magnesium sulphate or ammonium chloride) by the prolonged action of a feeble galvanic current; the iron may be then obtained as a dense

process, because sulphur and phosphorus do not burn out like carbon, silicon, and manganese.

The presence of manganese enables the sulphur to be removed with the slag, and the presence of lime or magnesia, which are introduced into the lining of the converter,

FIG. 94.-Bessemer converter, constructed of iron plate and lined with ganister. The air is carried by the tubes, L, O, D to the bottom, M, from which it passes by a number of holes into the converter. The converter is rotated on the trunnion d by means of the rack and pinion H, when it is required either to receive molten cast iron from the melting furnaces or to pour out the steel.

facilitates the removal of the phosphorus. This basic Bessemer process, or Thomas Gilchrist process, introduced about 1880, enables ores containing a considerable amount of phosphorus, which had hitherto only been used for cast iron, to be used for making wrought iron and steel. Naturally the greatest uniformity will be obtained by re-melting the metal. Steel is re-melted in small wind furnaces, in masses not exceeding 30 kilos; a liquid metal is formed, which may be cast in moulds. A mixture of wrought and cast iron is often used for making cast steel (the addition of a small amount of metallic Al improves the homogeneity of the castings, by facilitating the passage of the impurities into slag). Large steel castings are made by simultaneous fusion in several furnaces and crucibles; in this way, castings up to 80 tons or more, such as large ordnance, may be made. This molten, and therefore homogeneous, steel is called cast steel. Of late years the Martin's process for the manufacture of steel has come largely into use; it was invented in France about 1860, and with the use of regenerative furnaces it enables large quantities of cast steel to be made at a time. It is based on the melting of cast iron with iron oxides and iron itself-for instance, pure ores, scrap, &c. There the carbon of the cast iron and the oxygen of the oxide form carbonic oxide, and the carbon therefore burns out, and thus cast steel is obtained from cast iron, providing, naturally, that there is a requisite proportion and corresponding degree of heat. The advantage of this

mass.

This method, proposed by Böttcher and applied by Klein, gives, as R. Lenz showed, iron containing occluded hydrogen, which is dis

process is that not only do the carbon, silicon, and manganese, but also a great part of the sulphur and phosphorus of the cast iron burn out at the expense of the oxygen of the iron oxides. During the last decade the manufacture of steel and its application for rails, armour plate, guns, boilers, &c., has developed to an enormous extent, thanks to the invention of cheap processes for the manufacture of large masses of homogeneous cast steel. Wrought iron may also be melted, but the heat of a blast furnace is insufficient for this. It easily melts in the oxyhydrogen flame. It may be obtained in a molten state directly from cast iron, if the latter be melted with nitre and sufficiently stirred up. Considerable oxidation then takes place inside the mass of cast iron, and the temperature rises to such an extent that the wrought iron formed remains liquid. A method is also known for obtaining wrought iron directly from rich iron ores by the action of carbonic oxide the wrought iron is then formed as a spongy mass (which forms an excellent filter for purifying water), and may be worked up into wrought iron or steel either by forging or by dissolving in molten cast iron.

