Abstract: A high strength mortar has been developed for use with silica brick, in the construction of coke-oven heating walls. When fired to conventional coke oven temperatures of about 1100.degree. C., the mortar develops a tensile strength within the mortar itself, and a tensile bond to the silica brick, which exceeds the tensile strength of the silica brick. The mortar is composed of three primary solid constituents: 25 to 88 percent SiO.sub.2, 6 to 65 percent Al.sub.2 O.sub.3 and 4 to 12 percent P.sub.2 O.sub.5. To achieve such high tensile strength, the other solid constituents must be maintained at a minimum, desirably less than four percent and preferably less than two percent. Use of the high strength mortar permits construction of coke oven walls which can withstand significantly increased coking pressures--resulting in two significant benefits; (i) productivity increases of the order of 10 to 15 percent and (ii) doubling the service life of a coke oven wall.

Abstract: The invention is directed to an electrotreating apparatus, utilizing horizontal-pass electrotreating cells wherein the strip passes through the corridors of one or more of such cells. Electrolyte is caused to flow through the corridor(s) and overflow into a collector tank for recycle through the system. Electrode replacement is facilitated by inserting the electrodes through the outer walls of each corridor. Proper sealing of such electrodes is achieved by utilizing an electrode with a T-shape cross-section, in which the top of the T is a flange for exerting a bearing, liquid-tight sealing force against the outer surface of the corridor wall, while the vertical portion of the T comprises that part of the electrode which is inserted into a hole in the corridor wall.

Abstract: In the production of coined sheet products, particularly sheet steel, rolling pressures sufficient to produce a decorative pattern often result in the formation of undesirable "spikes" on the sheet surface. These "spikes" can require numerous paint coatings for effective coverage. Spikes are eliminated by use of a roll design in which the peaks of the pattern roll are provided with a severely sloping draft angle, the minimum angle for "spike" elimination being a function of the roll diameter, the coined depth of the pattern, the thickness and hardness of the sheet itself and the ratio of the volume of the pattern peaks to the pattern valleys.

Abstract: Large diameter pipes or culverts carrying water or other corrosion producing liquids are cathodically protected by securing, spaced-apart, segment-like elements along the bottom inner (invert) surface of the pipe to effect a partial damming of the liquid therein, causing such surface to remain wet during periods in which the input of liquid is substantially decreased or halted. The achievement of such a continuously wet invert surface provides continuous electrolyte conduction, resulting in both (a) enhanced corrosion protection and (b) greater efficiency in use of the protective anodes.

Abstract: A method for decreasing the extent of crop loss during rolling of ingots to semifinished products, such as slabs and blooms, in which a lighter than usual draft is taken during the odd pass, i.e. as the ingot bottom enters the rolls. During the subsequent even pass, as the ingot top enters the rolls, the draft taken is of the usual order of magnitude. These steps of alternate light and heavy passes are conducted until the ingot thickness is about twice the length of the maximum practically achievable contact arc--then the normal drafting sequence is utilized. A yield gain of about 1% or greater may thus be achieved by using such controlled counter-drafting.

Abstract: In the hot-dip coating utilizing molten metals in which the partial pressure of the metal vapor is substantial at the coating temperature, the resultant metal vapor in the snout area over the metal bath tends to cause pinhole type imperfections on the resultant coating. For example, substantial vaporization occurs during high temperature galvanizing and during hot-dip coating of Al-Zn, in which Al is a major constituent, such that the bath must be maintained at a high enough temperature to keep the aluminum molten. The accumulation of such vapors inside the snout area is minimized by (i) utilizing baffles within the snout to isolate it as much as possible from the cooling section of the annealing furnace, and (ii) venting a portion of the gas from the snout.

