Atlantic City Paper - Direct-Metal and Cupola-Metal Iron Castings

A short time ago, I had occasion to cast iron plates 1 in. thick, direct from metal containing Si, 0.51; 8, 0.045; Mn, 0.75; and P, 0.094 per cent. Much to my astonishment, I found that there was no trouble in planing them; whereas, if cupolaimetal of like composition had been used,*the planing would have been a difficult operation. I have often noticed a greater fluidity or " life " in furnace-metal, as compared with the cupola-product. Iron can be seen flowing down the furnace-runners from 50 to 100 ft., and reaching the last pig-bed in satisfactory condition, while cupola-metal might have solidified before it had flowed so far. I have seen Bessemer iron, which, on account of its low phosphorus-content, does not have the " life " of ordinary foundry-iron, held in a 30-ton ladle for nearly an hour and a half; and after skimming off the coke-dust, it still had to be cooled off' considerably before being cast. As a general proposition, it is known that the lower sulphur-content and the frequently higher temperature of direct-metal, compared with the same iron remelted in the cupola, has much to do with its greater life; yet some problems connected with this phenomenon seem to call for further study. For instance, furnace-metal containing more than 1 per cent. of silicon holds carbon, which is separated later as "kish." This separation does not take place to any great degree while the metal is very hot; but during its gradual cooling, at times, the kish is given off in such large quantities as to cover the ground from 20 to 30 ft. around the ladle. In making castings of direct-metal, especially with a high content of silicon, the separation of kish becomes an annoyance. Perhaps this throwing out of the excess of carbon makes the life of the metal shorter, after it has been remelted in a