Everybody is more or less familiar with the difference in the properties of steel and wrought iron. Iron is remarkable for its softness, pliability, and small elasticity, whilst steel may be characterised by its capability of attaining elasticity and hardness if it be cooled suddenly after having been heated to a definite temperature, or, as it is termed, tempered. But if tempered steel be re-heated and slowly cooled, it becomes as soft as wrought iron, and can then be cut with the file and forged, and in general can be made to assume any shape, like wrought iron. In this soft condition it is called annealed steel. The transition from tempered to annealed steel thus takes place in a similar way to the transition from white to grey cast iron. Steel, when homogeneous, has considerable lustre, and such a fine granular structure that it takes a very high polish. Its fracture clearly shows the granular nature of its structure. The possibility of tempering steel enables it to be used for making all kinds of cutting instruments, because annealed steel can be forged, turned, drawn (under rollers, for instance, for making rails, bars, &c.), filed, &c., and it may then be tempered, ground and polished. The method and temperature of tempering and annealing steel determine its hardness and other qualities. Steel is generally tempered to the required degree of hardness in the following manner: It is first strongly heated (for instance, up to 600°), and then plunged into water—that is, hardened by rapid cooling (it then becomes as brittle as glass). It is then heated until the surface assumes a definite colour, and finally cooled either quickly or slowly. When steel is heated up to 220°, its surface acquires a yellow colour (surgical instruments); it first of all becomes straw-coloured (razors, &c.), and then gold-coloured; then at a temperature of 250° it becomes brown (scissors), then red, then light blue at 285° (springs), then indigo at 300° (files), and finally sea-green at about 340°. These colours are only the tints of thin films, like the hues of soap bubbles, and appear on the steel because a thin layer of oxides is formed over its surface. Steel rusts more slowly than wrought iron, and is more soluble in acids than cast iron, but less so than wrought iron. Its specific gravity is about 7·6 to 79.

As regards the formation of steel, it was a long time before the process of cementation was thoroughly understood, because in this case infusible charcoal permeates unfused wrought iron. Caron showed that this permeation depends on the fact that the charcoal used in the process contains alkalis, which, in the presence of the nitrogen of the air, form metallic cyanides; these being volatile and fusible, permeate the iron, and, giving up their carbon to it, serve as the material for the formation of steel. This explanation is confirmed by the fact that charcoal without alkalis or without nitrogen will not cement iron. The charcoal used for cementation acts badly when used over again, as it has lost alkali. The very volatile ammonium cyanide easily conduces to the formation of steel. Although steel is also formed by the action of cyanogen compounds, nevertheless it does not contain more nitrogen than cast or wrought iron (001 p.c.), and

engaged on heating. This galvanic deposition of iron is used for making galvanoplastic clichés, which are distinguished for their great

these latter contain it because their ores contain titanium, which combines directly with nitrogen. Hence the part played by nitrogen in steel is but an insignificant one. It may be useful here to add some information taken from Caron's treatise concerning the influence of foreign matter on the quality of steel. The principal properties of steel are those of tempering and annealing. The compounds of iron with silicon and boron have not these properties. They are more stable than the carbon compound, and this latter is capable of changing its properties; because the carbon in it either enters into combination or else is disengaged, which determines the condition of hardness or softness of steel, as in white and grey cast iron. When slowly cooled, steel splits up into a mixture of soft and carburetted iron; but, nevertheless, the carbon does not separate from the iron. If such steel be again heated, it forms a uniform compound, and hardens when rapidly cooled. If the same steel as before be taken and heated a long time, then, after being slowly cooled, it becomes much more soluble in acid, and leaves a residue of pure carbon. This shows that the combination between the carbon and iron in steel becomes destroyed when subjected to heat, and the steel becomes iron mixed with carbon. Such burnt steel cannot be tempered, but may be corrected by continued forging in a heated condition, which has the effect of redistributing the carbon equally throughout the whole mass. After the forging, if the iron is pure and the carbon has not been burnt out, steel is again formed, which may be tempered. If steel be repeatedly or strongly heated, it becomes burnt through and cannot be tempered or annealed; the carbon separates from the iron, and this is effected more easily if the steel contains other impurities which are capable of forming stable combinations with iron, such as silicon, sulphur, or phosphorus. If there be much silicon, it occupies the place of the carbon, and then continued forging will not induce the carbon once separated to re-enter into combination. Such steel is easily burnt through and cannot be corrected; when burnt through, it is hard and cannot be annealed-this is tough steel, an inferior kind. Iron which contains sulphur and phosphorus cements badly, combines but little with carbon, and steel of this kind is brittle, both hot and cold. Iron in combination with the above-mentioned substances cannot be annealed by slow cooling, showing that these compounds are more stable than those of carbon and iron, and therefore they prevent the formation of the latter. Such metals as tin and zinc combine with iron, but not with carbon, and form a brittle mass which cannot be annealed and is deleterious to steel. Manganese and tungsten, on the contrary, are capable of combining with charcoal; they do not hinder the formation of steel, but even remove the injurious effects of other admixtures (by transforming these admixed substances into new compounds and slags), and are therefore ranked with the substances which act beneficially on steel; but, nevertheless, the best steel, which is capable of renewing most often its primitive qualities after burning or hot forging, is the purest. The addition of Ni, Cr, W, and certain other metals to steel renders it very suitable for certain special purposes, and is therefore frequently made use of.

