Abstract: A method is provided for detecting the spalling off of a significant portion of buildup of alkali and/or metal from the refractory lining of a metallurgical furnace. The method includes monitoring the rate of change of temperature of the refractory lining at a plurality of spaced locations and determining when the rate of change of temperature at a predetermined number of such locations exceeds a first threshold level that a significant portion of buildup has spalled off. The invention is particularly applicable to blast furnaces and permits the addition of heat to be made to the molten metal in the furnace before the spalled off portion descends through the furnace shaft and reaches the molten metal.

Abstract: A method of producing a fully stabilized extra low carbon porcelain enameling steel having excellent formability and fish scaling resistance as well as superior enamel adherence. The method includes hot rolling a slab to strip, the slab having a composition consisting essentially of in weight percent: 0.005 max. C, 0.35 max. Mn, 0.015 max. P, 0.015 max. S, 0.015 max. Si, 0.025 to 0.055 Al, 0.006 to 0.015 N, 0.03 to 0.06 Ti, 0.02 to 0.05 Cb, up to 0.03 Sb, the balance Fe and inevitable impurities. The hot rolled strip is cold rolled at least 65% and box annealed until a cold spot temperature within the range of 610 to 705 degrees C. is reached. The invention includes the product made according to the process.

Abstract: Chromium electroplating of steel strip, to make tin-free steel, is conducted in an electrolytic bath containing predominantly HCrO4− ions rather than the conventional [HCr2O7]− or Cr2O7= ions. The electrolytic bath is dilute, reducing the amount of chrome-containing waste, and the dilute chromic acid rinse water may be recycled to the electrolytic bath, thus eliminating the waste disposal problem of the rinse water.

Abstract: An inspection station and process for pipe or other ferromagnetic articles utilizes a generally straight flux field amplifier made of a multi-stranded cable surrounded by non-conducting resin, for inducing transverse lines of magnetic force. The flux field amplifier is surrounded by a coil which is also energized to make longitudinal lines of force; the two types of lines of force are vectored. The pipe or other ferromagnetic article is sprayed with UV-sensitive magnetic particles in a more or less conventional manner to display the vectored lines of force together with any flaws in the metal. The cable core of the flux field amplifier does not need a cooling system and is able to last longer than conventional solid cores.

Abstract: A method is provided for enhancing the adhesion of organic polymer coatings to electrolytically passivated (CDC) tin-plated steel strip. The method includes applying a solution comprising 0.1 to 7 percent of an adhesion promoter to the electrolytically tin-plated strip during the processing of the strip on an electrolytic tin-plating line. The adhesion promoter may be at least one selected from the group consisting of: where n is within a range of from 4 to 99; (b) C16H33+N(CH3) 3 M where M is member of the halogen group; and (c) Rn—Si—(X)4−n where R is a non-hydrolyzable organic radical selected from the group consisting of glycol, epoxy, amine, diamine or mercapto groups, and mixtures thereof, containing from 3 to 10 carbon atoms; the number n is an integer from 1 to 3; and X is a hydrolyzable group selected from the group consisting of Cl—, OCH3, OCH2CH5, OOCCH3, OCH2OCH3, amine, diamine, triamine, acyloxy and alkoxysilanes, and mixtures thereof.

Abstract: Radar is used to measure not only the level of slag on molten steel but also its thickness; the measurement is used to calculate the volume of slag, and, in turn the amount of additives for slag treatment. Time-of-flight data are used to identify peaks representing the distances of the surfaces of the slag and the surface of the underlying steel. The concept is applicable to other materials of differing composition, and particularly where the underlying material is relatively more conductive than the overlying material.

Abstract: A method for predicting the bulk density of coal after it is dropped from a known height into a container from measurements of bulk density and moisture content of the coal before it is dropped into the container. The method includes obtaining a plurality of samples of coal, measuring the bulk density of each coal sample by directing nuclear radiation through the coal, subsequently dropping each sample from said known height in a test facility and measuring the bulk density of each coal sample after drop, measuring the moisture content of each coal sample, determining a correlation between the bulk density of said coal samples after drop with the bulk density determined before drop and the moisture content, and predicting the bulk density of coal after drop into a container from subsequent measurement of the bulk density and moisture content and the previously determined correlation from test facility measurements.

Abstract: Radar is used to measure not only the level of slag on molten steel but also its thickness; the measurement is used to calculate the volume of slag, and, in turn the amount of additives for slag treatment.

Abstract: A process of recovering iron values and separating zinc oxides and other contaminants from steel mill waste metal oxides, such as blast furnace dust, BOF dust, mill scale and oily sludges, characterized by iron metallization levels up to 95% or more and zinc oxide removal in excess of 99%, and including the steps of blending the oxides with coke breeze in an amount sufficient to provide a total carbon content of 16% to 22%, the coke breeze having a particle size of 50% or more plus 60 mesh or larger, briquetting the blend to form briquettes having a thickness ranging from 1/2" to 3/4", and firing the briquettes in a rotary hearth furnace to metallize the iron and evolve zinc and other oxide contaminants.

Abstract: A substantially carbon free (e.g. 50-80 ppm carbon max.) iron base melt is strip cast to provide a cast strip having a low strength, high ductility, essentially ferrite matrix substantially free of hardening acicular ferrite, bainite and martensite phases. The strip strength may be enhanced by subjecting the strip to a carburizing or nitriding treatment either directly after casting or after casting followed by cold rolling and annealing.

Abstract: A method is provided for machining threads on cylindrical parts, particularly oil country tubular goods, by mounting four thread-cutting chasers in a die head of a thread cutting machine. The thread chasers are each of unique profile, which enables the cutting of threads to close tolerance and decreases metal burrs on the first and last threads cut on the part by reducing the total tool cutting forces imposed on the part and said threading machine.

