:.:>;:v:S : '-V ' ' FSfflgSB .THE METALLOGRAPHY AND HEAT TREATMENT OF IRON AND STEEL- ALBERT SAUVEUR Professor of Mclnl/nrii,/ u/iliy in Harvard University mid Ihe Institute of Technology SECOND EDITION (THIRD THOUSAND) SAUVEUR AND BOYLSTON METALLURGICAL ENGINEERS CAMBRIDGE, MASS., U.S.A. 1916 COPTRIGHT, 1910, BY SAUVEUR AND BOYLSTON THE rxiVKHHITY PRKSS, TAMBRIDRK, C. 8.A. TO THE MEMORY OF &P Jfattier I REVERENTLY AND LOVINGLY DEDICATE THIS BOOK 331170 PREFACE TO THE SECOND EDITION THE sale in less than three years of two impressions of the first edition of this book justifies the author's belief expressed at the time that there_was a need in the educational and industrial world of a treatise on the metallography of iron and steel such as he has endeavored to supply. Dealing with a science so young, and there- fore still in full growth, it was to be expected that even after so short a period as three years there would be need of a revised edition that recent progress might be put on record and a more faithful picture offered of its present status. The neces- sary revisions and additions have been made to the best of the author's ability. Nearly every chapter has been revised, while some fifty pages of new text have been added and nearly one hundred new illustrations used. With the exception of the last sixty-four pages, the book has been entirely reset. In view of the fact that so large a portion of this work is devoted to the study of the heat treatment of iron and steel, the new title, namely, "The Metallography and Heat Treatment of Iron and Steel," appears to be more accurately descriptive of its contents. In the present edition, the author has continued to follow the course previously adopted by him, to utilize the best illustrations available rather than to use his own to the exclusion of others. Too many books purporting to be treatises on certain subjects are merely expositions of the author's views to the belittling of the opinions and work of others. Authors of treatises should be just and impartial and should not give undue prominence to their own views and opinions. This, obviously, they owe to their readers and to the public in general. The author of this book hopes that he has succeeded in adhering faithfully to that belief and, if he has failed in ever so small a degree, it has been unintentional. Of the 338 illustrations reproduced exclusive of illustrations of apparatus, 80 were prepared by the author himself, 82 by others in his laboratory, and 25 by correspondence course students. The author records here his indebtedness to the following gentlemen for illustrations borrowed from them, the figures in parentheses indicating the number in each case: Messrs. Andrews (2), Arnold (5), Bayley (1), Belaiew (5), Benedicks (2), Brearley (2), Carpenter and Keeling (2), Chappell (1), Coe (1), Sherard Cowper-Coles (1), Desch (7), Edwards (1), Ewing and Rosenhain (2), Franklin (4), Goerens (8), Guillet (16), Gulliver (3), Houghton (1), Law (7), Levy (1), Longmuir (2), Maurer (1), Mellor (1), Osmond (20), Peirce (4), Pulsifer (1), Roberts-Austen (3), Robin (1), Roland-Gosselin (1), Rosenhain (7), vi PREFACE TO THE SECOND EDITION Roozeboom (1), Ruff (1), Saladin (2), Sorby (1), Stead (19), Tschermak (3), Tscher- noff (1), Upton (1), Wittorff (1), Wiist (3), Ziegler (1). He also takes this opportunity of expressing his appreciation of the many kind and helpful criticisms and suggestions received from fellow-workers and other cor- respondents. The method which the author has always followed in his teaching of metallography to postpone until the closing chapters the study of the equilibrium diagram and of the phase rule rather than to introduce the subject with these complex, and, there- fore, at the time, forbidding, considerations has been adversely criticized by a few, but on the whole he believes that it has won out and he is more convinced than ever that it is the most effective and otherwise satisfactory method to follow. ALBERT SAUVEUR. HARVARD IJNIVERSITY, Cambridge, Massachusetts, November 17, 1915. PREFACE TO THE FIRST EDITION WHILE several excellent books on metallography have been_published and while numerous papers on the metallography of iron and steel have appeared in the scientific and technical press, a well-balanced, specific, and comprehensive treatise on the subject has not heretofore been written. In the belief that there is a real and urgent need of such a treatise the author has endeavored to supply it, craving for his effort the indulgent criticism of his readers. He offers his book to those seeking self- instruction in the metallography of iron and steel, their special needs having been carefully considered in the arrangement of the lessons; he offers it to teachers and students trusting that they will find it valuable and suggestive as a text-book; he offers it to manufacturers and users of iron and steel in the belief that he has given due weight to the practical side of the subject and has avoided discussions of ill- founded or purely speculative theories; he offers it to the general reader interested in the scientific or practical features of the metallography of iron and steel, as the language used should be readily understood by those lacking specialized knowledge of the subject; he offers it to experts in the hope that they will find it not entirely devoid of original thought, original treatment, and suggestiveness. In the matter of illustrations and especially of photomicrographs the author's aim has been to utilize the best available, using his own or those taken in his laboratory only when no better ones have, to his knowledge, been published by others. The original source of every illustration has been indicated and the author desires to ex- press his indebtedness to the following writers, the figures in parenthesis showing the number of illustrations from each: Andrews (3), Arnold (7), Bayley (1), Belaiew (5), Brearley (2), Carpenter and Keeling (l),Sherard Cowper-Coles (1), Desch (1), Edwards (2), Ewing and Rosenhain (2), Guillet (18), Gcerens (9), Gulliver (2), Hall (1), Houghton (1), Kroll (1), Law (8), Levy (1), Longmuir (2), Matweieff (1), Maurer (1), Mellor (1), Osmond (17), Roberts-Austen (1), Robin (1), Roland-Gosselin (1), Rosen- hain (2), Saladin (2), Sorby (1), Stead (13), Tschermak (3), Tschernoff (1), Wiist (5), Ziegler (1). All illustrations not otherwise inscribed are the author's. The author cannot refrain from expressing here the sorrow and sense of personal loss he experienced when the news was received, while this book was passing through the press, of the death of Floris Osmond, for to the author, as no doubt to many others, Osmond's work and Osmond's life have been an inspiration. Osmond belonged to that admirable class of French scientists, who, like Pasteur and Berthelot, have so lofty a conception of the duty of the scientist that they give to the world the fruit of viii PREFACE their genius and of their untiring labors with no thought of monetary return or even of honorary recognition. If Sorby was the pioneer of metallography and Tschernoff its father, Osmond has been its torch-bearer for he, more than any other, has been our guide. While he is no longer with us, his light will long continue to burn and to show the way to promising and productive fields of research. The author desires to place on record his warm appreciation of the assistance he received from Mr. H. M. Boylston in passing this book through the press, and also for many valuable suggestions. ALBERT SAUVETJR. HARVARD UNIVERSITY, CAMBRIDGE, MASSACHUSETTS, August 19, 1912. TABLE OF CONTENTS INTRODUCTION PAGE THE INDUSTRIAL, IMPORTANCE OF METALLOGRAPHY 1 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY THE MICROSCOPE 5 The stage 5 Plain stages 8 Mechanical stages 8 Objectives 8 Eye-pieces 8 Iris diaphragms 11 Specimen holders 11 UNIVERSAL METALLOSCOPE 14 Electromagnetic stage 15 Templets for the examination of small specimens 15 Support of non-magnetic specimens 16 Leveling-devices of stand and stage 16 Motion of the stage 16 Mechanical stage 17 Examination of transparent objects 18 ILLUMINATION OF THE SAMPLES 18 Vertical magnifier 23 SOURCES OF LIGHT AND CONDENSERS 23 Condensers 26 Monochromatic light 27 PHOTOMICROGRAPHIC OUTFITS 27 INVERTED MICROSCOPES 31 POLISHING APPARATUS 34 Hand polishing . 34 Polishing by power 34 Portable polishing motor 35 PYROMETERS AND ELECTRIC FURNACES 36 Pyrometers 36 Electric furnaces 39 CHAPTER II MANIPULATION Cutting of samples 40 Polishing by hand 40 Polishing by power .41 Polishing very small specimens 41 Etching 42 Nitric acid and alcohol 42 Picric acid. (Igevsky) 42 Concentrated nitric acid. (Sauveur) 42 Sodium picrate etching of cementite 43 Stead's reagent for the detection of phosphorus segregation in iron and steel 43 Heat-Tinting 44 Sulphur printing 44 Etching wrought iron 45 Etching pearlitic steel 46 Etching sorbitic steel 46 Etching troostitic steel 46 Etching martensitic steel 46 Etching austenitic steel 46 ix x TABLE OF CONTENTS PAGE Etching alloy steel 47 Etching cast iron '. . . 47 Etching for macrostructure 47 Examination 47 Photomicrography 48 Exposure 49 Diaphragms and shutters 50 Monochromatic light 50 Photographic plates 50 Development 50 Printing 50 CHAPTER III APPARATUS AND MANIPULATION (Continued) POLISHING AND POLISHING MACHINES 51 Polishing small specimens 61 DEVELOPMENT OP THE STRUCTURES 61 Polishing in relief 61 Polish-attack 62 Etching 62 Electrolytic etching 64 Hot etching 64 Washing and drying 64 Preserving 64 MOUNTING AND MOUNTING DEVICES 65 Plastic mounting 65 Leveling stages 66 METALLURGICAL MICROSCOPE 67 Le Chatelier <>7 Ernst Leitz 67 P. F. Dujardin 71 C. Reichert 71 Robin 73 Scientific Materials Co 73 Martens 75 Rosenhain 77 Osmond 77 Nachet 79 Cornu-Charpy Watson and Sons 79 Workshop microscopes 81 R. and J. Beck F. Koristka . . 84 Ph. Pellin ... 84 CarlZeiss 85 Spencer Lens Co Bausch and Lomb Optical Co 85 CHAPTER IV PURE METALS Microstructure 86 Crystallization . . . 86 Idiomprphic crystals Allotrimorphic crystals Crystallization of metals 87 Grains of metals 89 Crystalline orientation of the grains Cubic crystallization of metals. Etching pits 90 Summary 90 The amorphous cement theory and the boundaries of the crystalline grains . . . Straining of metals. Slip bands 92 The amorphous cement theory and the straining of metals Twinning and twin crystals 95 Lines of Neumann 96 Influence of mechanical treatment 96 Influence of thermal treatment 96 Amorphous cement theory vs. the heat treatment of pure metals 97 Impurities . . . 97 TABLE OF CONTENTS XI CHAPTER V PURE IRON PAGE Microstructure Cubic crystallization of iron 103 Ferrite : 104 Allotropy of iron Solidification and crystallization of pure iron 107 Twinnings and Neumann lines 109 Strains and slip bands Influence of mechanical treatment Influence of thermal treatment 110 Crystallizing properties of electrolytic iron t ^ Influence of impurities 112 CHAPTER VI WROUGHT IRON Chemical composition 114 Microstructure of longitudinal section 114 Microstructure of transverse section 115 Structural differences between various kinds of wrought iron 116 Chemical composition of slag 116 Microstructure of slag 116 Influence of thermal and mechanical treatments 117 CHAPTER VII LOW CARBON STEEL Normal structure 118 Grading of steels vs. carbon content 118 Low carbon steel vs. wrought iron 118 The structure of low carbon steel 119 Pearlite 120 Free ferrite 121 Cementite 122 CHAPTER VIII MEDIUM HIGH AND HIGH CARBON STEEL Medium high carbon steel 124 High carbon steel . . . 126 Eutectoid steel 126 Hyper-eutectoid steel 127 Free cementite 129 Hypo- vs. hyper-euteetoid steel 129 Etching of cementite 131 Carbon content of pearlite 131 Structural composition of steel 132 Chemical vs. structural composition 134 Micro-test for determination of carbon in steel 135 Physical properties of the constituents of steel 137 Tenacity of steel vs. its structural composition 138 Steel of maximum strength 140 Ductility of steel vs. its structural composition 141 Diagram showing the relation between the tenacity and ductility of steel and its carbon content 142 CHAPTER IX IMPURITIES IN STEEL Metallic impurities 143 Non-metallic or oxidized impurities 143 Metallic vs. non-metallic impurities 143 Gaseous impurities 143 Impurities vs. physical properties of steel 143 Silicon in steel 143 Phosphorus in steel 144 Sulphur in steel 145 Sulphur printing 148 Manganese in steel 148 Chemical vs. structural composition 148 Non-metallic or oxidized impurities 150 Segregation of impurities. Ghosts 153 Gaseous impurities 157 l xii TABLE OF CONTENTS CHAPTER X THE THERMAL CRITICAL POINTS OF IRON AND STEEL I'AQE Point of recalescence 158 Notation 159 Critical range. Transformation range 159 Position of An and Aci 159 Speed of cooling and heating vs. position of AI 161 Temperature from which cooling begins vs. position of Ari 162 Chemical composition vs. position of Ai 162 Upper critical points Thermal critical points in pure iron 163 Equilibrium temperature for A 3 and A 3 . 2 Peculiarities of the point A 2 164 Thermal critical points in very low carbon steel 164 Thermal critical points of medium high carbon steel 165 Merging of As and Aj 165 Thermal critical points in eutectoid steel 165 Merging of A 3 . 2 and Ai 165 Factors influencing the position of the upper points As and A 2 166 Thermal critical points in hyper-eutectoid steel 166 Merging of As. 2.1 and A c m 167 Minor critical points 167 Data showing the position of the critical points 167 Relative quantities of heat evolved or absorbed at the critical points 167 Graphical representation of the position and magnitude of the critical points 169 Determination of the thermal critical points 169 Cooling and heating curves 169 Use of neutral bodies 173 Additional illustrations of cooling curves 177 Self-recording pyrometers 178 Other methods for the determination of the critical points 178 Metallographic method for the determination of the critical points 179 Calorimetric method for the determination of the critical points 179 Thermo-electric method for the determination of the critical points 179 Melting-points method for the determination of the critical points 179 Magnetic method for the determination of the critical points 179 Historical 180 CHAPTER XI THE THERMAL CRITICAL POINTS OF IRON AND STEEL THEIR CAUSES Causes of the upper points As and A 2 in carbonless iron 182 Causes of the upper critical points A 3 and A 2 in low carbon steel 185 Cause of the point A 3 . 2 Cause of the point Ai 189 The point Ai an allotropic point Pearlite formation 190 Cause of the point A c m 191 Allotropy of cementite i92 Cause of the point As.z.i in eutectoid steel Cause of the point A 3 . 2 .i in hyper-eutectoid steel 194 Summary Another view of the allotropic changes 1 96 CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STEEL THEIR EFFECTS Changes at A 3 199 Dilatation 198 Electrical conductivity 200 Crvstallization 200 Tensile strength : 200 Dissolving power for carbon Structural properties Other properties 201 Changes at A 2 202 Dilatation 202 Magnetic properties 203 Crystallization 204 TABLE OF CONTENTS XU1 PAGE Tensile strength 204 Dissolving power for carbon Structural properties Specific heat ; 205 Changes at As. 205 Changes at Ai 205 Changes at As. 2.1 206 Changes at A c m 206 Structural change at Ai and A 3 .2.i 206 Prevailing conditions above and below the critical range 206 Properties of gamma, beta, and alpha iron 207 CHAPTER XIII CAST STEEL Crystallization of steel 208 Octahedric crystallization of austenite 215 Structure of cast cutcctoid steel 216 Structure of cast hypo-eutectoid steel 216 Structure of cast eutectoid vs. cast hypo-eutectoid steel 217 Structure of cast hyper-eutectoid steel 218 Ingotism 220 CHAPTER XIV THE MECHANICAL TREATMENT OF STEEL Hot working 221 Finishing temperatures 223 Structure of hot worked eutectoid steel 224 Structure of hot worked hypo-eutectoid steel 224 Structure of hot worked hyper-eutectoid steel 225 Sorbite 225 Hot working of steel vs. its critical range 226 Cold working 227 Mechanical refining 229 CHAPTER XV THE ANNEALING OF STEEL Purpose of annealing 231 Nature of the annealing operation 231 Heating for annealing 231 Time at annealing temperature 233 Cooling from annealing temperature 233 Rate of cooling vs. carbon content 234 Rate of cooling vs. size of object 234 Furnace cooling from annealing temperature 235 Air cooling from annealing temperature 235 Properties of sorbite 236 Influence of maximum temperature 236 Influence of time at maximum temperature 238 Oil and water quenching from annealing temperature 239 Double annealing treatment 240 Annealing eutectoid steel 242 Annealing hypo-eutectoid steel 243 Annealing hyper-eutectoid steel 244 Annealing of cold-worked steel 246 Annealing steel castings 248 Rate of cooling vs. the structure of steel 250 Structure vs. heat treatment 252 Spheroidizing of cementite 252 Varieties of pearlite 257 Graphitizing of cementite 257 Overheating 259 Burnt steel 259 Crystalline growth of austenite above the critical range 262 Crystalline growth of ferrite below the critical range 265 Brittleness of low carbon steel 271 Conclusions regarding the annealing of steel 273 CHAPTER XVI THE HARDENING OF STEEL Heating for hardening 274 Cooling for hardening 275 Structural changes on hardening 276 xiv TABLE OF CONTENTS PASE Austenite 277 Nature of austenite -<"' Occurrence of austenite 277 Etching of austenite Structure of austenite 280 Properties of austenite 281 Mai-tensite 283 Nature of martensite 283 Occurrence of martensite 284 Etching of martensite 284 Structure of martensite 284 Properties of martensite 285 Troostite Nature of troostite -'*."> Occurrence of troostite 288 Properties of troostite 289 Etching of troostite Structure of troostite 289 Sorbite 289 Troosto-sorbite 290 Hardenite 291 Rate of pooling through critical range vs. structure of steel Are the transition stages distinct constituents? Metarals and aggregates 293 Hardening eutectoid steel 294 Hardening hyper-eutectoid steel Hardening hypo-eutectoid steel ' Steel of maximum hardening power Hardening large pieces 296 Hardening and tempering in one operation 297 CHAPTER XVII THE TEMPERING OF HARDENED STEEL Tempering temperatures Tempering colors Time at tempering temperature Rate of cooling from tempering temperature Hardening and tempering combined Explanation of the tempering of steel Tempering austenitic steels Tempering martensitic steel Tempering troostitic steel Tempering troostito-martensitic steel Tempering troostito-sorbitic steel Osmondite Structural changes on slow cooling, quick cooling, and reheating Microstructure of hardened and tempered steel Carbon condition in tempered steel Decrease of hardness on tempering Heat liberated on tempering 307 CHAPTER XVIII THEORIES OF THE HARDENING OF STEEL Retention theories Solution theories Beta iron or allotropic theory Alpha iron theory Amorphous iron theory Carbon theories The hardening carbon theory The subcarbide theory The stress theory Interstrain theory Twinning and amorphous iron theory Tempering and the retention theories Tempering and tho stress theory Summary 313 CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL Composition of the iron and steel subjected to carburizing Carburizing temperature Time at carburizing temperature 316 TABLE OF CONTENTS XV PAGE Distribution of the carbon 316 Carburizing materials 318 Case hardening by gas under pressure 319 Mechanism of cementation 322 Cooling from carburizing temperature 324 Heat treatment of case hardened articles 324 Tempering case hardened steel 325 CHAPTER XX SPECIAL STEELS GENERAL CONSIDERATIONS Ternary steels 326 Influence of the special element upon the location of the critical range , _. ._. ^ 328 Pearb'tic steels 331 Martensitic steels 332 Austenitic (polyhedric) steels 332 Cementitic (carbide) steels 333 Treatment of special steels 333 Treatment of pearlitic steels 333 Treatment of martensitic steels 334 Treatment of austenitic steels 334 Treatment of cementitic steels 335 Quaternary steels 335 CHAPTER XXI SPECIAL STEELS CONSTITUTIONS, PROPERTIES, TREATMENT, AND USES OF MOST IMPORTANT TYPES Nk-kel steel 336 Manganese steel 343 Tungsten steels 346 Chrome steels 349 Vanadium steels 349 Molybdenum steels 351 Silicon steels . 352 Chrome-nickel steels 353 uaternary vanadium steels 353 hrome-tungstcn or high-speed steels 354 CHAPTER XXII CAST IRON Solubility of carbon in iron 364 Formation of combined and graphitic carbon 366 Cast iron containing only graphitic carbon 366 Cast iron containing only combined carbon 369 Cast iron containing both combined and graphitic carbon 373 Mottled cast iron 375 Structural composition of cast iron 375 Physical properties of cast iron vs. its structural composition 378 Chilled cast iron castings 378 Cast iron of euteetic composition 379 Eutectic cast iron vs. impurities 379 The strength of cast iron vs. the size and form of the graphite particles 380 Eutectic cast iron vs. the size and form of the graphite particles 380 Silicon and the rate of cooling vs. the matrix of cast iron and the formation of graphite . . . 380 Cast iron of maximum strength 381 Solidification of euteetic cast iron 381 Solidification of hyper-eutectic east iron 382 Solidification of hypo-eutectic cast iron 382 The graphitizing of cementite 384 Graphitizing of hyper-eutectic alloys 384 Graphitizing of euteetic alloys 384 Graphitizing of hypo-eutectic alloys 385 CHAPTER XX1I1 IMPURITIES IN CAST IRON Silicon in cast iron 3g6 Sulphur in cast iron 385 Manganese in cast iron 387 Phosphorus in cast iron 388 Critical points of cast iron containing phosphorus 394 Structural composition of phosphoretic cast iron 394 Chemical vs. structural composition 395 Other impurities 397 xvi TABLE OF CONTENTS CHAPTER XXIV MALLEABLE CAST IRON PAGE Graphitizing of cementite 398 Malleable cast-iron castings 398 Original castings 399 Annealing operation 400 Packing materials 400 Annealing for malleablizing 401 Annealing for "white heart" castings 401 Annealing for "black heart" castings 402 Cooling from annealing temperature 406 Gray cast iron vs. malleable cast iron 406 CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS Solidification of pure metals 407 Solidification of binary alloys the constituents of which form solid solutions 409 Fusibility curves of binary alloys whose component metals are completely soluble in each other when solid 411 Binary alloys forming definite compounds and solid solutions Binary alloys whose component metals are insoluble in each other in the solid state 415 Binary alloys whose component metals are partially soluble in each other when solid .... 423 CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IRON-CARBON ALLOYS Fusibility curve of iron-carbon alloys 420 Structural composition of iron-carbon alloys immediately after solidification 438 Iron-graphite fusibility curve 434 Combined graphite-cementite diagram 434 Graphitizing of cementite 434 Structure of iron-carbon alloys immediately after solidification 438 Complete equilibrium diagram 439 Historical 443 Upton's diagram 448 Ruff's diagram 449 Wittorff's diagram 450 CHAPTER XXVII THE PHASE RULE Enunciation of the phase rule 452 Equilibrium 452 Degrees of freedom 453 Phases 454 Components 454 The phase rule applied to alloys 454 The phase rule applied to pure metals 455 The phase'rule applied to binary alloys 455 The phase rule applied to iron-carbon alloys 457 APPENDIX NOMENCLATURE OF THE MICROSCOPIC CONSTITUENTS I. GENERAL PLAN 460 II. LIST OF MICKOSCOPJC SUBSTANCES 461 III. DEFINITIONS AND DESCRIPTIONS 464 Austenite ' Cementite 465 Martensite 466 Ferrite 466 Osmondite 467 Ferronite 468 Hardenite 468 Pearlite 468 Graphite 469 Troostite 470 Sorbite 470 Manganese sulphide 471 Ferrous sulphide 471 MISCELLANEOUS 471 INDEX 473-487 INTRODUCTION i THE INDUSTRIAL IMPORTANCE OF METALLOGRAPHY 1 Twenty years ago the science of metallography was practically unknown and it is only within the last fifteen years that it has been seriously considered by metal manufacturers and consumers as a valuable method of testing and investigating. That so much has been accomplished in so short a time is highly gratifying to the many workers, practical or scientific, who have contributed by their efforts to the progress of metallography. To realize the practical importance of metallography it should be borne in mind that the physical properties of metals and alloys that is, those properties to which these substances owe thejr exceptional industrial importance are much more closely related to their proximate" than to their ultimate composition, and that microscopical examination reveals, in part at least, the proximate composition of metals and alloys, whereas chemical analysis seldom does more than reveal their ultimate composition. The analytical chemist may tell us, for instance, that a steel which he has analyzed contains 0.50 per cent of carbon, without our being able to form any idea as to its properties, for such steel may have a tenacity of some 75,000 Ibs. per square inch or of some 200,000 Ibs., a ductility represented by an elongation of some 25 per cent, or practically no ductility at all; it may be so hard that it cannot be filed or so soft as to be easily machined, etc. The metal microscopist, on the contrary, on examining the same steel will report its structural, i.e. its proximate, composition, informing us that it contains, for in- stance, approximately 50 per cent of ferrite and 50 per cent of pearlite, and we know at once that the steel is fairly soft, ductile, and tenacious; or he may report the presence of 100 per cent of martensite, and we know that the steel is extremely hard, very tenacious, and deprived of ductility. Which of the two reports is of more immediate practical value, the chemist's or the metallographist's? Surely, that of the metallographist. Nor is it only in the domain of metals that we find such close relationship between properties and proximate composition, for, on the contrary, it is quite true of all substances. How many organic bodies, for instance, have practically the same ulti- mate composition and still are totally unlike in properties because of their different proximate composition, i.e. different grouping and association of their ultimate con- stituents. If we were better acquainted with the proximate composition of substances many unexplained facts would become clear to us. Unfortunately the chemist too often is able to give us positive information in regard to the proportion of the ultimate constituents only, his reference to proximate 1 Abstracted from a paper presented at the Congress of Technology at the fiftieth anniversary of the granting of the charter of the Massachusetts Institute of Technology, April, 1911. 1 2 INTRODUCTION THE INDUSTRIAL IMPORTANCE OF METALLOGRAPHY analysis being of the nature of speculation. Ultimate analysis has reached a high degree of perfection in regard to accuracy as well as to speed of methods and analyt- ical chemists have built up a marvelous structure calling for the greatest admiration, their searching methods never failing to lay bare the ultimate composition of sub- stances. But how much darkness still surrounds the proximate composition of bodies and how great the reward awaiting the lifting of the veil ! The forceful and prophetic writing in 1890 of Prof. Henry M. Howe naturally comes to mind. Speaking of the properties and constitution of steel, Professor Howe wrote: "If these views be correct, then, no matter how accurate and extended our knowl- edge of ultimate composition, and how vast the statistics on which our inferences are based, if we attempt to predict mechanical properties from them accurately we be- come metallurgical Wigginses . . . "Ultimate analysis never will, proximate analysis may, but by methods which are not yet even guessed at, and in the face of fearful obstacles. "How often do we look for the coming of the master mind which can decipher our undecipherable results and solve our insoluble equations, while if we will but rub our own dull eyes and glance from the petty details of our phenomena to their great out- lines their meaning stands forth unmistakably; they tell us that we have followed false clues and paths which lead but to terminal morasses. In vain we flounder in the sloughs and quagmires at the foot of the rugged mountain of knowledge seeking a royal road to its summit. If we are to climb, it must be by the precipitous paths of proximate analysis, and the sooner we are armed and shod for the ascent, the sooner we devise weapons for this arduous task, the better. "By what methods ultimate composition is to be determined is for the chemist rather than the metallurgist to discover. But, if we may take a leaf from lithology, if we can sufficiently comminute our metal (ay, there's the rub!) by observing dif- ferences in specific gravity (as in ore dressing), in rate of solubility under rigidly fixed conditions, in degree of attraction by the magnet, in cleavage, luster, and crystalline form under the microscope, in readiness of oxidation by mixtures of gases in rigidly fixed proportions, we may learn much. "Will the game be worth the candle? Given the proximate composition, will not the mechanical properties of the metal be so greatly influenced by slight and unde- terminable changes in the crystalline form, size, and arrangement of the component minerals, so dependent on trifling variations in manufacture as to be still only roughly deducible?" The above was written before the days of metallography, or at least when metal- lography had barely appeared in the metallurgical sky and when no one yet had fan- cied what would be the brilliant career of the newcomer. Metallography has done much to supply the need so vividly and timely depicted by Professor Howe, precisely because by lifting a corner of the veil hiding from our view the proximate composi- tion of metals and alloys it has thrown a flood of light upon the real constitution of these important products. Has the game been worth the candle? Will any one hesitate to answer in the affirmative Professor Howe's question? Professor Howe with his usual acumen was conscious of the fact that proximate analysis, while likely to reveal a great deal more of the constitution of metals than ultimate analysis ever could, might still leave us in such ignorance of their physical structure as to throw but little additional light upon the subject. His fear was cer- INTRODUCTION THE INDUSTRIAL IMPORTANCE OF METALLOGRAPHY 3 tainly well founded and surely if the proximate composition had been obtained by chemical analysis it would indeed have told us little of the structure or anatomy of the metals. In the domain of proximate composition chemistry cannot do more for the metallurgist than it does for the physician. Invaluable information chemistry does give, without which both the physician and the metallurgist would bo in utter darkness, but it throws little or no light upon the anatomy of living or inanimate matter. Its very methods which call for the de- struction of the physical structure of matter show how incapable it is to render assist- ance in this, our great need. The parallel drawn here between metals and living matter is not fantastic. It has been aptly made by Osmond, who said rightly that modern science was treating the industrial metal like a living organism and that we were led to study its anatomy, i.e. its physical and chemical constitution; its biology, i.e. the influence exerted upon its constitution by the various treatments, thermal and mechanical, to which the metal is lawfully subjected; and its pathology, i.e. the action of impurities and de- fective treatments upon its normal constitution. Fortunately metallography does more than reveal the proximate composition of metals. It is a true dissecting method which lays bare their anatomy that is, the physical grouping of the proximate constituents, their distribution, relative dimen- sions, etc., all of which necessarily affect the properties. For two pieces of steel, for instance, might have exactly the same proximate composition that is, might con- tain, let us say, the same proportion of pearlite and ferrite and still differ quite a little as to strength, ductility, etc., and that because of a different structural arrangement of the two proximate constituents; in other words, because of unlike anatomy. It is not to be supposed that the path trodden during the last score of years was at all times smooth and free from obstacles. Indeed, the truth of the proverb that there is no royal road to knowledge was constantly and forcibly impressed on the mind of those engaged in the arduous task of lifting metallography to a higher level. Its short history resembles the history of the development of all sciences. At the outset a mist so thick surrounds the goal that only the most courageous and better equipped attempt to pierce it and perchance they may be rewarded by a gleam of light. This gives courage to others and the new recruits add strength to the besieg- ing party. Then follows the well-known attacking methods of scientific tactics and strategy, and after many defeats and now and then a victorious battle the goal is in sight, but only in sight and never to be actually reached, for in our way stands the great universal mystery of nature : what is matter? what is life? Nevertheless there is reward enough for the scientist in the feeling that he has approached the goal, that he has secured a better point of vantage from which to contemplate it. The game was worth the candle. And if scientific workers must necessarily fail in their efforts to arrive at the true definition of matter, whatever be the field of their labor, they at least learn a great deal concerning the ways of matter, and it is with the ways of matter that the material world is chiefly concerned. Hence the usefulness of scientific investigation, hence the usefulness of metallography. Like any other science with any claim to commercial recognition, metallography has had first to withstand the attack and later to overcome the ill-will and reluctance of the so-called "practical man" with a decided contempt for anything scientific. He represents the industrial philistine clumsily standing in the way of scientific ap- plications to industrial operations. Fortunately, while his interference may retard 4 INTRODUCTION THE INDUSTRIAL IMPORTANCE OF METALLOGRAPHY progress, it cannot prevent it. Had he had his own way neither the testing machine, nor the chemical laboratory, nor the metallographical laboratory, nor the pyrometer would ever have been introduced in iron and steel works. Speaking in 1904 of the practical value of metallography in iron and steel making, the author wrote the following, which it may not be out of place to reproduce here: "History, however, must repeat itself, and the evolution of the metallographist bids fair to be an exact duplicate of the evolution of the iron chemist; the same landmarks indicate his course; distrust, reluctant acceptance, unreasonable and foolish expecta- tion from his work, disappointment because these expectations were not fulfilled and finally the finding of his proper sphere and recognition of his worth. The metal- lographist has passed through the first three stages of this evolution, is emerging from the fourth, and entering into the last. For so young a candidate to recognition in iron and steel making this record is on the whole very creditable." We may say to-day that he has definitely entered the last stage and that the ad- verse criticisms still heard from time to time, generally from the pen or mouth of ignorant persons, are like the desultory firing of a defeated and retreating enemy. In the United States alone the microscope is in daily use for the examination of metals and alloys in more than two hundred laboratories of large industrial firms, 1 while metallography is taught in practically every scientific or technical school. A. S. HARVARD UNIVERSITY, February, 1912. 1 As the second edition of this book goes to press, it may be safely affirmed that not less than four hundred industrial laboratories in the United States are equipped for metallographical testing. CHAPTER I APPARATUS FOR THE METALLOdRAPHIC LAPjORATORY 1 Those apparatus which the author has found most satisfactory are described in this chapter at some length; others more briefly in Chapter III. THE MICROSCOPE While any good microscope of the ordinary type, substantially built and provided with a satisfactory fine adjustment, may be used with a certain degree of success for the examination of metals and alloys, those who are restricted to its use will soon find themselves seriously handicapped in 'several directions and unable to obtain the desired results. The following considerations will make this clear. The Stage. Ordinary microscope stands being constructed for the examination of objects by transmitted light, i.e. by light proceeding from below the stage and passing through the object on its way to the eye, are provided with fixed stages. This, however, is a serious objection when the instrument is applied to the examina- tion of metals and other opaque objects, which must necessarily be illuminated by light directed upon them from above the stage, and which therefore require the use of an "illuminator" attached to the objective and consequently moving with it. It will be readily understood that it is of considerable importance that the position of this illuminator, and therefore of the objective to which it is attached, be kept constant, once the necessary adjustments are effected, since any change in its position would require a readjustment of the source of light, the condensing lenses, diaphragm, etc. To that effect the stage should be provided with a rack and pinion motion by means of which the coarse focusing at least may be done (Fig. 1). This rack and pinion motion of the stage, moreover, permits of a much greater working distance, allowing plenty of room for the insertion of the illuminator and nose-piece, the use of specimen holders, and the examination of bulky specimens with low-power objectives. In the microscope illustrated in Figure 1, the working distance measures over 5 inches as against 4 inches or less in ordinary stands. By not departing more than necessary from the usual construction of microscopes, none of the essential features required for the examination of transparent prepara- tions need be sacrificed, and the full efficiency of the microscope is retained for such examination, sub-stage condensers, polarizing prisms, etc., being readily attached when needed. The possibility of applying his instrument to all kinds of microscopical work with equally satisfactory results should appeal strongly to the metallographist, for there is no laboratory where, occasionally at least, examination of transparent objects is not desirable or even imperative. 1 Abstracted in part from papers by the author on "Apparatus for the Microscopical Examina- tion of Metals," American Society for Testing Materials, Vol. X, 1910; and "The Universal Metal- loscope," American Institute of Mining Knginoprs, June, 1911. 6 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY Fig. 1. Metallurgical microscope, eye-piece, vertical illuminator, objective, magnetic specimen holder, and mechanical stage. (0.5 actual size.) CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 7 Fig. 2. Student microscope. (0.5 actual size.) 8 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY Less expensive but satisfactory microscopes are shown in Figures 2 and 3. The latter illustration includes an auxiliary tube inserted between the objective and illu- minator for the examination of large samples which may be placed on the base of the microscope or supported in some other suitable way below the stage. (a) Plain Stages. While a mechanical stage adds greatly to the convenience of the manipulations, a plain stage may be used with satisfactory results. It should be provided with strong clips to hold in place the specimen holders soon to be described, and should preferably be circular and revolving (Fig. 4). When provided with cen- tering screws like the stage of the stand illustrated in Figure 1, the object may be moved gently while under examination, a very desirable feature especially when using high-power objectives, in which case the moving of the object entirely by hand is very jerky. In order to derive the full benefit of the use of the magnetic holder described later, the central opening of the stage should not be less than 1% inches in diameter. (6) Mechanical Stages. The great superiority of a mechanical stage permitting, as it does, a systematic examination of the object over its entire surface, need not be insisted upon. In connection with the magnetic holder it makes it possible, moreover, to examine repeatedly and at any time the same spot of any specimen, as will soon be explained. The mechanical stage illustrated in Figure 5 has been especially designed to fit the metallurgical microscope (Fig. 1), and is very readily substituted for the plain stage. The central opening measures 1% inches in diameter, permitting the convenient use of the magnetic holder. Objectives. Ordinary achromatic objectives give satisfactory results. They should, however, be corrected for uncovered objects, as the placing of cover glasses over bright metallic surfaces is accompanied by light reflection causing loss of clear- ness and definition. Some believe that the objectives should be provided with short mounts so as to bring the reflector of the vertical illuminator as near the back lens of the objective as possible, and thus, in their opinion, materially decreasing the amount of glare caused by the reflection of light by the lenses of the objectives. They are advisable only when a prism vertical illuminator is used. Three objectives, one of low, one of medium, and one of high power, will generally suffice for metallographic work. The following focal lengths are recommended: 32-mm. or IJ^-in., 16-mm. or -r-'s-in., and 4-mm. or J^-in. These objectives are shown in Figure 6. The 32-mm. objective is provided with a society screw at its lower end in order that the vertical illuminator may be inserted between the objective and the object, this being desirable with very low- power lenses. In case higher power is needed, a 1.9-mm. or ^-in. oil immersion ob- jective will be found very satisfactory. When a very low-power lens is required, as for instance in the examination of fractures or of very coarse structures, a 48-mm. or 2-in. objective will give good results. It is suggested that it be provided at its lower end with a society screw to permit the attachment of the vertical illuminator, which in the case of such low-power lenses should be placed between the object and the ob- jective, as explained later. Eye-Pieces. With achromatic objectives ordinary Huygenian eye-pieces are used. Two eye-pieces, respectively of 1-in. and 2-in. focal length, will generally cover the range of magnification needed. For the taking of photomicrographs, projection eye-pieces are said to possess some superiority, especially when high-power objectives are used, as they then yield CHAPTKR I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 9 Fig. 3. Student microscope fitted with auxiliary tube. 10 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY Fiu;. 4. Plain revolving stage, magnetic specimen holder, and specimen. Fig. 5. Mechanical stage to fit metallurgical microscope, magnetic specimen holder, and specimen. CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 11 flatter and more sharply defined images. The Zeiss projection eye-piece No. 2 is very satisfactory. Iris Diaphragms. Iris diaphragms are sometimes inserted between the objec- tives and the illuminator so as to control the size of the pencil of light proceeding from the object, with a view of securing sharper definition. Their use in that posi- tion, however, is of doubtful value, as it may cause some distortion of the image. It seems preferable to place the iris diaphragm between the source of light and the illuminator, thus regulating the amount of light entering the latter. When placed be- Fig. 6. Achromatic objectives. tween the objective and the illuminator it increases, moreover, their distance apart, which we have seen to be objectionable. If a diaphragm must be attached to the microscope, it is better to place it between the tube nose and the illuminator. When using low-power lenses it might also be screwed to the lower end of the objective, thus controlling the light returned by the object before entering the objective. Specimen Holders. In order to examine a piece of metal under the microscope, it is of course necessary that the polished and otherwise prepared surface be held in a plane accurately perpendicular to the optical axis of the instrument. This may be I Fig. 7. Specimen holder. accomplished by so shaping the sample that it will have two sides exactly parallel, and preparing one of them for microscopical examination. This operation, however, is at best tedious and laborious, and metallographists have endeavored to replace it by the use of more or less ingenious devices for holding the specimens in the proper position. Some embed their samples in wax or in some other plastic material, while others have recourse to stages provided with special leveling devices. The simple holder shown in Figure 7 gives better satisfaction, requiring no mount- ing whatever of the samples. The specimen, no matter how irregular in shape, is 12 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY held firmly in place by a rubber band and the holder placed on the stage like an ordinary slide. If the correction of the objective demands it, a cover glass may be inserted between the sample and the holder. It will be apparent that the required manipulations are very simple and quickly performed. In the case of specimens smaller than the opening of the holder, however, the use of a cover glass is necessary to hold them in place. This is objectionable, at least when using high-power objectives, which should be corrected for uncovered objects. To overcome this difficulty, a little templet may be used having a triangular opening and inserted between the specimen and the holder (Fig. 8). This templet is made very thin so as to permit the use of high-power objectives, which must be brought very close indeed to the object. It will also be noticed that one side of the upper part Fig. 8. (a) Specimen holder and large specimen. (6) Specimen holder, templet, and small specimen. of the holder has been removed, exposing to view a larger portion of the sample and permitting a more ready approach of high-power objectives. Large samples are, of course, placed in the holder without any templet. A still simpler and more effective device can be used to hold in place samples of iron and steel and other magnetic substances. The device consists of a V-shaped permanent magnet of special steel about 1 inch wide and 2J/ inches long (Fig. 9). This little magnet is placed on the stage of the microscope like an ordinary glass slide (Figs. 4 and 5) and the samples to be examined suspended to it from below, being held in place by the attraction of both poles. Small samples are suspended near the small end of the V-shaped opening, while larger ones are placed nearer the wider end of the opening. This holder, therefore, is universal in its application within the limits of samples of suitable size for microscopical examination. Its beveled edges make its use possible with high-power objectives and small specimens. If the opening of the stage be sufficiently large, say 1J4 inches or more in diameter, the magnet may be CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 13 kept permanently on the stage, as the samples may then be readily removed or at- tached to the magnet with the fingers from below the stage. This adds so much to the convenience of this little device that it is strongly urged, in case the central aper- ture of the stage is too small, to have it suitably enlarged. The magnet is kept in place, like any glass slide, by the clips of the microscope and, also like any glass slide, may be moved about for the inspection of the different parts of the specimen. The side of the magnet resting on the stage having been ground perfectly flat, it will be Sec 1 1 or? on fl- ff Fig. 9. Magnetic specimen holder with large and small specimens. evident that the surface of the sample under examination will always be accurately in the proper position, permitting the use of high-power objectives without fear of difficulty arising from ever so slight an inclination of the sample. When used in connection with a mechanical stage (Fig. 5) the convenience of this little holder becomes still more apparent and its usefulness is further increased. It then affords, moreover, a ready means for the repeated examination of the same spot of any sample at any time. To that effect the holder is laid upon the prepared surface Fig. 10. (a) Magnetic specimen holder. (6) Scratched specimen. and two scratches made by drawing a needle across the specimen along the sides of the Y-shaped opening, as shown in Figure 10. When it is desired to examine the sam- ple, the latter is suspended to the magnet so that the needle markings coincide closely with the sides of the magnet opening, in this way securing a permanent position for the sample. The position of the magnet itself is controlled, in the usual way, by means of the graduating devices of the mechanical stage. Finally, by placing the sample below the stage and bringing the prepared surface 14 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY on a level with the stage, considerably greater working distance is secured, a gain which has its importance. Universal Metalloscope. The instrument shown in Figures 11 to 15 was devised especially for the ready examination of large iron and steel samples, but it will be ap- parent that it can be used with equally satisfactory results for small samples both opaque and transparent. Owing to the fact, however, that the microscope proper and the stage are separate parts, it is absolutely necessary, especially for the use of high-power objectives, that the apparatus be placed on a support free from vibration, such for instance as a suit- Fig. It. Universal metalloscopc: stand, eye-piece, vertical illuminator, objec- tive, electromagnetic stage, and rail section. ably constructed concrete pier. With that precaution taken, excellent results are obtained. The microscope stand proper consists of a microscope tube, provided with both coarse and fine adjustments, and with a draw tube, rigidly mounted on a bar sup- ported at both ends on substantial and firm cast-iron legs. 1 The height between the table and the under side of the supporting bar is 5 inches and the distance between the supporting legs 12 inches. This arrangement affords free space below the objective for the examination of large specimens of metals, such as full rail sections, without detracting in the least from the value of the instrument when applied to the examination of the usual small specimens, as explained later. Many metal microscopists frequently have to examine 1 In a more recent model the supporting bar is mounted on three legs, permitting the ready lev- eling of the instrument. CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 15 bulky specimens, and this is altogether impossible with the ordinary microscopes as well as with the special metallurgical microscopes which have been designed and de- scribed from time to time. Recourse must be had to all sorts of makeshifts for the proper support of large specimens, or, more often, the microscopist gives up the attempt altogether, or else resigns himself to the cutting of the bulky samples into small pieces to be laboriously polished and separately examined. It is believed that an instrument permitting the examination of large as well as of small specimens with equal ease and accuracy will be welcomeoTby metallographists, and that it will lead to more frequent examinations of full sections of metal imple- ments, a departure which should bring fruitful results. Electromagnetic Stage. The perplexing question of the proper support for mi- croscopical examination of iron and steel specimens of all sizes and shapes has been -rf Fig. 12. (A) Electromagnetic stage and rail section. (B) Electromag- netic stage, templet, and medium-size specimen. (C) Electromag- netic stage, two templets, and small specimen. effectively solved by the use of the electromagnetic stage illustrated in Figure 12. This stage consists of a steel plate 7 by 14 inches having a V-shaped opening, and converted into a powerful electromagnet by means of two bobbins with solenoids surrounding the arms of the steel plate, as clearly shown in the illustration. Elec- trical connection is readily made with any suitable current, and the use of an incan- descent lamp in series provides in a simple way the necessary outside resistance to prevent heating of the solenoids. Large specimens of iron and steel, such as rail sec- tions, A, Figure 12, are firmly held in an accurate position by the attraction of the magnetic stage, the extremities of the flange only and a narrow space on each side of the head being hidden from view. The size and shape of the stage-opening make possible the ready support of specimens measuring from 2 to 6 inches in their greatest dimension. Templets for the Examination of Small Specimens. For the examination of iron and steel samples from 2 inches in length down to the smallest dimensions, a steel templet, also with a V-shaped opening, is placed on the stage, shown at B, Figure 12. This templet through its contact with the stage becomes strongly magnetized and the specimens to be examined are suspended to it. For the examination of very small specimens with high-power lenses the thickness 16 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY of this templet would prevent the necessary close approach of the objective. To make this approach possible a very thin steel templet (not exceeding 0.01 inch thick) is used, shown at C, Figure 12, which makes possible actual contact between a high- power objective and the smallest specimen. Support of Non-Magnetic Specimens. For the support of non-magnetic speci- mens, such as non-ferrous metals, rocks, cement, etc., a very simple device is provided, consisting of two crossbars and rubber bands, which is readily attached to the stage and by means of which the non-magnetic specimens, as well as the templets when needed, are firmly held in place regardless of their size or shape. Leveling-Devices of Stand and Stage. It is, of course, essential, especially when using high-power objectives, that the optical axis of the microscope be accurately perpendicular to the surface under examination. To secure this result both the stand Fig. 13. Back leg of electromagnetic stage and sliding plate. and the stage are provided with leveling-screws, as shown in Figure 11. For leveling the stage a small spirit-level may be placed upon it, or better, upon the sample under examination, and the necessary adjustment quickly made. For leveling the micro- scope stand the eye-piece should be removed, the small level placed on top of the tube, and the leveling-screws adjusted. By placing the instruments on a support having a smooth and flat top, it is evident that, barring accidents, the stand and stage will remain indefinitely accurately leveled. Motion of the Stage. In order to examine the entire surface of a large specimen it is necessary to bring in turn within the field of the microscope the different portions of the specimen, and this necessitates the moving of the stage in various directions. The weight of the stage, however, would create considerable friction between the legs and the supporting table, making the sliding motion jerky and otherwise unsteady. To overcome this difficulty the back leg of the stage is provided with a small wheel running in a groove cut in a small brass plate fastened to the table or desk, shown in Figure 13. The mounting of the wheel is provided with a pivot fitting snugly into a CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 17 hole in the leg. This construction makes possible the ready back-and-forth motion of the stage, as well as its free circular displacement around the axis of the back leg thus permitting to bring quickly any desired portion of the object under the objec- tive. As the bulk of the weight is supported by the back leg, the arrangement makes possible a very steady and smooth motion of the stage. Mechanical Stage. The use of a mechanical stage is often highly desirable. This is taken care of in the present instrument in two different ways: (1) by the use of a mechanical stage suitably attached to the electromagnetic stage^ and (2) by the use Fig. 14. Universal metalloscope: electromagnetic stage with mechanical stage, magnetic specimen holder, small specimen, and base-plate. of a mechanical stage independently mounted on a separate base of the usual horseshoe pattern. The first method is illustrated in Figure 14. A mechanical stage of usual construc- tion is screwed on a brass plate provided with two small pins fitting two correspond- ing holes in the magnetic stage, thus securing a firm and constant position for the mechanical stage. When using a mechanical stage, however, a rigid and constant position should also be secured between it and the microscope stand. To that effect a brass plate is provided, with recesses to receive the back legs of the stand as well as the front legs of the stage, shown in Figure 14. It is then possible at any time to place the microscope stand and the stage in exactly the same relative positions. The second method consists in the use of a mechanical stage separately mounted on an ordinary horseshoe base, shown in Figure 15. To secure a constant relative position between stand and stage, the foot of the latter fits into recesses provided for that purpose in the base-plate. 18 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC_ LABORATORY The use of this independently mounted mechanical stage offers the additional advantage resulting from the vertical up-and-down racking of the stage, rendering unnecessary any vertical adjustment of the light and condenser, as well understood by metallographists. Examination of Transparent Objects. To adapt the universal metalloscope to the examination of transparent objects, thereby converting it into an ordinary ^micro- scope or, if desired, into a petrographical microscope, a separate stage on horseshoe base should be used, as shown in Figure 1'5, when the necessary Abbe condenser, Fig. 15. Universal metalloscope: mechanical stage on horseshoe base, magnetic specimen holder, small speci- men, and base-plate. analyzer, polarizer, etc., can readily be attached. The instrument is then in no way inferior^to high-class microscopes for examination by transmitted or polarized light. ILLUMINATION OF THE SAMPLES Opaque objects such as metals and alloys must necessarily be examined by re- flectedjight, i.e. by light thrown upon them from above the stage, their treatment differing in this respect from that of other microscopic preparations, which are gen- erally examined by transmitted light, i.e. by light sent through them and proceed- ing from below the stage. With the low-power objectives there are two possible ways of illuminating opaque specimens: (1) by directing the light obliquely upon the object, and (2) by causing the light to fall perpendicularly upon it by means of so-called "vertical illuminators." CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 19 With medium-high and high-power objectives the second method only is possible, because the distance between the specimen and the front lens of the objective is now so small that obliquely reflected light cannot reach the surface under -examination. With very low-power objectives i.e. having a focal length of 1 inch or more the vertical illuminator may be placed between the lens and the object; but with higher power objectives it must of course be inserted between the objective and the microscope tube, the objective then acting as a light condenser and increasing the intensity of the illumination. Oblique illumination may be obtained (a) by allowing daylight or artificial light to fall freely upon the object; (6) by directing the light upon the object by means of mirrors, reflectors, or condensers; (c) by the use of a "lieberkuhn"; and (d) by the use of a "parabolic reflector." Vertical illumination may be produced (a) by means of an opaque reflector con- sisting of a totally reflecting prism or of a mirror covering only a portion of the ob- () (6) Fig. 16. (a) Oblique and vertical illuminations of bright surface. (6) Oblique and vertical illuminations of dull surface, (c) Oblique and vertical illuminations of hills and valleys. jective, the light returned by the object reaching the eye by passing through the uncovered portion; and (b) by means of a transparent reflector, generally a plain glass disk or glass square, reflecting upon the object a portion of the incident light and permitting the passage of a portion of the light returned by the object, which thus reaches the eye. When a highly polished surface is examined by obliquely reflected light, since the angle of reflection is equal to the angle of incidence, the totality of the light is reflected outside the objective (Fig. 16) and the object appears uniformly dark. In case the metallic specimen contains some portions duller in appearance, these will scatter a certain amount of light a part of which will enter the objective (Fig. 16), and those portions will therefore appear brighter. A similar effect is produced when the speci- men, instead of being perfectly flat, contains microscopic hills and valleys, the sides of which may be so inclined as to reflect some light into the microscope (Fig. 16), consequently appearing bright. Viewed by oblique light, therefore, the relative dark- ness or brightness of a constituent will vary inversely with its true appearance and 20 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY will also depend upon its orientation, since this will affect the angle of incidence of the light striking it. Generally speaking, the darker a constituent the brighter will it seem to be when illuminated by oblique light, the latter yielding, so to speak, a nega- tive image. Oblique illumination, moreover, cannot be made as intense as vertical illumination and, as already explained, is possible only with low-power objectives. For these and other reasons, while it is not without value, it is only used occasionally by metallographists. To increase the intensity of oblique illumination and to make its use possible with somewhat higher powers, such appliances as the " lieberkiihn " and the parabolic re- flector have been used. The " lieberkiihn," so called from the name of its inventor, consists of a small concave mirror attached to the objective and reflecting upon the object some light proceeding from below the stage and passing around the object. It will be evident that only small size objects can be thus illuminated. The parabolic reflector (Fig. 17), first constructed by Messrs. Beck of London for Dr. Sorby, consists of a parabolic mirror placed on one side between the objective (a) Fig. 17. (a) Parabolic reflector. (6) Sorby-Beck parabolic reflector. and the object and condensing the incident light upon the latter. It should be at- tached to the objective. Dr. Sorby later added a silver mirror in the shape of a half disk to the same mount, so as to be able to obtain at will vertical and oblique illumi- nation when using low-power objectives (Fig. 17). When vertical illumination is desired, the small mirror is swung over the objective, covering only a portion of it, and directing vertical rays of light upon the object. This combination is known as the Sorby-Beck reflector. The effects of a vertical illumination are precisely opposite to those of an oblique illumination, as clearly shown in Figure 16, highly polished surfaces reflecting the totality of the light into the objective, while dull ones appear dull because they reflect most of the light outside. To produce a vertical illumination we have the choice between an opaque or a transparent (glass) reflector. The opaque reflector consists of a totally reflecting right-angled prism, or of a mirror placed between the microscope tube and the objec- tive and covering only a portion (generally about one half) of its aperture. The beam CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 21 of light enters the illuminator through a side opening provided for that purpose and is reflected downwards by the reflector, being condensed upon the object by the lenses of the objective itself. The light sent back by the object reaches the eye through the uncovered part of the objective. The first vertical illuminator was designed by Prof. Hamilton L. Smith of Hobart College, Geneva, N. Y., and consisted of a small annular silver mirror V (W () w Fig. 18. (a) Annular mirror. (6) Semi-circular mirror. (c) Central mirror. (d) Totally reflecting prism. (e) Plain glass disk. (Fig. 18), forming an angle of 45 with the axis of the microscope, the light reflected by the object passing through the central opening on its way to the eye. Semi- circular mirrors, similarly mounted and partially covering the objective (Fig. 18), have been used with equal satisfaction, and the author has obtained good results with a very small central mirror (Fig. 18) suitably mounted, reflecting the light upon the -K A B Fig. 19. Vertical illuminator. Totally reflecting prism. (Zciss.) central portion of the objective lenses, and permitting the returned light to reach the eye through the free space surrounding the mirror. Instead of a mirror, a totally reflecting right-angled prism may be used as shown in Figures 18 and 19, covering half of the aperture of the objective. The prism is so mounted that it can be rotated around its horizontal axis, this being needed in order to secure the best illumination of the sample. Nachet, of Paris, provides his prism 22 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY with an additional motion permitting it to cover a greater or smaller portion of the objective. These reflecting prisms are now used much more than the reflecting mirrors. In 1874 Nachet constructed for the International Commission of the Meter some objectives provided with totally reflecting prisms as permanent parts of their mount- ings. In low-power objectives a prism was placed above the first lens (Fig. 20), while with higher power objectives it was necessarily inserted above the double or triple Fig. 20. Nachet illuminating objectives. lens system. These objectives are called illuminating objectives. This arrangement, however, has not been found very satisfactory and with one notable exception is seldom used by metallographists. In vertical illuminators having a transparent reflector, the latter consists of a plain glass disk covering the whole of the aperture of the objective (Figs. 18 and 21). The incident light is in part reflected upon the object, while another portion passes freely through the glass reflector. A part of the light returned by the object is again re- flected by the glass illuminator, while another portion passes through it and thus O4 Fig. 21. Bausch and Lomb plain glass disk vertical illuminator. reaches the eye. The glass reflector is so mounted that it can be rotated around its horizontal axis (Fig. 21). The amount of light permitted to enter the illuminator may be regulated by an iris diaphragm attached to the side opening or independently mounted and placed between it and the source of light, or by a revolving sleeve at- tached to the illuminator and provided with different size openings. The first plain glass illuminator was constructed by Mr. Beck of London. With very low-power objectives it is preferable to place the vertical illuminator between the objective and the object, attaching it to the former in some suitable way, CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 23 as for instance by providing the lower end of the objective with a society screw (see Fig. 6). While the author is well aware that some metallographists of note prefer the prism to the plain glass type of vertical illuminator, in his opinion the plain glass reflector is greatly superior. While the illumination obtained by its use is not quite as intense, it is certainly more uniform and less liable to produce a distortion of the image. An improved construction of the plain glass vertical illuminator is illustrated in Figure 21. The glass reflector is inserted into a brass ring which on the side opposite the milled head is screwed into the wall of the brass mounting, pFactically doing away with the frequent breaking of the glass and greatly facilitating its cleaning. The milled A- B Fig. 22. Vertical magnifier. head is large, which makes it possible to impart a more delicate motion to the glass reflector. Vertical Magnifier. For the examination of specimens after the polishing opera- tion in order to ascertain the absence of scratches, for the examination of fractures, etc., and more especially for the measurement of the diameters of the spherical de- pression of the Brinell test for hardness, the "vertical" magnifier, Figure 22, has been found very useful. The plain glass reflector G placed at an angle of 45 causes the specimen under examination to be brilliantly lighted by vertical light as in the vertical illuminator attached to metallurgical microscopes. For the measurement of small distances (as in the Brinell hardness test), a thin steel scale R, with proper graduations, is inserted in a slot A cut in the mounting and so placed that the grad- uated edge meets the optical axis of the lenses. SOURCES OF LIGHT AND CONDENSERS The illumination of opaque objects such as metals and alloys requires an intense source of light, especially for their photography. Daylight and ordinary gas or oil flames should be discarded as not suitable for the purpose, the sources of light which have been found most satisfactory being, in the order of their excellence, intensity, and decreasing cost: (1) the electric arc lamp, (2) the Nernst lamp, and (3) the Wels- bach gas lamp. The author has recently used with very satisfactory results, 250 and 500 watt, nitrogen filled, incandescent tungsten lamps. The Welsbach lamp outfits (Figs. 23 and 24) are very inexpensive and quite satis- factory for visual examination by low- and medium high-power objectives. In tak- 24 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY ing photomicrographs, however, their lack of intensity necessitates very long ex- posures, while with high-power objectives the light received upon the camera screen is so faint as to render proper focusing of the object a very difficult, if not impossible, operation. Fig. 23. Welsbaeh lamp and double-convex condensing lens. Two kinds of electric arc lamps are now supplied, one with large carbons (Fig. 25) and a smaller one with carbons measuring only }/ inch in diameter (Fig. 28). The carbons should be placed at right angles, as this arrangement directs the maximum amount of light into the condensers. Both carbons should be cored and for direct current the vertical or negative carbon should be smaller than the horizontal Fig. 24. Welsbaeh lamp and bull's eye condenser. carbon. While automatic feeding of the carbons (Fig. 27) is a valuable feature, it is not by any means essential, as remarkably effective hand-feed lamps are now constructed by which a very steady light can be maintained (Fig. 26). Automatic mechanisms, moreover, are liable to get out of order and occasional sudden shift- ings of the light are difficult to eliminate entirely. CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 25 The large carbon lamp yields, of course, by far the most intense illumination and is the only one suitable for direct projection of metallic samples upon a screen for public exhibition. In taking photomicrographs with the large arc lamp the needed exposures are often instantaneous and seldom exceed 5 or, at the most, 10 seconds. The lamp consumes from 15 to 20 amperes. Fig. 2.5. Largo arc lamp outfit. The small arc lamp (Fig. 28) is very satisfactory for visual examination and is, of course, much less expensive. It, however, requires longer exposures when photo- graphing. The position of the carbons can be regulated with great nicety by inde- pendent adjustments, thus securing a very uniform light. The lamp consumes about 5 amperes. The medium size arc lamp described on page 29 as part of a complete photomi- crographic outfit gives excellent results and is the one preferred by the author. Fig. 20. Hand-feed arc lamp. Fig. 27. Automatic-feed arc lamp. The Nernst lamp (Fig. 29) is used successfully by many microscopists and un- doubtedly affords a very satisfactory illumination both for visual examination and for photomicrography. In taking photographs, exposures of 10 seconds or more are needed, according to the magnification and the character of the specimen. Summing up, if we desire a cheap and convenient form of illumination for visual examination with objectives of low- and medium-high power, the Welsbach lamp will be found in every way satisfactory; while for the taking of photomicrographs and for 26 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY examination by high-power objectives the electric arc lamp, the 250 or more watt, nitrogen filled, tungsten lamp and the Nernst lamp should be recommended, bearing in mind that the large arc lamp will yield light of greatest intensity but will, on the other hand, be much more costly. When neither gas nor suitable electric current are Fig. 28. Small electric arc lamp, bull's eye condenser, and rheostat. available, an acetylene lamp should be used, provided tanks of acetylene gas can readily be obtained. Condensers. - Some kind of condensing attachment must be placed between the source of light and the vertical illuminator so that a large portion of the light may be utilized and a beam of suitable size directed into the illuminator. In the case of light proceeding from a luminous point or at least from a small luminous area, as for in- Fig. 29. Nernst lamp and special bull's eye condenser on adjustable supports. stance with the electric arc, at least two lenses or systems of lenses are needed, one system, PL and ML (Fig. 30), placed near the source of light, to collect the divergent rays and convert them into a parallel beam, and a second lens CL placed at some distance from the first, to convert the parallel beam into a converging one. The ver- . tical illuminator should be located at such a distance from the condensing lens that the beam of light will cover a little more than the opening through which it enters CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 27 the illuminator. With arc lamps using more than 5 amperes a glass cooling cell CC, filled with distilled water or some other suitable liquid, should be placed be- tween the two lenses in order to absorb a large amount of heat and thereby pre- vent injury to the objective. An iris diaphragm, /, should also be used to control the amount of light entering the vertical illuminator. This diaphragm should be placed in front of the converging lens and should be provided with clips for holding ground and colored glasses. These various parts should be mounted on a so-called "optical bench" B upon which they can slide. With a large luminous body such as the Welsbach mantle, a single double-convex lens (Fig. 23) or a bull's eye condenser (planoconvex) (Fig. 24) is sufficient to collect and condense the necessary amount of light. It should, of course, be placed at the proper distance both from the vertical illuminator and from the source of light. The use of an iris diaphragm attached to the lens or on a separate mount is advisable, CL CC PL ML Fig. 30. Condensing lenses, cooling cell, iris diaphragm, automatic shutter, and optical bench. since it affords a ready means of controlling the amount of light admitted into the illuminator. Monochromatic Light. The different lamps described above all yield, of course, white light, and since the correction even of apochromatic objectives for chromatic aberration is never perfect, it is evident that the use of monochromatic light i.e. light of one wave length is preferable, especially for photographing. Monochro- matic light may be obtained in two ways: (a) by using a source of light actually mono- chromatic, and (6) by causing white light to pass through colored glass screens or colored solutions (light filters), preventing the passage of some undesirable rays. The mercury arc lamp yields a nearly monochromatic light and has been tried by Le Chatelier with satisfactory results. It seems more convenient, however, when mono- chromatic light is wanted, to use light filters of suitable colors, in which case colored glass screens will be found easier to manipulate than glass cells containing colored solutions. PHOTOMICROGRAPHIC OUTFITS For taking photomicrographs, a light-tight connection should be established be- tween the microscope and a suitable (Fig. 31) camera. The Universal metalloscope already described is seen in Figure 32 with vertical camera and Nernst lamp. The arrangement the author has found by far the most satisfactory is illustrated 28 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY Fig. 31. Photomicrographic camera (vertical position), showing metal- lurgical microscope, mechanical stage, automatic shutter, etc. CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 29 in Figure 33. The microscope already described, camera, and arc lamp are mounted on the same rigid support, thereby securing accurate alignment and ease of manipula- tions. The supporting table is of such a height that the observer may be seated for visual work and in a comfortable standing position for the focusing of images on the screen of the camera (Fig. 34). Connection between the microscope and camera is very quickly and easily made. Plates measuring 5 by 7 inches and smaller sizes may be used. The source of light is an electric 90 arc lamp, supplied with a triple con- Fig. 32. Universal metalloscope, Nernst lamp outfit, and vortical camera. dousing system with lenses 4^ inches in diameter. The current may be direct or alternating. The lamp is enclosed in a small cylindrical hood with observation win- dows. The carbon adjustments are so arranged as to be conveniently reached by the observer either at the microscope or at the camera (Fig. 34). Clips fastened to the front of the lamp permit the use of monochromatic glass screens, ground glass, etc. The light may be tilted at any desired angle for transparent or for oblique illumination. The electric arc lamp may be replaced with very satisfactory results by a 250 watt, nitrogen filled, tungsten lamp. 30 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY Fig. 33. Photomicrographic apparatus with latest form of metallurgical micro- scope (0.1 actual size). CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 31 Fig. 34. INVERTED MICROSCOPES Le Chatelier was the first to suggest the use of an inverted microscope for the ex- amination of metallic surfaces. In this style of microscope the stage is placed hori- zontally above the objective, the latter being necessarily pointed upwards (Figs. 35 to 37). In the inverted type of microscope and photographic attachment illustrated in these pages, it has been attempted to simplify the construction with corresponding material decrease in price. The microscope is permanently connected with the camera by a totally reflecting prism P (Fig. 37) set rigidly below the vertical illuminator. A separate tube set at right angles to the first is provided for visual examination, another totally reflecting prism P' being fastened to the inner end and serving to reflect the image from the body tube through the eye tube to the eye. When a photograph is to be taken this prism P' is simply withdrawn from the field by means of the draw tube. The eye tube is fitted with pin and slot which mark the limits to which the small prism P' may be pushed in and withdrawn, so that the vertical illuminator being once set, the only adjustment necessary is at the arc lamp. With the Nernst and Welsbach lamps, after the light and the vertical illuminator are once set, no more adjustments are necessary. The two totally reflecting prisms need never be rotated and in fact can- not be moved, except for the sliding motion of the prism P' as already described. The stage, which is revolving and provided with centering screws, is of course equipped with both coarse and fine adjustment, and a mechanical stage may readily be substituted for the plain stage. With this inverted microscope the use of a magnetic holder will also be found very convenient, for the sample, instead of resting loosely on the stage, is then held firmly in place thereby increasing the usefulness of the mechanical stage. 32 CHAPTER I APPARATUS FOR THK MKTALLOGRAPHIC LABORATORY Fig. 35. Inverted metalloscopc (?, actual size). CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 33 The placing of the light on the same side of the microscope as the camera makes it possible for the operator to regulate his illumination while focusing the object on the camera's screen. One of the valuable features of this model is its compactness. While at the camera screen, the operator can easily reach the lamp adjustments, and the fine adjustment Fig. 36. Inverted metalloscope (rear view). Showing means of controlling fine adjustment. rv -t Fig. 37. Inverted metalloscope (vertical section, front view). R = Vertical illuminator reflector. P' = Totally reflecting prism which reflects image into the eye tube when latter is pushed in. P = Totally reflecting prism which reflects image into camera when eye tube is pulled out. S = Metalloscope stage. M = Magnetic specimen holder. O = Specimen. of the microscope is controlled from the same position by means of a thread belt actuated by a small milled head pulley placed on a standard at the end of the camera bed bar near the screen (Fig. 36). 34 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY POLISHING APPARATUS Hand Polishing. When, in spite of the length and laboriousness of the opera- tion, iron and steel samples are to be polished by hand, four smooth blocks of wood should be prepared, some 6 by 10 inches and 1 inch thick. Two of these should bo covered with canvas or linen duck and the others with fine broadcloth. The blocks are to be used as described in Chapter II. Polishing by Power. The power polishing machine shown in Figure 38 has been found very satisfactory. It consists of a heavy iron pedestal upon which is mounted Fig. 38. Power polishing machine. a grinder having emery-wheel and cast-iron disks revolving in a vertical piano, thus giving four polishing surfaces of graduated fineness. The polishing powders mixed with water are applied to the various disks by means of brushes, and shields are pro- vided to catch any surplus water that may be thrown off during the operation. Should a cloth become worn or torn it is readily and quickly replaced. This machine very much shortens the time necessary for the preparation of samples and is far superior to those where only one block is made to rotate at a time. A speed of 1200 revolu- tions per minute has been found most satisfactory for polishing iron and steel samples, CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 35 but by the use of a variable speed electric motor to run the polishing machine various speeds may be readily obtained. The polishing motor shown in Figure 39 possesses the advantage- of directly driven over belt driven machinery. It is provided with the same polishing disks as the pol- ishing machine and can be built both for constant and for variable speed. The operation of polishing with these machines is described in Chapter II. Fijj. 39. Polishing motor. Fig. 40. Portable polishing motor. Portable Polishiixj Motor. A portable polishing motor is shown in Figure 40. It has been devised for the purpose of polishing small spots (about % inch in diameter) on pieces too large to be treated in the ordinary way and from which samples of suit- able dimensions cannot readily be cut, as for instance finished forgings or castings, etc. It consists of a ^g H. P. motor, flexible shaft, grinding heads, and polishing disks suitably covered. A spot may be satisfactorily polished in some 15 to 20 minutes. 36 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY PYROMETERS AND ELECTRIC FURNACES Pyrometers. The Le Chatelier thermo-electric pyrometer is undoubtedly the instrument best adapted to the measurement of temperatures needed to control such heat treatments as are likely to be performed in a metallographical laboratory. The Fig. 41. Siemens and Halske galvanometer. Fig. 42. Leeds and Northrup thermo-couple potentiometer. thermo-couple consists of a wire of pure platinum and of a wire of platinum alloyed with 10 per cent of rhodium or iridium. To measure the electromotive force created an accurate direct reading galvanometer should be used (Fig. 41) or else the poten- CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 37 tiometer method (Fig. 42). Instructions for the use of these instruments are generally supplied by the makers. The use of cheaper couples and cheaper instruments is not to be commended, for they are unsuitable for accurate scientific work especially at high temperatures. An autographic recording pyrometer is very useful and quite indispensable for the detection of faint evolutions or absorptions of heat. Indeed without its use there are many delicate thermal treatments that could not be performed. Several auto- graphic instruments are now constructed. To meet the needs ofj.he metallographist Pt. Rli. Fig. 43. Saladin self-recording thermo-electric pyrometer. the author believes that the pyrometric recorder designed by Le Chatelier and Sala- din and constructed by Pellin of Paris (Figs. 43 to 45) will be found most satisfactory. In an early form the different parts were arranged as shown in Figure 43. The light proceeding from the source S after passing through a lens is received by the mirror of a sensitive galvanometer GI the deflections of whicli measure the difference in temperature between the sample under examination and the neutral body. This horizontal deflection of the beam of light is converted into a vertical deflection by passing through a totally reflecting prism M placed at an angle of 45 degrees. This vertically moving beam of light is received by the mirror of a second gal- vanometer (? 2 whose deflections are a measure of the temperature of the sample. The 38 CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY beam then passes through a lens and reaches the screen or plate P. L is a lens at the conjugate foci of which are placed the mirrors of the two galvanometers. Two motions are in this way imparted to the spot of light, (1) a horizontal motion pro- portional to the temperature of the sample and (2) a vertical motion proportional to Fig. 44. Le Chiitclicr-Saladin self-recording thermo-electric pyrometer. A For ordutary Cooliny Curves IVlOftlr. p. ( Sensitvfe Geivuns>mcfar Vacuous Porcetuifi. Z'ujte Fig. 4.5. Roberts-Austen method of connecting the sample, neutral body, and galvanometers. the difference in temperature between the sample and the neutral body. The result- in- curves are known as differential curves (see Chapter X). In recent models the apparatus has been simplified and made more compact (Fig. 44) by placing the galvanometers so near each other that the lens L, Figure 43, could be omitted and the entire instrument placed in a metallic or wooden case. The apparatus is mounted on an aluminium base B provided with three leveling- screws VV'V" and a level N. The optical and electrical parts are enclosed in a ver- CHAPTER I APPARATUS FOR THE METALLOGRAPHIC LABORATORY 39 tical aluminum box. The suspensions of the galvanometers are regulated through the milled head bbi attached to the suspension wires. The light proceeding from the source at L (Nernst or incandescent lamp) fall on the collimator provided with a diaphragm. D is the camera and R the screen. A small collimator C lighted by the source L throws its image on a small auxiliary mirror which projects through the slit F a luminous spot on the scale E, making it possible to follow from the outside the traveling of the luminous spot on the photographic plate during exposures. The connections between the sample and the neutral body_and between these and the galvanometers are made, as first suggested by Roberts-Austen, and as clearly shown in Figure 45. In this illustration galvanometer Gi corresponds to galvanom- eter (? 2 of Figure 43 and galvanometer G 2 to galvanometer Gi. ELECTRIC FURNACES For the experimental treatment of small samples of iron and steel an electric re- sistance furnace is extremely useful. Satisfactory types of platinum wound furnaces are supplied by makers. For temperatures not exceeding 1000 deg. C. furnaces wound with nichrome wire can be readily and cheaply built in any laboratory, both muffle and tube pattern. For very high temperatures (1200 to 1600 deg.) kryptol furnaces are to be recommended. When iron and steel samples are to be heated in vacuum, under pressure or in an atmosphere of various gases, special furnaces must be built provided with vacuum apparatus, pressure pumps, gauges, etc. CHAPTER II MANIPULATIONS The author's manipulations are described in this chapter, at some length; others more briefly in Chapter III. Cutting of Samples. Samples of iron and steel for microscopical examination should not generally exceed % inch square or round. If the metal is sufficiently soft they can be cut readily with a hand saw or, preferably, with a power hack saw. If too hard emery disks or diamond saws should be used. Suitable pieces of hard, brittle metals (white cast iron, spiegeleisen, etc.) may sometimes be obtained by breaking with a hammer. Polishing by Hand. The outfit described in Chapter I should be used. The sharp edges of the sample should be filed or ground in order to avoid tearing the polishing cloths in the following operations. The surface to be prepared should be filed first with a coarse and then with a smooth file so as to obtain a perfectly flat, smooth surface. This filing can be advantageously replaced by grinding on a fine emery-wheel. It is recommended that both filing or grinding be conducted with a very gentle pressure. A small amount of No. 80 emery-powder 1 mixed with sufficient water to form a thick paste should be placed on one of the polishing blocks covered with linen cloth. This paste should be spread over the block, conveniently by means of a spatula, and with the addition of a little more water if necessary. The sample of metal should now be rubbed back and forth over this block, being careful to rub always in the same direction until the marks left by the file or emery-wheel have all been removed and replaced by finer markings due to the action of the emery-powder. After this treatment the sample should be carefully washed, as well as the fingers of the operator, preferably in running water, and the sample rubbed over the second polishing block covered with linen cloth and a little flour-emery and water, precisely as before. On passing from the first to the second polishing block, the sample should be turned at right angles and kept in that position, in order that the new marks may be perpen- dicular to the old ones, and the polishing should be continued until the marks left by the coarse emery have been entirely effaced and replaced by finer ones. The sample after being carefully washed is ready for the next block. Some of the tripoli powder should be spread, with the addition of water, over one of the blocks covered with broadcloth, and the sample polished upon this block until the markings left by the previous polishing have been completely removed. After careful, washing the sample should now be rubbed over the last polishing block, covered with broad- cloth, rouge, 2 and water, holding as usual the sample so as to rub it at right angles to the markings left by the tripoli. After these markings have been removed the sample should have a very bright surface and be free from even microscopical scratches. 1 The polishing powders should be of the very best quality obtainable. 2 It is essential to use the best commercial grade of jeweler's rouge. 