It is worthy of attention that steel, besides temper, possesses many variable properties, a review of which may be made in the classification of the sorts of steel (1878, Cockerell). (1) Very mild steel contains from 0:05 to 0.20 p.c. of carbon, breaks with a weight of 40 to 50 kilos per square millimetre, and has an extension of 20 to 30 p.c.; it may be welded, like wrought iron, but cannot be tempered; is used in sheets for boilers, armour plate and bridges, nails, rivets, &c., as a substitute for wrought iron; (2) mild steel, from 0.20 to 035 p.c. of carbon, resistance to tension 50 to 60 kilos, extension 15 to 20 p.c., not easily welded, and tempers badly, used for axles, rails, and railway tyres, for cannons and guns, and for parts of machines destined to resist bending and torsion; (3 hard steel, carbon 0:35 to 0·50 p.c., breaking weight 60 to 70 kilos per square millimetre, extension 10 to 15 p.c., cannot be welded, takes a temper; used for rails, all kinds of springs, swords, parts of machinery in motion subjected to friction,

hardness. Electro-deposited iron is brittle, but if heated (after the separation of the hydrogen) it becomes soft. If pure ferric hydroxide, which is easily prepared by the precipitation of solutions of ferric salts by means of ammonia, be heated in a stream of hydrogen, it forms, first of all, a dull black powder which ignites spontaneously in air (pyrophoric iron), and then a grey powder of pure iron. The powdery substance first obtained is an iron suboxide; when thrown into the air it ignites, forming the oxide Fe3O4. If the heating in hydrogen be continued, more water and pure iron, which does not ignite spontaneously, will be obtained. If a small quantity of iron be fused in the oxyhydrogen flame (with an excess of oxygen) in a piece of lime and mixed with powdered glass, pure molten iron will be formed, because in the oxyhydrogen flame iron melts and burns, but the substances mixed with the iron oxidise first. The oxidised impurities here either disappear (carbonic anhydride) in a gaseous form, or turn into slag (silica, manganese, oxide, and others)—that is, fuse with the glass. Pure iron has a silvery white colour and a specific gravity of 7.84; it melts at a temperature higher than the meltingpoints of silver, gold, nickel, and steel, i.e. about 1400°-1500° and

spindles of looms, hammers, spades, hoes, &c.; (4) very hard steel, carbon 0·5 to 0·65 p.c., tensile breaking weight 70 to 80 kilos, extension 5 to 10 p.c., does not weld, but tempers easily; used for small springs, saws, files, knives and similar instruments.

The properties of ordinary wrought iron are well known. The best iron is the most tenacious-that is to say, that which does not break up when struck with the hammer or bent, and yet at the same time is sufficiently hard. There is, however, a distinction between hard and soft iron. Generally the softest iron is the most tenacious, and can best be welded, drawn into wire, sheets, &c. Hard, especially tough, iron is often characterised by its breaking when bent, and is therefore very difficult to work, and objects made from it are less serviceable in many respects. Soft iron is most adapted for making wire and sheet iron and such small objects as nails. Soft iron is characterised by its attaining a fibrous fracture after forging, whilst tough iron preserves its granular structure after this operation. Certain sorts of iron, although fairly soft at the ordinary temperature, become brittle when heated and are difficult to weld. These sorts are less suitable for being worked up into small objects. The variety of the properties of iron depends on the impurities which it contains. In general, the iron used in the arts still contains carbon and always a certain quantity of silicon, manganese, sulphur, phosphorus, &c. A variety in the proportion of these component parts changes the quality of the iron. In addition to this the change which soft wrought iron, having a fibrous structure, undergoes when subjected to repeated blows and vibrations is considerable; it then becomes granular and brittle. This to a certain degree explains the want of stability of some iron objects-such as truck axles, which must be renewed after a certain term of service, otherwise they become brittle. It is evident that there are innumerable intermediate transitions from wrought iron to steel and cast iron.

