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.

Abstract: A construction for the refractory lining member of a coke oven door is provided. The coke oven door lining includes a generally "U"-shaped frame with a castable refractory element formed therein. The frame is provided with a base portion and first and second legs which extend from the base. A series of diagonal cross-members are provided to be affixed at one end to the ends of the legs and at the other end to the central region of the base portion. The refractory member is formed from a castable refractory material and is designed to extend beyond the ends of the legs of the frame. In an alternative embodiment of the invention, the refractory member consists of a two-layer system to provide greater insulation.

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: 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: Metal particles are intimately mixed with at least about 1.5 wt. percent of an organic binder. The mixture is poured into a thermally degradable mold and heated to above sintering temperature to form a preform useful for hot forging. The mold provides integrity for the packed particles until the organic compounds carbonize, which in turn effect sufficient bonding until the particles actually sinter together.

Abstract: The apparent density of molding-grade, water atomized steel powder can be significantly decreased by employing the following prescribed treatment. Coarse particles are removed in order that at least 80% of the initial powders are finer than 80 mesh. The size distribution of the powders is then determined. The powders are then annealed to both reduce the carbon and oxygen contents and soften the particles. The annealed and agglomerated particles are then ground in a disk mill at specified speeds and gap spacings, depending on the size distribution of the initial powders. Apparent densities less than 2.8 gm/cc may be achieved by (a) employing powders with a finer particle size distribution, (b) decreasing the rotational speed of the disks and (c) increasing the mill gap.