40 CHAPTER II MANIPULATIONS 41 At this stage a magnifying-glass is very useful for inspecting the specimen in order to ascertain whether it is ready for the etching treatment. For this purpose the vertical magnifier described and illustrated in Chapter I will be found very satisfactory. The specimen should now be carefully washed and dried with a soft cloth, pref- erably a fine piece of old linen. Where an air blast is at hand, as is generally the case in chemical laboratories, it is advisable to dry the specimen with this blast (a hot blast is more effective than a cold one) instead of rubbing it with a cloth. The sample may then be passed gently once or twice on a piece _of_chamois leather stretched over a smooth piece of wood and carefully protected from dust when not in use, when it will be ready for the next or etching operation. When polishing, the sample should be pressed lightly upon the blocks and great care taken not to carry any coarse powder over a polishing block upon which a finer powder is used as the presence of but a few coarser grains will greatly lengthen the operation. It is of much importance, therefore, to keep all the blocks carefully covered when not in use as well as the bottles containing the powders. Polishing by Power. Polishing by hand is at best a tedious and laborious operation and whenever possible it is highly advisable to replace it by the use of a power polishing machine. Very satisfactory and effective polishing machines and polishing motors have been described in Chapter I. When using these polishing machines or polishing motors the manipulations are as follows: The metal surface to be prepared is pressed lightly upon the emery-wheel until a perfectly flat surface is obtained, when it should be washed with the usual precau- tions and pressed upon the cloth-covered cast-iron disk placed next to the emery- wheel and upon which flour-emery and water have been applied. Care should be taken to hold the specimen so that the new marks will cross the old ones at right angles and the grinding should be continued until the emery-wheel marks have been completely erased. After washing the specimen it is ready for treatment on the next surface covered with broadcloth upon which has been spread tripoli powder and water, here again turning the sample 90 degrees. When the marks left by the preceding operation have been removed, the specimen is washed and given the final polishing treatment by pressing it lightly upon the other side of the cast-iron disk upon which rouge and water is used. The various polishing powders mixed with water may be conveniently applied to their respective disks by means of flat and rather stiff brushes. The surface of a properly polished sample should be highly specular and free from scratches. Time will be saved by exerting a slight pressure only while polishing, especially on the emery-wheel and emery-disk, because deep marks due to these abrasers will be troublesome to remove with the finer powders. With these machines a sample of steel measuring Yz inch square or Yi inch in diameter is readily polished in 10 minutes. Polishing very Small Specimens. For the polishing of samples too small to be conveniently held in the hand and also for preventing the rounding off of the edges the author following Boylston's suggestions uses small iron caps, known in the trade as "malleable gas caps," in two sizes, namely, % inch and Y inches. -- They cost three to four cents each. The cap used as a crucible is heated to about 200 deg. C. by placing it on an iron plate heated by a bunsen burner. It is then filled with a fusible alloy recommended by Campion and Ferguson and consisting of 50 parts bismuth, 30 parts lead, 25 42 CHAPTER II MANIPULATIONS parts tin, and 3 parts zinc. This alloy melts below 100 deg. C. and if used in stick form, the heated iron cap can readily be filled with molten alloy. The temperature of the cap and its contents is kept a little above 100 deg. and the specimen to be polished pressed into it. After solidification and cooling, which can be hastened by dipping in water, the whole is polished in the usual way. By using iron caps instead of brass cylinders or other non-magnetic mounts the magnetic holders described in Chapter I can be used with great gain in simplicity and convenience. Etching. If the polished samples were now placed under the microscope it would be possible to detect the presence of inclusions such as graphite particles, slag, etc., and if a relief effect has been produced, the presence of constituents considerably harder than the matrix (free cementite in hyper-eutectoid steel, for instance) but the structure of the metallic matrix itself would not be revealed, because its con- stituents being equally bright and exactly in the same plane would reflect the light to the same extent, after the fashion of a mirror. To make the structure apparent under the microscope it is necessary to impart unlike appearances to the constituents. This is generally accomplished by producing a slight corrosion or etching of the pol- ished surface. For this purpose acid solutions are generally used which attack some constituents more deeply than others or to the exclusion of others, an action which may or may not be accompanied by the deposition of some precipitated matter. Arnold considers the operation of etching with dilute acids to be of an electro- lytic nature, some of the constituents being electro-negative to others, hence the attack of some of these (electro-positive constituents) to the exclusion of others (electro-negative constituents) and the darker coloration of the former. For the development of the microstructure of polished samples of iron and steel in general, the author's preference is as follows: (1) solution of nitric acid in alcohol, (2) solution of picric acid in alcohol, and (3) concentrated nitric acid. Nitric Acid and Alcohol. A solution should be prepared containing 10 per cent of concentrated, chemically pure nitric acid and 90 per cent of absolute alcohol. A small amount of this solution should be poured in a glass or porcelain dish, preferably a small crystallizing glass dish with cover, and the sample immersed in it for 10 seconds, when it should be removed, conveniently with a pair of pincers (preferably with platinum tips), and washed in alcohol. The sample should now be dried, prefera- bly by means of a blast for which a foot^blower will answer very well. After rubbing the sample very gently once or twice upon a smooth piece of chamois leather stretched on a wooden block and carefully kept free from dust, it will be ready for examina- tion. In case the etching is not sufficiently deep the treatment should be repeated. Picric Acid. (Igevsky.) An etching solution should be prepared containing 5 grams of picric acid, chemically pure, and 95 cubic centimeters of absolute alcohol. This should be kept in a well-stopped glass bottle. The samples should be immersed in it for 30 seconds, washed in alcohol, dried, and the treatment repeated if necessary. Concentrated Nitric Acid. (Sauveur.) The polished specimen conveniently held with a pair of pincers (preferably with platinum tips) should lie dipped in a beaker or other vessel containing concentrated nitric acid (1.42 specific gravity) and immediately afterwards held under an abundant stream of running water. When iron is immersed in concentrated nitric acid it assumes the passive state, that is it is not affected by it. As soon, however, as the layer of concentrated acid which covers the polished surface is diluted by the running water, the steel is vigorously attacked but CHAPTER II MANIPULATIONS 43 for so short a time (since the water soon removes all traces of acid) that there is little danger of etching too deeply. One such treatment is generally sufficient to bring out the structure sharply and clearly but if the specimen is found insufficiently etched, the etching should be repeated in exactly the same manner. The author believes that the simplicity of this etching treatment and the excellent results generally ob- tained have been overlooked by metallographists. Sodium- Picrate Etching of Cementite. Cementite is not acted upon by the usual reagents employed for the etching of steel sections but remains_brilliant and struc- tureless. Kourbatoff, however, discovered a reagent which deeply colors cementite while leaving the ferrite unaffected, thus affording a sure means of distinguishing between the two. The treatment consists in immersing the polished sample in a boiling solution of sodium picrate in an excess of sodium hydroxide for some 5 to 10 minutes, when the cementite assumes a brown to blackish coloration. The etching solution may be prepared by adding 2 parts of picric acid to 98 parts of a solution containing 25 per cent of caustic soda, for instance 2 grams of picric acid in 98 cubic centimeters of a solution made up of 24.5 grams of caustic soda and 73.5 cubic centi- meters of water. Stead's Reagent for the Detection of Phosphorus Segregation in Iron and Steel. For the detection of phosphorus segregation in iron and steel Stead recommends the fol- lowing method which he considers superior to his heat-tinting method: The reagent is made by mixing Cupric chloride 10 grams. Magnesium chloride .... 40 Hydrochloric acid 20 cubic centimeters. Alcohol to make up to . . 1000 " The salts are dissolved in hot water to saturation and the solution made up to 1000 cubic centimeters with alcohol. Magnesium chloride is not necessary, but better results are, if anything, obtained by having it present. "The specimens are simply covered with a thin layer of the reagent and must on no account be immersed in a bath of the liquid. The layer of liquid, after remaining on the surface for one minute, is shaken off and a second layer dropped on the surface and left there for the same period. This procedure is repeated as often as it is found desirable. The specimen is washed with boiling water, then with methylated spirits, and shaken to remove the spirit from the surface, the heat imparted by the boiling water rapidly evaporating the last traces of alcohol. The copper is usually left as a hard coherent layer, and is not readily removed by rubbing; indeed, the specimens may sometimes be repolished by rouged chamois leather without disturbing the de- posited copper. The reagent not only indicates variations of phosphorus, but by progressive etching one can get a very good idea as to the degree of difference between the phosphorus in different portions of the same metal. If the reagent be applied in successive portions and the difference in the proportion of phosphorus be slight, as stated above, the copper invariably precipitates on the purer portion first; but on re- peated application the copper gradually deposits also on the parts richer in phosphorus, and after many applications of the reagent the whole surface, including the phos- phorised parts, becomes coated with copper. If, however, the phosphorus be very much concentrated in one or more parts, these remain perfectly bright and free from copper even after ten applications of the reagent." 44 CHAPTER II MANIPULATIONS Heat-Tinting. Heat-tinting is described by Stead, its originator, as follows: "Heat-tinting consists in heating polished specimens of metals until their surfaces become colored by oxidation films. "Alloys of iron and phosphorus, and commercial steel, contain part of their mass richer in phosphorus than other portions. In fact the iron and the phosphide are seldom intimately mixed in ordinary steel. When polished specimens are placed on the surface of a molten bath of tinman's solder, 1 and the heat gradually raised, the portions of the specimens richest in phosphorus assume oxidation tints earlier than the purer parts; hence it follows that by the time the phosphorus-rich parts have passed through the transition stages of yellow-brown, to red and purple, the purer portions will have reached the yellow-brown or red stage, and if at this point the specimen be removed from the source of heat, the phosphorus-rich portions will appear under the microscope as purple or blue on a yellow-brown or red background. If the heating of the specimen be continued, the phosphorised part will assume a yellowish-white tint, while the purer part will reach the blue stage. Each part will pass through the complete range of color from yellow to blue and then to nearly white, but not at the same time, because the purer portions always lag behind, the degree of lag depending on the variation in the proportions of phosphorus in the different parts. Heat-tinting is also useful in intensifying the difference in color between ferrous sulphide and manganese sulphide when present together in steel. On heating polished metal containing inclusions of each sulphide until it appears to assume a uniform brown tint, the ferrous sulphide, which is naturally pale yellow, will be found under the microscope to have been colored purple, while the manganese sulphide, naturally a pale dove color, will have become white. If the heating be continued until the sur- rounding metal becomes blue, the ferrous sulphide will be blue and the manganese sulphide yellow. "To obtain good results by heat-tinting, it is absolutely necessary first to apply to the surface a very dilute solution of some acid in alcohol. Picric acid answers admi- rably, but care must be taken to remove the solution employed before it has time to develop the pearlite or sensibly to etch the metal. After thoroughly washing the specimen in water, it is dried with a perfectly clean rag and heated on a hot plate to about 150 deg. C. It is again rubbed with a warm clean cloth, and is then ready for heating to produce the color tint. "It is difficult to explain why the preliminary acid treatment is necessary, but that it is so is proved in practice, for if it is omitted, the tinting is always unsatisfactory. It is possible that, during polishing, some of the softer metal becomes spread over the harder part, forming an exceedingly thin layer. This, however, is only a surmise." Sulphur Printing. The presence of sulphur in steel, especially when segregated, can be sometimes clearly revealed by a laboratory test known as "sulphur printing." As first described by Heyn and Bauer, it consisted in pressing upon the previously polished steel surface strips of silk impregnated with mercuric chloride and hydro- chloride acid (10 grams mercuric chloride, 20 cubic centimeters of water, and 100 cubic centimeters of hydrochloric acid). The reaction between the acid and the sul- phides wherever present generates H 2 S (sulphuretted hydrogen) which in turn reacts with the mercury salt producing stains of mercury sulphide varying in intensity according to the amount of sulphur present in the steel and revealing the spots where the latter occurs. 1 An iron plate heated by a bunsen gas burner may be used instead (Author). CHAPTER II MANIPULATIONS 45 A better method (Baumann) consists in substituting for the silk ordinary silver bromide (photographic) paper moistened with dilute sulphuric acid, the generated H 2 S producing dark stains on the paper where metallic sulphides were present in the steel. The following more explicit instructions may be followed with good results. The sample to be tested should be filed flat and rubbed on two or three grades of emery-paper, finishing with French paper No. 0. Sheets of Velox printing paper or its equivalent should be soaked until saturated in dilute sulphuric acid (2 per cent solution). The paper should then be placed on a piece of plate" glass and the steel specimen after washing it in clear water, gently pressed upon it for some 20 seconds, when it should be removed and the paper placed in sodium hyposulphite to remove the excess bromide, washed and dried. While theoretically areas containing phos- phorus should also darken the bromide paper Stead reports that the staining from this cause is almost imperceptible. Law covers the steel section with a coating of gelatine containing an acid solution of lead, mercury, or cadmium salt; the acid decomposes the iron or manganese sul- phides and the resulting H 2 S reacting with the lead or cadmium salt produces brown or yellow stains of lead, mercury, or cadmium sulphide. Rohl writes: "Care should be taken that the gelatine be as thick as possible, so as to be stiff enough to avoid its flowing off or shifting its position after being applied. The gelatine should be applied hot to the slide by means of a glass rod. This method permits of testing under the microscope, for its sulphidic nature, an enclosure placed in the microscope and ob- served thereon, the stage being screwed back for the purpose of applying the gelatine, so that the place observed by the eye may be at once observed again in the micro- scope. Weak magnification has been found sufficient and practical for this purpose." F. Rogers describes a method for taking sulphur prints of fractures, consisting in the use of a gelatine emulsion of silver bromide coated upon a very stiff grease clay and soaked in a dilute acid solution containing also a toughening agent. This emulsion is immediately pressed into contact with the clear fracture for a few seconds and withdrawn. According to Rohl, ferrous sulphide is considerably darkened by one per cent so- lution of organic acids in ethyl alcohol, after 5 minutes' etching, as compared with manganese sulphide. The same author writes that after a short preliminary etching with alcoholic solutions of organic acids (preferably picric acid), the successive temper- ing to dark yellow leaves the ferrous sulphide blue and the manganese sulphide a dull whitish. The reaction appears to be well adapted for distinguishing between the sulphides. Etching Wrought Iron. The polished samples should be immersed for 10 or 15 seconds in a 10 per cent alcoholic solution of nitric acid or for 30 seconds in a 5 per cent alcoholic solution of picric acid, washed in alcohol and dried with the usual precautions. Concentrated nitric acid may also be used. The etching treatment should have outlined the joints between the ferrite grains clearly and sharply. If the structure lacks clearness it is safe to infer that the etch- ing was not properly done. In that case the sample should be rubbed a few times on the chamois leather block and again examined without repeating the etching. If the structure remains ill-defined, rub the specimen a minute or two on the rouge block or disk, wash, dry, and repeat the etching treatment until satisfactory results are obtained. 46 CHAPTER II MANIPULATIONS Should the boundaries of the ferrite grains appear too faint, the etching treat- ment should be repeated without repolishing, so as to etch these lines more deeply. As the usual purpose of the microscopical examination of samples of wrought iron is to ascertain the quantity and mode of occurrence of the slag and the dimen- sions of the ferrite grains, it is not generally desired to etch the sample so deeply that some of the grains become deeply colored, still less that etching pits begin to appear. As an experiment, however, it is advisable to etch samples of wrought iron grad- ually so that the different stages of the structure may be clearly seen: (1) before etching: slag fibers and a brilliant structureless matrix, (2) after a slight etching: ferrite grains sharply defined but remaining uncolored or but slightly colored, (3) after a deeper etching: some of the ferrite grains deeply colored, and (4) after a still deeper etching: small cubic etching pits beginning to appear. The production of these etching pits, however, is often a troublesome and uncer- tain operation. Heyn recommends for that purpose etching with double chloride of copper and ammonium, others (Stead) "a sufficiently long immersion in lukewarm 20 per cent sulphuric acid, followed by cleaning in nitric acid," or again (Le Chatelier) an acidulated solution of ferric chloride. Etching Pearlitic Steels. Pearlitic steels should be etched with the reagents already indicated, namely, nitric acid and alcohol, picric acid and alcohol or concen- trated nitric acid, the manipulations being the same as those prescribed for etching wrought iron. An immersion of 10 seconds in nitric acid or of 20 seconds in picric acid generally suffices. The contrast between the bright ferrite or brilliant cementite and the dark areas of pearlite should be very marked. If considerable free ferrite is present its grains should appear like a delicate but distinct network. The absence of this network is generally due to too slight an etching. Under high powers the pearlite should appear distinctly laminated, although it is not always possible to bring out the structure of every particle of that constituent. Etching Sorbitic Steel. - The etching of sorbitic steel is similar to that of pearlitic steel both in regard to reagents used and manipulations with the exception that sorbite generally etches somewhat more quickly than pearlite. Immersions of 7 or 8 seconds duration in nitric acid or of 15 seconds in picric acid generally suffice. The sorbitic areas will have a granular but ill-defined structure. Etching Troostitic Steel. Troostite is etched more quickly and is more intensely colored than any other constituent of steel. For that reason very short immersions are advisable, namely 2 or 3 seconds in nitric acid or 5 seconds in picric acid or better still longer immersions in weaker acids (5 per cent nitric acid or 2 per cent picric acid). Such short etchings do not as a rule bring out the structure of the martensite which generally accompanies troostite, it being left white and structureless. To develop its structure deeper etchings are required. Etching Martensitic Steel. Martensite is colored more quickly than pearlite and sorbite but more slowly than troostite, hence the immersions of martensitic samples in the etching baths should be of relatively short duration, 5 seconds in nitric acid or 10 seconds in picric acid. The acicular or zigzag structure of martensite should be brought out, but high power may be needed to resolve it. Etching Austenitic Steel. Austenite does not occur in commercially treated carbon steel but may be produced by some drastic treatments as later explained. It also occurs normally in certain alloy steels, as for instance in Hadfield manganese steel. When present in carbon steels its structure may be revealed by short immersions in CHAPTER II MANIPULATIONS 47 nitric or picric acid. It generally remains bright while the martensite often accom- panying it is darkly colored. Some writers claim, however, that it may sometimes be colored darker than martensite. In the absence of much martensite its structure is polyhedral. Martensite is readily identified through its acicular or zigzag occur- rence. The etching of austenitic alloy steels is dealt with in the following paragraph. Etching Alloy Steels. While the reagents and methods used for the etching of ordinary carbon steels are frequently effective for the etching of alloy steels especially for those which after slow cooling become pearlitic, some of them are refractory to these treatments much longer immersions being required to bring out their structures while in a few instances the ordinary methods must be deeply modified. According to some manganese steels should be etched deeply in picric or nitric acid, washed in water and dried without any attempt at removing the dark colored films covering the surfaces of the specimens. High speed steel may be etched with nitric or picric acid alcoholic solutions of or- dinary strength but the time needed varies between a few minutes and more than an hour according to the thermal treatment to which the specimens have been sub- jected, high heating followed by quick cooling generally requiring long immersions. In the author's laboratory, Mr. M. Yatsevitch has developed a very useful method for high speed steel. Ten cubic centimeters of commercial hydrogen peroxide are mixed with 20 cubic centimeters of a 10 per cent solution of sodium hydrate in water. The steel samples are immersed in this solution for 10 to 12 minutes, washed first with water and twice with alcohol and dried, preferably with a blast. The re- agent should be prepared fresh every day. After the treatment indicated above the polished samples remain bright and their matrix structureless but the free carbide containing tungsten is found to have been colored dark. While it is probable that other special carbides such as carbide of molybdenum would be likewise colored, no other constituent appears to be acted upon by this reagent, not even iron carbide (cementite) . The method affords a means of bringing out clearly the amount of free carbide in high speed steel and of distinguishing between it and other constituents. Etching Cast Iron. The etching of polished samples of cast iron is conducted in every respect like the etching of steel specimens. To bring out clearly the phosphide eutectic and to prevent its being mistaken for pearlite areas or vice versa the heat testing method devised by Stead is very useful. Polished samples of gray cast iron should generally be first examined before etching, the distribution, size, and form of the graphite particles being then more clearly revealed. Etching for Macrostructure. To reveal the macrostructure, that is the structure visible with the naked eye, and also to detect local segregations, especially of phos- phorus, Portevin recommends the immersion of the polished samples for 3 min- utes in double chloride of copper and ammonium (10 grams of the double chloride in 120 cubic centimeters of water) followed by an immersion of 30 minutes in 10 per cent nitric acid. Heyn and Stead mentioned immersion of 2 minutes in a 10 per cent solu- tion of cupric ammonium chloride in water, the deposits of copper being removed under a stream of water, while gently rubbing the surface with the fingers or a piece of chamois leather. Similar results are obtained by etching in 20 per cent nitric acid in water, or in dilute hydrochloric or sulphuric acid. ti.minhtnli^ - 'Specimen Fig. 59. Stead's mounting device. (C. H. Desch's Metallography.) Fig. 60. Gulliver's mounting device. tion till the glass slide comes in contact with the brass ring. The specimen adheres to the wax and the mounting is complete. Gulliver (1908) describes the device (Fig. 60) for mounting specimens. It consists of a circular ring faced on its upper surface A, and screwed internally at B to fit the foot, of which the upper end C is also faced. The distance between the parallel faces A and C can thus be adjusted. The specimen is placed at D and a glass slide E with some soft modeling clay or wax is pressed upon it until the glass touches the ring at AA. Mechanical mounting devices working on the principle of the microtome have also been used. They have been described by M. A. Richards: "Projecting from a cylindrical metal base three inches in diameter, is a threaded upright three and one- half inches in diameter. A cylindrical nut or collar three inches high and two and one-half inches outside diameter screws on the threaded upright. A small circle of chamois skin is placed on the top of the thread upright to protect the etched face of the micro-section. To mount a section, place it face down on the chamois skin, press upon the upper projecting portion a lump of beeswax, and upon this place the ground glass (ground surface down). A few revolutions of the collar will cause the glass to rest upon the upper edge of the collar, and the adhesion of the glass and beeswax to the specimen may be made complete by slowly turning the collar down with one hand 66 CHAPTER III APPARATUS AND MANIPULATIONS while keeping the glass base in close contact with the collar-top with the other hand. In this manner, no matter how irregular the section, the parallelism of the etched surface and the glass base may be very quickly and accurately obtained." The mounting device (Fig. 61) is constructed by Watson and Sons. It consists of two horizontal plates, the upper one being capable of vertical movement but always Fig. 61. Watson and Sons' mounting device. Fig. 62. Watson and Sons' leveling stage. remaining parallel to the lower one. The specimen is placed with its polished surface on the lower plate, and the upper plate carrying a glass slip to which some suitable clay or wax is attached is lowered into contact. Leveling Stages. The leveling stage (Fig. 62) is one of several constructed by Watson and Sons, London. The specimen is held by two rotating jaws and can be leveled by means of the screws A and B BI. Fig. 63. Huntington's leveling stage. Professor A. K. Huntington devised the leveling stage shown in Figure 63. It is provided with a ball and socket joint for leveling, permitting the placing of the sample in any position. Other forms of leveling stages are shown in some of the illustrations in the follow- ing pages as part of some metallurgical microscopes. CHAPTER III APPARATUS AND MANIPULATIONS 67 M KTALLURGICAL MICROSCOPES The microscopes and accessories used by the author have been fully described. In the following pages instruments used by some other workers or described by them, as well as those manufactured by well-known makers, are mentioned. Fig. 04. Le Chatelior's invert ed metallurgical microscope. Early form. Fig. 65. Le Chatelier's inverted metallurgical microscope. Le Chatelier. In 1897 Le Chatelier devised an inverted microscope which later he greatly improved and which is now constructed with unimportant modifications by several microscope makers. An early form of Le Chatelier's instrument is shown in Figure 64 and its more recent construction in Figures 65 and 66. The objective 68 CHAPTER III APPARATUS AND MANIPULATIONS 0) 1 6 CHAPTER III APPARATUS AND MANIPULATIONS 69 B (Fig. 65) is directed upwards while the eye-piece 0, placed horizontally, receives the image by the reflection of a totally reflecting prism F placed below the objective. The prism F may be rotated by means of the milled head P and the light reflected by the objective turned at will into the tube G and the eye-piece for visual examination Fig. 67. Le Chatelier's inverted metallurgical microscope. or into another tube connected with a camera for photographing (Fig. 66). The light is condensed by the lens A and, being deflected at right angles by the prism J, passes through the objective B and reaches the object M placed on the stage E. In Fig. 68. Device for placing specimens on the stage of the Le Chatelier micro- scope in a fixed position. (Le Grix.) case the light is placed at a higher level than the condensing lens A, it must be re- ceived by a totally reflecting prism H which directs it into the condenser A. D is a diaphragm placed at the principal focus of the complex optical system composed of the objective B, the illuminating prism J, and the lens A. The opening as well as the 70 CHAPTER III APPARATUS AND MANIPULATIONS position of the diaphragm may be altered. Another diaphragm placed at I affords a means of stopping the light which would fall upon parts of the preparation outside of the portion examined and which would increase the blur resulting from the reflec- tion of useless rays by the back lenses of the objective. In the early construction of Fig. 69. Inverted metallurgical microscope constructed by E. Leitz. Fig. 70. Inverted metallurgical microscope constructed by E. Leitz. this instrument when the object was to be photographed the prism F was withdrawn from the path of light and the image allowed to form on a photographic plate placed below (Fig. 64). A slightly different construction is shown in Figure 67. For photographic pur- poses the image forms on a plate placed in a holder rigidly connected with the instru- CHAPTER III APPARATUS AND MANIPULATIONS 71 ment, no eye-piece being used. As the distance between the photographic plate and the objective is short, very small photomicrographs are obtained, which must gen- erally be subsequently enlarged. Z is a plate carrying an eye-piece for use with the long bellows camera (Fig. 66). The Le Chatelier microscopes are constructed by Ph. Pellin of Paris. In order to be able to examine identical portions of the same specimen at different times with the Le Chatelier microscope, Le Grix (1907) suggested the arrangement shown in Figure 68. A circular metallic disk with rectangular opening RR' and carry- ing two pointed stops A and B is fitted to the stage. A file mark E is made in the specimen .17, which is then placed on the stage so that the stop A enters the groove E Fig. 71. Metallurgical microscope con- structed by E. Leitz. Fig. 72. Metallurgical microscope constructed by E. Leitz. while the specimen presses against the other stop B, in this way securing a constant position for the object. Ernst Leitz. A slightly modified form (Fig. 69) of the Le Chatelier inverted microscope is made by Ernst Leitz of Wetzlar, Germany. The modifications were suggested by Guertler. The stage and illuminating appliances are shown on a larger scale in Figure 70. The same maker also manufactures the microscope shown in Figures 71 and 72 designed by W. Campbell. The stage can be removed and the upper part of the instrument attached to the base for the examination of large surfaces. P. F. Di/jiinll/i. P. F. Dujarclin and Co. of Diisseldorf construct a Le Chatelier inverted microscope as shown in Figure 73. They also make the microscope (Fig. 74) in which the vertical illuminator carries its own source of light and condenser. C. Reichert. The metallurgical microscope (Fig. 75) designed by Professor Rejto is made by C. Reichert of Vienna. The position of the vertical illuminator immediately below the eye-piece should be noted. The stage is provided with a level- ing mechanism. The same maker manufactures an inverted Le Chatelier microscope as shown in Figure 76. By means of a mirror Sp (Fig. 77) placed in the camera box it is possible to focus the image on a ground glass M, on the same side of the instrument as the observer, 72 CHAPTER III APPARATUS AND MANIPULATIONS o O Q fa 01 p. f 0> s I c CHAPTER III APPARATUS AND MANIPULATIONS 73 thereby facilitating the manipulations. During exposure the mirror which is hinged is folded close to the side M permitting the image to form on the photographic plate at K. Robin. The microscope and photographic attachment shown in Figure 78 was designed by Robin. Visual examination is possible only on the screen of the camera. Oc Fig. 74. Metallurgical microscope constructed by P. F. Dujarclin and Co. Fig 75. Metallurgical microscope constructed by C. Reichert. The stage consisting of a smooth disk is tilting and the specimen is fastened upon it with wax. To secure an accurately horizontal position of the polished surface, a plug with a perfectly flat surface is screwed into the microscope in place of the ob- jective and the stage raised until the specimen coming in contact with the plug, the latter through gentle pressure causes the polished surface to assume a horizontal position. The plug is then removed and the objective inserted. Scientific Materials Co. The inverted microscope and photographic attachment (Fig. 79) are made by the Scientific Materials Co. 74 CHAPTER III APPARATUS AND MANIPULATIONS Fig. 76. Inverted Metallurgical microscope. (C. Reichert.) C.REIOHERT I M Fig. 78. Metallurgical microscope designed by Robin. CHAPTER III APPARATUS AND MANIPULATIONS 75 Martens. The Martens metallurgical microscope (1899) made by Zeiss of Jena is shown in Figure 80. It can be used horizontally only, the tube is very wide and the vertical, mechanical stage is provided with both coarse and fine adjustments Y and Z and with leveling-screws act. The flexible connection / permits the focusing 6 .3 a f adjacent crystals having undergone the slipping described by Ewing and Rosenhain. To the formation of this cement may Fig. 112. Twinnings in marble (caused by pressure). Magnified about 5 diameters. (Bayley.) be ascribed the marked changes of properties accompanying the cold working of metals, such as increased tenacity and hardness, decreased ductility and density, etc. According to Tamman and others the crystalline deformations caused by me- chanical straining are sufficient to account for the altered properties of cold-worked metals, it being unnecessary to conceive the formation of films of amorphous cement covering the gliding surfaces after the slipping process. Humfrey having observed the behavior of slip bands in the vicinity of the grains boundaries and assuming the existence of intercrystalline cement, writes: "All the observations demonstrate the resistance to plastic deformation by slip which occurs at the crystal junctions, and suggest the idea that each crystal is surrounded by and firmly attached to a continuous skin, which, while hard and plastically undeform- able, is yet thin and capable of elastic bending and stretching . . . The state of affairs can best be conceived by imagining that after overstrain each crystal is enclosed and held within a stretched skin holding it so as to oppose further strain in the same direction." CHAPTER IV PURE METALS 95 Twinning and Twin Crystals. By twinning is meant the grouping of two or more crystals or parts of crystals in such a way that they are symmetrical to each other with respect to a plane between them (the twinning plane) which plane, how- ever, is not a plane of symmetry. Twins result generally from a portion of a crystal Fig. 113. Twinnings in copper produced by straining followed by annealing. Magnified 12.") diameters. (F. C. Langenberg in the author's laboratory.) Fig. 114. Lines of Neumann in a low carbon steel sheet. Magnified 100 diameters. turning by a definite angle, say 180 (leg. They are sometimes produced by straining alone (Fig. 112), when they are called mechanical twins, but more often by straining followed by annealing. Many metals after such treatments contain numerous twins (Fig. 113). The production of twin crystals in the complete absence of strain is doubtful. 96 CHAPTER IV PURE METALS Lines of Neumann. The crystalline grains of metals are sometimes found to be crossed by a number of parallel lines or bands (Fig. 114) called "Lines of Neu- mann" and which might at first be taken for slip bands but which, according to Osmond and Cartaud and others, are undoubtedly mechanical twins. They follow the orientation of the grains. Lines of Neumann can be distinguished from slip bands by repolishing and etching the sample, when slip bands do not reappear while the lines of Neumann do. Influence of Mechanical Treatment. Metals are frequently subjected to power- ful pressure exerted by rolls, presses, hammers, etc., with a view of producing metallic objects of desired shapes. This treatment affects the structure and, therefore, the properties of the metal. Roughly speaking such vigorous kneading has a tendency to reduce the size of the final grains, either through preventing the formation of large grains or by breaking up or distorting preexisting grains. A smaller grain in turn generally implies greater ductility (provided it be not distorted) and often greater strength. The effect of work upon the structure and properties of commercial iron and steel will be duly considered. Influence of Thermal Treatment. The size of the crystalline grains of pure metals varies in different metals even when cast and cooled under identical condi- tions. Their dimension is generally affected also by the rate of cooling during solidi- fication and, therefore, by the size of the casting, since a large casting will cool more slowly than a smaller one. The common belief is that the prolonged exposure of pure metals to a high tem- perature (annealing) tends to enlarge the grains, the enlargement being the greater the higher the temperature, the longer the time of exposure, and the slower the cooling. While such growth undoubtedly takes place in the case of commercial and, therefore, impure metals, at least after straining, it is held by some metallurgists that in absolutely pure metals the grain will not grow on annealing even after straining. This view is based upon a theory brilliantly conceived by Ewing and Rosenhaiu and supported by the results of skilfully conducted experiments. These scientists argue that even so-called pure metals always contain a certain amount of impurities, and that even a very minute amount of im- purity would suffice to form a thin but practically continuous film of eutectic in the crystalline boundaries. They contend "that there is constant diffusion from the surface of the crystal into the eutectic and equally constant re-deposition of metal upon the crystal from the eutectic. If there are several crystals in contact with the same eutectic, there will be, under some conditions, a state of dynamic equilibrium between* them, the amount dissolved from each being exactly counter- balanced by the amount deposited upon it; if, however, there is any difference in their solution pres- sure in respect to the eutectic, then the less soluble will grow at the expense of the more soluble. The metal constituting the eutectic films being much nearer its melting-point than the rest of the mass, would thus be favorable to comparatively rapid diffusion, but the rate of such diffusion, and, consequently, the rate of growth of crystals, would be enormously increased by heating the metal to a temperature above the melting-point of the eutectic in question." The theory proposed depends upon the existence of a difference in the solubility of the two crys- tal faces in contact with the eutectic film. The only difference between these two faces is, appar- ently, in the orientation of the crystalline elements, but this difference is sufficient, in the authors' opinion, to produce a difference in their rate of solution in the eutectic film, seeing that it results in such marked difference in their solubility in the etching acid, which, as is well known, attacks some grains much more readily and deeply than neighboring ones whose elements have another orienta- tion. To account for the influence of the orientation of the elements upon the solubility of the crys- tals, the authors suggest to extend to alloys the electrolytic theory of solution. "Such differential actions," they say, "may most probably be attributed to differences of electrical potential in the CHAPTER IV PURE METALS 97 surfaces involved. If we accept this view of the mutter, then the diffusion across films of eutectic' becomes a case of electrolysis." This theory explains why only strained crystals of the metals examined will grow, while un- strained crystals show no tendency to change, even at high temperatures. "The explanation, on the electrolytic theory, is that in the unstrained state the crystals are surrounded by practically con- tinuous films of eutectic, and that electrolysis only becomes possible when severe distortion has broken through these films in places, allowing the actual crystals to come into contact; the electro- lytic circuit would then be for each pair of crystals, from one crystal to the other by direct contact and back through the eutectic film." If the authors' conception be true, recrystallization by annealing in a perfectly pure metal would not occur but. as they rightly say, it is almost hopeless to obtain a sample of metal suffi- ciently pure to prove or disprove the theory. They argue, however, that if the growth of crystals is due to the presence of a eutectic film between them, the absence of such film would be a barrier to all such growth, and that a weld between two clean-cut surfaces should show no growth of crystal across the weld. This they actually proved to be so in the case of lead. If they are right, it likewise follows that in metals contaminated by impurities with which they form solid solutions there should be no growth of grains on annealing, because of the absence of the needed eutectic film. , The remarkable crystalline growth of very low carbon steel after severe straining followed by annealing, at suitable temperatures, described in another chapter, is a .striking instance of the action of straining (cold working) in promoting grain growth in subsequent annealing. Notwithstanding Ewing and Rosenhain's strong argument, satisfactory evi- dences are still lacking in support of the contention that both straining and the presence of impurities are necessary conditions to grain growth on annealing. So far as the matter has been investigated it does seem that the grain of a pure metal will not grow unless it has been previously strained, but that it must also contain some eutectic forming impurities has not been satisfactorily demonstrated. Amorphous Cement Theory vs. the Heat Treatment of Pure Metals. It is be- lieved by Rosenhain and Ewen that the amorphous films cementing together the crystalline grains of pure metals act as a vehicle for crystal growth under suitable tem- perature conditions. This intercrystalline amorphous cement might play the part ascribed to eutectic films in Ewing and Rosenhain's earlier theory. While according to the former theory the grains of strictly pure metals could not grow on annealing, even after straining, owing to the absence of eutectic films, the amorphous cement theory permits such growth and this is in better harmony with observed facts. The annealing of cold-worked metal should result in the transformation of some of the strong but hard and brittle cement resulting from the cold working, as pre- viously explained, into crystallized metal and this should be accompanied by de- creased hardness and increased ductility, thus accounting for the well-known influ- ence of annealing on cold-worked metal. Impurities. It is well known that the addition of surprisingly small amounts of impurities or foreign substances often affect very greatly some of the most important properties of metals, such as their strength, ductility, fusibility, electrical conduc- tivity, etc., and we naturally look for correspondingly marked changes of structure. In order to understand this important influence of impurities upon the properties of metals it will be necessary to consider at some length the nature of the union which exists between the metal and the impurity. Let us first note that by impurity we mean a very small proportion of some foreign substance which may be any other metal, a metalloid, or a definite compound. 98 CHAPTER IV PURE METALS The metal or metalloid contaminating the metal may (1) remain uncombined or (2) it may combine with some (generally a small amount) of the metal to form a definite chemical compound. The uncombined contaminating metal or metalloid or resulting chemical compound may then (a) be soluble in the solid metal forming with it a "solid solution" or (6) be insoluble in the solid metal in which case it is rejected by the crystalline grains, in the form of an eutectic alloy. The meaning of the expressions "solid solutions" and "eutectic alloys" should now be explained. As Professor Howe has well expressed it the essential features of an ordinary liquid solution are (1) a complete merging of the constituents and (2) in indefinite proportions. By complete merging is meant a union so intimate that the separate existence of the constituents cannot be detected by any physical means, such for instance as microscopic examination under the highest magnification. The homogeneity of the substance is such that it resists any physical attempt at breaking it. The merging moreover must remain complete and absolute for varying propor- tions of the constituents, for it is evident that if it existed only for certain well-defined proportions of the component parts, the resulting substance would be of the nature of a definite chemical compound and not of a solution. Bearing in mind these characteristics of ordinary solutions, we find that in some substances, while passing from the liquid to the solid state, the constituents remain completely merged and in indefinite proportions. The essential characteristics of liquid solutions are retained in the solid state. Hence the name of solid solutions given to such substances. A common and excellent example of solid solutions is found in the case of glass in which the three usual constituents, silica, lime, and alkali, are so completely merged that their existence cannot be detected by physical means; the microscopical examination of glass under the highest magnification fails to reveal the presence of its component parts. Glass on solidifying passes from the condition of a liquid solution to that of a solid solution. Many metals likewise form on solidifying solid solutions, i.e. they solidify into a mass so absolutely homogeneous that the identity of the component metals is entirely lost. The union between some metals and metalloids also frequently forms solid solutions. It is held by some crystallographers that in order to form solid solutions the unit- ing subtances must be "isomorphous," that is, must be capable of yielding crystals of the same form, hence the name of "isomorphous mixtures" frequently given to solid solutions. 1 The homogeneous crystals formed by solid solutions are often called "mixed crystals" and that expression frequently used as an equivalent for solid solution. There are some crystallographers, however, who believe that isomorphism of the constituents is not essential to the formation between them of solid solutions, and that the use, therefore, of isomorphous mixtures as synonymous of solid solu- tion is not warranted. The use of the expression mixed crystals is likewise to be discouraged because it suggests a mixture, and, therefore, heterogeneity, which is precisely contrary to the nature of solid solutions. Considering now those impurities, whether metals, metalloids, or definite com- pounds, which form solid solutions with the metal they contaminate, it is found 1 If isomorphism favors the formation of solid solutions, as it undoubtedly does, seeing that most metals are isomorphous, we naturally infer that they will readily form solid solutions. We now know that such is the case, for if metals are not generally soluble in each other (when solid) in all proportions there are few instances of metals entirely insoluble in each other in the solid state. The formation of solid solutions between metals is therefore very frequent. CHAPTER IV PURE METALS 99 as might have been expected that their presence has no great influence upon the character of the structure. Suitably prepared surfaces of such impure metals still exhibit the polygonal network structure characteristic of pure metals. The small polyhedra of which the impure metal is composed, however, are now allotrimorphic crystals of a solid solution instead of a pure metal. While the character of the struc- ture remains the same, the dimension of the grains may be markedly affected, by the presence of a small amount of impurity forming a solid solution with the metal. The second group of impurities, namely those foreign substances, whether they remain or not uncombinecl, which do not form solid solutions with the contaminated metal may usually be readily detected under the microscope as they are generally rejected to the grain boundaries during the process of solidification (or afterwards) as shown in Figure 115. These insoluble impurities are not, however, rejected as such by the crystalline grains, but on the contrary unite mechanically with a small amount Fig. 115. Gold containing 0.20 per cent lead. Magnified 100 diameters. (Andrews.) of the metal to form what is known as an "eutectic alloy," that is an alloy of lowest melting-point, and it is this alloy which is expelled by the solidifying grains. The formation and nature of eutectic alloys will be considered at greater length in a sub- sequent chapter. It will be apparent that those contaminating substances which fail to be dissolved by the metal, may form actual membranes surrounding each grain, the membranes being of the nature of an eutectic alloy. As might be anticipated, the presence of such membranes, whether continuous or not, have generally a very marked influence upon the properties of the metals, frequently decreasing their ductility, weldability, electrical conductivity, etc., and often increasing their fusibility, hardness, etc. The rejection during solidification and subsequent cooling of those impurities which fail to be retained in solid solution by the metal, to the grain boundaries or other crystallographic planes, reveals the crystalline forms of the grains themselves. The location of these impurities affords additional evidence of the cubic crystalliza- tion of metals. It will be shown later that the cubic crystallization of iron is in this way clearly revealed. 100 CHAPTER IV I'L'KK MKTALS The above remarks are of a very general character and refer more especially to the behavior of impurities while the metal solidifies. In the majority of cases no further changes take place in the nature of the constituents as the metal cools to atmospheric temperature, i.e. the constituents formed on solidification are those found in the metal after complete and slow cooling. In some instances, however, and notably in the case of iron and its usual impurities, carbon, silicon, phosphorus, manganese, and sulphur, some important changes take place at temperatures con- siderably below the solidification point of the metal which will be duly described at the proper time. Some writers believe that in slightly impure metals the impurities may form nuclei from which crystal growth may s.tart, thus accounting for the apparent fact that slightly impure metals have often smaller grains than metals of greater purity. This assumption demands an early solidification of small particles of impurities within the liquid metal and, therefore, can be true only in the case of foreign substances having a higher melting point than the metal itself. It is not easily conceived how it can be applied to impurities forming solid solutions with the metal, since they then solidify together, nor to impurities forming eutectic alloys, since such alloys constitute the constituent of last solidification. CHAPTER V PURE IRON Chemically pure iron is not a commercial product. It can only be obtained in small quantities by carefully conducted laboratory manipulations when, even with the most refined care, it is quite impossible to produce it absolutely pure. Until quite recently the purest commercial iron was of Swedish origin and contained as much as 99.8 per cent of iron. A commercial product known as "American Ingot Iron" l is now manufactured which the makers claim to contain 99.94 per cent of Fig. 11(>. Electrolytic iron. Magnified 75 diameters. Slightly etched, i Sin-rani Cowper-Coles.) iron. Iron, or rather very low carbon steel, of a high degree of purity is also produced at the present time through refining in electric furnaces. Finally iron has been ob- tained in relatively large quantity, by electrolytic deposition, of a degree of purity exceeding 99.9 per cent iron. 1 The expression "ingot" iron is applied to iron containing very little carbon, obtained molten and, therefore, cast, after removal from the furnace, whereas by wrought iron is meant iron (also generally low in carbon) obtained pasty and, consequently, always containing a certain amount of slag. Ban-ing the presence of slag in wrought iron, both ingot iron and wrought iron may have identical chemical compositions. The expression ingot iron is seldom used in the United Slates, where iron obtained in a liquid state, and containing little carbon, is called low or very low carbon steel, or mild, very mild, extra mild steel, or again soft, very soft, dead soft steel. 101 102 CHAPTER V PURE IRON Microstructure. When a sample of nearly pure iron is suitably prepared and examined under the microscope some regions can readily be found absolutely free from carbon and slag and exhibiting, therefore, the structure of the pure metal. Such structure is illustrated in Figure 116 after a slight etching of the polished surface. It will be noted that it is similar to the structure of pure gold and of pure copper Fig. 117. Ferrite grains. Natural size. Etched 10 minutes in nitric acid (1 to 10 water). (Stead.) described in the preceding chapter: like gold and copper and, indeed, like most metals, iron is made up of polyhedral crystalline grains (allotrimorphic crystals). Upon deeper etching the dissimilarity, as to coloration, of adjacent iron grains is clearly brought out as shown in Figure 117. As explained in Chapter IV, this appearance is due to the fact fhat the grains of iron are composed of crystalline elements having the same orientation in the same grain but different ones in different grains. CHAPTER V PURE IRON 103 As explained in the preceding chapter it is believed by some that the crystalline grains of iron like those of other pure metals are surrounded by thin membranes of amorphous cement (the network in Fig. 116) holding the grains together, this amor- phous metal being harder and stronger but less ductile than the crystalline grains themselves. Before this theory had been advanced it was universally assumed that Fig. US. Etching pits in iron. (Desch.) Fig. 120. Silicon steel, 4.5 per cent silicon. Magnified 60 diameters. Part of a single grain. Etched 3 hours in nitric acid (1 to 10 water). (Stead.) Fig. 119. Etching pits in ferrite. (J. F. Hoyland, Correspondence Course student.) Fig. 121. Cubic crystals of iron. Magnified 250 diameters. Obtained through the reduc- tion of forrous chloride. (Osmond.) the grains were held together by surface contact alone or cohesion and that the net- work revealed on etching merely indicated sections through these contact surfaces made apparent owing to slight differences of solubility of adjacent grains (because of their different orientation) and resulting in slight differences of level after etching. Cubic Crystallization of Iron. A still deeper etching indicates clearly the cubic character of the crystallization of pure iron. This is illustrated diagrammatically in Figure 118 and by means of a photomicrograph in Figure 119. It will be noted that 104 CHAPTER V PUKE IRON the etching pits are similarly oriented in the same grain hut that the orientation in adjacent grains differs. As seen in Figure 118, the etching figures may appear as triangular wedges. This occurs when the section cuts the small cubes of a grain at a certain angle, i.e. when it cuts obliquely a corner of each cube. This cubic structure is further illustrated in a remarkable manner in Figure 120, in the case of iron contain- ing 4i/ per cent of silicon after etching three hours in dilute nitric acid. The photo- graph shows a portion of a single grain, hence the constancy of orientation noted. The presence of so much silicon apparently favors the development of a coarse cubic crystallization. Osmond, through the reduction of ferrous chloride and the crystallization of the resulting metallic iron, obtained perfect isolated cubic crystals (Fig. 121). Finally almost perfect cubes have been separated by Stead from a large granule of phos- Fig. 122. Cubic crystals of phosphoretic iron. Magnified 5 diameters. Phosphorous 0.7i3 per cenl, carbon per cent. (Stead.) phoretic iron (Fig. 122). Another indication of the cubic crystallization of iron is found in the occurrence of large crystallites (Fig. 123), generally resembling pine trees, in cavities of large castings of iron and steel, under conditions, therefore, favorable to the free development of crystals, these crystallites being composed of small octa- hedra, a crystalline form of the cubic system. Finally it will be shown later that the structural location of some of the impurities generally present in commercial iron affords further proof of the cubic crystallization of iron. Ferrite. Mineralogical names have been given to the constituents of iron and steel, and pure iron, or rather carbonless iron, considered as a microscopical con- stituent has been called "ferrite," a name suggested by Prof. H. M. Howe and universally adopted. 1 Pure iron, therefore, is composed of polyhedral crystalline 1 This constituent was called "free iron' 1 by Sorby, who was Hie first scientist to describe the microscopical structure of iron and steel. For further description of the nature and properties of ferrite see the report of the Committee of the International Association for the Testing of Materials, "On the Nomenclature of the Micro- scopic Substances and Structures of Steel and Cast Iron" in the Appendix. Stead has suggested that when ferrite consists only of pure iron it should be called "ferro-ferrito." CHAPTER V PURE IRON 105 Fig. 123. Iron crystallite about half natural size. (Tschernoff.) 106 CHAPTER V PURE IRON grains of ferrite. It will be seen in subsequent chapters that the ferrite of commercial grades of iron and steel is not pure iron, but rather iron holding in solid solution small amounts of silicon, phosphorus, and possibly other impurities. Allotropy of Iron. The study of the crystallization of iron is complicated by the existence of several allotropic forms of that metal. Physicists and chemists do not agree as to the exact meaning of allotropy, still less as to the phraseology by which it should be denned. Allotropy certainly implies marked and sudden reversible changes taking place in some of the properties of a substance at certain critical temperatures excluding formation or dissociation of chemical compounds and changes of state although the latter might be considered as major instances of allotropy. Opinions differ, however, as to whether a well-defined change in a single property constitutes a proof of allotropy, while some scientists insist that unless a crystallographic change is observed at the critical temperature the transformation cannot be considered as an allotropic one. 1 Again it is claimed by some and denied by others that a spontaneous evolution of heat on cooling at a cer- tain critical temperature and absorption of heat on heating at the same or nearly the same temperature is sufficient proof of an allotropic change. Others still con- sider the occurrence of a sudden dilatation on cooling and contraction on heating as the best criterion of the existence of allotropy. Finally, in discussing the allotropy of iron it has been attempted by some writers, arbitrarily it would seem, to exclude magnetic changes from those indicative of allotropy. Many substances undergo allotropic changes. It is a matter of common knowl- edge, for instance, that sulphur exists under two distinct conditions, namely, as pris- matic sulphur and as octahedral sulphur, the prismatic form being the one stable above 95.6 deg. C. and the octahedral, the stable form below that critical tempera- ture. On heating octahedral sulphur it begins to change into the prismatic form at the temperature of 95.6 deg. and, likewise, on cooling, prismatic sulphur begins to pass to the octahedral form at that temperature. Many of the physical properties of sulphur (crystalline form, specific heat, heat of combustion, etc.) undergo sudden changes as the substance passes from one allotropic form to another. At those critical temperatures which mark the passage of one allotropic form into another, spontaneous evolutions of heat take place on cooling and spontaneous ab- sorptions of heat on heating. These thermal disturbances indicate a change of in- ternal energy which when not accompanied by changes of state or by chemical changes are in the author's opinion evidences of allotropy. The usual method of detecting the existence of such thermal critical points will be described in another chapter. Osmond's momentous discovery of the existence of two thermal critical points in pure iron respectively at about 768 and 900 deg. C. was at first accepted as proving the occurrence of iron under three allotropic varieties, 7 (gamma) iron stable above the upper critical point, /3 (beta) iron stable between the two points, and a (alpha) iron stable below the lower point. The allotropic character of gamma and alpha iron is still universally accepted, and indeed has been firmly established, but it is contended by some that the condition of iron between its two critical points does not differ allo tropically from its condition below its lower critical point; in other words that the belief in beta iron as a distinct allotropic variety should be abandoned. This important question will be considered at greater length in the chapters of this book 1 The property of some substances of crystallizing in more than one form is called polymorphism. The expression, however, should not be used .as an equivalent of allotropy. CHAPTER V PURE IRON 107 dealing with the Thermal Critical Points of Iron and Steel, with the Hardening of Steel and with the Equilibrium Diagram of Iron-Carbon Alloys, when it will be shown that these opposite views result apparently from different conceptions as to the nature of allotropy. For our present purpose it will be assumed that iron exists, as first described by Osmond, under three allo tropic conditions. Solidification and Crystallization of Pure Iron. As should be expected the pas- sage of one allotropic form into another implies corresponding and, generally, sudden changes in many of the physical properties of iron. Gamma,_bea, and alpha iron differ widely in regard to many of their physical characteristics. It is only desired in this chapter, however, to inquire into the possible differences of crystallization Fig. 124. Twinnings in gamma iron. Mag- nified 200 diameters. (Osmond.) which may exist between the three allotropic conditions of iron, leaving for later consideration the modification of the other properties. Osmond and, later, Osmond and Cartaud have carefully investigated the difficult problem of the crystallization of the different allotropic forms of iron. Their con- clusions were (1) that the three allotropic forms of iron crystallize in the cubic sys- tem, 1 (2) that octahedra are the prevailing crystalline forms of gamma iron, (3) that the cube is the prevailing form of beta and of alpha iron, (4) that beta and alpha iron are capable of forming isomorphous mixtures (solid solutions), (5) that gamma iron does not form isomorphous mixtures with beta or alpha iron. We also have the statement of Osmond that the transformation of gamma iron into beta iron appears to include a change in the planes of symmetry, at least in car- burized iron. Again it has been shown by Osmond and confirmed by other investigators that the occurrence of twinnings is frequent in gamma iron (Fig. 124), while beta and alpha iron are free from it. 1 In Le Chatelier's opinion there is no proof of the cubic form of gamma iron. He thinks that the facts observed are contrary to that hypothesis and that it is more probable that gamma iron is rhombohedral or orthorhombic. 108 CHAPTER V PURE IRON It follows from Osmond's experiments that the allotropy of iron could not he proved by its crystallography, since the thermal critical points are not accompanied by changes in the crystalline form of iron. While, however, in the instances of allo- tropy which have been noted and studied allotropic changes are generally accom- panied by changes of crystalline forms, it does not by any means follow that any allo- tropic transformation must necessarily imply a crystalline change. Bearing in mind the existence of three allotropic conditions of iron, let us follow in our imagination the crystallization of iron during solidification and its subsequent cooling to atmospheric temperature. On solidifying iron crystallites are formed con- sisting of octahedral crystals of gamma iron. Upon further cooling below the solidi- fication point, no change of crystalline form should take place unless it be the granula- tion described by Belaiew (Chapter XIII) until the first critical temperature (900 deg. C.) is reached when the iron changes from the gamma to the beta condition. Does this allotropic change affect the preexisting crystallization of gamma iron or does it consist merely in a transformation in situ of each crystalline grain of gamma iron into a grain of beta iron, retaining the original external form of the gamma grain, and leaving undisturbed, therefore, the polygonal structure observed under t he- microscope? It may reasonably be supposed that the allotropic transformation takes place without affecting the external form of the crystalline grains, but in view of Osmond's statement that the octahedron is the prevailing crystalline form of gamma iron and bearing in mind that the small crystals revealed by suitable etching of pure iron are generally cubic, we naturally infer that the octahedral character of each grain of gamma iron has been obliterated, the small octahedral elements of gamma iron having been replaced by small cubic elements of beta (and later of alpha) iron. These conclusions, however, should lie accepted with reserve, as we lack evidences of a very conclusive character. It has been shown that the change of gamma iron into beta iron is accompanied by an abrupt expansion of the cooling metal which expan- sion is followed by the normal contraction of cooling substances. We infer from this that, momentarily at least, each grain of beta iron occupies more space than its gamma iron progenitor. At 750 deg. C. or thereabout, the iron passes from the beta to the third or alpha form. We may here ask the same questions as to the probable effect of this change upon (1) the outward form of each beta grain and (2) upon the internal crystalline structure of each grain. Since both beta and alpha iron crystallize in the cubic sys- tem, the cube being the prevailing crystalline form of both, and since, according to Osmond, they are isomorphous, that is capable of forming solid solutions, it seems probable that the change of beta to alpha iron affects neither the external form inn the internal crystalline arrangement of the beta grains; in other words that each small cubic element of beta iron is converted bodily (although probably gradually and not abruptly) into a cubic element of alpha iron. If the above represents the real mechanism of the allotropic changes, it will lie evident that the polyhedral grains revealed through the etching of polished sections of pure iron were formed during solidification and consisted originally of gamma iron, these grains having retained their external shape while undergoing allotropic transformation, but having probably undergone at the upper critical point an internal change, the octahedral form of the crystalline elements having been replaced by the cubic form. Hosenhain and Humfrey by straining a bar of iron heated to a high tempcr;ilure CHAPTER V PURE IRON 109 at the center (the temperature, therefore, decreasing towards both ends) have made evident the existence of three distinct kinds of distortions with sharp lines of de- marcation between them, corresponding in all probability to the distortion respect- 12o. Iron before straining. (Rosenhain.) l\ Fig. 126. Same as Fig. 125 but strained. (Rosenhain.) ively of gamma, beta, and alpha iron. The estimation of the temperature of different portions of the bar by means of fusible salts appears to sustain the authors' conten- tion thus furnishing an additional support, and a substantial one, to Osmond's bril- liant theory of the allotropy of iron. 110 CHAPTER V PURE IRON Nevertheless information of a more positive and concordant nature is still needed to settle to the satisfaction of all the question of the relation between the thermal critical points of pure iron and possible crystallographic changes. Twinnings and Neumann Lines. It has been already stated that according to Osmond and Cartaud twin crystals frequently occur in gamma iron. It will be shown later, however, that gamma iron which exists normally only above the upper critical point of iron requires for its preservation at atmospheric temperature the presence of a considerable amount of carbon, if not, also, of other elements such as manganese and nickel. The twin crystals of gamma iron shown in Figure 124 do not refer to pure gamma iron but to gamma iron containing a considerable amount of nickel. Iron or at least very low carbon steel not unfrequently exhibit the presence of Neumann lines which as previously stated are probably mechanical twins. In Fig- ure 114 an interesting instance of the occurrence of such lines has been shown. . It has been mentioned in the preceding chapter that in order to distinguish be- tween slip bands and Neumann lines the specimen should be repolished and again etched, a treatment which should result in the reappearance of the Neumann lines but not of slip bands since the latter are merely slight differences of level erased by the polishing operation. Strains and Slip Bands. It has been shown by Ewing and Rosenhain that like other metals, iron when subjected to a strain exceeding its elastic limit yields through a succession of small crystalline slips readily distinguishable on a polished surface as one or more systems of parallel lines (Figs. 125 and 126). It has been observed by these authors that this slipping occurs most readily along octahedral planes from which it would seem to follow, as already noted, that these gliding planes are not identical to cleavage planes since the latter are cubic. According to Humfrey the slip bands which form first are confined almost entirely to the central parts of the crystals and only spread gradually towards the boundaries as the straining becomes more severe when they show a tendency to become narrower and to bend so as to meet them at a smaller angle. As explained in Chapter IV it is believed by some that the severe straining of the iron crystals at the gliding planes must result in the formation of thin layers of amor- phous metal and that this theory affords a satisfactory explanation of the marked in- fluence of cold working on the physical properties of iron. Influence of Mechanical Treatment. Like that of other metals the structure of iron is affected by mechanical work. Undisturbed cooling being a necessary condi- tion to the free development of crystals, it will be evident that if the metal be vigor- ously worked, that is subjected to powerful mechanical pressure, while cooling from a high temperature, the formation of crystalline grains will be greatly hindered or preexisting crystals broken or distorted. The important influence of work upon the structure (and therefore upon the properties) of iron and steel will be duly considered in these pages. Influence of Thermal Treatment. The size of the crystalline grains of iron is affected as is the case with other metals, by the speed of its solidification and subse- quent cooling, slow cooling promoting the formation of large grains. When the iron is produced in a pasty condition as in the puddling process and the charcoal hearths, the dimensions of its grains depend essentially upon the temperature from which the metal is allowed to cool undisturbed by mechanical work. CHAPTER V PURE IRON 111 As explained in the preceding chapter, it seems probable that pure metals do not undergo any crystalline growth on reheating (annealing) unless they have been pre- viously strained. For similar reasons we may doubt the occurrence of any crystalline growth on annealing chemically pure iron in the complete absence of strain. The be- havior of electrolytic iron, however, presently to be described appears to oppose this view. The possible part played, during the annealing operation, as described in the preceding chapter, by the thin films of amorphous cement believed by some to be present between the grains applies to pure iron as well as to other pure metals. The influence of heat treatment upon the structure and physical properties of commercial irons and steels will be dealt with at length in these pages. Crystallizing Properties of Electrolytic Iron. Stead and Carpenter have made the important discover}' that electrolytic iron of very great purity appears to possess v s A /V . - v ,W 1 .^.7 ' Fig. 127. Thin sheet of electrolytic iron a portion of which was heated to 925 deg. C. for one minute and the whole sheet cooled in air. Magnified 4 diameters. (Stead.) crystallizing properties radically different from those of other irons. When sheets of electro-deposited iron not exceeding 0.012 in. thick (preferably not over 0.01 in.) are heated above the upper critical point of iron and then cooled below that point, enormous crystals are formed in three seconds after cooling below the critical point. The coarse crystals are sometimes "equi-axed" and sometimes "radial," but accord- ing to their discoverers there is no reason for thinking that they are constitutionally different. This remarkable crystalline phenomenon is well illustrated in P^igure 127, which represents, under a magnification of only four diameters, the structure of a strip of electrolytic iron heated to between 920 and 930 deg. for one minute and cooled in air. It was then cleaned with hydrochloric acid, dipped into strong nitric acid, washed, and dried. The central portion where the crystals are small represent a por- tion which was not heated above the upper critical point, its structure remaining un- altered. The lower portion of the strip is composed of what the authors called "ra- dial" or "columnar" crystals of great size, while in the upper part of the strip the ordinary polyhedral or "equi-axed" crystals have formed. The sharp boundaries 112 CHAPTER V PURE IRON between the fine-grained unaltered metal and the portions having assumed a coarse crystallization should be noted. The authors write that once the coarse crystals are formed they cannot be de- stroyed except either by cold mechanical work, or by heating above the upper crit- ical point followed by quenching, or by a very extended heating above that point followed by slow cooling. They add that very prolonged heating above the upper critical point followed by slow cooling does not result in the formation of coarse crystals. Bearing in mind that above its upper critical point iron exists in the gamma allotropic form, the above phenomenon seems to indicate that on cooling through its upper point the small crystals of gamma iron existing above it are converted into very large crystals of beta iron, or if we doubt the existence of beta iron, then of alpha iron, which is the view held by Stead and Carpenter. The striking features of this extra- ordinary crystalline transformation are (I) the fact that unless the sheets be very thin (less than 0.012 in. thick) the growth does not occur, (2) the very large size of the resulting crystalline grains, and (3) the great speed with which they form. Benedicks believes that the condition required for the occurrence of the phenome- non is extreme purity and absence of mechanical inclusions. The influence of the thickness of the sheet has been explained on the ground that in very thin sheets the crystals can grow, so to speak, only in two directions, and thus appear extremely large, although their volume may be relatively small. In other words the thinner the sheet the larger the new crystals would appear to be, since crystals of equal vol- ume would necessarily occupy a larger area they would be spread over a greater surface. Influence of Impurities. Commercial iron is always contaminated by the pres- ence of at least five elements, namely, manganese, silicon, phosphorus, sulphur, and carbon, generally referred to, although often wrongly, as impurities. The important question of the influence of these substances upon the structure and, therefore, upon the properties of iron and steel will be fully considered in another chapter, when it will be shown that these elements form definite compounds with iron, FeSi, Fe 3 C, Fe 3 P, or with each other, Mn 3 C, MnS, and that some of these compounds, FeSi, Fe 3 P, are retained by the iron in solid solution, while others, Fe 3 C, Mn 3 C, MnS, arc rejected to the boundaries of the crystalline grains or along other crystallographic planes, the former two giving rise to the formation of eutectoid mixtures. This behavior of the impurities of iron and steel conforms with the general behavior of impurities described in Chapter IV. CHAPTER VI WROUGHT IRON Wrought iron is the 11:11110 given To commercial iron free enough from carbon and other impurities to lie malleable when such metal is manufactured through the re- duction of iron ores or the refining of east iron at a temperature so low that it is obtained in a pasty condition and, therefore, mechanically mixed with a considerable amount of the slag formed during the operation. When the refilling treatment is conducted at a temperature sufficiently high to deliver the resulting products in a molten condition, the refined metal which is then free from slag is called steel. Wrought iron and steel may otherwise have identical chemical composition, although usually steel contains more manganese and less silicon than wrought iron, often more carbon and less phosphorus. Commercial iron which is not malleable is called cast (pig) iron. The modern method of producing wrought iron consists in refining cast iron in a non-regenerative reverberatory furnace (the puddling furnace), while the refining of cast iron for the production of steel is conducted (1) in the Bessemer converter or (2) in a regenerative reverberatory furnace (the Siemens open-hearth furnace). Cast (pig) iron is the result of smelting iron ore in blast-furnaces. Wrought iron is sometimes called "puddle" or "puddled" iron, from the name of the furnace in which it is now generally manufactured. Wrought iron made in the old charcoal hearths either directly from the ore or from pig iron (Catalan, Lancashire, or Walloon processes) is called "charcoal hearth" or "charcoal" iron. Wrought iron produced in the puddling furnace from small pieces of steel scrap is known as "bush- eleil" iron, apparently from the fact that the small pieces of steel used can be gath- ered in bushel baskets. The product resulting from the reheating to a welding heat and subsequent working of piles (fagots or faggots) of pieces of wrought iron and steel scrap is called "fagoted" iron, also spelled "faggoted" iron. Knobbled iron is wrought iron produced by the knobbling process which resembles the South Wales process in which pig iron is first melted down in a coke refinery, considerable silicon and carbon being eliminated, and then treated in a charcoal hearth somewhat as in the Lancashire process. Puddled iron and charcoal hearth irons are generally freer from manganese than fagoted and busheled irons, while charcoal hearth iron generally contains less phos- phorus and less slag than puddled iron. In England wrought iron is also called malleable iron. When wrought iron contains enough carbon to bo hardened by quenching it was at one time called wrought steel, but this expression is now obsolete. In the puddling process the pasty lumps of iron removed from the furnace at the end of the operation are called "puddle (puddled) balls" while the roughly elongated 113 114 CHAPTER VI WROUGHT IRON masses resulting from the squeezing of puddle balls are sometimes called "blooms." The blooms are rolled into "muck bars," or "puddle (puddled)" bars. The product re- sulting from the cutting, piling, heating, and rolling of muck bars is known as "refined iron," "refined bar," "merchant bar," "single rolled iron," "single refined iron," or "No, 2 iron"; if subjected to a second piling, heating, and rerolling, as "double (doubly) refined iron," "double rolled iron," "No. 3 iron," "best bar," "wire iron," or also "refined bar." (H. P. Tiemann.) Chemical Composition. Wrought iron contains, besides an appreciable amount of slag, a small proportion of carbon and small quantities of the usual impurities, manganese, silicon, phosphorus, and sulphur. Microstructure of Longitudinal Section. Upon being withdrawn from the pud- dling furnace, the white hot, pasty balls of wrought iron are subjected to vigorous Fig. 128. Wrought iron. Longitudinal section. Magnification not stated. (Longmuir.) Fig. 129. Wrought iron. Magnified 100 diameters, thor's laboratory.) Longitudinal section. (Boynton in the au- forging or squeezing, thus expelling a large amount of slag and firmly welding to- gether the particles of iron. Through additional heating and forging or rolling the metallic mass is converted into such elongated shapes as blooms, billets, bars, etc. These operations so affect the structure as to impart unlike appearances to sections cut longitudinally, i.e. in the direction of forging or rolling, and sections cut trans- versally, i.e. at right angles to that direction. The microstructure of the longitudinal section of a wrought-iron bar is shown in Figures 128 and 129. From our knowledge of the chemical composition of wrought iron we should be able to anticipate its microstructure. The ground mass or matrix of the metal consists of polyhedral crystalline grains of iron, that is of ferrite, similar in every respect to the crystalline grains of pure iron and of pure metals in general described in Chapters IV and V. The ferrite of wrought iron, however, as explained in Chapter V, is not pure iron but rather a solid solution of iron in which are dissolved small quantities of silicon, CHAPTER VI WROUGHT IRON 115 phosphorus, and other minor impurities. This true character of commercial ferrite is too often lost sight of and the constituent considered as pure iron. The difference in coloration between adjacent grains of this commercial ferrite should be noted, and will of course be readily understood in view of the explanation given in Chapter IV to account for this phenomenon. Many irregular black lines, varying much in thickness and length, but all running in the same direction are clearly seen. These lines indicate the location of the slag which has assumed the shape of fibers or streaks running in the direction of the rolling or forging, thus imparting. a jibrous appearance to the metal. The presence of a small amount of carbon in wrought iron results in the occurrence of a new constituent in the shape of small dark particles located between some of the grains. Under low magnification these carbon-holding particles are not readily dis- - .-. . .. /*. . *- *-/M ".'* Ifr 9 -."."'**'*" ' - - .' Fig. 130. Wrought iron. Transverse Fig. 131. Wrought iron. Transverse section, section. Magnification not stated. Magnification 100 diameters. (Boylston.) (Longmuir.) tinguishable from slag particles and as this carburized constituent is not a very im- portant one in the case of wrought iron it seems advisable to postpone its description. Summing up, wrought iron consists essentially of a mass of ferrite containing many elongated particles of slag. Microstructure of Transverse Section. The microstructure of the transverse section of a wrought-iron bar is illustrated in Figures 130 and 131. Like the structure of the longitudinal section, it consists of a polygonal network, indicating that the metal is made up of polyhedral crystalline grains of ferrite. The slag, however, which in the longitudinal section occurred as fibers running in a direction parallel to the rolling or forging, here assumes the shape of irregular, dark areas, corresponding to the cross sections of the slag fibers. It will be noted that in both the longitudinal and transverse sections the ferrite grains are equi-axed, that is, they show no sign of having been elongated in the direction of the rolling. It was thought for many years that wrought iron actually had a fibrous structure and, indeed, the number of persons still holding this view is surprisingly large. Many valuable properties were attrib- .11(1 CHAPTKH VI WROUGHT IRON uted to puddled iron on account of its "fibrous structure" which were denied to steel because of its "crystalline structure." The microscope has summarily dis- posed of this erroneous belief in showing that the ferrite constituting the bulk of wrought iron is in no way different from the ferrite forming the bulk of low carbon steel. Both are equally crystalline. Structural Differences between Various Kinds of Wrought Iron. According to W. Campbell charcoal hearth iron can sometimes be distinguished from puddled iron through the presence in the former of bands of ferrite containing more or less pearlite (the carburized constituent of steel soon to be described) especially in their centers. The occurrence of these bands is ascribed to the carburizing of the iron by the glowing charcoal during the process of manufacture. Fagoted iron also contains ferrite and pcarlite bands from the steel scrap used in its production but in these the pearlite Kiji. 132. Particle of slag in wrought, iron. Magnified 200 diameters, ((iiiillet.) does not decrease from center to outside, sharp lines of division existing between tin- bands and the ferrite matrix of the iron. It is difficult to distinguish between the structure of busheled iron and that of puddled iron on the one hand and of charcoal iron on the other; when ferritc-pearlite bands occur in busheled iron they resemble those present in charcoal iron, while in the absence of such bands the structure re- sembles that of puddled iron. Chemical Composition of Slag. - The essential chemical constituents of the slag produced in the puddling furnace and retained in part by the iron are iron oxides, both ferric (Fe 2 O.-i) and ferrous (FeO), oxide of manganese (MnO), silica (SiO 2 ), and phosphoric acid (PaOr,). Of these the oxides of iron and manganese are basic in their chemical affinity while silica and phosphoric acid are acid. These bases and acids combine with each other to form neutral compounds: silicates and phosphates of iron and manganesei Microstructure of Slag. When highly magnified (Fig. 132) it is found that the slag fibers are really made up of at least two constituents, a dark and a lighter one, the light constituent moreover often occurring in the form of small rounded areas. CHAPTER VI WROrdHT 1KOX 117 We are naturally led to speculate us to the nature of these two distinct constituents of the slag, and in view of our knowledge of the chemical composition of slug as stated in the preceding paragraph we are tempted to conclude that one of the constituents is a silicate of iron and manganese while the other is a phosphate of the same bases. The accuracy of this deduction, however, remains to be proven. According to Matweieff the rounded light ureas consist of iron oxide mixed or not with manganese oxide, and the darker background of silicate of iron and man- ganese. Matweieff recommends tho following method to distinguish between the different constituents of slag. The polished sample placed in a tube is heated and treated by a current of pure hydrogen which causes i he reduction of the metallic oxides while the silicates are unaffected. To detect the presence of ferrous oxide (FeO) the sample heated to a red heat is acted upon by steam, a treatment resulting in oxidizing the ferrous oxide into magnet ie oxide (Fc 3 ().i), while the silicates again remain unaltered. To detect the presence of manganese in the particles of oxides revealed by the hydrogen treatment the previously treated sample is repolished and etched with a dilute solution of ferric chloride in alcohol: if the white metallic grains resulting from tin- hydrogen treatment are colored darker than the surrounding iron they contain some manganese. Finally to detect the presence of iron and manganese sulphide the polished sample is etched with a dilute solution of tartaric acid which colors sulphide of manganese lightly and iron sulphide decidedly. Rosenhain considers it probable that the two distinct constituents of wrought- iron slag are two different silicates or, possibly, oxides of iron. It is seen that writers generally ignore the presence of phosphoric acid in the slag from the puddling furnace, and still it generally contains from 3 to 5 per cent of it, and occasionally considerably more. If we assume that this phosphoric acid forms with iron a phosphate of the formula SFeO.P-A,, a simple calculation, according to atomic weights of the elements involved, will show that the presence of 5 per cent of' phosphoric acid would mean the formation of over 12.50 per cent of this phosphate of iron. It is hardly to be supposed that this phosphate is absorbed by some other constituent of the slag. On the contrary it seems highly probable that it must be present as a distinct constituent. Influence of Thermal and Mechanical Treatments. The dimensions of the fer- rite grains of wrought iron are affected by the treatments, both thermal and mechan- ical, received by the metal. The effect of these treatments upon the structure of iron and steel will be considered in another chapter. CHAPTER VII LOW CARBON STEEL In this and the following chapters steel will be considered as a pure alloy of iron and carbon, i.e. free from the impurities (silicon, manganese, sulphur, and phosphorus) always present in commercial products. The influence of these elements upon the structure of steel will form the subject of another chapter. Normal Structure. The structures described in this and the next chapter refer to the condition of steel after forging followed by heating to, and slowly cooling from, a high temperature (900 to 1000 deg. C.). Such treatments, for reasons that will be understood later, promote soundness, remove internal strains, prevent excessive coarseness of structure (as in castings) , and permit a state of stable equilibrium to be assumed by the constituents. The resulting structure may be conveniently called the "normal" structure and it will be so called in these pages. Grading of Steel vs. Carbon Content. Steel is generally graded according to the amount of carbon it contains. The following terms are those most commonly used: Very low carbon steel, very mild, or extra mild steel, very soft or dead soft steel carbon not over 0.10 per cent Low carbon steel, mild steel, soft steel carbon not over 0.25 per cent Medium high carbon steel, half hard steel . . . * . . carbon 0.26 to 0.60 per cent High carbon steel, hard steel carbon over 0.60 per cent Very high carbon steel, very hard, or extra hard steel carbon over 1.25 per cent This classification is somewhat arbitrary as there are no sharp lines of demarcations universally recognized between the various grades. It will be seen in another chapter that steel containing about 0.85 per cent carbon is also known as eutectoid steel, steel containing less carbon as hypo-eutectoid steel, and more highly carburized metal as hyper-eutectoid steel. Low Carbon Steel vs. Wrought Iron. As already mentioned the distinction between low carbon steel and wrought iron is based upon the difference between the methods employed for their respective manufacture rather than upon unlike chemical or physical properties, for these metals may indeed be quite identical both physically and chemically. The mere melting of wrought iron would undoubtedly, in accord- ance with the universally accepted definition of steel convert it into steel since we would now have a malleable metal initially cast. Such treatment would of course result in the elimination of the slag mechanically retained by the wrought iron: the melted metal would be slagless, barring cemented steel, another essential property of steel. Since wrought iron generally contains but a small amount of carbon, melting it would convert it into low carbon steel. 118 CHAPTER VII LOW CARBON STEEL 119 The Structure of Low Carbon Steel. From the above considerations regarding the resemblance between wrought iron and low carbon steel, the structure of the latter may fairly be anticipated. Seeing that low carbon steel may be considered as wrought iron from which the mechanically held slag has been expelled through melt- ing, we should expect the absence of slag to be the only marked difference between the structure of low carbon steel and that of wrought iron. The microstructure of low carbon steel is illustrated in Figures 133 to 138. It will be seen (Figs. 133 to 136) to consist chiefly of a mass of ferrite (carbonless iron) ex- hibiting the usual polyhedral crystalline grains described in preceding chapters. The ferrite present in low carbon steel is similar in every respect to the ferrite of wrought iron. At the junctions of many ferrite grains, however, some dark areas will be noted, Fig. 133. Steel. Carbon 0.08 per cent. Fig. 134. Steel. Carbon about 0.20 per cent. Magnification not stated. (Arnold.) Magnified 200 diameters. (Guillet.) an evidence of the existence in the metal of another constituent. Since ferrite is prac- tically free from carbon, it is evident that the carbon present in the steel must have segregated into these small dark masses. As to the exact nature of this dark constit- uent it will be apparent that it cannot consist of pure carbon for it is well known that the carbon present in steel does not exist in the free state but on the contrary is com- bined with some of the iron forming a definite chemical compound or carbide of iron whose formula is Fe.iC. 1 This iron carbide must necessarily be located in the dark areas, but are these made up exclusively of this carbide? To find an answer to this question let us examine the structure of steel under a higher magnification (Figs. 137 and 138). This reveals the existence of two components in each dark particle occur- ring as small wavy or curved parallel plates or lamellae alternately dark and white. As to the nature of these two components, it is evident that one of them must be the 1 The existence of the carbide FesC in unhardened steel was first shown in 1885 by Abel and Muller, working independently, and has since been confirmed by many other investigators. Its existence is proved by dissolving unhardened steel in a suitable solvent and analyzing the carbona- ceous residue. 120 CHAPTKH VII LOW CAHBOX STKKL carbide Fe^C and the other necessarily iron or ferrite, since according to the proxi- mate analysis of steel, these are the only two constituents which, to the best of our knowledge, are present in pure unhardened carbon steel. Pearlite. Howe named the microscopical constituent just described pearlite (originally written pearlyte) following in this Dr. Sorby who was the first observer to describe it and who had proposed for it the name of "pearly constituent" because it frequently exhibits a display of colors very suggestive of mother-of-pearl, especially when viewed by oblique illumination. This appearance is due to the fact that these plates are extremely thin, seldom measuring over . 