained with this wonderful compound.

Hewitt Mercury-Vapor Lamp.

From quite another side Mr. Peter Cooper Hewitt enters the field of light production, utilizing the glow of a vapor instead of a solid stick. His lamp is a long, slender tube of glass; within each end is sealed a metallic wire; at one end is a little mercury. When a powerful pump has exhausted the tube to a high degree it is sealed, and its wire terminals are placed in an electric circuit. On tilting the tube the mercury flows from end to end, an arc is formed, and the mercury vapor becomes luminous. This vapor remains unconsumed, and the lamp asks no attention whatever. Its rays are greenish, so that where normal colors are desired, it is well to use supplementary lamps of carbon filaments to furnish red rays. For streets, squares, freight-sheds and the like, the Hewitt light is capital just as produced, its rays being widely diffused and casting no heavy shadows. Its high actinic power makes it specially useful to photographers, while in factories, drafting rooms, composing rooms and so on, its color is unobjectionable. Its cost is small, as a candle-power is produced in large tubes with but 0.55 of a watt. A Hewitt lamp of automatic type, recently devised, has a small solenoid or magnet on the suspension bar just above the holder. On closing the circuit the current flows through this solenoid which instantly tilts the tube and starts the light. This lamp is particularly suited to places, such as the lofty ceilings of foundries, where it would be difficult to tilt the tube by hand. Hewitt lamps use either a direct or an alternating current.

In an earlier chapter we glanced at reflectors and refractors, newly invented, which give light its most useful paths with as little avoidable loss as possible. These devices, applied to Welsbach burners and the new electric lamps, greatly economize modern illumination in comparison with that of former times.[13]

CHAPTER XIII
PROPERTIES—Continued. STEEL

Its new varieties are virtually new metals, strong, tough, and heat resisting in degrees priceless to the arts . . . Minute admixtures in other alloys are most potent.

From a brief consideration of illuminants let us pass to a rapid survey of a most important group of structural materials, the steels. Here, as always, we shall find how abundant are the harvests reaped in a searching study of properties. Within the past fifty years new steels have been produced in so ample and rich a variety that we have gained what are virtually many new metals of inestimable qualities.

Steels for Strength.

In 1781 Professor Torbern Bergman, of the University of Upsala, in Sweden, showed that steel mainly differs from iron in containing about one fifth of one per cent. of plumbago, or carbon, as we would say now. Steels may contain all the way from one tenth to one and a half per cent. of carbon; the lower this percentage, the more nearly does the steel approach wrought iron in softness; as the proportion of carbon increases up to one per cent. the steel increases in tenacity, beyond one per cent. tenacity diminishes and brittleness is augmented. Hardness depends upon the percentage of carbon a steel contains. Physical conditions are almost as important as chemical composition; a mass of red-hot steel, carefully hammered or pressed is thereby strengthened, an effect due either to minimizing the process of crystallization, or to breaking up crystals as fast as they form. The microscope reveals many details of structure in steel, and has enabled the analysts greatly to economize the manufacture of desired varieties. Under the microscope steels much resemble crystalline rocks in structure, with constituents differing widely. Of these the most important is ferrite, a pure or nearly pure metallic iron, soft, weak, ductile, of high electric conductivity. Next in importance is cementite, an iron carbide (Fe₃C), harder than glass and nearly as brittle, but probably very strong under gradually and axially applied stress. A third constituent, austenite, is a solid solution of carbon, or perhaps of an iron carbide, in gamma allotropic iron (there being also alpha and beta irons). Austenite is hard and brittle when cold, is stable at high temperatures, and is slowly transformed by reaction into compounds of ferrite or cementite. Several other ingredients of importance, as pearlite, illustrated on the opposite page, have also been studied.[14]

While carbon is the most decisive element in admixture, other ingredients have marked influence, silicon and manganese especially. The process invented by Bessemer, described by himself in another chapter of this book, as introduced in 1855, revolutionized the steel manufacture by its directness, cheapness and speed. It consists in burning out from pig-iron, by a hot air blast, all or nearly all its carbon. Then spiegeleisen, or other mixture, containing a definite quantity of carbon and manganese, is added to the molten mass, yielding steel of the quality desired. This method produces more rails for railroads than any competing method; in other fields it is being rivalled more and more severely by the open hearth process.