At the present day the greater part of the cast iron manufactured is converted into steel, generally cast steel (Bessemer's and Martin's). I may add the Urals, Donetz district, and other parts of Russia offer the greatest advantages for the development of an iron industry, because these localities not only contain vast supplies of excellent iron but also coal, which is necessary for smelting it.

ore,

below the melting point of platinum (1750°). But pure iron becomes soft at a temperature considerably below that at which it melts, and may then be easily forged, welded, and rolled or drawn into sheets and wire. 11 bis Pure iron may be rolled into an exceedingly thin sheet, weighing less than a sheet of ordinary paper of the same size. This ductility is the most important property of iron in all its forms, and is most marked with sheet iron, and least so with cast iron, whose ductility, compared with wrought iron, is small, but it is still very considerable when compared with other substances---such, for instance, as rocks. 12

The chemical properties of iron have been already repeatedly mentioned in preceding chapters. Iron rusts in air at the ordinary temperature that is to say, it becomes covered with a layer of iron oxides. Here, without doubt, the moisture of the air plays a part, because in dry air iron does not oxidise at all, and also because, more

11 According to information supplied by A. T. Skinder's experiments at the Oboukoff Steel Works, 140 volumes of liquid molten steel give 128 volumes of solid metal. By means of a galvanic current of great intensity and dense charcoal as one electrode, and iron as the other, Bernadoss welded iron and fused holes through sheet iron. Soft wrought iron, like steel and soft malleable cast iron, may be melted in Siemens' regenerative furnaces, and in furnaces heated with naphtha.

11 bis Gore (1869), Tait, Barret, Tchernoff, Osmond, and others observed that at a temperature approaching 600-that is, between dark and bright red heat-all kinds of wrought iron undergo a peculiar change called recalescence, i.e. a spontaneous rise of temperature. If iron be considerably heated and allowed to cool, it may be observed that at this temperature the cooling stops-that is, latent heat is disengaged, corresponding with a change in condition. The specific heat, electrical conductivity, magnetic, and other properties then also change. In tempering, the temperature of recalescence must not be reached, and so also in annealing, &c. It is evident that a change of the internal condition is here encountered, exactly similar to the transition from a solid to a liquid, although there is no evident physical change. It is probable that attentive study would lead to the discovery of a similar change in other substances.

12 The particles of steel are linked together or connected more closely than those of the other metals; this is shown by the fact that it only breaks with a tensile strain of 50-80 kilos per sq. mm., whilst wrought iron only withstands about 30 kilos, cast iron 10, copper 35, silver 23, platinum 30, wood 8. The elasticity of iron, steel, and other metals is expressed by the so-called coefficient of elasticity. Let a rod be taken whose length is L; if a weight, P, be hung from the extremity of it, it will lengthen to 1. The less it lengthens under other equal conditions, the more elastic the material, if it resumes its original length when the weight is removed. It has been shown by experiment that the increase in length 7, due to elasticity, is directly proportional to the length L and the weight P, and inversely proportional to the section, but changes with the material. The coefficient of elasticity expresses that weight (in kilos per sq. mm.) under which a rod having a square section taken as 1 (we take 1 sq. mm.) acquires double the length by tension. Naturally in practice materials do not withstand such a lengthening, under a certain weight they attain a limit of elasticity, i.e. they stretch permanently (undergo deformation). Neglecting fractions (as the elasticity of metals varies not only with the temperature, but also with forging, purity, &c.), the coefficient of elasticity of steel and iron is 20,000, copper and brass 10,000, silver 7,000, glass 6,000, lead 2,000, and wood 1,200.