3 of an inch in thickness, and that the plates of carbide, being much harder than the ferrite plates, stand in relief V-j ' , Fig. 13.5. Steel. Carbon 0.08 per cent. Magnified 100 diame- ters. (Boylston.) after polishing, resulting in an arrangement very similar to the refraction gratings of physicists. Mother-of-pearl likewise is made up of very thin alternate plates of dif- ferent colors and possibly of different hardness. The carbide plates remain bright not being affected by the usual etching reagents, while the ferrite plates appear dark because of their being somewhat tarnished by the etching and also because, being depressed owing to their greater softness, they stand in the shadow of the carbide plates. It will be shown in another chapter that in many series of alloys of two metals the alloy of lowest melting-point called the "eutectic" alloy, nearly always exhibits a composite structure like that of pearlite, i.e. made up of parallel plates alternately of one and the other constituents. It will also be shown that in spite of this very great structural resemblance pcai-litc is not a true eutectic alloy. Howe proposed CHAPTER VII LOW CARKOX STKKL 121 to call "eutectoid" the kind of mechanical mixture found in pearlite and this most appropriate term has been universally adopted. Because of the minute dimensions of the lamella' of pearlite a high magnifica- tion, generally not less than 250 or 300 diameters, is required for its resolution. It should be stated here that pearlite does not always assume such a distinctly laminated structure. In many instances its structure remains ill defined or has a granular rather than a lamellar appearance, while its behavior towards the etching reagents likewise varies. It will be shown at the proper time that this is due to the treatments to which steel may be subjected and that the exact nature of these ill- defined forms of pearlite (often called transition constituents) has given rise to a large amount of discussion and has been the object of many investigations. It may be assumed for the present that any pearlite which is not distinctly lamellar is not true pearlite. It will be noted that in Figure 134 the pearlite occupies about twice the area cov- ered by the same constituent in Figure 133. We infer from this that the amount of , -.-*. O***^* A -_l <* ^J ^"fc 4 ' - V ',- c"I rfV" ' -* ^r" vr.^^-f ^ * Jf ,. . v > '$mi * * L* * i S** *; J-' Fig. 13(5. Steel. Carbon about 0.20 }icr cent. pearlite in low carbon steel at least increases progressively with the carbon content. Doubling the amount of carbon doubles of course the proportion of the iron carbide in the steel, and since the amount of pearlite is apparently also doubled it follows that iron carbide and ferrite must unite with each other in fixed ratio to form pearlite, in other words that pearlite always contains the same proportion of carbide and hence also of carbon. The accuracy of this conclusion will soon be shown. Free Ferrite. - To distinguish between the ferrite included in pearlite and the ferrite forming the balance of low carbon steel, the latter is sometimes called "free" ferrite, "structurally free" ferrite, "excess" ferrite, "massive" ferrite, "non-eutec- toid 1 ' or " pro-eutectoid " ferrite, "surplus" ferrite. In these lessons it will be re- ferred to as free ferrite while the ferrite forming part of the pearlite will be called pearlite-ferrite. Some writers refer to the latter as eutectoid-ferrite. In the absence of any conclusive evidence to the contrary, it is natural to infer that free ferrite and pearlite-ferrite are identical, that is, pure iron in pure steel and 122 CHAPTER VII LOW CARBON STEEL iron holding in solution small quantities of silicon and phosphorus, and possibly of other impurities, in impure (commercial) steel. 1 Cementite. The name of cementite has been given by Howe to the carbide FesC and universally adopted. The term is derived from "cement" steel (cementa- Fig. 137. Steel. Structure of pearlite. Magnified 1000 diameters. (Osmond.) Fig. 138. Steel. Hypo-euteetoid. Magnified 750 diameters. Pearl- ite particles and surrounding ferrite. (Goerens.) tion steel, blister steel, converted steel) which being generally a high carbon steel contains a great deal of this carbide, that is, of cementite. According to the atomic weights of iron (56) and of carbon (12) cementite must contain 12 X 100 3 X 56 + 12 = 6 ' 67 P The carbon present in cementite is frequently referred to as "cement" carbon, occasionally as carbide carbon, to distinguish it from other forms of carbon found in iron and steel and to be described later (hardening carbon, graphitic carbon, temper carbon, etc.). Cementite is an extremely hard substance, being in fact the hardest of all the constituents occurring in iron and steel, harder even than hardened, high carbon steel. Howe states that it is harder than glass and nearly as brittle. As it scratches 1 This has been doubted by some writers, however, who have noted that the ferrite of some pearl- ites was more readily colored on etching than free ferrite and they saw in this and in some other evidences an indication that pearlite-ferrite may be less pure than free ferrite. Benedicks for in- stance believes, or at least believed at one time, that the pearlite-ferrite of some steels could con- tain as much as 0.27 per cent of carbon dissolved in beta iron, whereas free ferrite is in the alpha condition. This carburized and allotropic ferrite Benedicks called "ferronite." CHAPTER VII LOW CARBON STEEL 123 feldspar but not quartz it is generally assigned to rank 6 or 6.5 in the Mohs scale of hardness. 1 It will be shown later that when steel contains an appreciable amount of manga- nese, as is nearly always the case in commercial products, a portion at least of this manganese also forms a carbide Mn 3 C and that this carbide unites with the iron carbide FeaC to form cementite. It is well to bear in mind, therefore, that in com- mercial steel cementite generally contains besides Fe 3 C varying amounts of this car- bide of manganese. As the atomic weight of manganese is nearly the same as that of iron, 55 compared to 56, it so happens that the presence of manganese in cementite affects but very little its carbon content, which for all practical purposes may be taken as 6.67 regardless of the amount of manganese it may contain. Cementite containing much manganese has been called manganiferous cementite by some writers. Recent investigations tend to show that cementite may also contain small amounts of silicon and sulphur dissolved in it possibly as silicide and sulphide of iron respec- tively, although Stead and W. H. Hatfield mentioned the presence of silicon carbide. It will be shown elsewhere that some of these elements (manganese and sulphur) ap- parently increase the stability of cementite while silicon decreases it. Baykoff has advanced the theory that cementite is not a definite compound or mixture of definite compounds but a solid solution. Cementite generally remains bright and brilliant after the ordinary etching treat- ments employed to reveal the structure of steel. Sodium picrate, however, colors it deeply (see Chapter VIII). 1 The Mohs scale is as follows, beginning with the softest and ending with the hardest mineral and each mineral being capable of scratching the preceding ones: (1) Talc, (2) Gypsum, (3) Calcite, (4) Fluorite, (5) Apatite, (6) Feldspar, (7) Quartz, (8) Topaz, (9) Corundum, and (10) Diamond. CHAPTER VIII .MEDIUM HIGH AND HIGH CARBON STEEL Medium High Carbon Steel. The normal structure of steel (i.e. its structure .after working, reheating to a high temperature and slow cooling) containing about 0.30 per cent carbon is illustrated by a drawing in Figure 139 and by a photomicro- graph in Figure 140. It will be noted, on comparing this structure with that of lower carbon steels (Chapter VII), that the introduction of more carbon in the iron has re- sulted, as would be expected, in the occurrence of a greater amount of pearlite and of a correspondingly smaller proportion of ferrite. The pearlite occupies now roughly about one third of the total area. The junction lines between the grains of ferrite Fig. 139. Steel. Carbon 0.38 per cent . Magnification not stated. (Arnold.) Fig. 140. Steel. Carbon 0.30 per rent. Mag- nified 1 50 diameters. Forged and annealed. (C. C. Buck, Correspondence Course student.) should be noted. Under sufficiently high power the pearlite areas exhibit the char- acteristic lamellar structure described in Chapter VII. On further addition of carbon, the amount of pearlite, which is evidently propor- tional to the percentage of carbon, increases correspondingly, as shown in Figures 141 and 142 illustrating the microstructure of steel containing about 0.50 per cent car- bon. The pearlite occupies here over one half of the total area. It will be noticed that the ferrite areas are only occasionally resolved into polyhedral grains, appar- ently because the ferrite now occurs in particles often too small to be made up of several crystalline grains. These small masses of ferrite, however, are still made up 124 CHAI'TKH VIII MKDIOI HIGH AND HKiH CARBON STKKI, 125 Fig. 141. Steel. Carbon ()./><> per cent. Magnification not stated. (Arnold.) Fig. 142. Steel. Carbon ()..")() per cent. Magnified 100 diameters. Heated to 1000 deg. C. and slowly cooled in furnace. (Burger.) Fig. It:;. Sled. Carbon 0.4."> per cent. Magnified 1000 diameters. (Osmond.) 126 CHAPTER VIII MEDIUM HIGH AND HIGH CARBON STEEL of crystalline matter as described and illustrated in Chapter V. A high-power photo- micrograph of 0.45 per cent carbon steel is shown in Figure 143. The laminations of pearlite are clearly seen. When steel contains but a small, although appreciable, amount of ferrite, as is the case with carbon contents between 0.50 and 0.70 per cent the ferrite frequently forms envelopes or membranes surrounding the pearlite grains, an arrangement generally described as a network structure the pearlite forming the meshes and the free ferrite the net proper. These pearlite meshes are also described as "cells" or "kernels" and the ferrite membranes as "cell walls" or "shells." It will be shown later that this network structure is promoted by rather rapid cooling from a high temperature, as for instance by cooling small pieces in air. Structures of this type are illustrated in Figures 144 and 145. The latter illustra- Fig. 144. Steel. Carbon 0.59 per cent. Magni- fied 100 diameters. Heated to 1000 deg. C. and cooled in air. (Burger.) tion is of special interest being a reproduction of one of Sorby's original drawings and, therefore, the first drawing of pearlite ever published. High Carbon Steel. Since the introduction of increasing amounts of carbon in steel results in the formation of a correspondingly increasing proportion of pearlite and decreasing proportion of ferrite, a degree of carburization must necessarily be reached, when the whole mass will be made up of pearlite, the ferrite having finally disappeared. This critical point in the structure of steel is attained when the metal contains somewhere between 0.80 and 0.90 per cent of carbon, exceptionally pure steel requiring the larger proportion of carbon and impure steel the smaller for the complete disappearance of ferrite. Eutectoid Steel. Steel made up exclusively of pearlite is now quite universally called "eutectoid" steel, after Howe, the name suggesting the great resemblance between pearlite and eutectic alloys while, at the same time, clearly indicating that CHAPTER VIII MEDIUM HIGH AND HIGH CARBON STEEL 127 pearlite is not a real eutectic alloy. Previous to Howe's happy suggestion this steel was commonly described as "eutectic" or "saturated" steel. It has also been termed "aeolic" or "benmutic" steel but these names have now been abandoned. The structure of eutectoid steel is illustrated in Figures 146 and 147. Fig. 145. Steel. Hypo-eutectoid. (Sorby.) Fig. 146. Steel. Eutectoid. Magnified 410 diameters. .'////, Fig. 147. Steel. Eutectoid. Magnified 1000 diameters. (J. V. Emmons.) Steel containing less than 0.85 per cent carbon or thereabout, and in which, therefore, some free ferrite is present, is called "hypo-eutectoid," while steel more highly carburized than eutectoid steel is called "hyper-eutectoid." It will be shown presently that hyper-eutectoid steel contains free cementite. Hyper-Eutectoid Steel. --The normal structure of steel containing from 1.10 to 1.50 per cent carbon is illustrated in Figures 148 to 151 both under low and high 128 CHAPTER VIII MKIMTM HIGH AND HIGH CARBON STKKL magnification. These steels will be seen to consist, like hypo-eutectoid steel, of two constituents, one of which is pearlite as clearly shown when examined under high power. The other constituent remains bright after etching and might at first be taken for ferrite. Upon reflection, however, it will be evident that such cannot be its Fig. 148. Steel. Carbon 1 .20 per cent. Magnification not stated. (Arnold.) Fig. 149. St K N <\J * M- v ft o p. * C\J o g o to CHAPTER VIII MEDIUM HIGH AND HIGH CARBON STEEL 137 pearlite. After a little experience and by taking the necessary precautions it will be found that, in the case of decidedly hypo-eutectoid steels at least (steels containing say less than 0.60 per cent carbon), results are obtained fully as accurate as those of the colorimetric method and, on the whole, more reliable, since the possibility of serious errors is practically eliminated. By the micro-test, for instance, a steel with 0.25 per cent carbon might be reported as containing 0.20 or 0.30 per cent of that element, but it could hardly be reported as containing 0.15 or 0.35 per cent. With chemical methods on the contrary, even with the combustion method, such errors are possible, and occasionally occur, through mechanical loss, faulty manipulations, im- pure reagents, mistakes in weighing or figuring, etc. Chemical analysis calls for the complete destruction of the anatomy of the metal, destroying at the same time evi- dences of serious error; micrographic analysis, on the contrary, is based upon the anatomy itself, and therefore very serious errors are quite impossible. In order to yield results at all satisfactory, however, care should be taken that all samples be first annealed, that is reheated to 900 or 1000 deg. C. and cooled slowly, so that the normal amounts of pearlite may be formed. To attempt to apply the micro-test to forged samples for instance is certain to lead to failure. Nor can the test be applied to hypo-eutectoid steel containing but a slight amount of free ferrite, for instance to steel with from 0.60 to 0.80 per cent carbon, because of the difficulty of estimating accurately the area occupied by so small a proportion of the constituent in excess, and therefore by the pearlite itself. In the case of hyper-eutectoid steel, the differences between the contents of free cementite in steels of materially different carbon contents is so small as to resist accurate determination. For instance, steels respectively with 1.10 and 1.40 per cent carbon will contain 95.3 and 90.2 per cent pearlite, a difference of less than 5 per cent in their contents of pearlite, a quantity too small to be estimated with satisfactory accuracy under the microscope. To sum up, the micro-test for the determination of carbon in steel, if it is to replace chemical determinations, should be applied only to steels containing less than some 0.60 per cent carbon which have been annealed as above stated. The author has found the following method to yield in some instances satisfactory results: the sample after annealing and quick polishing and etching (a few small polishing scratches will not matter) is placed under the microscope, using a 16-mm. objective and a 5X eye-piece, and its image thrown on the screen of the camera. In place of the ordinary camera screen, however, another screen is substituted of ground glass, ruled into 81 squares (9X9), so that every square covered by pearlite evidently means very nearly 0.01 per cent of carbon in the steel (exactly 0.01 per cent carbon if we assume pearlite to contain 0.81 per cent carbon). It is then sufficient to esti- mate the number of squares occupied by pearlite to arrive at the carbon content of the steel. The result may be checked by estimating the carbon in two or more dif- ferent spots and reporting the average if the agreement is sufficiently close. Physical Properties of the Constituents of Steel. It will now be timely and profitable to inquire into the physical properties of the three constituents, ferrite, cementite, and pearlite of which steel in its normal condition is composed. It will be evident that the physical properties of commercial ferrite must resemble closely those of wrought iron and of very low carbon steel. Ferrite, therefore, is very- soft, very ductile, and relatively weak, having a ductility corresponding to an elonga- tion of at least 40 per cent and a tensile strength of some 50,000 pounds per square inch. It is magnetic, has a high electric conductivity, and is deprived of 138 CHAPTER VIII MEDIUM HIGH AND HIGH CARBON STEEL hardening power, industrially speaking at least, since carbonless iron cannot be ma- terially hardened by rapid cooling from a high temperature. The properties of pearlite are evidently those of eutectoid steel in its normal, i.e. pearlitic condition, from which we may infer that pearlite has a tenacity of some 125,000 pounds per square inch, an elongation of some 10 per cent, that it is hard, and for reasons later to be explained, that it possesses maximum hardening power. With the exception of its very great hardness little is positively known as to the physical properties of cementite. It may be assumed, however, that so hard and brittle a substance must greatly lack tenacity. Its tensile strength probably does not exceed 5000 pounds per square inch and may be considerably less, while its duc- tility must be practically nil. It possesses no hardening power. These properties of the constituents of steel in its normal condition are tabulated below: CONSTITUENTS TENSILE STRENGTH LB8. PER 8Q. IN. ELONGATION % IN 2 IN. HARDNEBS HARDENING POWEH Ferrite 50,000 * 40 * Soft None Pearlite 125,000 * 10 * Hard Maximum Cementite 5000 (?) Very hard None Tenacity of Steel vs. Its Structural Composition. Knowing the physical prop- erties of the three constituents of steel, it should be possible to foretell with some degree of accuracy the physical properties of any steel of known structural com- position, on the reasonable assumption that these constituents impart to the steel their own physical properties in a degree proportional to the amounts in which they are present. The properties of steel made up for instance of 50 per cent ferrite and 50 per cent pearlite should be the means of the properties of ferrite and of pearlite. Let us assume such reasoning to be correct and let us apply it to the tensile strength first of hypo-eutectoid steel and then of hyper-eutectoid steel. The tensile strength (T) of any hypo-eutectoid steel will be expressed by the fol- lowing formula in terms of its structural composition, that is in terms of the per- centages of ferrite (F) and pearlite (P) which it contains : 50,000 F + 125,000 P T = 100 in which 50,000 represents the tensile strength of ferrite and 125,000 the strength of pearlite. Or simplifying: T = 500 F + 1250 P or again in terms of pearlite alone, since F = 100 P T = 500 (100 - P) + 1250 P or T = 50,000 + 750 P or finally in terms of carbon, since P = 120 C T = 50,000 + 90,000 C CHAPTER VIII MEDIUM HIGH AND HIGH CARBON STEEL 139 On applying this simple formula to steels containing respectively 0.10, 0.25, and 0.50 per cent carbon we find for these metals tensile strengths respectively of 59,000, 72,500, and 95,000 pounds per square inch. These values agree closely with our knowledge of the average tenacity of such steels when in a pearlitic condition, and prove the value of the formula derived from the considerations outlined above as to the relation existing between the physical properties of steel and its structural com- position. It should be borne in mind that in working out this formula it has been assumed that pearlite contains 0.834 per cent carbon. The values obtained for various hypo-eutectoid steels should be accurate only for steel in what has been termed in these chapters its normal condition, that is steel which has been worked, reheated to a high temperature, and slowly cooled. It should be noted, however, as later explained, that steel worked and finished at a fairly high temperature is practically in this so-called normal condition, so that the formula may be used, and fair results expected, to calculate the tensile strength of such hot worked steel. If the steel be worked until its temperature is quite low and, especially, if it be cold worked, it is well known that its tensile strength is generally increased. Neither can the formula be used, of course, in the case of hardened steel or of steel castings. It may, however, be applied to steel castings which have been properly annealed, when the tensile strength may be brought up to the level of steel forgings finished fairly hot as explained in another chapter. Again the formula is of value only in case of commercial steels containing the usual proportions of impurities especially of manganese. It applies only to steels in which the percentage of manganese varies roughly with the carbon content from some 0.20 to 0.80 per cent. The presence of a larger proportion of manganese would increase the tenacity materially. Passing to the tensile strength of hyper-eutectoid steel, our ignorance as to the tenacity of cementite does not permit the writing of a formula with the same degree of confidence. Let us assume, tentatively, however, that cementite has a tensile strength of 5000 pounds per square inch and then proceed as we did in the case of hypo-eutectoid steel. The tensile strength of any hyper-eutectoid steel may be expressed by the follow- ing formula in terms of the percentages of pearlite (P) and cementite (Cm) which it C ntainS: = 125,000 P + 5000 Cm 100 or simplifying: T = 1250 P + 50 Cm or in terms of pearlite only, since Cm = 100 P, T = 1250 P + 50 (100 - P) T = 5000 + 1200 P or since, as previously shown, P = 800 120 C ? T - 5000 + 1200 or simplifying : ^ 995,000 - 144,000 C 7 or approximately T = 142,000 - 20,600 C. 140 CHAPTER VIII MEDIUM HIGH AND HIGH CARBON STEEL Applying this formula to steels containing respectively 1.25 and 1.50 per cent carbon, we find for their respective strength 116,250 and 111,100 per square inch, which are fair values for the average tenacity of pearlitic steels of those degrees of carburization. 1 Steel of Maximum Strength. From the preceding considerations it seems evi- dent that eutectoid steel must possess maximum tensile strength since the influence of the presence of ever so small an amount of free ferrite in hypo-eutectoid steel or of free cementite in hyper-eutectoid steel must necessarily be a weakening one, be- cause of the relative weakness of free ferrite and free cementite as compared to the strength of pearlite. By most writers, on the other hand, steel of maximum tenacity is often stated to contain in the vicinity of 1 per cent carbon, that is to be slightly hyper-eutectoid. It is not clear, however, that the results upon which the statement is based were obtained in testing steel in its pearlitic condition. On the contrary it seems probable that a large number of the steels tested were in a sorbitic rather than in a pearlitic condition because of relatively quick cooling through the critical range as explained in a subsequent chapter. And while it appears that pearlitic steel must have its maxi- mum tenacity when composed entirely of pearlite, it may well be that when in a sor- bitic condition maximum strength corresponds to a higher degree of carburization, i.e. 1 per cent, because sorbite may contain and indeed often does contain more carbon than pearlite. Indeed the cases on record show that when the steels were made pearl- itic through very slow cooling maxium tenacity corresponds closely to the eutectoid composition. Arnold, for instance, tested a series of very pure carbon steel and after slow cooling in the furnace from 1000 deg. C. he found a very sharp maximum in the tenacity corresponding to 0.89 per cent carbon. On cooling these same steels in air, on the contrary, and therefore making them sorbitic, maximum tenacity corresponded to 1.20 per cent carbon. Harbord likewise ascertained the tenacity of very pure steels and found after slow cooling (in the furnace) from 900 deg. C that the maxi- mum tenacity corresponded to 0.947 per cent carbon. 1 Empirical formulas have often been suggested to express the relation between the tenacity of steel and its carbon content. Deshayes proposed for unannealed steel T = 30.09 + 18.05 C + 36.11 C 2 Thurston (minimum values) for unannealed steel T =42.32 + 49.37 C and for annealed steel T= 35.27 + 42.32 C Bauschinger for Bessemer steel T = 43.64 (1 +C 2 ) Weyrauch (minimum values) T = 44.17 (1 + C) Salom (average values) T = 31.74 + 70.53 C The above formulas express the tenacity in kilograms per square millimeter. Campbell, for acid open hearth steel, gives T = 40,000 + 1000 C + 1000 P + xMn + R and for basic open hearth steel T = 41,500 + 770 C + 1000 P + yMn + R in which x and y are values given in a table and dependent upon the percentage of manganese and of carbon present. R is a. variable to allow for heat treatment. CHAPTER VIII MEDIUM HIGH AND HIGH CARBON STEEL 141 Ductility of Steel vs. Its Structural Composition. From the known ductility, as expressed by its elongation under tension, of ferrite and the known elongation of pearlite, respectively 40 and 10 per cent in two inches, it should be possible to work out a formula expressing the ductility of any hypo-eutectoid steel in the annealed (pearlitic) condition. In terms of ferrite and pearlite the ductility should be 40 F + 10 P D = 100 or simplifying : D = .4F + .IP or in terms of pearlite alone since F = 100 P D = .4 (100 - P) + .1 P = 40 - .3 P and since P = 120 C, the ductility in terms of carbon will be D = 40 - 36 C Pearlitic steels for instance containing 0.25 and 0.50 per cent carbon should have elongations respectively of 31 and 22 per cent. 1 a eo -K 24 sea 30 CO Fig. 155. Diagram showing the relation between the tenacity and ductility of annealed (pearlitic) steels and the carbon content. 1 It is interesting to compare this formula with some others that have been proposed. Howe gives for the elongation in 8 inches of steel under 0.50 per cent carbon D = 33 -60 (C 2 +0.1) and for steel between 0.50 and 1.00 per cent carbon: D = 12 -11.9-v/C -0.5 Deshayes for the elongation in S inches, gives D = 42 -56C and for the elongation in 4 inches D = 35 -30C These formulas give lower values for the elongation of steel than the author's formula, but all indi- cations point to the fact that they refer to steel in a rather sorbitic condition and, therefore more tenacious and less ductile, whereas the formula here suggested is for truly pearlitic steel only. 142 CHAPTER VIII MEDIUM HIGH AND HIGH CARBON STEEL Diagram Showing the Relation between the Tenacity and Ductility of Steel and Its Carbon Content. By plotting the formulas suggested in this chapter to express the relation between the carbon content of steel and its tenacity and ductility the curves of Figure 155 are obtained. To the tenacity and ductility curves a third curve has been added showing the variation of the amount of pearlite with the carbon content. CHAPTER IX IMPURITIES IN STEEL Metallic Impurities. Commercial grades of steel always contain, besides carbon, varying amounts of silicon, phosphorus, sulphur, and manganese, often an appreciable proportion of copper and traces at least of many other metals and metalloids. These may be called the metallic impurities. Sulphur, however, is sometimes classified as a non-metallic impurity as later explained. Non-Metallic or Oxidized Impurities. Non-metallic or oxidized impurities, chiefly oxides, sulphides, and silicates of iron and manganese, are also frequently found in steel, principally through the retention by the metal of some of the slag produced during the refining operation. Hibbard has recently suggested the name of "sonims" for this class of impurities. They are also known as slag "enclosures" or "inclusions." Metallic vs. Non-Metallic Impurities. There is a sharp distinction between the behavior of metallic and non-metallic impurities, the former, with the exception of sulphur, forming true alloys with the contaminated metal, the latter being merely inclusions, their union with the metal being purely mechanical. Gaseous Impurities. Steel always contains some gases, apparently held in solu- tion and called "occluded" gases, chiefly hydrogen, nitrogen, and carbon monoxide (CO). Impurities vs. Physical Properties of Steel. It is well known that surprisingly small proportions of some of the metallic impurities just mentioned have a very marked influence upon the physical properties of steel. Some 0.2 per cent phosphorus, for instance, renders many grades of steel so brittle as to unfit them for most com- mercial uses. And as it is logical to suppose that there exists a very close relation between the structure of a metal and its physical characteristics, we naturally ex- pect to find important structural changes corresponding to marked alterations of physical properties. We should expect, for instance, the structure of a high phos- phorus, brittle steel to be quite different from the structure of a low phosphorus, tough steel of otherwise identical composition. In the present state of metallography the microscope does not always reveal such differences of structures as we are led to look for. We may reasonably anticipate, however, that, as the science progresses, structural differences will be detected of a magnitude fairly in keeping with the deep changes of physical properties brought about by slight changes of chemical composi- tion. Indeed in recent years material advance has been made in this direction and the influence of the usual impurities upon the properties of steel has been on the whole satisfactorily accounted for by metallographic methods as will be apparent from the description which follows. Silicon in Steel. All grades of steel contain a trace at least of silicon (Si) and occasionally as much as 0.5 per cent, and even more, most grades containing between 0.05 and 0.3 per cent. 143 144 CHAPTER IX IMPURITIES IN STEEL When present in such small proportion silicon is entirely dissolved in the iron with which it forms a solid solution. 1 It is probable, however, that it is not held in solution by the iron in its elementary condition, Si, but rather as a silicide of iron, FeSi. 2 Since the atomic weight of iron is 56 and that of silicon 28 it will be evident that 28 parts by weight of silicon produces 56 + 28 or 84 parts by weight of FeSi, or / ft -d \ that silicon produces exactly 3 times its own weight of FeSi ( - = 3 ) . For instance \28 / 0.1 per cent silicon in the steel will give rise to the formation of 0.3 per cent of FeSi and this small amount of iron silicide will be held in solid solution by the iron. The ferrite of commercial steel, therefore, always contains a small amount of silicon in the form of an iron silicide, and let it be borne in mind that this applies to the ferrite forming part of the pearlite of all slowly cooled steels as well as to the free ferrite of hypo-eutectoid steel. It has been stated in another chapter that when an impurity forms a solid solution with the contaminated metal, changes of crystalline forms are not generally ob- served. This is true in the present case for there is apparently no structural difference between a steel with some 0.3 or 0.4 per cent silicon and a steel nearly free from that element but otherwise of identical composition. The presence of silicon in steel can- not as yet be satisfactorily detected, even qualitatively, by metallographic methods, although we have the unquestionably accurate statement of Le Chat flier that silicon causes ferrite to etch more slowly. In view of the similarity of structure between steel containing much silicon (i.e. several tenths of 1 per cent) and steel practically free from it, we should expect that the presence of a small amount of silicon cannot affect materially the properties of steel, and this we know to be the case. Phosphorus in Steel. Steel of satisfactory quality contains from a trace to 0.1 per cent of phosphorus (P) . As in the case of silicon this small amount of phosphorus is held in solid solution by the iron, not, however, in the elementary state, P, but as the phosphide of iron Fe 3 P. The atomic weight of iron being 56, that of phosphorus 31, and the phosphide containing three atoms of iron for each atom of phosphorus, it will be obvious that 31 parts by weight of phosphorus will form 3 X 56 + 31 or 199 parts of the phosphide Fe 3 P, or roughly, 1 part by weight of phosphorus will give rise to the formation of 6 parts of phosphide. For instance, the presence in steel of 0.05 per cent phosphorus results in the formation of 0.3 per cent of Fe 3 P held in solid solution by the ferrite, this being true of the ferrite included in the pearlite of all slowly cooled steel as well as of the free ferrite of hypo-eutectoid steel. While phosphorus in common with other metallic impurities forming solid solu- tions does not alter the crystalline form of steel, it is believed by some to have a marked tendency to enlarge the grains of the metal, which tendency would account for the well-known brittleness imparted to steel by phosphorus when present in ex- 1 Some writers believe, apparently on good ground, that in oast iron at least, a metal which gen- erally contains a considerable amount of silicon, a portion of that element crystallizes with the romentite decreasing its stability as later explained. In steel, however, the proportion of silicon present is small and if any of it dissolves in the cementite it must be in so small a quantity as to be negligible. 1 Some writers mention FeSi2 as the formula of the iron silicide present in steel but this con- tention is not well supported by experimental evidences. CHAPTER IX IMPURITIES IN STEEL 145 cess of 0.1 per cent. The brittleness caused by a large grain will be considered further in another chapter. Except for this possible enlargement of the grains, microscopical examination does not reveal the presence of the usually small percentages of phosphorus occurring in steel, unless it be segregated, although it is said by some writers that phosphorus as well as manganese causes ferrite to etch darker. The existence of portions richer in phosphorus than others may be detected by means of Stead's reagent as described in Chapter II. Sulphur in Steel. Steel of satisfactory commercial quality Thay contain from a mere trace to some 0.1 per cent sulphur, generally between 0.01 and 0.05 per cent. It is universally known that manganese and sulphur have very great reciprocal affinity so that when brought together at a high temperature they combine chem- ically with each other to form the sulphide of manganese, MnS. This is what happens Fig. 156. Manganese sulphide in steel cast- Fig. 157. Steel. Forged. Hypo-eutectoid. ings. Magnified 640 diameters. (Boylston.) Manganese sulphide in ferrite areas. Magni- fied 300 diameters. (Levy.) in steel which always contains manganese as well as sulphur. From the atomic weight of manganese, 55, and that of sulphur, 32, it will be seen that 32 parts by weight of sulphur produces 87 parts of MnS, or approximately 2J^ parts of sulphide for each part of sulphur. Steel with 0.05 per cent sulphur, for instance, will contain about 0.125 per cent of MnS, provided, of course, there is enough manganese present to satisfy the sulphur which must necessarily be so in properly made steel. The existence of the sulphide of manganese, MnS, in steel has been conclusively proven. In steel castings it occurs as rounded areas the color of which is generally described as pale or dove gray or slate color. In forgings it occurs in elongated particles, bands, or strings of the same tint, running parallel to the direction of the forging or rolling (Figs. 156 and 157). According to Le Chatelier MnS has a melting-point superior even to that of iron, solidifying, therefore, first, and the bulk of it rising to the top of the bath or ingot, the manganese is in this way helpful in removing sulphur from steel. Some writers, 146 CHAPTER IX IMPURITIES IX STEEL however, question this higher melting-point of MnS. Levy reports that the melting- point of pure MnS is probably not far from 1400 cleg. C. and, therefore, below the melting-point of hypo-eutectoid steel at least, while the presence of some FeS would lower materially its melting-point. 1 It appears probable that the solidification of tin- sulphide globules must follow and not precede that of the iron. This view seems to be supported by the location of the sulphide particles at the boundaries of the pearlite grains of eutectoid steel, in the free ferrite of hypo-eutec- toid steel or in the free cementite of hyper-eutectoid steel. What MnS is retained by the solid steel, since it occurs as shown in the shape of small individual grains or elongated particles, can only injure the metal through breaking up its continuity and, in view of the very small amount of sulphur and, therefore, of MnS, present in steel of good quality, it is evident that this breaking up and its action upon the prop- erties, must be very slight. This is in agreement with the known fact that a small amount of sulphur in steel containing also the proper amount of manganese has no appreciably injurious effect. Seeing that steel seldom contains much more than some 0.05 per cent sulphur, hence more than 0.125 per cent MnS, it is not to be expected that this compound will always be detected in polished and etched steel sections. Indeed whenever detected it points to a segregation of the sulphide together with other impurities (ghost lines) as described later. In case sulphur occurs in excess over the amount needed to form the sulphide MnS with the manganese present in the steel, the excess sulphur, that is the sulphur left over after satisfying the manganese, combines with some of the iron, forming the iron sulphide FeS. It should be noted at once, however, that it requires less than 2 parts by weight of manganese (atomic weight 55) to combine with 1 part of sulphur (atomic weight 32). In other words if the steel contains twice as much manganese as it does sulphur, this should theoretically be enough to convert the whole of the sulphur into the sulphide MnS. As it is very seldom indeed that steel does not con- tain a much larger proportion of manganese than that compared to its sulphur con- tent, the occurrence of free FeS in steel should be very rare. It is not to be expected in metal of good quality, its presence pointing to a very abnormal composition, namely, high sulphur content and very low percentage of manganese. According to Levy, however, MnS and FeS are readily soluble in each other in the solid state, MnS being capable of holding as much as 50 per cent of FeS in solid solution. Accord- ing to this writer MnS is seldom free from FeS even when the steel contains consid- erable manganese, the mass action exerted by the presence of so large a proportion of iron preventing the manganese from taking hold of the totality of the sulphur in spite of its greater affinity for it. MnS nearly free from FeS has a clear dove gray color free from yellowish tints, while its color becomes more yellowish as the proportion of FeS increases. Levy notes also that in high carbon steel the MnS areas are generally colored darker than in low carbon steel, indicating greater freedom from FeS, ap- parently owing to the fact that in high carbon steel the mass- action exerted by iron is not so great since it contains less iron. The sulphide FeS exhibits a marked tendency to form continuous envelopes or membranes surrounding each grain of pearlite (Fig. 158), and probably consisting of a 1 Rohl reports that the freezing-point of pure MnS is 1620 cleg. C. but that the compound FejMnjSs which, in his opinion, is gnu-rally the composition of the sulphide inclusions freezes at 1365 deg. C. CHAPTER IX IMPURITIES IX STEEL 147 eutectic alloy of iron and iron sulphide (the composition of the eutectic is apparently: FeS 85 per cent, Fe 15 per cent). These membranes being weak and brittle impart weakness and brittleness to the steel. The well-known red-shortness caused by sul- phur in the absence of a sufficient amount of manganese (to form MnS) is probably due to the low melting-point (950 deg. C. according to some writers) of this iron- iron sulphide eutectic. At a high temperature the melting of this eutectic destroys the cohesion between the grains of the metal resulting in cracks being developed dur- ing the process of forging or rolling, and in extreme cases in the metal actually break- ing into several pieces. The presence of a large amount of FeS in some Bessemer steel at the end of the blow, before the addition of manganese, is undoubtedly largely responsible for the marked red-shortness of the metal at this stage of the operation. Under the microscope FeS appears yellow or pale brown. Fig. 158. Red-short steel. Magnified 300 diameters. Sulphur 0.54 per cent. Unetched. Network of FeS. (Ziegler.) The following is quoted from Stead: "The researches of Rohl have' demonstrated beyond doubt that ferrous and manganese sulphides crystallize together in the proportions of 60 per cent FeS and 40 per cent MnS = Fe 3 Mn 2 S5 and in mixtures containing increasing quantities of manga- nese sulphide up to 100 per cent, forming homogeneous isomorphous compounds of FesMnoSs all of which under the microscope have the same appearance. Levy and Law, however, state that the homogeneous substance which contains the most FeS is lighter in color than that containing less. When the FeS exceeds 60 per cent in the mixture a eutectic consisting of 7 per cent MnS and 93 per cent FeS appears, having a freezing point of 1181 deg. C. When iron in excess is present in addition to an excess of FeS over the mixture FesMnzSs, a ter- nary eutectic is formed freezing at 980 deg. Rohl found the freezing point of pure MnS to be 1620 deg., or about 120 deg. higher than that of pure iron, and the freezing point of the compound Fe.,Mn,S 5 , 1365 deg. Judging from these most valuable researches, it may be accepted beyond any doubt that when iron sulphide, and what appears to be manganese sulphide, are found associated together in the same sulphide inclusions what looks like MnS is not that compound but is Fe 3 Mn 2 S5." It has been contended by some that a portion of the sulphur present in steel and cast iron is dissolved in the cementite and that its presence increases the stability of that constituent. It seems probable, however, in view of the very small amount of sulphur generally present in steel and of the relatively large amount of manganese 148 CHAPTER IX IMPURITIES IN STEEL that this possible contamination of cementite by sulphur, if it occurs at all, may be neglected. This has been done in the present chapter, it having been assumed that the totality of the sulphur is present as MnS or as MnS and FeS in the form of mechanical inclusions. Sulphur Printing. As explained in Chapter II the presence of sulphur in steel and iron, especially when segregated, may sometimes be detected by the taking of so-called "sulphur prints." Manganese in Steel. It has been seen that manganese combines readily with sulphur and that the resulting manganese sulphide, MnS, either alone or combined with some FeS, can be detected in polished steel sections as a pale or dove gray con- stituent assuming the shape of rounded areas in castings and of bands or threads in forgings. Manganese silicate is also occasionally found in steel as later explained and may sometimes be mistaken for MnS. Satisfactory tests for the distinction of these two constituents will be described. When manganese occurs in excess over the amount required to form MnS with the totality of the sulphur present, as is almost universally the case, the manganese in excess combines with some of the carbon to form the carbide of manganese, Mn 3 C, and this carbide is found associated with the iron carbide, Fe 3 C, in cementite. The cementite of commercial steel, therefore, is seldom a pure iron carbide, containing on the contrary varying amounts of Mn 3 C. Since iron and manganese have practi- cally the same atomic weight, however (55 and 56 respectively), it remains practically true that carbon forms 15 times its own weight of cementite, even when the latter contains a large proportion of Mn 3 C. There is no metallographic test by which cementite free from manganese can be distinguished from cementite rich in Mn 3 C. Some authors mention the possible presence of the manganese silicide, MnSi, in steel, while solid solution between manganese and iron is frequently referred to. While manganese and iron (ferrite) undoubtedly form solid solutions, it does not seem likely that these are produced when manganese is present in small proportion, say not over 1 per cent. In that case it seems more probable that manganese is found in the two forms described above, (1) as a manganese sulphide MnS, containing prac- tically the totality of the sulphur in steel of good quality, that is, containing not over 0.05 per cent sulphur and not less than 0.25 per cent manganese and (2) as the man- ganese carbide Mn 3 C, associated with Fe 3 C in cementite. Chemical vs. Structural Composition. Knowing the probable chemical forms of the five metallic impurities always present in steel, carbon, silicon, phosphorus, sul- phur, and manganese, as well as their structural associations, it will be interesting and profitable to consider accordingly the proximate chemical composition as well as the ultimate and proximate structural compositions of a steel of known ultimate chemical composition. Let us assume a steel of the following ultimate chemical composition : c 0.50 per cent Mn 0.80 " " S 0.05 " " P 0.04 " " Si 0.10 " " Fe (by diff.) 98.51 100.00 CHAPTER IX IMPURITIES IX STEEL 149 Bearing in mind the atomic weights of these elements (Fe, 56; C, 12; Mn, 55; S, 32; P, 31; Si, 28) and the formulas of the chemical compounds formed (MnS, FeSi, Fe 3 P, Mn 3 C, Fe 3 C), it will be readily seen that: (1) 0.05 per cent S will give rise to the formation of 0.13 per cent MnS. (2) 0.13 per cent MnS contains about 0.08 per cent Mn. (3) This leaves 0.80 0.08 = 0.72 per cent manganese in excess to combine with C. (4) 0.72 per cent Mn will form 0.77 per cent Mn 3 C. (5) 0.77 per cent Mn 3 C contains about 0.05 per cent carbon.. (6) This leaves 0.50 0.05 = 0.45 carbon to combine with iron. (7) 0.45 per cent carbon results in the formation of 6.75 per cent of Fe 3 C. (8) 0.04 per cent of P corresponds to about 0.25 per cent of Fe 3 P. (9) 0.10 per cent Si gives 0.30 per cent FeSi. The proximate chemical composition of the steel considered will be Fe 3 C 6.75 per cent Mn 3 C 0.77 " " Fe 3 P 0.25 " " FeSi 0.30 " " MnS 0.13 " " Fe (by diff.) 91.80 " " 100.00 As to the ultimate structural composition of the steel, we know that the cemen- tite contains the Fe 3 C and the Mn 3 C hence we have 6.75 + 0.77 = 7.52 per cent cementite. In pure steel the percentage of cementite would have been 0.50 X 15 = 7.50 per cent. The slight difference between the two numbers is due to the presence of manganese in the commercial steel, and to a slight difference between the atomic weights of manganese and that of iron (55 compared to 56), a difference so slight that for all practical purposes we may assume that in commercial steels as well as in pure steel the percentage of carbon multiplied by 15 gives the amount of cementite formed. The total ferrite present in this steel contains all the free iron, as well as the small proportions of Fe 3 P and FeSi present, hence this steel contains 91.80 + 0.25 + 0.30 = 92.35 total ferrite. In pure steel the proportion of total ferrite would have been 100 7.50 or 92.50 per cent. The difference between the two values is evi- dently due to the presence of a trifle greater amount of cementite, and to the presence of 0.13 per cent MnS. The ultimate structural composition of the steel under consideration is, there- Total ferrite 92.35 Cementite 7.52 MnS 0.13 100.00 Finally its proximate structural composition will be, since the pearlite of hypo- eutectoid steel contains 8 times the weight of total cementite (assuming the euter- toid carbon point to be 0.834 per cent) : Pearlite 7.52 X 8 = 60.16 Free ferrite (by diff.) 39.71 MnS .13 100.00 150 CHAPTER IX IMPURITIES IN. STEEL Ignoring the presence of impurities the quick method described in Chapter VIII would have given pearlite 60 per cent, ferrite 40 per cent, i.e. values which may be considered identical for any practical purposes. It follows from this that in calcu- lating the structural composition of any carbon steel of ordinary commercial quality the presence of the impurities need not be considered; the steel may be treated as if it was made exclusively of iron and carbon. The relation between chemical and structural compositions, both ultimate and proximate, is further shown in the following table. CHEMICAL COMPOSITION STRUCTURAL TOM POSITION ULTIMATE PROXIMATE ULTIMATE PROXIMATE % Fe(by cliff.) 98.51 Si 0.10 P 0.04 C O.rtO Mn 0.80 S 0.05 % Fe(bydiff.)91.80] FeSi 0.30 [ Fe 3 P 0.25 1 Fe 8 C 6.75 \ MnsC 0.77 j MnS 0.13 % % ( Free Ferrite 39.71 Free Total Ferrite 92.35 | Ferrite ( Pearlite Ferrite 52.64 1 00.16% Pear- Cementite 7.52 J lite MnS 0.13 0.13 100.00 100.00 100.00 100.00 Non-Metallic or Oxidized Impurities. As already mentioned steel generally contains varying amounts of non-metallic, oxidized impurities frequently called slag "enclosures," or "inclusions," while Hibbard proposed for them the name of "sonim," in which "so" stands for solid, "n" for non-metallic and "im" for impurities. They consist chiefly of iron and manganese oxides and silicate although the sulphides of iron and manganese are generally considered also as slag enclosures. These impur- ities are derived mainly (1) from the retention by the metal of minute particles of the slag formed during the process of manufacture, (2) from small pieces of refractory materials detached from the linings of furnaces and ladles, and (3) from the reaction- products resulting from the introduction of recarburizers or other additions. According to Hibbard the formation of slag enclosures is due almost entirely to the "washing" action of the additions, principally of manganese, in combining with the dissolved oxides, sulphides, and silicates which are present in the steel at the end of the melting process before the manganese is added since enclosures rich in manga- nese must necessarily have formed after the addition of that constituent. Stead on the other hand expresses the belief that the silicate enclosures at all events are due to oxidation of manganese and silicon occurring during the passage of the molten steel through the air in passing from the ladle into the molds. In the case of iron oxide it seems probable that minute particles of it remain in suspension in the molten steel forming as many minute inclusions after solidification, while another portion, dissolved in the liquid metal, is in part precipitated during solidification. In Rosenhain's opinion it is not proven that the sulphides and silicates are not soluble in molten steel. After solidification the association between the slag enclosures and the steel re- mains a purely mechanical one; they commonly occur as rounded or elongated par- ticles embedded in the metal. CHAPTER IX IMPURITIES IX STEEL 151 MnS can generally be readily distinguished from other inclusions because of its characteristic dove gray color, its globular shape in castings (Fig. 156) and, owing to its plasticity, the ease with which it is elongated in forgings (Fig. 157). It seems reasonable to assume that the paler its color the greater its purity, and that a yellowish tint points to the presence of some FeS. Pure FeS, a very rare constituent of steel, has a decidedly yellow color and is more brittle. MnS generally occurs in the free fer- rite of hypo-eutectoid steel, between the pearlite grains of eutectoid steel or in the free cementite of hyper-eutectoid steel. Silicates are decidedly darker than MnS (Figs. 159 and 160) which affords a means of distinguishing between them even when they are associated in the same particles as it sometimes happens (Fig. 159). Silicates because of their relative brittleness are . Fig. 159. Manganese sulphide (light constituent) and manganese sili- cate in steel. Magnified 1000 diameters. (Law.) frequently broken and torn by the forging operation (Fig. 160). Sometimes the man- ganese sulphide forms dendrites embedded in a silicate matrix. Stead recommends the placing of a drop of sulphuric acid on the polished speci- men, when H 2 S gas will be evolved where MnS is present, particles of silicates of manganese, on the contrary, evolving no gas. The dissolving of MnS also leaves pits. Stead also advises heat tinting as the best means of distinguishing between the sul- phide and the silicate, the heating to be continued until the specimen has assumed a light brown coloration, when the MnS remaining bright can be sharply differen- tiated from the silicate. No very satisfactory metallographic tests have so far been found to distinguish between oxides and silicates or between iron silicate and manganese silicate. Mat- weieff's attempts in that direction have been described in Chapter VI. They are summed up by Rosenhain as follows: "According to their behavior under these reagents (hydrogen and superheated steam), the enclosures may be divided into three groups or classes. 152 CHAPTER IX IMPURITIES IN STEEL "A. Stable bodies which are not acted upon either by hydrogen at 300 C, by superheated steam, or by weak organic acids. These are the silicates of iron and manganese. "B. Bodies which are reduced to the metallic state by the action of hydrogen at 300 C and are acted upon by steam but are unaffected by weak organic acids. These Fig. 160. Manganese sulphide (light constituent) and iron silicate in mild steel. Unetched. Magnified 1000 diameters. (Law.) Fig. 161. Ghost lines in low carbon steel. Magnified 95 diameters. (Boylston.) are the oxides of iron and manganese. Oxide of manganese is not reduced by hy- drogen when by itself, but in the presence of iron oxide reduction of both metals takes place. On re-polishing a sample after heating in hydrogen, the regions previously occupied by oxides appear as bright metal, like the ferrite of the surrounding iron or steel, but the presence of manganese may be detected by etching with very dilute CHAPTER IX IMPURITIES IN STEEL 153 alcoholic solution of ferric chloride. Iron free from manganese is only very slightly colored, but if manganese is present, the reagent produces rapid coloration. "C. Not affected by hydrogen or steam, but attacked by weak organic acids (such as tartaric acid). These are the sulphides of iron and manganese; the former is rapidly colored by this acid while sulphide of manganese is only slowly attacked. The behavior of the sulphides which are mixtures or solid solutions of the iron and manganese sulphides is not considered by Matweieff, but in the light of the work of Levy these mixed sulphides require particular study from this^ point of view." Rosenhain rightly adds that the use of gaseous reagents at moderately high temperatures is a somewhat cumbrous manipulation, particularly because, if general tarnishing of the polished specimens is to be avoided, the hydrogen must be specially Fig. 162. Ghost lines in low carbon steel. Magnified 2000 diameters. Manganese sulphide and pearlite particles. (Law.) purified. It is to be hoped, therefore, that future research may yet find simpler means of identifying these substances. At the end of the refining operation by which steel is produced, especially towards the latter part of the Bessemer blow, a considerable amount of iron oxide is formed and in spite of the steps taken for removing it from the bath (addition of manganese, etc.) some of it, occasionally quite a little, is retained by the metal, when it is a source of red-shortness besides having other detrimental effects. This iron oxide generally occurs as small dark points visible in the polished section before etching. Segregation of Impurities. Ghosts. The very small proportions of impurities generally found in steel of good quality have little, if any, injurious effect upon its most important and useful physical properties, so long as they remain uniformly distributed throughout the metallic mass, i.e. so long as the steel is chemically homo- geneous. These impurities, on the contrary, may become extremely injurious when they show a tendency to "segregate," i.e. to collect in certain portion or portions of steel castings and forgings, when the segregated portions may contain so large an 154 CHAPTER IX IMPURITIES IN STEEL amount of impurities as to have their useful properties utterly destroyed. Segre- gated metal is generally brittle, weak, and hard. Under the microscope a metal suffering from this segregation of impurities gen- erally is found to contain bands of varying widths and lengths, technically known as Fig. 163. Ghost lines in low carbon steel. Magnified 10 diameters. (Law.) -^5r!^w^?< -%^%. :? ? 5 *% "3 - ^rO? J "/ *.'*?. it^V K "'^- &tLf^^-l-%fS^^- ; ^%f4^^%4?^ ^r ^g? .- . V'rsL. .-"'- '~ - ' " Fig. 164. Ghost lines in low carbon steel. Magnified 200 diameters. (Law.) "ghosts" or "ghost lines," in which the presence of abnormally large proportions of MnS and phosphorus can generally be detected by the ordinary metallographic tests. Photomicrographs of ghost lines are shown in Figures 161 to 167. Ghost lines etch more rapidly than the surrounding metal therefore appearing darker after etching even CHAPTER IX IMPURITIES IN STEEL 155 to the naked eye. These lines can generally be detected before etching because of the manganese sulphide which they contain. Stead describes "ghost lines" as lines of ferrite in which are embedded lenticullar particles of drawn out sulphide inclusions and he adds that when manganese sulphide is found segregated it may be taken for granted that phosphorus also is segregated in the same regions. He believes that the white ferrite lines sometimes observed in forgings arc due to phosphorus segregation, the presence of that element having ex- pelled the carbon on slow cooling. He writes that the higher the. phosphorus in the steel the thicker and more pronounced are these white carbonless lines in forged A B Fig. 105. Forged steel containing about 0.3 per cent carbon and 0.3 per cent phosphorus. A. Polished and etched in the ordinary way. B. Heat-tinted until the phospho-ferrite bands are oxidized to a brown tint. (Stead.) steels. In Figure 165 Stead shows the effect of heat tinting specimens exhibiting these ferrite bands. Stead's cupric reagent (Chapter II) is also very effective in revealing the existence of ferrite bands rich in phosphorus. The lighter portions contain the most phos- phorus, copper being precipitated on the portions freer from that element. Rosenhain and Haughton likewise bring out clearly the banded structure of cer- tain steels by the electro-chemical deposition of copper from a solution of ferric chloride and hydrochloric acid containing a small amount of copper chloride. This reagent, Rosenhain writes, develops the banded structure of steel containing phos- phorus in a striking manner, as illustrated in Figure 166. Figure 167 shows another typical instance of a banded structure. Rosenhain accepting Ziegler's view that the particles of slag enclosures act as so many nuclei for the crystallization of ferrite in hypo-eutectoid steel and of cementite 156 CHAPTER IX IMPURITIES IN STEEL in hyper-eutectoid steel argues that the "banded" structure of some forged steels may be accounted for through the crystallizing of ferrite around strings of enclosures formed by the rolling operation. He writes: "Again we commonly find in commercial steel a banded arrangement of ferrite and pearlite, such as that shown in Figure 167 and although this is obviously traceable to the rolling process which the steel has undergone, the banded structure is extremely persistent in spite of repeated anneal- ing. If we consider that the enclosures present in the steel have been rolled out into long lines, and that each time the steel cools down through Ar, the ferrite tends to deposit upon these lines of enclosures, the persistent recurrence of these bands is explained. Heat treatment could, in that case, only destroy these bands if time enough were allowed for the gradual migration of the enclosures at a high tempera- Fig. 166. Banded structure in steel containing phosphorus. (Rosen- hain.) V %^*^ ~ F ^?^v *c <^ ^ j> f _^r > - - Tf % *- - :^S^ ^>V v fr$ f^ir\ ^* -+ S.J^* < ^or * s>* ^Jfir^*~& CTA jc---^"-. ** "^ :*? ^-.^~^. **^%/ ^r r Fig. 167. Banded structure in steel. Magnified 100 diameters. (L. T. Holt, Correspondence Course student.) ture and very prolonged annealing does break up the banded structure. The oc- currence and persistence of the comparatively wide carbonless bands, studded with enclosures, which are sometimes termed 'ghosts' may be accounted for in a similar way by the original rolling out into a long band of an austenite boundary containing a comparatively large mass of enclosure." Rosenhain would account as follows for the persistence of ferrite bands rich in phosphorus: "In the case of steel, phosphorus occurs typically in this way, being present in solid solution in the ferrite of the ingot, but in the form of solid-solution cores, so that the phosphorus content of each crystal increases from its center to its periphery. When rolled out, these crystal cores assume the form of elongated masses, and although the ferrite itself undergoes complete re-crystallization, possibly re- peatedly, there is nothing to cause the phosphorus to migrate except the process of diffusion, which is particularly slow in that case. The result is that in the finished material the phosphorus-rich ferrite still remains in long bands or streaks, and these CHAPTER IX IMPURITIES IN STEEL 157 bands pass indifferently through numbers of individual crystals indeed, an indi- vidual crystal may lie partly within and partly outside one of these bands the growing ferrite crystal has simply used the material it found at hand, whether rich in phosphorus or not." Gaseous Impurities. It has not been possible so far to detect the presence of occluded gases in steel by means of metallographic methods. While the problem seems a very difficult one to solve, the statement that it can never be solved would not be justified for the discovery of some metallographic treatment by which a metal rich in certain gases may be distinguished from a similar metal free from them is well within the limits of reasonable expectation. CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL THEIR OCCURRENCE The structure of steel described in the preceding chapter, i.e. its normal structure, is greatly affected by the treatment or treatments, both mechanical and thermal, to which the metal may be subjected during the process of manufacture of finished objects. It is to the close relation existing between the treatment and the structure on the one hand, and between the structure and the physical properties of the metal on the other, that metallography owes its industrial importance. It is essential, therefore, that the student should have a clear understanding of these relations. As a preparation to this important study, however, it will be necessary to describe a phenomenon of the greatest moment in the treatment of steel, namely, the occurrence of spontaneous absorptions or evolutions of heat during the heating or cooling of the metal. These are generally termed the "thermal" critical points or simply "critical points," also "retardations," "transformation" points, and "critical tem- peratures." Point of Recalescence. If a piece of steel containing some 0.60 per cent carbon be heated to a high temperature, say to 1000 dog. C., and allowed to cool slowly from that temperature, and if its rate of cooling be carefully ascertained, conveniently by means of a Le Chatelier pyrometer, it is found that the cooling proceeds at first at a nearly uniformly retarded rate. If, for instance, it requires 10 seconds for the metal to cool through the first five degrees (from 1000 to 995 deg.), and 12 seconds to cool through the next five degrees (995 to 990 deg.), it will require some 14 seconds for the next five degrees, 16 seconds for the following five, and so on, the cooling through each range of five degrees being a little slower than the preceding cooling of five degrees. All cooling bodies, whatever their nature, generally follow this law. The plotting of time and temperature as coordinates yields smooth curves, sometimes approaching straight lines (see curve B, Fig. 177). In the case of the steel we are now considering, when a certain temperature is reached, in the majority of cases some 675 to 725 deg. C., a most interesting and significant phenomenon takes place ; the cooling of the metal is momentarily arrested, the pyrometer, for a certain length of time, failing to record any further fall of tem- perature. Indeed, when the circumstances are favorable, the temperature of the cooling mass actually rises; the metal becomes visibly hotter; it "recalesces," hence the name of "recalescence" given to this thermal critical point. If the experiment be conducted in a dark room, this recalescence or spontaneous glow of the steel is plainly visible. After a while the metal resumes its normal rate of cooling which is then continued down to atmospheric temperature. It is evident that at this critical point the surrounding atmosphere does not cease 1.58 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 159 to abstract heat from the piece of steel and, since its temperature nevertheless re- mains stationary or even rises, it must be that heat is here spontaneously generated within the metal in amount sufficient to make up, or more than make up, for the heat lost by radiation and conductivity. In heating, as might be expected, the reverse phenomenon takes place: an absorp- tion of heat causing a retardation in the rise of the temperature, or even a momentary stop, the pyrometer failing for a few moments to record any further increase of temperature or recording only an abnormally low increase, although heat continues to be applied to the steel at the same speed. Actual lowering of the temperature of the steel is not generally observed at this critical point on heating, i.e. the steel does not grow perceptibly colder. Notation. Osmond, who was the first to determine accurately the position and magnitude of the point of recalescence and who is the discoverer of the upper critical points soon to be described, adopted Tschernoff s previous notations, and designated the critical points by the letter A. 1 To distinguish critical points on cooling from those occurring on heating the former are called Ar (from the French refraidissement, meaning cooling) and the latter Ac (from the French chauffage, heating). To dis- tinguish further between the point of recalescence and its reversal on heating on the one hand, and critical points occurring at higher temperatures on the other, the nota- tions Ari and Aci are used for the recalescence point and its reversal, and Ar 2 , Ac 2 , Ar 3 , Ac 3 , for the two upper reversible critical points soon to be described. The nota- tions Ai, A 2 , A 3 , are frequently used when the points and their reversals are consid- ered collectively. By the notation AI, for instance, is meant the point of recalescence Ari and its reversal Aci. These notations will be used in these chapters. Brinell, in his important work on the heat treatment of steel, used the letter V for the point of recalescence and W for its reversal on heating. These symbols, however, are now very seldom used. The expression "point of recalescence" is frequently used indifferently for the point on cooling, where heat is evolved causing a recalescence of the metal, and for the reverse phenomenon on heating, at Aci, where, of course instead of a recalescence taking place, an absorption of heat occurs causing the metal to lose heat. It is ob- vious that the term "recalescence" should not be applied to the point Aci. The point of recalescence is also called sometimes " recalescent " point and, seldom, "Gore's phe- nomenon" (see Historical Sketch at end of chapter). The point Aci has been called point of " decalescence " by some writers and one of them at least refers to it as the "calescence" point. Critical Range. Transformation Range. When the various critical points oc- curring in steel are considered collectively the range of temperature they cover is frequently called the "critical range," or, more seldom, but very appropriately, the "transformation range." It will soon be shown that the critical range may include one, two, or three critical points. The meaning of the expressions "critical range on heating" and "critical range on cooling" is obvious. Positions of Ari and Aci. The critical points Ari and Aci do not occur at ex- actly the same temperature, Aci being generally situated some 20 to 40 deg. higher than Ari. When the point Ari, for instance, is found at 690 deg. C., the point Aci will generally occur somewhere between 710 and 730 degrees. 1 The point A of Tschevnoff indicated the temperature at which steel suddenly acquires harden- ing properties on heating or loses them on cooling. 100 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL Stead submitted samples of very pure steel containing 0.9 per cent carbon to 16 well-known investigators with the request that they ascertain the Aci and Ari points. The reported results indicated for Aci temperatures varying between 719 and 740 deg., and for Ari temperatures between 097 and 721. This apparently great dis- crepancy may be accounted for in part at least by the influence of the rate of heating and cooling on the positions of Aci and Ari respectively, as later noted, and by the influence of the temperature from which cooling starts on the position of Ari. Unless standard conditions are maintained in regard to rate of heating and cooling, tem- perature from which cooling begins and length of time at that temperature, very close agreement between various investigators is not to be expected. It is also essential that the temperatures recorded should correspond to exactly the same stage of the critical point, namely its beginning or its apex. Howe argues that the beginning of Ari and Aci should be taken as indicating the position of these points on the ground that the beginning of the transformation is less affected by lag. Rosenhain, on the contrary, and his views are shared by the author, contends that the peaks should be read since they represent the temperatures at which the bulk of the specimen undergoes transformation. In commercially pure carbon steels Ari almost always occurs between 690 and 720 deg. and Aci some 20 to 40 deg. higher. The fact that the critical point on cooling lags behind the point on heating and vice versa, is evidently a case of hysteresis so often observed in physical phenomena and which implies a resistance of certain bodies to undergo a certain transformation, when theoretically the transformation is due, the delayed transformation finally taking place with added violence. This was vividly depicted by Howe some twenty years ago in the case of iron. He wrote : "Just as we can cool water below its freezing-point without completely freezing it, thereby rapidly increasing the strength with which the water tends to freeze, so by a relatively rapid cooling we can carry the metal considerably below Ari, without giv- ing the Ar x change time to proceed far, strengthening the while the tendency toward this change, which keeps kindling more and more till it bursts into a blaze, with such evolution of heat as actually to recalesce, to raise the temperature of the metal by some 10 deg., in spite of the continued abstraction of heat by the continued cooling of the furnace." The slower the heating and cooling the nearer will the two points approach each other, so that with infinitely slow cooling and heating they would undoubtedly occur at exactly the same temperature. If there remained any doubt as to the points Aci and Ari representing the opposite phases of the same phenomenon, i.e. of A being a reversible point, it would suffice to dispel it to consider the fact that in order to induce the retardation Ar t the steel must first be heated past the point Aci; and re- ciprocally the retardation Ac t cannot take place unless the metal has first been cooled to a point below Ari. To illustrate : the melting of ice and the freezing of water are undoubtedly the opposite phases of the same phenomenon, each one undoes the work of the other, and in order to freeze the water we must first melt the ice and likewise to melt the ice the water must first be frozen; one change cannot, be induced unless the opposite one has last taken place. Indeed it is possible through very slow and undisturbed cooling to lower the temperature of water below its freezing-point before it starts freezing, a clear instance of hysteresis, although in this case called "surfusion," and when freezing takes place the temperature of the water rises to its normal freezing-point, a clear case of recalescence although deprived of glow. CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 161 The diagram shown in Figure 168 illustrates further this reversibility of the point AI. Let two parallel lines represent the phases Ac and Ar of the critical point. Let condition A represent the state of the metal stable above Ac and condition B the state of the metal stable below Ar. The gap between Ac and Ar is due to hysteresis. MN is the temperature at which both the Ac point and the Ar point would occur if there was no hysteresis as, for instance, if the metal could be heated and cooled in- finitely slowly. Assuming the metal to be in condition B at a, below Ar, on heating it from a to b above Ac on reaching the Ac point at x it passes from_the condition B to the condition A with absorption of heat causing a retardation in the heating; on cooling from b to c, that is to a temperature below Ac but above Ar, the condition A is retained so that upon heating from c to d no transformation can take place at x' Cond/f/on A M- -/v A, due fo /-/ysferes/s Cone// f / on 168. Diagram showing reversible critical point. on passing through the Ac point and therefore no critical point observed. If the metal be cooled from d to e, however, on passing through Ar at y it changes from condition A to condition B with evolution of heat, causing a retardation in the rate of cooling; if it now be heated again from e to/ above Ac, a critical point will be ob- served at x" since the metal now in condition B will pass to condition A. It will be evident that between Ar and Ac the metal may be in condition A or condition B depending upon whether it was last cooled from above Ac or heated from below Ar. Howe uses the notation Aei for the equilibrium temperature for AI that is, for the temperature at which the transformation Ar! and its reversal, Aci, would both take place, the former on cooling and the latter on heating, in the complete absence of hysteresis. From a very careful weighing of the available data Howe concludes that the position of this equilibrium temperature is probably 723 deg. C. Speed of Cooling and Heating vs. Position of A,. It has been seen that the 162 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL faster the cooling the lower is the position of the point Ar t and the faster the heating the higher the point Aci, that is, the faster the cooling and heating the greater the gap between the opposite phases Ari and Aci of the reversible point AI. The cooling of a piece of steel may be so rapid, as in quenching, as to prevent altogether the retardation Ari from taking place, because a low temperature is so quickly reached that the rigidity of the metal prevents the transformation of which Ari is a manifestation. In other words time and a certain amount of plasticity are required for the transformation Ari to occur, and in quenching time is denied when the metal is sufficiently plastic (i.e. at a red heat), while when time is given (i.e. after quenching) the metal has lost its plasticity. It remains untransformed or but par- tially transformed. It will be shown in another chapter that this suppression of the point Ar! is probably the cause of the hardening of carbon steel by sudden cooling. 1 Le Chatelier rightly reminds us that the speed of the transformations occurring at the critical points of steel follows the general laws which govern the speed of all chemical phenomena. In other words that the speed of the transformation is the greater (1) the higher the absolute temperature and (2) the wider the range between the actual temperature and the temperature of equilibrium, that is the temperature at which the transformation is due. Above the critical temperature both influences act in the same direction and the speed of transformation increases without limit. Below the critical temperature these influences act in opposite directions necessarily giving rise to the existence of a maximum speed. According to Le Chatelier this notion of variable speeds of transformation accounts for all the peculiarities of the hardening treatment. On heating it is hardly possible to raise the temperature of transformation more than 100 deg. C. through very rapid heating, while during cool- ing the speed reaches its maximum at about 600 deg. C., is very feeble below 200, and nearly null at atmospheric temperature. Temperature from which Cooling begins vs. Position of Ar!. It was first observed by Tschernoff that as the temperature to which steel is heated before being allowed to cool increases, the position of the Ari point is gradually, although slowly, lowered. This influence of what Howe calls the maximum temperature or T max , has been re- peatedly confirmed. Benedicks would explain it on the assumption that at a higher temperature a greater number of nuclei or centers of crystallization are destroyed and that the fewer nuclei left the lower the temperature at which recalescence occurs. Howe believes that the phenomenon may be further explained (1) through the steep- ening of the thermal gradient during the critical transformation caused by cooling from a higher temperature, (2). through increase of internal pressure resulting from the steepening of the thermal gradient, and (3) through a better diffusion of the pro- eutectoid element and the pearlite element, so that their re-assembling for the purpose of undergoing the transformation in cooling is more difficult. A long sojourn at a high temperature also appears to have a tendency to lower Ari, while according to Rosenhain the position of Aci is slightly raised if the previous cooling has been very slow and vice versa. Chemical Composition vs. Position of AL Generally speaking impurities have a tendency to lower the position of Aci and Ari, some of them decidedly. According to Howe manganese lowers the Ari point some 24 to 50 deg. C. for each per cent of manganese, while Osmond indicates the position of Ari in a steel con- 1 It will be explained later that some writers have doubted the suppression of the transforma- tions on rapid cooling and have suggested another explanation of the hardening of steel. CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 163 taining 1 per cent of Mn as 685 deg. whereas with 4 per cent of manganese the same point was lowered to 590 deg. It is conceivable that further increase of that element must lower still more the critical point, so that finally it may be lowered below at- mospheric temperature, being apparently eliminated. It will be shown in another chapter that this is precisely what occurs in the cases of manganese steel and high nickel steel, containing respectively some 13 per cent of manganese or some 25 per cent of nickel. These steels exhibit no retardation on cooling from a high temperature to atmospheric temperature. When cooled to lower temperatures, however, by immers- ing them in freezing mixtures or, if need be, in liquid air, the retardations may again occur, at least in the case of nickel steel. G. H. Clevenger found that 4.5 per cent copper lowers the Ari point of steel con- taining some 0.5 per cent carbon from 730 to 635 deg. C. or approximately 20 deg. for each per cent of copper. According to J. H. Andrews the absorption of 0.25 per cent of nitrogen by a steel containing 0.6 per cent carbon lowers the point Ari in a marked degree. In the case of commercial steel of good quality the proportion of impurities, with the possible exception of manganese, varies within relatively very narrow limits, so that no great variation should be expected in the position of the critical point AI. Neither is it clear that the amount of carbon present in steel haj. a marked effect upon the position of the point AI, although some writers state that the point is lifted as the carbon increases. As previously stated in pure carbon steel the point Ari al- most invariably occurs somewhere between 690 and 720 deg. C. and its reversal Ad 20 to 40 deg. higher. Both Ari and Aci would probably occur at about 720 deg. could the cooling and heating be infinitely slow. Upper Critical Points. The existence of upper critical points, that is, of thermal retardations occurring at temperatures higher than that of the recalescence point, has already been alluded to. These points were discovered by Osmond and their dis- covery ushered in a new epoch in the scientific study of iron and steel. To describe these points it is advisable to consider first the thermal retardations occurring in cooling and heating carbonless iron and then similar retardations exhibited by steel containing increasing amounts of carbon. Thermal Critical Points in Pure Iron. On cooling from a high temperature, say 1000 deg. C., a piece of the purest iron obtainable and ascertaining its rate of cooling as previously explained, the metal is found to cool normally, i.e. at a uniformly re- tarded rate, until a temperature of some 900 to 880 deg. C. is reached when a marked retardation is observed in the rate of cooling, indicating a spontaneous evolution of heat, in this case, however, insufficient to cause an actual rise of temperature, i.e. a recalescence of the metal. The cooling then resumes, or nearly resumes, a normal rate of cooling, until at about 760 deg. C. a second evolution of heat takes place causing another retardation in the rate of cooling, not so marked, however, nor so sharply defined as the first one. The metal then cools normally or quite so to atmos- pheric temperature. We have thus detected two unmistakable spontaneous evolu- tions of heat in the cooling of pure iron. The corresponding critical points are called Ar 3 and Ar 2 , the latter symbol indicating the lower point. It should be noted that the recalescence point which should occur at some 700 deg. is here absent. Carbon- less iron has no point of recalescence. These two upper points like the point of recalescence are reversible critical points, i.e. on heating the opposite phases of the transformations (whatever those trans- 164 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL formations may be) take place with absorption of heat, causing a retardation in the rate of heating and the corresponding points being designated by the symbols Ac 3 and Ac 2 . The point Ac 3 occurs at a temperature some 10 to 30 deg. higher than its reversal Ar 3 , while Ac 2 occurs at nearly the same temperature as Ar 2 . Dr. J. K. Burgess and J. J. Crowe (Bulletin American Inst. Mining Engineers, October 1913, p. 2537) made a large number of determinations of the critical points of the purest irons obtainable using great refinement in manipulations, and found Ac 3 to occur at 909 deg. C., Ar 3 at 898 deg. and Ac 2 and Ar 2 both at 768 deg. Peculiarities of the Point A 2 . The point A 2 is generally less marked than the points A 3 and AI. Unlike A 3 its position is little affected by the carbon content, and unlike A 3 and A! the point on heating, Ac 2 , occurs at nearly the same temperature as the point on cooling, Ar 2 . To these peculiarities must be added another one, namely, the fact that A 2 appears to cover a wide range of temperature. While its intensity decreases with fall of temperature its lower limit probably extends to considerably below 700 deg. In other words the transformation of which A 2 is a manifestation is not completed by the time the point AI is reached. Indeed Osmond mentions 550 deg. C. as the probable lower limit of the point A 2 . Some explanations of these pecu- liarities of the point A 2 will soon be offered. Arnold insists that with satisfactory apparatus the point Ar 2 always shows a double peak, the upper one at about 765 deg., the lower at 752 deg. This statement is generally opposed by the results of other investigators. None of the 130 curves, for instance, taken with the greatest care and skill by Dr. Burgess shows a double peak at Ar 2 . Thermal Critical Points in Very Low Carbon Steel. Let us now take a sample of steel containing some 0.10 per cent carbon, and let us ascertain its rate of cooling from a high temperature precisely as before. Three thermal retardations will be de- tected, Ar 3 at about 850 deg., Ar 2 near 760 deg., and A^ (point of recalescence) near 700 deg. Of these three spontaneous evolutions of heat the upper one at Ar 3 will be the most marked, while at Ar 2 and at An they will be quite faint, their satisfactory detection calling for the use of delicate instruments and careful manipulations. On heating corresponding retardations will occur, due to spontaneous absorptions of heat, the resulting critical points being designated as Ac 3 , Ac 2 , and Aci. Of these Ac 3 and Aci will occur at temperatures some 20 deg. or more higher than Ar 3 and Ari, while Ac 2 will occupy nearly the same position as Ar 2 on the temperature scale, that is about 760 deg. Thermal Critical Points of Medium High Carbon Steel. The determination of the rate of cooling of a steel containing some 0.45 per cent carbon reveals the exist- ence of two critical points, one, evidently the point of recalescence, Ari, at the usual temperature (680 to 720 deg.) and one upper point in the vicinity of 740 deg. Does the presence in this steel of only one upper point mean that one of the two upper points detected in carbonless iron and in very low carbon steel has disappeared, because of the presence of more carbon, or does it mean that the two upper points have now united into a single one? The latter view is generally assumed to be the correct one and this single upper point of medium high carbon steel is designated accordingly by Ar 3 . 2 . This notation clearly implies that the two distinct evolutions of heat which in carbonless iron and in very soft steel occur separately at Ar 3 and Ar 2 here occur at one and the same temperature. Increasing the carbon content CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 165 decreases the interval of temperature between the two upper points until, finally, for a certain carbon content the points meet to form the double point Ar 3 . 2 . Merging of A 3 and A 2 . It has been seen that as the carbon increases the point A 3 is gradually lowered until finally it merges with A 2 , whose position is not greatly affected by the presence of carbon, to form the point A 3 .2- It would be interesting to know the exact proportion of carbon required to cause this merging. This, however, is difficult to ascertain because of the experimental difficulty of separating two crit- ical points situated very near each other as they must be in thejvicinity of the merg- ing point, and also because this merging will be shifted somewhat by speed of heating and cooling and by slight changes of chemical composition. According to A. Meu- then's calorimetric work later referred to, A 3 and A 2 merge for a carbon content corresponding to 0.32 per cent, while Howe indicates 0.438 per cent carbon as the prob- able merging point. From the mass of experimental evidences which have been pub- lished it seems probable that in commercial steels the merging takes place at about 0.30 per cent carbon. Equilibrium Temperatures for A ;t and A 3 . 2 . Howe uses the notations Ae 3 for the equilibrium temperature for A 3 , that is the temperature at which the transforma- tion Ar 3 on cooling and its reversal, Ac 3 on heating, would take place in the complete absence of hysteresis. A close examination of the available data leads to the con- clusions that the position of Ae 3 is given by the formula T = 917 - 306 X C in which C represents the percentage of carbon in the steel and T the temperature in degrees C. for Ae 3 . For the equilibrium temperature of A 3 .2 Howe gives the formula T = 820 - 105.5 X C Thermal Critical Point in Eutectoid Steel. Eutectoid steel, that is steel con- taining some 0.85 per cent of carbon, exhibits but one critical point, the point of recalescence, very marked at about 700 deg. C. on cooling. Shall it be inferred from the occurrence of this single point that in eutectoid steel the transformations of which the upper points A 3 and A 2 or the double point A 3 . 2 are manifestations do not take place? Or shall it be assumed that these transformations now take place at the same temperature as the transformation corresponding to the critical point AI? In other words that increasing the amount of carbon has so depressed the position of the two upper points as to cause them to unite with the lower point, forming now a triple point to be designated as Ar 3 . 2 .i? This is the view generally held. The critical point on heating is designated by the notation Ac 3 . 2 .i. It will be explained in another chapter why the points A 3 , A 2 , or A 3 . 2 cannot exist in eutectoid or hyper-eutectoid steel, when it will also be shown that the single point of eutectoid steel is not in fact a merging of A 3 , A 2 , and AI, but merely the point AI, the upper points having dis- appeared. Merging of A 3 .2 and AI. As the carbon content of the steel increases still more after the merging of A 3 and A 2 has been effected, the interval between the points A 3 . 2 and AI gradually diminishes until these two points, in turn, appear to merge to form the triple point A 3 . 2 .i. Theoretically this apparent merging should occur when the steel is composed entirely of pearlite, that is, when it contains in the vicinity of 0.85 per cent carbon, for reasons that will later be made clear. As a matter of fact, 166 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL however, the merging seems to take place long before so large a proportion of carbon is present, for the point A 3 . 2 is seldom detected in steel containing more than some 0.50 or 0.60 per cent of carbon; this is probably due, as already explained, to the difficulty of separating, experimentally, two critical points so close to each other. Factors Influencing the Positions of the Upper Points A 3 and A 2 . It has been made clear that as the carbon increases the point A 3 is gradually lowered until with some 0.30 or 0.40 per cent carbon it merges with the A 2 point, while the resulting double point A 3 . 2 is further lowered with increasing carbon and merges with the AI point at about 0.85 per cent carbon. The position of the A 2 point on the contrary so long as that point remains independent, that is in alloys containing less than some 0.40 per cent carbon, is unaffected by variations in carbon content. Like the points of recalescence, the upper points on cooling Ar 3 , Ar 2 , and Ar 3 . 2 are probably lowered (1) by rapid cooling, (2) by increasing the temperature from which cooling starts, (3) by a long sojourn at a high temperature, and (4) by the presence of notable pro- portions of some elements such as manganese, nickel, silicon, etc., while the cor- responding points on heating Ac 3 , Ac 2 , and Ac 3 . 2 are probably slightly raised by in- creased speed of heating. P. Oberhoffer reports that one per cent of manganese lowers the point A 3 or A 3 .a about 70 deg. C. while Charpy and A. Cornu (Comptes Rendus, 1913, Vol. CLVII, p. 319) found (1) that the point A 3 of iron and low carbon steel vanishes when the silicon-content reaches 1.5 per cent and (2) that the point A 2 remains distinct but that each increase of one per cent of silicon lowers its position by about 11 deg. C. Thermal Critical Points in Hyper-Eutectoid Steel. Carefully conducted obser- vations reveal the existence of an upper critical point in hyper-eutectoid steel, at least in steel containing a decided amount of free cementite and, of course, of the point of recalescence. It seems proper to designate this upper point by the symbol A cm (Ar cm on cooling, Ac cm on heating) for reasons later to be given, cm standing for cementite. At least one writer, however, has designated this point on cooling by the notation Ar mo , me standing for massive cementite. Other writers have called it an A 3 point, a notation from which one would naturally infer that this upper point of hyper-eutectoid steel is similar to the upper point of iron and of very low carbon steel, which is not the case. Purely theoretical considerations lead us to infer that the position of the point A cm is lowered as the proportion of carbon decreases, finally merging with the point Aa.2.1 at the eutectoid point. It would follow from this that the single point of eu- tectoid steel is really a merging of four points A 3 , A 2 , Ai, and A cm and that it should accordingly be designated by A 3 . 2 .icm. It is, however, the universal custom to ignore this contribution of A cm to the single point of eutectoid steel and to use for the latter the notation A 3 . 2 .i. The amount of heat evolved at Ar cm is very slight, hence the difficulty of detect- ing this point. Carpenter and Keeling ascertained its existence in steels containing respectively 1.31, 1.51, 1.69, 1.85, and 1.97 per cent carbon at the following corre- sponding temperatures: 883, 911, 985, 1030, and 1042 deg. C. With lower carbon contents, that is nearer the eutectoid composition, the heat evolved is so slight that the detection of Ar cm as a separate point is quite impossible. In theoretical dia- grams, however, the existence of this point is always indicated in all hyper-eutectoid steels with a sharp merging with A 3 . 2 .i at the eutectoid point. The point Ar cm then should occur in all hyper-eutectoid steels at temperatures CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 167 increasing from some 700 to 1050 deg. C. as the carbon increases from 0.85 to 2.00 per cent. Merging of A 3 .2.i and A,. m . As already explained theoretically the merging of the points A 3 . 