The Open Hearth Process.

Steel making by the open hearth process is chiefly due to the late Sir William Siemens. In a gas producer he gave his fuel the gaseous form, in which it is more easily controlled and more efficient than when solid. Of more importance were his regenerators, chambers of brickwork, heated by the products of combustion, and then employed to warm incoming currents of air and gas on their way to the furnace. The Siemens furnace has been modified in many ways and much improved in its details. A good example of an open hearth furnace, as planned by the late Mr. Bernard Dawson, is shown on page 165. It centers in a large hearth built of refractory materials, upon which the metal is melted as flames play over it. At each end are two regenerators filled with checker firebricks through which air or gas passes on its way to the furnace, and through which, at due intervals, the products of combustion emerge as they pass to the stack. On each side, one of the regenerators is for air, the other for gas; between them is a substantial wall to prevent any mixing before their currents reach the hearth. It is in the regenerator, which utilizes heat which otherwise would be wasted, that the open hearth displays its best feature. Its products vary in composition as its raw materials vary, whether pig-iron of a specific kind, a particular ore, or scrap; and just as in the Bessemer process, a harmful element, as phosphorus, is removed almost wholly by the addition of a suitable ingredient, such as lime. In excellence and uniformity of quality open hearth steels are preferred to those of the Bessemer converter, even for railroad rails which for years were made solely by the Bessemer process.

The Gayley Dry-Blast Process.

A remarkable improvement in blast-furnace practice, cheapening cast or pig-iron, and therefore lowering the cost of derived steels, is the dry-blast process due to Mr. James Gayley, of Pittsburg. It has long been known that blast-furnaces ask more fuel in warm and damp weather than in cold and dry weather; beginning with this familiar fact Mr. Gayley proceeded to dry the air blown into his furnaces, by passing it around large coils of iron pipes through which a freezing mixture circulated, melting the snow as formed by passing hot brine through the pipes, a few of them at a time. The air thus dried was then heated by being sent through hot blast stoves in the usual mode. This simple drying of the blast saves about 19 per cent. of the fuel, and makes the action of the furnace much more regular than when ordinary air is used. It lowers the temperature of the gases which escape from the top of the furnace, and raises their percentage of carbon dioxide, symptoms of the great increase in fuel efficiency. Atmospheric moisture has a cooling effect on the lower part of a furnace, just where the highest temperature is needed to melt the iron and slag, remove the sulphur and deoxidize the silica. A comparatively small increase of temperature by broadening the margin of effective heat, which margin at best is narrow, has the astonishing effect of economizing fuel to the extent stated, 19 per cent.[15]

Steels to Order.

What is chiefly sought in steel is tensile strength, next in value is elasticity; in some cases hardness is indispensable. By varying the proportions of the carbon, silicon and manganese added to his iron, the steel-maker produces an alloy with the tenacity, elasticity or hardness he wishes. Nickel, as a further ingredient, in certain proportions yields an astonishing gain. A steel containing fifteen per cent. of nickel has shown a tensile strength of 244,000 pounds to the square inch, four times as much as before admixture; the elastic limit also was much increased. Hardness and strength tend to exclude ductility, but nickel steel is at once strong, hard and extremely ductile; hence its use for armor plate, great guns, and the barrels of small arms. Nothing but the high price of nickel prevents these alloys from having wide utilization, for they mean lighter and therefore more economical machines and engines than those of ordinary steel. Many turbines actuated by water, steam or gas, are best operated at speeds forbidden to common steel, which would fly to pieces under the centrifugal stress exerted, yet these speeds are quite feasible and safe when nickel steel is employed. This alloy brings nearer the day of mechanical flight, first promising to transportation on land and sea engines increased in power while much diminished in weight. In exceptional cases, where the expense may be borne, we may expect soon to see nickel steel used for higher towers, longer bridge-spans, thinner boilers, than those of to-day. Part of the bridge crossing Blackwell’s Island, New York, is built of nickel steel. Even with costs at their present plane, it is worth while for the designer of machinery to remember that friction is reduced when masses become smaller, power for power. It is found profitable, for instance, to use nickel steel for the cylinders of automobiles of high power.

