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By Leonard C. Grimshaw

The idea of bonding two dissimilar ferrous metals, and making use of both, is an old one. Tips have been brazed onto tool shanks for many years. The bonding of larger pieces to form whole bars and sheets has also been accomplished, but has received little attention in the technical literature, although a number of patents have been issued covering various methods for its accomplishment. There are three main motives behind the manufacture of composite steels. One is that the physical properties of one steel may supplement those of another; a useful, but at the same time, hard, brittle steel may be backed by a soft ductile one, or a stainless steel may be backed by a steel possessing greater strength. Another motive is direct lowering of cost; an expensive steel may be backed by a less expensive one, bringing down the cost of the piece as a whole. The third motive is an indirect lowering of cost, as when a useful steel is backed by a steel that is easier to machine, so that machining cost on a finished product is lowered considerably. Often more than one of these motives lead to a decision to use a composite steel. Previous Methods There are two methods in use that result in tolerably good bonds between ferrous metals: (1) the casting method, and (2) what we shall call the "heat-pressure" method. This "heat-pressure" method covers processes in which the bond is made between two prepared surfaces by heating them and then applying pressure. Usually sufficient pressure must be used to produce appreciable spread and elongation, or else we arc merely brazing and not truly welding. Casting methods for welding together ferrous metals have been used more than 74 years, and are described in the technical literature as applied

Jan 1, 1936

By W. C. Schroeder, A. A. Berk

Practical experience has shown that at elevated temperatures solutions containing sodium hydroxide may attack stressed steel in a manner that cannot be explained in terms of ordinary corrosion. Because the ductility of the metal has been greatly reduced during the reaction, the entire phenomenon is usually called "embrittlement." Thus, after several years of operation caustic evaporators have been so badly embrittled that rivets could be cracked off with the blow of a hammer. Since fine intergranular cracks are almost always present in the zone of fracture, it has often been assumed that a process of selective corrosion in grain boundaries was responsible for the failure, although this has not been clearly proved experimentally. Concentrations of sodium hydroxide below those necessary for the uniform, rapid attack of the steel surface are reported to be most effective in producing embrittlement2, 3. In the operation of steam boilers a similar type of failure has been found, mainly in riveted seams or other capillary spaces where the solution may concentrate and where high stresses may also exist. It is believed that in such localized areas the dissolved solids may reach a value many times the few hundred parts per million prevalent in the body of the boiler. While this type of boiler failure has been the subject of investigation for a period of 20 years1, an understanding of its mechanism and a rational basis for complete protection have not yet been secured. To procure this information the present investigation was

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By P. W. Bridgman

It is characteristic of most scientific investigators that they are not satisfied with the discovery of new facts, no matter how curious or unexpected, but that along with the factual discovery there is a constant effort to understand. It appears that one's interest in, and satisfaction with, the discovery of an array of new experimental facts is enormously increased if one has at the same time a theory or hypothesis guiding one's expectation of what sort of new experimental discovery may lie around the corner. Conversely, as a theoretical physicist one's satisfaction with his theory is greatly enhanced if along with the development of the theory can go the discovery of new experimental facts, confirming or perhaps modifying the theory as it grows. Of course, there have been long arid stretches in the history of physics in which new data of unquestioned ultimate importance have piled up, without much inspiration or illumination in the way of understanding. For 50 years spectroscopy had such an arid history, but how irksome this was felt to be is plainly shown by the almost audible relief that greeted the first success by Bohr in injecting understanding into the situation, and by the fresh rush of experimenters into this field when the prospect of understanding had once been offered. The investigations in the field of high pressure, which have occupied me for a long time,' until the last few years have been in very much the same sort of situation as spectroscopy before the advent of Bohr. A great many kinds of data were collected for a great many solid and liquid substances, and there could be no question of the importance of these data, because the uniform change of dimensions produced by hydrostatic pressure is perhaps the simplest conceivable type of alteration to which a body can be subjected. But except for a few isolated flashes, there was no theoretical illumination, so that it had to be to a large extent the enthusiasm of the collector that kept me going. However, within the last few years the wave-mechanics theory of solids has progressed so rapidly that

Jan 1, 1938

By J. D. Shaw, E. B. Gebert, D. O. Noel

It is, of course, expected that manufacture of the various metal powders should involve numerous methods adapted to the specific characteristics of the metals themselves. Several methods for powdering a particular metal may be available, but the physical characteristics of the powder as produced by the several methods may be quite different. In the final analysis, the application of the metal powder dictates the physical properties that the metal powder must possess, and this, to a very large extent, will determine which of several possible methods of manufacture is adopted. Sometimes powder of the same metal is produced by more than one method, each powder having specific characteristics that make it particularly suitable for its application. For purposes of classification, the various methods of powdering metals can be grouped as follows: 1. Machining. 2. Milling (by ball mills, stamps, attrition mills, etc.). 3. Shotting (pouring molten metal into water, air, etc.). 4. Granulation (by stirring molten metal while solidifying). 5. Atomizing (disintegrating by steam, compressed air, etc.). 6. Condensation of metal vapor. 7. Reduction of oxide powders. 8. Chemical precipitation. 9. Electrolytic deposition. 10. Sintering (for producing alloy powders). 11. Formation of an alloy followed by dissolving or otherwise removing one of the alloying constituents. Machining Turnings, cuttings, filings, etc., are, of course, produced as by-products in machine work of various kinds, and find certain applications as metal powders. For example, iron powder so produced is used extensively as a reducing or precipitating agent and as a constituent in certain hard-finish cements.