2 .i and A cm should take place at the eutectoid composition, that is, for steel containing in the vicinity of 0.85 per cent carbon. Experimentally, however, the point A cm cannot be detected in steel containing less than some 1.20 per cent carbon. Bearing in mind that hypo-eutectoid steels containing more than 0.60 per cent carbon or thereabout have likewise but one critical point so^far as experimental evidences are concerned, it will be seen that for all practical purposes we may con- sider all grades of steel containing from 0.60 to 1.20 per cent carbon as having but one critical point, namely, the point of recalescence, at some 700 deg. C. on cooling, although theoretically eutectoid steel only should have but one such point. Minor Critical Points. Some experimenters believe to have discovered some critical points other than those so far described. These points, which may be referred to as minor critical points, correspond to very faint evolutions or absorptions of heat, and produce, therefore, but very slight jogs in the thermal curves. Their existence is not fully established and they appear to have but little if any influence upon the practical side of our subject. They should, however, be mentioned in these pages so that the student may at least have some idea of their nature and claims to recogni- tion. Roberts-Austen in 1898 detected a slight evolution of heat between 550 and 600 on cooling in iron and hypo-eutectoid steel, and this point was again detected by Carpenter and Keeling in 1904. The latter observers named it the Ar point, following in this Roberts-Austen. Roberts-Austen detected another evolution of heat in pure iron between 450 and 500 deg. C. the existence of which he ascribed to the presence of hydrogen resulting in a separation of hydroxide of iron taking place at this critical point. Finally the same observer described one more slight evo- lution of heat in pure iron at about 270 deg. C. which he tentatively ascribed to the formation of an iron-iron hydroxide eutectic. Arnold believes in the existence of a critical point between A 3 and A 2 , of maximum intensity when the steel contains some 50 per cent of pearlite (about 0.45 per cent carbon) which he thinks is due to the formation or segregation of pearlite and hardenite, a constituent later to be described. Data Showing the Position of the Critical Points. A very comprehensive set of determinations of the critical points of iron and steel was made by Carpenter and Keeling. Their results are tabulated on page 168. The table includes the criti- cal points occurring during the solidification period of the various steels and irons investigated. These will be considered in another chapter. The position of the critical points as determined by Burgess, Stead, and others has already been indica- ted. There is substantial agreement between the results of these investigators. Relative Quantities of Heat Evolved or Absorbed at the Critical Points. The various critical points that have been considered in the preceding pages do not indi- cate evolutions or absorptions of equal quantities of heat; they are not of equal in- tensity. The point A 3 is very marked and sharply defined in carbonless iron but decreases rapidly in intensity as the carbon increases. The point A 2 is relatively feeble and not very sharply denned and as already mentioned shows a tendency to cover a considerable range of temperature. Its intensity moreover is little affected by the carbon content of the steel. The point A 3 . 2 , being a merging of A 3 and A 2 , is more intense than A 2 but less intense than A 3 in carbonless iron owing to the fact that when the merging takes place the A 3 point has lost much of its intensity. The point Ai is feeble in. very low carbon steel but its intensity increases rapidly with the carbon content, becoming so great as to cause the metal to glow or recalesce as pre- viously described and being maximum for steel of eutectoid composition. These 168 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL s of Sol 83S83:88&ii888S?38SS?8 gggS8 tt p v g S< : :S :; :^eo5"a ' ' *ad ' CO tc^-"'~lrH Kg g S. - 1 : f v y> .u. .u asssa SSS^r: = ;s^gg i I - I _ L - t - 1 - I - 1 - t , I - I I i - 5f S . " -f I' 00 - I B3S 5 : s "-' :: g :: fe :: i > a aaa saa Hr^ . . .t- o SSSSfe JJtr t : ^; : ^r^i5; f ~ < :^j^ ; js : ^OD ttS" 3l Sets' Oit^^S" MO Q :S^^- ^^^^^v-r 5^-* OOOOOOO OOOOOOO O^rH^l^i-l^-l i 1 -? a c II 1! I J I c. . g 2 = : I I i :i ass-: I CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 169 differences in the thermal values of the critical points will be explained in another chapter. A. Meuthen (Ferrum, 1912, Vol. X, p. 1) found by careful calorimetric experi- ments (1) that one gram of pearlite requires 15.9 calories for its transformation into austenite (a transformation which occurs at Aci or Ac 3 .2.i, as explained in the follow- ing chapter) ; (2) that the transformation of one gram of 13 iron into a iron develops 5.6 calories (a transformation which occurs at Ar2); (3) that the transformation (at Ar 3 ) of one gram of 7 iron into ft iron also develops 5.6 calories; arid_(4) that the sep- aration of one gram of a iron (free ferrite) from the solid solution (austenite), a separation which occurs between Ar 3 and An. produces 14.1 calories. Graphical Representation of the Position and Magnitude of the Critical Points. The position of the critical points corresponding to various percentages of carbon is illustrated graphically in Figure 169. The diagram refers to the critical points in cooling, i.e. the Ar points, and it should be borne in mind that the corresponding points on heating, the Ac points, occur some 20 to 40 deg. higher, with the exception of the point Ac2 which seems to occupy nearly the same position as the point Ar2. An attempt has been made in this diagram to indicate the relative intensities of the various points by shaded areas of proportional thickness on both sides of the lines indicating their position. This is based chiefly on theoretical considerations and is in accordance with the generally accepted views regarding the causes of the critical points as explained in the next chapter. An examination of the diagram shows (1) that the point Ar 3 intense in carbonless iron decreases gradually in intensity as the carbon increases, (2) that the intensity of Ar2 is not greatly affected by the carbon content, (3) that Ar 3 . 2 fairly intense at first becomes rapidly feebler and finally dis- appears just as it meets Ari, (4) that Ari at first very faint becomes more marked with increased carbon, being maximum for a carbon content of some 0.85 per cent (the eutectoid point), (5) that the point Ar 3 .2.i very intense at the eutectoid point gradually loses some of its intensity, although always remaining pronounced, and (6) that the point Ar cm very faint near the eutectoid composition increases in in- tensity with the carbon content. These theoretical inferences are well supported by experimental evidences in the case of the magnitude of the points Ari and Ar 3 . 2 .i and quite satisfactorily in regard to Ar 3 and Ar cm . They ascribed to the points Ar 2 and Ar 3 . 2 , however, a magnitude and a sharpness which is not borne out by experiments as later explained when it will also be seen that some writers doubt the accuracy of the explanation generally offered to account for the point A 2 . The diagram, therefore, while undoubtedly useful, is probably but approximately accurate and likely to be modified with increased knowledge of the facts it aims to depict. Determination of the Thermal Critical Points. The thermal critical points are universally determined by means of the Le Chatelier thermo-electric pyrometer. Indeed it is the invention of this invaluable instrument that made the detection of the upper critical points possible. Had it not been invented we probably would still be in ignorance of the existence of the upper points, while we would have but little knowledge of the exact position of the point of recalescence. Cooling and Heating Curves. The determination of the thermal critical points calls for the construction of heating and cooling curves. In these curves successive falls (or rises) of temperature, say of 10 deg. C., 6 10, 6 20, 6 30 . . . are plotted 170 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL o o CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 171 as ordinates, while as abscissae are plotted (a) the corresponding time intervals in seconds, t, t', t", t'" . . . elapsed since the beginning of the observation, or (b) the actual intervals of time t' t, t" - t', t'" - t" . . . required for each noted fall of temperature. In other words the coordinates are 6 and t in the first instance, 6 and dt in the second. The curve obtained by the first method is known as a time-tem- perature curve while the second method yields an inverse rate curve. 1 Time-temperature curves representing the heating and cooling of pure iron are shown in Figure 170. While in these curves the evolutions or absorptions of heat cor- 1600 14CO 1300 1300 foe s, g ION MO 800 700 too M s Solid! n nation PC int \ l A Iron j 3 A t 1 \ /& \ \ / // 0064- \ **Cg , / ^^^ 88< ^ r 3 800 Acs \ v |3 Iron / 1 fltX^ \ // \ fC Iron / ^ X W 20 SO 40 60 60 70 80 X 100 Minutes Fig. 170. Time-temperature curves. Heating and cooling of pure iron. (Goerena.) responding to the points A 3 and A 2 can be detected, they do not stand out very con- spicuously, and it may well be feared that slight thermal retardations might escape detection in curves of this kind since they would cause but very slight jogs in the curve. These considerations led Osmond to adopt the inverse rate method for the plotting of thermal curves. Curves of this type are shown in Figures 171 and 172. 1 It is evident that similar curves would result from reversing the observations, i.e. noting the successive falls of temperatures 6, 6', 6" . . . corresponding to equal intervals of time, say of 15 seconds, t + 15, t + 30, t + 45 . . . and plotting the former as ordinates and the latter as abscissa;. The coordinates in this case would be dS and t. 172 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL Fig. 171. Inverse rate curves. Cooling of steels containing respectively 0.02, 0.14, 0.45, and 1.24 per cent carbon. (Osmond.) CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 173 The thermal points correspond to sharp peaks in the curves, the lengths of which are roughly proportional to the amount of heat evolved on cooling or absorbed on heating. This method is quite universally applied unless, as later explained, a neutral body is used for the determination of the critical points. Use of Neutral Bodies. The method described above for the detection of the thermal critical points is open to the objection that the rate of cooling or heating of the steel under observation is necessarily affected by any irregularity in the cooling or heating of the furnace itself and by other outside agencies. These disturbing fac- tors introduce irregularities in the thermal curves which may render their interpreta- tion difficult and may indeed altogether hide the existence of critical points where but a very small amount of heat is evolved or absorbed. Again, on cooling for in- stance, when a critical point is reached the temperature of the metal is affected in opposite directions (1) by the cooling furnace which has a tendency to lower its tern- TIM IN SEC( E NDS 76 70 60 50 40 30 20 to LU 1- ra ARBOr> o c 0* -L ^ r y <^ttti I b 5*^-~ ^_ t^r ~~Z^^~ T^ MAN_Gl?S E - JIEEi 20%,' ^ -oo' Fig. 173. Difference curves. Cooling and heating of various steels. (Saladin.) ical points, when heat is evolved or absorbed by the metal while the neutral body is, of course, free from any such thermal disturbance. Any difference of temperature between the two pieces, therefore, would indicate a critical point. Since it is generally impossible,, however, to use a neutral body having exactly the same heat capacity as that of the metal under observation, it will be apparent that there will always be a CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 175 difference between the temperatures of the two pieces, one always lagging behind the other, and that the critical points will correspond to sudden increase in the difference between their respective temperatures. Since, however, the critical points are now caused solely by abrupt differences between the temperatures of the two bodies, they are freed from the irregularities mentioned above as well as from the masking in- fluence of the falling or rising temperature of the furnace, seeing that both pieces are now equally affected, and the curves obtained should indicate more sharply and con- spicuously the existence of even faint absorptions or evolutions of_heat. The neutral body should, of course, be free from any thermal transformation within the range of temperature covered by the experiments. Platinum, porcelain, clay, 25 per cent nickel steel, and (by the author) austenitic manganese steel have been used. The plotting of the thermal curves when a neutral body is used may be 900 Fig. 174. Difference curves. Cooling and heating curves taken on same photographic plate. (Saladin.) done in two different ways, (1) successive falls (or rises) 6 10, 20, 6 30 ... of the temperature of the metal as indicated by one of the galvanometers may be plotted as ordinates against the corresponding differences in temperature 6 6\, 6' d'\, 6" - d'\ ... of the two cooling bodies, as indicated by the second galvanometer, the coordinates in this case being 6 and 6 61, and the curve known as a "difference" curve, or (2) according to Rosenhain, successive falls of temperature may be plotted as ordinates against the corresponding rate of cooling for each degree of temperature e - e l tf - e' 1 e" - e\ > > as abscissae, the coordinates being in this method and (6 ~ do and the curve known as a "derived differential" curve. Difference curves are shown in Figures 173 to 175. The curves of Figures 173 and 174 were taken with a Saladin-Le Chatelier-Pellin instrument. Figure 173 shows the critical points on heating and cooling of a series of carbon steels containing from 0.06 to 0.66 per cent carbon, the cooling and heating curves having been taken on separate photographic plates. In Figure 174 is shown the heating and cooling curves taken on the same plate of two steels containing respectively 0.36 and 0.46 per cent carbon. 176 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL Fig. 175. Difference curves. Cooling of a scries of very pure carbon steels. (Carpenter and Keeling.) The curves of Figure 175 are difference curves of a series of very pure carbon steels taken by Carpenter and Keeling. The purpose of Rosenhain's derived differential method of plotting is to eliminate the irregularities from which difference curves still suffer and which are due chiefly to differences between the heat capacities and emissivities of the sample and neutral CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 177 body resulting in differences in their rates of cooling and heating. The resulting curves cannot, of course, be autographically recorded. They call for the replotting of the data afforded by the difference (0 vs. - 61) curves. Some of Carpenter and Keeling's results replotted by Rosenhain according to his derived differential method are shown in Figure 176. J - 1.000 02 /0-05 12 Carbon, per cent. : Fig. 176. Derived differential curves of carbon steels replotted from the data of Carpenter and Keeling. (Rosenhain.) BSD 030 S20 SIO Temperature-time curve. At A0 Inverse rale curve. 6-0, Difference curve. Derived differen- tial curve. Fig. 177. Different types of cooling curves. (Desch.) Additional Illustrations of Cooling Curves. The different types of cooling curves described in the preceding pages are well illustrated in Figure 177. These curves were constructed from the data given in the following table, in which each unit in t represents intervals of time of 15 seconds, 6 the corresponding temperatures of the sample, and 6 0i corresponding differences of temperature between the sample and a neutral body cooling under identical conditions. The curve B, representing the cooling curve of a neutral body free from critical transformations, has been added for comparison. 178 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL t e e e { t 0-0, 5 850.0 8.5 18 829.0 11.0 6 848.0 8.5 19 825.0 8.2 7 844.7 7.5 19.5 823.3 7.3 8 842.0 7.0 20 822.2 6.7 9 839.5 6.3 21 821.7 7.7 10 838.5 7.0 22 821.5 8.5 11 838.2 8.8 23 821.3 9.8 12 838.1 10.2 24 821.1 10.1 13 838.0 12.0 24.5 819.0 9.5 14 837.9 13.6 25 815.0 o.O 15 837.5 15.5 26 813.0 5.0 16 836.0 14.6 27 811.6 4.7 17 833.0 13.0 Self -Recording Pyrometers. With the use of neutral bodies self-recording in- struments are generally employed. The Saladin-Le Chatelier-Pellin autographic pyrometer has been described in Chapter I. The self-recording may be by means of photographic plates or by some other mechanical devices. The former method calls for the use of mirror galvanometers sending a beam of light upon the photo- graphic plate while in other autographic recorders needle galvanometers are used. The relative merits between photographic recorders and other types are summed up by Burgess as follows: "It is evidently of great advantage to use self-recording apparatus when possible, and it then becomes necessary to choose between the photographic type and the autographic. The latter possesses the advantage that the experimenter may watch any part of the record, and can therefore control the operation and at any moment vary the conditions affecting the experiment; whereas with a photographic recording apparatus, as usually constructed, the observer does not know whether or not the experiment is progressing properly until it is finished and he has developed the sen- sitive plate. The manipulation by the photographic method is usually also more delicate and time consuming and the adjustment less sure, and the record often re- quires further graphical interpretation. The autographic method is in general not adapted for interpreting phenomena taking place within an interval of a few seconds, so that for very rapid cooling it is necessary to employ the photographic method. It is possible to construct the photographic recorder so as to obtain a very considerable range of speeds with the same apparatus, while it is difficult and costly to construct an autographic recorder having more than two speeds." Other Methods for the Determination of the Critical Points. The spontaneous evolutions or absorptions of heat observed at the critical points are obviously man- ifestations of transformations taking place within the metal and it will be seen in the next chapter that many other properties of iron and steel undergo at these tempera- tures sudden and marked changes. It is obvious, therefore, that the determination of the change taking place in any one of these properties in function of the tempera- ture will afford a means of detecting the existence and location of the critical points. The method fully described in the preceding pages, and by far the most generally used, may be termed the " thermal method." Other methods based on the discon- CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 179 tinuity in the variation of certain properties occurring at the critical points will now be briefly described. Metallographic Method for the Determination of the Critical Points. Howe and A. G. Levy have used, with marked success, a metallographic method for the determination of the critical points, notably of the point A 3 . The method for Ac 3 con- sists in noting the temperature at which the re-absorption of ferrite is found to be com- plete, and for Ar 3 , the temperature at which rejection of ferrite begins. It will be explained in the next chapter that these phenomena correspond to the occurrence of the Ar 3 and Ac 3 points. The samples of hypo-eutectoid steels are first heated to a high temperature (1200 to 1450 deg.) and slowly cooled in the furnace in order to assemble the ferrite into coarse masses. Specimens of this coarsened steel are then heated to various temperatures below and above the supposed position of Ac 3 hold- ing the temperature stationary for from 30 to 60 minutes. The specimens are then quenched and preferably reheated to some 300 or 400 deg. in order to convert the mar- tensite into troostite and thus secure greater contrast between the free ferrite and the matrix into which it is embedded and hence readier distinction of small amounts of free ferrite. These structural changes are explained in Chapters XVI and XVII. The Ar 3 point is determined in a similar manner by noting the temperature at which free ferrite first makes its appearance in cooling down. The successive heatings may be 10 deg. apart. Calorirnetric Method for the Determination of the Critical Points. A. Meuthen (Ferrum 1912, Vol. X, p. 1) has determined by the vacuum method of Oberhoffer (Bunsen ice calorimeter and electric resistance furnace) the quantities of heat evolved when iron carbon-alloys cool through their critical points and the method may be used for the determination of these points. . Thermo-Electric Method for the Determination of the Critical Points. - W. Broniewski (Comptes Rendus 1913, Vol. CLVI, p. 1983) has applied a thermo- electric method to the determination of the critical points which he considers at least equal in accuracy to other methods. It consists in determining the thermo-electro- motive force of the iron or steel in relation to copper. The occurrence of discontinuity in the variations of the electro-motive force indicates the positions of the critical points. With 0.07 per cent carbon the point A 2 was found at about 730 deg. In pure iron A 3 occurred at 950 deg. and in steel with 0.07 per cent carbon its position was 850 deg. With more than 0.44 per cent carbon the points A 2 and A 3 were merged with the recalescence point. Melting-Points Method for the Determination of the Critical Points. Stead has devised an ingenious method for the determination of the critical points Ari and Aci (Journal Iron and Steel Institute 1913, II, p. 399) by which the use of pyrometers may be dispensed with, the method being based on the known melting- point of sodium chloride and of some metals in the form of wire. Magnetic Method for the Determination of the Critical Points. It will be ex- plained in the following chapter that iron-carbon alloys lose their ferro-magnetism, or at least the bulk of it, on heating in passing through the points Ac 2 , Ac 3 . 2 , or Ac 3 .2.i as the case may be, and recover it in cooling at the points Ar 2 , Ar 3 . 2 , or Ar 3 . 2 .i. By ob- serving these magnetic transformations and noting the temperatures at which they occur, the position of the critical points may be accurately determined. The author has found the following procedure very satisfactory. A (Fig. 178) is an electric re- sistance furnace; DD two round bars of iron (the author uses American ingot iron, a 180 CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL product nearly free from carbon) suitably held in position; C is the piece of iron or steel the magnetic critical points of which are to be determined; X is the hot junc- tion of a thermo-electric couple introduced into a hole drilled in the sample C ; E is an electro magnet surrounding a portion of the bar D; G is an iron needle so balanced that it is readily attracted. by the end H of the composite bar DCD when the latter is magnetized. As long as the temperature of the piece C remains below its Aci point (or Acs, or Acs.2.i according to the carbon content) the bar DCD attracts the needle Fig. 178. Magnetic test for the determination of the thermal critical points in iron and steel. or keeper G but when the critical point is reached the magnetic flux ceases to pass through C and the needle drops. The point on heating is in this way sharply recorded. On cooling as soon as the point Acs is reached the steel recovers its magnetism and the needle G is again attracted. The method is sufficiently delicate to detect the A 2 point in carbonless iron, and in very low carbon steel. Historical. A brief historical sketch of the discovery of the critical points of iron and steel will not be without interest. In 1868 Tschernoff in studying the har- dening of steel used the notation A for the temperature at which hardening by rapid cooling becomes suddenly possible in high carbon steel. This was the point AS^.I. In 1869 Gore noted that at a dark red heat steel exhibited on cooling a spon- CHAPTER X THE THERMAL CRITICAL POINTS OF STEEL 181 taneous dilatation of short duration followed by normal contraction. Evidently the point of recalescence Ari or Ars.2.i. In 1873 Barrett repeated Gore's experiments and discovered, on heating, a mo- mentary contraction at nearly the same temperature as the dilatation on cooling. This was the point Aci or Acs.2.i. He further noted that this dilatation or contraction was very feeble in iron (the Ai point in very low carbon steel) and very marked in hard steel (the point A 3 . 2 .i). Barrett also discovered the spontaneous glow taking place on cooling a wire and gave it the name of "recalescence." In 1879 Barrus showed that the increase of hardness resulting from quenching was not gradual but sudden, thus pointing to the existence of a thermal critical point (the AI point). In 1885 Osmond published his discovery of the upper critical points As and A2 in iron and low carbon steel and gave the first accurate determination of the position of the point A!. CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL THEIR CAUSES The thermal critical points described in the preceding chapter are evidently out- ward manifestations of internal transformations taking place spontaneously at cer- tain critical temperatures. We should now inquire into the nature of these trans- formations. Let us remember that there are but three well-known causes of spontaneous evo- lutions of heat in cooling bodies and of spontaneous absorptions on heating. These are: (1) formation of chemical compounds, a phenomenon which is almost always accompanied by a spontaneous -evolution of heat (the heat of formation), and the reverse phase, the dissociation of the compound with absorption of heat (the heat of dissociation), (2) changes of state, that is, the passage of a substance from the solid to the liquid or from the liquid to the gaseous state, or directly from the solid to the gaseous state, which changes are always accompanied by spontaneous absorptions of heat, and the opposite phases of the same phenomena, the passage of a body from the gaseous to the liquid or from the liquid to the solid state, when heat is evolved (the latent heat of solidification in case of a substance passing from the liquid to the solid state, etc.) these evolutions or absorptions of heat, as the case may be, main- taining the temperature of the substance constant while a change of state is in progress as, for instance, during solidification or melting, (3) allotropic or polymorphic trans- formations which are always accompanied by an evolution of heat when the body passes from one allotropic condition to another, and by an absorption of heat when it returns to its first allotropic form or vice versa. The meaning of allotropy has been discussed in Chapter V. Causes of the Upper Points A 3 and A 2 in Carbonless Iron. It has been seen that at these points spontaneous evolutions or absorptions of heat occur in chemically pure iron which, since they are not accompanied by any change of state (the metal being considerably below its solidification point) must, it seems, necessarily indicate the existence of iron under three allotropic forms. It has been mentioned in Chapter V that the allotropic form stable above AS is known as 7 (gamma) iron, that stable between A 3 and A 2 as (beta) iron, and the form stable below A 2 as a (alpha) iron. The following then takes place during the cooling and heating of pure iron: as the metal cools from a high temperature when the point Ar 3 is reached, it passes from the gamma to the beta condition with evolution of heat, while at Ar 2 it passes from the beta to the alpha form also with evolution of heat. On heating the reversals take place, the iron passing with absorptions of heat from the alpha to the beta con- dition at Ac 2 and from the beta to the gamma condition at Ac 3 . That the point A 3 indicates an allotropic transformation is universally admitted, no one doubting the 182 CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL 183 existence of iron in at least two allotropic conditions. Many authoritative writers believe with Osmond that the point A 2 also indicates an allotropic transformation, and that iron, therefore, assumes three distinct allotropic forms, as explained above. While some writers have expressed doubts as to the allotropic character of the point A 2 , as will presently be explained, in these pages iron will be assumed to exist in three allotropic conditions, of which A 3 and A 2 are the transformation points, this theory being, in the author's opinion, the one best supported. The A 2 Point and Beta Iron. The arguments which have been offered in sup- port of the contention that the point A 2 of pure iron and of low carbon steel is not an allotropic point and that, consequently, beta iron does not exist, should be briefly considered. (1) It was claimed by Benedicks and Carpenter that the point A 2 or at least Ac 2 does not occur in strictly pure iron but in view of the results obtained by Dr. Burgess at the Bureau of Standards, and by others, the claim had to be withdrawn and the existence of A 2 as an independent point is no longer a debatable question. (2) The point A 2 , it has been said, notably by Benedicks and H. Le Chatelier, cannot be an allotropic point because of the absence of hysteresis between the two phases Ac 2 and Ar 2 of the transformation. While it may be that hysteresis has always been observed in allotropic transformations, it does not by any means follow that its absence indicates the non-existence of allotropy. Indeed the freezing and melting of crystalline substances which may be considered as major instances of allotropy occur normally without hysteresis. (3) The point A 2 , we are told, cannot be an allotropic point because no crystal- lographic change has ever been found to occur at that point. The argument is valid only in case it is accepted that an allotropic transformation necessarily implies a crystalline change, a definition of allotropy which is far from being generally en- tertained. It is quite possible, moreover, that a slight crystallographic change occurs at A 2 which has so far eluded observation. (4) The absence of dilatation as iron cools through its Ar 2 point reported by some (Charpy and Grenet, and Benedicks) has been claimed to preclude the existence of allotropy. This argument is based on the arbitrary view that an allotropic trans- formation must necessarily be accompanied by dilatation on cooling and contraction on heating. Some investigators, moreover, believe to have detected a dilatation at Ar 2 , while even the results 'of Benedicks' careful experiments do not conclusively prove the absence of dilatation. (5) While admitting that a marked transformation takes place at A 2 in the mag- netic properties of iron, it has been argued that it was not of an allotropic character (H. Le Chatelier, Weiss, Honda, Benedicks, and others) (a) because it was not suffi- ciently sudden to imply discontinuity, and (6) because in general magnetic trans- formations of that kind are not allotropic. Ac 2 we are told marks the end of a pro- gressive transformation having its starting point at a considerably lower temperature, while Ar 2 marks the beginning of the reverse change. Starting and end points of progressive transformations, however, are not accompanied by sudden evolution or absorption of heat; slight changes of direction only should occur in the thermal curves. While it is apparently true that the magnetic transformation starts at a temperature considerably below A 2 , the very existence of that point with its notable heat evolution indicates a sharp discontinuity in the progressive-ness of the transforma- tion and hence suggests allotropy; or, differently expressed, iron on being heated from 184 CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL atmospheric temperature to just below its Ac 2 point loses progressively possibly 50 per cent of its ferro-magnetism, while in passing through its Ac 2 point it loses abruptly the remaining 50 per cent. It is unjustifiable to describe the phenomenon as merely a progressive transformation. The recent theories put forward to show that the loss of ferro-magnetisrn suffered by some metals on being heated should not be regarded as allotropic transformations are purely arbitrary and speculative. It remains more consistent to regard the mag- netic and non-magnetic conditions of the same substance as two allotropic states of that substance. (6) It has been contended that no discontinuity in any of the properties of iron has ever been proved to take place at A 2 and that, therefore, the transformation can- not be an allotropic one. To this it may be answered (a) that the existence of a marked thermal critical point indicates a sharp discontinuity in the internal energy of iron, and that as an evidence of allotropy it is at least as conclusive as a discon- tinuity in any other property, (b) that discontinuity undoubtedly exists at A 2 in the magnetic properties of iron, and (c) that several investigators have noted a discon- tinuity in the dilatation of the metal (Rosenhain and Humfrey, although denied by others), in its tensile strength (Rosenhain and Humfrey), in its specific heat (Weiss and Beck, and Meuthen) and in its electrical resistance (G. K. Burgess and I. N. Kelberg). In regard to the latter property Burgess and Kelberg write: "The exact determination of the variation of the electrical resistance of pure iron (99.98) in terms of temperature has been made over the range to 950 deg. C., particular attention being given to the form of the curve over the A 2 and A 3 critical ranges . . . No anomalies are found in the resistance of iron until the A 2 region is approached, and at A 2 there is an inflection at 757 deg. C. in the resistance tempera- ture curve shown as a sharp cusp in the temperature coefficient. At Ac 3 the resist- ance of iron falls abruptly by some 0.005 of its value,, which is recovered within a 25 deg. interval, and above Ac 3 it increases greatly again. On cooling, the Ar 3 is accom- panied by slight increases of resistance with falling temperature. Ac 3 and Ar 3 begin at the same temperature, 894 deg. C., and each extends over a temperature interval of 25 degrees. These resistance measurements show that A 2 is a strictly reversible transformation and A 3 is a transformation taking place at a higher temperature on heating than on cooling. These experiments are in agreement with the thermal ob- servations previously recorded in Scientific Paper No. 213. Whether or not either or both of these critical ranges A 2 and A 3 are to be consid- ered allotropic points will depend upon the definition of allotropy, about which there does not appear to be agreement." (7) To explain the existence of A 2 in impure iron without having recourse to al- lotropy, Benedicks attempted to show, through ingenious speculations, that the point Ar 2 indicated the end of the Ar 3 transformation, some gamma iron remaining untrans- formed below Ar 3 owing to the presence of impurities, the phenomenon being one of supercooling, and the resulting equilibrium therefore metastable. What had been hitherto called beta iron was in reality, then, a solid solution of gamma iron in alpha iron. As this highly speculative hypothesis demands the absence of A 2 (at least of Ac 2 ) in strictly pure iron, it may be considered as untenable. Benedicks, however, facing this difficulty attempted to explain that unless the cooling be very slow the point Ar 2 might still occur in pure iron without disproving his theory and likewise Ac 2 , on quick heating. He admits, however, that the intensity of A 2 should gradually CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL 185 decrease as the purity of the iron increases. The facts are that both Ac2 and Ar2 occur sharply in the purest irons obtainable on very slow heating and cooling and that there are "no indications of their decreasing in intensity in the purer metals. Benedicks' attempt to replace a theory simple in its conception and well supported by experimental evidences by a product of intellectual gymnastics has failed. Os- mond's theory originated and grew in the laboratory, in close harmony with nature, while Benedicks' theory was evolved in the quiet of one's study. From the foregoing considerations the following conclusions appear warranted: (1) A 2 is an independent thermal point and is a manifestation of a transformation taking place spontaneously in iron and low carbon steel, (2) A 2 can in no way be re- garded as the end point or starting point of the As transformation, and (3) whether A 2 marks or not an allotropic transformation depends on our definition of allotropy. If it be insisted that allotropy necessarily implies a change of crystalline forms, then it may be argued that A 2 is not an allotropic point. If, on the contrary, it is considered that a discontinuity in the internal energy of iron, made evident by spontaneous evolution or absorption of heat, is the criterion by which to judge of allotropy, then we are justified in believing in the existence of beta iron. This view is strengthened by the undoubted existence of a discontinuity in the magnetic properties of iron at the A 2 point, and of discontinuities observed by some investigators in other prop- erties. Causes of the Upper Critical Points A 3 and A 2 in Low Carbon Steel. As might be expected the points A 3 and A 2 occurring in very low carbon steel also indicate allotropic changes in the metal. According to most writers, however, only that por- tion of the metal which at ordinary temperature exists as free ferrite is here affected. To make this matter clear it will be necessary to anticipate somewhat our subject while the diagram shown in Figure 179 will be useful. In this diagram the three critical points of steel containing 0.20 per cent carbon, As, A 2 , and AI as well as its solidification point and atmospheric temperature are represented by parallel lines drawn at suitable intervals in the scale of temperature. The metal is represented by the rectangular area A BCD. The diagram illustrates the following facts later to be discussed at greater length: (1) in the molten condi- tion steel is considered to be a liquid solution of iron and carbon, (2) on reaching its solidification point the metal is converted into a solid solution of gamma iron and carbon known as austenite, (3) upon reaching Ar 3 some ferrite begins to be set free, (4) the ferrite as it is set free assumes the beta state, this liberation of ferrite and its allotropic transformation being probably one and the same phenomenon, (5) the formation of free ferrite continues as the steel cools from Ar 3 to Ari, EFG represent- ing the ferrite thus liberated, (6) on reaching the point Ar 2 the ferrite liberated be- tween Ar 3 and Ar 2 , ML in the diagram, passes from the beta to the alpha condition, (7) the ferrite liberated between Ar 2 and Ari, LNF in the diagram, assumes the alpha condition (according to some writers) without passing by the beta condition, while in the opinion of others the beta condition is assumed but is immediately followed by the alpha state, (8) while ferrite is being set free, the balance of the steel, EKIF, (according to most writers) preserves its condition of solid solution, gamma iron plus carbon, (9) upon reaching the point Ari the residual solid solution, FI is cpn- verted bodily into pearlite, (10) from Ari down to atmospheric temperature no fur- ther structural change takes place, the steel being finally made up of BH = GF per cent ferrite and of HC = FI per cent pearlite. 186 CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL On 'heating the opposite changes take place: (1) at Aci transformation of FI pearlite into FI solid solution (gamma iron + carbon = austenite), while this solid solution begins immediately to assimilate some of the free ferrite, Avhich as it is as- free Scfa _ A/pha_ B D Liquid Solution of /f~on one/ Car-h&n Sa//d/f/'cafian /ic/ -Sa/ution of ' and Co/- ban CAc/stsnite} So//c/ *5 o/vf/on (Ausfen/'fe ) So/uf/on -A, Pearti fe fi Fig. 179. Diagram depicting structural changes in 0.20 per cent carbon steel as it cools slowly from the molten condition to atmospheric temperature. similated passes to the gamma condition, (2) between AI and A 3 absorption of free ferrite continues, being completed at Ac 3 , (3) on reaching the point Ac 2 the ferrite, ML in the diagram, which has not been absorbed between Act and Ac 2 now passes to CHAPTKR XI THE THERMAL CRITICAL POINTS OF STEEL 187 the beta condition. This diagram depicts accurately the generally accepted views in regard to the meaning of the critical points. If these views are correct several inter- esting inferences may be drawn as to the relative intensities of the critical points. The point A 3 in low carbon steel does not indicate a complete transformation, as too often loosely stated, but merely the beginning, at Ar 3 , or the end, at Ac 3 , of a trans- formation extending over a considerable range of temperature, i.e. from Ai to A 3 . Theoretically, therefore, it would seem as if the point A 3 must correspond to a mere change of direction in cooling and heating curves rather than to well-marked jogs. The fact that a decided jog marks the point Ar 3 in very low carFon steel might be ascribed to hysteresis, the metal cooling to a temperature below that at which the A 3 change is due so that when the transformation begins to take place it does so with added intensity, hence the jog. The jog corresponding to the Ac 3 point of very low carbon steel is not so readily explained. But is not this jog much less pronounced than the one corresponding to Ar 3 ? The point Ar 2 marks (1) a complete transforma- tion, namely, the passage from the beta to the alpha state of the free ferrite liberated between Ar 3 and Ar 2 and (2) the beginning of a transformation, namely, the passage to the alpha condition of the ferrite which continues to be liberated between Ar 2 and Ai'i. Because of the complete transformation implied by the point A 2 we readily understand that it should correspond to a jog both in the heating and cooling curves, and since Ar 2 is due chiefly to the allotropic transformation of the ferrite liberated between Ar 3 and Ar 2 , we readily understand why it should occur at nearly the same temperature regardless of the carbon content. In the light of what precedes, how- ever, the point A 3 in steel instead of being regarded as the manifestation of trans- formations occurring and completing themselves at a certain temperature, in reality indicates the beginning or end of transformations extending over a considerable range of temperature, namely, from A 3 to AI. Cause of the Point A 3 . 2 . It has been seen that the point A 3 . 2 is apparently a merging of the points A 3 and A 2 of lower carbon steel and it seems natural to infer that the transformations which these points indicate, namely the two allotropic changes, are here likewise merged, that is, that they now take place at the same tem- perature. In other words that when the point Ar 3 . 2 is reached on cooling the iron passes from the gamma to the beta and then immediately to the alpha state, the heat evolved being due to this double allotropic transformation. Some writers have claimed, however, that at the point Ar 3 . 2 the iron passes directly from the gamma to the alpha condition, the change of gamma to beta being suppressed in steel contain- ing over 0.35 per cent carbon or thereabout. If such hypothesis were true it would have some important bearing upon the probable theory of the hardening of steel as explained in another chapter. In the author's opinion the more generally accepted view is better supported by experimental facts and other evidences and in these chapters the point A 3 . 2 will be considered as implying a double allotropic change. Most metallographists believe that like the independent points A 3 and A 2 the double point A 3 . 2 is the result of allotropic changes affecting the free ferrite only. This setting free and allotropic transformation of ferrite is depicted diagrammati- cally in Figure 180 in the case of steel containing 0.60 per cent carbon and having, therefore, the two critical points A 3 . 2 and A t . EOF indicates the gradual liberation of ferrite and its conversion to the alpha state as the metal cools from Ar 35 to Ar b the steel, after complete cooling, being made up of BH = GF per cent ferrite and HC = FI per cent pearlite. 188 CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL If, as generally stated, the allotropic transformation of which A 3 . 2 is a manifesta- tion affects only the free (pro-eutectoid) ferrite, the intensity of the point A 3 . 2 must decrease rapidly with decreasing pro-eutectoid ferrite, i.e. as the eutectoid composi- iron and car-ban So/id solution iron and cc/r-bon (Austens fe) Temperature Fig. 180. Diagram depicting structural changes in 0.60 per cent carbon steel as it cools slowly from the molten condition to atmospheric temperature. tion is approached, and this point must vanish altogether as it meets the point AI (see Chapter X, Fig. 169), from which it further follows that the single point of eutec- toid steel is not in reality a triple point as the notation A 3 . 2 .i would imply, resulting CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL 189 from the merging of AI and A 3 . 2 , but that on the contrary it remains a single point, being merely the continuation of the AI point of hypo-eutectoid steel. Cause of the Point AI. It has been seen that the point AI does not occur in carbonless iron, only feebly in iron containing little carbon, and with increased in- tensity as the carbon increases to the eutectoid point. The conclusion seems irre- sistible that the point AI must be closely related to the carbon, that it must indicate a sudden change in its condition. If steel be rapidly cooled from above the point Aci and then treated with certain dilute acids, practically all the Carbon escapes as hydrocarbons, whereas the same steel after slow cooling through Ari when similarly treated yields a carbonaceous residue, which upon being analyzed is found to consist of the carbide Fe 3 C. It is assumed that upon quick cooling we retain the carbon, partially at least, in the form in which it normally exists above AI, and seeing that when subjected to a similar treatment this carbon behaves so very differently from the carbon of slowly cooled steel, the conclusion is very logical that carbon exists above AI in a different condition from that normal below AI. Above AI it is called "hardening" carbon, below AI "cement" carbon. On heating steel past the point Aci the carbon changes from the cement to the hardening condition, and vice versa on cooling at Ari from the hardening to the cement condition. It is, moreover, gen- erally believed that this hardening carbon is carbon in solid solution in the iron. If it be so the heat evolved at Ari is clearly in part at least the heat of formation of the carbide Fe 3 C and the heat absorbed at Aci clearly the heat of dissociation of that carbide which now is resolved again into its elements according to the reversible reacti n The intensity of the AI point should then increase as the carbon increases or, rather, as the amount of pearlite increases, and should be maximum, therefore, at the eutectoid point as indicated in Figure 169, Chapter X. With higher carbon con- tent it diminishes slightly because the free (pro-eutectoid) cementite which is now present takes no part in the transformation occurring at Ari, having been formed at a higher temperature, namely, at Ar cm , as later explained. It would seem that the cause of the AI point, i.e. the point of recalescence, is in this way explained in a perfectly satisfactory manner. The correctness of this theory appears to be further supported by microscopical evidences which reveal the presence of Fe 3 C in slowly cooled steel while pointing to the probable absence of it in suddenly cooled steel. In recent years, however, it has seemed more and more probable to students of metallography that it is not carbon in its elementary state which is dissolved in iron at a high temperature, but rather the carbide Fe 3 C itself and that the difference between the behavior of the carbon in hardened steel and in slowly cooled steel might well be satisfactorily accounted for on the ground that in hardened steel Fe 3 C is dis- solved in iron and in that form is much more readily acted upon by acids, being there- by converted into hydrocarbons, whereas Fe 3 C when in the free crystallized condi- tion, as in slowly cooled steel, resists the action of the acids and remains undissolved. If it is Fe 3 C and not C which is dissolved in iron above the critical range, it is evident that the point Ari cannot be caused by the formation of Fe 3 C. But it may well be due to the crystallization or falling out of solution of Fe 3 C. To be sure this is a fall- ing out of a solid solution, but cannot we conceive that the falling out of a constit- uent of a solid solution is accompanied by an evolution of heat even if it does not |U) til \rrii; \l Till: TIIKIiMU. CKl'I'ICAL 1'OIX'I'S Oh' STKK1, implx a change df state? In other words is il not possible, or ex en probable, lhal u \ .( a Hi :il i. Hi in I ho solid stair I accompanied l>y an ex olulion of lira I'.' Surely this crystalli/.alion implies an allolropie or al Irasl a polymorphic I ransl'oniial ion and arc mil snrh transformations always accompanied by heat evolutions'.' The author ol'l'rrs llirse thoughts as possibly worthy of allrntion anil as a possible explanation of the evolution of lieal at Ar, if \ve assiiine llial l'V ;1 t ' and not ( ', as il ni'\\ seems so probable, is dissolved in iron al>ovr lhal poinl. The I'oint A, an Allotropir Point \h> I unlers describe the point A, as piirelx a carbon point, lhal is, a mamfeslal ion of a change affect ing I hr condilion of the carbon only as explained in the foregoing pages. These same wrilrrs, ho\\ever. as- sert lhal Ihr npprr rritical points, A ; and A- in low carbon steel or V; in higher car bon slrrl. affect only the condilion of the free i pro enlivloidl ferrile. In this I hex are inconsistent, for if the upper point or points indicale allot ropir transformation ot Ihr free frrrite onlx then (he lo\\er poinl A, is decided!) an allot ropic poinl seeing thill it corresponds to allot ropie transform.'!! ions of the pearlilr-frrritr and thai in sirel containing more than some 0.10 per cent carbon ihere is move pearlite ferrile than free ferritr. In other \\ords the point A, is always an allolropie poinl indicating an allolropie I ran-.loniiMtion of the prarlilr-ferrilr similar to the allotropic transfor million of Ihr free ferrite occurring al Ihr upper points, and in ease of sled with morr than 0,10 per cent carbon ihe allolropie change taking place at AI atVects a larger bulk of iron than the change al A,... To make the mailer clear let us consider , I i:v I Sin ; , Meet conl .'lining some O.i'.O per cenl of carbon and, therefore, made up H,ft or slo\\ COOling of 72 per COU I ol pearhle and '.'S per COH< of free I'ernte. Tills steel will contain about 7'J \ ; s M prr cenl of pearlilc ferrilc represeiiled by !'(> in Ki.uure ISO. \Vhrn the point A, is reached this (\'.\ per cent of iron is slill in i hr ^amma condition (ftOOOrding lo the general belief 1 ! and now passes to the alpha condilion rilhrr dirrclly or tirsl assuming thr brla slate. The allolropie character of the point \, is thcrrforr rvident. Indred H is sullicient lo account for the heal evolved at Ar, or absorbed ill Ac, wilhoul the assistance of any change occurring in ihe carbon condilion, for it is in perfect agreement with the increased intensity of the poinl \ M , ilu- carbon inorotisos and \\ nh il-. ma \nnnm at I he en I eel old compv-n ion. since a-~ ihe carbon increases the amount of prarlilr and therefore of pearlile-ferrile likrwisr itUToasrs. Summing up, three reasons may be iiiven for ihe evolution ot heal al Ar,: ^P lor- - million of the carbide I'r.jl ' ba-ed on ihr assumption that carbon as such is dissolved m iron. (8) cr\stalli-ation of the carbide 1'e.r ba-ed on the assumption that this car bidr is dissolvrd in iron .and lhal erysialli.-aiion not implying a change of slate max produce heat, and v : >^ allolropie transform;!! ion of ihr iron prrsenl in austrnilr ot eutecloid composition. It seems probable that both C- M :'ul i,:^ contribute to the heat developed ill Al'i. rr.uhte Foim.ition \\haicvei ditVerrmvs ol opinion max exist a- to ihe exact CHUSO 01 causos of the evolution ol lioal oorwspoiulinjj (o the poinl \r all agrc ihai il is due to the transformation of austcnito of euteeloid composition v s omet lines called hardrnitrl into pearlite. i.e. the conversion of a solid solution into an aggre- ..,,:, ferrite plus comentito) li IS well to be*I m mind tlie ohMfes m il;e coiuluion of the iron and carbon which this transformation seems to imply: (Jl passage of the non from the giimma lo (he beta condition. ^ immediaiely followed by its conver- sion into alpha iron or. according to some wrilrrs, v l and L n the conversion of gamma CIIAI'TKK \l Till' TIIKK'MAI, CRITICAL I'olNTS OK STM I I !H iron directly inlo alpha iron, skipping Ihe liela stale, (ii) Ihe crvslalli/inj;- of alpha iron inlo parallel plates or lamella', and ( In) Ihe formal ion and cr\ slalli/.iiiK, or (!/>) Ihe cryslalli/illii' '>nl\ of l''e.,( ' inlo parallel plates alternalinn \vilh Ihe ferrilt- plates. gamm iron one/ cordon ii clr|iicl lii(j; slMirl nr:il rhniipys in |.L>:, pn' ,TII[ r:irl.,m .sln-l as it ('(Mils sluu l\ I I'm 1 1 ll Olten Condition In :ilinns|>liri-ic Irinprralui'r. Cause Of the Point A ,. The point Ar, , nmloiililcdly indicates (he I le^il of I lie lilier.'llioii of free eemelilile in livper eiilecloid sleel as if cools from A,.,,, In AlV'i. This gradual formation of free eemelilile is well shown in l''inurc IS! \\here il 192 CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL is represented by the triangle EFG. When the point A 3 . 2 .i is reached the residual austenite, now of eutectoid composition, is converted bodily into pearlite, the steel consisting finally of BH = GF per cent free cementite and HC = FI per cent pearl- ite. It will be seen that this uppor point of hyper-eutectoid steel, like the points A 3 and A 2 of hypo-eutectoid steel, does not indicate a complete transformation but merely the beginning of a transformation covering a wide range of temperature, namely, from A cm to A 3 . 2 .i. If it corresponds to a jog rather than to a mere change of direction in cooling curves this must be ascribed to hysteresis and its tendency to accentuate the beginning of a transformation as previously explained. The evolu- tion of heat corresponding to the liberation of free cementite may be explained in two ways: (1) actual formation of Fe 3 C, carbon and not the carbide being in solution above Ar cm or (2) crystallization or falling out of solution of Fe 3 C based on the more probable assumption that Fe 3 C and not C is dissolved by the iron above Ar cm , and on the further assumption that this crystallization in the solid state, since it evidently implies an allotropic or, at least, polymorphic change, must be accompanied by an evolution of heat. Since in hyper-eutectoid steel containing even as much as 1.5 per cent carbon there is but a small proportion of free cementite (some 1 1 per cent) the point Ar cm is caused by the evolution of but a small amount of heat and must therefore be faint. Its intensity, moreover, must decrease as the carbon decreases and the point must disappear altogether as the eutectoid composition is reached, that is, just as it meets the single point of eutectoid steel. This is indicated in Figure 169 of Chapter X. Allotropy of Cementite. If we believe, as most metallographists now do, that Fe 3 C and not C forms a solid solution with carbon above the point AI or A 3 . 2 .i, it follows that this dissolved Fe 3 C crystallizes or falls out of solution at certain critical temperatures, namely, Ar cm for the free cementite of hyper-eutectoid steel and AT, (or Ar 3 . 2 .i) for the pearlite-cementite of all steels, and that this crystallization is ac- companied by an evolution of heat. This falling out of solution really implies a spontaneous change of crystalline form and is therefore an evidence of polymorphism, hence of allotropy, for if allotropy does not necessarily imply polymorphism, poly- morphism implies allotropy. Are we not then justified in believing that Fe 3 C may exist under two allotropic forms: (1) an allotropic variety soluble in iron, which we may call gamma cementite and (2) an allotropic variety insoluble in iron, which we may call alpha cementite, constituting the free cementite of hyper-eutectoid steel and the hard plates of pearlite? The fact that the crystallizing or falling out of solution of free ferrite in hypo- eutectoid steel implies an allotropic transformation of the liberated ferrite, points with force to a similar transformation forming part of the liberation of free cementite in hyper-eutectoid steel. In the case of iron we are able to actually prove this allo- tropy through the cooling of very pure iron and the testing of its properties while in the case of cementite such direct proof is not yet at hand because of the difficulty of obtaining pure cementite and of testing it after producing it. To generalize, it would seem as if the crystallizing or falling out of solution of a substance at certain critical temperatures always implies a spontaneous change of crystalline form and, therefore, an allotropic transformation of the substance separat- ing from the solution, whether .that solution be liquid or solid. In the former case the falling out of solution implies a change of state, the separating substance passing from the liquid to the solid state, but does it make it less of an allotropic change? CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL 193 Allot ropic transformations which also imply changes of state might be called in- stances of major allotropy to distinguish them from those instances in which changes of internal energy are not accompanied by changes of state. l-iquicf so/tjfion iron and carbon 5o//cf gamma /ran and carbon (Ausfenrfe) PearJ/fe 3 C I''ig. 1SU. Diagram depicting structural changes in eutectoid steel as it cools slowly from the molten condition to atmospheric temperature. Cause of the Point A 3 . 2 .i in Eutectoid Steel. In the case of eutectoid steel the solid solution (austenite) is originally of eutectoid composition and, therefore, on cooling reaches the point Ar 3 . 2 .i without rejecting either ferrite or cementite, hence 194 CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL the absence of upper points in eutectoid steel. On passing through the point Ar 3 . 2 .i (Fig. 182) this austenite is converted into pearlite. Pearlite contains 87.50 per cent of ferrite which undergoes allotropic transformation at Ar 3 . 2 .i, hence the intense allo- tropic character of this point. The crystallizing of cementite probably contributes also to the heat evolved at Ar 3 . 2 .i whether it implies the formation of Fe 3 C or not as explained before. It has also been argued that this crystallizing of cementite probably implies an allotropic transformation, in which case the point A 3 . 2 .i (and Ai as well) would be solely an allotropic point, resulting from the simultaneous allotropic transformation of both the iron and the Fe 3 C of austenite of eutectoid composition. Finally let us bear in mind that notwithstanding its notation the single point of eutectoid steel does not in fact result from the merging of the several points of hypo- eutectoid steel, being merely a continuation of the point Ai. This point Ai is essen- tially a "pearlite" point while the upper points of hypo-eutectoid steel are "ferrite" points and the upper point of hyper-eutectoid steel is a "cementite" point. Cause of the Point A 3 . 2 .i in Hyper-Eutectoid Steel. The point A 3 . 2 .i in hyper- eutectoid steel is of exactly the same nature as the point A 3 . 2 .i of eutectoid steel and the point AI of hypo-eutectoid steel. It marks the formation of pearlite, bearing in mind the various changes in the condition of the carbon and iron implied by that formation. As the proportion of pearlite now decreases with increase of carbon the intensity of the point A 3 . 2 .i likewise diminishes. Summary. The apparent causes of the thermal critical points of iron and steel may be briefly summed up as follows : The point Ar 3 of carbonless iron and of steel containing less than some 0.35 per cent carbon marks the beginning of the liberation of ferrite (which liberation con- tinues down to the point An) and the transformation of that ferrite from the gamma to the beta condition, this setting free of ferrite and its allotropic transformation being probably simultaneous. The point Ar 2 of carbonless iron and of steel containing less than some 0.35 per cent carbon indicates the transformation from the beta to the alpha condition of the ferrite liberated between Ar 3 and Ar 2 and the beginning of the passage of the ferrite, which continues to be liberated as the metal comes from Ar 2 to AT,, from the gamma to the beta and then to the alpha condition or, as some writers claim, directly from the gamma to the alpha state. The point Ar 3 . 2 of steel containing somewhere between 0.35 and 0.85 per cent carbon marks the beginning of the liberation of ferrite which takes place between Ar 3 . 2 and Ari and the passage of that ferrite from the gamma to the beta condition and immediately to the alpha state or, according to some writers, directly from the gamma to the alpha condition. Since only the formation and transformation of free ferrite is involved at the points A 3 , A 2 , and A 3 . 2 these points may properly be called "ferrite" points. The point AI of hypo-eutectoid steel, as well as the point A 3 . 2 .i of eutectoid and hyper-eutectoid steel, marks the rather sudden transformation of the residual solid solution (austenite), now of eutectoid composition, into pearlite, bearing in mind the changes in the conditions of the iron and carbon which such transformation implies. The points AI and A 3 . 2 .i may properly be called "pearlite" points. The point Ar cm of hyper-eutectoid steel marks the beginning of the setting free of cementite as the metal cools from Ar cm to Ar 3 . 2 .i, the liberation of cementite prob- ably involving an allotropic change of that constituent as previously explained. CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL 195 In Figure 183 an attempt has been made at showing diagrammatically the rela- tion between the critical points of steel and its structural composition after slow cooling. It will be readily understood. The upper part of the diagram shows the location of the critical points, the lower part the structural composition in percent- ages of ferrite, pearlite, and cementite. Taking, for instance, a steel containing 0.25 per cent carbon : above A 3 at A it is a solid solution of carbon and iron (austenite) ; on cooling through Ar 3 at B some beta ferrite is set free, this liberation continuing from B to C; on cooling through Ar 2 at C the free beta ferrite is converted into alpha ferrite while additional alpha ferrite forms as the metal cools to Ari, that is from C to D. The ferrite liberated on cooling from B to D, that is on cooling through the criti- ical range, is represented in the lower part of the diagram by DE which is also the final percentage of free ferrite in the steel. As the metal cools through its Ari point //OO' 900 Cr/f/ccr/ Range 70 O' -/-Ausfenrte Ar 5o//d So/uf/on /ron and Carbon fA usfen/fe) Cemenf/fe -f-Ausfenrfe %C O a.o Fig. 183. Diagram showing the relation between the critical points and the structural composition of slowly cooled steel. at D, the residual austenite, at present of eutectoid composition, is converted into pearlite, EF representing the pearlite here formed, i.e. the percentage of pearlite in the steel. The structural formation of any steel can be followed in the same way in this diagram. It will be obvious that the vertical distances representing the per- centages of ferrite, pearlite, or cementite in any steel may also be regarded as propor- tional to the intensities of the corresponding critical points. For instance, the dis- tance ED may be assumed to be proportional to the combined intensities of the points Ar 3 and Ar 2 of a 0.25 per cent carbon steel and the distance EF proportional to the intensity of the Ai point. Interpreted in this way the diagram indicates what has already been pointed out: (1) that the intensities of A 3 and A 2 decrease as the carbon increases, these points vanishing on reaching the eutectoid composition, (2) CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL that the'point AI, very faint at first, increases rapidly with increased carbon, becom- ing maximum at the eutectoid point and then decreasing, and (3) that the point A cm , always faint, increases slightly as the carbon increases above 0.85 per cent. A A,- G 7-<^e A/f>/>o_ Fcrr/tc r D S/c/ -Solution of anaf Cartoon 3 of/c/tftccjft on point So/id Solution of Go/77/?7O Iron and Carbon { Austin ite -A 3 /ron on Cartion ( A/tar f So//& <5o/L//,a/i of - A Ipho /ron and Carbon iTroostifis A, A fr > /y c Fig. 184. Diagram depicting structural changes in 0.20 per cent carbon steel slowly cooled, assuming that the iron remaining in solution as well as the free iron (ferrite) undergoes allotropic changes. To bo compared with Figure 180. Another View of the Allotropic Changes. It will be obvious from the description of the underlying causes of the critical points given in the foregoing pages that, according to the general belief, iron must first be freed from solid solution before it can undergo any allotropic changes or, at CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL 197 least, its liberation from solution and its allotropic transformation take place simultaneously, the latter never preceding the former. In 1906 the author expressed the opinion that it was far from certain that its liberation from solution must precede, or at least be simultaneous with, the allotropic changes affecting iron at certain critical temperatures. He ventured to put forward, in a tenf alive J!^^^ bo way, the hypothesis that iron in solution might first undergo an alJotropic transformation and then be expelled in its new allotropic form. This view was not favorably received but, as it has not been shown to be by any means untenable, the author still believes it worthy of record in these pages. It is evident that if the allot ropic transformation of iron from the gamma to the beta and then to the 198 CHAPTER XI THE THERMAL CRITICAL POINTS OF STEEL alpha state precedes its liberation from solution, three solid solutions of carbon in iron are formed during the slow cooling of steel, namely, carbon (or the carbide Fe 3 C) dissolved (1) in gamma iron, (2) in beta iron, and (3) in alpha iron. The first solid solution is universally called austenite while the hypothesis leads almost irresistibly to regarding the solid solution in beta iron as martensite and the solid solution in alpha iron as troostite, two constituents to be described later. With the assistance of the diagram, Figure 184, and by comparing it with Figure 179 the working of the present hypothesis will be readily understood. In Figure 184 are depicted the structural changes taking place during the slow cooling of steel containing 0.20 per cent carbon and therefore exhibiting the three critical points A 3 , A 2 , and Ai. On cooling through the point A 3 the solid solu- tion of carbon and gamma iron (austenite) existing above As is converted into a solid solution of carbon in beta iron (martensite?). In the beta condition, however, iron cannot be retained in solu- tion and begins immediately to be liberated, and its liberation continues as the metal cools down to AZ. Between As and A 2 we have a solid solution of beta iron decreasing in amount and increasing free beta ferrite. On cooling through Ar 2 both the free beta ferrite and the dissolved beta ferrite pass to the alpha state, giving rise to the formation of free alpha ferrite and of a solution of carbon in alpha iron (troostite?). On cooling from Ar 2 to An additional alpha ferrite is liberated while the propor- tion of carbon-alpha iron solution decreases correspondingly. At An the remaining solution has become of eutectoid composition and is converted bodily into pearlite, the mechanism of this trans- formation being well understood. It will be evident that in the case of hypo-eutectoid steel having but one upper critical point, Ar 3 . 2 , in cooling through that point the metal would pass from the condi- tion of a solid solution of carbon in gamma iron to that of a solid solution in beta iron and then immediately to that of a solid solution in alpha iron, the steel between Ar 3 . 2 and An being composed of this solution in alpha iron (troostite?) and of free alpha ferrite. With eutectoid steel the following changes would take place as it cools through its single critical point Ar 3 . 2 .i: (1) transformation of gamma iron solid solution (austenite) into beta iron solid solution (martensite?), (2) immediately followed by the formation of alpha iron solid solution (troostite?), (3) immediately followed by formation of pearlite. The author thinks that the decreasing intensities of the points A 3 and A 2 as the carbon content increases is the fact most difficult to reconcile with the hypothesis just outlined, for if these points are due to allotropic transformations affecting the entire bulk of the steel their intensities should be quite independent of the amount of carbon present. To be sure, this gradual diminution of the magnitude of the points A 3 and A 2 as the carbon increases is likewise difficult of explanation in the light of the universally accepted hypothesis that free iron only can be allotropically transformed, for it has been made clear in the foregoing pages that these points must indicate then the beginnings of transformations and not transformations carried to completion at those critical points, so that the intensities of the points should be little affected by the magnitude of the transformations themselves, that is, by the amount of free ferrite undergoing allotropic transformation or, which is the same thing, by the percentage of carbon in the steel. The view just outlined as to the mechanisms of the allotropic changes is further depicted dia- grammatically in Figure 185, in which the critical points are represented as covering certain ranges of temperature making it possible to show, graphically, the changes taking place within these ranges. Taking an iron-carbon alloy having, for instance, the composition a (some 0.20 per cent carbon), the diagram shows that above Ar 3 it is made up of aa', i.e. of 100 per cent austenite; on cool- ing through Ar 3 it is gradually converted into martensite; between Ar 3 and Ar 2 beta ferrite is liberated; in passing through Ar 2 the emaining martensite is gradually converted into a solid solu- tion of carbon and alpha iron (troostite?) while the free beta ferrite is converted into free alpha ferrite; between Ar 2 and An additional alpha ferrite is liberated; in cooling through An the remain- ing solid solution (troostite?), now of eutectoid composition, is converted into pearlite. The struc- tural changes occurring in steel having but one upper critical point and in steel of eutectoid composition are similarly depicted. This diagram is reproduced from the "Journal of the Iron and Steel Institute," No. IV for 1906, Plate LII. CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STEEL THEIR EFFECTS It has been shown in preceding chapters that the thermal critical points of iron and steel are due chiefly if not wholly to allotropic transformations of the iron. It is a well-known fact that when a substance undergoes an allotropic transformation many of its properties undergo likewise deep and sudden changes at the critical temperatures. Color, crystallization, dilatation, conductivity both for heat and elec- tricity, strength, ductility, hardness, specific gravity are properties frequently affected as a body passes from one allotropic form to another. We should expect, therefore, such changes to take place, as iron undergoes its allotropic transformations, if not in all, at least in some of the above properties. And it is because such changes do take place that a clear understanding of the occurrence and significance of the critical points is of much practical importance to the iron and steel metallurgist. CHANGES AT A 3 It has been shown that the point A 3 occurs in carbonless iron and in steel con- taining less than some 0.35 per cent of carbon and that it is universally believed that this point indicates an allotropic change, the iron passing from the gamma to the beta condition, or according to some to the" alpha condition, on cooling at ATS, and vice versa, from the beta (or alpha) to the gamma condition on heating at Ac 3 . It should be borne in mind, however, as fully explained in Chapter XI that the general belief is that free ferrite only undergoes this change. As the metal cools past its point Ar 3 the following abrupt changes in some of its properties have been noted. Dilatation. The metal, which above the point Ar 3 was contracting, as is the general rule with all cooling bodies, on passing through the point Ar 3 undergoes sud- denly a marked dilatation, amounting to over iVoo of its length, immediately fol- lowed again by a normal contraction. Such dilatation implies that the change of gamma into beta iron takes place with augmentation of volume, or in other words that gamma iron is denser, has a higher specific gravity than beta iron. The dilata- tions occurring at Ar 3 in the case of steels containing respectively 0.05 and 0.15 per cent carbon are shown graphically in Figure 186. On heating, at Ac 3 a spontaneous contraction occurs of the same magnitude as the dilatation on cooling. Benedicks determined with great care the dilatation of pure iron between 700 and 950 deg. C. and some of his results are shown in Figure 187. The sharp occurrence of a marked dilatation at C, the A 3 point, will be noted. Had we no other evidence of an allo- tropic transformation at this critical temperature, this sudden dilatation taking place as it does in pure iron would justify our belief in its existence. 199 200 CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STKKL Electrical Conductivity. Above the point A 3 the metal has an electrical resis- tance some ten times greater than its resistance at ordinary temperature. As it cools from a high temperature to the point Ar 3 there is but a feeble decrease of its electrical resistance, but as soon as Ar 3 is reached it begins abruptly and sharply to decrease and keeps on decreasing at a normal rate to atmospheric temperature. At A 3 , there- fore, we have a sudden and marked change in the variation of the electrical conduc- tivity corresponding to a sharp break in the curve expressing the relation between temperature and electrical resistance as shown in Figure 188. On heating, at Ac ;t the opposite change takes place, that is, the electrical resistance quite suddenly ceases 10 200- 40O 6OO 300' /OCX? /MX)' Fig. 186. Dilatation curves of various carbon steels. increase. So marked and sudden a change in a physical property is in itself a proof of an allotropic transformation. Crystallization. It has been shown in Chapter V that while gamma and beta iron both crystallize in the cubic system (Osmond) octahedra are the prevailing form of gamma iron while the cube is the crystalline form of beta iron, and that the trans- formation of gamma into beta iron includes a change in the planes of symmetry, at least of carburized iron (Osmond). Tensile Strength. Rosenhain and Humfrey have shown the existence of a dis- tinct discontinuity in the tensile strength of iron at the A 3 point. Dissolving Power for Carbon. Above the point A 3 iron possesses dissolving power for carbon, while according to some writers it loses that. power on passing- through Ar 3 ; in other words gamma iron can dissolve carbon but beta iron is deprived of that power. It does not, however, seem, by any means, proven that beta iron cannot dissolve carbon, many authoritative workers holding the opposite view. This question will be discussed at greater length in another chapter. CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STEEL 201 mm. 1500 600 ^500 \ S i i. x C N. c J h 1 100 1 J7 tf /?// *EREM 'AL Dl .ATATIL N OF J 9ON-G OLD X { B \ C ^ '? \ a 80 O/Mifflfflt 70 70' 700" 600 300" /000C TEMPERATURE > Fig. 187. Dilatation of pure iron. (Benedicks.) Structural Properties. It has been explained at length in Chapter XI that the point Ar 3 corresponds to an abrupt structural change, namely, the beginning of the setting free of ferrite (Fig. 179, Chapter XI). Other Properties. Le Chatelier mentions a change in the variation of the thermo-electric force and a sudden but slight variation in magnetic properties as 202 CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STEEL taking place at A 3 . Meuthen reports a discontinuity in the specific heat of iron be- tween 880 and 900 deg. C., that is at the A 3 point. CHANGES AT A 2 As a separate point A 2 occurs in carbonless iron and in steel containing less than some 0.35 per cent of carbon. The changes of properties taking place at A 2 are not generally as abrupt nor are they as marked as those occurring at the other critical points. It is precisely because of this lack of sharpness and suddenness that some metallographists have questioned the accuracy of the view that this point like A 3 indicates an allotropic transformation. Careful consideration of the evidences at hand appear to show, however, that changes of properties do occur at A 2 sufficiently marked and sudden to warrant the classification of this point as an allotropic one. The fact that these changes-are more gradual than at the other critical points is | O 2OO 4OO 6OO GOO" /OOO /2OO Fig. 188. Electrical resistance curves of iron and high carbon steel. logically explained by Osmond on the ground that beta and alpha iron are isomor- phous, that is, capable of forming solid solutions and that therefore the passage of one variety into the other must necessarily be gradual as well as the variations of the properties of iron which the transformation implies. Dilatation. According to Le Chatelier, to Charpy and Grenet, to Benedicks, and others, no dilatation takes place as the metal cools past the point Ar 2 and they see in this an indication that A 2 is not an allotropic point. Osmond's reply is that the curves obtained by Charpy and Grenet, for instance, do indicate a dilatation at Ar 2 which, however, the authors fail to notice because the transformation not being sudden the dilatation likewise is gradual, whereas the authors were looking for sud- den dilatations only. Some of Benedicks' careful measurements of the dilatation of pure iron are shown graphically in Figure 187. The contraction observed on heating, between A and B, that is during the A 2 range is described by him as a "slight, fully continuously occurring contraction (under heating) which entirely coincides with the gradual disappearance of the ferro-magnetism." Considering, however, that the striction which clearly reveals the position of A 2 covers a range of temperature not exceeding some 15 deg., it seems to point to a discontinuity in the dilatation of the metal rather than to a perfectly progressive transformation. CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STEEL 203 Magnetic Properties. Above the point A 2 steel is non-magnetic, it is not at- tracted by a magnet, but in passing through Ar 2 it suddenly becomes strongly mag- netic. Or, to use physicists terms, above A 2 iron is para-magnetic, below A 2 it is ferro-magnetic. Is not this abrupt and momentous change alone, in the magnetic properties of a metal, sufficient proof of an allotropic transformation? It is true that magnetism is not fully regained until a considerably lower temperature is reached, probably some 550 deg. C., according to Osmond, but the fact remains that the greatest part of the final magnetism of the metal is abruptly acquired as it cools past the point A 2 . What transformation other than an allotropic one can satisfactorily account for this? The relation between the carbon content of steel and the temperatures at which the metal loses its magnetism on heating and regains it on cooling is shown graphically in Figure 189. The points plotted in this diagram represent the average values of a great number of determinations made by Madame Sklodowska Curie with a series of 0.1 OJ OJ a* Fig. 189. Temperatures of magnetic transformations of various carbon steels. very pure carbon steels. It will be noticed that the points of magnetic changes cor- respond closely to the thermal critical points A 2 , A 3 .2, or A 3 .2.i. With little carbon there is but a small gap between the appearance of magnetism on cooling and its dis- appearance on heating, because the points Ar 2 and Ac 2 occur at nearly the same temperature; with 0.50 per cent carbon the magnetic points are lowered and so, like- wise, the point A 3 . 2 while the gap increases, this being consistent with the greater gap between Ar 3 . 2 and Ac 3 . 2 ; with 0.84 per cent carbon the magnetic points are further lowered and the gap between them increased still more, this being in harmony with the location of the point A 3 . 2 .i which is lower than A 3 . 2 and with the greater gap be- tween Ar 3 . 2 .i and Ac 3 . 2 .i. Further experimental evidences that the points of magnetic transformations coin- cide with the thermal critical points are given in the following tables showing the re- sults of several hundred determinations. All the steels used in connection with the results given in Table II contained in the vicinity of one per cent carbon. A magnetic method for the determination of the A 2 , A 3 . 2 or Aa^.i points has been described in Chapter X. 204 CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STEEL TABLE I. COMPARISON OF THE MAGNETIC METHOD WITH THE ORDINARY OR COOLING-CURVE METHOD. (BOYLSTON.) APPROXIMATE CARBON CONTENT OF STEEL METHOD Ac,,, NUMBER OF TESTS A,.,, NUMBER OF TESTS MEAN MAX. MlN. MEAN MAX. Mm. Magnetic .... 773 '{788 1 759 7 708 {711 1706 7 1.25% Ordinary .... 764 {781 1764 4 718 {736 1701 4 Ac 3 .., Ar,,. 2 Magnetic .... 780 {790 1770 7 741 {750 1734 7 0.40% Ordinary .... 827 {830 1822 3 754 {756 1 753 3 Ac a Ait Magnetic .... 764 {772 I 755 6 764 (771 1758 7 0.15% Ordinary .... 768 {772 1764 2 767 {783 1748 3 TABLE II. RESULTS OBTAINED BY STUDENTS AT HARVARD UNIVERSITY STEEL NUMBER METHOD Ae,.j.i NUMBER OF TESTS Arj.j., NUMBER OF TESTS I Magnetic .... 753 72 679 75 Ordinary .... 739 14 688 12 2 Magnetic .... 752 131 695 136 Ordinary .... 750 13 695 17 Q Magnetic .... 761 55 704 .->.-> Ordinary .... 757 55 70S 55 4 Magnetic .... 762 50 700 50 Ordinary .... 751 45 701 45 5 Magnetic .... 776 40 720 40 Ordinary .... 760 30 727 30 Crystallization. The cube being the crystalline form both of beta and of alpha iron and these two allotropic varieties being capable of dissolving each other in all proportions (Osmond) a crystalline transformation at the point A 2 is not to be ex- pected. The crystallography of iron so far as it has been investigated does not re- veal the existence of the point A 2 . Tensile Strength. Rosenhain and Humfrey have shown the existence of a dis- tinct discontinuity in the tensile strength of iron at the A 2 point. CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STEEL 205 Dissolving Power for Carbon. Most metallographists believe that alpha iron does not possess any dissolving power for carbon, or at least that it is only capable of dissolving a very small amount of that element. On the other hand, as already men- tioned, it is far from certain that beta iron is incapable of dissolving carborv state- ments to the contrary notwithstanding. It is possible, therefore, that on cooling through Ar 2 , iron loses its dissolving power for carbon. Structural Properties. By referring to Figure 179 of Chapter XI it will be seen that there is no apparent structural change connected with the pojnt_A 2 . As the steel cools past Ar 2 the liberation of ferrite started at Ar 3 merely continues, to end only at An. Of course the ferrite liberated above Ar 2 now passes from the beta to the alpha condition but this allotropic transformation does not appear to include any struc- tural change. Specific Heat. Weiss and Beck and Meuthen have shown that a sharp dis- continuity occurred in the specific heat of iron at the A 2 point. CHANGES AT A 3 . 2 It has been shown that the point A 3 . 2 resulting from the merging of AS and A 2 occurs, theoretically at least, in steels containing from some 0.35 to 0.85 per cent carbon. As might be expected the changes of properties corresponding to the point A 3 . are the same as those taking place in lower carbon steel at A 3 and A 2 . As the metal cools through Ar 3 . 2 the following variations of properties are, therefore, noted: (1) a marked dilatation, (2) a sudden decrease of electrical resistance, (3) a gain of magnetism, (4) a discontinuity in the variation of the tensile strength and of the specific heat, (5) a probable loss of dissolving power for carbon, (6) the beginning of the liberation of alpha ferrite (see Chapter XI, Fig. 180). CHANGES AT AI The point AI occurs in steel containing from a mere trace to 0.85 per cent carbon. It corresponds, as explained in Chapter XI, to the transformation of the residual austenite (now of eutectoid composition) into pearlite. This formation of pearlite implies that the iron contained in this residual austenite (and forming about 85 per cent of its bulk) undergoes on cooling through An the same allotropic changes as those affecting the free ferrite on cooling through Ar 3 and Ar 2 (or Ar 3 . 2 ). It follows from this that, theoretically at least, the following sudden changes of properties should be noted on cooling through An: (1) a dilatation increasing with the carbon content and being maximum with 0.85 per cent carbon caused by the allotropic transformation of the iron, (2) increased magnetism because of the transformation of additional non-magnetic gamma iron into magnetic alpha iron, (3) decreased elec- trical resistance because of additional transformation of high resistance gamma iron into low resistance alpha iron, and (4) additional loss of dissolving power for carbon because of the formation of additional alpha iron. The point AI is not generally associated with critical variations of the electrical and magnetic properties of steel, but on purely theoretical ground it does not seem possible to avoid the conclusion that such critical variations must exist provided of course that we are right in assuming that in austenite of eutectoid composition the 206 CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STEEL iron is still in the gamma condition, that is, non-magnetic and of high electrical re- sistance. Recent investigations have indeed shown that AI is distinctly a magnetic point. CHANGES AT A 3 . 2 .i The point A 3 . 2 .i occurs in eutectoid and in hyper-eutectoid steel and marks the transformation of the austenite or eutectoid steel or of the residual austenite of hyper- eutectoid steel, into pearlite, as shown in Figures 181 and 182, Chapter XI. In these steels, however, no liberation of free ferrite occurs above the point Ar 3 . 2 .i from which it follows that the totality of the iron undergoes its allotropic change or changes on passing through Ar 3 . 2 .i. The variations of the properties which in hypo-eutectoid steel occur at A 3 , A 2 , and AI must therefore, in the case of eutectoid and hyper- eutectoid steel all take place at the point A 3 . 2 .i. These sudden changes of properties are, on cooling: (1) a marked dilatation, maximum in eutectoid steel (Fig. 186), (2) a sudden decrease of electrical resistance, (3) a sudden gain of magnetism, (4) a loss of dissolving power for carbon. Le Chatelier mentions the fact that on cooling through Ari or Ar 3 . 2 .i steel ac- quires a temporary malleability. If a steel bar, for instance, of sufficient length be held horizontally by one extremity while cooling, it at first remains rigid, but on passing through its point of recalescence it quite suddenly bends. According to Howe this phenomenon was first observed by Coffin. Structural Change at AI and A 3 . 2 .i. The spontaneous transformation of aus- tenite of eutectoid composition into pearlite, that is, of a solid solution into an aggre- gate, at Ari or Ar 3 . 2 .i and the reverse transformation, from aggregate to solid solu- tion, at Aci or Ac 3 . 2 .i, imply structural changes of momentous importance to the steel metallurgist. While these will be dealt with at length in another chapter it seems proper to record here their significance. These structural changes give the key to the rational treatment of steel. They make possible the refining of steel by heat treat- ment seeing that on heating steel through its critical range we may change it from the condition of a coarse aggregate (a coarse structure) to the condition of a fine, nearly amorphous, solid solution. They also make possible the hardening of steel through sudden cooling from above the critical range as will be fully explained in another chapter. CHANGES AT A cm The point Ar cm occurs in hyper-eutectoid steel and marks the beginning of the liberation of free cementite as the metal cools from Ar cm to Ar 3 . 2 .i (see Fig. 181, Chapter XI). Except for this structural change no other marked changes of prop- erties have so far been connected with this point. Prevailing Conditions Above and Below the Critical Range. The following- condensed statement of some of the most significant conditions prevailing above and below the critical range of iron-carbon alloys may be useful in keeping these fundamental facts in mind. By critical range is, of course, meant here the critical points, both on heating and cooling, considered collectively and it will be understood that the conditions described as existing above the range change quite abruptly to the conditions prevailing below the range as the metal cools through the range, or vice versa as it is heated above it. The references made to the crystallizing of the CHAPTER XII THE THERMAL CRITICAL POINTS OF IRON AND STEEL 207 metal, and to the influence of work both above and below the range will be under- stood after reading the following chapters dealing with the treatment of steel. CONDITIONS AND PROPERTIES OF IRON-CARBON ALLOYS AND OF THEIR CONSTITUENTS Above Critical Range Solid solution (austenite). Hardening (dissolved) carbon. Gamma iron. Alloys containing a sufficient amount of carbon possess hardening power. Alloys are non-magnetic. Metal crystallizes on slow cooling. Work prevents crystallization. Below Critical Range Aggregate (ferrite + cementite). Cement carbon (Fe 3 C). Alpha iron. Same alloys deprived of hardening power. Alloys are magnetic. Metal does not crystallize on slow cooling. Work distorts structure. Properties of Gamma, Beta, and Alpha Iron. - Tne various properties of gamma, beta, and alpha iron described in the preceding pages, have been tabulated below as well as some other data of interest. These are in accordance with the views held by many, but the author is well aware that those entertaining different views may take exception to some of the entries. GAMMA IRON BETA IRON ALPHA IRON Metallurgical name Austenite Bel a ferrite Ferrite, alpha ferrite, pcarlite ferrite Solvent power for C (or dissolves carbon up to probably some but opin- probably none, but Fe,C) 1 .7 per cent or Fe 3 C up ions differ opinions differ to 25.5 per cent Range of temperature above A 3 , A 3 . 2 , or A 3 . 2 .i in as free beta ferrite be- below A 2) A 3 . 2 , or AS.M in which stable case of pro-eutectoid tween A 3 and A 2 ferrite, above At or A 3 . 