In many tools and implements two different kinds of steel are united with decided gain. Thus the cutting edge of a cold chisel is hard and brittle, while its shank, much less hard, is tough and able to resist the shocks it receives. So also a projectile is hardened at its point and nowhere else. Plowshares are often made very hard on their surfaces, with a backing which is comparatively soft but elastic enough to suffer no harm in the blows dealt by rough ground and stones. One of the drawbacks in the use of steel is its liability to corrosion. An alloy of 30 per cent. nickel and 70 per cent. steel has proved to be corrodible in but slight measure, affording a material of great value to the arts.

Heat Treatment.

While the chemical composition of a steel is of prime importance, the quality of the steel will next depend upon its heat treatment in manufacture. The temperature to which heating is carried, the period during which it is maintained, the rate at which cooling takes place, and the circumstances of cooling, each has its effect on the character of the product. It is chiefly in this field that the steel-maker within wide limits is able to turn out an alloy either hard or soft, brittle or ductile, tenacious or weak, at pleasure. While much has been learned within the past few years as to the proper treatment of steel by heat, much still remains to be discovered.

To quote typical instances from Professor Henry Marion Howe, of Columbia University, New York:—“In the case of steel with less than 0.33 per cent. of carbon the temperature from which slow cooling occurs appears to have little influence on the tensile strength; but it is the general belief that if that temperature approaches the melting-point, the tensile strength decreases. In the case of higher-carbon steel, the tensile strength at first increases as the temperature from which slow cooling occurs rises to 800°, or even to 900° or 1000° C. Then, after varying somewhat, it falls off very abruptly in the case of steel of 0.50 per cent. of carbon, when that temperature approaches 1400°.”[16]

Tempering and Annealing.

For rock drills, cold chisels, milling and other tools it is necessary to use steel carefully tempered, so that brittleness is greatly reduced while considerable hardness and cutting power remain. Other changes of properties, as remarkable, follow upon subjecting steel to greater heat than that used for tempering. Says Professor Roberts-Austen:—“Three strips of steel identical in quality are taken. By bending one it is shown to be soft; if it is heated to redness and plunged in cold water it will become hard and will break on any attempt to bend it. The second strip, after heating and rapid cooling, if again heated to about the melting point of lead, will at once bend readily, but will spring back to a straight line when the bending force is removed. The third piece may be softened by being cooled slowly from a bright red heat, and this will bend easily and remain distorted. The metal has been singularly altered in its properties by comparatively simple treatment, and all these changes, it must be remembered, have been produced in a solid metal to which nothing has been added, and from which nothing has been taken away.”

It is the comparative slowness of cooling in oil, the greater slowness of cooling in air, that make these by far the best tempering processes, because the molecular re-arrangement, in which tempering consists, requires time. Often the critical temperature, at which a desired re-arrangement takes place, is declared by the metal losing all power of response to a magnet: this fact affords the steel-maker welcome aid; he has only to shut off heat as soon as his steel ceases to attract a magnet and plunge the steel into water in order to obtain the hardness he wishes.

The complex phenomena of heat treatment in steel manufacture are fully discussed by Professor H. M. Howe, in his “Iron, Steel and Other Alloys,” second edition, 1906.

Steel for Railroad Rails.