Abstract: Hot-dip coated steel articles having a coating containing about 55% aluminum, 43% zinc, 2% silicon, are known to exhibit an optimum combination of general corrosion resistance, more durable than zinc coatings; while providing more galvanic protection to cut edges and areas of mechanical damage than hot-dip aluminum coatings. It has now been found that coatings containing 12 to 24% zinc, up to 4% silicon, balance aluminum, provide galvanic protection equal to or superior to such known coatings, while providing enhanced general corrosion resistance, approaching that of aluminum coatings.

Abstract: The invention is directed to an electrotreating apparatus, utilizing a vertical-pass electrotreating cell wherein the strip passes over a conductor roll, through one corridor of the cell, around the sink roll, up through a second corridor of the cell and over a second conductor roll. Electrolyte is caused to flow from the lower portions of each corridor, up through the corridors and overflow into a collector tank for recycle through the system. Rather than support electrodes from the top of each corridor, electrode replacement is facilitated by inserting the electrodes through the outer walls of each of the corridors. Proper sealing of such electrodes is achieved by utilizing an electrode with a T-shape cross-section, in which the top of the T is a flange for exerting a bearing, liquid-tight sealing force against the outer surface of the corridor wall, while the vertical portion of the T comprises that part of the electrode which is inserted into a hole in the corridor wall.

Abstract: Conductor rolls used for masking one face of a metal strip while electro-treating the other face thereof, comprise an elastomeric-covered cylinder having a metallic contact ring in the center thereof for electrical contact with the strip being treated. To minimize high transfer current densities, the edges of these contact rings have been provided with a cantilevered flange overlying a portion of the elastomer. It has been found, due to differential thermal expansion, at operating temperature, of both the elastomer and the metal contact ring, that the cantilevered flange section of the contact ring is forced up to an excessive extent, resulting in high bending stresses generated in the strip at the region of the contact ring-elastomer interface. By providing a taper on the cantilever flange section to compensate for the difference in thermal expansion, bending stresses in the strip are reduced to insignificant values, thereby eliminating creases and scratches in the strip.

Abstract: In the decarburization annealing of steel strip, wherein the annealing atmosphere flows counter to the strip motion in the furnace, there is an undesirable buildup of carbon monoxide in the zone where the strip enters the furnace. Carbon monoxide is undesirable because it slows the decarburization of the strip by a back reaction. The carbon monoxide is removed from the buildup zone and catalytically converted to methane and water by a known reaction with hydrogen, and the water and methane are in-turn recycled near the buildup zone of the furnace. It was found that the presence of water at temperatures up to 1600.degree. F. prevents methane from acting as a carburizing agent.

Abstract: In the hot-dip coating of wire, a sinker assembly is utilized for guiding the wire during its travel through the molten metal bath. The outer perimeter or bearing surface around which the wire is wrapped is composed of alumina or other refractory segments housed within the sinker assembly. The discrete segments are provided with a small clearance to permit some movement, within the confines of the housing, along the locus of the wire travel. The outer surface of the discrete segments is grooved, so that the wire wrapped therearound bears solely on the internal sides of the groove.

Abstract: A pierced billet is fed to a plug rolling mill, wherein the first rolling pass is effected in conventional manner, i.e. the shell is rammed over a forming plug mounted on the front end of the mandrel and then drawn over the plug by the work-rolls. Rather than removing the shell from the mandrel and returning it to the entry side of the mill, the second pass on the shell is effected by reversing the rotation of the work-rolls and pushing the shell back through the reverse rotating work-rolls over the same plug whereby, in effect, the original exit side of the mill now becomes the entry side. This double passing over the same plug is achieved through the use of a newly designed plug, tapered in both directions, wherein the plug is connected to the mandrel so as to transmit the tension force on the plug to the mandrel.

Abstract: A high-strength, low-alloy steel sheet containing 0.01 to 0.1 percent C, 0.3 to 1.2 percent Mn, 0.03 to 0.15 percent Cb consistently produces yield strengths ranging from 75 to 100 ksi when the potential for placing and maintaining the Cb in solution in austenite is maximized, by adding sufficient titanium to combine with the nitrogen in the steel. The amounts of titanium employed, i.e. 0.010 to 0.045 percent, are substantially leaner than heretofore thought necessary to achieve such high yield strengths.

