The importance of the chemical laboratory to a tool-steel plant cannot be over-estimated. Every heat of steel is analyzed for each element, and check analyses obtained; also, every substance used in the mix is analyzed for all impurities. The importance of using pure base materials is known to all manufacturers despite chemical evidence that certain detrimental elements are removed in the process of manufacture.
The manufacture of high-speed steel represents the highest art in the making of steel by tool-steel practice. Some may say, on account of our increased knowledge of chemistry and metallurgy, that the making of such steel has ceased to be an art, but has become a science. It is, in fact an art; aided by science. The human element in its manufacture is a decided factor, as will be brought in the following remarks:
The heat treatment of steel in its broad aspect may be said to commence with the melting furnace and end with the hardening and tempering of the finished product. High-speed steel is melted by two general types of furnace, known as crucible and electric. Steel treaters, however, are more vitally interested in the changes that take place in the steel during the various processes of manufacture rather than a detailed description of those processes, which are more or less familiar to all.
In order that good high-speed steel may be furnished in finished bars, it must be of correct chemical analysis, properly melted and cast into solid ingots, free from blow-holes and surface defects. Sudden changes of temperature are to be guarded against at every stage of its manufacture and subsequent treatment. The ingots are relatively weak, and the tendency to crack due to cooling strains is great. For this reason the hot ingots are not allowed to cool quickly, but are placed in furnaces which are of about the same temperature and are allowed to cool gradually before being placed in stock. Good steel can be made only from good ingots.
Steel treaters should be more vitally interested in the important changes which take place in high-speed steel during the hammering operations than that of any other working the steel receives in the course of its manufacture.
QUALITY AND STRUCTURE
The quality of high-speed steel is dependent to a very great extent upon its structure. The making of the structure begins under the hammer, and the beneficial effects produced in this stage persist through the subsequent operations, provided they are properly carried out. The massive carbides and tungstides present in the ingot are broken down and uniformly distributed throughout the billet.
To accomplish this the reduction in area must be sufficient and the hammer blows should be heavy, so as to carry the compression into the center of the billet; otherwise, undesirable characteristics such as coarse structure and carbide envelopes will exist and cause the steel treater much trouble. Surface defects invisible in the ingot may be opened up under the hammering operation, in which event they are chipped from the hot billet.
Ingots are first hammered into billets. These billets are carefully inspected and all surface defects ground or chipped. The hammered billets are again slowly heated and receive a second hammering, known as "cogging." The billet resulting therefrom is known as a "cogged" billet and is of the proper size for the rolling mill or for the finishing hammer.
Although it is not considered good mill practice, some manufacturers who have a large rolling mill perform the very important cogging operation in the rolling mill instead of under the hammer. Cogging in a rolling mill does not break up and distribute the carbides and tungstides as efficiently as cogging under the hammer; another objection to cogging in the rolling mill is that there is no opportunity to chip surface defects developed as they can be under the trained eye of a hammer-man, thereby eliminating such defects in the finished billet.