A number of micro-sections of the rail and of the shaft were made and examined.
“Numerous micro-sulphur flaws were found, varying in size from 0.015 inch downward, interspersed or segregated in the intercrystalline junctions of the ultimate crystals of the steel, and being located in such a manner as to prevent metallic cohesion between the facets of the crystals, thus inducing lines of internal weakness liable to be acted upon by the stress and strain of actual wear.”
The dimensions of these flaws in the rail varied from .0150 × .0012 to .0010 × .0004 parts of an inch.
In the shaft from .0160 × .0030 to .0020 × .0016 parts of an inch.
In the rail he found as many as 14 flaws in an area of only 0.00018 square inch, equal to nearly 60,000 flaws per square inch.
In the shaft he found as many as 34 flaws in an area of only 0.00018 square inch, equal to nearly 190,000 per square inch.
In speaking of the shaft he says: “In addition to blow-holes, air-cavities, etc., the interior of the shaft was literally honeycombed with micro-sulphide of iron flaws, which were meshed about and around the primary crystals of the metal in every direction.” “The deleterious effects of an excess of manganese in interfering with the normal crystallization of the normal carbide of iron areas were also perceptible.”
As the number of micro-sulphur flaws in the shaft were about three times as many as in the rail, we may assume that the shaft contained at least as large a percentage of sulphur as the rail, and, owing to the general honeycombed structure, it would not be a far guess to assume that the steel was teemed wild.
“The deleterious effect of these treacherous sulphur areas and other microscopic flaws, with their prolonged ramifications spreading along the intercrystalline spaces of the ultimate crystals of the metal and destroying metallic cohesion, will be easily understood.”
“Constant vibration gradually loosens the metallic adherence of the crystals, especially in areas where these micro-flaws exist. Cankering by internal corrosion and disintegration is induced whenever the terminations of any of the sulphide areas or other flaws in any way become exposed at the surface of the metal, either to the action of sea-water, or atmospheric or other oxidizing influences. In many other ways, also, it will be seen how deleterious is their presence.”