2.1 in case of eutec- toid ferrite System of crystalliza- cubic (orthorhombic ac- cubic cubic tion cording to Le Chatc- lier) Prevailing crystalline octahedra cubes cubes forms Other crystalline char- frequent twinnings no twinnings no twinnings acteristics Specific gravity greater than beta and greater than alpha iron smaller than gamma alpha iron (dilatation (gradual dilatation at and beta iron at Ar 3 ) Ar 2 , Osmond) Electric conductivity ten times smaller than greater than that of gam- greater than that of that of alpha iron at ma iron and increasing beta iron and increas- ordinary temperature with falling tempera- ing with falling tem- ture perature Magnetic properties non-magnetic feebly magnetic strongly magnetic Hardness softer than beta iron, very hard soft harder than alpha iron CHAPTER XIII CAST STEEL The structural and other changes taking place at the thermal critical points of steel account for the deep changes of properties resulting from the treatments to which steel is subjected in the process of manufacture of steel objects. We are now in a position to understand these changes, to anticipate them, and to arrive at the rationale of the treatment of steel which for so many centuries remained purely em- pirical. It is logical that we should first consider the structure of steel before it has re- ceived any treatment whatsoever, namely, the structure of the metal in its cast con- dition. To this study the present chapter will be devoted. The structure of cast steel is different from what, in these chapters, has been termed the normal structure of the metal because, having been developed during very slow and undisturbed cooling from the molten condition, crystalline growth has been promoted, whereas in working and reheating such large growth is hindered or cor- rected. It may well be expected then that the structure of steel castings will be coarser, as is generally expressed, that is, made up of larger crystalline grains, than the normal structure so far considered, and therefore that steel castings will suffer from all the ills that pertain to a coarse structure, namely, weakness, lack of ductility, or even brittleness, etc. It will be profitable to consider first the crystallization of steel in general and then the genesis of the structure of cast eutectoid, hypo-eutcc- toid, and hyper-eutectoid steel. Crystallization of Steel. We are indebted to Captain Belaiew more than to any one else for our knowledge of the crystallization of steel. His views will be briefly described. The crystallization taking place during the solidification period is called by Belaiew "primary crystallization"; it consists in the formation of dendrites of a solid solution of iron and carbon (austenite), all steels immediately after solidifica- tion being built up of juxtaposed and interlocked dendrites mutually limiting each other. If during the process of solidification the molten mother-metal is withdrawn "isolated crystals" are exposed to view (see Chapter V, Fig. 123). The dendrites of the primary crystallization are composed of octahedra, the octahedron being the crystallographic form of iron and steel. According to Belaiew this primary crystal- lization may be detected on the surface of steel samples under favorable conditions while it may be brought out on polished surfaces by a prolonged etching with dilute acids as recommended by N. J. Belaiew. The~structure is then frequently "mac- roscopic" that is visible with the naked eye. A remarkable instance of this primary dendritic structure in manganese steel is shown in Figure 190. Stead depicts this primary crystallization in Figure 191 which represents the gradual growth of three separate crystals. The dark crystallites in A feed and cle- 208 CHAPTER XIII CAST STKKL 209 velop out of liquid, abstracting the iron and concentrating the carbon in portions that still remain liquid. The white junctions in (' and D represent the last portions of liquid metal, rich in carbon, also sulphur and phosphorus, if any happens to be present. Stead writes: "The fine fir-tree crystallites, containing probably a fraction of the amount of the carbon in the liquid steel, grow steadily forward from the cold surfaces of the containing moulds. The crystallites develop branches in three direc- Fig. 190. Manganese steel magnified til* diameters. lions corresponding to the axes of the cube, and these branches throw out similar branches themselves. Eventually parts of the most fusible portions are trapped between the branches and are the last to solidify. When there is much phosphorus or some sulphur in the metal, they are always present together with an excess of the i-arbon in the la-t residue of metal that remains liquid and although in cooling down. after the liquid has solidified, the excess carbon diffuses out of it into the purer part. A. Fiji. I'.H. Diagram representing the gradual growth of three separate crystals. (Stead.) the sulphides and phosphides do not, but remain fixed, and can generally be detected in the solid metal." Immediately after the solidification is completed a crystalline transformation starts in, which Belaiew calls "granulation." This granulation continues until the critical range of the metal is reached, all steels being then made up of a number of grains, each grain built up of small octahedra and having its own orientation. This granulated structure generally called austenitic or polyhedral (C.uillet) may be re- 210 CHAPTER XIII CAST STEEL vealed by etching the steel while still in its granulating zone, that is above its critical range, with hydrochloric acid (Osmond's method) . It will be shown elsewhere that in the case of some alloy steels, notably with certain manganese and nickel steels, this granulated structure is preserved at atmospheric temperature when it can be $ * . -v 1 \ . Fig. 192. Manganese steel. Cast. Heated to 1000 deg. C. and quenched in water. Reheated for two hours at 700 deg. C. and furnace cooled. Magnified 100 diameters. Fig. 193. Steel containing about 0.50 per cent carbon. Cast. Magnified 100 diameters. (R. W. Smyth in the author's laboratory.) revealed by the ordinary etching methods (Fig. 192). Generally speaking the longer the sojourn in the granulation zone and the slower the cooling the larger will be the austenite grains on reaching the critical range and, as later explained, the coarser the final structure of the steel after slow cooling through the range. CHAPTER XIII CAST STEEL 211 In passing through the critical range as previously described the excess ferrite of hypo-eutectoid steel or the excess cementite of hyper-eutectoid steel is rejected by each austenite grain until finally in cooling through An the remaining portions of Fig. 194. Steel. Hyper-eutectoid. Magnified 100 diameters. (R. W. Smyth in the author's laboratory.) Fig. 195. Hypo-eutectoid steel. Cast. Free ferrite rejected chiefly between cleavage planes. Magni- fied 100 diameters. (W. J. Burger, Correspondence Course student.) each grain, now necessarily of eutectoid composition, are converted bodily into pearl- ite. This important crystalline transformation taking place as the steel cools through its critical range is called by Belaiew "secondary crystallization." The resulting 212 CIIAI'TKI! Mil CAST STKKL structures which are retained after complete cooling are readily revealed by the or- dinary etching methods. Very slow cooling while this secondary crystallization is taking place promotes the rejection of the excess constituent (ferrite or cement it e) to the boundaries of the grains giving rise after complete cooling to so-called net- work or cellular structures which are so frequent in steel forgings, and in which each grain of pearlite is surrounded by a membrane of ferrite in hypo-eutectoid steel and of cementite in hyper-eutectoid steel (Figs. 198 and 194). If during the second- ary crystallization, however, the cooling is quite rapid, the excess constituent is for Fig. 190. Stool. Carbon 0.55 per cent. Widmanstatten structure. Magnified (i diameters. ( Helaiew. ' the most part retained between the cleavage planes of the small octahedra compos- ing each grain, probably because the necessary time is denied for this excess constit- uent to reach the boundaries of the grains. This type of structure is of frequent occurrence in steel castings (Fig. 195) and is intensified by a long sojourn in the gran- ulation range of temperature because such treatment results in the formation of larger grains. This structure which might be described as "cleavage" structure is frequently called "Widmanstatten" structure in memory of A. Widmanstatten who in 1808 discovered its existence in certain meteorites. To sum up, the network or CHAPTER XIII CAST STEEL 2K5 cellular type of structure is developed in steel castings by slow cooling through the critical range, especially through the upper part of the range (i.e. through Ar 3 , Ar 2 , Ar 3 . 2 . or Ar ( . m , as the case may be, down to An) when the excess constituent separates from the solid solution. The longer the exposure of the metal in the granulation range, that is between the end of the solidification and the beginning of the critical range, the larger generally the meshes or cells and, therefore, also the pearlite grains. Very slow cooling through the granulation range also promotes the formation of large grains first of austenite and later of pearlite. The cleavage or Widmanstatten type of structure is promoted by long sojourn in the granulation range and slow cooling in that range and by relatively quick cooling through the critical range, especially Fig. 197. Section parallel to the surface of a cube. (Tschennak.) Fig. U)8. Steel. Carbon 0. 55 per cent. Sect ion parallel to the surface of a cube. Magnified 30 diameters. (Belaiew.) through the upper part of the range while the excess constituent is being rejected. The Widmanstatten structure is, generally speaking, more brittle than the network type. Belaiew succeeded in a remarkable manner in reproducing the Widmanstatten structure by subjecting carbon steels to suitable treatments. The structures ob- tained by him in the case of steel containing 0.55 per cent carbon and otherwise of commercial quality are shown in Figures 196 to 203. They are typical structures of steel castings of the same grade but on a much larger scale, for it should be noted that the magnification of Figures 198 to 203 is only 30 diameters while Figure 196 is magnified but 6 diameters. Figure 196 is a beautiful illustration of that type of structure in which the free ferrite has been rejected both to the grain boundaries forming a sharply outlined network and between crystallographic planes. In Figure 198 to 203 the free ferrite is seen massed between cleavage planes. 214 CHAPTER XIII CAST STEEL Fig. 199. Section parallel to the sur- Fig. 200. Steel. Carbon 0.55 per cent. Section parallel to face of an octahedron. (Tsehermak.) the surface of an octahedron. Magnified 30 diameters. (Belaiew.) Fig. 201. Section parallel to the sur- Fig. 202. Steel. Carbon 0.55 per cent. Section parallel face of a dodecahedron. Magnified 30 to the surface of a dodecahedron. Magnified 30 diame- diameters. (Tsehermak.) ters. (Belaiew.) CHAPTER XIII CAST STEEL 215 Octahedric Crystallization of Austenite. It will be noted that the ferrite bands shown in Figures 198 to 203 .;ut each other at right angles or, more frequently, form equilateral triangles. According to crystallographers these are indications that austenite crystallizes in regular octahedra. That this inference is correct appears to be conclusively proven by the following remarks of Belaiew: "Let us consider an octahedron and let us assume that four systems of lamellae locate themselves in this octahedron along its crystallographic planes, that is, parallel to the four pairs of its surfaces, a fact that has been long known in the case of meteoric irons. " If we now examine any section of the octahadron, we shall find that not only the angles formed by the projections of the lamella? vary in different sections, but that the number itself of different sections varies likewise from two to four. For instance, when the section is parallel to the surface of the cube, the number of different sections is minimum, that is, two, and in the entire section we Fig. 203. Steel. Carbon 0.55 per cent. Four systems of lamellae. Magnified 30 diameters. (Belaiew.) find only two systems of lamella; forming right angles. Figure 197 is a diagram of such section and Figure 198 a corresponding section of the steel. "A section parallel to one of the surfaces of the octahedron will yield equilateral triangles formed by three systems of lamella) forming 00 angles; the fourth system coincides with the section con- sidered (see Figs. 199 and 200). "In a section parallel to the surface of the dodecahedron, two systems of lamellae are observed forming an angle of 109 28 l 16''; the other two systems coincide and divide this angle in half (Figs. 201 and 202). Finally any section will give four different systems cutting each other at different angles (Fig. 203). "All these cases, as we have just seen, can very well be illustrated by different samples of our alloy which, firstly, affords a rather weighty proof of the octahedric crystallization of steel and, sec- ondly, brings out the remarkable analogy of this structure with that of meteorites and warrants us to allude to the synthesis of the structure so called of Widmanstatten . . . this structure is the neces- sary consequence of the uniform orientation of the elementary octahedra within a volume of greater or less dimension ; it is, therefore, in no way related with the carbon content and must be obtained 216 CHAPTER XIII CAST STEEL in any alloy of iron and carbon whenever (lie conditions are favorable to the format ion of that structure. "Moreover, in practice this structure is met (although certainly much less developed than in our alloys) every time that the metal is subjected to an intense heating followed by slow cooling as is the case with cast steel or, better still, with burnt or overheated steel. "The very brittleness of these steels may be due to a certain extent to the uniform orientation of the elementary octahedra which are the cause of that structure." Let it be noted that in the case of meteorites the length of time during which the metal is main- tained at a high temperature is so long that generally but one crystal is formed, that is, all the ele- mentary octahedra formed on solidification have assumed the same orientation. In steel the con- ditions being less favorable to uniformity of orientation we have several grains. Structure of Cast Eutectoid Steel. Above its melting-point eutectoid steel consists, like all steels, of a liquid solution of carbon or of the carbide Fe 3 r in iron. It solidifies as a solid solution (austenite) of the same constituents, dendritic crystals Fig. 204. Eutectoid steel. Cast. Mag- Eig. 20"). Hypo-euteetoid steel. Cast. Free ferrite nified 500 diameters. (Boylston.) rejected chiefly to the boundaries. Magnified 100 diameters. (H. C. Cridland in the author's labora- tory. I made up of small octahedra being formed. After solidification granulation takes place and remains active down to the beginning of the critical range which in eutec- toid steel is reduced to the single point Ar 3 . 2 .i, the metal being now made up of crystal- line grains of austenite. In passing through this point the austenite grains are con- verted bodily into as many pearlite grains, as explained in Chapter XI, a coarse austenitic structure acquired at a high temperature giving rise to a coarse pearlitie structure at ordinary temperature. The polyhedral .structure, therefore (Fig. 204), observed after complete cooling indicates the original polyhedral structure of austenite formed above the critical point. Because of a coarser grain and coarser pearlite cast eutectoid steel is weaker and less ductile than eutectoid steel properly worked or annealed or both. Structure of Cast Hypo-Eutectoid Steel. Let us now consider the genesis of the structure of hypo-outectoid steel, and let us select as an example steel containing CHAPTER XIII CAST STKKL 217 0.60 per cent carbon and, therefore, composed after complete slow cooling of 72 per cent of pearlite and 28 per cent of free ferrite. The formation of the structure of this steel has been depicted in Figure 180, Chapter XI, to which the reader is referred. This steel on solidifying passes, like all steels, from the condition of a liquid solution of iron and carbon to that of a solid solution of carbon (or more probably Fe 3 C) in gamma iron, first dendrites and then, through granulation, crystalline grains of aus- tcnite being formed. These grains continue to grow as the steel cools slowly to its upper critical point Ar 3 . 2 when, as explained in Chapter XI,_ferrite begins to be liberated and continues to be liberated as the metal cools to its lower point Ari. This setting free of ferrite is apparently brought about by each grain of austenite rejecting the ferrite in excess of the eutectoid composition, so that by the time the point Ari is reached each residual grain of austenite has the eutectoid composition and on cool- ing through Ari is converted bodily into a grain of pearlite. Microscopical examina- tion reveals the fact that the pro-eutectoid ferrite is rejected (1) to the boundaries of the decreasing austenitic grains and (2) between the cleavage or crystallographic planes of these crystalline grains, so that three types of structures may be distin- guished in cast hypo-eutectoid steel, (a) structures in which the free (pro-eutectoid) ferrite has been rejected chiefly to the boundaries of the austenitic grains (Fig. 205), clearly indicating that these grains were polyhedral, (b) structures in which the free ferrite has been rejected chiefly between the cleavage planes of austenite (Fig. 195), proving the crystalline character of that constituent and suggesting that its crystal- lization is cubic, and (c) structures in which the free ferrite has been rejected partly to the grain boundaries and partly between the cleavage planes. Long exposure to high temperatures followed by rapid cooling through the critical range appears to favor the massing of free ferrite between crystallographic planes, whereas short ex- posure and slower cooling promotes the expulsion of free ferrite to the grain bounda- ries, resulting in sharply denned network structures. The structure of cast hypo-eutectoid steel is coarse (1) because its slow and un- disturbed cooling promotes the formation of large austenite grains and hence, later, of large pearlite grains, (2) because its slow cooling between the upper and lower critical points favors the rejection of a maximum amount of free ferrite which rejec- tion makes for coarseness of structure, and (3) because its slow cooling from the upper critical point to atmospheric temperature promotes the crystallization of free ferrite into large grains, this influence, however, being material only where there is a large amount of free ferrite, i.e. in very low carbon steel. Because of its coarser structure cast hypo-eutectoid /steel is less tenacious and less ductile than forged or properly annealed steel of similar composition. Structure of Cast Eutectoid vs. Structure of Cast Hypo-Eutectoid Steel. Although the pearlite grains of eutectoid steel may be and often are larger than the pearlite grains of hypo-eutectoid steel, the latter, especially when judged by its frac- ture, is the coarser of the two. This greater coarseness of hypo-eutectoid steel in spite of smaller pearlite grains is due to the presence of free ferrite, relatively small pearlite grains surrounded by coarse ferrite envelopes or holding coarse ferrite par- ticles imparting a coarse appearance to the fracture of steel. The dimension of the pearlite grains, therefore, while not without influence, is not the criterion by which to judge of the coarseness or fineness of the structure and fracture of hypo-eutectoid steel, the amount of free ferrite present and its mode of distribution having to be taken into consideration. In very low carbon steel, moreover, there is but little 218 CHAPTER XIII CAST STEEL pearlite and the small amount present occurs as small irregular particles exerting but little influence upon the character of the fracture which now depends quite exclu- sively upon the dimension of the ferrite grains. As ferrite grains, however, no matter how small never impart as fine a structure or fracture to steel as pearlite grains, it follows that low carbon (ferritic?) steels can never have as fine a structure or frac- ture as higher carbon (pearlitic) steels. Structure of Cast Hyper-Eutectoid Steel. The genesis of the structure of cast hyper-eutectoid steel has been depicted diagrammatically in Figure 181, Chapter XL Between its solidification point and its upper critical point (A cn) ) this steel is com- posed, like all steels, of crystalline austenite grains. Upon reaching the point Ar cm the setting free of cementite begins, ending only at the lower point Ar s .2.i- This free Fig. 206. Hyper-eutectoid steel. Cast. Free cementite rejected partly to the boundaries and partly between cleavage planes. Magnified 114 diameters. (Boylston.) cementite, like the free ferrite of hypo-eutectoid steel, is rejected (1) to the bounda- ries of the diminishing austenite grains and (2) between the cleavage planes of this crystalline austenite, giving rise to the three types of structure described in the case of hypo-eutectoid steel, but in which free ferrite is replaced by free cementite, namely, (a) structures in which the free cementite is found chiefly at the grain boundaries, (6) structures in which the free cementite is chiefly located between cleavage planes, and (c) structures in which the free cementite is partly at the boundaries and partly between crystallographic planes (Fig. 206). Like the structure of cast hypo-eutec- toid steel, the structure of cast hyper-eutectoid steel bears witness (1) to the poly- hedric form of the austenite grains, (2) to the crystalline character of these grains, and (3) to their probable cubic crystallization. Long exposure to high temperatures followed by relatively rapid cooling between Ar cm and Ar 3 . 2 .i promotes in hyper-eutectoid steel the rejection of cementite to the cleavage planes, while short exposure and slower cooling favor the rejection of cemen- tite to the boundaries. CHAPTER XIII CAST STEEL 219 The rejection of free cementite, like the rejection of free ferrite, makes for coarseness of structure and fracture, from which it follows that cast and slowly cooled hyper- eutectoid steel will be coarser than cast and slowly cooled eutectoid steel, and that the more free cement ite it contains, that is, the higher the carbon, the coarser it will be. The structure and fracture of hyper-eutectoid steel, however, will generally be decidedly finer than that of hypo-eutectoid steel because of the very small amount of free cementite present in the former compared to the amount of free ferrite in the latter, unless, indeed, the hypo-eutectoid steel be very near the eutectoid composition. This is due to the fact, now well understood, that starting from the eutectoid com- position (carbon 0.85 per cent), as the carbon decreases the amount of free ferrite increases rapidly, while as the carbon increases above the eutectoid ratio the amount B D E H Hot Arj.i. line H710C. 695 C. i Cold CARBON PEE CENT 0.12 0.20 0.50 O.Go 0.75 0.90 1.10 1.40 1.60 Fig. 207. (Stead.) of free cementite increases slowly and remains small even with high carbon content. Steel with 0.50 per cent carbon, for instance, contains 40 per cent of free ferrite, hence its coarseness both of structure and fracture, while steel with say 1.25 per cent carbon contains but 6.4 per cent of coarsening free cementite, hence the relative fineness of both its structure and fracture. The rejection of the "excess" constituent (ferrite or cementite) and the formation of the final pearlitic structure in steels of varying carbon contents has been interestingly depicted by Stead (Fig. 207). A, B, C, D, and E are hypo-eutectoid steels containing increasing percentages of carbon, F is steel of eutectoid composition, G, H, and I hyper-eutectoid steels of increasing carbon contents. The diagram clearly shows (1) that in hypo-eutectoid steel, as the carbon increases, the rejection of the free ferrite (the white constituent) by the solid solution (the black portion) begins at progressively lower temperatures (the Ara or Ars.2 point) and that the amount re- jected decreases steadily, (2) that in hyper-eutectoid steels, with increasing carbon, cementite is rejected in larger proportions and at increasing temperatures (the Ar cm 220 CHAPTER XIII CAST STEEL point), (3) that at the Ar^ or Ars.s.i point the remaining solid solution (black portion) is converted bodily into pearlite (the shaded portion), (4) that a coarse austenitic structure developed above the ATI point implies the formation of a coar.se pearlitic structure below that point, and (5) that with some 0.50 or more per cent carbon the excess constituent frequently forms membranes surrounding pearlite grains and giv- ing rise to so-called network, cellular, or polyhedral structures. Ingotism. Howe has suggested the term "ingotism" to designate the structure of cast steel described in the foregoing pages and characterized (1) by large pearlite grains and (2) by coarse ferrite or cementite membranes surrounding them and by irregular masses of these constituents located in some of the cleavage planes of the original austenite grains. CHAPTER XIV THE .MECHANICAL TREATMENT OF STEEL Forged steel objects are manufactured by subjecting the cast metal (1) to pres- sure exerted by rolls, presses, or dies, or to blows from hammers and (2) by reheating it to various temperatures for various lengths of time and cooling it at various rates. In other words we have to consider (1) the mechanical treatment of steel and (2) its heat or thermal treatment. The machining of steel is not here mentioned since it can evidently have no effect upon the structure and properties of the metal, unless it be a very superficial one. While the primary purpose of working steel is to shape it into useful appliances and while the primary purpose of reheating it may be, and often is, to impart to the metal such plasticity as will facilitate its being so shaped, both mechanical and heat treatments deeply affect the structure of steel and therefore its physical properties. To this very important subject the next four chapters will be devoted. We shall first consider the influence of mechanical treatment and then that of heat treatment. The effect of work upon the structure and properties of steel greatly depends upon the temperature of the metal while it is being worked, the expressions "hot work- in"" and "cold working" being common ones, the former meaning working the steel while hot, and the second working it while cold, more specifically at atmospheric temperature. In these pages the expression hot working will be applied to working the metal while above its critical range, and cold working to work performed below that range. In justification of this course it will be shown that the effect of work changes quite sharply as the critical temperature of steel is passed. Hot Working. Hot working may be applied to steel (1) after it has solidified but before it has cooled to a much lower temperature so that it still possesses the necessary plasticity, or (2) the steel ingot may be allowed to cool to atmospheric tem- perature or at least to a temperature so low that reheating is required as a preliminary step to successful hot working. The following considerations will show that so far as the influence of hot work is concerned it is quite immaterial whether the steel ingot has or has not been completely cooled before being brought to the forging tempera- ture. Let us assume that the steel ingot be allowed to cool to atmospheric tempera- ture, that it is then reheated to a temperature well above its critical range and then subjected to hot working. An attempt has been made in Figure 208 to depict graphically the influence of hot work on the structure of steel. The diagram will be readily understood. The critical range both on heating and cooling is represented by a double line, but the reader will, of course, bear in mind that the critical range on heating does not coincide with the range on cooling and that each range may include one, two, or three critical points, as fully explained in previous chapters. For the present purpose it is preferable 221 222 CHAPTER XIV THE MECHANICAL TREATMENT OF STEEL (0 4- + 4- + + + + + 4- + + ' (-4- -' H- + + + v S|! * o^; I 5 I E C * I 1^ 3 v o 5 ilif () per cent. Finishing temperature near critical range. Magnified 100 diameter*. (Burger, Correspondence Course student.) into a fine pearlitic structure. The metal will then have as fine a structure as can l>e imparted to it by work alone, followed by slow cooling through the range. If eutectoid steel be worked until its temperature is still considerably above its critical point (/, Fig. 208), and then allowed to cool undisturbedly, austenite grains begin to form and increase in size as the metal cools to its critical point, i.e. from/ to / when these austenitic grains are converted into as many pearlitic grains. The final grain size therefore will depend upon the temperature at which work ceased and will be the greater the higher that temperature. The structure of hot worked eutectoid steel is shown in Figure 209 under a mag- nification of 100 diameters. Structure of Hot Worked Hypo-Eutectoid Steel. If hypo-euteetoid steel be worked until its temperature is but slightly above its critical range (/", Fig. 208) and then allowed to cool undisturbedly, small grains of austenite are formed which on passing through the critical range at r" are converted into pearlite grains with rejection of excess ferrite as now well understood (Fig. 210). When finished at CHAPTER XIV THE MECHANICAL TREATMENT OF STEEL 225 higher temperatures, "network" structures are often produced (Fig. 211) the bulk of the free ferrite forming- membranes surrounding grains of pearlite (or of sorbite). Generally speaking the meshes of the network will be the larger, the higher the finishing temperature. 1 In the case of low carbon steel, however, containing say less than 0.30 per cent carbon the proportion of free ferrite is so large, i.e. the ferrite net so thick, that the structure consists of particles of pearlite embedded in a matrix of ferrite (see Fig. 212 and also Fig. 207, A and B). Structure of Hot Worked Hyper-Eutectoid Steel. If hypeT-cntectoid steel be hot worked until its temperature is very near its critical range (/", Fig. 208) and then allowed to cool undisturbedly, small austenite grains are formed which on cooling through the range are converted into small pearlite grains with rejection of Fig. 211. Hot worked hypo-eutectoid steel. Fig. 212. Hot worked hypo-eutectoid steel. Carbon O.oO percent. Finishing temperature Carbon 0.05 percent. Magnified 114 diame- considerably above the critical range. Mag- ters. (Boylston.) nified 56 diameters. free cementite, as shown in Figure 213. If the work be stopped at a temperature considerably above the critical range (/, Fig. 208), the final pearlite grains will be larger while the free cementite will be located chiefly at the grain boundaries, a net- work structure being produced. It will be evident that a close relation exists between the size of the meshes of these network structures and the corresponding finishing temperatures. Sorbite. High magnification of the structure of the meshes of both hypo- and hyper-cutectoid steel described in the foregoing pages often fails to reveal the char- acteristic features of pearlite, namely, (1) sharply defined parallel plates alternately 1 The accuracy of this statement has been questioned by some recent writers, notably by W. R. Shinier, who studying the microstructure of steel rails finished at different temperatures con- cludes that the structure is affected more by the rate of cooling than by the finishing temperature. The author's investigations, on the contrary, have always pointed consistently to the marked in- fluence of finishing temperature on grain-size. 226 CHAPTER XIV THE MECHANICAL TREATMENT OF STEEL of ferrite and cementite and (2) a constant or nearly constant carbon content. The structure of these meshes instead remains indistinct and presents a granular rather than a lamellar aspect (Fig. 214). It is also frequently noted in connection with these network structures that the full amount of free ferrite or of free cementite has not been rejected, the pearlitic grains having retained some of the constituent in excess of the eutectoid ratio. To this imperfectly developed pearlite the name of sorbite has been given (Osmond) and quite universally adopted in spite of recent and regrettable efforts to eliminate it from nietallographic nomenclature. It will be apparent that the formation of sorbite results from a relatively quick cooling through the critical range, time being denied for the crystallization of distinct lamella; of ferrite and Fig. 213. Hot worked hypor-eutectoid steel. Carbon 1.50 per cent. Finishing temperature near critical range. Magnified 100 diameters. (Reinhardt in the author's laboratory.) cementite and, in the cases of hypo- and hyper-eutectoid stool, for the rejection of the full amount of free ferrite or free cementite. The cooling in air of hot worked pieces, especially when of small size, is often sufficiently rapid to cause the formation of sorbite rather than of pearlite. The production and nature of sorbite will be dealt with at greater length in an- other chapter. It should be mentioned here, however, that while sorbite is less ductile than pearlite it has a higher tenacity, higher elastic limit, and greater hardness (hence greater wearing power). When these qualities are required, in hot forged objects, they may consequently be obtained, although necessarily at the sacrifice of some ductility and softness, by hastening the cooling through the critical range, after work has ceased, when sorbitic rather than pearlitic steel will be produced. Hot Working of Steel vs. Its Critical Range. In conducting the hot working of steel so as to impart to the metal the finest grain that can result from finishing at suitable temperatures, it is generally necessary only to consider its lower critical CHAPTER XIV --THE MECHANICAL TREATMENT OF STEEL 227 point on cooling, namely, Ar, or Ar 3 . = .i. The following considerations will justify this statement. In the case of hypo-entertoid steel if the working be continued while the metal cools from its upper point or points to its lower point, it will make for fine- ness of structure by preventing a coarse massing of the free ferrite while the cold working of that constituent, if taking place at all, must be very slight. The same reasoning applies, with greater force, to the hot working of hyper-eutectoid steel from its upper point (denoting the formation of free cementite) to its lower point Ar 3 . 2 .i. (ireater fineness of structure will result with very little, if any, distortion of the free cementite. It is apparent, therefore, that in order to secure the finest grain obtainable through mechanical refining without appreciable structural distortion steel objects should be Fig. 214. Hot worked sled. Carbon <)..->() per cent. Magnified 650 diameters. finished slightly above their lower critical point, that is, in the vicinity of 700 deg. C. for all grades of commercial carbon steel. Cold Working. By the cold working of steel is meant in these pages the work- ing of it while its temperature is below its critical range. .It will now be shown that the effect of cold working upon the properties of the metal is very different from that of hot working. This should not be a cause for surprise if it be borne in mind that steel above its critical range is in a condition totally different from its condition below it. Above the critical range we have to deal with a solid solution of iron and carl .on, below it with an aggregate of ferrite and cementite. The solid solution exist- ing above the range will crystallize if allowed to cool undisturbedly and it has been shown in the foregoing pages that working in this range, i.e. hot working, is effective in preventing or at least retarding this crystallization, thus imparting a smaller grain to the metal. The aggregate of ferrite and cementite existing below the range, on 228 CHAPTER XIV THE MECHANICAL TREATMENT OF STEEL the contrary, exhibits no tendency to crystallize during slow and undisturbed cooling, because this .aggregate was formed and fully developed while passing through the range, the size of its elements, that is its coarseness, depending (1) upon the coarse- ness of the solid solution immediately before its transformation and (2) upon the time occupied in cooling through the range. Working this aggregate, therefore, as it cools to atmospheric temperature, or working it while at atmospheric temperature, i.e. cold working steel, does not prevent its crystallization. Its effect consists in dis- torting the existing aggregate structure, chiefly through the stretching or elongation of its crystalline elements (free ferrite, free cementite, pearlite) in the direction of the forging, and such distortion in turn means decreased ductility and eventually extreme brittleness. The effect of cold working upon the structure of steel is illustrated in Eig. 215. Cold worked hypo-cut eel oid steel. Car- bon 0.30 per cent. Magnified 100 diameters. (Burger, Correspondence Course student.) Figures 215 and 216 in the case of hypo-eutectoid steel. It is also depicted in the diagram of Figure 208. While the structural distortion caused by cold working is very slight near the critical range of the metal, it rapidly increases as the temperature decreases, becoming very pronounced at atmospheric temperature. The manufacture of wire by cold drawing affords a familiar instance of the effect of work performed at atmospheric temperature both on the structure and properties of the metal. It is well known that after the wire has been passed through several dies it becomes so brittle that annealing is necessary in order to make further reduction in size possible, the annealing operation removing the structural distortion and brittleness produced by working at atmospheric temperature. The cold working of iron and steel affects deeply many of the properties of these metals, its action increasing in intensity as the temperature falls, being therefore more severe at atmospheric temperature. The elastic limit, tensile strength, and hardness are increased in a marked degree, while the ductility as represented both by elongation and reduction of area is reduced, extreme brittleness being eventually produced. 1 1 is generally believed that cold working decreases the density of iron and steel and CHAPTER XIV THE MECHANICAL TREATMENT OF STEEL 229 that the annealing of the cold worked metals increases their density. Both magnetic permeability and remanence are diminished by cold working while the coercive force is increased. Electrical resistance is slightly increased as well as the solubility of the inelals in acids. The specific heat does not appear to be affected. It has been explained in Chapter V that the straining of metals does not involve an actual distortion, an elongation for instance, of their crystalline elements, but rather a yielding through successive crystalline slips. It should also be recalled that many believe in the existence of amorphous iron produced by^seyere straining, as in cold working, and that the influence of that operation on some of the properties of _ *^ ** v*T~H T^"^" . ' ^L^ife^^r^--* ^-^ -^^ay-^^. 5^lrB"^ -^v*, - ., ^>i*- v -^ ifT- 216. Cold worked hypo-eutertoid steel. Carbon 0.30 per cent. Magnified loO diameters. (Buck, Correspondence Course student.) the metal, as mentioned above, may be accounted for in accordance with that hypothesis. Mechanical Refining. It would seem as if with the use of pyrometers at least it should be a relatively simple matter to finish steel objects very near the desirable temperature and thus secure for them the best structure that can be imparted by work alone. Upon reflection, however, it will be manifest that the problem is on the contrary an insoluble one, for the reason that unless the objects are of very small cross-sections, it is quite impossible to finish them so that their temperature will be uniform throughout, the central portions being necessarily hotter than the outside. Should the forging be so conducted that the temperature of the outside be very near the critical range, the center, being materially hotter, will coarsen on cooling, while if the implements, on the contrary, are finished so that their center may have the fine structure produced by ceasing the work at the proper temperature, their outside must necessarily suffer from cold working. The limitations of work alone as a means of imparting the best possible structure to steel are therefore quite evident. CHAPTER XIV THE MECHANICAL TREATMENT OF STEEL While a, uniformly fine grain cannot be imparted to steel objects of considerable size through hot working alone, the value of hot work as a means of refining the structure of steel remains very great as exemplified by the structure of properly hot forged steel when compared with the structure of steel castings of similar composi- tion. The finer grain imparted to steel by working it has been called by some writers "mechanical" refining to distinguish it from the refining produced by heat, i.e. from "thermal" refining. In practise hot work should be so conducted, that is, the finish- ing temperatures so regulated, that the central portions of the finished implements will not suffer unduly from the coarsening influence of too high a finishing tempera- ture, while at the same time the outside will not suffer unduly from the effect of cold working. The natural tendency of rolling and other forging mills is to finish work at too high temperatures for the simple reason that the metal is then more plastic and consequently requires less power for its working. In some manufactures, how- ever and, especially in the rolling of rails, the importance of proper finishing tempera- tures has been given careful attention and the rolling operation so modified as to deliver rails of much finer grain and therefore better physical quality, than formerly. Besides its important grain refining influence hot work further improves the quality of steel by closing and, if the carbon be low enough, welding, the blow-holes and otherwise increasing its soundness and by removing cooling strains. CHAPTER XV THE ANNEALINC OF STEEL Purpose of Annealing. The purpose of annealing steel may be (1) to increase its softness and ductility that it may, for instance, be more easily machined or (2) to secure a desirable combination of high strength and elastic limit with fair ductility that it may successfully stand the strains to which it is to be subjected. These changes of physical properties result from corresponding changes in the structure of the metal brought about by proper heat treatment. In annealing steel it is generally intended to impart to it as fine a structure, that is as small a grain, as is consistent with the nature of the treatment and the grade of the steel. Hot forged steel objects may be improved by annealing for certain purposes, because of their structure being often (1) relatively coarse owing to high finishing temperature and (2) heterogeneous as explained in Chapter XIV. Cold worked steel must generally be annealed in order to increase its ductility. A large amount of cold drawn wire, however, is used in its cold-worked condition when very high yield point and tensile strength are desired and relatively low ductility permissible, as in spring wires, piano (music) wire, wires for wire ropes, etc., when a tensile strength exceeding 350,000 Ibs. per sq. in. may be obtained. 1 Finally, steel cast ings have so coarse a structure as to be very deficient both in strength and ductil- ity and should always be refined by annealing. Nature of the Annealing Operation. The annealing operation comprises three distinct steps: (1) heating the steel, (2) keeping its temperature constant at the an- nealing temperature, and (3) cooling it from the annealing to atmospheric tempera- ture. These steps will be considered separately. Heating for Annealing. The first step in annealing always consists in heating the metal past its critical range because by so doing the preexisting structure, how- ever coarse, is obliterated; the metal, for the time being, assuming a nearly amorphous structure. It is true that, as later explained, cold drawn wire is very frequently re- heated to a temperature inferior to its critical range for the purpose of removing the loss of ductility occasioned by cold working but it may well be contended that such an operation is not, strictly speaking, annealing, for it does not imply a complete obliteration of the preexisting structure such as takes place when steel is heated past its critical range. This important structural change is due, as we now understand it, to the pas- sage of the steel from the state of an aggregate of ferrite and cementite to that of a homogeneous solid solution, and it is not to be wondered at that so radical a struc- tural change should destroy effectively any preexisting crystallization. The anneal- ing of steel castings, however, constitutes an apparent exception to the rule that 1 The author's attention was called to these important uses of cold worked wire in the un- aime;ded condition by Mr. K. H. IVirpe of the American Steel and Wire Co. 231 232 CHAPTER XV THE ANNEALING OF STEEL heating just through the range is sufficient to break up effectively the preexisting structure, for their successful annealing often requires a materially higher tempera- ture. Should the temperature of the steel remain below its critical range, no struc- tural change would take place and the annealing would be ineffective (I, Fig. 217) unless, indeed, in the case of cold worked hypo-eutectoid steel when the distorted fer- rite may be restored to its normal crystalline structure by heating slightly below the critical range as later explained. 1 Should, on the contrary, the temperature of the steel be carried considerably above the range, its structure, which was finest as it emerged from the range, begins to coarsen on further heating and continues to grow as the metal cools slowly to the range, so that its final structure would be at least 27 Ar m J_ I Cnf/caf 3fruc fure Coarse structure O f~/ne A structure F Very f/ne structure Strong, etosf/c, one" /ot/p/j O Hardest, sfronues/, uno* /east duc//7e duct/fa Fig. 217. Diagram dnpirtintj 1lu> annealing of steel. relatively coarse (II, Fig. 217). Clearly, therefore, to anneal .steel forgings they should be heated through their critical range and kept at a temperature as close to the upper part of that range as possible (III, Fig. 217). The annealing temperature will, of course, vary with the carbon content since the position of the critical range, or rather its width, varies likewise. The structural refining taking place in heating through the critical range is strikingly illustrated by Stead in Figure 218, which shows coarsely crystalline soft steel heated at one end to above 900 deg. C. The re- fined portion was heated above the critical range. The sharp demarcation between the original coarse structure and the fine structure produced by annealing should be noted. 1 When steel contains hardening carbon it may lie softened and made more ductile by heating it to temperatures lower than its critical range (as in the tempering of hardened steel) but such treat- ment is not, or at least should not be, called annealing. Cooling strains may also be removed, at least in part, by heating below the range. CHAPTER XV THE AXXEALIXG OF STEEL 233 The following ranges of temperatures are recommended by the Committee on Heat Treatment of the American Society for Testing Materials. The report of the Committee states that for steels containing more than 0.75 per cent manganese slightly lower temperatures suffice. RANGE OF CAKBON CONTENT Less than 0.12 per cent 0.12 to 0.2.5 per cent 0.30 to 0.49 per cent 0.50 to 1.00 per cent RANGE or ANNEALING TEMPERATURE S75 to 925 deg. C. (1607-1697 deg. F.) 840 to 870 deg. C. (1544-1598 deg. F.) 815 to 840 deg. C. {1499^1554 deg. F. ) 790 to 815 deg. C. (1454-1499 deg. F.) The proper temperatures to which to heat carbon steels of ordinary commercial quality for the purpose of annealing as well as of hardening are indicated graphic- ally in Figure 219 for various percentages of carbon. Fig. 218. Coarsely crystalline soft steel heated at one end to above 900 deg. C. (Stead.) Time at Annealing Temperature. The steel object should be kept at the anneal- ing temperature long enough to be heated right through to that temperature. The ( lommittee on Heat Treatment, referred to above, states that an exposure of one hour should be long enough for pieces twelve inches thick. Thicker pieces, of course, need a longer heating. The usefulness of pyrometers in conducting annealing operations is obvious. Their use is to be strongly recommended. Cooling from Annealing Temperature. Having imparted a fine structure to the steel the next step must be to retain it. The most effective way of accomplishing this consists in cooling the steel very quickly, by quenching it in water for instance, as time is then denied for the structure to coarsen at all while the metal cools to at- mospheric temperature. Such rapid cooling, however, as is well known, hardens the metal and deprives it of ductility (unless, indeed, it contains very little carbon), and this would defeat the purpose of annealing which always demands the retention of considerable ductility. It follows from these considerations that, in annealing, cool- ing from the annealing temperature cannot be so rapid as to very materially harden the steel. 1 Its rate should, moreover, be regulated in accordance with the kind of 1 1'nless (lie double treatment presently to be described is resorted to. 234 CHAPTER XV THK ANNEALING OF STEEL properties we most desire the steel object to possess. For instance, (1) if softness and ductility are wanted (for ease in machining), necessarily at a certain sacrifice of strength and elasticity, the cooling should be very slow, to wit, with the furnace in which the object was heated, (2) if greater hardness (for wearing power), strength, and elasticity are desired, at the necessary sacrifice of some ductility, the cooling should be more rapid as, for example, in air or, in the case of low carbon steel, in oil or, with very low carbon steel, even in water (III, Fig. 217). Rate of Cooling vs. Carbon Content. The lower the carbon content the more rapid may be the cooling from the annealing temperature without affecting too deeply 950 40 3O 20 10 <300 90 80 70 60 850 4O 30 to 10 800 1742T 6 -7 CARBON -8 -9 1O PER CENT 1.2 Fig. 219. Diagram showing suitable temperatures for annealing (and hardening) carbon steel forgings. the ductility of the metal. For instance, (1) steel containing not over 0.15 per cent carbon may be quenched in water, therein" increasing its strength and elastic limit and still remain very ductile, (2) steel with less than 0.20 or 0.30 per cent carbon may be quenched in oil with satisfactory results, (3) with a larger proportion of carbon such rapid cooling is no longer possible, as it would destroy the ductility of the metal, recourse having then to be had to cooling in air for the desired combination of strength and ductility or to the double annealing treatment soon to be described. Rate of Cooling vs. Size of Object. --- Since large objects necessarily cool more slowly than smaller ones when subjected to the same cooling influences, it is evident that the external conditions should also be regulated in accordance with the dimen- sions of the objects treated. To secure maximum softness and ductility, for instance, the cooling of small objects should be more effectively retarded than the cooling of CHAPTER. XV THE ANNEALING OF STEEL 235 larger ones. Assume, for example, two objects made of the same steel, one large and one small, and both cooled in air from the annealing temperature; the smaller object will be harder and less ductile than the larger one, because of its quicker cooling. To render it as soft and ductile as the larger object cooling in the furnace may be neces- sary. Similarly, to give strength and high elastic limit the cooling of large objects must be more vigorously hastened than that of smaller objects as, for instance, cool- ing in oil against cooling in air for the smaller piece. Furnace Cooling from Annealing Temperature. As an example of the effect of furnace cooling upon the structure of steel, let us take a steel bar }^ inch square, con- taining 0.50 per cent carbon, heated to 1000 deg. C. and slowly cooled with the fur- nace. Its structure is shown in Figures 220 and 221. It will be seen to be composed Fig. 220. Steel. Carbon 0.50 per cent. Magni- fied 100 diameters. Heated to 1000 deg. C. and slowly cooled in furnace. (R. W. Smyth in the author's laboratory. ! of the normal proportions of pearlite and free ferrite, namely, some 60 per cent of the former, and it will also be noted that the pearlite is distinctly laminated (Fig. 221), and that in places at least the ferrite forms characteristic polyhedral grains. This structure is due to the slow cooling of the steel through its critical range, which per- mits the rejection of the full amount of free ferrite and a distinct crystallization of the constituents of the residual austenite into plates of ferrite and cementite. The relative softness and great ductility of the steel in this condition is due (1) to the presence of the full amount of soft ferrite in relatively large areas and (2) to the pres- ence of distinctly laminated pearlite indicating the absence of hardening carbon as explained later. Air Cooling from Annealing Temperature. To illustrate the influence of air cooling upon the structure of steel, let us take likewise a steel containing some 0.50 per cent carbon, heated to 1000 deg. C. and cooled in air. Its structure is shown in 236 CHAPTER XV THE ANNEALING OF STEEL Figure 222. It will be found quite unlike the structure of the same steel after fur- nace cooling (Figs. 220 and 221). It contains a much smaller proportion of free fer- rite, apparently not over 20 per cent, in the form of a distinct net surrounding dark meshes which a high magnification fails to resolve into distinct parallel plates. Rela- tively quick cooling through the critical range has prevented the separation of the normal amount of free ferrite, from which it necessarily follows that the dark con- stituent contains more ferrite than true pearlite; nor has it the structure of true pearlite, time also having been denied on cooling through the range for the forma- tion of distinct plates of ferrite and cementite. Sorbite is the name of this constituent. The structure of pearlite passing into sorbite is shown in Figure 223. Properties of Sorbite. Sorbite has already been briefly described in Chapter XIV, where it was shown that it could be produced in steel forgings of small sections Fig. 221. Steel. Carbon 0.50 per cent. Magnified 670 diameters. Heated to 1000 deg. C. and slowly cooled in furnace. (C. C. Buck, Correspondence Course student.) through simple air cooling from a finishing temperature superior to the-critical range, and in larger sections by hastening somewhat their cooling through that range. It has also been stated that sorbite is harder, stronger, and less ductile than pearlite. By so regulating the cooling from the annealing temperature, therefore, that sorbitic steel is produced, hardness, strength, and elasticity will be promoted at the sacrifice of some ductility (III, Fig. 217). It will be explained in another chapter that sorbite is generally regarded as one of the transition stages assumed by the metal as it passes from its austenitic condition, stable above the critical range, to its pearlitic condition, stable below that range. Influence of Maximum Temperature. The influence of the maximum tem- perature to which steel is heated before being allowed to cool is well shown in Figures 224 to 227 which should be compared with Figures 220 to 223. They refer to steel CHAPTER XV THK AXXKAIJXG OF STEEL 237 Fig. 222. Steel. Carbon 0.50 per cent. Magnified 100 diameters. Heated to 1000 deg. C. and cooled in air. (Boynton in the author's laboratory.) Fig. 223. Steel. Carbon 1.00 per rent. Magnified 1500 diameters. Pearlite (laminated ) passing into sorbite. (Osmond.) Fig. 224. Magnified 100 diameters. Healed to Fig.. 225. Magnified 100 diameters. Healed to 800 deg. C. and slowlv cooled in furnace. SOO deg. C. and eooled in air. Fig. 226. Magnified 070 diameters. Healed to Fig. 227. Magnified 070 diameters. Healed 800 deg. C. and slowly cooled in furnace. to SOO deg. C. and cooled in air. Figs. 224-227. Steel. ( !arbon 0.50 per cent. (C. C. Buck, Correspondence Course student.) 238 CII.U'TKK XV THK ANNKAI, IXC OF STKKL 239 containing 0.50 per cent carlion and heated to 800 deg. (.'., while the structures illustrated in Figures 220 to 223 refer to the same steel but heated to 1000 deg. The constituents are the same, namely, ferrite and pearlite in the furnace cooled samples, ferrite and sorbitc in the air cooled samples, but the higher temperature resulted in the formation of larger particles of pearlite or sorbite, evidently because of the forma- tion above the critical range of larger austenitie grains. Influence of Time at Maximum Temperature. Maintaining steel for a long time at a high temperature causes the formation of large austenite grains, which in passing through the range are converted into large pearlite or~Rorbite grains with Fifi. 22S. -Steel. Carbon O.oO prr cent. Magnified 100 diameters. Heated to 11 ">0 deg. C. for two hours and cooled in air. (Hoynton in (lie author's laboratory.) rejection of free ferrite in hypo-eutectoid steel and of free cenientitc in hyper-eutec- toid steel. It is also noted that the more prolonged the heating the smaller the amount of the excess constituent (free ferrite or free cementite) separating on rapid (air) cooling through the range. This is shown in Figure 228 in which is depicted the structure of steel containing 0.50 per cent carbon heated to 1150 deg. C 1 . for two hours and air cooled. The very large sorbitic grains should be noted as well as the very small proportion of free ferrite. Oil and Water Quenching from Annealing Temperature. As already explained only steel containing very little carbon may be quenched in oil or water for purposes of annealing, unless, indeed, the double treatment soon to be described be employed when higher carbon steels may be so quenched. The structure of steel containing O.K) per cent carbon, heated to !)50 deg. and quenched in water, is shown in Figure 229 while in Figure 230 is seen the structure of steel containing 0.20 per cent carbon 240 CHAPTER XV THE ANNEALING OF STEEL quenched in oil from a temperature of 850 deg. Rapid cooling through the range did not prevent the separation of the bulk of the large amount of excess ferrite present in these steels, hence their softness and ductility even after quenching. They are, however, somewhat stronger and more elastic than similar steels more slowly cooled, (1) because they contain a somewhat smaller proportion of soft free ferrite, (2) be- cause the free ferrite they contain has crystallized into smaller grains, and (3) because their carburized constituent is sorbitic or even nmrtensitic 1 rather than pearlitic. Double Annealing Treatment. It has been stated that the most effective way of retaining in the cold the very fine structure acquired by steel in passing through its critical range consisted in cooling it very rapidly as soon as it emerged from that range, as for instance by quenching it in water. This treatment, however, unless the metal contains very little carbon, hardens the steel and deprives it of ductility, where- Fig. 229. Steel. Carbon 0.10 per cent. Mag- nified 100 diameters. Heated to 950 dog. C. and quenched in water. (Boylston.) Fig. 2:ilt. Steel. Carbon 0.20 per cent. Mag- nified 100 diameters. Heated to 850 deg. C. and quenched in oil. (Boylston.) as annealed steel should not be very hard and should possess much ductility. If this fine grained but hard steel, however, be reheated to a temperature close to but below its critical range, say to from 500 to 650 deg. C., it loses its hardness but re- tains its fine structure and again becomes ductile (IV, Fig. 217). The double treatment outlined above fulfils admirably the aims generally sought in annealing, namely, the production of a very fine structure possessing high strength and elastic limit with fair ductility, in other words toughness and high resistance to wear, to shock, and to fatigue. The change of structure taking place on heating hard- ened steel close to the lower limit of its critical range will be considered at some length in Chapter XVII. It will suffice to note here that the metal passes from a fine mar- tensitic or troostitic condition (the ordinary condition of well-hardened steel) to an equally fine sorbitic condition, possessing in a high degree the physical properties 1 Martensite is the ordinary constituent of steel hardened by quenching. It is hard and deprived of ductility. CHAPTER XV THE ANNEALING OF STEEL 241 desired. The first heating is sometimes called "grain refining" treatment and the second "toughening" treatment. The quenching of a piece of steel from above its critical range, while simple enough in the case of very mild steel, presents increasing difficulties as the carbon increases. It should be conducted with care and intelligence and only by experts. Steel con- taining but little carbon, say not over 0.30 per cent, may be quenched in water, others should be quenched in oil. The ( 'ommittee on Heat Treatment of the Amer- ican Society for Testing Materials recommends, in order to lessen the danger of Fig. 231. Steel. Carbon 0.60 per cent. Magnified 150 diameters. Heated to 850 deg. C., quenched in water, reheated to 000 deg., and cooled in air. cracking, that the object be removed from the oil or water bath before its tempera- ture has fallen below 160 deg. C., or in any event below 100 deg., and that the second treatment be applied within a few hours after the quenching, preferably without ever allowing the piece to cool below 100 deg. and certainly not below 20 degrees. The final properties of the steel will depend upon the temperature of the second heating; the higher that temperature the softer and more ductile will it be, but also the less strong and elastic. For great strength, high elastic limit, and little ductility reheating to 400 or 500 deg. should be applied, while for great ductility, at tjie sacrifice of consid- erable strength, the reheating should be carried to some 700 deg. For intermediate tensile strength, elastic limit, and ductility such as are desired in the majority of cases, the temperature of the second treatment should be between 550 and 650 deg. C. While from purely theoretical considerations it might be argued that the rate of cool- 242 CHAPTER XV THE ANNEALING OF STEEL ing from this second treatment is immaterial, there is little doubt but that the strength of the steel increases somewhat and its ductility decreases with the rapidity of cool- ing. This cooling may be performed in the furnace, in air, in oil, or in water. The double annealing treatment described in the foregoing paragraphs was first suggested by Wallerant of the Creusot Steel Works, France. It was also described by Andre 1 Le Chatelier and adopted by the French navy. Its use is now general when high physical requirements are to be met. In Figure 231 is shown the structure of steel, containing some 0.50 per cent carbon, after double annealing. The fineness of the structure should be noted as well as the Fig. 232. Steel. Eutectoid. Magnified 412 diameters. Heated to 800 deg. C. and slowly cooled in furnace. (C. C. Buck, Correspondence Course student.) lack of laminations and the absence of free ferrite. This steel is composed wholly of finely divided sorbite. Annealing Eutectoid Steel. While the mechanism of the structural changes taking place on annealing steel has been made clear in the preceding pages, it may not be without interest to consider further and in succession the annealing of eutec- toid, hypo-eutectoid, and hyper-eutectoid steel, as these three types of steels have different structures and their annealing involves different structural changes. Slowly cooled eutectoid steel is composed wholly of pearlite which, upon being heated through the single critical point of the metal, namely Ac 3 .2.i, is converted into a solid solution (austenite). The grains of this austenite are very fine as the steel emerges from its range and they are kept from growing by preventing the steel from reaching a higher temperature. On cooling through Ars.2.i the metal again becomes pearlitic if it be given time, as for instance in cooling in the furnace, while it becomes sorbitic if cooled more quickly, as for instance in air in the case of small objects. CHAPTER XV THE ANNEALING OF STEEL 243 Should the steel be quenched in water or oil from the annealing temperature and then reheated near but below the point Acs.2.i, the finely martensito-troostitic structure produced by quenching from above the range is converted into very fine sorbite. It has been explained in Chapter XIII that, for like treatments, the structure of eutectoid steel is finer than that of either hypo-eutectoid or hyper-eutectoid steel and this holds true in the case of annealed samples, although the difference may not be noticeable when comparing the structure of eutectoid steel with that of hyper-eutec- toid steel containing but a slight excess of free cementite. In Figure 232 is shown the structure of eutectoid steel heated~to~800 deg. C. and slowly cooled in the furnace. It is made up of well-developed pearlite. The struc- Fig. 233. Steel. Eutectoid. Magnified 720 diam- eters. Heated to 825 deg. C., quenched in oil, reheated to 050 dog., and cooled in air. (Boylston.) ture of the same steel, quenched in oil at 825 deg., reheated to 650 deg., and cooled in air, is exhibited in Figure 233. The metal is now composed of fine grained sorbite. Annealing Hypo-Eutectoid Steel. Slowly cooled hypo-eutectoid steel is an ag- gregate of pearlite and free ferrite. On being heated through its critical range, as soon as the point Aci is reached, the pearlite is bodily converted into austenite, while the ferrite still remains free. On further heating, however, it begins to be absorbed by austenite, its absorption being completed as the metal emerges from its Ac 3 point. Above Acs the steel is composed wholly of homogeneous austenite. On cooling through the critical range unless, indeed, the cooling be very rapid and sufficient carbon be present, ferrite is again liberated in amount proportional to the slowness of the cooling up to the maximum quantity consistent with the carbon content in the steel. If the cooling be very slow then, for instance in the furnace, the totality of the excess ferrite will be rejected and the. residual austenite converted into well- defined pearlite (Figs. 221 and 226), while if the cooling be more rapid, for instance in air in the case of small objects or in oil with larger ones, a portion only of the excess 244 CH.U'TKK XV THK ANNKAMNC, OF STKKL ferrite is liberated while the residual austenite is converted into sorbite (Figs. 222 and 227).' The liberation of ferrite taking plaee during the slow cooling of hypo- eutectoid steel coarsens its structure and is the chief reason why annealed hypo- ^^1$=%,. .-.' $feuc?^^4&> ^L-. , -- frj -^ >., Fig. 234. Steel. Hypo-eutectoid. 0.20 per cent carbon. Annealed. Magnified 100 di- ameters. (W. .1. Burger, Correspondence Course student.) Kip. 235. Steel. Carbon 1.43 per cent. Magnified ";00 diameters. Heated above critical range and slowly cooled in furnace. (Boyn- ton in the author's laboratory.) eutectoid steel cannot have as fine a structure as annealed eutectoid steel. Howe further contends that as hypo-eutectoid steel is heated from Act to Ac 3 a new crystal- line growth takes place which is the coarser the greater the distance between A, and CHAPTER XV THE AX.XEALIXC, OF STEEL 245 A :) , that is the less carbon in the steel, so that by the time the old structure has been obliterated, i.e. at Ac s , a new grain has formed which is an additional reason why the structure of hypo-eutectoid steel cannot be refined to the same extent as that of eutectoicl steel. The structure of hypo-eutectoid steel after double annealing has been shown in Figure 231. The rapid cooling through the range prevented the liberation of ferrite, while the second treatment produced sorbite, but this sorbite is not as fine grained as that produced in eutectoid steel by similar treatment. An additional illustration of the fine structure that can be imparted to hypo- eutectoid steel by annealing is given in Figure 234 in the case of steel containing 0.20 per cent carbon. Fin- - : >'>. Steel. Carbon 1.25 per cent. Magnified 670 diameters. Heated to SOO deg. C. and quenched in oil, reheated to (>()() deg. and air cooled. (C. C. Buck, Correspondence; Course student.) MO Annealing Hyper-Eutectoid Steel. Slowly cooled hyper-eutectoid steel is an aggregate; of pearlite and free cementite. On heating it through its critical range, i.e. through its Ac ;) .->.i. and Ac,., n points, pearlite is converted into austenite at the lower point and this austenite absorbs the free cementite as the metal is further heated from A(VJ.I to Ac,.,,,. At Ac,.,,, the absorption is complete and the metal composed entirely of austenite. On cooling through the range, if time be given, as for instance in cooling in the furnace, the full proportion of free cementite is again liberated and the residual austenite converted at Ar :) . 2 .i into clearly laminated pearlite (Fig. 235). If the cooling be more rapid, as for instance in cooling small pieces in air, a portion only of the free cementite is set free, while the residual austenite is converted into sorbite. This setting free of cementite, like the liberation of ferrite in hypo-cirtec- toid steel, coarsens the structure. The coarsening influence of free cementite, how- 246 CHAPTER XV THE ANNEALING OF STEEL ever, is far from being as marked as that of free ferrite, chiefly because free cementite is generally present in much smaller proportions. Steel containing as much as 1.50 per cent carbon, for instance, contains but 11.50 per cent of coarsening cementite, while steel with 0.40 carbon contains 52 per cent of coarsening ferrite. In Figure 236 is shown the structure of hyper-eutectoid steel subjected to the double annealing treatment, which resulted in the production of fine grained sorbito. For the purpose of annealing hyper-eutectoid steel, it is seldom advisable to heat it much above its lower critical point Acs.j.i, because while at A cm the free cementite would be completely reabsorbed and, through relatively quick cooling, could be prevented, to a certain extent at least, from again separating, the coarseness of structure resulting from so high a temperature would generally more than offset the gain resulting from the presence of a smaller proportion of free cementite. Fig. 237. Steel wire. 0.08 per cent car- Fig. 238. Steel wire. 0.08 per cent car- bon. Cold drawn. Magnified 100 diam- bon. Cold drawn and reheated below its eters. (E. H. Peirce.) critical range. Magnified 100 diameters. (E. H. Peirce.) Annealing of Cold Worked Steel. It has already been mentioned that the cold working of steel, that is, the application of severe compression or tension when its temperature is below its critical range, and more specifically at atmospheric tem- perature, results in a marked distortion of its structural elements, a decided elonga- tion for instance if the steel is subjected to tension as in wire drawing (Fig. 237, also Figs. 215 and 216, Chapter XIV), and that such distortion causes a great increase of tenacity and hardness but that it lowers the ductility decidedly, eventually produc- ing brittleness. It has also been stated that many other properties of steel are deeply affected and that this action of cold working is ascribed by some to the formation of a certain amount of amorphous iron (Chapter XIV). When it is desired to increase the ductility of cold worked steel in order that it may be subjected to additional drafting or because the uses to which it is to be put call for greater ductility and softness, the metal should be subjected to suitable heat treatment. In the case of cold worked hypo-eutectoid steel which is composed of elongated particles of ferrite and pearlite it is sufficient in order to restore its due- CHAPTER XV TIIK ANNEALING OF STEEL 247 tility to heat it to a temperature varying between 550 and 600 cleg. C. and, therefore, considerably below its critical range (see Fig. 238). This is especially so when the carbon content does not exceed 0.40 per cent and when therefore the metal contains a large amount of free ferrite. It has been stated by some that 520 deg. C. marks the temperature which should be reached in order to produce the desired results in very low carbon steel. This heating of cold worked steel below the critical range to increase its ductility is sometimes called at the works "process" or "works" annealing (J. T. Tinsley) . The treatment causes the free ferrite to recrystallize in its normal polyhedral pattern (Fig. 238) or, if we believe in the existence of amorphous iron in cold worked steel, the return of that amorphous iron to the crystalline condition and hence decreased hardness and strength and increased ductility. It should be noted, however, that the elongated particles of pearlite remain elongated (Fig. 238), the Fig, 239. Steel wire. Cold drawn and re- Fig. 240. Patented steel wire. 0.85 per heated above its critical range. Magnified cent carbon. Magnified 1000 diameters. 100 diameters. (Boylston.) (E. H. Peirce.) ferrite particles alone being affected by the treatment. When maximum softness is required the cold worked steel must be annealed by heating it above its critical range followed by slow cooling. This treatment, of course, removes the distortion of the pearlite as well as of the ferrite (Fig. 239) since both constituents above the critical range form a homogeneous solid solution. In wire mills this is known as "dead soft" annealing (Tinsley) . When it is desired to produce wires having a very high yield point and very great tenacity (300,000 to 400,000 Ibs. per sq. in.) while retaining considerable toughness, the heat treatment is so conducted as to produce sorbite to the practical exclusion of pearlite, free ferrite, or free cementite, and is generally applied to steel wires contain- ing some 0.35 to 0.85 per cent carbon (Tinsley). The process is known as "patent- ing" and the product as "patented" wire. To produce sorbite the cooling through the critical range should be relatively rapid but not so rapid as to cause the retention of martensite or even troostite lest the steel be brittle, nor should it be slow enough to permit the formation of pearlite since this would imply decreased tenacity. Ac- cording to Tinsley, patenting in practice is usually conducted as a continuous 248 CHAPTER XV THE ANNEALING OF STEEL operation, the wire being led through the heated tubes of a furnace and cooled by being brought into the air or into a bath of molten lead comparatively cooled but seldom below 700 deg. F. (367 deg. C.). The structure of patented wire is shown in Figure 240. Tinsley writes that by a proper combination of drafting and patenting it is possi- ble to obtain music wire from a 0.70 per cent carbon steel which will have a tensile strength of 400,000 Ibs. per sq. in., and be sufficiently tough to be wrapped about itself without breaking and be swaged flat to one half its original thickness without split- ting. The same author also states that although it might at first be supposed that wire annealed to a pearlitic condition because of its greater softness and ductility should withstand drafting to a greater extent than patented (sorbitic) wire the facts Fig. 241. Steel. Cast. Carbon 0.30 per cent. Magnified 100 diameters. Annealed. (W. .1. Burger, Correspondence Course student.) are that owing to the rapid loss of ductility characteristic of a pearlitic structure it will not withstand drawing to anywhere near the same degree as will the patented structure. Annealing Steel Castings.- It has been mentioned that the very coarse struc- ture of steel castings, called "ingotism" by Howe, was not as readily refined as the structure of steel forgings, its satisfactory annealing often necessitating prolonged heating slightly above the range or short heating to temperatures considerably higher than the critical range. Notwithstanding their greater resistance to the annealing treatment, successfully annealed castings may possess physical properties fairly equal to those of forgings. In Figure 241 is shown the structure of cast steel containing some 0.30 per cent of carbon and properly annealed. The presence of a relatively small amount of free ferrite will be noted. When highly magnified the carbon-hold- ing constituent should have a sorbito-pearlitic appearance. The Committee on Heat Treatment of the American Society for the Testing of Materials recommends, for the purpose of annealing, heating carbon-steel castings l''ig. 244. Heated tn S75 de-;. ( '. fur five hours and ail' i-onlnl. Fig. 243. Heated to S75 licit. C. and furnace cooled. Fig. 245. Heatod to 875 dcjj. C. and air cooled. l-'is;. L'lti. - llcati'il in 11(1(1 ili'K. C. and air muled, rt- Fig. 247. Heated to 875 deg. C. and quenched in heated to 875 ilc;;. ( '. and air rooli'd. water, reheated to 660 deg. C. and quenched in oil. Aimpaling of cast sled rout Mining 0.30 ])1 in the case of steels containing respectively 0.30 and 0.50 per cent carbon and otherwise of good commercial quality. The treatments corresponding to each struc- ture are indicated in the accompanying legenda. Spheroidizing of Cementite. It is now well understood that on slow cooling through the critical range austenite of eutectoid composition is converted into well- defined pearlite made up of distinct parallel plates or lamella; alternately of ferrite and cementite, while in hyper-eutectoid steel the excess cementite tends to form at the boundaries of the pearlite grains and between the cleavage planes of the austen- ite. This condition of the cementite of pearlite as well as of the free cementite is not, however, final, not being structurally stable, for if the steel be kept for a suffi- ciently long time at a temperature but slightly below its critical range, preferably between 600 and 700 deg. C. the cementite shows a marked tendency to collect in the form of rounded particles embedded in a matrix of ferrite. The phenomenon has been called "spheroidizing" by Howe, or when restricted to the pearlite-cemen- tite, "divorcing," on the ground that it constitutes a true divorce between the con- stituents of pearlite, namely ferrite and cementite. Pearlite that has undergone spheroidizing is sometimes called "granular" or "globular" pearlite. Both hypo- and hyper-eutectoid steels are reported to spheroidize more readily than eutectoid steel, the free ferrite or cementite probably acting as nuclei. Even eutectoid steel, hcjwever, can be completely spheroidized if the heating be continued long enough. Howe states that the transformation is more rapid in a 0.21 per cent carbon than in a 0.59 per cent carbon steel. It seems probable that sorbite yields to the spheroidizing treatment more readily than true pearlite from which it follows that for the purpose of spheroidizing the steel should first be made sorbitic. This can be done by relatively quick cooling through the critical range or as later explained (Chapter XVI) by very quick cooling through the range, thereby producing marten- site or troostite, followed by reheating slightly below the critical range which is also the temperature at which the spheroidizing operation should be conducted. Howe and Levy state that both high heating and long heating above the range CHAPTER XV THK AXXEALIXG OF STEEL 253 Fig. 250. Various st ructures of steel containing 0.30 per cent carbon. Magnified about 30 diameters. 8 9 10. 11 12. 14. 1.5. 10. LKCKNUA FOR FHJUKE 250 Cast condition. Cast and improperly annealed. Cast and properly annealed. li^-in. rolled bar heated for 2 hours at 1000 (leg. C. and cooled in furnace. J^-in. rolled bar heated to 1000 deg. C., cooled in furnace. IJ^-in. round rolled bar heated to 1000 deg. C. and cooled in furnace. K-in. round rolled bar heated to 1000 deg. C. and cooled in furnace. Yz-m. round rolled bar heated to 900 deg. C. and cooled in furnace. 3/2-in. round rolled bar heated to 900 deg. C. and cooled in air. 1 2-in. round rolled bar heated to 900 deg. C. and cooled in oil. '2-111. round rolled bar heated to !)()() deg. C. and cooled in water. Yy\\\. round rolled bar heated to 900 deg. C. and cooled in oil; reheated to 050 deg. C. and cooled in oil. \Vf\\\. round rolled bar heated to 900 deg. C. and cooled in oil; reheated to 650 deg. C. and cooled in oil. J^-in. round rolled bar finished at proper temperature. 114-in. round rolled bar finished at high temperature. Cold worked. 254 CHAI'TKH XV THE ANNEALING OF STEEL 9 Fig. 251. Various structures of steel containing 0.50 per cent carbon. Magnified about 30 dmi LKGENDA FOR FIGURE 251 1. Cast steel. 2. Cast steel improperly annealed. 3. Cast steel properly annealed. 4. >2-in. round rolled steel cooled from 1100 deg. C. in the furnace. 5. Yz-va. round rolled steel cooled from 1000 deg. C. in the furnace. 6. %-in. round rolled steel cooled from 900 deg. C. in the furnace. 7. J^-in. round rolled steel soaked 2 hours at 900 deg. C. and cooled in the furnace. 8. y-f-m.. round rolled steel cooled from 900 deg. C. in the air. 9. J^-in. round rolled steel cooled from 1000 deg. C. in water. 10. K-in. round rolled steel cooled from 900 deg. C. in water. 11. J^-in. round rolled steel cooled from 900 deg. C. in oil. 12. J^-in. round rolled steel quenched in water while passing through critical range. 13. Ji-in. round rolled steel quenched in oil from 850 deg. C.; reheated to 600 deg. C. and quenched in oil. 14. }^-in. round steel finished at proper temperature. 15. Large forging showing finishing at too high a temperature. 16. Cold worked. CHAPTER XV THE ANNEALING OF STEEL 255 retard the divorcing of pearlite. According to Belaiew the patterns of Damascus steel and its remarkable physical properties are probably caused by a divorcing of ferrite and comentite in macroscopically visible, masses produced by prolonged exposure to Fig. 252. Steel. Carbon 0.85 per cent. Magnified 1000 diameters. Spheroidized eemontite. (E. H. Peiroe.) Fig. 253. Steel. Carbon 1.10 per cent. Mag- nified 1000 diameters. Spheroidized cemen- tite. (W. J. Burger, Correspondence student.) Fig. 254. Steel. Carbon 1.24 per cent. Magnified 1000 diameters. Spheroidized cementite. (Osmond.) a temperature not exceeding redness. The spheroidizing treatment greatly decreases the strength and elastic limit, while increasing the ductility and softness and also the resistance to wear (Abbott), these effects being more marked in high than in low carbon steels. Steel in the spheroidized condition is shown in Figures 252 to 254. 256 CHAPTER XV THE ANNEALING OF STEEL Skoicin;/ tlm Properties of Pearlite and its Decomposition Product. Fe.jC repr&ieittetl Black. Mechanical 1 Properties of M.crostructure. Mass. Segregation Stages. Maximum tensile stress about 70 tons per square inch. Elongation on 2 inches =about 10 per cent. IST PHASE. ' ' Sorbitic ' ' ! pearlite with emulsified Fe 3 C. (lark on etching. Verv Maximum tensile stress about 55 tons per square inch.. Elongation on 2 inches=aboutl5percem. 2xi) PHASE. Normal pearlite with semi- segregated FejC. Dark on etching. Maximum tensile stress about 35 tons per square inch. Elongation on 2 inches=about 5 per cent SRD PHASE. Laminated pearlite with completely segregated Fe ;) C. Exhibiting a play of gorgeous colours when lightly etched. Maximum tensile stress about 30 tons per square inch. 4TH PHASE. Laminated pearlite passing into massive Fe 3 C and ferrite. NOTE. It is important to remember tliat in a single section of sleel two or even all three phases of pearlite may be observed in juxtaposition gradually merging into each other. Fig. 255. (Arnold). CHAPTER XV THE ANNEALING OF STEEL 257 Varieties of Pearlite. From the foregoing it will be evident that several varie- ties of pearlite are to be considered and that the physical properties of steel will de- pend greatly upon the character of the pearlite it contains. Arnold considers four varieties of pearlite which are well illustrated in Figure 255. His first phase, which he calls "sorbitic" pearlite, is generally called sorbite by other writers. The char- acter and physical properties of sorbite have been described, as well as some of the conditions necessary to its formation. His second and third phases, to which he gives the names respectively of "normal" and "laminated" pearlite, are both true pearlite, the thicker lamellae of the latter being due to a slower cooling through the critical range. His fourth phase is pearlite in the process of spheroidizing. It is now understood that true, i.e. clearly laminated, pearlite only has a con- stant composition, being in this respect similar to all eutectic and eutectoid alloys as explained in Chapter XXV. In hypo-eutectoid steel sorbite generally contains more ferrite and, therefore, a smaller percentage of carbon than pearlite, while in hyper-eutectoid steel it generally contains more cementite, hence a larger per- tentage of carbon. Moreover, while in true pearlite the carbon is probably wholly present as crystallized Fe 3 C (cement carbon), in sorbite a part of it remains dis- solved (hardening carbon) and it is probably to the presence of carbon in solution that sorbite owes its greater strength and its decreased ductility. Graphitizing of Cementite. It will be explained in another chapter that the carbide Fe 3 C (cementite) is not the most stable form that can be assumed by carbon when alloyed with iron. It will be shown that cementite tends to break up into iron and graphite according to the reaction Fe 3 C = 3Fe + C i i I cementite ferrite graphite and that the graphite form is the final stable condition of carbon. This graphitizing tendency of cementite remains latent unless the conditions be favorable to its activity. These conditions are (1) long exposure to a temperature exceeding the critical range and slow cooling, (2) the presence of much carbon, and (3) the presence of silicon or of some other elements exerting a similar influence. It will be shown that this ten- dency of cementite to be converted into graphite and iron is responsible for the pro- duction of so-called malleable castings and, probably, also for the production of gray cast iron. In the case of steel, because of the relatively small amount of carbon present (not exceeding 1.75 or at the most 2 per cent), the graphitizing tendency is slight. Long exposure of hyper-eutectoid steel, especially if it contains more than one per cent carbon, however, to a temperature exceeding its critical range, is always likely to produce a small amount at least of graphitic carbon greatly impairing thereby, if not ruining, the metal. An instance of graphite formation in high carbon steel is shown in Figures 256 and 257. There is little doubt but the free cementite present in hyper-eutectoid steel, and formed as the steel cools from its Ar cm to its Ar 3 . 2 .i point, is more readily converted into graphite than the cementite included in the pearlite. Once the graphitizing is started, however, it may be carried to comple- tion and include the whole of the cementite present. This indeed is what happens in certain grades of malleable cast iron and of gray cast iron which contain practically the totality of their carbon in the form of graphite. The presence of some free cemen- 258 CHAPTER XV THE ANNEALING OF STEEL :;, - l 'i^ftt ''i\SS'->^WMX^^|-^;:j: S|S " Fig. 256. Steel. Carbon 1.25 per cent. Magnified 150 diameters. An- nealed five hours at 830 deg. C. (C. C. Buck. Correspondence Course student.) Fig. 257. Steel. Carbon 1.25 per cent. Magnified 670 diameters. An- nealed five hours at 830 deg. C. (C. C. Buck, Correspondence Course student.) CHAPTER XV THE ANNEALING OF STEEL 259 tite appears to be necessary to start the graphitizing, which would explain why it does not take place in hypo-eutectoid steel. The author at least never had a case of graphite formation in such steels brought to his attention nor was he ever able to produce graphite in hypo-eutectoid steel. Over Heating. Long exposure of steel to a high temperature necessarily de- velops a very coarse structure and the metal is then said to have been overheated. Stead describes the coarse crystalline structure of overheated steel containing from 0.20 to 0.50 per cent carbon as triangular arrangements of ferrite and pearlite, and that of steel containing from 0.50 to 0.70 per cent carbon as large ferrite cell walls and offshoots of ferrite penetrating the pearlite (Fig. 258). Overheating should not be confounded with burning: overheated steel can be readily restored to a normal Fig. 258. Steel. Carbon about 0.50 per cent. Heated to about 1100 deg. C. (P. J. Neely, Correspondence Course student.) condition by merely heating above the critical range, and is neither red short nor cold short, while burnt steel is extremely brittle. Burnt Steel. When high carbon steel is heated to a temperature approaching its melting-point, it becomes extremely red short as well as cold short while its frac- ture becomes very coarse and shiny. The steel in such condition is said to be burnt. It was generally believed that the red shortness of burnt steel could not be cured short of remelting, but Stead now insists that if burnt steel be allowed to cool com- pletely and is then reheated to a proper temperature it can be rolled and forged as well as if it had not been burnt. It is held by some that the burning of steel is due to the evolution of gases under the influence of a high temperature, chiefly carbon monoxide, resulting from atmospheric oxygen finding its way through the pores of the metal and combining with some of the carbon, although according to Howe other occluded gases, such as hydrogen and nitrogen, may also contribute. These gases force the crystalline grains apart, destroying their cohesion, hence the brittleness of the metal. Oxidized membranes are also frequently found surrounding some of the 260 CHAPTER XV THE ANNEALING OF STEEL grains, their presence readily explaining the impossibility of restoring burnt steel by forging since they would prevent the welding of adjacent grains. Instances of the structure of burnt steel are shown in Figures 259 and 260. Howe defines burning as being "a mechanical separation of the grains on extreme overheating." Some writers have argued, apparently on good ground, that burning will not take place unless the steel has been heated to so high a temperature that it has actually begun to melt, the explanation being perfectly consistent with the well-known fact that high carbon steel burns much more readily than low carbon steel. To make the matter clear let us consider the diagram of Figure 261 in which the solidification period of steel is shown as influenced by its carbon content. This diagram will be discussed at greater length in another chapter. Let us for the present note (1) that as the carbon increases from to 2.0 per cent the solidification of the steel is lowered from A to B, that is s -* V\K. 25!). Burnt steel. Carbon 1 .24 per cent . Fiji. 2(i<). Burnt steel. Magnified :) Magnified 20 diameters. Quenched at a white diameters. iStead.' heat. Unotched. (Osmond.) from 1500 deg. C. to 1325 cleg., (2) that while carbonless iron solidifies at a constant temperature, namely 1500 dog., as the carbon increases, the range of temperature covered by the solidification period increases likewise, extending from B to (' with 2 per cent carbon, that is from 1325 to 1130 deg. ('. ABC then represents the solidi- fication zone of steels of increasing carbon content and the heating of the metal to any point within this zone, when it is partly melted, will cause it to burn. It follows from this that carbonless iron and. very low carbon steel can be heated to a very high temperature without burning, while the danger of burning increases with the carbon. With 0.50 per cent carbon, for instance, the burning zone extends from 1400 to 1450 deg., with 1.0 per cent it extends from 1310 to 1400 deg., with 1.50 per cent carbon from 1210 to 1360 deg. In short, as the carbon increases the steel burns more read- ily (1) because its melting-point is lowered and (2) because its solidification zone, which is also its burning zone, is widened. According to the theory it should not be possible to burn carbonless iron, and indeed the author does not know thai the claim has ever been made that carbonless iron could be burnt. CHAPTER XV THE ANNEALING OF STEEL 261 If ABC represents a burning zone into which steel cannot be brought without having its useful qualities destroyed, we naturally ask why all steels are not so in- jured seeing that they must pass at least once through this zone in cooling from the molten condition. The reason why steel does not burn on solidifying and further cooling is explained by Howe on the ground that while steel ingots or other castings solidify, much hydrogen is given out which may mechanically restrain the oxygen from entering and also counteract it, preventing thereby the evolution of CO from within and the formation of oxidized films, the chief causes of_burning. It is also possible, Howe says, that the greater kneading which an ingot undergoes cures burn- /5OO o Carbon per cenf Fig. 261. Diagram depicting the burning temperature range. ing, while the slight kneading possible in reworking a steel bar does not. This, how- ever, would not explain why steel castings, which undergo no work at all, are not burnt, unless it is because they are generally protected from atmospheric oxidation by their molds (Howe) . Burning should not be confounded with overheating. Overheated steel has a very coarse structure and fracture, but it can be restored by heat treatment alone, or at least by heating and forging, while burnt steel is believed by many to be incur- able. Overheating results from heating close to but below AC (Fig. 261), generally for a considerable length of time, while, as explained, the temperature in burning is carried above AC. Important results recently obtained by Gutowsky would place the end of the 262 CHAPTER XV THE ANNEALING OF STEEL solidification of various carbon steels as indicated by the dotted line in Figure 261. If these are the correct temperatures at which solidification is complete, it follows that the burning zone is wider than was generally believed before the publication of these results. Stead rejecting the oxidizing gases theory believes that the burning of steel resulting from heating the metal to incipient fusion, causes the formation of globules or envelopes rich in phosphorus (hence fusible) round the crystals and that their presence or absence is a proof of the steel having been burnt or not. When they occur they are readily detected by etching the metal with his cupric reagent (Chapter II). The burnt steel in Fig. 262 has been etched with this reagent. The white net- Fig. 262. Burnt steel etched with Stead's cupric rea- gent showing globules and envelopes rich in phosphorus. Magnified 50 diameters. (Stead.) work and white particles show the segregation of portions rich in phosphorus. Stead writes : "The question is often asked of the expert, when steel samples have broken up at the rolls, whether the material is naturally red short or has been burnt. The sides of cracks found in the steel, whether simply red short or burnt, are always lined with oxide; and the expert, in conducting his examination, must be careful to select por- tions free from cracks and to polish and etch them. If they be free from globular specks rich in phosphorus, it may be concluded that the material has not been burnt and is naturally red short, but if such specks be present the reverse conclusion will be justified." Crystalline Growth of Austenite Above the Critical Range. Above its critical range steel is composed of polyhedral crystalline grains of austenite, which are made up of small crystals (probably octahedra) similarly oriented in the same grain but whose orientation changes from one grain to the next. Indeed it is this lack of uni- formity of the orientation of the crystalline matter building up the grains that gives CHAPTER XV THE ANNEALING OF STEEL 263 existence to these grains, for if all the small crystals of which they are composed were similarly oriented, clearly there would be but a single allotrimorphic crystal or grain. If steel be maintained for a long time above its critical range, the austenite grains of which it is composed show a tendency to grow in size through adjoining grains assum- ing like crystalline orientation and, therefore, merging into a single and correspond- ingly larger grain. This growth increases with the temperature and with the duration of the treatment. Given a sufficiently long time and sufficiently high temperature, but one grain must be formed. This, as already seen in Chapter XVI, is actually what takes place in meteorites during the cooling of which the prevailing conditions are such as to produce this uniformity of orientation. It follows from the above considera- tions that on annealing, if the metal be kept a long time above its critical range, even but slightly above it, a coarser austenite will be formed which in turn implies, after slow cooling, a coarser pearlitic or sorbitic structure. In hypo-eutectoid steel the grains of austenite will expel some free ferrite, and in hyper-eutectoid steel some free cementite, before being converted into pearlite, but the final pearlite grains will nevertheless increase in size with the size of the original austenite grains. The struc- ture of steel containing 0.50 per cent carbon kept two hours at 1150 deg. C. and cooled in air has been shown in Figure 228. The very large sorbitic grains formed prove the existence above the range of equally large, or even larger, austenitic grains. The cooling through the range was so rapid that but a small amount of free ferrite was separated, the sorbite grains, therefore, representing nearly the exact size of the auste- nite grains. In Figure 263 an attempt has been made to depict this relation between the austenitic structure above the range and the corresponding pearlitic or sorbitic struc- ture below the range. The steel considered is supposed to be hypo-eutectoid and to contain, after slow cooling, a large proportion of free ferrite. A is intended to rep- resent a piece of this steel made up of nine relatively small austenitic grains formed on short exposure above the range. On cooling through the range ferrite is liberated and the residual austenite grains converted into as many pearlite grains as shown in A'. The small squares of the matrix surrounding the pearlite grains represent as many small ferrite grains. After a longer exposure, possibly at a higher temperature, the steel will be made up of larger austenite grains, say of four grains as shown in B, and these, on slow cooling through the range, will be converted after rejection of fer- rite into four pearlite grains as indicated in B'. Theoretically, at least, we may assume that the temperature above the range may be so high and the exposure at that tem- perature so long that but a single austenite grain is formed, the entire mass having assumed a uniform crystalline orientation as shown in C. On slow cooling a single pearlite grain would then be formed surrounded by free ferrite in the form of small grains as depicted in C'. An exceedingly slow cooling through and below the range would have a tendency to cause the free ferrite to crystallize into larger grains and eventually to form but a single grain as indicated in C". 