Creative Chemistry: Descriptive of Recent Achievements in the Chemical Industries

by Edwin E. Slosson

The phosphate bath is not expensive and can be used continuously for months by adding more of the concentrated solution to keep up the strength and removing the sludge that is precipitated. Besides the iron the solution contains the phosphates of other metals such as calcium or strontium, manganese, molybdenum, or tungsten, according to the particular purpose. Since the phosphating solution does not act on nickel it may be used on articles that have been partly nickel-plated so there may be produced, for instance, a bright raised design against a dull black background. Then, too, the surface left by the Parker process is finely etched so it affords a good attachment for paint or enamel if further protection is needed. Even if the enamel does crack, the iron beneath is not so apt to rust and scale off the coating.

These, then, are some of the methods which are now being used to combat our eternal enemy, the rust that doth corrupt. All of them are useful in their several ways. No one of them is best for all purposes. The claim of "rust-proof" is no more to be taken seriously than "fire-proof." We should rather, if we were finical, have to speak of "rust-resisting" coatings as we do of "slow-burning" buildings. Nature is insidious and unceasing in her efforts to bring to ruin the achievements of mankind and we need all the weapons we can find to frustrate her destructive determination.

But it is not enough for us to make iron superficially resistant to rust from the atmosphere. We should like also to make it so that it would withstand corrosion by acids, then it could be used in place of the large and expensive platinum or porcelain evaporating pans and similar utensils employed in chemical works. This requirement also has been met in the non-corrosive forms of iron, which have come into use within the last five years. One of these, "tantiron," invented by a British metallurgist, Robert N. Lennox, in 1912, contains 15 per cent. of silicon. Similar products are known as "duriron" and "Buflokast" in America, "metilure" in France, "ileanite" in Italy and "neutraleisen" in Germany. It is a silvery-white close-grained iron, very hard and rather brittle, somewhat like cast iron but with silicon as the main additional ingredient in place of carbon. It is difficult to cut or drill but may be ground into shape by the new abrasives. It is rustproof and is not attacked by sulfuric, nitric or acetic acid, hot or cold, diluted or concentrated. It does not resist so well hydrochloric acid or sulfur dioxide or alkalies.

The value of iron lies in its versatility. It is a dozen metals in one. It can be made hard or soft, brittle or malleable, tough or weak, resistant or flexible, elastic or pliant, magnetic or non-magnetic, more or less conductive to electricity, by slight changes of composition or mere differences of treatment. No wonder that the medieval mind ascribed these mysterious transformations to witchcraft. But the modern micrometallurgist, by etching the surface of steel and photographing it, shows it up as composite as a block of granite. He is then able to pick out its component minerals, ferrite, austenite, martensite, pearlite, graphite, cementite, and to show how their abundance, shape and arrangement contribute to the strength or weakness of the specimen. The last of these constituents, cementite, is a definite chemical compound, an iron carbide, Fe₃C, containing 6.6 per cent. of carbon, so hard as to scratch glass, very brittle, and imparting these properties to hardened steel and cast iron.

With this knowledge at his disposal the iron-maker can work with his eyes open and so regulate his melt as to cause these various constituents to crystallize out as he wants them to. Besides, he is no longer confined to the alloys of iron and carbon. He has ransacked the chemical dictionary to find new elements to add to his alloys, and some of these rarities have proved to possess great practical value. Vanadium, for instance, used to be put into a fine print paragraph in the back of the chemistry book, where the class did not get to it until the term closed. Yet if it had not been for vanadium steel we should have no Ford cars. Tungsten, too, was relegated to the rear, and if the student remembered it at all it was because it bothered him to understand why its symbol should be W instead of T. But the student of today studies his lesson in the light of a tungsten wire and relieves his mind by listening to a phonograph record played with a "tungs-tone" stylus. When I was assistant in chemistry an "analysis" of steel consisted merely in the determination of its percentage of carbon, and I used to take Saturday for it so I could have time enough to complete the combustion. Now the chemists of a steel works' laboratory may have to determine also the tungsten, chromium, vanadium, titanium, nickel, cobalt, phosphorus, molybdenum, manganese, silicon and sulfur, any or all of them, and be spry about it, because if they do not get the report out within fifteen minutes while the steel is melting in the electrical furnace the whole batch of 75 tons may go wrong. I'm glad I quit the laboratory before they got to speeding up chemists so.

