Oxidation cast iron

Siemens s process A method of steel manufacture by addition of scrap metal, iron oxides and ferromanganese to molten pig (cast) iron. 

Metallurgy. The strong affinity for oxygen and sulfur makes the rare-earth metals useflil in metallurgy (qv). Mischmetal acts as a trap for these Group 16 (VIA) elements, which are usually detrimental to the properties of steel (qv) or cast iron (qv). Resistance to high temperature oxidation and thermomechanical properties of several metals and alloys are thus significantly improved by the addition of small amounts of mischmetal or its siUcide (16,17). 

Technical molybdic oxide can be reduced by reaction of ferrosiUcon in a thermite-type reaction. The resulting product contains about 60% molybdenum and 40% iron. Foundries generally use ferromolybdenum for adding molybdenum to cast iron and steel, and steel mills may prefer ferromolybdenum to technical molybdic oxide for some types of steels. 

Silicon [7440-21-3] Si, from the Latin silex, silicis for flint, is the fourteenth element of the Periodic Table, has atomic wt 28.083, and a room temperature density of 2.3 gm /cm. SiUcon is britde, has a gray, metallic luster, and melts at 1412°C. In 1787 Lavoisier suggested that siUca (qv), of which flint is one form, was the oxide of an unknown element. Gay-Lussac and Thenard apparently produced elemental siUcon in 1811 by reducing siUcon tetrafluoride with potassium but did not recognize it as an element. In 1817 BerzeHus reported evidence of siUcon occurring as a precipitate in cast iron. Elemental siUcon does not occur in nature. As a constituent of various minerals, eg, siUca and siUcates such as the feldspars and kaolins, however, siUcon comprises about 28% of the earth s cmst. There are three stable isotopes that occur naturally and several that can be prepared artificially and are radioactive (Table 1) (1). 

Although more and more zinc sheet and strip are produced in continuous mills, some is stiU produced by rolling slabs cast in open or closed book-type molds made of cast iron (124—127). The casting temperatures are between 440 and 510°C, mold temperatures between 80 and 120°C. The contact surfaces of the mold must be smooth and clean to allow unrestricted shrinkage of the cast slab. Mold lubricant is not necessary, but if used should be held to a minimum. Slabs cast in open molds must be skimmed immediately to remove surface oxide. Rolling slabs are cast 1.87—10 cm thick. 

The reaction vessel (nitrator) is constructed of cast iron, mild carbon steel, stainless steel, or glass-lined steel depending on the reaction environment. It is designed to maintain the required operating temperature with heat-removal capabiUty to cope with this strongly exothermic and potentially ha2ardous reaction. Secondary problems are the containment of nitric oxide fumes and disposal or reuse of the dilute spent acid. Examples of important intermediates resulting from nitration are summarized in Table 3. 

Enamels used on cast iron and aluminum have traditionally been composed of Si02, B2O2, 2 5 PbO. The lead oxide produces good surface... 

Aluminum-surfaced roofing 100 0.216 Cast iron, rough, strongly oxidized 100-480 0.95... 

High-silicon cast irons have excellent corrosion resistance. Sih-con content is 13 to 16 percent. This material is known as Durion. Adding 4 percent Cr yields a product called Durichlor, which has improved resistance in the presence of oxidizing agents. These alloys are not readily machined or welded. 

Corrosion resistance of nickel allovs is superior to that of cast irons but less than that of pure nickel. There is uttle attack from neutral or alkaline solutions. Oxidizing acids such as nitric are highly detrimental. Cold, concentrated sulfuric acid can be handled. 

On mild steel and cast irons, rust accumulates at crevice mouths. Darker oxides often are present within crevices (Figs. 2.18 and 2.19). 

In oxygenated water of near neutral pH and at or slightly above room temperature, hydrous ferric oxide [FelOHla] forms on steel and cast irons. Corrosion products are orange, red, or brown and are the major constituent of rust. This layer shields the underl3dng metal surface from oxygenated water, so oxygen concentration decreases beneath the rust layer. 

Oxygen corrosion only occurs on metal surfaces exposed to oxygenated waters. Many commonly used industrial alloys react with dissolved oxygen in water, forming a variety of oxides and hydroxides. However, alloys most seriously affected are cast irons, galvanized steel, and non-stainless steels. Attack occurs in locations where tuberculation also occurs (see Chap. 3). Often, oxygen corrosion is a precursor to tubercle development. 

Sulfides are intermixed with iron oxides and hydroxides on carbon steels and cast irons. The oxides are also produced in the corrosion process (Reaction 6.6). Although theoretical stoichiometry of 1 to 3 is often suggested between sulfide and ferrous hydroxide, empirically the ratio of iron sulfide to ferrous hydroxide is highly variable. Sulfide decomposes spontaneously upon exposure to moist air. Additionally, corrosion-product stratification is marked, with sulfide concentration being highest near metal surfaces. 

Graphitically corroded cast irons may induce galvanic corrosion of metals to which they are coupled due to the nobility of the iron oxide and graphite surface. For example, cast iron or cast steel replacement pump impellers may corrode rapidly due to the galvanic couple established with the graphitically corroded cast iron pump casing. In this or similar situations, the entire affected component should be replaced. If just one part is replaced, it should be with a material that will resist galvanic corrosion, such as austenitic cast iron. 

Gaseous corrosion is a general form of corrosion whereby a metal is exposed to a gas (usually at elevated temperatures). Direct oxidation of a metal in air is the most common cause. Cast iron growth is a specific form of gaseous corrosion in which corrosion products accumulate onto the metal surface (and particularly at grain boundaries) to the extent that they cause visible thickening of the metal. The entire metal thickness may succumb to this before loss of strength causes failure. 

The scope of the term stainless steel has not been precisely defined, but for general purposes it may be considered to include alloys whose main constituent is iron but which also contain not less than 10% Cr. As with low-alloy steels, a distinction between low or medium carbon grades and high carbon grades must also be drawn, the latter being more in the nature of alloy cast irons. These are used mainly for oxidation resistance at high temperatures and for applications where abrasion resistance allied to a certain amount of corrosion resistance is required, and will not be considered in this section. 

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