1 Finally, as will be later explained, on very long exposure to a high temperature the cementite should, theo- retically at least, be converted into as many graphite particles as there are austenite grains and, therefore, into a single graphite particle in case there is but a single grain of austenite, the steel then consisting, after slow cooling, of a kernel of graphite sur- rounded by uniformly oriented ferrite as shown in C'". As already explained, how- 1 Such slow cooling, as previously explained, would also have a tendency to cause the spheroi- dizing of cementite. 264 CHAPTER XV THE ANNEALING OF STEEL CO Ibs. per sc|. in. Fig. 269. Tensile stress, 42,000 Ibs. per sq. in. Fig. 270. Tensile stress, 40.000 Ibs. per sq. in. Fig. 271. Tensile stress, 44,000 Ibs. per. sq. in. so readily to the annealing treatment and over-strained metal, if not absolutely re- calcitrant, at least extremely refractory to the treatment. In subjecting electrolytic iron of great purity to the treatments producing the crystalline growth of ferrite described above, Stead reports that he was unable to 270 CHAPTER XV THE ANNEALING OF STEEL cause its grain to grow. The author likewise has never succeeded in producing a growth, at least in any appreciable degree, in wrought iron nor in practically carbon- less iron such as American ingot iron. It seems certain that a small amount of car- bon, preferably in the vicinity of 0.05 per cent, must be present. On the other hand -21 -20 -19 -18 -17 -16 -15 -14 -15 a a a. 3 O -C 3 he has never succeeded in coarsening appreciably, by similar treatments, the grain of steel containing over 0.12 per cent carbon. It would seem therefore that we must also recognize the existence of a critical carbon content (0.04 to 0.12 per cent) above or below which ferrite grains will not grow on annealing below the range, even if they have been critically strained. From what has been said of the crystalline growth of strained ferrite under its CHAPTER XV THE ANNEALING OF STEEL 271 critical range, and considering that cold drawn steel wires are frequently annealed at such temperature, it may reasonably be asked why they are not rendered thereby coarsely crystalline and brittle. Obviously because steel wires when subjected to the annealing treatment are generally in a decidedly over-strained condition. If very low carbon steel wire be given a draft so light that it is critically strained, heating it for a sufficient length of time at some 600 deg. C. will cause the crystalline growth of ferrite as should be expected. In such critically strained metal, however, the growth may be prevented by heating to a decidedly lower temperature, as for instance to 525 or 550 deg. C., which is sufficient to remove materially the brittleness result- ing from cold working or, of course, by annealing above the critical range. According to Kenneth B. Lewis, in wire drawing the reduction should not be less than 20 per cent in order to avoid the production of critically strained metal and hence dangerous crystalline growth on subsequent annealing below the thermal critical range. Robin believes that the straining of ferrite results in the creation of a number of nuclei (germes) from which new grains will grow on annealing. To account for the existence of a critical strain it might be argued (1) that in under-strained metal these nuclei are not formed, (2) that in critically strained metals a few nuclei are produced giving rise on annealing to a few large grains, and (3) that in over-strained metal a great many nuclei form, producing on annealing a great many and therefore, neces- sarily, smaller grains. Beilby's amorphous theory briefly explained in Chapter V seems to afford the most acceptable explanation of the crystalline growth of strained ferrite below its critical range, on the ground that the amorphous iron produced by straining, re- crystallizes below the range. Howe has suggested the following ingenious hypoth- esis to account for the existence of a critical strain: (1) the crystalline growth of ferrite is an electrolytic process in which the amorphous iron acts as electrolyte, (2) if the iron be over-strained the quantity of amorphous iron is so great, that is there is so much electrolyte, that electrolysis can take place across it only very slowly, hence the slowness or entire absence of crystalline growth, (3) in under-strained iron there is no growth because of the presence of an insufficient amount of amorphous iron, that is of electrolyte, and (4) in critically strained metal the proportion of amor- phous iron is such as to lead to rapid electrolysis, that is to rapid growth. "In short," Howe writes, "the very rapid coarsening implies the presence of enough electrolyte to give electrolysis a chance, yet not so much electrolyte as to cause too great a bar- rier to electrolysis by its width. Again, if the quantity of the electrolyte was exces- sive that would mean that the quantity of crystalline iron remaining was small. Now it is only the crystalline iron which can form grains and hence can coarsen, and if this iron is reduced to too small a quantity it might readily follow that the residual crystalline iron was not abundant enough to form large grains." Brittleness of Low Carbon Steel. The crystalline growths and other structural changes described in the foregoing pages lead naturally to the consideration of the brittleness occasionally exhibited by low carbon steel. Since steel containing very little carbon is essentially made up of ferrite, its occasional brittleness must be due to the occasional brittleness of ferrite, a constituent by nature soft and ductile. Stead has indicated two kinds of brittleness from which ferrite may, and occasionally does suffer, namely, (1) "inter-granular" brittleness and (2) "inter-crystalline" or "cleav- age" brittleness. 272 CHAPTER XV THE ANNEALING OF STEEL By inter-granular brittleness is meant a lack of cohesion between the ferrite grains leading to ready fracture under shock, the line of fracture following the boundary lines of the grains. Such brittleness is usually due to the presence of impurities form- ing brittle and more or less continuous membranes surrounding the grains. The presence of much phosphorus, however, appears to produce inter-granular brittleness without producing surrounding membranes. Inter-crystalline or cleavage brittleness is caused by the ferrite grains assuming nearly the same crystalline orientation so that the plane of fracture follows the cleav- age planes and passes from grain to grain almost in a straight line. The diagram shown in Figure 273 will make this clear. The cross lines represent the cleavage planes in each grain. In B the metal is made up of large ferrite grains but the crys- talline orientation of these grains is so heterogeneous that a line of fracture cannot A B l-'ig. 273. (Stead). readily be developed and pass from grain to grain, the abrupt change of crystalline orientation encountered at each boundary line acting as an effective obstruction to its advance. In A, on the contrary, while the grains are smaller they have nearly the same orientation, hence fracture may proceed from grain to grain with much greater ease and in a nearly straight line. Fortunately, so uniform a crystalline orien- tation is not often met with and cleavage brittleness is a rather rare occurrence. It can be cured by reheating the steel to 900 deg. or higher. Stead also noticed that low carbon steel plates rolled below t he critical range and, therefore, strained, and annealed likewise below the range, often exhibit a tendency to break in three directions, namely, at 45 deg. to the direction of rolling and at right angles with the surface of the plates, that is, in the directions of the three cleavage planes of a cube having four faces at 45 deg. to the edges, and two faces parallel to the surface of the plates. This he calls "rectangular" brittleness. "We are led from this to conclude," Stead writes, "that, just as light impresses a latent image on a bromide photographic plate which cannot be seen but is developed and made mani- CHAPTER XV THE ANNEALING OF STEEL 273 fest by the action of certain chemical agencies, so the rolling appears to impress a latent disposition in the steel to crystallize in certain fixed positions, and annealing develops it afterwards." The brittleriess here referred to is undoubtedly caused by the crystalline growth of strained ferrite when annealed below its critical range, as fully explained in this chapter, the formation of large ferrite grains naturally causing brittleness. This kind of brittleness is sometimes called "Stead's brittleness." No very satisfactory explanation has so far been offered to account for this greater brit- tleness in certain directions. It may be that the large crystalline grains of ferrite produced have nearly the same orientation and that they are so oriented as to lead to easy inter-crystalline rupture in the directions indicated. Conclusions Regarding the Annealing of Steel. From the foregoing considera- tions it appears that (1) in annealing for softness and ductility steel should be heated slightly above its critical range (Ac 3 or Ac 3 . 2 for hypo-eutectoid steel, Ac 3 .2.i for eutec- toid and hyper-eutectoid steel) and cooled slowly, as for instance with the furnace in which it was heated, or for greater strength in air, (2) in annealing for strength and high elastic limit combined with fair ductility as well as for resistance to wear, to shock, and to fatigue, steel should be heated to slightly above its critical range followed by cooling in water, or in oil according to carbon content and requirements and reheated to some 500 to 650 deg. C. in accordance with the physical properties desired, the lower temperature yielding the greater strength but the less ductility, (3) in annealing cold drawn wire and other cold worked objects, especially of hypo- eutectoid steel, reheating close to but below the critical range (550 to 650 deg.) is generally sufficient for the aim in view, unless in the case of very low carbon steel so strained as to lead to ferrite growth when the temperature should be kept below 550 deg. or carried above the critical range, (4) in annealing castings they should (a) be kept several hours slightly above their critical range, or (b) be heated to a tempera- ture considerably above the range followed by a reheating of short duration slightly above the range, or (c) be subjected to the double treatment applied to forgings, and (5) by subjecting hyper-eutectoid steel to the spheroidizing treatment its softness and ductility can be considerably increased as well as its resistance to wear. CHAPTER XVI THE HARDENING OF STEEL References have already been made in these chapters to the invaluable property possessed by iron, containing a sufficient amount of carbon, of becoming extremely hard when suddenly cooled from a high temperature as, for instance, by quenching in water from a bright red heat. This operation is known as the hardening of steel. The close relation existing between the hardening of steel and its critical range, which has also been alluded to, provides the key to the rationale of the hardening opera- tion. This operation consists of two distinct steps (1) heating to the hardening tem- perature and (2) cooling from that temperature. Heating for Hardening. In order to harden steel it is necessary first to heat it above its critical range, because it is in passing through that range that it acquires hardening power. Any attempt at hardening it by cooling it suddenly from a tem- perature inferior to its critical range would result in but a very slight, if any, increase of hardness. It is evident, therefore, that to possess hardening power steel must be in the condition of a solid solution since the aggregate of ferrite and cementite formed on slow cooling through the critical range cannot be hardened by sudden cooling. The metal should not be heated much above the top of its range, because in so doing we coarsen its structure as explained in previous chapters, while we do not increase, materially at least, its hardening power, and our aim in hardening should be to secure maximum hardness and finest possible structure. Quenching from a temperature greatly exceeding the critical range, moreover, increases the danger of warping and cracking the objects in the quenching bath. Nor should the steel be heated to a temperature much above its critical range and then cooled to that range 'before quenching, as sometimes recommended, because its structure is then likewise coars- ened by the heating and slow cooling preceding the quenching. Clearly the rationale of the hardening operation consists in heating the metal just through its critical range, thus conferring to it both full hardening power and finest possible structure, and then in cooling it suddenly as soon as it emerges from its range, lest its structure be coarsened by heating above the range or by prolonged exposure at the quenching temperature. This judicious method of conducting the hardening operation is some- times described as "hardening on a rising temperature." Let it be borne in mind that, since the position and width of the critical range vary in different steels, the most desirable quenching temperature will vary likewise. Low and medium high carbon steels should be quenched at higher temperatures than high carbon steel, for in order to acquire full hardening power they should be heated past their upper critical points, namely, Ac 3 or Ac 3 .2, as the case may be. In practice the quenching temperature should be some 20 to 50 deg. C. above Ac! in hardening eutectoid and hyper-eutectoid steels or above Ac 3 .2 in hardening 274 CHAPTER XVI THE HARDENING OF STEEL 275 hypo-eutectoid steel. The proper temperatures to which carbon steels should be heated for hardening purposes and which are also those generally suitable for anneal- ing the same steels have been shown graphically in Figure 219, Chapter XV. Heating for hardening should be slow enough to permit the steel to acquire grad- ually and evenly a uniform temperature throughout, and should not be too sudden as for instance by placing cold steel in red hot furnaces. Generally speaking large pieces should be heated to somewhat higher tempera- tures than small pieces for hardening purposes it having been found (Benedicks and Mathews) that a higher temperature produces a quicker rate of cooling in the quench- ing bath. Mathews for instance states that a 3 /ie-in. round bar of tool steel will harden at 750 deg. C. while a M-in. round liar of the same steel should be heated to 780 deg. C. The use of lead or salt baths (chlorides and nitrates of sodium, calcium, potas- sium, and barium) for heating steel to the desired hardening temperature is to be commended since it promotes uniformity of temperature throughout the pieces while a suitably selected salt bath can readily be heated to, and maintained at, any desired temperature. Cooling for Hardening. To harden the steel the metal should be cooled very quickly from the temperatures mentioned in the above paragraphs through its critical range, generally by immersing it in a medium capable of rapidly abstracting heat from it. The increase of hardness will be the greater the higher the carbon content, at least up to the eutectoid point, and the more rapid the cooling, the latter, in turn, depending upon the size of the object hardened and the nature of the quenching bath, i.e. its power of abstracting heat from the cooling mass. It was long thought that this so to speak cooling power of the bath depended chiefly, if not solely, upon its temperature at the time of immersion and upon its heat conductivity. It was be- lieved, for instance, that mercury was a more effective cooling medium than water because of its greater conductivity for heat, that cold water was more effective than tepid water because of its lower temperature, etc. Recent investigations appear to show, however, that the cooling power of a quenching bath is, within limits, quite independent of its actual temperature and of its heat conductivity, and even of its specific heat. Benedicks contends that it depends almost exclusively upon its latent heat of volatilization. Its temperature, however, should be low enough to prevent the adherence of vapor bubbles to the metal. In accordance with these views mer- cury, in Benedicks' opinion, is inferior to water while saline solutions are not superior to it. Methyl alcohol, on the contrary, is a more effective cooling medium for hard- ening than water. According to Le Chatelier, also, mercury is less effective than water but in his opinion because of its lower specific heat. Le Chatelier believes that the specific heat of the liquid is the most important factor influencing its value as a cooling medium, its conductivity being of secondary importance, the loss of heat taking place more through circulation than through conductivity. On the other hand Benedicks contends that the rate of flow has very little influence. According to Mathews (1) the rate of cooling in water quenching remains quite constant up to a water temperature of 37 deg. C., (2) brine solutions not only pro- duce a quicker rate of cooling but retain their cooling power practically unimpaired so long as their temperature remains below 65 deg. C., (3) while oil baths produce a slower rate of cooling they can be heated to considerably higher temperatures than water or brine before having their cooling power seriously diminished. 276 CHAPTER XVI THE HARDENING OF STEEL Structural Changes on Hardening. Bearing in mind the enormous difference between the properties of hardened steel and those of the same metal unhardened, we should naturally expect to find the structure of hardened steel likewise totally different from that of unhardened steel. And so indeed it is as shown in Figure 274, in the case of hardened steel containing some 0.50 per cent carbon. To account for this structure let us remember that, initially, this steel consisted of an aggregate of ferrite and cementite which, upon being heated through its critical range, was con- verted into a solid solution (austenite) of carbon or carbide in gamma iron. This was necessary to impart hardening power. Had the metal been allowed to cool slowly through its critical range it would have been converted back into a mixture of ferrite and cementite. On rapid cooling, however, this transformation was pre- vented, at least in part, the time necessary for its completion having been denied. Fig. 274. Steel. Carbon 0.45 per cent . Mag- nified 1000 diameters. Heated 1<> S25 deg. C. and quenched at 720 deg. (Osmond.) Fig. 275. Steel. Carbon 1.57 per cent. Mag- nified 1000 diameters. Heated to 1050 dpg. C. and quenched in ire-water. (Osmond.) A conclusive evidence that the transformation does not occur in its entirety is af- forded by the absence of a marked critical range on quick cooling. If the trans- formation of the solid solution could be effectively prevented austenite should be the constituent of hardened steel. In the commercial hardening of steel, however, the cooling is not sudden enough to prevent at least a partial transformation of austenite, not into ferrite and cementite but into a more or less transitory form, marking t In- first step of that transformation and called "martensite." Very frequently the rate of cooling is not sufficiently rapid to prevent the martensite from further partial transformation into a second transition constituent known as "troostite." Marten- site and troostite, then, are the ordinary constituents of commercially hardened steel. It will now be profitable to consider at some length the occurrence, nature, and prop- erties of the three constituents chiefly concerned in dealing with hardened steel, namely, austenite, martensite, and trooslilc. CHAPTER XVI THE HARDENING OF STEEL 277 AUSTENITE Nature of Austenite. 1 Austenite is universally considered as a solid solution of carbon or, more probably, of the carbide Fe 3 C in gamma iron. 2 All steels above their critical range are made up of this solid solution. It follows that the carbon con- tent of austenite varies, like that of steel, from a mere trace to some 1.75 or 2 per cent. It is not, therefore, a constituent of constant composition. Occurrence of Austenite. While present in all steels above, their critical range austenite is very rarely found in ordinary steels cooled to atmospheric temperature. This is due to the rapidity with which austenite is transformed on cooling through the critical range if not into an aggregate of ferrite and cementite, at least into some Fig. 276. Steel. Carbon 1.57 per cent. Magnification not stated. Heated to 1050 deg. C. and quenched in ice-water. (Osmond.) transition stages. In the commercial hardening of ordinary carbon steel the pas- sage of the metal through its range is never sufficiently rapid to retain in the cold a small amount even of undecomposed austenite. To prevent the transformation of a portion of the austenite the conditions generally affecting the hardening of the metal must be, so to speak, greatly intensified: (1) the steel should be highly car- burized, (2) quenching should be from a high temperature (1000 deg. C. or more), and (3) a very effective quenching bath should be used such as ice-cold water. In Figure 275 is shown, after Osmond, the structure of steel containing 1.57 per cent 1 This name was suggested by Osmond in honor of the late Sir William Roberts-Austen. Aus- tenite has also been called mixed crystals and gamma iron and by some writers, wrongly, martensite. 2 Arnold believes that austenite is the carbide Fe^C (hardenitc) holding in solution ferrite in hypo-eutectoid steel and cementite in hypor-eutectoid steel. 278 CHAPTER XVI THE HARDENING OF STEEL carbon heated to 1050 deg. C. and quenched in ice-water. The magnification is 1000 diameters. The dark-colored, zigzag constituent is martensite; the light matrix, or background, is austenite. The structure of the same steel, under lower magnifica- tion, is seen in Figure 276. By the drastic quenching treatment just described it is possible, in the case of high carbon steel, to retain more than one half of the steel in its austenitic condition. The retention of austenite in the cold is greatly helped by the presence of some elements such as manganese and nickel which lower the position of the transforma- tion range, eventually depressing it below atmospheric temperature and, therefore, Fig. 277. Steel. Carbon l.CO per cent, manganese 1.00 per cent. Magnified 300 diameters. Heated to 1400 deg. C. and quenched in ice-cold water. (Robin.) causing the steel to remain austenitic even after slow cooling. This actually takes place in the presence of some 12 per cent manganese or 25 per cent nickel. Robin, by quenching in ice-cold water from a temperature of 1400 deg. C. a very small piece of steel (1 to 2 cubic centimeters) containing 1.60 per cent carbon and 1 per cent manganese, was able to retain it in an austenitic condition (Fig. 277). Mau- rer, likewise, succeeded in retaining in its austenitic condition a steel containing 2 per cent manganese and 2 per cent carbon by quenching it in ice-cold water from a temperature of 1100 deg. (Fig. 278). As the manganese increases the retention of austenite becomes easier, that is, the quenching need not be so drastic nor the carbon content so high. Finally with 10 or more per cent of manganese and one or more per cent carbon the steel remains austenite after slow cooling. The structure and properties of manganese steel will be considered in another chapter. To sum up: (1) austenite is never produced in the commercial hardening of or- dinary carbon steel; (2) it may be retained in the cold, however, associated with CHAPTER XVI THE HARDENING OF STEEL 279 considerable martensite in quenching very high carbon steel, from a very high tem- perature in ice-cold water as, for instance, by quenching steel containing not less than 1.50 per cent carbon from 1000 deg. C. or higher; (3) in the presence of 1 per cent of manganese very small pieces of very high carbon steel may be retained wholly in their austenitic condition by quenching them from a very high temperature as, for instance, by quenching in ice-cold water from 1400 deg. C. small pieces of steel containing 1 per cent of manganese and not less than 1.5 per cent carbon (Robin); (4) with increasing proportions of manganese the transformation^of austenite may be prevented in steel containing less carbon and quenched from lower temperatures (Maurer); (5) manganese steels containing, for instance, 10 or more per cent manga- nese and one or more per cent carbon remain austenitic after slow cooling; (6) nickel steel containing some 25 per cent of nickel likewise remains austenitic on slow cooling. Benedicks contends that in the preservation of austenite in carbon steel by rapid cooling an important part is played by the very great pressure to which the metal Fig. 278. Steel. Carbon 1.94 per cent, manganese 2.00 per cent. Heated to 1100 deg. C. and quenched in ice-cold water. (Maurer.) is subjected, (1) because of the shrinkage of the exterior portion or outer shell on the interior and (2) because of the dilatation accompanying the change from gamma to beta iron. Were it not for this pressure Benedicks believes that the transforma- tion of austenite could not be prevented. As an evidence of this he shows that aus- tenitic steels produced by quenching are austenitic only in their interior, i.e. where the pressure had been greatest, the outside layers in which the pressure was small or nil being martensitic. He shows, further, that on removing by grinding the marten- sitic shell the austenitic core, in turn, becomes martensitic owing to the removal of the pressure exerted upon it by that shell. Again the quenching of steel cylinders surrounded by cast-iron shells resulted in the formation of austenite close to the skin of the steel cylinders owing apparently to the very great pressure exerted upon the steel by the contraction of the iron shells. Etching of Austenite. - - The etching reagents usually applied to bring out the structure of unhardened steel, namely, picric acid, nitric acid, tincture of iodine, etc., do not always yield satisfactory results in the case of hardened steel. Kourbatoff discovered a complex reagent which often produces greater contrasts between the 280 CHAPTER XVI THE HARDENING OF STEEL various constituents. It is made up by mixing one part of amyl alcohol, one part of ethyl alcohol, one part of methyl alcohol, and one part of a 4 per cent solution of nitric acid in acetic anhydride and should be prepared just before use. Heyn recommends for etching hardened steel a solution containing one part of hydrochloric acid and 99 parts of absolute alcohol. More uniform results are ob- tained if a weak current of electricity be passed through the solution, the samples to be etched forming the positive pole while the negative electrode may consist con- veniently of a piece of sheet lead. With the assistance of the electric current the use of a very dilute aqueous solution is advisable, namely, one part of hydrochloric acid in 500 parts of distilled water. Osmond, likewise, used successfully a solution of 10 per cent of hydrochloric acid in water by which the martensite is colored darker than austenite, the treatment re- quiring several minutes. Osmond writes: "There is more regularity obtained by having the specimen connected, by means of a platinum wire, with the positive pole of a bi-chromate cell, a strip of platinum placed in the acid being connected with the negative pole. In this way the specimen becomes the anode, and the platinum the cathode." Benedicks recommends for the etching of martensito-austenitic steel a 5 per cent alcoholic solution of metanitrobenzol-sulphonic acid which always darkens marten- site more than austenite. Immersions of some fifteen seconds are generally sufficient. Structure of Austenite. When austenite and martensite occur in the same sam- ple the latter is generally colored darker than the former (Figs. 275 and 276) . Marten- site, moreover, is readily distinguishable because of its zigzag or needle shape. Some writers claim that martensite is sometimes colored less than austenite. Indeed Maurer contends that this is always so, arguing that if most photomicrographs indicate the contrary it is because the martensite had undergone a certain amount of tempering resulting in the formation of some troostite as later explained. According to this writer, in order to prevent any tempering of the martensite, and therefore the forma- tion of dark-colored troostite, great care must be exercised in sawing, polishing, etc. To this Benedicks replies that it cannot always be so for in quenching austenite in liquid air martensite is formed which must be free from troostite and which, never- theless, is darker than austenite. It may be asked, however, whether it is certain that the martensite produced in this way is actually free from troostite. Evidences of a more conclusive nature are needed to account satisfactorily for the shifting in the relative coloration of austenite and martensite when occurring side by side. Pure austenite is made up of polyhedral grains, 1 (see Figs. 277 and 278) which, as explained in previous chapters in connection with the structure of gamma iron, are undoubtedly made up of true crystals, small octahedra according to Osmond. It should be noted that when austenite occurs in the presence of much martensite (Fig. 275) its poly- hedral structure is not brought out. Twinnings are frequently observed in austenite (see Chapter V, Fig. 124) although it has been claimed that they form only after straining, especially if followed by annealing. Baykoff succeeded in etching austenite above the critical range of the steel, that is, in a range of temperature where it is stable. He accomplished this by heating polished steel samples in a porcelain tube through which a current of hydrogen was 1 Because of this structure Guillet and some other writers refer to si eels composed of austcnite as "polyhedral" steels. Tnis doss not ssem advisable as it may lead to confusion, for other steels also have polyhedral structures, to wit, very low carbon (ferritis; steels. CHAPTER XVI THE HARDENING OF STEEL 281 kept circulating and by passing through it gaseous hydrochloric acid when the de- sired temperature had been obtained. The resulting structures were found to be polyhedral even in the presence of very little carbon, thus confirming the previous belief as to the crystalline character of austenite. Carbon per cent 0.8( 0.91 .0! .1C .20 .30 .40 1.50 1.55 1.50 1.40 1.30 1.20 1.10 l.OC l.Of O.S( O.TC O.fM 0.50 0.40 0.3(1 HarUc.uitc and Martcnsite Austenite and Hardenite ! Hardenite and ! Martensite Fig. 279. Showing the relative softness of austenite. (Osmond.) Properties of Austenite. Since the carbon content of austenite varies from a mere trace to nearly 2 per cent it may well be expected that its physical properties will likewise vary, i.e. that it will increase in hardness and strength and decrease in ductility as the carbon increases. Osmond has shown conclusively that austenite was softer than martensite of identical carbon content. When it is remembered that 282 CHAPTER XV1--THK HARDEXIXG OF STEEL in order to produce austenite in ordinary carbon steel all the factors generally in- creasing the hardness of the metal must be intensified, it is at first surprising that the energetic quenching treatment required should yield a softer metal. The con- clusion must be that gamma iron is softer than beta iron. This relative softness of austenite is well shown by Osmond in Figure 279 which represents the structure of a bar of steel containing 1.55 per cent carbon in the center and a gradually decreasing amount towards the outside. This bar was heated to 1050 deg. C. and quenched in mercury at a temperature of 9 deg. C. After polishing but before etching a needle was repeatedly drawn across it from end to end with even pressure. The photograph clearly shows that the needle scratched the steel (1) where it contains so little carbon Fig. 280. Nickel austenitic steel quenched in liquid air. Magni- fied 250 diameters. (Osmond.) (0.40 to 0.60 per cent) that it was only partly martensitic and hence relatively soft, (2) in those regions which because of very high carbon content (1.30 to 1.55 per cent) were partly austenitic, and (3) that it failed to scratch it in those regions which be- cause of a more moderate amount of carbon (0.70 to 1.20 per cent) were fully marten- sitic and, therefore, very hard. It is also well known that high carbon austenitic manganese steel, while extremely difficult to machine, can be readily scratched by a needle, being mineralogically softer, therefore, than high carbon, martensitic steel. Rosenhain and Humfrey have shown that above the critical range austenite (gamma iron) was much softer than beta iron. Since steel above its critical range is non- magnetic we should expect steels which remain austenitic in the cold to be non- magnetic. This we know to be the case, for manganese as well as nickel austenitic steels are non-magnetic. Some of the physical properties of austenite may be inferred from the known CHAPTER XVI THE HARDENING OF STEEL 283 properties of austenitic steels such as manganese and high nickel steels. These are known to be very ductile (after suitable heat treatment), tenacious, of low elastic limit, to possess very high resistance to wear although their mineralogical hardness is not excessive and to be machined only with great difficulty. They have, like gamma iron, a very high electrical resistance. It has already been pointed out that the crystallization of austenite is probably cubic, the octahedron being its prevailing crystalline form. Le Chatelier, however, believes that austenite crystallizes in the orthorhombic system with octahedral cleavage. On slow cooling through the critical range in the absence of considerable quantities of retarding elements such as manganese and nickel, austenite rejects a sufficient amount of ferrite in hypo-eutectoid, or of cementite in hyper-eutectoid, steel to assume the eutectoid composition (0.85 per cent C. or thereabout) when it is converted bodily into pearlite. This transformation is not sudden, however, several transition constituents being formed, namely, martensite, troostite, and sor- bite. It will be seen in another chapter that on tempering austenite, that is, on reheat- ing it below the critical range of the metal it is likewise converted gradually and suc- cessively into martensite, troostite, and sorbite or according to some writers directly into troostite and then into sorbite. Quenching nicke! austenitic steel in liquid air results in the formation of marten- site with increased volume causing swellings of the polished surface as shown in Figure 280. MARTENSITE Nature of Martensite. 1 It is very generally believed that martensite corre- sponds to an early stage in the transformation of austenite in passing through the critical range. Opinions differ, however, as to its exact nature. Accepting the possi- bility of iron existing under three allotropic forms, namely, as gamma, beta, and alpha iron, and the carbon under two distinct conditions, namely, as the crystallized car- bide FesC or cement carbon and of this carbide or possibly elementary carbon being dissolved in iron, i.e. as hardening carbon, what are the probable conditions of these two constituents in martensite? Osmond and many others believe that in martensite iron is present chiefly in its beta condition, holding carbon in solution, hence the great hardness of that constituent. Since martensite is magnetic, however, it must also contain an appreciable quantity of magnetic alpha iron. This theory, which may be called the allotropic theory, was at one time widely held. Le Chatelier, not believ- ing in the existence of beta iron, considers martensite as essentially a solid solution of carbon in alpha iron, owing its great hardness to its state of solid solution and its magnetism to the presence of alpha iron. Edwards and Carpenter contend that austenite and martensite are in reality the same constituent, namely, a solid solu- tion of carbon in gamma iron, differing only in structural aspect, the needles of martensite resulting from the twinning of austenite caused by the severe pressure exerted upon it during rapid cooling. Kroll also speaks of martensite as represent- ing the "mutilated structure of austenite due to twinning." Arnold believes that 1 This name was selected by Osmond in honor of A. Martens, a distinguished German metallur- gist and testing engineer. 284 CHAPTER XVI THE HARDENING OF STEEL martensite is, like austenite, the carbide Fe 24 C holding in solution ferrite in hypo- eutectoid steel and cementite in hyper-eutectoid steel. Careful consideration of the evidences at hand leads to the adoption of the first theory (Osmond's) as the one best supported. That martensite is to a great extent a solid solution seems evident from the fact that it contains a great deal of hardening, i.e. dissolved carbon, and it seems probable that beta iron is the solvent, for if gamma iron were the solvent it would not explain the greater hardness of martensite com- pared to that of austenite while we have good reason to doubt the power of alpha iron to dissolve carbon seeing that below the critical range, i.e. when in its alpha form, iron will not absorb carbon. Occurrence of Martensite. Martensite is most readily obtained through the quenching of small pieces of high carbon steel in cold water; in the case of large Fig. 281. Steel. Carbon 1.25 per cent. Mag- nified 150 diameters. Heated to 1232 deg. C. and quenched in oil. (C. C. Buck, Cor- respondence Course student.) pieces, while the outside portion may be martensitic their center is likely to be partly troostitic. In low carbon steel it is more difficult still to prevent the formation of some troostite while in steel containing very little carbon free ferrite as well is likely to be present. In very high carbon steel some free cementite is generally associated with the martensite. Etching of Martensite. Dilute alcoholic solutions of picric, nitric, or hydro- chloric acid generally bring out satisfactorily the structure of martensite but the Kourbatoff reagent, already described, sometimes yields better results. Martensite generally darkens more quickly than austenite but always remains much lighter than troostite. Structure of Martensite. Martensitic structures are shown in Figures 274 and 281. Osmond describes the structure of martensite as consisting of three systems of fibers, respectively parallel to the three sides of a triangle and crossing each other frequently. Osmond also states that when the metal contains less carbon the needles CHAPTER XVI THE HARDENING OF STEEL 285 are longer and more clearly differentiated, other things being equal. According to crystallographers these markings, in reality cleavages of octahedra, indicate crystal- lites of the cubic system and, therefore, afford an additional evidence of the cubic crystallization of austenite from which martensite is derived. Osmond and Cartaud refer to them as probable pseudomorphs of twinnings due to tension, occurring in gamma iron through partial formation of the bulky beta and alpha modifications. Properties of Martensite. The carbon content of martensite varies from a mere trace to as much as one per cent, and possibly more, in very suddenly cooled hyper- eutectoid steels. In high carbon steels, however, it is difficult to prevent the setting free of much of the excess cementite even on very quick cooling. From this varia- tion of its percentage of carbon it follows that the properties of martensite must also vary. As the carbon increases its hardness and strength increase while its ductility decreases, martensitic steels being generally hard and brittle and, therefore, unforge- able in the cold. It will be seen in another chapter that on heating martensite below the critical range, i.e. on tempering it, it is converted first into troostite and then into sorbite. TROOSTITE Nature of Troostite. 1 = While most writers believe that troostite represents a condition of the steel resulting from the transformation of martensite and, therefore, a further step in the transformation of austenite, much difference of opinion exists as to its exact nature. The controversy has given rise to a very large and apparently exaggerated amount of discussion. Here, as in the case of martensite, we must con- sider the possibility of the iron existing in the gamma, beta, or alpha form or in two or even all three of these conditions, while the carbon may exist as cement carbon or as hardening carbon or partly as cement and partly as hardening carbon. Then the association between iron and carbon may be of the nature of an aggregate or of a solid solution or partly aggregate and partly solution or, indeed, half way between aggregate and solution, namely, resembling a colloidal solution, an emulsion, or an uncoagulated substance. Nearly every conceivable hypothesis has been suggested to account for the nature of troostite. It has been described as a solid solution of car- bon or of carbide in gamma iron, in beta iron, and in alpha iron. It has also been suggested that it might be pure beta iron. In later years, thanks chiefly to the enlightening discussions of Benedicks sup- ported by the weighty evidence of skilfully conducted experiments, metallographists have come to regard troostite as an uncoagulated mixture of the constituents of martensite and sorbite, that is, of (1) carbide dissolved in beta iron, (2) crystallized FesC, and (3) crystallized alpha iron clearly martensite passing to sorbite. Bene- dicks compares it to a colloidal solution 2 while Arnold had previously described it as 1 The name troostite was selected by Osmond in honor of the French chemist Troost. 2 A colloid may be regarded as a substance passing from the state of solution to that of an ag- gregate or vice versa; it is no longer a solution but not yet an aggregate. To express it more scien- tifically, while not a true solution the particles of solvent and solute arc ultra-microscopic. Accord- ing to Le Chatelk-r so-called colloidal solutions are in no way solutions, but merely liquids holding in suspension very finely divided particles; the expression, he says, should not be used. 286 CHAPTER XVI THE HARDENING OF STEEL Fig. 282. Troostite in steel containing 1.50 per cent carbon. Magnified 150 diameters. Fig. 283. Same as Figure 282 but magnified 800 diameters. CHAPTER XVI THE HAKDKMXC OF STEEL 287 Fig. 284. Troostite in steel containing 1.50 per cent carbon. Magnified 1.50 diameters. Fig. 285. Same as Figure 284 but magnified 500 diameters. 288 CHAPTER XVI THE HARDENING OF STEEL "emulsified" pearlite. 1 The existence of considerable dissolved (hardening) carbon in troostite is proven by analysis as well as the existence of considerable crystallized Fe 3 C (cement carbon). Its relatively great hardness points strongly to the presence of a considerable amount of beta iron while its magnetism demands the presence of alpha iron. Benedicks' hypothesis is consistent with what we know of the formation of troostite and of its properties. McCance considers troostite to be amorphous alpha iron associated with carbon or a carbide, the nature of the bond between the two not being clearly stated. ^ Fig. 286. Troostite and martensito-austenitic matrix in steel containing 1.50 per cent carbon. Magnified 150 diameters. (Boylston.) - In the report of the Committee on the Nomenclature of the Microscopical Con- stituents of Iron and Steel of the International Association for Testing Materials, troostite is defined as follows: "probably aggregate. In the transformation of aus- tenite, the stage following martensite and preceding sorbite ... An uncoagulated conglomerate of the transition stages." Occurrence of Troostite. In order to produce troostite on cooling steel from above its critical range, it is necessary that the cooling through the range should be so regulated as to allow it to form and at the same time prevent its further trans- formation (into sorbite and pearlite). These conditions may prevail (1) in cooling slowly to the middle of the range, thus permitting the formation of troostite (see 1 "Emulsified carbide present in an excessively fine stale of division in tempered steels." (1895.) CHAPTER XVI THE HARDENING OF STEEL 289 Fig. 288), and then quickly to atmospheric temperature, thus retaining troostite, and (2) in cooling through the range at a rate uniform throughout but so regulated as to cause the production and retention of troostite (Fig. 288) as, for instance, quenching large pieces in water when the central portions at least will be troostitic, or quench- ing smaller pieces in oil. It will be explained in the next chapter that troostite may also be produced by tempering (i.e. reheating below the critical range) austenitic and martensitic steels. Troostite is readily produced by heating a bar of steel, containing 0.50 per cent carbon or more, white hot at one end and quenching it in waterj-when at some dis- tance from the heated end the temperature must necessarily have been such as to produce troostite. This can generally be detected by means of a file, the martensitic portion of the bar being too hard to be marked while the troostitic part, although hard, can be scratched. The sorbitic and pearlitic portions are decidedly softer. Properties of Troostite. It will be obvious from the foregoing description of the nature and formation of troostite that its physical properties must be intermediate between those of martensite and of sorbite. For like carbon content troostite is softer and more ductile than martensite but harder and less ductile than sorbite. It will be shown that at some 400 deg. C. it begins to be transformed into sorbite. Etching of Troostite. Troostite is colored decidedly darker than any other con- st it uent by the ordinary etching reagents. While dilute alcoholic solutions of nitric, picric, or hydrochloric acid yield satisfactory results, Kourbatoff's reagent is pre- ferred by some. Structure of Troostite. Troostite generally occurs as dark-colored, irregular areas, representing sections through nodules generally accompanied by martensite or sorbite or both or as membranes surrounding martensite grains (Figs. 282 to 287). On deeper etching the martensitic structure of the matrix is generally revealed as shown in Figure 286. In hypo-eutectoid steel free ferrite, and in hyper-eutectoid steel free cementite, may also be present and, indeed, even well-developed pearlite (Fig. 287). Osmond describes the structure of troostite as "almost amorphous, slightly granular, and mammilated." The steel shown in Figure 287 was quenched during its critical range and contains martensite (bright), troostite (dark), sorbite (lighter than troostite and ill-defined), and pearlite (laminated). Sorbite. Sorbite is not, properly speaking, a constituent of hardened steel. It seems appropriate, however, to again mention it here seeing that it constitutes the connecting link between annealed (pearlitic) steels and hardened (troostito-marten- sitic) steels, and also because it results from the transformation of troostite, thus completing the various stages assumed by iron-carbon alloys in passing from the condition of austenite, stable above the range, to that of pearlite, stable below the range. These stages are (1) austenite, (2) martensite, (3) troostite, (4) sorbite, and (5) pearlite. Sorbite is now generally regarded as an uncoagulated mixture of the constituents of troostite and of pearlite; it apparently contains (1) some hardening carbon, i.e. carbon or FeaC dissolved in beta iron, hence the greater hardness and strength of sorbite compared to the hardness and strength of pearlite, (2) a considerable quan- tity of alpha iron, hence its magnetism and relative softness, and (3) a considerable quantity of crystallized FesC (cement carbon) as proven by analysis. While sorbite probably contains the same constituents as troostite it holds considerably less unde- composed solid solution and considerably more alpha iron, hence it is much softer 290 CHAPTER XVI THE HARDENING OF STEEL and more ductile than troostite. In other words the transformation which eventually must lead to the formation of pearlite is more advanced in sorbite than it is in troost- ite. The nomenclature committee, already referred to, describes sorbite as follows: "Aggregate ... In the transformation of austenite, the stage following troostite . . . and preceding pearlite. Most writers believe it essentially an uncoagulated con- glomerate of irresoluble pearlite with ferrite in hypo- and cementite in hyper-eutec- toid steels respectively." The occurrence, etching, structure, and properties of sorbite have been described in Chapters XIV and XV when it was shown that it is formed (1) in small pieces of steel cooling in the air from above their critical range, (2) in larger pieces quenched in oil from above the range, or (3) in small pieces quenched in water from near the Fig. 287. Steel. Carbon 0.80 per cent. Quenched in the critical range. Magnified 430 diameters. (Boylston.) bottom of the range. In other words to form sorbite we must so regulate the cool- ing through the critical range that it is allowed to form but prevented from further transformation (into pearlite). It will be seen in the next chapter that sorbite is also formed on tempering austenitic, martensitic, and troostitic steels. By its physical properties sorbite occupies an intermediate position between troostite and pearlite; as previously mentioned it is stronger, harder, and less ductile than pearlite but softer and more ductile than troostite. Troosto-Sorbite. Kourbatoff gives the name of "troosto-sorbite" to a constituent associated with martensite and austenite in quenching, from a high temperature, steels very high in carbon. It is not clear that this constituent is more than a mixture of troostite and sorbite. We may talk of troosto-sorbite as we do of a greenish blue tint to indicate shades intermediate between green and blue, and similarly the ex- pressions martenso-austenite, troosto-martensite, and sorbitic-pearlite, or like expres- sions, are useful and their meanings obvious. In the report of the Committee on the CHAPTER XVI THE HARDENING OF STEEL 291 Nomenclature of the Microscopical Constituents of Iron and Steel of the International Association for Testing Materials, troosto-sorbite is thus denned: "Indefinite aggre- gate, the troostite and the sorbite which lie near the boundary which separates these two aggregates." Hardenite. The name of "hardenite" is frequently given both to austenite and to martensite of eutectoid composition, 1 i.e. to the original austenite of eutectoid steel and to the residual austenite of hypo- and hyper-eutectoid steel after rejection of the full amount of free ferrite or of free cementite. In other words Ihe^ name is applied (1) to the condition of austenite in slowly cooled steels immediately preceding its conversion into martensite and (2) to the resulting martensite (necessarily of eutec- toid composition if the cooling to the range has been sufficiently slow). It is unfor- tunate that the same term is used to designate both austenite and martensite, two apparently sharply different constituents, as it is likely to lead to confusion. Its use should be restricted to the designation of austenite of eutectoid composition. Giving it this meaning it will be apparent, as later explained, that hardenite possesses maxi- mum hardening power and, therefore, that steel made up exclusively of hardenite, i.e. eutectoid steel, possesses maximum hardening power. Rate of Cooling through Critical Range vs. Structure of Steel. It has been made clear in the foregoing pages (1) that in order to retain some austenite in the cold the metal should be highly carburized and very quickly cooled from a high temperature, (2) that pearlite is produced by very slow cooling through the critical range, and (3) that in order to cause the formation of any of the three recognized transition con- stituents, namely martensite, troostite, and sorbite, the steel should be cooled through its critical range in such a way as to allow the formation of the desired constituent while preventing its further transformation as, for instance, (a) by cooling the metal slowly to that portion of the range in which the constituent is formed and then quickly to atmospheric temperature or (fc) by cooling the metal through its range at a uni- form speed but so regulated that the transformation of austenite proceeds only to the desired extent, to wit, cooling in water for martensite, in oil for sorbite. An attempt has been made in Figure 288 to give a graphical illustration of the cooling conditions needed for the production of the various constituents of steel. Its interpretation will be obvious. The critical range, or rather the lower critical point, Ari or Ar 3 .2.i, is represented as covering a considerable range of temperature so as to afford the necessary room for the diagrammatical representation of the for- mation, within that range, of the transition constituents. The diagram indicates that as the metal cools slowly through its range it does not pass abruptly from an austenitic to a martensitic condition and then to troostite, etc., but that these trans- formations are, on the contrary, gradual, the following types of structure being formed, theoretically at least: austenite, austenite plus martensite, martensite, martensite plus troostite, troostite, troostite plus sorbite, sorbite, sorbite plus pearlite, and pearlite. The transformations depicted refer to eutectoid steel or to the residual aus- tenite (necessarily of eutectoid composition) of hypo- and hyper-eutectoid steel formed on slow cooling to Ari after rejection of free ferrite or free cementite. In the case of these steels, therefore, free ferrite or free cementite is present in the above structures 1 Originally the name hardenite was applied by Howe to austenite and martensite of any com- position (1888). Osmond used it to designate austenite saturated with carbon (1897). Both these meanings have been withdrawn by their proposers. Arnold calls hardenite the carbide Fe 2 CHAPTER XVIII THEORIES OF THE HARDENING OF STEEL 313 a more stable condition, supporting, therefore, the retention theories and opposing the stress theories. Interstrain Theory. Andrew McCance believes that on cooling steel quickly from above its critical range the whole of the carbon remains in solution while the bulk of the gamma iron is converted into alpha iron. This alpha iron however is in an interstrained condition owing to the fact that its crystalline units have been denied the time to assume an homogeneous orientation and the hardness of quenched steel is due to this interstrained condition. It is further contended that strained iron can- not be described as amorphous because if it were amorphous it could not be ferro- magnetic, interstrain in his opinion being a better term to describe its condition. McCance writes: "On quenching steel, the carbon is retained in solution and in turn it retains a proportion of the iron in the gamma condition, but the majority of the iron is alpha iron. At the quenching temperature the crystal grains had the crystal- line symmetry of gamma iron, and the gamma iron retained in the quenched state by the carbon will form an internal network in these original steel grains. The rest of the iron will be transformed, and will form crystal units of alpha symmetry, but these will be prevented by lack of time, by internal friction, and by the gamma iron network, from arranging themselves to form homogeneously oriented alpha iron crystals. The alpha iron will be in a condition similar to interstrain, and great hardness trill result." Twinning and Amorphous Iron Theory. Carpenter and Edwards argue that in quenching steel very severe internal stresses are set up causing internal straining of the metal which in turn results in the formation of numerous twins and of hard amorphous layers. The markings of martensite in their opinion correspond to these twins. Edwards writes: "That the material is internally strained is evident from the facts which have been published, namely, the metallic crystals are broken up into an exceedingly large number of twin lamellae. Further we believe that the hardness produced by quenching is brought about by crystal twinning and possibly direct slipping and the formation of amorphous layers as a result of the internal deformation." Tempering and the Retention Theories. The tempering of hardened steel, as already explained, is readily accounted for by the retention theories on the ground that the metal being in an unstable condition is ever eager to assume a more stable form, implying a return, partial at least, of the iron to the alpha condition and of the carbon to the cement condition. On heating the steel but slightly above atmospheric temperature its rigidity is sufficiently diminished to permit a slight transformation of this kind, the higher the temperature the more pronounced of course being its tempering. Tempering and the Stress Theory. The stress theory, likewise, satisfactorily accounts for the tempering of hardened steel on the ground that upon slight reheat- ing the internal strains are sufficiently released to produce an appreciable decrease of the specific effects of hardening, namely, decrease of hardness, of strength, of elastic limit and increased ductility. Summary. It seems quite possible, even probable, that the various theories, while apparently antagonistic, bring each their contribution to the elucidation of the problem. Should we not believe with the allotropists that the hardness of steel is due chiefly to the retention of a large quantity of a hard allotropic variety of iron, possi- bly amorphous and of the dissolved or hardening carbon of the carbonists. Should we not with the advocates of the stress theories believe in the hardening influence of 314 CHAPTER XVIII THEORIES OF THE HARDENING OF STEEL the strains created on quick cooling (a) because of the shrinkage of the outer layers of the metal and (6) because of the expansion accompanying the transformation of gamma into beta iron? None of these theories alone gives a fully satisfactory ex- planation: Beta iron cannot be retained in the absence of carbon and if it could be it is not certain that it would be intensely hard; the presence of intensely hard car- bon or iron carbide as the chief cause of hardening is contrary to evidences; the strained condition of hardened steel alone does not account satisfactorily for its ex- treme hardness; Le Chatelier's contention that quickly cooled steel is hard although its iron is in the soft alpha condition because of its being in a state of solution is open to objection; Arnold's theory that hardened steel owes its hardness to the retention of a hard subcarbide of iron lacks experimental support and is scientifically un- tenable. The author concluded as follows a recent paper on "Metallography and the Hardening of Steel" presented at the International Engineering Congress in Sep- tember, 1915, in San Francisco: "It will be obvious from the foregoing that the many recent attempts at arriving at a satisfactory explanation of the hardening of steel are based on one or more of the following conceptions: (1) existence of a hard allotropic variety of iron, (2) existence of solid solutions involving the occurrence of so-called "hardening" carbon, and (3) existence of strains in quenched steel causing or not an amorphous condition of the iron. "It will likewise be obvious that no theory so far presented fully satisfies our craving for a scientifically acceptable explanation of the many phenomena involved. "It would seem as if the methods used to date for the elucidation of this complex- problem have yielded all they are capable of yielding and that further straining of these methods will only serve to confuse the issue, a point having been reached when this juggling, no matter how skilfully done, with allotropy, solid solutions, and strains is causing weariness without advancing the solution of the problem. The tendency of late has been to abandon the safer road of experimental facts and to enter the maze of excessive speculations, in which there is great danger of some becoming hopelessly lost. "The conclusion seems warranted that new avenues of approach must be found if we are ever to obtain a correct answer to this apparent enigma." CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL The affinity of iron for carbon is so great that when heated to a sufficiently high temperature in contact with some suitable carbonaceous matter it readily absorbs carbon. If the heating be protracted (several days) and the amount of carbon ab- sorbed considerable, the operation is known as "cementation" and the resulting metal as "cemented," "converted," or "blister" steel, or in Sheffield, England, as "blister bar," while if the treatment be of relatively short duration (a few hours) and the absorption of carbon in consequence superficial, it is called "case hardening." Cementation is generally applied to wrought-iron bars which are afterwards melted (crucible process) and shaped into finished articles by casting or forging, while case hardening is applied directly to finished objects generally of low carbon steel. The purpose of cementation is to introduce carbon into wrought iron, thereby converting it into steel, the subsequent treatments (melting, forging) producing a uniform distribution of the carbon, whereas the purpose of case hardening is to man- ufacture steel objects with hard skins or cases while retaining their soft and tough centers or cores. The quantity of carbon thus absorbed by iron at a high temperature but below its melting-point depends chiefly upon (1) the composition of the iron or steel subjected to carburizing, (2) the carburizing temperature, (3) the length of time at that tem- perature, and (4) the nature of the carburizing material. Composition of the Iron or Steel Subjected to Carburizing. It is probably true that the smaller the proportion of carbon in the iron the more eagerly will it take up carbon, from which it follows that as the carburizing proceeds, that is, as the metal becomes more highly carburized, additional introduction of carbon requires progres- sively longer time, the metal acting in this way not unlike a solution approaching its saturation point. In the cementation process bars of very pure wrought iron and in "case harden- ing" steel objects containing at the most 0.20 per cent carbon are subjected to the carburizing treatment. The steel should not generally contain over 0.40 per cent of manganese lest the case be too brittle. The presence of certain elements appear to hinder the carburizing operation while others facilitate it. According to Guillet the absorption of carbon is favored by those special elements which exist as double carbides such as manganese, tungsten, chromium, molybdenum, and opposed by those which form solid solutions with iron such as nickel, silicon, and aluminum. Carburizing Temperature. While it has been claimed that iron below its critical range will absorb some carbon this absorption, if taking place at all, is very slow, from which it is logical to infer that alpha iron has very little, if any, dissolving'power 315 316 CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL for carbon. In order to produce quick and intense carburization the iron should be in its beta or, more probably, in its gamma condition, and steel, therefore, in the con- dition of a solid solution. Cementing and case hardening operations must conse- quently be conducted above the critical range of the iron or low carbon steel treated, that is, at a temperature exceeding 825 deg. C. It is also certain that the higher the temperature the quicker will carbon be absorbed and the deeper will it penetrate into the steel, that is, the deeper the "case." At Sheffield, England, where the cementa- tion process is used more extensively than anywhere else the carburizing tempera- ture is in the vicintiy of 950 to 1000 deg. Most case hardening treatments are prob- ably conducted in the vicinity of 900 to 950 deg. C. Time at Carburizing Temperature. The amount of carbon absorbed, and there- fore the thickness of the case as well, increases, of course, with the length of the Fig. 295. Steel. Case hardened. Magnified 20 diameters. operation but, as already mentioned, carburization takes place more and more slowly as the carbon content increases. The maximum amount of carbon which iron can take up while in the solid state is probably not far from 2.50 per cent, this, however, requiring a protracted treatment at a very high temperature. While in the manu- facture of blister steel considerably more than one per cent of carbon is frequently introduced into the wrought-iron bars, in carburizing finished steel articles it is seldom desired to produce a case containing more than one per cent of carbon near the out- side, a superficial, carburized layer of eutectoid composition (0.85 per cent C.) being generally considered to yield the best results. The length of time needed to produce the desired degree of carburization and desired depth of case must necessarily de- pend upon the nature of the metal, the kind of carburizing material used, and the temperature. Distribution of the Carbon. It will be apparent from the nature of the opera- tion that in this carburizing of solid iron carbon travels slowly from the outside towards the center and that, therefore, the proportion of carbon absorbed must CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL 317 decrease from outside to center, unless indeed the objects treated are very thin or the treatment so long and conducted at so high a temperature as to cause even the center to absorb the maximum amount of carbon. The decrease of carbon as one ap- proaches the core of the object is well illustrated in Figures 295 and 296. A band of hyper-eutectoid steel characterized by the presence of free cementite is frequently noted (Fig. 295) followed by a band of eutectoid composition characterized by the absence of both free cementite and free ferrite and this in turn is followed by a band showing abrupt and rapid decrease of carbon characterized by an increasing amount of free ferrite. In case hardening operations the penetration of the carbon may be very slight indeed, not exceeding 0.5 mm., while it may measure as much as 5 mm. In the 'ft Fig. 296. Steel. Case hardened. Magnified 100 diameters. (G. A. Rein- hardt in the author's laboratory.) majority of instances the penetration does not exceed 2 mm. This depth of pene- tration or thickness of case must be regulated according to requirements. It will depend upon temperature, time, composition of steel, and kind of carburizing mate- rial. Lake mentions 0.87 mm. per hour as an average speed of penetration. As already stated, it is not generally advisable to produce a case containing more than some 0.90 per cent carbon. The production of a deep case, while at the same time keeping the carbon content of the outside of the case below one per cent, may be brought about by a rather long treatment at a relatively low temperature, namely, some 850 deg. Some results ob- tained by Guillet in regard to the influence of temperature and of time on the depth of penetration are shown graphically in Figure 297 as plotted by Bauer. The carbu- rizing material used was not stated. The full line represents relative penetrations at 1000 deg. after different lengths of time, namely, one, two, four, and six hours, while 318 CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL the broken line represents the depths of penetration resulting from heating for eight hours at different temperatures. It will be obvious that the process of case hardening can be controlled by the microscopical examination of test pieces much more readily and accurately than by chemical analysis. Carburizing Materials. A great variety of carbonaceous materials is used for introducing carbon in iron and steel in the solid state. These substances may be solid, liquid, or gaseous. Solid materials are used more extensively than liquid or gaseous ones, the most important being charcoal (both wood and bone), charred leather, crushed bone, horn, mixtures of barium carbonate (40 per cent) and char- coal (60 per cent) or of salt (10 per cent) and charcoal (90 per cent), both recom- mended by Guillet, and for quick but very superficial hardening, powdered potassium cyanide and potassium ferro-cyanide or mixtures of potassium ferro-cyanide and potassium bichromate. A molten bath of potassium cyanide heated to 850 deg. and in which the steel articles are immersed produces quickly superficial but hard and 900 4 800 2 700 ^/ ^ x ^^-; < ' ,-->*"' .** / s y / / 7 IO 15 20 25 PeneXraXian, in- m / m ,. Fig. 297. Temperature and time-penetration curve. (From Brearley': " The Heat Treatment of Tool Steel.") even cases. The poisonous character of the escaping gases, however, is a serious ob- jection to the use of this method. The carburizing of iron may also be performed at the proper temperature by means of gases such as illuminating or other coal or oil gases rich in carbon monoxide and in hydrocarbons. At the Krupp Avorks in Ger- many gases are used for carburizing the faces of armor plates. Abbott states that out of 100,000 tons of carburizing material used in the United States in 1911, 85 per cent was granulated bone. The relative merits of wood charcoal, charred leather, and a mixture of barium carbonate and of wood charcoal for carburizing are shown graphically in Figure 298, in which are plotted some results obtained by Shaw-Scott. While wood charcoal causes a slow carburization it is the best material and the one invariably employed for the production of very deep cases as, for instance, in making blister steel. Giolitti surrounds the pieces to be case hardened with charcoal and then passes through the annealing box carbon monoxide or carbon dioxide gas, the latter upon coming in contact with red hot charcoal being converted into carbon monoxide CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL 319 (C0 2 + C = 2CO) which gas as later explained is the most active agent in car- burizing. In Giolitti's opinion, however, CO when used alone generally fails to in- troduce enough carbon, but becomes much more effective when mixed with hydro- carbons or better still with finely divided solid carbon. Under these conditions the maximum concentration does not exceed 0.90, per cent carbon even after 8 hours at a constant temperature between 900 and 1100 deg. C. If the temperature be per- mitted to fluctuate, however, between 1000 and 1100 deg., the outer layers take up as much as 1.10 per cent carbon after an annealing of 3 hours' duration. Many so-called secret mixtures are offered for sale as case hardening substances for which extraordinary virtues are claimed, the usual statement being that by their use steel of ordinary or inferior quality may be converted into high grade metal com- 4. ~6 a 10 12 Time of Heating, (hours) Fig. 298. Time-penetration curve. (From Brearley's "The Heat Treatment of Tool Steel.") parable to the best crucible tool steel. On investigation they are generally found to be chiefly mixtures of carbonaceous and cyanogen compounds possessing the well- known carburizing properties of those substances. Case Hardening by Gas under Pressure. Dr. F. C. Langenberg has con- ducted in the author's laboratory an extensive series of experiments dealing with the case hardening of American ingot iron with various gases under varying con- ditions of temperature, time, flow of gas, and pressure. Some of the most conclu- sive results obtained will be recorded. Illuminating gas of the following composition: Hydrogen 40.10 per cent Methane 26.10 " " Nitrogen 14.04 " " Carbon Dioxide 1.64 " " Oxygen 0.58 per cent Carbon Monoxide 11.38 " " Heavy Hydrocarbons 4.95 was passed through a tube furnace electrically heated and containing near the in- let end a plug of finely divided charcoal and, immediately following, small cylin- 320 CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL ders of American ingot iron to be case hardened. The passing of the illuminating gas through the highly heated charcoal converted the C0 2 originally present into CO (CO-2 + C = 2CO) and may also have produced some changes in the hydro- carbons present. It is not probable that the hydrogen content was greatly, if at all, affected. Maintaining the flow of gas constant, at 5 liters per hour, the tem- perature likewise constant at 990 deg. C. for 3 hours, but varying the pressure from to 115 Ibs. per sq. in., a gradual increase in the carbon absorbed was ob- served as indicated both by increase of weight and depth of case. This is clearly shown by the curves of Figure 299. It will be noted that the increase is greatest 15 14 13 12 II 10 Increase of We lent _or Depth in mm. 6 5 4 3 2 I F'ressure-Carbur/z&tion Cur ye Temperature 9/0" C. oj C<5L se Curve Jncrea.se of We/gM Cur-ye. 10 20 30 40 50 60 70 80 90 100 110 120 130 I4O 150 160 Pressi/e-/6syber sc/.in.. Fig. 299. Case hardening by gas. Pressure-penetration curve. (F. C. Langenberg in the author's laboratory.) as the pressure rises from to some 40 Ibs. per sq. in., both curves for higher pressure showing a tendency towards an horizontal deflection. This occurrence was found to be still more marked when the case-hardening operation was con- ducted at lower temperatures. In every instance, however, the bend in the curves occurred in the vicinity of 40 Ibs. pressure. The photomicrographs (Fig. 300 to 302) clearly reveal the increasing depth of case resulting from increasing gas pressure, other conditions remaining unchanged. It should be observed that it is the hyper-eutectoid portion of the case which is chiefly affected, increasing in thick- ness with the pressure, while the width of the eutectoid band remains practically the same. CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL 321 fs ^>^ Jgp^ Pc*^ ^: |p S5 ': - j?<3S?fe <"$?* r. wis ..r- OsSfe) !'*# w/ %fA - ; i i iit-y -k^ -^ o ft '^ == IM O CO bb ;Q "O 0) ^--. " tf iO O rf? s a te - M I 8 I" 3 ^ a bJD d J ^ 2 O Ho: he E '^^rv.-o ^- ffitfr-n*- T /-' ^ _g d* 0! 0> h ta CA G 03 bD II be o O tJ r^ o to 12 rvi ^" U) S bo '3 322 CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL Maintaining a constant atmospheric pressure, constant flow of gas (5 liters per hour), constant time (3 hours), but varying the temperature from 600 to 1000 deg. C., the curves of Figure 303 were obtained. They indicate the increasing amount of carbon taken up as estimated both by increasing weight and increasing depth of case. The following inferences appear justified: (l) at 700 deg. C. or at any lower tem- perature there was no absorption of carbon whatever, from which it may be con- cluded that a iron, under the prevailing experimental conditions, cannot dissolve carbon, (2) at 800 deg. C. there was a noticeable carbon absorption, hence the Increase of We/gM Curve ~-~-"~~ of Case Curve 500 3 .6 4- .8 5678 no. 1.0 1.2 1.4 1.6 of Ca.se - Trim. 9 1.8 IO 2.O Fig. 303. Case hardening by gas. Temperature penetration curves. (F. C. Langenberg in the author's laboratory.) power to dissolve carbon is acquired between 700 and 800 deg. C., that is during the range of temperature where ft iron also is formed and it may be reasonably believed that the two occurrences are closely linked, (3) at 900 deg. there is a break in both curves indicative of a slower rate of increase, and this appears to be closely related to the formation of j iron. Figure 304 shows the structure of American ingot iron after the case-hardening operation just outlined conducted at 720 deg. C., while when performed at 810 deg. C. the structure of the same metal was as represented in Figure 305. There is no indication of the former having absorbed any carbon while the carburizing of the latter is very appreciable. Mechanism of Cementation. It was held for many years that in the cementa- tion of iron solid carbon passed bodily from the packing material into the metal, fol- CHAPTER XIX THK CEMENTATION AND CASE HARDENING OF STEEL 323 '" HP . ' < ' t>":rv' : ;* -' . "*." i Fig. 304. American ingot iron case hardened by gas for 3 hours at 720 deg. C. Magnified 100 diameters. (F. C. Lan- genberg in the author's laboratory.) * - A . ~~ . Fig. 305. American ingot iron case hardened by gas for 3 hours at 810 deg. C. Magnified 100 diameters. (F. C. Lan- genberg in the author's laboratory.) 324 CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL lowed by a slow migration towards the center. Recent investigations, however, have made it evident that the transfer of the carbon from the packing material to the metal is accomplished chiefly, if not altogether, by means of some gases liberated or formed during the annealing treatment. It has been shown quite conclusively, for instance, that if a piece of steel surrounded by pure carbon be heated in vacuum, thus precluding the formation of gases, it will not take up carbon, although one ob- server has noted that if decided pressure be applied some carbon will pass into the iron even in the absence of gases. Whether this be so or not it is apparently certain that the carbon must first be volatilized before becoming very active as a carburiz- ing agent in the cementation and case hardening treatments. Carbon monoxide (CO) and volatilized cyanogen (CN) compounds are the gases which seem most effective. The carbon monoxide is derived from a partial combus- tion of the carbon of the cementing material by atmospheric oxygen while the cyan- ogen results from a combination of that carbon with atmospheric nitrogen or from the decomposition of cyanide compounds such, for instance, as potassium cyanide and ferro-cyanide. It may be assumed that the carbon monoxide once formed gives up its carbon to the iron according to the reaction, 2CO + 3Fe = Fe 3 C + CO 2 , the resulting Fe 3 C or cementite being dissolved by the austenite very much as salt is dissolved in water and the C0 2 being again reduced to CO on coming in contact with fresh carbon (C0 2 + C = 2CO). The marked activity of cyanogen compounds compared to the slower action of charcoal have led some to believe that cyanogen gases are especially effective in carburizing iron. It should be noted, however, that while cyanide compounds produce a much quicker carburization they soon lose their carburizing power so that when deep cases are needed, as in the manufacture of blister bars, charcoal, acting chiefly through the production of carbon monoxide, i.s preferable. Cooling from Carburizing Temperature. It is generally desired that articles subjected to the case hardening treatment should have a very hard surface. To pro- duce this hardness the case hardened articles should be quenched from above their critical range. The prolonged heating at a very high temperature to which these articles have been exposed, however, has developed a coarseness of structure both in the core and in the case which would be retained if they were, as they sometimes are, quenched from the carburizing temperature or after cooling to a somewhat lower temperature. It is obvious that in order to impart a fine structure both to the core and to the case the articles should be cooled and then subjected to suitable heat treatments. Heat Treatment of Case Hardened Articles. In order to refine the structure of the core which has been coarsened by a long exposure to a high temperature the metal should be reheated slightly above the critical range of that core and since its carbon content seldom exceeds 0.15 per cent carbon a temperature of at least 900 deg. C. should be used. Guillet recommends 1000 to 1025 deg. The finer structure thus imparted to the core will then be retained most effectively by quenching the metal in water or oil. By such treatment, however, the case, although hardened, is still relatively coarse since its quenching was effected at a temperature considerably exceeding its critical range. In order to refine it while leaving the structure of the core undisturbed the article should now be reheated slightly above the critical range CHAPTER XIX THE CEMENTATION AND CASE HARDENING OF STEEL 325 of the case, that is, to some 775 or 825 deg. C., and then quenched in oil or water. By this double treatment we have hardened the case while conferring to it as well as to the core a fine structure. It has been observed that the low carbon steel cores of case hardened articles are frequently coarser than the same steel after like heat treatment conducted in the absence of carburizing material. This is generally ascribed to the action of hydrogen, most carburizing 'agents evolving some of that gas at the annealing temperature. This increased coarseness of the cores of case hardened implements is an additional reason why their structure should be refined by suitable heat treatments. Tempering Case Hardened Steel. The properties of quenched case hardened steel may often be further improved by tempering, i.e. by reheating to some 200 to 400 deg. C. in order to toughen the case and remove strains while losing but little hardness. CHAPTER XX ALLOY STEELS GENERAL CONSIDERATIONS The steels so far considered in these chapters are the ordinary steels of commerce, at present often called "carbon" steels to distinguish them from the "special" or "alloy" steels of relatively recent origin but of rapidly growing importance. By special steels is meant those steels which owe their properties in a marked degree to the presence of one or more special elements whereas the properties of carbon steels depend chiefly, if not exclusively, for like treatment, upon the proportion of carbon present. Alloy steels containing but one special element are commonly called "ter- nary" steels, being considered to be made up of three constituents, namely iron, car- bon, and the special element, while steels containing two special elements are called " quarternary " steels because of the presence of four constituents: iron, carbon, and the two special elements. These two classes of special steels will be considered separately. Ternary Steels. We are indebted to Guillet for a brilliantly conceived and vigorously developed theory of the ternary steels. Too rigorous an application of the theory, however, should not be insisted upon for there are some facts not yet satis- factorily explained by it. Its use, nevertheless, will be found an invaluable guide in directing researches dealing with the manufacture and the application of these steels. Guillet's theory of the structure and properties of ternary steels may be briefly formulated by a few propositions. It is also represented graphically in Figure 306. (1) On the introduction of a special element in carbon steel the latter remains at first pear li tic, but as the proportion of the special element increases, the carbon re- maining constant, it becomes first martensitic and then austenitic (polyhedral), as shown graphically in Figure 306, and sometimes cementitic (carbide steel) 1 as later explained. (2) By increasing the amount of carbon present in a special steel, the proportion of the special element being kept constant, it is generally converted from a pearlitic into a martensitic condition or, if already martensitic, into an austenitic condition. (3) The greater the amount of carbon the smaller the proportion of the special element needed to cause a structural transformation, as for instance pearlite into mar- tensite or martensite into austenite. This is indicated in Figure 306. 1 Guillet uses the term "polyhedral" to designate an austenitic structure and "carbide" steel (acier a carbure) to indicate the presence of cementite (generally in special steels a double carbide of iron and the special element) . It seems to the author that the terms austenitic and cementitic are preferable because they suggest unmistakably the nature of the constituents. Austenitic steels are not the only ones exhibiting a polyhedral structure; ferritic (low carbon) steels for instance are also polyhedral. 326 CHAPTER XX ALLOY STEELS 327 (4) The greater the amount of the special element the smaller the proportion of carbon needed to cause a structural transformation. This is also shown in Figure 306. (5) No very sharp lines of demarcation are observed between the different types of structures mentioned in the preceding propositions, relatively wide ranges of com- position existing, on the contrary, in which the steel may be partly pearlitic and partly martensitic or partly martensitic and partly austenitic, etc. These transition ranges are indicated by shaded areas in the diagram of Figure 306. Greater refinement in the construction of this diagram would undoubtedly lead to the introduction of a troostitic zone between the pearlite and martensite areas and possibly also of a sor- bitic zone between pearlite and troostite. To sum up, constituents may be formed during the slow cooling of many alloy steels which in carbon steels can only be produced by very rapid cooling through the .2 <* .6 .5 i.o /.2 14 is Percent carbon. * Fig. 306. Constitutional diagram of alloy steels. critical range. Carbon steels, moreover, even after very rapid cooling cannot be re- tained wholly in an austenitic condition while several special steels remain austenitic after slow cooling. It is evident from the above and from the diagram that in order to produce a certain structure, (1) the proportion of carbon may be kept constant while the proportion of the special element is increased until the desired structure is obtained, or (2) the proportion of the special element may be kept constant and the proportion of carbon increased, or (3) both the proportion of carbon and of the special element may be increased when the desired structure will be obtained more quickly. The usefulness of Quillet's diagram is obvious. Should we desire, for instance, to know the kind of structure, and therefore the physical properties, of a steel contain- ing 0.60 per cent carbon and 8 per cent of the special element, the diagram shows that such composition falls within the martensitic range. Likewise a steel contain- 328 CHAPTER XX ALLOY STEELS ing one per cent carbon and 15 per cent of the special element would be austenitic according to the diagram. Or one may wish to know what proportion of the special element should be added to a carbon steel containing, say, 0.5 per cent carbon, to make it martensitic; the diagram shows that 7 per cent will be needed. Again, hav- ing an austenitic steel containing 10 per cent of the special element it may be desired to know the minimum amount of carbon that may be present without causing the steel to become martensitic; the diagram shows 0.80 per cent of carbon to be the smallest proportion of carbon permissible. The construction of such diagrams requires the preparation of a number of alloys varying in their contents of carbon and of the special element, their microscopical examination and the plotting of their structure. It is quite essential to know the rate of cooling adopted in the construction of the diagram, i.e. whether the samples were cooled in air or more slowly in the furnace, for it is evident that their structure may be deeply affected by thus varying the speed at which they cool. Some special steels, for instance, may be pearlitic when cooled very slowly in the furnace, martensitic when cooled in air, and austenitic after water quenching. Influence of the Special Element upon the Location of the Critical Range. The production of martensitic and austenitic structures on slow cooling is due to the fact that the special element lowers the position of the critical point to a temperature so low (1) as to permit only a partial transformation, namely, of austenite into marten- site, the steel being too rigid to allow a more complete transformation, or (2) as to prevent even a slight transformation, the steel in that case remaining austenitic. This influence of the special element in lowering the position of the critical range is depicted in Figure 307 in which it is assumed that the proportion of carbon remains constant. It has been further arbitrarily assumed in this diagram that the critical point was progressively and uniformly lowered from 700 deg. C. to deg., as the pro- portion of the special element increased from to 6 per cent. From many observa- tions it appears (1) that as long as the critical point remains above 300 deg. C. the steel becomes pearlitic on slow cooling, (2) that when the critical point is lowered below 300 deg. it becomes martensitic, the rigidity of the metal preventing further transformation, and (3) that when the critical point is lowered to atmospheric tem- perature or below it the metal remains untransformed, that is austenitic. These inferences are offered here because of their apparent usefulness and suggestiveness, but the author realizes that the lines indicating the relation between the position of the critical points and the corresponding structures cannot be sharply drawn, for they are likely to shift according to the nature of the special element, the rate of cooling, etc. Again, troostitic and possibly also sorbitic steel are likely to form be- tween pearlite and martensite, that is, whenever the critical point is lowered, say below 400 or possibly below 500 deg. To make the meaning of the diagram of Figure 307 clear let us consider three steels: I, II, and III, all containing one per cent of carbon, but respectively 1, 4.50, and 7 per cent of the special element. As steel I cools it undergoes its transformation at about 600 deg. At that temperature the metal is so plastic that the transformation of austenite into pearlite readily takes place; the steel becomes pearlitic. The critical point of steel II is slightly below 200 deg. At this temperature the transformation of austenite into martensite will take place, but the metal is now too rigid to permit further transformations ; the steel remains martensitic. Steels which remain marten- CHAPTER XX ALLOY STEELS 329 sitic after slow (air) cooling are said to be "self-hardening." In the case of steel III, since its critical point is lowered below atmospheric temperature it necessarily remains austenitic. Since austenitic special steels have their points of transformation situated below atmospheric temperature, it should be possible through cooling to a sufficiently low temperature, as for instance by immersion in liquid air, to cause at least their partial transformation, that is, they should become martensitic after such treatment and this indeed is precisely what happens in some cases. The transforma- 800 TOO F I ^ 3 4 5 6 N / a 0 50 60 10 80 80 IOQ Fig. 310. Influence of .nickel on the critical points of iron. (Osmond.) other words, nickel up to 25 per cent greatly increases the hysteresis. Taking a steel, for instance, with 10 per cent nickel cooling from a high temperature, it remains non- magnetic until a temperature of some 400 deg. C. is reached when it undergoes the magnetic and other transformations. On reheating this magnetic steel, however, it does not again lose its magnetism until a temperature of some 675 deg. is attained. Between 400 and 675 deg. this nickel steel will be magnetic, therefore, in case its last transformation resulted from cooling below 400 deg. and it will be non-magnetic if it resulted from heating above 675 degrees. When this hysteresis gap between the transformation is considerable the alloys are said to be irreversible, meaning by that expression that the reverse transformation cannot be produced at or near the same temperature. Nickel steels containing between 5 and 25 per cent nickel are therefore often spoken of as irreversible alloys. It should be noted, that when the nickel content does not exceed some 3 per cent the alloys are really reversible, that is, the gap between the critical transformations on heating and cooling is not excessive. According to Osmond, for instance, with 3.82 per cent nickel the critical point on heating occurs at 710 deg. and on cooling at 628 degrees. A gap of 100 deg. might b e 338 CHAPTER XXI ALLOY STEELS arbitrarily selected as a line of demarcation between reversible and irreversible alloys. Returning to Figure 310 it will be seen that as the nickel content increases above 25 per cent the transformations become abruptly reversible (the gap between them not exceeding 50 deg.), that their position is now gradually lifted, reaching a maximum for about 70 per cent nickel, and that it is then again lowered. Iron-nickel alloys containing more than 25 per cent nickel are therefore reversible. The diagram also shows that with some 25 per cent nickel the transformation is lowered below atmospheric temperature which means that the metal on cooling from above B' remains non-magnetic at atmospheric temperature and that its iron, there- fore, is in the gamma condition and its structure austenitic. 75 10. IZ.5 15. 17.5 20. 