The quality of the steel depends upon the presence and the relative proportions of these ingredients, and a variation of a tenth of 1 per cent. in certain of them will make a different metal out of it. For instance, the steel becomes stronger and tougher as the proportion of nicked is increased up to about 15 per cent. Raising the percentage to 25 we get an alloy that does not rust or corrode and is non-magnetic, although both its component metals, iron and nickel, are by themselves attracted by the magnet. With 36 per cent. nickel and 5 per cent. manganese we get the alloy known as "invar," because it expands and contracts very little with changes of temperature. A bar of the best form of invar will expand less than one-millionth part of its length for a rise of one degree Centigrade at ordinary atmospheric temperature. For this reason it is used in watches and measuring instruments. The alloy of iron with 46 per cent. nickel is called "platinite" because its rate of expansion and contraction is the same as platinum and glass, and so it can be used to replace the platinum wire passing through the glass of an electric light bulb.

A manganese steel of 11 to 14 per cent. is too hard to be machined. It has to be cast or ground into shape and is used for burglar-proof safes and armor plate. Chrome steel is also hard and tough and finds use in files, ball bearings and projectiles. Titanium, which the iron-maker used to regard as his implacable enemy, has been drafted into service as a deoxidizer, increasing the strength and elasticity of the steel. It is reported from France that the addition of three-tenths of 1 per cent. of zirconium to nickel steel has made it more resistant to the German perforating bullets than any steel hitherto known. The new "stainless" cutlery contains 12 to 14 per cent. of chromium.

With the introduction of harder steels came the need of tougher tools to work them. Now the virtue of a good tool steel is the same as of a good man. It must be able to get hot without losing its temper. Steel of the old-fashioned sort, as everybody knows, gets its temper by being heated to redness and suddenly cooled by quenching or plunging it into water or oil. But when the point gets heated up again, as it does by friction in a lathe, it softens and loses its cutting edge. So the necessity of keeping the tool cool limited the speed of the machine.

But about 1868 a Sheffield metallurgist, Robert F. Mushet, found that a piece of steel he was working with did not require quenching to harden it. He had it analyzed to discover the meaning of this peculiarity and learned that it contained tungsten, a rare metal unrecognized in the metallurgy of that day. Further investigation showed that steel to which tungsten and manganese or chromium had been added was tougher and retained its temper at high temperature better than ordinary carbon steel. Tools made from it could be worked up to a white heat without losing their cutting power. The new tools of this type invented by "Efficiency" Taylor at the Bethlehem Steel Works in the nineties have revolutionized shop practice the world over. A tool of the old sort could not cut at a rate faster than thirty feet a minute without overheating, but the new tungsten tools will plow through steel ten times as fast and can cut away a ton of the material in an hour. By means of these high-speed tools the United States was able to turn out five times the munitions that it could otherwise have done in the same time. On the other hand, if Germany alone had possessed the secret of the modern steels no power could have withstood her. A slight superiority in metallurgy has been the deciding factor in many a battle. Those of my readers who have had the advantages of Sunday school training will recall the case described in I Samuel 13:19-22.

By means of these new metals armor plate has been made invulnerable—except to projectiles pointed with similar material. Flying has been made possible through engines weighing no more than two pounds per horse power. The cylinders of combustion engines and the casing of cannon have been made to withstand the unprecedented pressure and corrosive action of the fiery gases evolved within. Castings are made so hard that they cannot be cut—save with tools of the same sort. In the high-speed tools now used 20 or 30 per cent, of the iron is displaced by other ingredients; for example, tungsten from 14 to 25 per cent., chromium from 2 to 7 per cent., vanadium from 1/2 to 1-1/2 per cent., carbon from 6 to 8 per cent., with perhaps cobalt up to 4 per cent. Molybdenum or uranium may replace part of the tungsten.