The sun. [volume] (New York [N.Y.]) 1833-1916, 1876-03-06
HOW STEELRA1LSAREMADE
ONE INDUSTRY THAT THRTTES DE-
SPITE TINE HARD TIMES.

HARRIsBuRo, Pa, Feb. %. The manufac-
ture Of steel rails by the Bessemer process has
Increased to such a degree in this country within
the past few years that the importation Of them
from sheffield has altogether ceased. Up to the
present time eleven establishments for making
rails of this description have been erected in the
United States They are located at the follow
ing places and were put up In the order here
stated I, Troy, n. Y; 2, Baldwin, Pa; B. Cleye-
land Ohio ; 4, Johnstown, Pa. ; b. North Chicago
I'LL Q, South Chicago ILL.,. :, Joliet, ILL.,; s, Beth
lehem, Pa; o. Scranton, Pa; 10, Diaddock's
Field, Pa; H. 81. Louis. Mo-, the last named
being not yet completed. Although the steel
works at Troy the nrst erected In this
country, those at Baldwin, three miles below
Harrisburg, were the first to go into operation
the original works at Troy having been destroyed
by nre about the time OF their completion.
Visiting Baldwin for the purpose of learning
what we can about the manufacture Of steel
rails. we nrst survey huge pile Of pig iron,
tanning at the present time 1j,0OO tons. About 30
per cent OF the metal used Is iron manufactured
In western Pennsylvania from Lake Superior
ore about 20 per cent. Of 1t is made at Baldwin,
about 40 per cent. comes from anthracite fur
naces In the neighborhood of the works. aud the
balance Il spcgel-eison from Germany or other
countries In Europe. spierel-eisen, or mirror
iron, contains 50 per cent. Of iron. IL per cent.
manganese. per cent. carbon, and 3per cent.
of other elements
TuE BESsrMER DEPARTMENT.
Following the pig metal that Is being drawn
nto the Bessemer Mills, we reach four large
cupola furnaces. Two Of these are in use at one
time (thc other two being reserved for changci
and they smelt about $50 tons Of metal IN TWEEN
ty-four hours. From the cupolas tho molten
metal is tapped every fifteen minutes into
lade capable Of holding 1900 pounds. This
iadle is raised by hydraulic pressure. and is so
ged as to weigh the metal while pouring
1t into large egg-shaped vessels called convert
ers Each OF the cUnNcrter- has in its bottom
thirteen cylinders called tuNeres ana there are
twelve is-inch holes in each tuNere;
The converter lies ON is side while the molten
metal i being poured into u, So thai the metal
may not run down the holes in It's bottom hut rs
soon As the required quantity has been run in,
the converter assumes pcrpehdlculAr position
blast Of cold air. with pressure Of - pounds
90 the square inch, being lot on nj the same mo-
ment. The molten metal lies about II inches
deep on the bottom of the converter. but the
thr"ush the tuyere.. The blast. witch is fur,
pished lay two engines of 30 horse power erch.
j. kept up on an average about i minutes. The
oxygen of the air uniies with the carbon IN
the iron and forms carhonic oxide. The
carbon passes on in the form Of gas and the ,ili-
con 'of which there Is about per cent. In the
mass rises 10 the top and = eventually removed
In the shape Of Stag after the metal is poured.
The metal Il now thoroughly dcChrbouiIcd-
60 thoroughly that II has To- hc recarboni1cd in
order to convert it into steel. The removal of
the carbon gives malleehility and strength TO
the iron. hut steel must contain certain
amount of carbon. Ordinary cast iron contains
from four to four and - half per cent. of ear;
bon cast steel one-half ror cent. No method
has a. yet been discovered 10y which, in the
elbow "a it Is called. it can he known precise
y when one-halt per cent. 81 II remains in the
fused metal. All must Therefore he driven out,
aud REORGANIZATION effected.
srIEGEL-EIsEN's IMPORTANT WORK.