Abstract: A high performance weathering steel having a minimum yield strength of 70-75 ksi and a yield/tensile ratio less than about 0.85 is produced from a steel composition consisting essentially, in weight percent, of about: carbon 0.08-0.12%; manganese 0.80-1.35%; silicon 0.30-0.65%; molybdenum 0.08-0.35%; vanadium 0.06-0.14%; copper 0.20-0.40%; nickel 0.50% max.; chromium 0.30-0.70%; phosphorous 0.010-0.020%; columbium up to about 0.04%, titanium up to 0.02%, sulfur up to 0.01%, iron, balance except for incidental impurities; heating the steel to a hot rolling temperature, rolling the steel to a thickness about 2 to 3 times the final desired thickness, air-cooling the steel to a temperature of about 1800-1850.degree. F. (RCR) or about 1600-1650.degree. F. (CCR), recrystallize control rolling or conventionally control rolling the steel with finish rolling at a temperature of about 1700-1750.degree. F. (RCR) or about 1400-1500.degree. F. (CCR), then water-cooling the steel to about 900-1200.degree. F.

Abstract: Continuous electrolytic tin plating is accomplished in a bath containing 90-160 g/L sulfuric acid, 4-70 g/L tin ion and a grain refiner, and 1-4% nonylphenol ethoxylated with 8-10 ethylene oxide groups, having a weight average molecular weight of 616.+-.18, at a speed of 900-1600 feet per minute and a current density as much as 1500 amperes per square foot or more.

Abstract: A system is provided for measuring the concentration of an element in molten metal such as silicon, chromium, manganese or aluminum. The system includes a probe with a sensor having a solid electrolyte, a reference electrode in contact with a first surface of the electrolyte and an auxiliary electrode at a second surface thereof. The auxiliary electrode includes an oxide of the element to be measured and a metal-silicate selected from the group consisting of alkali metal-silicates, alkaline earth metal-silicates and mixtures thereof. The metal-silicate has a working point at about the temperature of the molten metal so as to form a viscous semi-molten mass adjacent the second surface of the electrolyte. The metal-silicate is capable of diffusing oxygen in the semi-molten state. Preferably the metal-silicate is in the form of a fibrous material so that it can be easily applied to the surface of the electrolyte.

Abstract: The present invention is of a mandrel bar assembly for a seamless pipe mill. The assembly includes a pair of tooling sections each having a tapered end, a reduced diameter portion axially inward of the tapered end adapted to be gripped by a retaining means of the mill, and a working portion adjacent the reduced diameter portion extending from the reduced diameter portion to the end opposite the tapered portion. The assembly includes a coupling for connecting the tooling sections together end-to-end with the tapered ends facing oppositely outward therefrom. An adapter is provided to cover the reduced diameter portion and provide a working surface thereon of one tooling section that is to be positioned as the lead end into the mill. When one tooling section wears the adapter can be removed and installed on the other tooling section, and the assembly is reversed end-to-end to use the other tooling section as the lead end, extending the useful life of the assembly.

Abstract: A ladle preheating system and method in which heat input rate to the ladle is calculated and monitored throughout the preheating period, calculating the moving average slope representing change over time of the rate of change of heat input, correcting the moving average slope for unavoidable variations in the measurements of the heat input rate, calculating the change of the moving average slope over time (the approximate second derivative), and signaling to an operator the readiness of the ladle based upon this second derivative's falling below a preset criteria indicating a fully preheated ladle.

Abstract: A method is provided for extending the life of a refractory lining of a blast furnace hearth. The refractory hearth has temperature probes embedded in the floor and walls thereof. The method includes periodically measuring temperatures indicated by the probes and determining the campaign maximum and current average temperature readings to locate two solidification isotherm representing the wear line of the refractory and the inner surface of the protective metal layer. The thickness of the protective layer is determined from the distance between the solidification isotherms representing the refractory wear line and the inner surface of the metal skull. From this determination sufficient thickness of the protective layer is maintained during actual operation of the furnace.

Abstract: A desulfurization composition contains from about 3% to about 20% particulate metallic aluminum, about 5% to about 30% particulate alumina, about 0.5% to about 12% particulate hydrocarbon material or other gas generating composition and the balance lime plus impurities. Preferably aluminum dross is the source of aluminum and alumina. The desulfurization composition is injected into molten iron from a blast furnace preferably in an amount of 4 to 20 pounds desulfurizer per ton of hot metal. The desulfurizing composition can be injected as a blend or co-injected into the hot metal through a lance using a carrier gas or dumped into the hot metal as it is being poured into the ladle. At least for torpedo ladles, the desulfurization composition can be placed in the ladle before the hot metal is poured into it.

Abstract: A method is provided for determining the thickness of a protective layer of solidified metal skull formed on the refractory hearth of a blast furnace. The refractory hearth has temperature probes embedded in the floor and walls thereof. The method includes periodically measuring temperatures indicated by the probes and determining the campaign maximum and current average temperature readings to locate two solidification isotherms representing the wear line of the refractory and the inner surface of the protective metal layer. The thickness of the protective layer is determined from the distance between the solidification isotherms representing the refractory wear line and the inner surface of the metal skull.

Abstract: A method of determining the conditions of heat transfer at the interface of the refractory and a metal shell of the furnace by calculating the interface temperature from thermoprobes in the refractory and then from a thermoprobe in the metal shell and the temperature of cooling water applied to the shell, and comparing these interface temperatures to determine whether a gap has formed between the refractory and shell and whether cooling of the shell is sufficient.