Jan 1, 1938

By Gregory J. Comstock

There is a growing interest in the possibilities presented by the manipulation of metal powders, which justifies an attempt to summarize their character and potential value. A summary of this kind presents an opportunity for making a classification of metal powder products into several general types. Our present knowledge of the finer and more abstract aspects of many of the principles involved in metal powder technique is extremely limited. Any conclusions as to the ultimate value of the process will, therefore, for the present at least, be of doubtful value unless they are substantiated by its products. The number of such products is increasing. A study of their diverse and unusual characteristics; an examination of the methods by which they are made, and a consideration of the reactions that take place during their fabrication, in so far as we can define them, should afford as good an evaluation of this interesting development as it is possible to make at this time. A critical study of this kind results in a formidable list of special attributes, which apparently are characteristic of applied powder metallurgy. A comparison of these special effects with the end products and well defined limitations of the melting and casting process indicate that often they may very well be considered as being special advantages. They are subject, of course, to certain not as yet so well defined limitations of their own. Based on current products only, a necessarily condensed summary of the more striking special attributes of the metal powder process follows. Manipulation of Highly Refractory Metals The powder process presents a means of manipulating highly refractory metals, which cannot be cast and formed in the usual melting and casting process. Tungsten, molybdenum and tantalum are the classic examples of the adequacy of the metal powder process for meeting unusual conditions of this character. The development and application of these metals by means of it, and their importance in the electrical

Jan 1, 1938

By Clarence W. Balke

Small buttons of fused tantalum have been produced by are fusion in a vacuum, by drawing an arc between sticks of pressed tantalum and a tantalum-faced water-cooled copper block. However, ingots of appreciable size can be produced only by the heat-treatment of bars pressed from powder. The following outline covering the production of finished bars of tantalum by the methods of powder metallurgy is also used for the production of columbium, taking into account the difference in the melting points of these two metals. Pressing the Powder With possibly a few exceptions, a pressing operation is one of the essential steps in the practice of powder metallurgy. In fact, the author's experience with a number of high-melting-point metals and with numerous types of hard carbide compositions has led him to believe that this operation is often one of the most important in the entire process, and frequently one of the most difficult to carry out in a satisfactory manner. Defects due to improper pressing can readily lead to a defective finished product. It is the author's opinion that rarely is a bar or other article pressed from metal powder in such a way that all parts of the piece are uniformly pressed. The nearest approach to uniformity of pressing is possibly attained when the powder is contained in a flexible receptacle, such as rubber, and is pressed under a liquid by hydrostatic pressure. However, this method is not generally applicable. Hydraulic pressing in steel dies where one or two punches are forced into the die must usually be resorted to. As the pressure in such a die is built up, the powder begins to cling to the walls of the die with a tenacity dependent upon the nature of the powder, and this results in a bridging action, so that the layers of powder adjacent to the moving punch are pressed more heavily than those further removed in the mass. Frequently, as the pressure is carried higher, there may be a mass slippage of the powder upon itself, with the result that slip cracks are formed within the pressed

Jan 1, 1938

By W. P. Sykes

Seven years ago, Dr. S. L. Hoytl presented a masterful discussion of the hard metal carbides and cemented tungsten carbide. His lecture summarized most of the data then available in the field; many of the details relating to the production, properties and structure of cemented tungsten carbide had never been previously published, for, in fact, this information was only then being acquired. During the intervening years, the cemented carbides have assumed a place of real importance in the commercial field, with an ever widening variety of applications due to constant improvement in the control of production technique and the unremitting search for new compositions that might better the performance of the alloys in one or another type of service. The most recent summary of production methods, properties and guides for the successful application of the cemented carbides appears in the 1936 edition of the Metals Handbook. Of necessity, much detailed information relating to structures and physical properties is not included in such a summary, and it is with such details that the present discussion is concerned. Steps in Preparation While the past 25 years have contributed a valuable store of working knowledge in the field of powder metallurgy, many of the process controls are derived entirely from experience and are not as yet finally explained by a specific physical or chemical phenomenon. For most of the cemented carbides such difficulties are aggravated by our lack of knowledge not only of the complex alloy systems involved, but also by the possible changes in structure and even in composition which may accompany variations in temperature, heating time, and furnace atmospheres. The principal steps in the preparation of these cemented carbide alloys are fairly well known, but to supply a foundation for discussion these steps are briefly outlined as follows : 1. Formation of the metal carbide in the form of powder by heating a mixture of carbon and the metal powder or oxide for several