When all the carbon has been expelled. the
name which has been ru,hins out Of thG top "it
this point the spitgel-e!sen performs its i'm
venient to the converter, which Is turned on it,
side To receive II. and the blast shut on. 1t Is run
In to the extent Of eight Per cent Of the whole
this quantity 1t carries in precisely enough Of
carbon and manganese TO convert the molten
From the converter the steel is run into the
steel Idle,' whence 1t pr~-e- thrgueh nozzle
IN the bottom To a sand-inrd tube called a
eprue and thence flows through channels in
the top of Ilask into ast iron moulds. where il
IL formed into ingofs. This mode Of casting Is
know ~ the bottom cast Earl charge makes
eight ingot, and each iusot two rails. Ingot Of
various weights are made. according to the
weight OF the rail required. but all the ingots OF
one charge are alike Ia -.2e.
As soon rs the ingnt lnosens itself from the
mould 10y contraction n cooling. the mould Is
stripped ~. Both muald- and ngot- are manp-
power !, derived FROM two Warrington pump.
that furnish a pressure Of 2J pounds 20 the
ten pounds is detached from each charge and
sent To the lahoratorv a. he tested for carbon
by the chemist. Every charge Is numbered. aud
n core ponding number rii' un every rail made
from it, WIN the year III watch 1t was made and
Thu, each rail has H. record, and II any one
were taken our Of the track twenty wears after
II had been laid down. and the number on it
given to the steel company they could tcll pre-
cisely the materials used Ia making IT, the day
Il was cast and rolled. and the conditions under
which II was manufactured.
TIE FORGE DEPARTMENT.
Generally, though not always. after the moulds
are stripped oG, the ineos are passed in red or
nearly r.d-hut condition To the forge depart
ment Here they are put in furnaces and heated
70 IA white heat. They are then nut under a
-14-ton hammer and hammered out to square
OF seven inches when they are g5nt through.
each ngot making two hiooms. This hammer
has maximum force Of 80 tons and j. 80 well
regulated that IL can hammer steel from the
largest Size down TO 2H inches square. u is
one year as has been done IN that period OF time
ty any three hammers Of the ,nme capacity in
England. The anvil block weighs ~ tons
There are two other hammers In this depart
ment. one Of these weighs seven tons. 1t la.
longer stroke than tine large hammer, and
therefore delivers a heavier blow 40 ton- in
hammer for merchant work. Heavy shaft
and all kinds Of forging are done,
both straight or, shaped. There are
one exception, capable Of heating six ingotS al
II l. claimed that The f. eat advantage OF this
pmernJ n nne' instsad of v Hi0oninn miIis
Sir john Browne. of England, whose steel was
50 long regarded uneqiallcd in quality, and who
brought to this country. gained his reputation
by this hannering process.
THE RAIL MILL.
From the forge the blooms 90 to the rail mill,
where they are relocated and rolled. Here there
are eight furnaces. FIVE Of which are now work
Jng. Three Of the 1--WE are gas and two coal fur
lnaces. Each gas furnace heats eighteen blooms
at charge, and each coal furnace eight. The
gas furnaces are making twelve heats each pei
day and the others ten.
From the furnace the bloom goes frat to the
coughing rolls and then 10 the finishing rolls. II
tasse- eight times through the former and nin'
times through the latter diminishing in thick
mes, aid increasing IN length AT each passage
rintil II comes out roll OF ,he desired pattern
weight, and length IT. last run through th'
rolls draws IL out 10 the length OF about z
feet. It is then placed under two circula
saws ~ feet ~ inches apart and IN twink
ding Of the eye both ends are cut Of leaving ]
exactly "a feet long after II contracts In cool
ing. The rail Is then placed on a straghte nini
plate to cool. As it does not become perfect.
straight. however, 1t is taken in hand by two
men and Strengthened 10y means Of press called
cold strnightener. Then holes for fasteI mi
the hsh plate are drilled in II, and IL l. ready I,
oil its l'lace in the road cd
From one Of the ends cut on rail out Of ever
charge a piece Is taken about foot long and Al
inch In thickness. This i tested hy bending