In another chapter of this book a word is said as to the form of rails at which Mr. P. H. Dudley has arrived as the outcome of years of experiment. He thus describes the properties which the steel should possess by virtue of due chemical composition and proper heat treatment:—

“Ductility to ensure power to resist the shock of the driving wheels, so that the steel may not break; resistance to abrasion, that it may not wear out; and high limit of elasticity, that it may not take a permanent set and be bent into a series of waves between its supporting ties, by the enormous pressures which the wheels of to-day throw upon it. The best composition is carbon 0.55 to 0.60 per cent., silicon 0.10 to 0.15, manganese 1.20, sulphur under 0.06, phosphorus under 0.06; with 50,000 to 60,000 granulations to the square inch. More granulations, or fewer, mean an increase of brittleness in the steel.”[17]

Invar: A Steel Invariable in Dimensions Whether Warmed or Cooled.

While the great strength of steel makes it of pre-eminent value in the arts, steel in the huge dimensions of modern roofs and bridges has the demerit of expanding with heat and contracting with cold in a troublesome degree. A notable case is that of the steel rails on the elevated railroad of New York. If this fault, common to all metals, can be materially reduced or abolished, then steel enters upon a new field of golden harvests. Here, by dint of acumen and skill the goal has been reached by M. Charles Edouard Guillaume, of the International Bureau of Weights and Measures in Paris. A few years ago he began investigating the singular magnetic qualities of nickel-steels. Then in studying expansibility by heat he discovered that when the nickel was increased to 36.2 per cent. the alloy was almost indifferent to changes of temperature, expanding but one part in one million when warmed from zero to 1° Centigrade. Because of this insensibility, the alloy at the suggestion of Professor Thury is named invar. In observations of invar which extended through six years, an elongation of one part in 100,000 was detected; subsequently its changes of length each year seemed less than one-millionth. This slight inconstancy may be overcome by further experiment; in the meantime while invar is not available for standards of length of the first order, such as those of the Bureau of Standards at Washington, there is a vast and useful field for the alloy. It offers itself for secondary standards, to be compared at intervals with primary standards at Washington or other capitals of the world.

A leading application will be in surveying. Already wires of invar have been employed by the Survey of France with the utmost success, dispensing with the burdensome apparatus formerly needed in compensating variations due to temperature. With invar wires ten men have advanced at the rate of five kilometers a day; ten years before, with ordinary steel measures, fifty men advanced one half a kilometer, that is, with but one fiftieth as much efficiency.

In time-keeping invar is likely to be as valuable as in surveying. At the Bureau of Standards and the Naval Observatory at Washington, pendulums of invar have been adopted with gratifying results. In ordinary watches and clocks the alloy will banish the compensating devices now requisite, of brass and steel which expand with heat and shrink with cold. For chronometers of the highest grade it is desirable that invar be improved with respect to its stability, an improvement which appears to be highly probable.

One other discovery by M. Guillaume deserves a word. He has found a nickel-steel which when warmed has the same expansibility as glass, so that it may displace platinum wire in leading an electric current into an incandescent lamp, a Crookes’ tube or similar illuminator. More singular still is another of his nickel-steels which shrinks slightly when warmed, holding out the hope of finding an alloy which will neither shrink nor expand as its temperature rises. With such a substance, of trustworthy stability, the arts would have a working material of inestimable value for theodolites, frames for microscopes and telescopes, and cameras for exact picturing.

Manganese Steel.