Abstract: The wear on surfaces subject to abrasion or erosion by abrasive particles is materially reduced or eliminated by providing such surface with a magnetic attraction sufficient to hold an amount of magnetic or magnetizable particles to provide a sacrificial layer of such particles, whereby such layer acts to protect the surface lying thereunder from wear.

Abstract: The resistance of AISI 4130-type steels to hydrogen-induced corrosion phenomena is materially enhanced by the addition of at least about 0.3% of a metal selected from the group consisting of platinum, palladium, silver or mixtures thereof.

Abstract: A method for preventing the overcharging of coal into a coke oven system in which preheated coal is transported from a storage container to the coke ovens by means of a substantially enclosed continuous conveyor system filled with inert gas. A portion of inert gas within the enclosed conveyor system is carried along with the coal into the coke oven itself. During filling of the oven, this inert gas is carried up and out of the oven standpipes. When the oven becomes filled, however, the standpipe escape route becomes blocked resulting in a rapid pressure build-up within the system. This rapid pressure build-up is utilized to generate a signal to stop further filling of the oven. The instant method may be employed as a primary regulating system, but is more preferably employed as a back-up to conventional sensor probes used for regulating the level of coal.

Abstract: A patching composition for developing a superior bond with silica refractories at temperatures of 1200.degree. to 2400.degree. F. The composition comprises three basic components: (1) a high melting phase, e.g. silica brick, fireclay grog, magnesia or high alumina grain, (2) a bonding component, e.g. sodium silicate and (3) a low melting phase, e.g. window glass. It will generally be desirable to employ a fourth component for fluxing, such as soda ash or other alkaline earth compounds. The improved results are achieved by the use primarily, of a low melting phase such as window glass, bulb glass or lead glass having a softening point between about 900.degree. and 1750.degree. F. (482.degree. to 954.degree. C.), employed in an amount of about 6 to 25% of the total solids composition.

Abstract: A patching composition for developing a superior bond with silica refractories at temperatures of 1200.degree. to 2400.degree. F. The composition comprises three basic components: (1) a high melting phase, e.g. silica brick, fireclay grog, magnesia or high alumina grain, (2) a bonding component, e.g. sodium silicate and (3) a low melting phase, e.g. window glass. It will generally be desirable to employ a fourth component for fluxing, such as soda ash or other alkaline earth compounds. The improved results are achieved by the use primarily, of a low melting phase such as window glass, bulb glass or lead glass having a softening point between about 900.degree. and 1750.degree. F. (482.degree. to 954.degree. C.), employed in an amount of about 6 to 25% of the total solids composition.

Abstract: In the bottom blown process for the refining of molten steel, additional heat is generated for melting greater amounts of scrap, by injecting at least one secondary stream of an oxygen-containing gas to the space above the molten metal bath so as to combust the CO and H.sub.2 evolving therefrom. The excess heat so generated is absorbed both by the bath and the furnace lining, causing overheating and rapid deterioration of the lining. For a given quantum of heat so generated the ability of the molten metal to absorb a greater portion of that heat and thereby maintain the temperature of the furnace lining within the practical limits has been found to depend to a significant extent on the design of the furnace itself. The invention is directed to conducting the refining process in vessels which provide, for a given bath capacity, greater top surface areas than has heretofore been employed.

Abstract: Steel compositions which provide a combination of high-strength with good low-temperature toughness, are made more economical to produce by the addition of small amounts of copper, molybdenum and chromium to reduce the amount of nickel required for such properties. For steels containing less than 1.5% nickel, low temperature toughness can further be improved without any sacrifice in strength by maintaining the silicon content below 0.1%, and preferably below 0.05%.