22.5 25 Nickel % 23 5. Fig. 311. Influence of nickel and carbon on the position of the critical point An and corresponding types of structure. An attempt has been made in Figure 311 to construct a diagram indicating the re- lation existing between carbon content, nickel content, position of the critical points on cooling, and corresponding types of structures as explained in Chapter XX. As already stated the pearlitic nickel steels are those most widely used. In the majority of cases the nickel content does not exceed 3.50 per cent while the carbon content is seldom over 0.50 per cent. These steels compared with carbon steels of equal ductility have a considerably higher strength and especially higher elastic limit, while compared with carbon steels of like elastic limit they have much greater ductility. To explain this in another way, the introduction of some 3.50 per cent nickel in a 0.50 per cent carbon steel, for instance, raises its elastic limit very con- siderably while decreasing its ductility but slightly. Pearlitic nickel steels are also somewhat harder than carbon steels of like properties, hence better able to resist wear. When properly heat treated their ability to resist shocks is likewise greater. CHAPTER XXI ALLOY STEELS 339 The structure of pearlitic nickel steel is shown in Figure 312. On comparing it with that of carbon steel of like carbon content it will be noted that the pearlite par- ticles are somewhat sharper and more angular and the ferrite grains smaller. When examined under high magnification the nickel pearlite is seldom found as distinctly laminated as ordinary pearlite. The hardening and annealing of nickel steels should be conducted at lower tem- peratures than the hardening and annealing of ordinary steels of similar carbon con- tent since their critical points occur at lower temperatures. From the evidences at hand it would seem as if between and 5 per cent nickel, and in" the case of low car- bon steels, each one per cent of nickel lowered the Ari point some 20 deg. C. and the *^l'^/M*% 4&&:i&&&M i*. si^^y^ a^s Fig. 312. Nickel steel. Carbon about 0.30 per cent. Nickel about 3 per cent. Magnified 100 diameters. (G. A. Reinhardt in the author's laboratory.) Aci point some 10 degrees. In the nickel pearlitic steels of commerce, therefore, the points Ari and Aci should occur at or near the temperatures indicated in the follow- ing table according to their percentage of nickel. 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00 750 745 740 735 730 725 720 715 710 705 700 A* 700 690 680 670 660 650 640 630 620 610 600 340 CHAPTER XXI ALLOY STEELS Fig. 313. Nickel steel. Nickel 3.44 per cent. Carbon 0.176 per cent. Case hardened and air cooled. Magnified 100 diameters. (G. A. Reinhardt in the author's laboratory.) Fig. 314. Same steel as in Figure 313. Same treatment. Magnified 50 diam- eters. (G. A. Reinhardt in the author's laboratory.) CHAPTER XXI ALLOY STEELS 341 Fig. 315. Nickel steel. Nickel 4.86 per cent. Carbon 0.115 per cent. Case hardened and air cooled. Magnified 100 diameters. (G. A. Reinhardt in the author's laboratory.) Fig. 316. Same steel as in Figure 315. Same treatment. Magnified 300 diam- eters. (G. A. Reinhardt in the author's laboratory.) 342 CHAPTER XXI ALLOY STEELS While nickel retards the carburization of iron by case hardening, the cores of nickel steel articles are not coarsened by the high temperature of the carburizing operation to the same extent as carbon steel cores, so that one treatment is often sufficient, namely, reheating to and quenching from a temperature slightly superior to the critical range of the case, that is, to some 700 to 750 deg. in the presence of some 3 or 3.5 per cent nickel. Higher nickel contents call for lower quenching tem- peratures. The case hardening of nickel steels offers the possibility already alluded to of producing a martensitic case without quenching. Nickel steel, for instance, contain- ing not over 0.25 per cent carbon and some 3.50 or more per cent nickel can readily be made martensitic near the outside by case hardening followed by air cooling as Fig. 317. Nickel steel. Cast. Nickel 10 percent. Carbon 0.80 per cent. Magnified 300 diameters. (Guillet.) Fig. 318. Nickel steel. Nickel 25 per cent. Carbon 0.80 per cent. Magnified 300 diameters. (Osmond.) shown in Figures 313 and 314. The martensitic grains owe their polyhedral form to the original austenitic grains from which they are derived. The thickness of the mar- tensitic case is about 0.5 mm. The occurrence of troostite should be noted. Under lower magnification (Fig. 314) a solid troostite band is seen to separate the marten- sitic and the sorbito-pearlitic portions. With a little more carbon and nickel mar- tensito-austenitic cases may be produced as shown in Figures 315 and 316. Nickel steels that are martensitic as cast are not utilized because like all mar- tensitic steels they are hard, brittle, and cannot be machined. Their case hardening should result in the formation of ductile, austenitic cases. Nickel steels which are martensitic after air cooling may be troostitic, sorbitic, or even pearlitic after very slow cooling in the furnace, while they may become austenitic on water quenching. The structure of martensitic nickel steel is shown in Figure 317. Austenitic nickel steels are not widely used, the high carbon, high manganese steels being preferred when an austenitic steel is desired, in part at least because of their lower cost. Like all austenitic steels they are non-magnetic, ductile, very diffi- cult to machine, and have a low elastic limit, Their structure is polyhedral (see CHAPTER XXI ALLOY STEELS 343 Fig. 318). Some types of austenitic nickel steels have, however, found interesting applications based chiefly on the marked influence of nickel on the dilatation of the metal. With 36 per cent nickel, for instance, the dilatation is nearly nil and the re- sulting alloy, discovered by Guillaume, and called by him "invar" is used success- fully for the construction of clocks and other instruments of precision. With some 46 per cent of nickel and 0.15 per cent carbon the coefficient of dilatation is nearly the same as that of glass and alloys of that composition called "platinite" are used in place of platinum for the construction of incandescent electric lamps. Austenitic nickel steel may be made martensitic and thereby regain its magnetism by immer- sion in liquid air. The increase of volume which accompanies this transformation produces a swelling of the polished surface which because of the resulting relief effect renders the structure of the metal apparent without etching, as shown in Figure 319. Fig. 319. Nickel steel. Nickel 15 per cent. Carbon 0.80 per cent. Cooled in liquid air (-180 deg. C.). Not etched. Magnified 300 diameters. (Guillet.) Manganese Steel. Manganese, when alloyed with iron and carbon in large proportion, is partly dissolved in the iron and partly present as a double carbide of iron and manganese. From this behavior of manganese the structural types formed by increasing both carbon and manganese may be anticipated. The steel should at first remain pearlitic and then become in succession martensitic and austenitic. With much manganese and carbon, however, the separation of carbide is to be expected. The constitutional diagram of manganese steels is shown in Figure 320 after Guillet, while a critical point structural diagram has been constructed tentatively in Figure 321. By comparing the constitutional diagram of manganese steel with that of nickel steel it will be noted that manganese is, roughly stated, twice as effective as nickel in producing a certain type of structure, as for instance in converting pearlitic into martensitic steel. Manganese is present in appreciable quantities in all ordinary carbon steels but unless the latter contain considerably more than one per cent of that element they are not regarded as manganese steels. With carbon not exceeding 0.80 per cent and 344 CHAPTER XXI ALLOY STEELS manganese not exceeding some 3 per cent the steels remain pearlitic and, therefore, not unlike the pearlitic nickel steels so widely used. Manganese pearlitic steels, however, are practically ignored by steel manufacturers and users apparently (1) be- cause of the wide-spread belief that such steels are brittle and (2) because of the difficulty of manufacturing low carbon manganese steels. The belief in the brittle- ness of pearlitic manganese steels is founded on Hadfield's statement that between 2 and 6 per cent of manganese the steels are hopelessly brittle. On closer examina- tion, however, it would seem as if this statement was true only in the case of rather high carbon steels cooled relatively quickly. Evidences have since been offered, AT ) Cb q 1800 1700 S I60O -tvo !P I5OO 0) -- I40O I3OO I20O 1100 IOOO IO / Carbon Fig. 347. Solubility of carbon in iron. results are indicated by crosses in the same diagram. Since the carbide Fe 3 C, or oementite contains 6.67 per cent carbon, it may be inferred from the results tabu- lated above, (1) that iron-carbon alloys saturated with carbon consist between 1130 366 CHAPTER XXII CAST IRON (the melting-point of the eutectic as later explained) and 1823 deg. of liquid solu- tions of iron and Fe 3 C, the proportion of the latter constituent increasing with the temperature, and (2) that at 1823 the alloy is liquid Fe 3 C. From the fact that the amount of carbon dissolved at 2220 deg. C., namely 9.60 per cent, is the amount called for by the carbide Fe 2 C it is further inferred (1) that between 1823 and 2220 deg. the alloys are liquid solutions of Fe 3 C and Fe 2 C the latter increasing and the former decreasing with the temperature, and (2) that at 2220 deg. the alloy is liquid Fe 2 C. At higher temperature some of the Fe 2 C breaks up into iron and graphite (Fe 2 C 2Fe + C) the resulting graphite floating to the top of the liquid bath, thus explain- ing the smaller and decreasing proportions of dissolved carbon at temperatures ex- ceeding 2220 deg. The break in the curve at 1823 (Fig. 347) corresponds to the formation of Fe 3 C, the break at 2220 deg. to the formation of Fe 2 C. Taking iron with its maximum proportion of carbon namely at 2220 deg. when it is capable of dissolving 9.60 per cent carbon, as previously stated, it then consists of liquid Fe 2 C. On cooling it is not capable of retaining so much carbon some of it being rejected as graphite through the transformation of some of the Fe 2 C into Fe 3 C and graphite (3Fe 2 C = 2Fe 3 C + C). This formation of Fe 3 C at the expense of Fe 2 C with rejec- tion of graphite continues until at 1823 deg. Fe 3 C only is present (6.69 per cent car- bon). On further cooling the alloy must continue to reject carbon, now through the transformation of some of the Fe 3 C into iron and graphite (Fe 3 C = 3Fe + C) a transformation which continues until a temperature of 1130 deg. is reached when the alloy contains 4.30 per cent carbon and when further cooling now causes its solidification. The possibility of the carbide Fe 3 C solidifying out of the liquid solu- tion being later converted wholly or in part into iron and graphite will be considered in the following pages. Formation of Combined and Graphitic Carbon. It will be explained in Chapter XXVI that when cast iron solidifies the carbon probably remains in the combined condition and that the resulting carbide, Fe 3 C, is partly free and partly in solid solu- tion in the iron. This Fe 3 C, however, is an unstable compound and when formed at a high temperature it is readily decomposed into graphite and iron according to the reaction Fe 3 C = 3Fe + C hence the formation of graphitic carbon in cast iron. Two factors are conspicuous in promoting the formation of graphitic carbon, (1) a slow rate of cooling through and below the solidification period and (2) the presence of silicon. The gray, i.e. gra- phitic, cast irons are generally those which have been cast in sand and hence slowly cooled and which contain a relatively large percentage of silicon. It follows that under otherwise identical conditions and compositions a large casting will become more graphitic on solidifying than a smaller one since it will cool more slowly; also that of two castings of equal size, cooled under like conditions and of identical com- position except as to their silicon contents, the one richer in silicon will contain more graphitic carbon. The conditions most effective in preventing the formation of graphitic carbon and in promoting, therefore, the retention of carbon in its combined form are (1) quick rate of cooling through and below the solidification range and (2) the presence of much sulphur or manganese. Cast Iron Containing only Graphitic Carbon. Cast irons containing a consider- able amount of graphitic carbon are known as gray cast irons because of the appear- CHAPTER XXII CAST IRON 367 ance of their fracture which is grayish or blackish and coarsely crystalline. Cast irons containing the whole of their carbon in the graphitic condition and therefore free from combined carbon are extreme types seldom produced. Their structure, however, should be considered. Proceeding as we did in the case of steel we shall first assume cast iron to be a pure alloy of iron and carbon, free, therefore, from its usual impurities. If the whole of the carbon is in the graphitic condition it is evident that cast iron can only contain the two constituents graphite and iron or ferrite. We may therefore anticipate its structure. It will, however, be interesting to study the mode -of -occurrence of the Fig. 348. Gray cast iron free from combined carbon. Magnified 100 diameters. Not etched. (F. C. Langenberg in the author's laboratory.) graphitic carbon. The structure of cast iron practically free from combined carbon is illustrated both before and after etching in Figures 348 and 349. The metal will be seen to consist of an iron or ferrite matrix in which are embedded many irregular and generally elongated and curved plates of graphite. These graphite plates break up so effectively the continuity of the metallic mass as to completely destroy the ductility and malleability of a substance (ferrite) by nature very ductile and malleable. The brittleness of high graphitic cast iron is not due so much to the brittleness of the graphite it contains nor even to its large proportion of graphite as to the thorough manner in which the continuity of its otherwise ductile matrix is destroyed by the shape and distribution of the graphite particles. It will be seen in another chapter that when the graphite occurs in small rounded particles as it does in malleable cast iron the ferrite matrix may retain considerable ductility and malleability. 368 CHAPTER XXII CAST IRON The ferrite matrix of this highly graphitic cast iron (Fig. 349) will be seen to he- made up of the polyhedral crystalline grains characteristic of carbonless iron, the fer- rite of cast iron being similar in this and other respects to the ferrite of wrought iron and of hypo-eutectoid steel. In impure cast iron it undoubtedly holds in solution silicon and possibly, to some extent, other impurities. Highly graphitic cast iron is brittle and deprived of ductility and malleability because of the presence of numerous plates of graphitic carbon; it is weak because of the presence of graphite plates and because of the relative weakness of its matrix; it is soft and therefore easily machined because of the softness both of its matrix and of the graphite it contains; it expands on solidifying because of the formation, with Fig. 349. Same metal as in Figure 348. Magnified 100 diameters. Etched. (F. C. Langenberg in the author's laboratory.) increase of bulk, during solidification of a large amount of graphitic carbon. It should be noted that because of its low specific gravity graphite will occupy a rela- tively large proportion of the bulk of the metal. Cast iron, for instance, containing by weight 3 per cent of graphite contains by volume some 12 per cent of that element- As might be expected the rate of solidification and further cooling has some in- fluence both upon the shape and size of the graphite particles as well as upon the size of the ferrite grains, and therefore upon the physical properties of the metal, very slow solidification promoting the formation of large graphite plates and of large ferrite grains. Were it possible to cause the graphite in cast iron to occur in small rounded particles instead of sharp, curved plates, its ductility and strength would undoubtedly be greatly increased. The diagram of Figure 350 shows graphically the structural composition of iron- CHAPTER XXII CAST IROX 369 carbon alloys in which the whole of the carbon occurs as graphite. Only those alloys, however, containing from 3 to 4.5 per cent carbon can be produced. Indeed in the absence of silicon even these are quite unobtainable. With less than 3 per cent car- bon it is well nigh impossible to prevent the retention of some combined carbon, while with less than 2 or at least with less than 1.50 per cent carbon the whole of the carbon is likely to be in the combined condition. The diagram, therefore, is only a theoretical one. It has, nevertheless, its interest for it will be shown in another chap- /OO Cast /ron free from ".ombinectcarkx. Graph //e by weighi". Percent Carbon Fig. 350. Structural composition diagram of iron-carbon alloys free from combined carbon. ter to represent the stable and final equilibrium of the iron-carbon system. The percentage of graphite by volume has also been indicated. Cast Iron Containing only Combined Carbon. Cast iron containing only com- bined carbon and free, therefore, from graphitic carbon is called "white" cast iron from the aspect of its fracture which is white, brilliant, and highly metallic. The absence of graphitic carbon is generally due (1) to the presence of much manganese and sulphur and of little silicon, (2) to quick cooling through and below the solidifica- tion period, or (3) to both low silicon, high manganese and sulphur, and quick solidi- fication. Cast iron, for instance, may contain so much sulphur and manganese and so little silicon as to be white even after slow solidification or it may solidify so quickly as to be white even in the presence of much silicon and little manganese and sulphur. A familiar instance of the marked influence of the rate of cooling is afforded by 370 CHAPTER XXII CAST IRON the casting in the metal molds of casting machines of cast iron which if cast in sand would have been gray, whereas it is now white. Small castings since they cool more quickly become white more readily than larger ones. In the absence of graphitic carbon the structure of cast iron should resemble the structure of a very high carbon steel, i.e. it should consist after slow cooling of pearlite and of a large amount of free cementite. This is found to be the case as shown in Figure 351 in which is illustrated the structure of white iron containing about 3 per cent of combined carbon. Theoretically this alloy should contain nearly 63 per cent of pearlite and 37 per cent of free cementite. The dark constituent in the photograph is pearlite, the light one, visibly in relief, cementite. The structure of white cast iron is also shown in Figure 352 under high magnification, the laminations of pearlite being clearly seen. The structure of white cast iron is further illustrated in Figures Fig. 351. White cast iron. Magnified 56 diameters. Fig. 352. White east iron. Magnified 500 diameters. (Wust.) 353 and 354 after Guillet. These photomicrographs are reproduced here because they afford an interesting example of the action of sodium picrate (Chapter VIII) in coloring free cementite while leaving pearlite uncolored. The structural composition of white cast iron is to be calculated like the composi- tion of any hyper-eutectoid steel of known carbon content as explained in Chapter VIII, the following relation existing between the percentage of pearlite and that of carbon in the iron, on the assumption that pearlite contains 0.834 per cent carbon: P = 800 - 120 C the balance of the metal being of course free cementite. While structurally it re- sembles high carbon steel, white cast iron is deprived of malleability being indeed very brittle and very hard. This brittleness and hardness are due to the very large proportion of free cementite present which itself is very hard and brittle. CHAPTER XXII CAST IRON 371 It will be evident that, starting from carbonless iron, as the carbon increases at first low carbon steel is produced and then in succession medium high carbon steel, high carbon steel, and finally white cast iron, each metal passing gradually into the next without any sharp line of demarcation between them. It is logical to base the distinction between high carbon steel and white cast iron upon the malleability of the former and the non-malleability of the latter and this is altogether a question of carbon content. The dividing line may be drawn somewhat arbitrarily at 2 per cent carbon. As a matter of fact steels are very seldom manufactured containing more than 1.75 per cent carbon while white cast iron rarely contaiusJess than 2.25 per cent carbon. Between the steel series, therefore, and the white cast-iron series there is a natural gap, the existence of which generally removes any doubt as to the nature of the metal under examination. Again if the process of manufacture be known there need be no doubt as to the classification of any highly carburized iron alloy: if made in the blast furnace from S& sfc-T^* ^v** i^v^c^ 1 v+'toer cent of combined carbon, for instance, the foregoing equations indicate the following structural com- position: pearlite 90.60 per cent, free cementite 7.40 per cent, and graphite 2 per cent. Ca-sf /ron w/fh Hypo- matr/x Cast /ron with Hyper-eufectoid matrtx Graphite *>; fx i o Pearlite (ei/fecfa/e/J-ferr/te. Fre Combined C fo Graphite C -ft. o. O-5"O &oo /.OO Z.5o /JO 2..OO 2.0O /.SO 2. SO /.OO. 30O OSO 3.3O O Fig. 360. Structural composition diagram of iron-carbon alloys containing a constant propor- tion of total carbon (3.50 per cent), but varying percentages of combined carbon (from to 3.50 per cent). The structural, graphical diagram of cast iron containing both combined and graphitic carbon has been constructed in Figure 360 in accordance with the scheme followed in these chapters. It is assumed in this diagram that the total carbon re- mains constant at 3.50 per cent and that the amount of combined carbon increases from to 3.50 per cent, in this way including the two extreme cases corresponding respectively to absence of combined carbon and of graphitic carbon. If this diagram be compared with that of the structural composition of steel, Chapter VIII, the steel nature of the metallic matrix of cast iron will be apparent. It will be noted that in the present diagram when the proportion of combined carbon exceeds 1.7 per cent there are two sources of free cementite indicated, namely, pro-eutectoid cementite 378 CHAPTER XXII CAST IRON and eutectic cementite; the origin of the latter will be made clear in Chapter XXVI. Both of these cementites constitute the free cementite present in cast iron, containing more than 1.7 per cent of combined carbon; while formed, as later explained, at dif- ferent periods of the cooling, they appear to coagulate together and cannot be dis- tinguished from each other under the microscope. Physical Properties of Cast Iron vs. its Structural Composition. The physical properties of cast iron must necessarily depend to a very great extent upon the prop- erties of its steel matrix from which it follows that its hardness and strength will increase with increasing combined carbon, the hardness indefinitely, the strength up to the eutectoid carbon ratio. It is evident, therefore, that cast iron of maximum strength (1) should have a steel matrix of maximum strength, i.e. should contain in the vicinity of 0.80 per cent combined carbon and (2) should contain as little graphitic carbon as possible since every graphite particle is a source of weakness; in other words, the nearer cast iron approaches a steel of maximum strength the greater will be its strength. After having secured the desired amount of combined carbon to give strength it is evident that a reduction of the graphitic carbon must mean a cor- responding reduction of the total carbon in cast iron. In ordinary cupola practise for the production of cast-iron castings, however, which consists in remelting pig iron of suitable composition, the proportion of total carbon is difficult to control, being nec- essarily between 3 and 4 per cent and we must depend to produce strength almost altogether upon the retention in the combined condition of a suitable proportion of carbon. The total carbon may be decreased, however, by the use of iron and steel scrap as part of the burden of the cupola resulting in increased strength, for same percentage of combined carbon, or by remelting in a so-called "air furnace," i.e. under oxidizing conditions when part of the carbon is burnt out. These low total carbon, and therefore tenacious, cast-iron castings are sometimes offered for sale under the name of semi-steels, a practise somewhat misleading for they are not steel in any sense of the word since they are not malleable, have very little ductility, and generally contain a considerable amount of graphitic carbon. If soft cast-iron castings are desired so that they may be easily machined they should contain as little combined carbon as possible. In the presence of but little combined carbon, however, the iron will not be very tenacious, strength and softness being antagonistic. If the castings are to be hard they should contain much com- bined carbon and, therefore, little graphite. In extreme cases they will be free from graphite, when their hardness will be very great, but they will then also be very brittle. In the majority of cases castings are wanted soft enough to be easily machined and at the same time of fair strength. This combination of properties is evidently to be obtained by producing a matrix corresponding to a medium high carbon steel, i.e. by causing the cast iron to retain some 0.30 to 0.60 per cent of combined carbon. The percentage of combined carbon in cast iron upon which its physical properties primarily depend, can be ascertained more quickly and readily by microscopical ex- amination than by chemical analysis and quite as accurately. Chilled Cast-iron Castings. It is sometimes desired to produce cast-iron cast- ings very hard near their outside but soft and relatively tough near their center. This may be done by so regulating the composition and solidification as to prevent the formation of graphite in those portions that should be hard while allowing it to form in the portions that should be soft. The means generally employed consist in using iron plates for those parts of the molds corresponding to the parts of the castings that CHAPTER XXII CAST IRON 379 are to be hard and sand for the other parts, the quicker solidification and further cool- ing of the metal coming in contact with the iron plates causing the retention of much combined carbon. The resulting castings are known as "chilled" castings. Impor- tant instances of the application of this method are to be found in the manufacture of chilled cast-iron wheels and of chilled rolls. It will be evident that the presence of sulphur and manganese in the cast iron should promote the retention of combined carbon on quick cooling while the presence of silicon and of large percentages of total carbon should hinder it. The chemical composition of cast iron to be converted into chilled castings should therefore be carefully regulated. Microscopical examination should prove of much value in examining the depth and quality of "chills." Cast Iron of Eutectic Composition. The alloy of iron and carbon containing 4.30 per cent carbon has the lowest melting-point (1130 deg. C.) of all alloys of that o i 2 PER CENT SILICON Fig. 361. Influence of silicon-content on the percentage of carbon in the eutectic alloy. series and is consequently known as eutectic alloy. The nature of eutectic alloys will be made clear in Chapter XXV. Those alloys solidify at a constant temper- ature whereas the solidification of alloys containing more or less carbon than the eu- tectic ratio covers a range of temperature which increases in width as the compo- sition of the alloy is farther removed from that of the eutectic as explained in Chapter XXVI. In other words eutectic alloys pass quickly from the liquid to the solid state while hypo- and hyper-eutectic alloys pass through a pasty or semi-fluid period which may be of considerable duration, a condition, as later explained, which must be favorable to the formation of large graphite particles. Eutectic Cast Iron vs. Impurities. While as stated in the preceding paragraph the eutectic point for pure alloys of iron and carbon corresponds to 4.30 per cent carbon it is quite certain that some at least of the impurities always present in commer- cial cast iron affect in a marked degree the percentage of carbon needed to produce the eutectic alloy, i.e. the alloy of lowest melting-point generally reducing the needed amount of carbon. From the work of Wust and Petersen, for instance, we are led to infer that the presence of 1 per cent of silicon lowers that carbon some 0.30 per cent. 380 CHAPTER XXII CAST IRON These authors' results may profitably be represented graphically as shown in Figure 361. The meaning of the diagram is obvious. The line AB divides cast iron into hyper- and hypo-eutectic metal according to its percentages of carbon and silicon. With 4 per cent of carbon and 2 per cent of silicon, for instance, the cast iron is hyper- eutectic, since its composition is represented by the point M in the hyper-eutectic range, while with the same amount of carbon but in the presence of only 0.5 per cent of silicon, the metal is hypo-eutectic, since its composition is represented by the point N in the hypo-eutectic range; with 3 per cent silicon some 3.50 per cent carbon suffices to produce the eutectic alloy, etc. The Strength of Cast Iron vs. the Size and Form of the Graphite Particles. Attention has already been called to the fact that the strength of cast iron is not only affected by the amount of carbon present but also, and in a marked degree, by the size and form of the graphite particles, long, curved plates of that constituent, for instance, being much more effective in reducing the strength than small rounded particles. Eutectic Cast Iron vs. the Size and Form of the Graphite Particles. It seems probable, as more fully explained in Chapter XXVI, that the bulk of the graphite present in cast iron forms during its solidification and since eutectic cast iron solid- ifies quickly while its temperature remains constant whereas the solidification of hypo- and hyper-eutectic alloys cover wider ranges of falling temperature it seem? reasonable to infer as already pointed out that in eutectic cast iron the graphite must occur in smaller and more rounded particles. In other words the mushy, semi-fluid condition of relatively long duration assumed by non-eutectic alloys on solidifying must promote the formation of coarse graphite particles. If this view- is correct it follows that for otherwise like composition and like treatment, cast iron of eutectic composition should be the strongest. In following that line of thought the influence exerted by some impurities on the eutectic carbon ratio should not be overlooked. With some 2 to 3 per cent silicon, for instance, some 3.50 to 3.75 per cent carbon should yield the eutectic alloy. Silicon and Rate of Cooling vs. the Matrix of Cast Iron and the Formation of Graphite. It is well known that the presence of silicon in cast iron promotes the for- mation of graphitic carbon while a rapid rate of cooling during solidification oppose - it and causes it to occur in particles of smaller size. The combined action of the rate of cooling and of the silicon content in determin- ing the character of the matrix of cast iron may be advantageously shown graphi- cally as in Figure 362. The abscissae correspond to percentages of silicon, the ordinates to rates of cooling represented by arbitrary numbers, 2 indicating quicker cooling than 1, 3 quicker cooling than 2, etc. Any point on the line A B corresponds to a set of conditions producing a eutectoid matrix, while any point above A B refers to rates of cooling and silicon contents resulting in hyper-eutectoid, and below AB, in hypo-eutectoid matrix. The point M, for instance, on A B corresponds to 1 per cent of Si and a rate of cooling represented by 1.5, while N corresponds to 3 per cent of Si and a quicker rate of cooling, 4.4. Both sets of conditions will produce castings having a eutectoid matrix but not identical properties, because the quicker cooling in the latter case must produce smaller and less angular graphite particles and hence a stronger metal. Cast Iron of Maximum Strength. From the foregoing considerations the follow- ing conclusions may be drawn: (1) to possess maximum strength, cast iron should be CHAPTER XXII CAST IRON 381 <>f rutectic composition because the graphite particles will then be smaller which in turn makes for greater strength, (2) the eutectic structure should be produced by high silicon and low carbon content since the latter promotes strength, (3) the cast iron should have a eutectoid matrix because it is the matrix of greatest strength, and (4) the eutectoid matrix should be produced by high silicon content and rapid cooling because the latter leads to the formation of small graphite particles. Solidification of Eutectic Cast Iron. The mechanism of the solidification of eutectic cast iron and of its subsequent transformation on slow cooling may be il- lustrated graphically as shown in Figure 363, assuming that no graphite forms. A BCD represents a block of eutectic cast iron cooling from above its melting-point to at- mospheric temperature. Above its liquidus-solidus line EF the metal is liquid. On PER CENT SILICON Fig. 362. Influence of silicon-content and of rate of cooling in determining the character of the matrix of cast iron. reaching that lire, which in pure iron-carbon alloys corresponds to a temperature of 1130 deg. C., it solidifies as an austenite-cementite eutectic containing EG (47.7 per cent) of austenite and GF (52.3 per cent) of cementite as later explained. On cool- ing from the solidus to the eutectoid line HL or Ari point, at about 700 deg. C., the eutectic austenite rejects cementite (pro-eutectoid cementite) until it reaches the eutectoid composition (0.85 per cent of C or 12.75 per cent of Fe 3 C). The pro- eutectoid cementite thus formed joins the eutectic cementite and is represented by the triangle GIK in the diagram. Clearly IL represents the total free cementite in the alloy when it reaches its eutectoid point. On cooling through this point the re- maining austenite, now of eutectoid composition, breaks up into ferrite and cemen- tite to form pearlite, a constituent which contains about 12.75 per cent of cementite (01 in the diagram) and 87.25 per cent of ferrite (HO in the diagram). Finally, then, the completely cooled alloy contains ND per cent of cementite of eutectic origin, MN per cent of cementite of pro-eutectoid origin, PM per cent of eutectoid cemen- tite and CP per cent of ferrite. The eutectic and pro-eutectoid cementite known 382 CHAPTER XXII CAST IRON collectively as "free" or "excess" cementite (MD) are so merged that they cannot be distinguished from each other, while the eutectoid cementite exists as a distinct constituent of pearlite. In the diagram PD represents the total cementite (free and eutectoid) in the alloy and CP the ferrite, that is its ultimate structural composition. Solidification of Hyper-Eutectic Cast Iron. The mechanism of the solidifi- cation of hyper-eutectic cast iron and of its subsequent transformation on slow cool- ing may be represented graphically, as shown in Figure 364. It is assumed in this diagram that no graphitic carbon is formed. On reaching its liquidus, EF, in the vicinity of 1,200 deg. C. in the case of a pure alloy containing 5 per cent of carbon, cementite begins to form, and its formation continues to the solidus line, as indicated by the triangle FGH. On reaching the solidus (1130 deg. C.) the molten portion of the alloy has the eutectic composition (4.30 per cent of carbon), and it solidifies as an austenite-cementite eutectic, IG, containing IK per cent of austenite and KG per cent of cementite. This is in ac- cordance with the solidification of the molten solution of any two metals capable of forming a eutectic alloy as explained in Chapters XXV and XXVI. On cooling from its solidus to its eutectoid or Ari point (700 deg. C.) the eutectic austenite rejects cementite, as indicated by the triangle KQN, until, on reaching the eutectoid point, it is of eutectoid composition, and is converted into pearlite containing LM per cent of ferrite and MQ per cent of cementite. The alloy will finally consist of UD per cent of pro-eutectic cementite, TU per cent of eutectic cementite, ST per cent of pro-eutectoid cementite, RS per cent of eutectoid cementite, and CR per cent of ferrite. The pro-eutectic, eutectic, and pro-eutectoid cementites are merged, and cannot be distinguished from each other under the microscope. Their sum, SD, constitutes the free cementite of the alloy. The eutectoid cementite, RS, on the contrary, remains intimately associated with the ferrite to form the constituent pearlite, represented by CS in the diagram. RD represents the total percentage of cementite in the alloy. Solidification of Hypo-Eutectic Cast Iron. The mechanism of the solidification of hypo-eutectic alloys may likewise be graphically represented as shown in Figure 365. On reaching its liquidus, EF, pro-eutectic austenite containing 1.70 per cent of car- bon begins to form. Assuming the cast iron to contain 3.50 per cent of carbon, its temperature would then be in the vicinity of 1225 deg. C. In cooling from the liquidus to the solidus or eutectic temperature, GK, austenite continues to form, the percentage of that constituent solidifying between the liquidus and the solidus be- ing represented by the triangle EGH. On reaching the eutectic temperature, the liquid portion of the alloy has reached the eutectic composition and now solidifies as an austenite-cementite eutectic, HK, containing HI per cent of austenite and IK per cent of cementite following in this the behavior of all binary alloys in which a eutectic alloy is formed (Chapters XXV and XXVI). On cooling from the eutectic to the eutectoid or Ari temperature, both the pro-eutectic and the eutectic austenite reject cementite, as indicated by the triangle IMN. At the eutectoid temperature, LO, the remaining austenite is of eutectoid composition and is transformed into pearlite, LM, containing LT per cent of ferrite and TM per cent of cementite. Below the eutectoid temperature, therefore, the cast iron consists of CR per cent of pearlite and RD per cent of free cementite, the pearlite containing CQ per cent of ferrite and QR per cent of cementite, and the free cementite RS per cent of cementite of eutectic CHAPTER XXII CAST IRON 383 H 3 I +a V <*> S3 -S x I? il O Q v , 1 Fig. 381. Black heart casting. Magnified 100 diameters. Xot etched. (F. C. Langonberg in the author's laboratory.) Fig. 382. Black heart malleable casting. Magnified 100 diameters. Total carbon 2.64 per cent. Silicon 0.76 per cent. Phosphorus 0.137 per cent. Sulphiir 0.031 per cent. Manganese 0.380 per cent. (Boylston.) CHAPTER XXIV MALLEABLE CAST IRON 405 The annealing of white cast iron may he so incomplete as to retain so much dis- solved carhon that in slow cooling free cementite as well as pearlite will be formed. In this case the austenite which existed above the range at the end of the annealing 1 Fig. 383. Partially malleablized cast iron. Magnified 100 diameters. Total carbon 2.55 per cent. Silicon 0.77 per cent. Phosphorus 0.164 per cent. (F. H. Franklin of Saunders and Franklin.) Fig. 384. Partially malleablized cast iron. Magnified 500 diameters. (Wiist.) operation was hyper-eutectoid, that is, it contained more than 0.85 per cent, or there- about, of dissolved carbon and on cooling through the range, therefore, liberated some free cementite. It is evident that partially malleablized cast iron, that is, cast 406 CHAPTER XXIV MALLEABLE CAST IRON iron still containing considerable combined carbon, cannot be as malleable as mallea- blized cast iron free from combined carbon since its metallic matrix is necessarily less malleable. Cooling from Annealing Temperature. According to B. L. Leasman, the cool- ing from the annealing temperature to 1250 deg. F. should be very slow (42 hours) while below it may be rapid. Gray Cast Iron vs. Malleable Cast Iron. From the foregoing description of the nature and manufacture of malleable cast-iron castings it is evident that gray cast iron and malleable cast iron may have exactly the same chemical composition, al- though, of course, the former will generally contain more silicon and total carbon. In spite of identical or nearly identical composition, however, these two metals differ enormously in physical properties, gray cast iron being weak and brittle, malleable cast iron much stronger, and endowed with remarkable shock-resisting qualities. To account for this we must look into the microstructure of both metals when it will be observed that in gray cast iron the graphite occurs in large, generally curved, flakes and plates whereas in malleable cast iron it is present in small rounded particles, and it may well be conceived that the mode of occurrence of graphite in gray iron breaks up the continuity of the metallic matrix much more effectively, therefore, weakening it and destroying its ductility. Were it possible during the solidification of cast iron to cause the graphite to occur as it does in malleable cast iron, there is no reason to doubt but that it would be as strong and as ductile. CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS For many years vague and conflicting opinions were entertained in regard to the nature of metallic alloys. It was not known whether these intimate associations of two or more metals were merely mechanical mixtures or chemical compounds while the existence of solid solutions was unsuspected. The application to the study of metallic alloys of the determination of the solubility curves which had proved so fruitful in investigating the mechanism of the solidification of ordinary (liquid) solu- tions and of mixtures of melted salts, soon followed by the microscopical examination of their structure have at last -revealed their true constitution. We know now that metallic alloys may be considered as solution of high freezing (solidification) point and, therefore, solid at ordinary temperature, whereas the old conception of solution applied only to substances liquid at that temperature. It is evident, however, that the location of the freezing-point of a substance in the temperature scale can have no bearing whatever upon its constitution, that is, upon the mode of occurrence of its constituents and the nature of the bond uniting them. In these chapters the constitution of metallic alloys will be considered only so far as necessary to understand the equilibrium diagram described in Chapter XXVI in which steel and cast iron are considered as alloys of iron and carbon, i.e. as solutions of these elements, liquid at a very high temperature, frozen at ordinary temperature. Since moreover steel and cast iron are considered as pure iron-carbon alloys it will suffice for our purpose to deal only with alloys of two metals, that is, with binary alloys. The constitution of alloys is revealed chiefly (1) through the mechanism of their solidification as disclosed by their "fusibility" curves, and (2) through the microscopi- cal examination of their structure after solidification. Solidification of Pure Metals. Let us first consider the solidification of a pure metal by observing its rate of cooling from the molten to the solid condition. This involves the use of a pyrometer, preferably a thermo-electric (Le Chatelier) instru- ment, the hot junction of which, suitably protected, is embedded in the cooling metal. By recording the successive intervals of time in seconds required for each successive cooling through ranges of temperature say of 10 deg. C., and plotting time against temperature a cooling curve of the type shown in Fig. 385 is obtained. 1 The teach- ings of such curves are obvious. Starting with the molten metal at A , its temperature being T, its cooling from A to B, while its temperature is falling from T to Ts is uni- formly retarded. This results in the smooth, nearly straight portion AB of the curve. The cooling of a molten metal above its solidification point is in this respect similar to the cooling of any substance free from thermal critical points; the cooling curves 1 Self-recording pyrometers may also bo used. 407 408 CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS obtained in such cases are always smooth curves indicating a uniform increase in time as the temperature of the substance falls. The curve of Figure 1 indicates the occurrence of a sharp critical point at the temperature Ts corresponding to the hori- zontal portion BC of the curve. It is evident that on reaching Ts the temperature of the metal suddenly ceased to fall and remained stationary during an interval of time represented by U'. The metal then resumed a normal rate of cooling which was continued to atmospheric temperature as indicated by the smooth portion CD which, were it not for the jog BC; would be a continuation of AB. We naturally connect this sudden appearance of a critical point in the cooling curve with the solidification of the r e Fig. 386. Cooling curves of various pure metals. Solidification of Binary Alloys the Constituents of which Form Solid Solutions. - The cooling or solidification curves of alloys of two or more metals may be constructed exactly like the cooling curve of a pure metal, namely, by observing the rate of cooling as the temperature is lowered from above the melting-point to atmospheric temperature and plotting the intervals of time against the corresponding temperature falls. A number of binary alloys are then found to yield cooling curves of the type shown in Fig. 387. From A to B, that is, as the alloy cools from T to Tb, the curve is smooth and, therefore, indicative of normal cooling. At B there is a sudden change of direction and from B to C, that is, from the temperature Tb to the temperature Tc, the cooling of the alloy is evidently abnormally slow. From C to D, that is, from the temperature Tc to atmospheric temperature, the cooling is again normal. Since the portion BC of the curve clearly indicates spontaneous evolutions of heat causing a marked retarda- tion in the cooling of the alloy and lasting t'-t seconds, we naturally infer that it cor- responds to its solidification. It follows from the appearance of the cooling curve 410 CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS that alloys yielding such curves do not, like pure metals, solidify at a constant tempera- ture but that their solidification, on the contrary, lasts t'-t seconds while their tempera- ture falls from Tb to Tc. Summing up, AB indicates the cooling of the molten alloy, B the beginning, and C the end of its solidification, It' the time required for its solidifi- cation, Tb Tc the fall of temperature during solidification, and CD the cooling of the solidified alloy. Above the point B, therefore, the alloy is entirely liquid, below C it is entirely solid, while between B and C it is partly liquid and partly solid. The point B is accordingly called the liquidus point and C the solidus point. Binary alloys whose cooling curves are of the type shown in Fig. 388 are known to be solid solutions. In these alloys the component metals which are completely merged in the liquid condition remain likewise so completely merged after solidifica- tion that their separate existence cannot be detected by microscopical examination or Fig. 387. Pure lead. Magnified 20 diameters. (F. C. Langenbcrg in the author's laboratory.) other physical means. They formed, on solidifying, homogeneous crystals containing both metals in indefinite proportions. These crystals are sometimes called "mixed crystals" and substances yielding them " isomorphous " mixtures by which it is meant that only isomorphous substances ' can yield mixed crystals or in other words can form solid solutions. The expression "solid solution" is much preferable and is now quite universally used, at least by the English and French. The mechanism of the formation of solid solutions of two metals should be ex- amined more closely. Let us assume that a certain proportion of the metal M of relatively low melting-point is alloyed with, or dissolved in, the metal M' of higher melting-point. The metal M may be considered as the solute and M' as the solvent. It is believed that when solidification begins homogeneous crystals of M and M' are formed but that they contain a smaller proportion of the fusible metal M than the 1 Isomorphous substances are those that are capable of crystallizing in the same crystallographic forms. CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS 411 liquid bath, which is thereby enriched in .I/.' On further cooling these crystals grow but the crystalline matter now deposited contains more of the metal M than the crystals first formed, although still less than the molten bath which is further enriched in M and so on, the crystals growing through successive additions of crystalline matter con- taining increasing proportions of the dissolved and relatively fusible metal M, and approaching, therefore, although not reaching, the composition of the molten metal until finally the last drop solidifies. Meanwhile, as the temperature is lowered through and below the solidification range, diffusion takes place within the crystals so that finally they become chemically homogeneous provided time be-given (through slow T -I . Diagram showing how fusibility curves are constructed. Co mp os if ion . Fig. 3()<>. Typical fusibility ctirve of binary alloys whose component metals are insoluble in each other in the solid state. of any alloy of the series. The solidification of an alloy whose composition corresponds to the point R, for instance, and which, therefore, contains 20 per cent of metal M and 80 per cent of metal M' evidently begins at N and ends at P. The fusibility curve is 418 CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS made up of three branches, namely, the two intersecting lines LE and L'E starting respectively from the melting-points of the two constituent metals and a horizontal line SS' passing by the point of intersection E of the first two. . This is the typical fusibility curve of binary alloys whose component metals are insoluble in each other in the solid condition. The solidification of these alloys should now be examined more closely. Several features are obvious. The different alloys begin to solidify at differ- ent temperatures according to their composition. At first, as the percentage of .!/ increases from to 40 (a proportio'n arbitrarily selected), the solidification point is lowered from L to E, while with further increase of M from 40 to 100 per cent, the solidification point is raised from E to L'. The solidification of all alloys, however, ends at the same temperature, namely, at the temperature S. Clearly, LEU is the liquidus and SES' the solidus. The alloy containing 40 per cent of M is evidently the most fusible alloy of the series since it remains liquid until the temperature S is reached while other alloys begin to solidify at higher temperatures. This alloy of lowest melting-point is known as the "eutectic" alloy, from the Greek meaning "well melt- ing." It is evident that, like pure metals, eutectic alloys solidify at a constant tempera- ture, namely the eutectic temperature. Many aqueous solutions also give rise to the formation of solutions of lowest freezing-points called " cryohydrates " and which were at- first supposed to be true chemical compounds, that is, hydrates containing salt and water molecules in atomic proportions. And, likewise, eutectic alloys were at first supposed to be definite chemical compounds of the two metals. They are now known to be aggregates of these metals generally very finely divided. This will be made clear by following the solidifications of three alloys, R, R' , and R" (Fig. 39(5). The alloy R contains, according to the diagram, 20 per cent of the metal .17 and 80 per cent of the metal M'. Since it contains less of the metal M than the eutectic alloy, we may for convenience refer to it as an hypo-eutectic alloy, although of course in regard to the content of M' it would be hyper-eutectic. In cooling from R to N the alloy remains liquid. At N solidification begins through the formation of pure crystals of M', that is, of the metal which is present in excess above the eutectic ratio. The formation of pure crystals of M' continues as the alloy cools from N to P and meanwhile the portion of the alloy remaining liquid (we may call it the mother metal) becomes gradually richer in M, i.e. it approaches gradually the composition of the eutectic alloy. Finally at P, temperature S, the remaining liquid has exactly the eutectic composition and now solidifies at a constant temperature, the solidification temperature of the eutectic alloy. In other words, as the alloy cools from N to P with formation of pure crystals of metal M' the composition of the portion of the alloy remaining liquid varies ac- cording to the line NKE, reaching the composition E, that is, the eutectic composition, always at the same temperature regardless of the initial composition of the alloy. When the alloy has cooled to 0, for instance, a point between LE and tiE, it is partly liquid and partly solid, its temperature is T and the composition of the liquid portion is represented by K, that is, it contains 30 per cent of the metal M. On further cooling from to P the composition of the mother metal shifts from K to E. In the case of the alloy R", containing a larger proportion of the metal M than the eutectic alloy and which we may, therefore, consider to be hyper-eutectic, when it reaches the point N' its solidification begins, pure crystals of the metal M being formed while the molten bath becomes gradually richer in M' gradually approaching, therefore, the composition of the eutectic alloy, until at the temperature S that com- position is reached when the remaining liquid solidifies at a constant temperature. CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS 419 Any point 0' situated between L'E and 8'E indicates an alloy in part solid and in part liquid; its temperature is 7" and the composition of the liquid is represented by K'. On cooling from 0' to P' additional crystals of pure M are formed, or those already formed continue to grow while the composition of the molten metal shifts from. K' to E. Starting with the alloy R' of eutectic composition, it remains liquid until at E, temperature S, it solidifies at a constant temperature, there being no excess metal to be rejected. Seeing that the branch LE corresponds to the formation of pure crystals of the metal M' and the branch L'E to the formation of pure crystals of-the metal M , the con- clusion seems irresistible that their point of intersection E must correspond to the Composition. l-'ifj;. :-i'.l7. - Dmfjnun depicting the mechanism of the solidification of alloys whose component metals are insoluble in each other in the solid state. simultaneous formation of crystals of metal M and of metal M' and that the eutectic alloy, therefore, must be a finely divided aggregate of M and M'. In other words, at any point on the branch LE, the alloy is saturated with the metal M' so that the lower- ing of its temperature must cause the separation of M' crystals with corresponding lowering of the saturation point, that is, of the solidification point of the bath. In a similar way, at any point on the branch L'E, the alloy is saturated with M and a fall in its temperature must result in the formation of M crystals while the solidification point of the portion remaining liquid is thereby lowered. At E the alloy is saturated with both metals so that any attempt at lowering its temperature must result in the simultaneous deposition of crystals of M and of M ' , and since the composition of the bath remains the same, solidification now takes place at a constant temperature. Hence the constitution of eutectic alloys and the reason for their constant freezing temperature. It has been attempted in Figure 397, to depict graphically the mechanism of the 420 CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS solidification of hypo-eutectic, eutectic, and hyper-eutectic alloys. As diagrams of this kind have already been used in these lessons the present one will be readily understood. When the alloy R, for instance, reaches the point A", crystals of M' form, their I 5 o I o 1 4 M % M'% Chemical composition. .Fig. 398. Diagram showing the structural composition of binaiy alloys whose component m-tals are insoluble in each other in the solid stale. 75 .SO. / Metaf M' /^ ^^ A I/ ^E fcufecfic- X, fe/W A^ 3O c 2. OO ] " " 1 i i O -4Q 6O '' "* u /O/*'/ 9 1 / rNv c , Oi /n fills. -O 5 o " A W / Eiyi-ec-, f-fc flflK "i o Ml i ^ n i A /I V X^ So. SI ' O / M llv ' /iff M -f-6"/ 3/U IflK ^ I. ^ji yf Sv -^ J* '"! /f s. " **" ~A ' /{* >v O jj j M /o c 3 ao 4o 6O QO 94 IOO M'/o 100 97 SO 60 -40 2.0 GO Fig. 406. Diagram showing the structural composition of binary alloys whose component metals are partially soluble in each other in the solid state. Figure 405. By comparing it with the fusibility curve of metals entirely insoluble (Fig. 396) it will be noted that the only differences between them are (1) that the eutectic line SES' instead of extending over the whole length of the diagram now st < >\ >s at the points S and S' corresponding respectively to 5 per cent of metal M and to 10 CHAPTER XXV CONSTITUTION OF .METALLIC ALLOYS 425 per cent of metal M', and (2) the introduction of the branches SA and S'B indicates the changes of solubility of the metals as the alloys cool from the eutectic to atmospheric temperature. These curves show that at atmospheric temperature M' retains in solution 3 per cent of 37 and that M retains in solution 6 per cent of M'. LEL' is the liquidus, LSES'L' the solidus. Clearly, any alloy containing less than 5 per cent of the metal M or less than 10 per cent of the metal M' solidifies as a solid solution, the diagram showing the absence of eutectic alloys. In other words, alloys contain- ing from to 5 per cent of M may be considered as alloys of M' and of a solid solution of .17' plus 5 per cent of .17, LM' being the liquidus and LS the_sqlidus of such alloys and their solidification taking place as explained in the case of any two metals form- ing solid solutions. And, likewise, alloys with less than 10 per cent of M' may be re- garded as alloys of the metal M and of a solid solution of M plus 10 per cent of M', their liquidus being represented by L'M and their solidus by US'. For all alloys containing between 5 and 90 per cent of M the diagram shows that a eutectic alloy is formed and that the mechanism of the solidification is apparently the same as the one 10 SO 3O +O SO O JO QO SO IOO % Cu ooo coo. 700 coo 100 1084-, 962 SolifL soiuiion. A. + Solid solution, B o 10 20 30 to so eo 70 ao so too A torn. / a Cu . Fig. 407. Fusibility curve of alloys of silver and copper. (Desch.) described in the case of alloys of insoluble metals. It should be noted, however, that the two components of these alloys are no longer the pure metals but two solid solu- tions, namely, a solution of M' containing 5 per cent of M and a solution of M con- taining 10 per cent of M', one of these solid solutions, therefore, crystallizing when the temperature of the alloy reaches any point on the lines LEL' and the eutectic alloy being made up of a fine conglomerate of these two solid solutions. To clarify let us consider an allo^ represented by the point R, Figure 405. At N its solidification be- gins, crystals of a solid solution of M' containing 5 per cent of M being formed. At P the residual molten mass, having reached the eutectic ratio, crystallizes at a constant temperature as a fine aggregate of the two solid solutions. Since the mutual solubili- ties of the metals M and M' decrease, however, as the alloy cools below the eutectic temperature, it is evident that each crystal must undergo a gradual transformation. These transformations are indicated by the branches SA and S'B. After the solidification of the eutectic, all alloys are aggregates of the two solid solutions whose compositions are represented by the points S and S', that is, in the case under con- sideration, arbitrarily, M' plus 5 per cent of M and M plus 10 per cent of M'. At atmos- pheric temperature all alloys are aggregates of two solid solutions whose compositions correspond to the points A and B, that is in the case considered M' plus 3 per cent of .17 426 CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS and M plus 6 per cent of .I/'. At any point below the eutectic line, the corresponding alloy is an aggregate of two solid solutions whose compositions are indicated by the corresponding points on the branches SA and S'B. At ( '. for instance, in case of alloy R, the structure is composed of free crystals of solid solution D and of eutectic, the com- '*&*$*#** .f> ^^^^^^^-' Fig. 408. Silver-copper alloy. Copper 15 per cent. Magnified 600 diameters. Dark constituent is silver containing a little copper. (Osmond. j Fig. 409. Silver-copper alloy eutectic. Copper 28 per cent. Magnified 600 diameters. (Osmond.) Fig. 410. Silver-copper tilloy. Copper (>."> per cent. Magnified 000 diameters. Light constituent is copper containing a little silver. (Osmond.) ponents of which are solid solution D and solid solution F. In other words, as the alloy cools from the eutectic line to atmospheric temperature, the composition of its two constituents shifts respectively from S to .1 and from 8' to R. The structural composition of alloys whose component metals are partially soluble when solid may be represented in the usual way as shown in Figure 406. Its interpre- CHAPTER XXV CONSTITUTION OF METALLIC ALLOYS 427 tation does not call for further elaboration. Between and 3 per cent of M and between and 6 per cent of M', solid solutions are formed of corresponding composi- tions. Between 3 and 40 per cent of M, the free solid solution formed is saturated with .]/. and between 40 and 94 per cent of M it is saturated with M', while the eutectic is made up of the two saturated solutions. The fusibility curve of silver-copper alloys is shown in Figure 407 as an example of alloys whose components remain partly solu- ble in each other after solidification and typical structures of these alloys are given in Figures 408 to 410. CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IRON-CARBON ALLOYS Fusibility Curve of Iron-Carbon Alloys. Steel and cast iron are essentially alloys of iron and carbon, and their fusibility curve or equilibrium diagram may be con- structed as in the case of any binary alloy, namely, by determining the independent cooling curves of a number of alloys of the series and plotting the evolutions of heat /Soo _ looo Percent C O Percent Fe 3 C O /.O 1.7 2.0 3.0 4.04.3 JTO 6.O 6.67 A5" 30 45 60 7^ 9O IOO Fig. 411. Fusibility curve of iron-carbon alloys. noted against the corresponding temperatures. The resulting curve is shown in the diagram of Figure 411. While it is not generally possible for molten iron slightly above its melting-point to dissolve more than 5 per cent of carbon, the diagram has been constructed so as to include a percentage of carbon up to 6.67 per cent which corresponds to 100 per cent, Fe 3 C. That portion of it, however, corresponding to more than 5 per cent of carbon, has been drawn in dotted lines. The complete equilibrium diagram should include the evolutions of heat occurring after solidification, known as the critical points, which have been fully described in these chapters, but they are purposely left out of the diagram of Fig. 412, it being desired first to confine our attention to the mechanism 428 CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IROX-CARBOX ALLOYS 429 of the? solidification of iron-carbon alloys. In view of the explanation of the meaning of fusibility curves given in Chapter XXV, it will be evident that iron and carbon al- loys are partially soluble in each other when solid, that LEU is their liquidus and LSS' their solidus and that the point E indicates the formation of a eutectic alloy. As carbon increases from to about 1.70 per cent, the alloys solidify as solid solutions of corresponding carbon content, LA being the liquidus and LS the solidus. These solid solutions considered as microscopical constituents are called austenite. The so- lidification of alloys containing between 1.7 and 4.3 per cent carbon begins when their temperature reaches the line LE, crystals of a solid solution containing 1.70 per cent carbon (sometimes called saturated austenite), being then formed which keep on growing until the line SS', temperature 1130 deg., is reached when, clearly, a eutectic /~/ypo -e ui~e eft c a / ' /ot/s Hyper- eufecfic /oo Hypo . f-/yper- o u i~e c t'

rc ^-eutecfic A V P'ro-evfect'i c Safurafed / V Cement/ fe c Ausfen ife /f[ .0 75 A " -N. / 5 /!' o A\\ufm^'f*f ^ |. Sol lu \SOIUi tOD /\\\ \ *- t// e i r\ O ,- (A sf& YeJ A^afurafed Ausfenite \ o 5o A + Cemer ,f/y e j \" ~~Q t K X ' K / \ S5 i V 2s y y' Ik o k %C o '/.o >.o so 4.o ^O 6.O 6.67 /o/~ 3 C O A5~ 3O 45 60 75 90 too Fig. 412. Structural composition of iron-carbon alloys immediately after their solidification. is formed composed of that solid solution and of another constituent. The nature of the other constituent present in the eutectic alloy formed during the solidification of iron-carbon alloys has been in dispute. It seems at first natural to infer that elemental carbon, i.e. graphite, is that constituent, in which case the eutectic alloy would be made up of minute crystalline particles alternately of saturated austenite and of graphite. Many evidences, however, point to carbon being dissolved in molten iron as the carbide Fe 3 C (cementite) and to its always solidifying as Fe 3 C, although, as later explained, it may break up into iron and graphite (Fe 3 C = 3Fe+C) immediately after its solidification. If this hypothesis be correct, it follows that the eutectic alloy must be a mechanical mixture of minute particles of saturated austenite and of FeaC. It would seem at first as if the microscopical examination of alloys of suitable compo- sitions should readily reveal the nature of the eutectic alloy. It will soon be seen, however, that both cementite and graphite are generally found in solidified eutectifer- ous alloys, the microscopical test leaving us in doubt as to which of the two constitu- 430 CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IROX-CARBON ALLOYS ents formed first. In the author's opinion it seems more probable that when an iron- carbon alloy containing more than some 1.7 per cent carbon solidifies, a eutectic of saturated austenite and of cementite is always produced, or in other words, that in the diagram of Figure 411 the curve L' E indicates the crystallization of cementite and not of graphite. The opposite view will be considered later. Let us now follow the solidification of four typical alloys, namely, R, /(", K" ', R'", containing respectively 1 per cent, 3 per cent, 4.3 per cent, and 4.8 per cent of carbon, the first two being, therefore, hypo-eutectic alloys, the third the eutectic alloy, and the fourth a hyper- eutectic alloy. As the alloy R cools, it begins to solidify at Af through the formation of crystals of a solid solution the composition of which is represented by the point T on the solidus. On cooling from M to N these crystals grow through successive addi- tions of crystalline matter, the composition of which varies from T to N while the composition of the molten bath shifts from M to U, the last drop solidifying having the composition U. As soon as the crystalline matter is deposited, however, at least if time be given, diffusion takes place through each crystal so that finally they are chem- ically homogeneous and of composition N , the completely solidified metal being com- posed of homogeneous crystalline grains of austenite containing one per cent carbon. At any temperature V between the solidus and the liquidus the crystals in equilib- rium with the molten metal must have the composition Q. It may at least be con- ceived that if the cooling through and below the solidification period be rapid, the crystalline grains of austenite will not be chemically homogeneous, complete diffusion having been prevented; In the case of an alloy whose composition is represented by the point R' in the diagram, it begins to solidify at M' (some 1230 degrees ('.), when crystals of iron containing 1.70 per cent of carbon (saturated austenite) begin to form, the composition of the molten metal meanwhile shifting from M' to E. At 0', temperature 1130, the residual molten mass has reached the eutectic composition and now solidifies at a constant temperature, namely, the eutectic temperature, the completely solid metal being made up of crystalline grains of saturated austenite surrounded by a eutectic alloy composed of minute crystals of saturated austenite and minute crystals of cementite. The alloy K" has the eutectic composition (4.3 per cent carbon). It remains liquid until its temperature falls to 1130 deg. C. when it solidifies at a constant temperature after the fashion of eutectic alloys. The alloy R'" contains more carbon than the eutectic alloy. On reaching its solidification point M'" crystals of cementite begin to form, increasing in size as the metal cools from M'" to ()'" while the composition of the bath shifts from M'" to E. At 0'" the residual molten mass having now the composition of the eutectic alloy, freezes at a constant temperature, the completely solidified alloy being made up of crystals of cementite embedded in a ground mass consisting of the eutectic alloy. Structural Composition of Iron-Carbon Alloys Immediately after Solidification. - The structural composition of iron-carbon alloys immediately after their solidification, assuming that Fe 3 C and not graphite forms, may be represented in the usual way by the diagram of Figure 412. The diagram clearly shows (1) that alloys containing less than 1.70 per cent of carbon are made up wholly of solid solutions, (2) that alloys containing between 1.70 and 4.3 per cent carbon are made up of decreasing propor- tions of saturated austenite and increasing proportions of eutectic, (3) that alloys containing exactly 4.3 per cent of carbon are composed entirely of eutectic, and (4) that alloys containing more than 4.3 per cent carbon contain an increasing amount of free CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IROX-CARBON ALLOYS 431 cementito, and decreasing amount of euteetic the latter disappearing altogether when the metal contains 6.67 per cent carbon. 1 A modified form of the structural composition diagram may profitably be combined /Soo o I o loo 7-5 SO 2-5 Auste D O C F> H 2 3 <4 f~'erceni~ Carbon. F" 6.67 Fig. 413. Fusibility curve and structural composition diagram of iron-carbon alloys. with the equilibrium diagram as shown in Figure 413. Its interpretation should be obvious. The area A BCD represents the structural composition of all alloys contain- ing less than 1.7 per cent of carbon, and shows that they are made up of 100 per cent 1 Howe questions the existence below solidification of pro-eutectic cementite on the ground that it graphit i/.cs as soon as formed unless the cooling be extremely rapid or considerable manganese present. 432 CHAPTKK XXVI EQUILIBRIUM DIAGRAM OF IRON-CARBON ALLOYS of austenite. By dividing this area by the line AC, however, it is further shown graphi- cally that the composition of the austenite of these alloys varies, and that they may he considered as being made up of ABC saturated austenite diluted by ADC pure iron, clearly indicating that with carbon the alloy is entirely made up of iron and with 1.7 per cent carbon entirely of saturated austenite. The area BCH represents the proportion of free (pro-eutectic) saturated austenite formed during the solidification of any alloy containing between 1.70 and 4.3 per cent carbon. The area BEFH rep- resents the proportion of eutectic present in any alloy containing more than 1.7 per cent of carbon. By dividing this area in two portions, moreover, by means of the line BF we show graphically the relative proportions of saturated austenite and of cenien- tite in the eutectic. Finally, the area EOF indicates the percentage of pro-eutectic Temperature iv> oi * < < c \X x ^ NX ^O / ^P ^ // \ V-* W v y \ *^ ~9"i /** \ o** ^ ""*^ ("O/ \ ~~^? ? ' / Z' IIQO IOO6 Au $ ~/~e ni te -& ropht f~& eui~e ofic, sol if il ' e eu1~ec,1~i c. sol id i fie\5. i.o IS 2.O 30 J.O 4-S 4.Q GO SO 75 GO 9O 667 /OO Fig. 415. Combined graphite-cementite fusibility curves of iron-carbon alloys. In the first instance the two following equations (1) A + E = 100 100 100 will give the values of A and E for any known carbon content (C) while in the latter case the equations (1) Cm + E = 100 100 100 will likewise give the values of Cm and E. An alloy, for instance, containing 3 per cent of carbon will be found to contain 50 per cent of eutectic and 50 per cent of saturated austenite, while an alloy with 5 per cent carbon is composed of 70.5 per cent of eutectic and 29.5 per cent free cementite. 434 CHAPTER XXVI KQI'ILIBHIUM DIAGRAM OF IRON-CARBON ALLOYS Iron-Graphite Fusibility Curve. It has already been mentioned that some writers claim that graphite instead of ceinentite may, and if time be given docs, form on solidification; in other words, that the eutectic alloy may be' composed of saturated austenite and graphite, and that free graphite may separate during the solidification of alloys containing more than 4.3 per cent carbon. The diagram interpreting this assumption which may be called the iron-graphite fusibility curve is shown in Figure 414. It will be seen to be similar to the iron-cementite diagram (Fig. 411). Combined Graphite-Cementite Diagram. Recognizing the possibility of the formation of a graphite-austenite eutectic and of a cementite-austemte eutectic ac- cording to the rate of cooling, some writers, notably ('harpy and Crenel, Heyn, and Benedicks, recommend the use of double solidification curves in the equilibrium dia- gram of iron-carbon alloys. These double curves are shown in Figure 415, the dotted lines referring to the austenite-graphite system. It will be noted that free graphite and the graphite-austenite eutectic form respectively at temperatures slightly higher than those at which free ceinentite and the cementite-austenite eutectic form, the solidification of the latter constituents being regarded as due to surfusion or under- cooling. It is accordingly believed that only the iron-graphite system is stable, the iron-cementite system being "metastable." Our reasons for believing that graphite and not cementite is the final condition to be assumed by carbon are based on repeated and concordant observations that any condition promoting stable equilibrium results in the transportation of cementite into graphite as, for instance, very slow cooling during and below solidification or long exposure of cementite (as in the manufacture of malleable cast-iron castings) to a high temperature, while on the contrary, treat- ments opposing equilibrium, such as quick cooling, always result in the formation or retention of cementite. Roozeboom, when he first took up the study of the iron- carbon diagram, believed that cementite was the final stable condition of carbon, any graphite having formed during solidification combining with iron at some 1000 degrees C. to form cementite. The error of this view soon became apparent, however, to Roozeboom himself. Graphitizing of Cementite. Although recognizing the fact that graphite and not cementite must be the final condition assumed by carbon, the author believes with some other observers that graphite never forms directly as iron-carbon alloys solidify, its occurrence always resulting from the breaking up of cementite according to the reaction Fe 3 C = 3Fe + C from which it would follow that the iron-graphite fusibility curve need not be in- cluded in the equilibrium diagram. Even those who believe in the possibility of the direct formation of graphite do not deny that ceinentite is the constituent which generally forms first on solidification; they state that the separation of graphite from molten iron is possible only in the case of very slow cooling. As a matter of fact, how- ever, they offer no conclusive evidences that such separation ever takes place. From the formation of "kish," that is, of graphite floating on the surface of a ladleful of molten cast iron, it does not follow that such graphite formation was not preceded by the formation of cementite. If, on very slow cooling, graphite separated directly from molten iron, the bulk of it at least should rise to the top of the molten bath and the solidified mass should be found much richer in graphite near its surface than at some distance from it. The author does not understand such heterogeneity in the dis- tribution of graphitic carbon to be observed in the case of gray cast-iron cast- CHAPTKH XXVI EQUILIBRIUM DIAGRAM OF 1RON-CARBOX ALLOYS 435 ings. 1 On the contrary, on the assumption that graphite results from the breaking up of cementite soon after its solidification, it is readily understood why, in spite of their very great difference in specific gravity, iron and graphite are found uniformly distributed in. the various parts of castings. The microscopical examination of the structure of very .slowly cooled castings does not reveal the existence of a graphite-austenite eutectic. That cementite is unstable, being readily converted into iron and graphitic carbon, is also generally admitted. It is upon this instability of cementite that the important industrial operation of converting white cast-iron castings into graphitic malleable castings is based. And there is abundant evidence that the higher_the temperature, the more readily is cementite dissociated, from which it follows that the higher the temperature at which cementite forms the more readily will it be converted into graphitic carbon. Bearing this in mind, and with the assistance of the diagram of Figure 3, let us look more closely into the graphitizing of cementite. The diagram shows clearly that, during the solidification of alloys containing more than 1.70 per cent of carbon, (1) some cementite forms as pro-eutectic cementite if the metal con- tains more than 4.3 per cent carbon, (2) some cementite forms as eutectic cementite in all alloys, (3) some cementite remains dissolved in the eutectic-austenite of all alloys, and (4) some cementite remains dissolved in the free austenite of alloys containing less than 4.3 per cent carbon. Considering first the free cementite, that is, the pro-eutectic and the eutectic cementite, it is evident that the former is formed at a higher tempera- ture, and that the more carbon in the alloy the higher the temperature at which it begins to form. It seems safe to infer, therefore, that pro-eutectic cementite will break up into graphite and ferrite more readily than eutectic cementite, this being consistent with the well-known fact that hyper-eutectic alloys are generally rich in graphite even after relatively quick cooling. The presence of pro-eutectic cementite may also pro- mote the formation of graphitic carbon because once this graphitizing process is started, it is likely to extend, if time be given, to the bulk of the cementite, first the eu- tectic cementite and later the austenite-cementite undergoing the change. Alloys con- taining less than 4.3 per cent carbon and consequently free from pro-eutectic cementite should not become graphitic as readily because of the lower temperature at which eutectic-cementite forms. If a large proportion of cementite be formed, however, that is, if the alloys contain more than 3 or 3.5 per cent of carbon, a certain amount of graphitizing is readily induced through slow cooling. With decreasing carbon the breaking up of cementite becomes progressively more difficult until, in alloys con- taining less than 1.7 per cent carbon (the steel series), and, therefore free from eutectic cementite, graphitic carbon is very seldom formed. It should be borne in mind that while those alloys which contain but a small pro- portion of carbon cannot be made graphitic, when a large proportion of carbon is present, the graphitizing once started may be made to include the totality of the cementite, thus explaining the freedom of steel from graphite and the freedom of some cast irons from cementite. The foregoing remarks apply to pure iron-carbon alloys, the influence of the elements generally present in commercial products having been purposely ignored. When dealing with commercial steel and cast iron, the well-known influence of silicon in promoting the formation of graphitic carbon should be remembered as well as the opposite 1 influence of sulphur and manganese 1 . Because of the presence of a notable 1 Howe reports the segregation of graphite in the upper part of lash-bearing east iron, but this is readily explained on the ground that such irons must be liyper-eutectic in composition and that the pro-eutectic cementite beginning to graphitize while the iron is still partially liquid shows a tendency To rise to the top, hence indeed the formation of kish. Fig. 417. Magnified 7.~>l> diameters. Fig. 41(1. Magnified ">() dimnetora. \^. 11'.). Magnified 760 diameteis. Fig. 41S. Magnified ">" diameters. Fi K . IL>CI. - .M:igmlu:d."iOdianii-i.T.s.' Fig. 421. Magnified 760 diametew. Figs 41(i and 417. Iron-carbon alloy. Hypo-eutcctic. Structure immediately after solidification. Dark crystallite of nturated aiutenitc in a matrix of aurtenlte-oemwitiU ruti-ctic. Figs. 41S and 41!). - Iron-carbon alloy. Aiisir,,i:,.- ccnii'iititi. rutoctic. Figs. 420 and 421. Ir.m-<-:trl>.m alloy. Hyper-cuteotic. Strui'ture iinnifdiati'ly after snlidifi- cation. Nil-dies of fcinc'iititf in a matrix of ailsti'iiiti-cc'inc'iititc cutoctk-. (QorODB.) 436 CHAPTER XXVI EQI'ILIBKH M DIAGRAM OF IKOX-CARbOX ALLOYS 437 proportion of silicon, commercial cast irons after slow cooling are necessarily more graphitic than pure alloys of same carbon content. Structure of Iron-Carbon Alloys Immediately after Solidification. If the alloy contains less than some 1.70 per cent carbon it is made up after complete solidification of crystalline grains of austenite. It has been explained, however, that in the absence of manganese or other ''retarding" elements it is not possible to prevent, even through very rapid cooling, the transformation of some of the austenite at least into martensite. The polyhedric structure of austenite has been illustrated in these lessons in the case of special steels (manganese and nickel steels) and it is now welLunderstood that the r 6.67 Fig. 4122. Equilibrium diagram of iron-carbon alloys. frequent network structures of slowly cooled steel are due to the existence of poly- hedral austenitic structures above their critical range. If the alloy contains from 1.70 to 4.3 per cent carbon it is made up, after solidifi- cation, of crystals of saturated austenite and of eutectic alloy. This is well shown after (kurens in Figure 416, in which the dark "pine tree" crystals consist of saturated .Mistenite, while the ground mass is the cementite-austenite eutectic. 1 In Figure 417 the same structure is shown more highly magnified. If the alloy contains exactly 4 3 per cent carbon, it consists wholly of eutectic as shown under different magnifications m Figures 418 and 419. It has been seen that, theoretically, this eutectic contains 47.7 per cent, of saturated austenite (the dark constituent), and 52.3 per cent of cem- entite. Alloys containing more than 4.3 per cent carbon consist after solidification of free cementite in the form of needles embedded in a eutectic matrix as shown in Figures 420 and 421. It should be noted that the dark constituent occurring in these structures and described as saturated austenite may not be absolutely unaltered austenite because of 1 Wiist has suggested the name of " Ledcburite" for this eutectic in honor of the late well-known German metallurgist A. Ledebur. 438 CHAPTER XXVI KQl'ILIBRIUM DIAGRAM OF IROX-CARIiON ALLOYS CHAPTER XXVI I'XjriLIBKH'M DIACKA.M OF JHOX-CARBOX ALLOYS 439 the difficulty of completely preventing the transformation of that constituent even in the presence of a large amount of carbon and by very sudden cooling. If the aus- tenite has undergone some transformation, however, so that it contains some mar- tensite and even troostite those transformations must have taken place in situ and the structures reproduced in Figures 6 to 11 must represent accurately the structural aspect of the corresponding alloys after solidification. Complete Equilibrium Diagram. In the foregoing pages only the solidification curves of iron-carbon alloys have been considered and the probable mechanism of their freezing explained. Their equilibrium diagram, however, jnust include all heat evolutions observed on cooling from the liquid condition to atmospheric temperature; in other words, the thermal critic ;1 points fully described in previous chapters arc part of the complete equilibrium diagram as indicated in Figure 422. Since the meaning of every curve of this diagram has been discussed, it only re- mains to inquire into any possible structural or other changes taking place after solidification and before the alloys reach their respective thermal critical point or points, that is, while they cool from the solidus LSS' to the eutectoid line CDF. The changes which do or may take place as the alloys cool in this range are clearly stated in Figure 42:>. In this diagram the most likely significance of every curve is indicated as well as the nature of all structural transformations, and of all possible resulting structures after complete cooling. The author believes that it embodies those infer- ences best supported by analogy and by experimental evidences. Although neces- sarily involving some repetition, a methodical examination of the various parts of this complete diagram seems advisable, as it will permit a recapitulation of the various matters previously discussed. Let us consider (1) the solidification of iron-carbon alloys, (2) their cooling from the solidus LtfES' to the eutectoid temperature CDF, and (3) their cooling through the eutectoid temperature and their final structures. According to the mechanism of their solidification iron-carbon alloys are divided into three classes, namely, (1) alloys containing less than 1.70 per cent of carbon, (2) alloys containing between 1.70 and 4.3 per cent carbon, and (3) alloys containing more than 4.3 per cent of carbon. Alloys containing less than 1.70 per cent of carbon and including, therefore, all the steels of commerce solidify as solid solutions of the carbide Fe. ( ( ' (cementite) in gamma iron, these solutions being known as austenite. LA is the liquidus and LS the solidus of these alloys. Alloys containing between 1.70 and 4.3 per cent of carbon solidify through the formation of crystals of saturated austenite at gradually decreasing temperatures and through the final solidification, at the euteetic temperature, of the residual molten metal necessarily of eutectic com- position. Alloys containing more than 4.3 per cent of carbon solidify through the formation of cementite crystals at gradually decreasing temperatures, and through to final solidification, at the eutectic temperature, of the residual molten metal necessarily of eutectic composition. In cooling below their solidus, LS, alloys with less than 1.70 per cent carbon undergo no change until they reach their thermal critical points Ar 3 , Ar 3 .2, Ar 3 . 2 .i or Ar cm as the case may be, when, if they contain less than some 0.85 per cent of carbon (hypo- eutectoid steels), some iron is set free and converted into beta iron, while if they contain more carbon (hyper-eutectoid steels), cementite is liberated. In either case when the eutectoid temperature is reached the residual austenite, now of eutectoid composition (0.85 per cent carbon), is converted into pearlite. 440 CHAPTER XXVI EQUILIBRIUM DIACHAM OF 1ROX-CARBOX ALLOYS ISOO, 2 ^ 6_ F'ro - e u Te c ti c te \ Cerri entile Structural corn-position i rrtrn ec//a/e /y ofter- Solid if i cat I on SfrucTurol com po-s it/On /mm ed i a te/y Structural compos it ion /6e /ow 2 4 6 6.57 C-arbon /o Fig. 424. Equilibrium and struct unil composition cli:is>':uii of iron-carbon allovs. CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IRON-CARBON ALLOYS 441 After solidification, alloys containing between 1.70 and 4.3 per cent carbon are aggregates of saturated austenite (austenite containing 1.70 per cent C or 25.5 per cent cement it i 1 ) and of cenientite-austenite eutectic. On cooling below their solidus, cementite (pro-eutectoid cementite) is liberated both from the free and from the eutectic-austenite, while if the cooling be sufficiently slow both the eutectic and pro- eutectoid cementite may be partly or wholly dissociated into graphite and iron (ferrite). Indeed, the graphitizing may even include the eutectoid cementite, in which case the alloy is made up solely of ferrite and graphite. Alloys containing more than 4.3 per cent of carbon are, immediately after solidi- fication, aggregates of cementite (pro-eutectic cementite) and of cementite-austenite eutectic. On slow cooling below their solidus, cementite (pro-eutectoid cementite) is liberated from the eutectic austenite while the pro-eutectic, eutectic, and pro-eutectoid Fig. 425. The author's early equilibrium diagram (1896). cementite may be partly or wholly dissociated into graphite and ferrite, in some ex- treme cases the eutectoid cementite even being graphitized. On cooling through the eutectoid temperature, any remaining austenite is bodily converted into pearlite. The above consideration clearly shows that in alloys containing more than some 1.70 per cent carbon four types of structure may be formed according to the rate of cooling below the solidus: (I) Cementite plus pearlite, the structure of white cast iron, readily produced by quick cooling and representing a metastable equilibrium. (II) Ferrite and graphite, an extreme case, possible only after very slow cooling and in the presence of much silicon, little manganese, and sulphur, and representing stable equilibrium. (Ill) Cem- ent ite plus pearlite and graphite, the structure of gray cast iron with hyper-eutectoid matrix, resulting from slow cooling, promoted by the presence of silicon and opposed by sulphur and manganese. (IV) Pearlite, ferrite, and graphite, the structure of gray cast iron with hypo-eutectoid matrix, produced because of slower cooling or because of the presence of more silicon or of less sulphur and manganese. 442 CHAPTKH XXVI EQUILIBRIUM DIAGRAM OF 1RON-CAHHOX ALLOYS It will be explained in the next chapter that, according to the phase rule, only two components may be present in a binary alloy in a state of equilibrium from which it follows that gray cast irons, since they contain besides iron both cementite and graphite, are out of equilibrium. One of the components must disappear if the alloy is to assume equilibrium. Cementite is undoubtedly that component as proven by the malleablizing of cast iron when cementite is readily dissociated into graphite and ferrite on prolonged heating to a high temperature. In Figure 424 the complete equilibrium diagram is shown combined with three constitutional diagrams showing graphically the structural composition of iroii-car- bon alloys (1) immediately after their solidification, (2) immediately before the eutec- toid temperature, and (3) below the eutectoid temperature, on the assumption that no graphitic carbon is formed. The structural changes taking place while the alloys 1.500- 1.400" * 1.300- S 1.200- ^1,100- it l ' 1 2 i 4 Fig. 426. Roberts-Austen's first equilibrium diagram (1897). cool below their solidus down to the eutectoid temperature are, in this way, clearly depicted. The following facts, for instance, are graphically shown, (1) the pro-eutectic cementite formed during the solidification of hyper-eutectic alloys and the eutectic cementite present in all alloys containing more than 1.70 per cent carbon remain un- changed as the alloy cools to atmospheric temperature, (2) the free saturated austenite of hypo-eutectic alloys, as well as the eutectic-austenite, are converted into eutectoid austenite through the liberation of cementite (pro-eutectoid cementite), the area EDH representing the cementite thus set free, and (3) in hypo-eutectoid alloys iron is set free as shown by the area FJG. The lower diagram shows that, in cooling through the eutectoid temperature, the remaining austenite, now necessarily of eutectoid composition, and sometimes called hardenite is converted into pearlite. Taking, for instance, the metal whose composition and temperature are represented by the point R, its transformations and final structure are clearly shown. At M it begins to solidify through the formation of crystals of saturated austenite; from M to N the austenite crystals continue to grow, the percentage of free austenite present in the solidified metal being represented by the distance OP; at N the residual bath CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IROX-CARBOX ALLOYS 443 solidifies as a eutectic alloy, the percentage of which is proportional to the distance KO; this eutectic contains KL = PQ = TU per cent of cementito and LO per cent of saturated austenite; LI' is the total amount of austenite in the alloy; after solidifi- cation in cooling from N to K, pro-eutectoid cementite is liberated both from the free and from the eutectic-austenite, Q8 representing the percentage of cemeiitite finally expelled; on reaching the point K, the remaining austenite, ST, is of eutectoid composition, when it is sometimes called hardenite, and in cooling through K this austenite is converted into pearlite, the metal being finally made up of TU per cent of eutectic cementite, UV per cent of pro-eutectoid cementite, and VX per cent of pearlite, the latter containing VW per cent of cementite, and WX per cent of ferrite, or of TV per cent of free cementite and VX per cent of pearlite, or again of TW per cent of total cementite and WX per cent of ferrite. Historical. In view of the scientific and practical importance of the equilibrium 3-0 &Z CARBON PER CENT * *Z tti.fi s ft S * l-'ig. 427. Roberts-Austen's second equilibrium diagram (1899). diagram of iron-carbon alloys, a brief historical sketch of its evolution should be of interest to the reader. The first diagram was published by the author in 1896. 1 It is reproduced in Figure 425. It will be noted that, although the diagram includes only the thermal critical points, it is otherwise substantially accurate. In describing it the author wrote in part: "Figure 1 shows graphically the position of the critical points in cooling steels of various carbons. The width of the black lines does not refer to the intensity of the retardations, but only indicates the range of temperature which they cover. For instance, it shows that the single retardation of high carbon steel begins at about 680 deg. C. and ends at about 640 deg. C. The maximum evolution of heat lies some- where between these limits, but not necessarily in the middle. ' This graphical representation was obtained by plotting the results of the investi- gations of Osmond, Howe, Roberts-Austen, Arnold, and the writer; and, with one or two exceptions all their figures fall very nearly within the limits here indicated." 1 "The Microstructure of Steel and the Current Theories of Hardening," ALBERT SAUVEDK, Transactions American Institute of Mining Engineers. 1896, p. 867. 