The magnetic properties of steel, to-day of supreme importance, have for ages excited curiosity. As long ago as 1774, Rinman observed that steel alloyed with manganese is non-magnetic. Here was a material for time-pieces which would free them from magnetic derangement. In the hands of Mr. R. A. Hadfield, of the Hecla Works, Sheffield, England, manganese steel has been produced in remarkable varieties. As the proportion of manganese is increased, the alloys manifest singular changes in their properties. When the manganese is four to six per cent., and the carbon less than one-half per cent., the alloy is brittle enough to be readily powdered by a hand hammer. When the proportion of manganese is doubled, the alloy displays great strength, which reaches its maximum when the manganese is fourteen per cent. No other material approaches manganese steel in its ability to resist abrasion; it outwears ordinary steel four times, much reducing the need for repairs, renewals, or pauses in work while worn-out parts are being replaced. It gives equally good service as the pins and bushings of dredges of the bucket-ladder type, lifting gold-bearing gravels and sands. It is used for centrifugal pumps in dredging sandy harbors, slips, or ponds, where the grit borne in the water plays havoc with ordinary steel surfaces. In ore-crushing manganese steel is particularly effective; a pair of jaws built of it have crushed 21,000 tons of flinty ore and were still good for 4,000 to 6,000 tons more, while the best chilled iron plates failed to crush as little as 4,000 tons.

This alloy is so hard that it cannot be machined or drilled by ordinary means; it must be treated by emery or carborundum wheels. Yet it is so malleable that it can be used for rivets when headed cold. It is so tough that it may be bent and twisted at will without rupture, so that it forms railroad switches, frogs, and crossings of great durability.

High-Speed Tool Steels.

Until 1868, the steel tools used in lathes and drills, planers and so on, were limited to the moderate pace at which they remained cool enough to keep their temper. Beyond that quiet gait they became worthless, snapped apart, or melted as if wax. In 1868 Robert Forester Mushet, of the Titanic Steel and Iron Company, Coleford, England, discovered an alloy of steel, tungsten and manganese which took rough cuts at a depth and with a speed unknown before. This alloy, because hardened simply in air, was called “air-hardening” or “self-hardening.” Thirty years afterward at the Bethlehem Steel Works, Pennsylvania, a tool of this steel was heated to what was feared to be a ruinously high temperature; experiment proved that the tool could be used at a heat, and therefore at a speed, never attained before in the workshop. From that hour hundreds of investigators have proceeded to combine steel with tungsten in various percentages, adding manganese, molybdenum, chromium, silicon, and vanadium. Of these ingredients much the most important are tungsten and molybdenum. Particular pains must be taken thoroughly to anneal the alloy when worked into bars.

As to the gain introduced by high-speed tool steels let Mr. J. M. Gledhill testify from the experience of the Sir W. G. Armstrong, Whitworth & Company’s works at Manchester:—

“Formerly where forgings were first made and then machined with ordinary self-hardening steel, a production, from bars eighteen and one half by six and five eighth inches, of eight bolts in ten hours was usual. With the new steel forty similar bolts from the rolled bar are now turned out in the same time, further abolishing the cost of first rough forging the bolt to form. The speed is 160 feet a minute, the depth of cut three-quarter inch, of feed ¹⁄₃₂ inch, the weight removed from each bolt sixty-two pounds, or 2,480 pounds per day, the tool being ground only once in that time. This is a fairly typical case. Just as striking is the behavior of this steel in twist drills, which supersede the punching process by passing through stacks of thin steel plates quite as swiftly and economically as a punch, while avoiding the liability to distress which accompanies the action of a punch.”

With the quickening of pace due to these steels, the designer is asked to remodel machine tools so that they may stand up against new pressures and speeds. A lathe thus re-patterned is mentioned by Mr. Gledhill: it absorbs sixty-five horse power as against twelve formerly, and has a belt trebled in width so as to measure twelve inches. Mr. Oberlin Smith expects high-speed steel to have other effects on machine design than the conferring of new strength: he looks for a rivalry keener than ever between rotary and reciprocating tools. In his judgment the milling tool, which can be speeded indefinitely, will encroach more and more on the planer, limited as the planer is by its movement being to and fro.

When work on cast iron must proceed at the utmost pace, a jet of air, delivered to the chips with force enough to clear them off as fast as they are formed, enables the speed to be quickened, while, at the same time, the life of the cutter is lengthened.[18]