Jan 1, 1938

By Philip M. Mc Kenna

When a new material becomes available to industry, it is useful to describe its properties as a guide to its most effective application; and when the new material may be produced in compositions having a series of graded properties, tests to select the combination of properties best adapted for various uses are helpful. The class of materials to be considered in this paper are hard tool materials produced by processes of powder metallurgy from hard carbide constituents and various matrices of iron, nickel or cobalt, or alloys of them with tungsten, or tungsten and carbon. The customary use of carbide hard alloys is for metal-cutting tools; although wire-drawing dies, lathe centers, follow rests, grinding rests, burnishers, rolls, extrusion dies, measuring gauges and micrometers, and a number of other tools are also made with these hard alloys as the essential wear-resisting parts. The properties and tests to be considered are those affecting these uses. In the development of tool materials since the industrial revolution we have had carbon tool steels, Mushet steel, high-speed steels, stellites, and now cemented carbide compositions. For an understanding of the latter category of materials their properties and uses relative to the older and more familiar tool materials will be considered. Hardness has been the property of greatest practical interest in tool materials. The word "hardness" is a generalized term lacking definite-ness unless the specific test used is described. However, efforts to explain physical properties as a consequence of chemical bond, and distance between atoms in chemical compounds have been illuminating. This seems the most generalized attack on the problem, and is based upon the idea that atoms in a lattice are held together as the square of the valence and inversely as the square of the distance between the atoms. The compounds compared must all be of the same crystalline arrangement. 100 W2 It is interesting to note the values of the figure 7 A 3 /3for a number of

Jan 1, 1938

By M. Gensamer

In applied mechanics and in metallurgy the transition from elastic to inelastic action is a matter of considerable interest and importance. Often the first inelastic deformation is apparently quite homogeneous; that is, uniformly distributed throughout the specimen. Sometimes this deformation is heterogeneous; that is, localized; inelastic deformation proceeds to some definite amount in restricted regions before adjacent regions of the specimen are inelastically deformed. In such cases the deformation does not become homogeneous until the whole specimen has been deformed the amount corresponding to that for each localized deformation. If the test is stopped before uniform extension sets in, the heterogeneous character of the deformation is apparent on the surface of the specimen through characteristic markings, which have been called "LÜders'" lines, "Hartmann's" lines, the "Piobert effect," or simply "flow figures." These markings are the source of considerable trouble in fabricating operations, particularly in the deep drawing of steel sheet. In many cases where the transition is of this nature, the stress developed at the upper limit of the elastic range is greater than the stress during the period of heterogeneous deformation, giving rise to the familiar "drop of the beam" effect in testing. The amount of the yield-point elongation, as well as the value of the stress at the lower yield point (the value to which the stress drops when yielding begins), are functions of the temperature and the testing speed. Lower temperatures and faster rates of testing increase both the yield-point elongation and the yield-point stress. These matters have been ably discussed in a recent paper by Winlock and Leiterl though, as brought out by the discussion of that paper, the phenomena are but little understood. The purpose of the present paper is to clarify the problem through the application of a simple principle, and to show that, through the application of this principle, a number of phenomena in the plastic deformation of metals become more readily understood. The principle is this: During homogeneous flow, the rate of work-hardening is greater than the rate of change of stress resulting from change

Jan 1, 1938

By John B. Baker, Bernard B. Betty, H. F. Moore

For several years there has been in progress in the Materials Testing Laboratory of the University of Illinois an investigation of creep and fracture of lead and lead alloys. In the course of this investigation it has been shown that the phenomenon of creep occurs in part at the grain boundaries of lead and lead alloys. To study the occurrence of creep and the development of fracture within crystalline grains, two series of tests of single crystals of lead have been carried out. The first of these, a preliminary series, by Mr. Betty, has been described.l,2 The second, pursued by Mr. Baker for his doctoral dissertation, was carried out under the direction of Professor Moore, with the assistance of Prof. G. L. Clark in the X-ray work, and the cooperation and advice of Mr. Betty. This paper is based on the test data obtained in this second series. Single crystals of a very pure commercial lead have been prepared, some of them tested to measure creep, others tested to fracture under long-continued steady load, and still others tested under cycles of repeated tension. An interpretation of the test data of these single-crystal tests is offered, which is a combination of parts of several well-known theories. Specimens The single-crystal specimens were made from a piece of very pure commercial lead sheathing. A spectroscopic analysis of one of the single crystals showed the presence of 0.005 per cent Bi, 0.0001 per cent Cu and 0.0003 per cent Ag. Preparation.—The Bridgman method of casting single-crystal specimens was used.3 The specimens were cast to the shape and size shown in Fig. 1 (dimensions in Fig. 4c) in a duralumin mold. Molten lead does not stick to duralumin. Fig. 1 shows the mold and the blast flames for heating. After the mold had been heated to the temperature of molten

Jan 1, 1938