444 CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IRON-CAKBOX ALLOYS It is from this modest beginning that the present diagram was evolved. 1 In 1897 Roberts-Austen published in his fourth report of the Alloys Research Com- mittee of the Institution of Mechanical Engineers the diagram reproduced in Fig. 426. Two years later, in 1899, the diagram shown in Fig. 427 was published by Roberts- Austen and Stansfield in the fifth report of the Alloys Research Committee. Some of the conspicuous features of this diagram should be noted. The solidification point of pure iron was indicated to be 1600 degrees C. whereas we know now that it is nearly 1500 deg. No attempt had been made yet at ascertaining the end of the solidification, that is, the solidus, of alloys forming solid solutions; the formation of a eutectic on solidification was indicated as taking place in alloys containing more than one per cent carbon; graphite was supposed to crystallize during the solidification of alloys con- 'too' soo 000* Warte isite Fsrr'le* PerUff 3L- -P* *** Ma Ci 'rbon Per 3 Wart, visit* ~!ra/t hike nfrJ-s T.is =r2 Liquid. yCrafi/iite F' a & R Fig. 428. Roozeboom's equilibrium diagram (1900). taming more than 4.3 per cent carbon, there being in the diagram no indications of pos- sible formation of cementite; the eutectic alloy was assumed to be a graphite-iron eu- tectic ; critical points occurring below the eutectoid temperature were represented in the diagram and marked "hydrogen points" (see Chapter X, "Minor Critical Points"); the Ar cm curve was arbitrarily extended to yield a V-shaped curve. Roberts- Austen mentioned the formation of a solid solution, free in hypo-eutectic steels, and as a con- stituent of the eutectic in alloys of eutectic composition, and he ascribed the presence of free cementite in cast iron to the liberation of that constituent from solid solution. In 1900 Roozeboom took up the study of Roberts-Austen's diagram, and applying to it the teachings of the phase rule published the diagram of Fig. 428 as a probably accurate representation of the solidification mechanism of iron-carbon alloys and of the structural transformations taking place after solidification. In this diagram, the line 6a, that is, the solidus of alloys forming solid solutions, is for the first time indicated ; 1 Since these remarks were written Prof. H. M. Howe has expressed the opinion that credit for the first equilibrium diagram is due to Rcinhard Mannosmann. CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IROX-CARBOX ALLOYS 445 1500 X? 5 X I40O X S 2 1300 X 1200 1 kl 5 "00 f- z ) 10 ' li ft D < Jj 900 I kl H ^ 800 CARBON PER CENT Tig. 429. Carpenter's and Kcrlinij's equilibrium diagram (190-1). 446 CHAPTER XXVI EQUILIHUH M D1.U1KAM OF IRON-CARBON ALLOYS the word martensite is used instead of austenite to denote the solid solution of iron and carbon; free graphite is assumed to form during the solidification of alloys con- taining more than 4.3 per cent carbon and the constituents of the eutectic alloy are supposed to be martensite (solid solution) and graphite. The Ar ( . m curve of hyper- eutectoid steels is arbitrarily extended as an horizontal line starting from E (1.75 per cent carbon and 1000 deg. C.) and extending to the end of the diagram. Roox,eboom argued that, while graphite formed on solidification in all alloys containing more than 2 per cent carbon, this graphite at 1000 deg. (line EF) recombined with iron to yield cementite so that, finally, alloys in equilibrium would contain only ferrite and cementite, thus conforming to the phase rule which forbids the presence of more than two com- ponents in binary alloys. It has since been conclusively shown that Roozeboom was in error, that while the ferrite-cementite system is in equilibrium according to the TEMPER ATURE 1500' 1400 1300 1100 IOOO 900 600 700 600 500 IF A ^ -^s -^ Li au D \ S LI ^\ 3UIC ^^ ^^^ A ) 4\ QtHO ENTI' M *; & M \ < XEC RSI ALS "^ Ss 9*' r*r\ CEM YtT M IXE > gr __. - _ __ - ^ s . "'%' .... r- 'E" 1 r> f 11 CR\ 'STA V '/ 1 1 1 U ' / ' h IXE ) CR YSTfi LS E' JTE :TIC & \ 1 & E r" TE :TIC C ;MEr TITE CRY STAL^ -^ 'E t ^t PER ITE p EAR LITE & c EME NTI re PEAR LITE Pt /? CA wr ?Aff6 ON ION Fe r f j -f 5 6 CEM -TIT Fig. 430. Benedicks' double equilibrium diagram. phase rule, it is in metastable equilibrium, the ferrite-graphite system being the only stable one. The hypothetical horizontal line EF is now consequently omitted from the equilibrium diagram, and the Ar ( . m curve made to join the eutectic line at its origin (a). In 1904 Carpenter and Keeling made a series of very careful experiments in order to ascertain the evolutions of heat taking place in cooling pure iron-carbon alloys from the liquid state to atmospheric temperature. By plotting their results, the equilibrium diagram reproduced in Figure 429 was obtained. The solidification of pure iron is shown to take place at 1500 deg. C. The curves arc otherwise identical to those of Roozeboom, the horizontal line EF having been introduced. The faint evolutions of heat occurring in the vicinity of u'OO deg. ( '. already discovered by Roberts-Austen and ascribed by him to the presence of hydrogen, were also observed by Carpenter and Keeling, as well as some faint evolutions in the vicinity of 775 deg., the meaning of which remains uncertain. CHAPTER XXVI EQUILIBKITM DI.UIKAM OF IROX-CARBOX ALLOYS 447 When it became apparent that graphite and not cementite must he the final stable form of carbon, several authorities argued that two equilibrium conditions could exist according to the rate of cooling during solidification, one of them stable, the other metiistable, and that this should be indicated in the diagram. This view was presented notably by ('harpy and Grenet, by Benedicks and by Heyn. The double diagram advocated by them is represented in Figure 430. The solidification of free cementite and of the cementite-austenite eutectic being assumed to be due to the well-known phenomenon of surfusion or undercooling, the corresponding curves are arbitrarily outlined at temperatures slightly lower than those pertaining to the formation of free 500- a 1 Carbon, per Cent,. Fig. 431. Rosenli.-iin's equilibrium diagram (1911). graphite and of graphite-austenite eutectic. The author has already shown why, in his opinion, the graphite curves should bo left out. The view that cementite always forms during the solidification of iron-carbon alloys but that being unstable it is readily dissociated into ferrite and graphite, seems to be better supported by experi- mental evidences and more consistent with practical facts. Rosenhain has recently plotted the experimental results of Carpenter and Keel- ing, of Gutowsky and of himself, obtaining the diagram reproduced in Figure 431. He considers Gutowsky's results in regard to the form of the solidus curve of alloys form- ing solid solutions as more accurate than those previously published, arid he incorpo- rates them in the diagram as shown in Fig. 431, the solidus line being rounded instead of straight as heretofore represented. In justification of his course, Rosenhain writes : " We have now to consider the curved portion of the 'solidus,' the line AD. This 448 CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IROX-CARBOX ALLOYS represents the temperatures at which the alloys have just completed their freezing process, that is, have just become completely solid, or, conversely, it represents the temperature of incipient fusion on heating. In the earlier investigations, and even in those of Messrs. Carpenter and Keeling, these temperatures were obtained by esti- mating the point on each of the cooling-curves where the heat-evolution due to solidi- fication came to an end. Unfortunately, the end of a heat-evolution is never sharply indicated on the curves, so that this estimation was admittedly vague. Quite recently that determination has been repeated, and with considerable greater accuracy, lie- cause a very much more satisfactory method was available . . . "The method of determining the 'solidus' was to take small pieces of steel, of known composition, heat them, and suddenly cool them from successively higher temperatures; afterward each specimen was examined by means of the microscope. IfiOO A ^ *^* 1200 2 f \3 + liquid ^ liquid ^ gra. phite + iquid N, -A ^ ~v5--'^ D 9 ^*^ r+grap TitC 1145-^ F H 7 El H 1095"/ G ,915 / J tFe.C o Fe c C f grap! ite \78S I CO R ^800 T K M or-tt \ 1 r + F< : 3 C X 725" * Fe 3 C - graphit e S a + Fe,C S S 1 ,615 > W 600 V u o ^y ^. jTgo C 400 Percent carbon N a X & 123 4 567891 * Fig. 432. Upton's equilibrium diagram. It is easy, as the photographs show, to determine what is the particular point at which you have reached a temperature where there was a small quantity of liquid metal present at the moment of quenching." Upton's Diagram. The rather revolutionary diagram shown in Figure 432 has been proposed by G. B. Upton. He considers it more satisfactory than the double diagram, as it does away with the necessary conception of a metastable and a stable equilibrium at nearly the same temperature. Upton argues that cementite decom- poses above 800 deg. C. into graphite and iron, but that even after prolonged an- nealing some 3.5 per cent carbon remains combined from which it is inferred that the carbide Fe 6 C forms (carbon 3.46 per cent) stable in the region LEFK in the dia- gram although he adds that it might be a solid solution containing that amount of carbon which forms at about 800 deg. Fe 6 C is claimed to be converted into Fe 3 C thus accounting for the evolutions of heat in this region reported by Carpenter and Keel- ing. At about 600 deg. according to the diagram Fe 3 C is converted into Fe = C thus explaining the evolutions of heat detected at that temperature by many observers. It is very difficult to accept the hypothesis that graphite is not the stable condition of CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IRON-CARBON ALLOYS 449 carbon in the area LEHR and that Fe2C and not Fe 3 C is the condition of the carbon remaining combined after complete slow cooling. The existence of both FeeC and Fe 2 C is based on chemical tests the significance of which is far from evident. Justi- fication for the line EF is claimed on the ground that evolutions of heat have been reported by Carpenter and Keeling as occurring at 1050 to 1100 deg. Other ob- servers, however, have generally failed to detect these retardations. There are 2700 2500 - 2300' 8100 1900 1700 700 S 1 2 3 4 5 6 7 3 Fig. 433. Ruff's equilibrium diagram. 10 other serious objections to Upton's diagram and its construction is so highly specula- tive as to render its closer study inadvisable in these pages. Ruff's Diagram. Professor Ruff has published the equilibrium diagram repro- duced in Figure 433, which, it will be noted, is of the double type, GK representing equilibrium with graphite and SK with cementite. The diagram does not extend below the eutectoid line PK but includes alloys containing as much as 10 per cent carbon. The line D'H indicates the increasing solubility of carbon in iron with in- creasing temperature. At some 2200 deg. C. molten iron saturated with carbon contains nearly 10 per cent of that element. At this temperature Ruff believes that the alloy consists of the carbide Fe 2 C as explained in Chapter XXII. As the tem- perature increases above 2200 deg. the solving power of iron for carbon decreases as 450 CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IRON-CARBON ALLOYS indicated by the line HI, carbon being rejected, probably through the breaking up of some Fe 2 C into iron and graphite (see Chapter XXII). At some 2700 deg. iron can retain but a little over 7 per cent of carbon in solution. In cooling below 2200 deg. (line HD') graphite and Fe 3 C are formed from the transformation of Fe 2 C (3Fe 2 C = 2 Fe 3 C + C). 1 234 SO 1 8 9 10 Fig. 434. Wittorff's equilibrium diagram. Wittorff 's Diagram. N. M. Wittorff worked out the diagram reproduced in Figure 434. It will be noted that (1) starting with an alloy containing some 11 per cent carbon, as it cools from T to R, that is, from some 2400 to 2000 deg. C. the carbide FeC 2 crystallizes out according to the diagram, (2) between R and M (2000 to 1700 deg.) Fe 3 C forms through the transformation of some FeC 2 (3) between M and D (1700 to 1350 deg.) both FeC and Fe 4 C are formed necessarily at the expense of FeC 2 which disappears and possibly also through the transformation of some of the Fe 3 C, and (4) below D (1350 deg.) the liquid phase disappears. CHAPTER XXVI EQUILIBRIUM DIAGRAM OF IRON-CARBON ALLOYS 451 Investigations of a region of the equilibrium diagram but little explored should be welcomed but in view of the fact that the experimental results of the different observers as well as the conclusions based upon them are at such variance, it seems advisable to omit from these pages a closer scrutiny of these recent diagrams. When some of the points that need clearing up have been settled the matter involved will be duly incorporated in a subsequent edition of this treatise. CHAPTER XXVII THE PHASE RULE The Phase Rule to which references have been made in the preceding chapters should now be considered as it has been found of much assistance in interpreting cor- rectly the iron-carbon equilibrium diagram. Enunciation of the Phase Rule. The phase rule was enunciated in 1878 by Wil- lard Gibbs, at the time Professor of Physics in Yale University. It is one of the most notable contributions ever made to physical chemistry. The phase rule deals with the equilibrium of systems and is generally expressed by the formula: F = C + 2-P showing the relation existing between the degrees of freedom (F) of a system, the num- ber of components (C), and the number of phases (P); it tells us that the number of degrees of freedom of any system is equal to the number of its components plus two, minus the number of phases present. In order to understand the phase rule and its application, it is necessary and sufficient to have an accurate understanding of the meaning of the terms employed in its enunciation, namely, equilibrium, degrees of freedom, components, and phases. Equilibrium. A substance or system may be said to be in a state of equilibrium when it is chemically and physically at rest, meaning by chemical rest that chemical compounds are neither being dissociated nor formed, and by physical rest, not the absence of motion but the absence of molecular transformation, such as changes of state or allotropic changes. It is necessary, however, to distinguish between homo- geneous and heterogeneous substances. A substance is said to be homogeneous when it is chemically and physically uniform throughout, i.e. when any two portions of it pos- sess identical chemical and physical properties. Homogeneous substances are neces- sarily gaseous mixtures, elements, chemical compounds, or liquid and solid solutions. The equilibrium of a homogeneous system is sometimes called homogeneous equi- librium. A heterogeneous substance is made up of two or more physically separate parts, that is, of parts having different physical properties. Ice and water, many rocks, and many alloys are instances of heterogeneous substances. If the com- ponent parts of heterogeneous substances may be present in indefinite proportions, the substances are mechanical mixtures; if they occur in definite proportions, the substances are eutectic or eutectoid alloys. The equilibrium of heterogeneous systems is sometimes called heterogeneous equilibrium. Howe has recently suggested that the homogeneous constituents of alloys be called "metarals" because of the great analogy between the constitution of metallic alloys and of rocks, the minerals being the homogeneous components of the latter, while the word aggregate is very frequently used to designate heterogeneous alloys. In metal- 452 CHAPTER XXVII THE PHASE RULE 453 lography, therefore, metarals and aggregates may conveniently replace the equivalent terms, homogeneous and heterogeneous substances, of the physical chemist. Only three independently variable factors can affect the equilibrium of a system, namely, (1) the temperature, (2) the pressure, and (3) the concentration or composi- tion. If arbitrary values may be given to one or more of these factors without destroy- ing the chemical and physical rest of the system, its equilibrium is said to be stable. On the contrary, if a change in value of any one of these three factors results in chemi- cal or physical transformation, i.e. in atomic or molecular activity such as dissociation or formation of chemical compounds, changes of state, or allotropic changes, the equilibrium of the system was unstable. Water under atmospheric pressure is in stable equilibrium, for we may change its temperature within wide limits without causing it to undergo a change of state, while of course its chemical composition remains likewise unaffected. All elements are generally in a state of stable equilib- rium, as well as an infinite number of substances composed of two or more elements, for they may be heated, for instance, through wide ranges of temperatures without upsetting their physico-chemical equilibrium. Examples of unstable equilibrium, however, are far from uncommon. During the solidification of substances, for in- stance, stages must generally be passed through during which the equilibrium of the substance is unstable, and it is often possible through very rapid cooling to retain in the cold the unstable conditions, because of the rigidity of the substance now opposing the changes needed for a return to stable equilibrium. It has been seen in these chapters that hardened steel is, for the above reason, unstable, hence the possibility of tempering it by slight reheating. The kind of equilibrium known as metastable remains to be described. Liquids may be cooled, when taking the necessary precautions, below their normal freezing- point, without freezing, the phenomenon being known as superfusion, surfusion, or undercooling, and the substance being said to be in metastable equilibrium. Water, for instance, may be cooled below deg. C. and still remain liquid. The introduction of a solid fragment of the substance, a piece of ice in the case of water, results in the solidification of the liquid while its temperature rises to its normal freezing-point. Otherwise, the substance may be kept liquid below its solidification point for any length of time. If the temperature of the liquid con- tinues to fall, however, a point is reached when its equilibrium becomes unstable, i.e. when further lowering of temperature causes the liquid to solidify. To state the case broadly, the failure on the part of a system to undergo a certain chemical or physical transformation when that transformation is due, although given the necessary time, results in metastable equilibrium, while its failure to undergo a transformation because of the necessary time being denied, as in quenching, results in unstable equilibrium. Metastable equilibrium is stable, at least within narrow limits of temperature, while, theoretically at least, slight heating of a substance in unstable equilibrium should result in a partial return to a more stable condition, that is, in a partial occurrence of the transformation that was suppressed by quick cooling. Degrees of Freedom. By the degrees of freedom (sometimes called degrees of liberty), of a system is meant the number of the three independently variable factors, temperature, pressure, and concentration, which may arbitrarily be made to vary without disturbing the system's physico-chemical rest. It has already been noted that a system, in order to be in stable equilibrium, must have at least one degree of free- dom. It will also be understood that no system can have more than two degrees of freedom because in the case of arbitrary values being given to two of the factors, the 454 CHAPTER XXVII THE I'll ASK Kl'LK value of the third is necessarily fixed, this being due to the known rigid relations existing between temperature, pressure, and concentration. Systems which have no degree of freedom are said to be "unvariant" or "non- variant." Their equilibrium is necessarily unstable. Systems having one degree of freedom are called "univariant" or "monovariant," and those with two degrees of freedom "bivariant" or "divariant." Phases. By the phases of a system are meant the homogeneous, physically dis- tinguishable, and mechanically separable constituents of that system. Water and ice, for instance, are possible phases of the water-ice system; quartz, felspar, and mica are phases of granite, that is, of the silica-alumina-potash system. It will be apparent that phases must necessarily be gaseous mixtures, elements, definite chemical compounds, or solutions. As previously mentioned, Howe, following the petrographical nomencla- ture, and noting that the minerals are the phases of rocks, calls "metarals" the phases of metals and alloys. Components. The components of a system are described by Findlay as "those constituents the concentration of which can undergo independent variation in the different phases," by Bancroft as "substances of independently variable concentra- tion," by Mellor as those "entities which are undecomposable under the conditions of experiments," by Howe as "free elements and those compounds which in the nature of the case are undecomposable under the conditions contemplated, and so play the part of elements." The components of a system may be either chemical compounds or elements, but there is at times some difficulty in grasping the distinction between the components of a system and its ultimate chemical constituents. The criterion by which to decide whether an entity is or is not a component, is the possibility of in- dependent variation in the different phases. Take the system water, for instance: evidently water and not hydrogen and oxygen is the component, because any variation in the proportion of hydrogen would necessarily imply a corresponding and well-defined variation in the proportion of oxygen and vice versa. Findlay writes : "In deciding the number of components in any given system, not only must the constituents chosen be capable of independent variation, but a further restriction is imposed, and we obtain the following rule: As the components of a system there are to be chosen the smallest number of independently variable constituents by means of which the composition of each phase participating in the state of equilibrium can be expressed in the form of a chemical equation." In the case of alloys, however, such difficulty does not arise, for the constituent metals are always the components of the systems. The Phase Rule Applied to Alloys. In dealing with alloys we may for all practi- cal purposes ignore the influence of pressure, seeing that because of their feeble vola- tility they are practically always subjected to atmospheric pressure. Omitting the influence of pressure necessarily reduces by one the possible number of degrees of freedom so that in the case of alloys the phase rule may be expressed by the formula : F = C + 1 - P signifying that the number of degrees of freedom is equal to the number of components plus one, minus the number of phases. Since to be in stable equilibrium a system must have at least one degree of freedom, it is obvious that an alloy made up of n metals cannot have more than n phases. If it had n + 1 phases it would have no degree of freedom, that is, its equilibrium would be unstable. With n - 1 phases it would have CHAPTER XXVII THE PHASE RTLE 455 two degrees of freedom. It could not have less than n 1 phases, since it cannot have more than two degrees of freedom. The Phase Rule Applied to Pure Metals. Pure metals have only one component, hut their possible phases are (1) liquid metal, (2) solid metal, (3) several allotropic con- ditions of the solid metal. Let us consider Figure 435, which represents the solidi- fication of a pure metal as explained in Chapter XXV. Above the temperature T the metal is entirely liquid; it has but one phase, and consequently one degree of freedom (F =1 + 1 1 = 1). The system above T is univariant; its temperature may be altered within wide limits-^vjthout disturbing its I ^ T / /me Fig. 4:i r >. Equilibrium of pun; metals according to the Phase Rule. equilibrium: it remains liquid. At the temperature T two phases are present, solid metal and liquid metal, the metal having, therefore, no degree of freedom (F = 1 + 1 2 = 0): it is non-variant. Liquid and solid metal can exist only at one temperature, the critical temperature of solidification, any change of its temperature resulting in the disappearance of one of the phases, that is, in a return to stable equilibrium. Increasing the temperature must result in the disappearance of the solid phase, while lowering the temperature must cause the disappearance of the liquid phase. Below the temperature T the system contains only the solid phase, being, therefore, univari- ant: its temperature may be varied arbitrarily. The Phase Rule Applied to Binary Alloys. Binary alloys having for components the two alloying metals, the formula of the phase rule becomes: F = 2+ 1 - P or F = 3 - P 456 CHAPTER XXVII THE PHASE RULE Clearly binary alloys when in a condition of stable equilibrium cannot have more than two phases. With one phase they will be bivariant, with two phases univariant, and with three phases non-variant. Let us apply the rule to the fusibility curves of binary alloys of metals partially soluble in each other when solid (Fig. 436). Above the liqui- dus MEM' there is but one phase present, namely the liquid phase, the system being, therefore, bivariant (F = 3 - 1 = 2), i.e. both temperature and concentration may be varied arbitrarily without upsetting the equilibrium of the system, which means, in the case under consideration, without causing its solidification. On reaching any point L of the liquidus the alloy begins to solidify, and two phases are now present, namely, solid solution and liquid alloy, the system becomes univariant (F = 3 - 2 = 1). Having but one degree of freedom only the temperature or the concentration may be Fig. 436. Equilibrium according to the Phase Rule of binary alloys whose component mchils .-ire partially soluble in each other in the solid state. arbitrarily varied. Should we, for instance, lower the temperature of alloy R from T to T' (Fig. 436) the composition of the liquid phase necessarily shifts from L to L', and that of the solid phase in equilibrium with it from s to s'. In the region MSES'M' of the diagram bounded by the liquidus and solidus lines, therefore, the alloys are uni- variant, any arbitrary change of temperature resulting in a well-defined change of concentration and vice versa. At E, corresponding to eutectic composition and eutectic temperature, three phases are present, namely two solid solutions and liquid alloy, the system having no degree of freedom (F = 3 3 = 0) . Neither the tempera- ture nor the concentration may be altered without causing the disappearance of at least one of the phases. Increasing the temperature must result in the disappear- ance of both solid solutions, the system becoming bivariant, while lowering it must be followed by the disappearance of the liquid phase. Again, shifting the concen- tration to the left or right of E must yield the univariant system solid solution plus liquid. Clearly two solid phases and a liquid phase can only exist at one critical temperature and for one critical composition of the alloy; in the case of a eutectic CHAPTER XXVII THE PHASE RULE 457 alloy these three phases can exist only at its freezing temperature. In the areas AMSB and DM'S'C single homogeneous solid solutions only are present, that is, but one phase exists, and the corresponding alloys have, therefore, two degrees of freedom. Arbitrary changes both of temperature and composition within these areas do not disturb the equilibrium of the system. Within the region BSS'C two phases occur, solid solution M and solid solution M', the corresponding alloys having, therefore, but one degree of freedom. Increasing the temperature from P to P', for instance, must result in shifting the composition of the solid solutions respectively from R to R' and from to 0'. The Phase Rule Applied to Iron-Carbon Alloys. Since iron-carbon alloys belong to the class of binary alloys the constituents of which are partially soluble in each other in the cold, the application of the phase rule to their equilibrium diagram should not present any difficulty, but we have now to consider allotropic changes as well as changes of state. Their possible phases or metarals are: (1) liquid iron, (2) liquid solution of carbon (or FesC) in iron, (3) solid solution (austenite) of carbon (or FesC) in gamma iron, (4) solid gamma iron, (5) solid beta iron, (6) solid alpha iron (ferrite), (7) solid solution (martensite) 1 of carbon (or FesC) in beta iron, (8) solid cementite, (9) graphite, and possibly others. The exact nature of troostite and sorbite being still in doubt, they are not here classified as phases, seeing that they may be, and probably are, aggregates of two or more phases, unless indeed they be, according to Benedicks, emulsions or colloidal solutions. Scientists do not agree, however, as to whether colloidal solutions are or are not phases, opinions differing in regard to their homogeneity. Indeed some writers like Le Chatelier question the existence of colloidal solutions which they consider as finely divided aggregates. Pearlite evidently is not a phase, but an aggregate of the two phases, ferrite and cementite, in constant pro- portion after the fashion of eutectic and eutectoid mixtures. Let us now apply the teachings of the phase rule to the iron-carbon equilibrium diagram (Fig. 437) . The number and kinds of phases existing at different temperatures, and for different proportions of the components, iron and carbon, have been clearly indicated and will be readily understood in view of the foregoing considerations. Above the liquidus LEU all alloys^ are composed of but one liquid phase, and have, therefore, two degrees of freedom; between the liquidus and solidus, that is, in the region LSE and L'S'E, two phases are present, liquid solution plus solid solution (austenite), or liquid solution plus solid FesC, hence the corresponding alloys have here but one degree of freedom^ (alloys of composition E and at the corresponding temperature are evidently made up of three phases, namely liquid solution plus solid austenite plus solid cementite, being, therefore, non-variant; in the region LADS all alloys being com- posed of but one phase, namely, solid austenite, are bivariant; at D the alloy contains three phases, ferrite, cementite, and austenite, and is, therefore, non- variant; in the area DSS'F two phases are present, solid solution (austenite) plus cementite, and the system has but one degree of freedom. If, as is often the case, cementite is in this region decomposed into iron and graphite the alloys are for the time being non-variant, becoming again univariant on the complete disappearance of cementite. In the region ABH beta iron and austenite are present, the alloys having in consequence but one degree of freedom; in the region BCDH alpha ferrite and austenite are present and the alloys, therefore, are univariant. Finally below CDF three possible cases should be considered: (I) the cementite formed during solidification and subsequent cooling 1 All investigators do not, agree as to the homogeneity, that is the phase-like character of marten- site, some still regarding it as an aggregate. 458 CHAPTER XXVII THE Pi [ASK RULE <0 CHAPTER XXVII THE PHASE RULE 459 remains unchanged, in which case the alloys are made up of the two phases ferrite and cementite, being, therefore, univariant, their equilibrium, however, as previously ex- plained, is supposed to be metastable; (II) the cementite has been completely con- verted into ferrite and graphite, only those two phases being present, undoubtedly representing the stable equilibrium of all iron-carbon alloys; (III) the dissociation of cementite has been incomplete, both cementite and graphite being present, which with ferrite give three phases, the corresponding alloys being non-variant and, there- fore, their equilibrium unstable. Condition (I) generally prevails in all grades of steel, and is readily produced in cast iron by rapid cooling especially Jnjthe absence of con- siderable silicon, the resulting alloys being known as white cast iron. Condition (II) never obtains in steel, but may be produced in highly carburized alloys by very slow cooling through and below solidification, especially in the presence of much silicon and in the absence of manganese and sulphur. Condition (III) is the condition of the gray cast irons of commerce, their compositions and other influences prevailing during their cooling being such as to cause the graphitizing of varying proportions of cementite. APPENDIX REPORT OF COMMITTEE 53 OF THE INTERNATIONAL ASSOCIATION FOR TESTING MATERIALS ON THE NOMENCLATURE OF THE MICROSCOPIC SUBSTANCES AND STRUCTURES OF STEEL AND CAST IRON Presented by the Chairman H. M. HOWE and the Secretary of the Committee ALBERT SAUVEUR at the VI th Congress, New York, September, 1912 The Committee for studying this problem is constituted as follows: Professor H. M. HOWE, Chairman, New York. Professor ALBERT SAUVEUR, Secretary, Cambridge, Mass. Members: F. OSMOND, Paris; Dr. H. C. H. CARPENTER, Manchester; Prof. W. CAMPBELL, New York; Prof. C. BENEDTCKS, Stockholm; Prof. F. WUST, Aachen; Prof. A. STANSFIELD, Montreal; Dr. J. E. STEAD, Middlesbrough; Prof. L. GUILLET, Paris; Prof. E. HEYN, Berlin-Lichterfelde; Dr. W. ROSENHAIN, Teddington. I. GENERAL PLAN We first enumerate the substances of such importance as to warrant it, indicating roughly their constitution, and then define and describe certain of them. The conditions which we meet are (1) that we need definitions on which all can agree; and this implies that they must be free from all contentious matter and be based on what all admit to be true; (2) that the reader must needs know the current theories as to the constitution of these substances, and these theories are necessarily contentious. We meet these conditions by the plan of giving (1) the Name which we recommend for general use, followed immediately in parentheses by the other names used widely enough to justify recording them; (2) the Definition proper, based on an undisputed quality, e.g. that of austenite, which we base on its being an iron-carbon solid solution, purposely omitting all reference to the precise nature of solvent and solute; and (3) Constitution, etc., etc., in which we give the current theories as to the nature of solvent and solute and appropriate descriptive matter. The distinction between these three parts should be understood. (1) The Names actually used are matters of record and indisputable. (2) The Definitions are matters of convention or treaty, binding on the contracting parties, though subject to de- nouncement, preferably based on some determinable property of the thing defined as distinguished from any theory as to its nature, or if necessarily based on any theory it should be a theory which is universally accepted. It is a matter purely of conven- tion and general convenience what individual property of the thing defined shall form the basis of the definition. The name and the definition should endure perma- nently, except in the case of a definition based on an accepted theory, which must be 460 APPENDIX NOMENCLATURE OF THE MICROSCOPIC CONSTITUENTS 461 changed if the theory should later be disproved. (3) Theories and Descriptions are not matters of agreement or convention but dependent on observation, and therefore always subject to be changed by new discoveries. They are temporary in their nature as distinguished from the names and definitions which should be fixed, at least rela- tively. This case of austenite illustrates the advantage of non-indicative names. The names which we propose to displace, "gamma iron" and "mixed crystals," imply definite theories as to the nature of austenite, and hence might have to be abandoned in case those theories were later disproved. The name "austenite" implies nothing, like mineralogical names in general, and hence is stable in itself. Our infant branch of science may well learn from its elder sister, which has tried and proved the advan- tage of this non-indicative naming. In those cases in which a name has been used in more than one sense we advise the retention of one and the abandonment of the others, having obtained the consent of the proposers of such names for their abandonment. Many whose judgment we respect object to our including certain of the less used names, e.g. from i to n in our list, holding them either to be confusing or to be needless. It is true that several names (hardenite, martensite, sorbite, etc.), have been used with various meanings, and hence confusingly, in spite of which most of them should be retained, each with a single sharp-cut definition, because they are so useful. As regards the alleged needlessness of certain names it is for each writer to decide whether he does or does not need names with nice shades of meaning, such as osmon- dite and troosto-sorbite. Those who look only at the general outlines and not at the details have no right to forbid the workers in detail from having and using words fitting their work; nor have those whose needs are satisfied by the three primary colors a right to forbid painters, dyers, weavers, and others from naming the many shades with which they are concerned. Like the lexicographer we must serve the reader by explaining those words which he will meet, whether we individually use or condemn them. We feel that we have exhausted our powers in cautioning writers that certain words are rare and not likely to be understood by most readers, or are improper for any reason, and in urging the complete abandonment of those with- drawn by their proposers. Needless words will die a natural death; needed ones we cannot kill. The good we might do in hastening the death of the moribund by omitting them from this re- port is less than the good we do by teaching their meaning to those who will meet them in ante-mortem print. These readers have rights. We serve no class, but the whole. Illustrations. At the end of the several descriptions the reader is referred to good illustrations in Osmond and Stead's "Microscopic Analysis of Metals," Griffin & Co., London, 1904. II. LIST OF MICROSCOPIC SUBSTANCES The microscopic substances here described consist of 1. Meiarals, true phases, like the minerals of nature. These are either elements, definite chemical compounds, or solid solutions and hence consisting of definite sub- stances in varying proportions. These include austenite, ferrite, cementite, and graphite. 462 APPENDIX NOMENCLATURE OF THK MICROSCOPIC CONSTITUENTS 2. Aggregates, like the petrographic entities as distinguished from the true minerals. These mixtures may he in definite proportions, i.e. eutectic, -or eutectoid mixtures (ledeburite, pearlite, steadite), or in indefinite proportions (troostite, sorbite). Those aggregates which are important for any reason are here described. (Many true minerals, such as mica, felspar, and hornblende, are divisible into several different species so that these true mineral names may be either generic or specific. These genera and species are definite chemical compounds in which one element may replace another. Other minerals, such as obsidian, are solid solutions in varying proportions, and in these also one element may replace another. Metarals like minerals differ from aggregates in being severally chemically homogeneous.) These two classes may be cross classified into : (A) The iron-carbon series, which come into being in cooling and heating. (B) The important impurities, manganese sulphide, ferrous sulphide, slag, etc. (C) Other substances. The most prominent members of the iron-carbon series are: I. molten iron, metaral, molten solution, but hardly a microscopic constituent; II. the components which form in its solidification : (a) austenite, solid solution of carbon or iron carbide in iron, metaral, (6) cementite, definite metaral, Fe 3 C, (c) graphite, definite metaral, C; III. the transition substances which form through the transformation of austenite during cooling: (d) martensite, metaral of variable constitution; its nature is in dispute; (e) troostite, indefinite aggregate, uncoagulated mixture, (/) sorbite, indefinite aggregate, chiefly uncoagulated pearlite plus ferrite or ce- mentite; IV. products 1 of the transformation of austenite: (g) ferrite, (/*) pearlite. This transformation may also yield cementite and graphite as end products in addition to those under 6 and c. In addition to the above, the names of which are universally recognized and in general use, the following names have been used more or less: (i) ledeburite (Wiist), definite aggregate, the austenite-cementite eutectic; (j) ferronite (Benedicks), hypothetical definite metaral, ft iron containing about 0.27 per cent of carbon; (k) steadite (Sauveur) , definite aggregate, the iron-phosphorus eutectic (rare) ; and three transition stages in the transformation of austenite, viz. : (I) hardenite (Arnold), collective name for the austenite and martensite of eutec- toid composition; (m) osmondite (Heyn), boundary stage between troostite and sorbite; (ri) troosto-sorbite (Kourbatoff ) , indefinite aggregate, the troostite and the sorbite which lie near the boundary which separates these two aggregates (obsolescent) . 'In hypo-eutectoid steels these habitually play the part of end products, though according to the belief of most the true end of the transformation is not reached till the whole has changed into a conglomerate of ferrite plus graphite. APPENDIX NOMENCLATURE OF THE MICROSCOPIC CONSTITUENTS 463 III. DEFINITIONS AND DESCRIPTIONS Carbon-Iron Equilibrium Diagram, Figure 438. Under the several substances about to be described an indication will be given of the parts of the carbon-iron equi- librium diagram Figure 438 to which they severally correspond. Austenite, Osmond (Fr. Austenite, Ger. Austenit, called also mixed crystals and gamma iron. Up to the year 1900 often called martensite and wrongly sometimes still so called). Metaral of variable composition. Definition. The iron-carbon solid solution as it exists above the transformation 1500 1400 1300 1200 A iooo- rj I* o B 900- o H 800- M 700- 600- 500- 1. Molten Iron (Per Fondu) Molten (Per Fondu) f flusbenibe C / 3. /Austenite 5. Austenite + Cementite Pearl ite 8.B. Cementite Pearl ite K 1 2 3 4 5 Carbon per cent Y\K. 438. A,: The line PSK is often called "Ai". A 3 : The line COS is often called "A,", and this name is sometimes applied to the line SE. range or as preserved with but moderate transformation at lower temperatures, e.g. by rapid cooling, or by the presence of retarding elements (Mn, Ni, etc.), as in 12 per cent manganese steel and 25 per cent nickel steel. Constitution and Composition. A solid solution of carbon or iron carbide (prob- ably Fe 3 C) and gamma iron, normally stable only above the line PSK of the carbon- iron diagram. It may have any carbon content up to saturation as shown by the line SE, viz.: about 0.90 per cent at S (about 725 deg. C.) to 1.7 per cent at E (about 1130 deg.). The theory that the iron and the carbide or carbon, instead of being dis- solved in each other, are dissolved in a third substance, the solution of eutectoid com- 464 APPENDIX NOMENCLATURE OF THE MICROSCOPIC CONSTITUENTS position (Fe 24 C, called hardenite) is not in accord with the generally accepted theory of the constitution of solutions, and is not entertained widely or by any member of this committee. Crystallization. Isometric. The idiomorphic vug crystals are octahedra much elongated by parallel growth. The etched sections show much twinning. (Osmond and most authorities.) Le Chatelier believes it to be rhombohedral. Cleavage octahedral. Varieties and Genesis. (l) Primary austenite formed in the solidification of carbon steel and hypo-eutectic cast iron; (2) eutectic austenite, interstratified with eutectic cementite, making up the eutectic formed at the end of the solidification of steel con- taining more than about 1.7 per cent of carbon, and of all cast iron. Equilibrium. It is normal and in equilibrium in Region 4, and also associated with beta iron in Region 6, with a iron in Region 7, and with cementite in Region 5. It should normally transform into pearlite with either ferrite or cementite on cooling past AI into Region 8. Transformation. In cooling slowly through the transformation range, Ar 3 - Ari, austenite shifts its carbon content spontaneously through generating pro-eutectoid ferrite or cementite, to the eutectoid ratio, about 0.90 per cent, and then transforms with increase of volume at Ari into pearlite, q.v., with which the ejected ferrite or cementite remains mixed. Rapid cooling and the presence of carbon, manganese, and nickel obstruct this transformation, (1) retarding it, and (2) lowering the temperature at which it actually occurs, and in addition (3) manganese and nickel lower the temperature at which in equilibrium it is due. Hence, by combining these four obstructing agents in proper proportions the transformation may be arrested at any of the intermediate stages, martensite, troostite, or sorbite, 1 q.v., and if arrested in an earlier stage it can be brought to any later desired stage by a regulated reheating or "tempering." For instance, though a very rapid cooling in the absence of the three obstructing ele- ments checks the transformation but little and only temporarily, yet if aided by the presence of a little carbon it arrests the transformation wholly in the martensite stage; and in the presence of about 1.50 per cent of carbon such cooling retains about half the austenite so little altered that it is "considerably" softer than the usually darker needles of the surrounding martensite, with which it contrasts sharply. Again, either (a) about 12 per cent of manganese plus 1 per cent of carbon, or (6) 25 per cent of nickel, lower and obstruct the transformation to such a degree that austenite per- sists in the cold apparently unaltered, even through a slow cooling. (Hadfield's man- ganese steel and 25 per cent nickel steel, manganiferous and nickeliferous austenite respectively.) Occurrence. When alone (12 per cent manganese and 25 per cent nickel steel and Maurer's 2 per cent carbon plus 2 per cent manganese austenite) polyhedra, often coarse, much twinned at least in the presence of martensite, and readily developing slip bands. In hardened high-carbon steel it forms a ground mass pierced by zigzag needles and lances of martensite. Etching. All the common reagents darken it much more than cementite, less 1 Though the transformation can be arrested in such a way as to leave the whole of the steel in the condition of martensite, it is doubted by some whether it can be so arrested as to leave the whole of it in any of the other transition stages. Troostite and sorbite caused by such arrest are habitually mixed, troostite with martensite or sorbite or both, and sorbite with pearlite or troostite or both. APPENDIX NOMENCLATURE OF T1IK MICROSCOPIC CONSTITUENTS 465 than troostite or sorbite, and usually less, though sometimes more, than martensite, which is recognized by its zigzag shape and needle structure. With ferrite and pearlite it is never associated. Physical Properties. Maurer's austenite of 2 per cent manganese plus 2 per cent carbon is but little harder than soft iron, and 25 per cent nickel steel and Had- field's manganese steel are but moderately hard. Yet as usually preserved in hardened high carbon steel, the hardness of austenite does not fall very far short of that of the accompanying martensite, probably because partly transformed in cooling-. (Os- mond's words are that it is "considerably" softer than that martensite.) Specific Magnetism. Very slight unless perhaps in intenselieTds. In Hadfield's manganese steel and 25 per cent nickel steel, very ductile. Illustrations. "Microscopic Analysis of Metals," Figures 20, 50, and 51 on pp. 39, 100, and 101. Cementite (Sorby, "intensely hard compound"; Ger. Cementit, Fr. Cementite; Arnold, crystallized normal carbide). Definite metaral. Definition. Tri-ferrous carbide, Fe 3 C. The name is extended by some writers so as to include tri-earbides in which part of the iron is replaced by manganese or other elements. Such carbides may be called " manganiferous Cementite," etc. Occurrence. (a) Pearlitic as a component of pearlite, q.v.; (6) eutectic; (c) primary or pro-eutectic; (d) pro-eutectoid; (e) that liberated by the splitting up of the eutectic or of pearlite; and (/) uncoagulated in sorbite, troostite, and perhaps mar- tensite. (c), (d), and (e) are grouped together as "free" or "massive." Primary cementite is generated in cooling through Region 3; eutectic cementite on cooling past the line EBD; pro-eutectoid cementite in cooling through Region 5; pearlitic cementite on cooling past the line PSK, or AI. Though the several varieties of cementite are generally held to be all metastable, tending to break up into graphite plus either austenite above AI or ferrite below A], yet they have a considerable and often great degree of persistence. The graphitizing tendency is completely checked in the cold but increases with the temperature and with the proportion of carbon and of silicon present, and is opposed by the presence of manganese. Crystallization. Orthorhombic, in plates. Structure. (a) Pearlitic, in parallel unintersecting plates alternating with plates of ferrite; (6) eutectic, plates forming a network filled with a fine conglomerate of pearlite with or without pro-eutectoid cementite; (c) primary, in manganiferous white cast iron, etc., in rhombohedral plates; (d) in hyper-eutectoid steel, pro-eutec- toid cementite forms primarily a network enclosing meshes of pearlite through which cementite plates or spines sometimes shoot if the network is coarse; (e) cementite liberated from pearlite merges with any neighboring cementite; (/) the structure of uncoagulated cementite cannot be made out. On long heating the pro-eutectoid and pearlitic cementite spheroidize slowly, and neighboring particles merge; (a) in white irons rich in phosphorus in flat plates embedded in iron-carbon-phosphorus eutectic. Etching, etc. After polishing stands in relief. Brilliant white after etching with dilute hydrochloric or picric acid; darkened by boiling with solution of sodium picrate in excess of sodium hydrate. Physical Properties. Hardest component of steel. Hardness = 6 of Mohs scale. Scratches glass and felspar but not quartz; very brittle. Specific magnetism about two thirds that of pure iron. 460 APPENDIX NOMENCLATURE OF THE MICROSCOPIC CONSTITUENTS Illustrations. "Microscopic Analysis of Metals," Figures 42 and 43 on pp. 84, 85. Martensite (Fr. Martensite, Ger. Martensit). Metaral. Its nature is in dispute. Definition. The early stage in the transformation of austenite characterized by needle structure and great hardness, as in hardened high-carbon steel. Constitution. I. (Osmond and others.) A solid solution like austenite, q.v., ex- cept that the iron is partly beta, whence its hardness, and partly alpha, whence its magnetism in mild fields. II. (Le Chatelier.) The same except that its iron is essen- tially alpha, and the hardness due to the state of solid solution. III. (Arnold.) A spe- cial structural condition of his "hardenite" (austenite); not widely held. IV. A solid solution in gamma iron. V. (Benedicks.) The same as I, except that the iron is wholly beta and that beta iron consists of alpha iron containing a definite quantity of gamma iron in solution. Equilibrium. It is not in equilibrium in any part of the diagram, but represents a metastable condition in which the metal is caught during rapid cooling, in transit between the austenite condition stable above the line Ai and the condition of ferrite plus cementite into which the steel habitually passes on cooling slowly past the line AI. Occurrence. The chief constituent of hardened carbon tool steels, and of medium nickel and manganese steels. In still less fully transformed steels (1.50 per cent carbon steel rapidly quenched, etc.) it is associated with austenite; in more fully transformed ones (lower carbon steels hardened, high carbon steels oil hardened, or water hardened and slightly tempered, or hardened thick pieces even of high carbon steel) it is associated with troo'stite, and with some pro-eutectoid ferrite or cementite, q.v., in hypo- and hyper-eutectoid steels respectively. In tempering it first changes into troostite; at 350 deg. -400 deg. it passes through the stage of osmondite; at higher temperatures it changes into sorbite; and at 700 deg. into granular pearlite. On heating into the transformation range this changes into austenite, which on cool- ing again yields lamellar pearlite. Characteristic specimens are had by quenching bars 1 cm. square of eutectoid steel, i.e. steel containing about 0.9 per cent of carbon, in cold water from 800 (leg. C. (1472 deg. F.). Structure. When alone, habitually in flat plates made up of intersecting needles parallel to the sides of a triangle. When mixed with austenite, zigzag needles, lances, and shafts. If produced by quenching after heating to 735 deg. C., it consists of minute crystal- lites resembling the globulites of Vogelsang, which are rarely arranged in triangular order. At times so fine as to suggest being amorphous. Etching. With picric acid, iodine or very dilute nitric acid etches usually darker than austenite, but sometimes lighter, always darker than ferrite and cementite, but always lighter than troostite. Illustrations. "Microscopic Analysis of Metals," Figure 19 on p. 38, Figure 52 on p. 102. Ferrite (Fr. Ferrite, Ger. Ferrit). Definite metaral. Definition. Free alpha iron. Composition. Nearly pure iron. It may contain a little phosphorus and silicon but its carbon content, if any, is always small, at the most not more than 0.05 per cent, and perhaps never as much as 0.02 per cent. APPKXDIX XOMKXCLA'ITKK OF THE MICROSCOPIC COXSTITUENTS 467 Occurrence. (a) Pearl i tic as a component of pearlite, q.v.; (b) pro-eutectoid ferrite generated in slow cooling through the transformation range; (c) that segre- gated from pearlite, i.e. set free by the splitting up of pearlite, especially in low car- bon steel; (d) uncoagulated as in sorbite, and probably troostite. (b) and (c) are classed together as free or massive. Thus ferrite is normal and stable in regions 7 and 8. Crystallization. Isometric, in cubes or octahedra. Structure. (a) Pearlitic ferrite, unintersecting parallel plates alternating with plates of ceincntite; (b) pro-eutectoid ferrite in low carbon steel forms irregular poly- gons, each with uniform internal orientation. In higher carbon steel after moderately slow cooling, especially in the presence of manganese, it forms a network enclosing meshes of pearlite. In slower cooling this network is replaced by irregular grains separated by pearlite; (c) the ferrite set free by the splitting up of pearlite merges with the pro-eutectoid ferrite, if any; (d) the structure of the ferrite in sorbite, etc., cannot be made out. Etch ini/. Dilute alcoholic nitric or picric acid on light etching leaves the ferrite grains white with junctions which look dark. Deeper etching, by Heyn's reagent or its equivalent, reveals the different orientation of the crystals or grains, (a) as square figures parallel to the direction of the etched surface, (b) as plates which dip at varying angles and become dark or bright when the specimen is rotated under oblique illumination. Still deeper etching reveals the component cubes (etching figures, Atzfiguren), at least if the surface is nearly parallel to the cube faces.. Physical Properties. Soft; relatively weak (tenacity about 40,000 Ibs., per sq. in.); very ductile; strongly ferro-magnetic ; coercitive force very small. drain Xize. For important purposes (1) etch deeply enough, e.g. with copper- ammonium chloride, to reveal clearly the junctions of the grains; (2) count on a photo- graph of small magnification the number of grains in a measured field so drawn as to exclude fragments of grains; after (3) determining the true grain boundaries by ex- amination under high powers (Heyn's method). Deep nitric acid etching is inaccurate, because an apparent grain boundary may contain several grains. Illustrations. " Microscopic Analysis of Metals," Figures 41, 56 on pp. 79, 116. Osmondite (Fr. Osmondite, Ger. Osmondit). Definition. That stage in the transformation of austenite at which the solubility in dilute sulphuric acid reaches its maximum rapidity. Arbitrarily taken as the boundary between troostite and sorbite. Earlier Definition. Denned by the V th Congress as having the "maximum sol- ubility in acids and by a maximum coloration under the action of acid metallographic reagents." The present definition is confined to maximum rapidity of dissolving, because we do not yet know that this in all cases co-exists with the maximum depth of coloration, and in any case in which these two should not co-exist, the old defini- tion does not decide which is true osmondite. Constitution. The following hypotheses have been suggested, none of which has firm experimental foundation: (1) A solid solution of carbon or an iron carbide in alpha iron. (2) The colloidal system of Benedicks in its purity, troostite being this system while forming at the expense of martensite, and sorbite, being this system coagulating and passing into pearlite. (3) The stage of maximum purity of amor- phous alpha iron on the way to crystallizing into ferrite. Occurrence. Hardened carbon steel of about 1 per cent of carbon when reheated 468 APPENDIX NOMENCLATURE OF THE MICROSCOPIC CONSTITUENTS (tempered) to 350-400 deg. C. passes through the stage of troostite to that of osmondite, and on higher heating to that of sorhite. What variation if any from this temperature is needed to bring hardened steel of other carbon content to the osmond- ite stage is not known. In that it represents a true boundary state between troostite and sorbite it differs in meaning from troosto-sorbite, which embraces both the troost- ite and the sorbite which lie near this boundary. Indeed osmondite has sometimes been used in this looser sense. Writers are cautioned that, however useful these terms may prove for making these nice discriminations, they are not likely to be familiar to general readers. Etching. According to Heyn it differs from troostite and sorbite in being that stage in tempering which colors darkest on etching with alcoholic hydrochloric acid. The present definition and description of osmondite should displace previous ones, because they have the express approval of Professor Heyn, the proposer of the name, and M. Osmond himself. Ferronite (Fr.Ferronite, Ger. Ferronit) (Benedicks). Hypothetical definite metaral. Definition. Solid solution of about 0.27 per cent of carbon in beta iron. Occurrence (hypothetical). In slowly cooled steels and cast iron containing 0.50 per cent of combined carbon or more, that which is generally believed to be fer- rite, whether pearlitic or free, is supposed by Benedicks to be ferronite. Hardenite (Fr. Hardenite, Ger. Hardenit). Definition. Collective name for austenite and martensite of'eutectoid composi- tion. It includes such steel (1) when above the transformation range, and (2) when hardened by rapid cooling. Observations. On the generally accepted theory that austenite is a solid solution of carbon or an iron carbide in iron, hardenite is the solution of the lowest transforma- tion temperature, i.e. the eutectoid. The theory that instead it is a definite chemical compound, Fe2.iC, is considered under Austenite. Its proposer includes under hardenite both eutectoid (0.90 per. cent carbon) austenite when above the transforma- tion range and the martensite into which that austenite shifts in rapid cooling (hard- ening). Other Meanings. Originally (Howe, 1888) collective name for austenite and martensite of any composition in carbon steel. Osmond (1897), austenite saturated with carbon. Both these meanings are withdrawn by their proposers. Pearlite (Sorby's "pearly constituent." At first written "pearlyte" Fr. Perlite, Ger. Perlit). Aggregate. Definition. The iron-carbon eutectoid, consisting of alternate masses of ferrite and cementite. Constitution and Composition. A conglomerate of about 6 parts of ferrite to 1 of cementite. When pure, contains about 0.90 per cent of carbon, 99.10 per cent of iron. Occurrence. Results from the completion of the transformation of austenite brought spontaneously to the eutectoid carbon content, and hence occurs in all carbon steels and cast iron containing combined carbon and cooled slowly through the transformation range, or held at temperatures in or but slightly below that range, long enough to enable the ferrite and cementite to coagulate into a mass microscopic- ally resoluble. Hence it is the normal constituent in Region 8. Its ferrite is stable but its cementite is metastable.and tends to transform into ferrite and graphite. Varieties and Structure. Because pearlite is formed by the coagulation of the APPENDIX NOMENCLATURE OF THE MICROSCOPIC CONSTITUENTS 469 ferrite and cementite initially formed as the irresoluble emulsion, sorbite, (Arnold's sorbitic pearlite) there are the indefinitely bounded stages of sorbitic pearlite (Arnold's normal pearlite), i.e. barely resoluble pearlite, in the border-land between sorbite and laminated pearlite; granular pearlite, in which the cementite forms fine globules in a matrix of ferrite; and laminated or lamellar pearlite, consisting of fine, clearly defined, non-intersecting, parallel lamellae alternately of ferrite and cementite. The name granular pearlite was first used by Sauveur to represent what is now called sorbite. This meaning has been withdrawn. An objection to Arnold's name "normal poarlite" is that ii^ is likely to mislead. "Normal" here apparently refers to arising under normal conditions of cooling, but (1) it rather suggests structure normal for pearlite, which surely is the lamination characteristic of eutectics in general, and (2) the general reader has no clue as to what conditions of cooling are here called normal. Many readers are not manufacturers, and even in manufacture itself air cooling is normal for one branch and extremely slow furnace cooling for another. Arnold calls troostite "troostitic pearlite" and sorbite "sorbitic pearlite." This is contrary to general usage, which restricts pearlite to microscopically resoluble masses. Etching. After etching with dilute alcoholic nitric or picric acid it is darker than ferrite or cementite but lighter than sorbite and troostite. A magnification of at least 250 diameters is usually needed ^or resolving it into its lamellae, though the pearlite of blister steel can often be resolved with a magnification of 25 diameters. The more rapidly pearlite is formed, the higher the magnification needed for re- solving it. Illustrations. Lamellar pearlite. Osmond and Stead, "Microscopic Analysis," Figure 11 on p. 19, Granular pearlite, idem, Figure 18 on p. 36; Heyn and Bauer, "Stahl und Eisen," 1906, Figure 14, opposite p. 785. Graphite (Ger. Graphit, Fr. Graphite). Definite metaral. Definition. The free elemental carbon which occurs in iron and steel. Composition. Probably pure carbon, identical with native graphite. Genesis. Derived in large part, and according to Gcerens wholly, from the de- composition of solid cementite. Others hold that its formation as kish may be from solution in the molten metal, and that part of the formation of temper graphite may be from elemental carbon dissolved in austenite. It is the stable form of carbon in all parts of the diagram. Occurrence. (1) as kish, flakes which rise to the surface of molten cast iron and usually escape thence; (2) as thin plates, usually curved, e.g. in gray cast iron, representing carbon which has separated during great mobility, i.e. near the melting range; (3) as temper graphite (Ger. Temperkohle, Ledebur) pulverulent carbon which separates from cementite and austenite, especially in the annealing process for mak- ing malleablized castings. Graphite and ferrite are sometimes associated in a way which suggests strongly that they represent a graphite-austenite eutectic. But the existence of such a true eutectic is doubted by most writers. Properties. Hexagonal. H. 1-2. Gr. 2.255. Streak black and shining, luster metallic; macroscopic color, iron black to dark steel gray, but always black when seen in polished sections of iron or steel under the microscope; opaque; sectile; soils paper; flexible; feel, greasy. 470 APPENDIX NOMENCLATURE OF Till: MICROSCOPIC COXSTlTTKVrs Troostite (Fr. Troostitc, Ger. Troostit). Probably agrregate. (Arnold, troostitic pearlite.) Definition. In the transformation of austenite, the stage following martensite and preceding sorbite (and osnionditc if this stage is recognized). < 'oH.fliltilion an/I Composition. An uncoagulated conglomerate of the transition stages. The degree of completeness of the transformation represented by it is not definitely known and probably varies widely. Osmond and most others believe that the transformation, while generally far advanced, yet falls materially short of comple- tion; but Benedicks and Arnold (9) believe that it is complete. The former belief that it is a definite phase, e.g. a solid solution of carbon or an iron carbide in either /3 or 7 iron, is- abandoned. Its carbon content like that of austenite and martensite varies widely. Occurrence. It arises either on reheating hardened (e.g. martensitie steel) to slightly below 400 deg., or on cooling through the transformation range at an inter- mediate rate, e.g. in small pieces of steel when quenched in oil, or quenched in water from the middle of the transformation range, or in the middle of larger pieces quenched in water from above the transformation range. With slightly farther reheating it changes into sorbite; with higher heating into sorbitic pearlite, then slowly into granular pearlite, and probably indirectly into lamellar pearlite. It occurs in irregular, fine- granular or almost amorphous areas, colored darker by the common etching reagents than the martensite or sorbite accompanying it. A further common means of dis- tinguishing it from sorbite is that it is habitually associated with martensite, whereas sorbite is habitually associated with pearlite. Areas near the boundary between troostite and sorbite are sometimes called troosto-sorbite. Properties. Hardness, intermediate between that of the martensitic and the pearlitic state corresponding to the carbon content of the specimen. In general the hardness increases, the elastic limit rises, and the ductility decreases, as the carbon content increases. Its ductility is increased rapidly and its hardness and elastic limit lowered rapidly by further tempering, which affects it much more markedly than sorbite. Sorbite (Fr. Sorbite, Ger. Sorbit). Aggregate. (Arnold, sorbitic pearlite.) Definition. In the transformation of austenite, the stage following troostite and osmondite if the stage is recognized, and preceding pearlite. Constitution and Composition. Most writers believe that it is essentially an un- coagulated conglomerate of irresoluble pearlite with ferrite in hypo- and cementite in hyper-eutectoid steels respectively, but that it often contains some incompletely transformed matter. Occurrence. The transformation can be brought to the sorbitic stage (1) by re- heating hardened steel to a little above 400 deg., but not to 700 deg. at which tem- perature it coagulates into granular pearlite; (2) by quenching small pieces of steel in oil or molten lead or even by air cooling them; (3) by quenching in water from just above the bottom of the transformation range, An. Sorbite is ill-defined, almost amor- phous, and is colored lighter than troostite but darker than pearlite by the usual etching reagents. It differs further from troostite in being softer for given carbon content, and usually in being associated with pearlite instead of martensite, and from pearlite in being irresoluble into separate particles of ferrite and cementite. As sorbite is essentially a mode of aggregation it cannot properly be represented APPENDIX NOMENCLATURE OF THE MICROSCOPIC CONSTITUENTS 471 on the equilibrium diagram. Its components at all times tend to coagulate into pearlite, yet it remains in its uncoagulated state at all temperatures below 400 deg. Properties. Though slightly less ductile than pearlitic steel for given carbon content, its tenacity and elastic limit are so high that a higher combination of these three properties can be had in sorbitic than in pearlitic steels by selecting a carbon content slightly lower than would be used for a pearlitic steel. Hence the use of sorbitic steels, e.g. first hardened and then annealed cautiously, for structural pur- poses needing the best quality. Manganese Sulphide (Fr. Sulphur de Manganese, Ger^ Schwefelmangan), MnS (Arnold and Waterhouse). Metaral. Occurrence, etc. Sulphur combines with the manganese present in preference to the iron, forming pale dove or slate gray masses, rounded in castings, elongated in forcings. Ferrous Sulphide (Fr. Sulphure de Fer, Ger. Schwefeleisen), FeS. Metaral. Occurrence. The sulphur not taken up by the manganese forms ferrous sulphide, FeS, which, probably associated in part with iron as an Fe-FeS eutectic, forms by preference more or less continuous membranes surrounding the grains of pearlite. Color, yellow or pale brown. Sulphur Prints. When silk impregnated with mercuric chloride and hydrochloric acid (Heyn's and Bauer's method) or bromide paper moistened with sulphuric acid (Baumann's method) is pressed on polished steel, the position of the sulphur-bearing areas, whether of FeS or MnS, records itself by the local blackening which the evolved H 2 S causes. Phosphorus bearing areas also blacken Baumann's bromide paper. MISCELLANEOUS Eutectoid, Saturated, etc. The iron-carbon eutectoid is pearlite. Steel with more carbon than pearlite is called hyper-eutectoid, that with less is called hypo-eutectoid. Arnold's names "saturated," "unsaturated," and "supersaturated," for eutectoid, hypo-eutectoid, and hyper-eutectoid steel respectively, have considerable industrial vise in English-speaking countries, but are avoided by most scientific writers on the ground that they are misleading, because, e.g. there is only one specific temperature, AI, at which eutectoid steel is actually saturated, and, if any other temperature is in mind, that steel is not saturated. Above AI it is clearly undersaturated. The objection to the names sorbite, troostite, martensite, and austenite, that each of them covers steel of a wide range of carbon content, is to be dismissed because a like objection applies with equal force to every generic name in existence. The theoretical matter in this report is given solely for exposition and the com- mittee disclaims the intent to impose any theory. This report is offered for adop- tion subject to this disclaimer on the ground that the adoption of theories is beyond the powers of a Congress. INDEX A, AT, Ac, Ar 3 , Ac 3 , Ar 3 . 2 , Acs. 2 , Ar 3 . 2 .i, Ac 3 . 2 .i, Ar cm , Acc m . See critical points, notation. Allotropic theory of the hardening of steel, 87, 309 Allotropy, definition of, 106 of cementite, 192 iron, 106 Alloy steels. See special steels. Alloys, constitution of, 407 , fusibility curves of, 411 to 427 , microstructure of, 411 to 427 of iron and carbon, equilibrium diagram of, 439 to 448 , fusibility curves of, 428 to 448 , phase rule applied to, 457 to 459 , structural composition immediately after solidification of, 429 , phase rule applied to, 454 to 459 , solidification of, 409 to 427 , structural composition of, 421 to 448 , whose component metals form solid solutions, solidification and constitution of, 411 to 415 are insoluble in each other in the solid state, solid- ification and constitution of, 415 to 423 partially soluble in each other in the solid state, solidification and constitution of, 417 to 448 Alpha iron, 182, 207 , crystallization of, 107 , description of, 106 theory of the hardening of steel, 310 Alumina powder for polishing, preparation of, 52, 53 American ingot iron, 101 Amorphous cement vs. boundaries of crystalline grains, 91, 103 heat treatment of pure metals, 97 the straining of metals, 94 Anhedrons. See allotrimorphic crystals. Annealing, air cooling in, 235 cold worked steel, 246 , cooling in, 233 , double treatment in, 240 for malleablizing cast iron, 401 , furnace cooling in, 235 , heating for, 231 , influence of maximum temperature in, 236 time at maximum temperature in, 239 , nature of operation, 231 of steel, 231 to 273 , oil and water quenching in, 239 '473 474 INDEX Annealing, purpose of, 231 , rate of cooling vs. carbon content in, 234 size of objects in, 234 steel castings, 248 temperatures for steel, 233 Austenite, crystallization of, 215, 262 , definition, description, occurrence, and structure of, 277 to 280 , Osmond's test showing relative softness of, 281 , relative softness of, 286 , saturated, 429 Austenitic and pearlitic structures, relation between, 263 special steels, 332 steel, tempering of, 300 B Baumann on sulphur printing, 45 Beilby on amorphous cement, 91, 94 Belaiew on the crystallization of steel and meteorites, 288 to 216 Benedicks' equilibrium diagram of iron-carbon alloys, 446 Beta iron, 183 , crystallization of, 107 , description of, 106 theory of the hardening of steel, 309 Binary alloys. See alloys. Bismuth, crystalline grains of, 90 Bivariant equilibrium, definition of, 454 Black heart castings, 401 , annealing for, 402 Brittleness, intercrystalline, 271 , intergranular, 271 of low carbon steel, 271 Burnt steel, production and structure of, 259 C Cameras, 27 to 33 Campion and Ferguson fusible alloy, 41 Carbide steel, 326 Carbon, condition of, in hardened and tempered steel, 305 , hardening and combined in steel, 305 in pearlite, 131 in steel, 119 solubility in iron, 364 temper, 398 theory of the hardening of steel, 310 Carpenter and Keeling's cooling curves of steels, 167 determinations of the critical points, 167 equilibrium diagram of iron-carbon alloys, 445, 446 Case hardened articles, heat treatment of, 324 steel, tempering of, 325 hardening by gas, 319 , composition of iron or steel subjected to, 315 , cooling after, 324 , distribution of carbon after, 316 , duration of, 316 , materials used for, 318 , mechansim of, 322 of steel, 315 to 325 INDEX 475 Case hardening, temperatures for, 315 Cast iron, calculation of structural composition of, 370, 375, 394 , chilled castings of, 378 , constitution, properties, and structure of, 304 to 397 containing only combined carbon, 369 graphitic carbon, 366 , eutectic, 379, 381 , formation of combined and graphitic carbon in, 366 , impurities in, 386 to 397 , influence and occurrence of manganese in, 387 phosphorus in, 388 silicon in, 386 sulphur in, 386 , malleable, 398-406 , solidification and cooling of, 381 , structural composition vs. physical properties of, 378 steel, structure of, 208 to 220 Castings suitable for malleablizing, 399 Cement carbon, definition of, 122 Cementation. See case hardening. 'o! iron and steel, 315 to 325 Cementite, allotropy of, 192 , definition and description of, 122 , etching of, 131 , free, definition of, 129 , graphitizing of, 257, 384, 398 in high carbon steel, 128 , primary. See cementite, pro-eutectic. , pro-eutectic, 432 , spheroidizing of, 252 Cementitic special steels, 326, 333 Chilled castings, 378 Chrome-nickel steel, 353 steel, 349 , uses and properties of, 349 -tungsten steel. See high-speed steel. Chromium, influence on critical points of iron of, 349 Cleavage, brittlenoss. See intercrystalline brittleness. definition of, 86 Cold working, crystalline growth after, 96 , influence on structure and properties of steel of, 227 Colloidal solution, 285 Components, definition of, 454 Condensers, 26, 27 Cooling and heating curves of iron and steel, 169 to 181 curves of pure metals, 407 Copper, microstructure of, 86 , twinnings in, 95 Critical points and crystallization, 200, 204 dilatation, 199 electrical conductivity, 200 magnetic properties, 203 , calorimetric method for determination of, 179 , Carpenter and Keeling's determination of, 167 , causes of, 182 to 198 , definition of, 158 , determination of, 169 to 181 , graphical representation of the position and magnitude of, 169 476 INDEX Critical points, heat absorbed or evolved at, 167 in high carbon (hyper-eutectoid) steel, 166 iron, description of, 163 medium high carbon steel, 165 pure iron, 163 very low carbon steel, 164 , influence of chemical composition on position of, 162 speed of heating and cooling on, 161, 162 , magnetic method for determination of, 179 , melting-points method for determination of, 179 , merging of, 165, 167 , metallographic method for determination of, 179 , minor, 167 , notation, 159 , occurrence of, 159 to 181 , relation between structure of steel and, 195 , their effects, 199 to 207 , thermo-electric method for determination of, 179 , use of neutral bodies in detecting, 173 range. See critical points, temperatures. See critical points. Crystalline grains. See grains. growth in metals on annealing, 96 of strained ferrite, 265 to 271 Crystallite of iron, 105 Crystallites, definition of, 87 Crystallization and critical points, 200, 204 , cubic, of metals, 90 of austenite, 208 iron, 103 steel, 208 , process of, 86, 87 Crystallography, systems of, 91 Crystals, allotrimorphic, definition of, 87 , cubic, of iron, 103 , definition of, 86 , formation of, 86 , idiomorphic, definition of, 87 , mixed. See mixed crystals. Cubic crystallization of iron, 103 metals, 90 Degrees of freedom, definition of, 452 liberty. See degrees of freedom. Desch's types of cooling curves, 177 Dilatation and critical points, 199 Divariant equilibrium. See bivariant equilibrium. Ductility of steel, structural composition vs., 141 E Electric arc lamps, 23 to 27 furnaces, 39 Electrical conductivity and critical points, 200 Electrolytic iron, crystallizing properties of, 111, 112 microstructure of, 101 Electromagnetic stages, 15 INDEX 477 Equilibrium, bivariant, definition of, 454 , definition of, 452 diagram. See fusibility curves. of iron-carbon alloys, 439 to 448 , Benedicks' diagram, 446 , Carpenter and Keeling's diagram, 445 , Roberts-Austen's diagrams, 442, 443 , Roozeboom's diagram, 444 , Rosenhain's diagram, 447 , Ruff's diagram, 449 , the author's early diagram, 441 , Upton's diagram, 448 , Wittorff's diagram, 450 , metastable, definition of, 453 , stable, definition of, 452 , univariant, definition of, 454 , unstable, definition of, 453 , unvariant, definition of, 454 Ktching, 42,_43, 62, 64 figures. See etching pits, for macrostructure, 47 of cementite, 43, 131 wrought iron, 45 pits, formation of, 90 in iron, 46, 104 nitric acid, 42 picric acid, 42 sodium picrate, 43 Stead's reagent, 43 Kutcctic alloys, 99, 120 , constitution and occurrence of, 415 to 427 , definition of, 418 , cast iron, 379 , iron-carbon, 429 Eutectoid, definition of, 121 steel, definition and structure of, 126, 127 Ewing and Rosenhain, straining of iron by, 110 metals, 92 Rosenhain's theory of crystalline growth of metals on annealing, 96, 97 F 1'errite, crystalline growth of, 265 , definition of, 104 , free, 121 in cast iron, 367 low carbon steel, 1 19 wrought iron, 114 Fibers in wrought, iron, llo Finishing temperatures, influence on the structure and properties of steel of, 223 Free cementite, definition of, 129 ferrite, 121 Furnaces, electric, 39 Fusibility curves of alloys, 411 to 427 iron-carbon alloys, 428 to 450 G Gamma iron, 182, 207 , crystallization of, 107 478 INDEX Gamma iron, description of, 106 , twinning in, 107 Ghost lines in steel, 153 to 157 Grading of steel vs. its carbon content, 118 Grain refining treatment, 241 Grains, crystalline orientation of, 90 , ferrite, 102 , orientation of, 102 , growth of, on annealing, 96 of metals, definition and formation of, 89 , heterogeneousness of, 89 Graphitic carbon, factors influencing formation of, 366 in cast iron, 366 Graphitizing of cementite, 257, 384, 398 in malleablizing cast iron, 398 Granulation of steel, 209 Gray cast iron, 366 vs. malleable cast iron, 406 Guillet's theory of special steels, 326 H Hadfield steel.. 345 Hard castings, 399 Hardened and tempered steel, microstructure of, 304 Hardening and tempering in one operation, 297, 299 carbon, definition of, 305 theory of the hardening of steel, 311 , cooling for, 275 , heating for, 274 of steel, 274 to 297 , theories of, 308 to 314 , structural changes on, 276 theories of the hardening of steel, classification of, 308 Hardenite, definition, occurrence, and properties of, 291 Heat tinting, 44 treatment of case hardened articles, 324 iron, influence of, 110, 111 metals, influence of, 96 Heating and cooling curves of iron and steel, 169 to 181 High-speed steel, 354 to 363 , composition of, 355 , discovery by Taylor and White of, 354 , etching of, 47, 361 , heating and cooling curves of, 357 to 361 , microstructure of, 355 , properties of, 354 , theory of, 356 , treatment of, 354 Hot working, influence on structure and properties of steel of, 221 to 225 Hyper-eutectoid steel, definition and structure of, 127 Hypo-eutectoid steel, definition and structure of, 127 I Idiomorphic crystals, definition of, 87 Igevsky, picric acid etching, 42 Illumination for microscopical work, 18 to 27 Illuminators, vertical, 20 to 22 Impurities in cast iron, 386 to 397 INDEX 479 Impurities, in metals, influence of, 97 to 100 steel, 143 to 157 , segregation of, 153 influence on iron of, 112 Ingot iron, 101 Ingotism, 220 Intercrystalline brittleness, 271 Intergranular brittleness, 271 Interstrain theory of the hardening of steel, 313 Invar (nickel steel), 343 Inverted microscope, 31 to 33 Iris diaphragms, 11 Iron, affinity for carbon of, 315 , allotropy of, 106 , alpha, 182, 207 , description of, 108 , beta, 182, 207 * , description of, 108 -carbon alloys, equilibrium diagram of, 439 to 450 , fusibility curves of, 428 to 450 , phase rule applied to, 455 to 459 , structural composition immediately after solidification of, 430 eutectic, 429 , cementation of, 315 to 325 -cementite fusibility curve. 428 , cooling and heating curves of, 169 to 181 , critical points of, 163, 182 crystallite, 104 , crystallization of, 102, 107 , crystallizing of, 111, 112 , cubic crystals of, 103, 104 , electrolytic, microstructure of, 101 , etching in hydrogen, 117 pits in, 104 , gamma, 182, 207 , description of, 108 -graphite fusibility curve, 434 , influence of chromium on critical points of, 349 heat treatment of, 110, 111 impurities on, 112 mechanical treatment of, 110 nickel on dilatation of, 343 tungsten on critical points of, 346 , microstructure of, 101 oxide in steel, 153 , slip bands in, 110 , straining of, 92 sulphide in steel, 146 Irreversible steels, 337 Isomorphous mixtures, definition of, 98 K Kourbatoff's etching to color cementite, 43 reagent for hardened steels, 63, 280 L Le Chatelier's inverted microscope, 67 to 71 Ledebur's temper carbon, 398 480 INDEX Lieberkuhn, 20 Lights for microscopical work, 18 to 27, 50 Liquidus, definition of, 410 M Macrostructure, etching for, 47 Magnetic properties and critical points, 203 method for determination of critical points, 179 specimen holders, 12 Magnifier, vertical, 23 Malleable cast iron, 398 to 406 , annealing for the manufacture of, 400 , packing materials for the manufacture of, 400 vs. gray cast iron, 406 castings. See malleable cast iron. Manganese in cast iron, influence and occurrence of, 387 steel, 148 oxide in steel, 150 steel, 343 to 346 , austenitic, 345 , martensitic, 345 , pearlitic, 344 , water-toughening of, 345 sulphide in steel, 145, 151 Manipulations, 40 to 50 Martensite, definition, description, occurrence, properties, etching, and structure of, 283 Martensitic special steels, 332 steel, tempering of, 302 Matweieff's etching to color cementite, 43 method of etching slag in wrought iron, 1 17 Maurer, production of austenite by, 279 Mechanical refining, 229 stages, 8 treatment of iron, influence of, 110 metals, influence of, 96 steel, 221 to 225 Metallic alloys. See alloys. , constitution of, 407 to 427 Metallographic laboratory, apparatus for, 5 Metallography, industrial importance of, 1 Metalloscope, universal, 14 to 18 Metals, cooling curves of, 407 , crystalline growth on annealing, 96 , crystallization of, 87 , cubic crystallization of, 90 , definition and formation of grains of, 89 , influence of heat treatment, 96, 97 mechanical treatment of, 96 , latent heat of solidification of, 408 , phase rule applied to, 455 , solidification of, 407 Metarals, definition of, 293 Metastable equilibrium, definition of, 453 Meteorites, microstructure of, 212 Microscopes and accessories, 5, 67 to 85 , inverted, 31 to 33, 67 Microstructure of cast steel, 208 to 220 electrolytic iron, 101 INDEX 481 Microstructure of hardened and tempered steel, 304 high carbon steel, 126 sulphur steel, 145 impure gold, 99 low carbon steel, 119 medium high carbon steel, 124 meteorites, 212 pure copper, 86, 89 gold, 86 iron, 101 metals, 86 worked steel, 221 to 230 wrought iron, 113 to 117 Mixed crystals, definition of, 98 Mohs scale of hardness, 123 Molybdenum steel, 351 Monovariant equilibrium. Sec univariant equilibrium Mottled cast iron, 375 N Nachet illuminating objectives, 22 prism vertical illuminator, 21 Nernst lamp, 25 Neumann's lines, 96, 109 Neutral bodies for the detection of critical points, 173 Nickel, influence of, on critical points of iron, 337 dilatation of iron, 343 steel, 336 to 343 , austenitic, 342 , case hardening of, 342 , critical points of commercial, pearlitic, 339 , hardening and annealing of, 339 , martensitic, 342 , pearlitic, 337 , properties of pearlitic, 338 Nitric acid etching, 42 Non-variant equilibrium. See unvariant equilibrium O Objectives, 8 Orientation of crystalline grains, definition of, 90 ferrite grains, 102 Osmond,' and Cartaud on the crystallization of iron, 107, 108 , on polishing, 51, 61 , production of austciiite by, 277 Osmondite, definition, description, and occurrence of, 303 Overheating, 258 , P Parabolic reflector, 20 Patented wire, 247 Patenting, 247 Pearlite, carbon content of, 131 , definition and description of, 120 , formation of, 190 in high carbon steel, 126 low carbon steel, 120 , varieties of, 256 482 INDEX Pearlitie special steels, 331 Phase rule applied to alloys, 454 iron-carbon alloys, 457 metals, 455 , definition of, 454 , enunciation and explanation of, 452 Polymorphism, 1()ti Phosphorus in cast iron, influence and occurrence of, 388 steel, 144 Photography. See photomicrography. Photomicrographic cameras, 27 to 33 Photomicrography, 48 Picrate of sodium etching, 43 Picric acid etching. 42 Pits. See etching pits. Planes of cleavage. See cleavage. Platinite (nickel steel), 343 Point of recalescence. See recalescence point. Polishing, 40, 41, 51 to 62 machines, 34, 35, 51 to 61 Polyhedral special steels, 326, 332 Polymorphism. See allotropy. Portevin's etching for macrostructure, 47 Potentiometer, 36 Preserving samples. 64 Prism vertical illuminator, 21, 84 Pseudomorphism, definition of, 304 Pure metals, crystallization and microstructure of, 86 Pyrometer, Lc Chatelier thermo-electric, for the determination of the critical points, 36 Pyrometers, 36 , self-recording, 37 to 39, 178 Q Quaternary steels, 335. See also special steels, vanadium steels, 340 Quenching in annealing, 240 Recalescence point, description and occurrence of, 158 Red-shortness in steel caused by sulphur, 147 Refining, mechanical, 229 Retardations. See critical points. Retention theories of the hardening of steel, 308 Reversible steels, 337 Revillon on preparation of alumina for polishing, 53 Roberts-Austen's equilibrium diagrams of iron-carbon alloys. 444 use of neutral bodies for detecting critical points, 39, 173 Robin, 'on preparation of alumina for polishing, 53 production of austenite by, 278 Rohl on sulphur printing, 45 Roozeboom's equilibrium diagram of iron-carbon alloys, 444 Rosenhain and Ewen, on amorphous cement, 91 Ewing. See Ewing and Rosenhain. Humfrey, straining of iron by, 110 Rosenhain's equilibrium diagram of iron-carbon alloys, 447 Ruff's equilibrium diagram of iron-carbon alloys, 449 INDEX 483 Saladin self-recording pyrometer, 37 to 39 Saladin's cooling and healing curves of steels, 175 Segregation of impurities in steel, 153 Self-hardening steel, 348 -recording pyrometers, 37 to 39, 178 Silicates in steel, 150 Silicon in cast iron, influence and occurrence of, :>sii steel, 143, 144 steel, 352 Slag in wrought iron, 114, 110, 117 , composition of, 11G Matweieff's method of etching, 117 , microstructurc of, 116 Slip bands, description and production of, 92 in iron, 110 Sodium picrate etching, 43 Solid solutions, 409 , definition of, 98 Solidus, definition of, 410 Solution theories of the hardening of steel, 309 Sonims, 143. 150 Sorbitc, definition, description, and formation of, 225, 230, 289 Sorby-Beck parabolic reflector. 20 Special steels, 326 to 363 , austcnitic, 332 , cementitic, 333 , constitution, properties, treatment, and uses of most important types, 320 to 335 , definition and general character of, 326 to 335 , influence of special elements on position of critical range in, 328 , martensitic, 332 . pearlitie, 331 , polyhedral, 332 , treatment of, 333 Specimen holders, 11 to 11 Spheroidizing of cementite, 252 Stable equilibrium, definition of, 453 Stages, electromagnetic, 15 , leveling 60 , mechanical, 8 Stead and Carpenter on the crystallizing properties of electrolytic iron, 111, 112 on heat-tinting, 44 phosphorus in cast iron, 388 to 392 the briulcness of low carbon steel, 271 crystalline growth of very low carbon steel, 265 on polishing, 53 to 55 Steadite, definition and description of, 390 Stead's brittlcness, 273 etching reagent for detection of phosphorus, 43 Steel, annealing of, 231 to 273 , temperatures of, 232 , brittlenesis of low carbon, '271 , burning of, 259 , calculation of structural composition of, 132, 148 , carbon in, 119 , case hardening of, 315 to 325 484 INDEX Steel castings, annealing of, 248 , causes of critical points in, 182 to 198 , cementation of, 315 to 325 , chemical tests for the detection of sulphur in, 44, 45, 148 vs. structural composition of, 134, 148 , chrome, 349 -nickel, 353 , constitution, properties, treatment, and uses of most important types of special, 33(i to 363 , cooling and heating curves of, 169 to 181 , critical points of, 158 to 207 , crystallization of, 208 , ductility vs. structural composition of, 141 , effects of critical points in, 199 to 207 , eutectoid, definition and structure of, 126, 127, 216 , formation of graphite in high carbon, 257 , ghost lines in, 153 to 157 , grading of, 118 , hardening of, 274 to 297 , high carbon, cementite in, 127 to 131 , microstructure of, 126 to 131 , pearlite in, 126 -speed, 354 to 363 , etching of, 47 , hyper-eutectoid, definition and structure of, 127, 218 , hypo-eutectoid, definition and structure of, 129, 216 , impurities in, 143 to 157 , influence of cold working on the structure and properties of, 227 finishing temperatures on the structure and properties of, 223, 229 hot working on the structure and properties of, 221 , iron oxide in, 153 sulphide in, 146 , irreversible, 337 , ferrite in, 119 , microstructure of, 119 to 121 , pearlite in, 120 vs. wrought iron, 118 , manganese, 343 to 346 in, 148 oxide in, 152 sulphide in, 145, 151 , maximum strength of, 140 , mechanical refining of, 229 treatment of, 221 to 225 , medium high carbon, microstructure of, 124, 125 , micro-test for determination of carbon in, 135 , pearlite in, 124 , nickel, 336 to 343 , normal structure of, 118 , occurrence of critical points in, 158 to 181 of maximum hardening power, 296 overheated, 259 phosphorus in, 144 , physical properties of constituents of, 137 , production and structure of burnt, 259 , relation between structure above and below the critical range of, 262 and critical points of, 195 , reversible, 337 INDEX 485 Steel, segregation of impurities in, 153 to 157 , self-hardening, 34-S , silicates in, 150 , silicon, 352 in, 142, 143 , special, 326 to 363 , structural changes on cooling in, 187 composition of, 132, 133 , structure of cast, 208 to 220 worked, 221 to 230 , sulphur in, 145, 151 , tempering of hardened, 298 to 306 , tenacity vs. structural composition of, 138 to 140 , theories of hardening of, 308 to 314 , tungsten, 346 , vanadium, 349 vs. carbon content, grading of, 118 , \\idmanstatten structure in, 212 Straining of iron, 92, 110 , crystalline growth after, 96 of metals, 92, 94 Stress theories of the hardening of steel, 311 Structural composition of alloys, 221 to 226 cast iron, calculation of, 370, 375, 395 iron-carbon alloys immediately after solidification, 430 steel, calculation of, 92, 132 to 134' Subcarbide theory of the hardening of steel, 311 Sulphur in cast iron, influence and occurrence of, 388 steel, 145 , chemical tests for the detection of, 44, 45, 151 printing, 44, 45, 148 Taylor and White's discovery of high-speed steel, 354 Temper carbon, 398 Temperatures for annealing steel, 232 Tempering and the retention theories of the hardening of steel, 313 stress theory of the hardening of steel, 313 colors, 298 , decrease of hardness on, 306 , explanation of, 298 , heat liberated on, 307 , influence of rate of cooling in, 299 time in, 299 of austenitic steel, 300 case hardened steel, 325 hardened steel, 298 to 306 martensitic steel, 302 troostitic steel, 302 temperatures, 298 Tenacity of steel vs. structural composition, 138 to 140 Ternary steels, 326. See also special steels. Thermal critical points. Sec critical points. treatment. See heat treatment. Toughening treatment, 241 Transformation points. See critical points, range. See critical points. 486 INDEX Transition const it uents. See also martensite, troostite, and sorbite. , definition and formation of, 293 Troostite, definition, description, occurrence, properties, etching, and structure of, 285 Troostitic steel, tempering of, 302 Troosto-sorbite, 290 Tschernoff iron crystallite, 105 Tungsten, influence on the critical points of iron of, 346 steel, :;iii Twinnings, and amorphous iron theory, 313 definition of, 95 in copper, 95 gamma iron, 107 marble, 94 produced by pressure, 95 > U Univariant equilibrium, definition of, 454 Universal metalloscope, 14 to 18 Unstable equilibrium, definition of, 453 Unvariant equilibrium, definition of, 454 Upton's equilibrium diagram of iron-carbon alloys, 448 Vanadium steel, 349, 353 Vertical illuminators, 18 to 23 magnifier, 23 W Water-toughening of manganese steel, 345 Welsbach lamp, 23 Widmanstatten structure, 212 Wittorff's equilibrium diagram of iron-carbon alloys, 450 White, cast iron, 369 heart castings, 401 , annealing for, 401 Maunsel. See Taylor and White. Workshop microscopes, 81 to 84 Wrought iron, composition of, 113 , definition of, 113 , etching of, 45 , fibers in, 115 , microstructure of, 114 to 116 , slag in, 114, 116, 117 vs. low carbon steel, 118 Y Yatscviteh, M., etching of high-speed steel, 47 Z Zciss prism illuminator, 21 UNIVERSITY OF CALIFORNIA LIBRARY BERKELEY Return to desk from which borrowed. This book is DUE on the last date stamped below. 8 1947 LD 21-100m-9,'47(A5702sl6)476 6 >,' . -H THE UNIVERSITY OF CALIFORNIA LIBRARY