COMPARISON OF HOT AND COLD MODULUS OF RUPTURE FOR SILICA BRICK

Purpose of the Investigation .—(1) To obtain relative values for the cross-breaking strength of silica brick at temperatures encountered in coke oven practice. (2) To correlate the hot modulus of rupture test, if possible, with the cold modulus of rupture, or cold crushing test, either of which is cheaper and more easily conducted. This report gives the method of making the test, difficulties encountered and results obtained. The report shows a comparison of cold crushing, cold modulus of rupture and hot modulus of rupture on a series of silica brick made from special mixes, commercially burned. Conclusions .—The modulus of rupture of a silica brick at 1350°C is approximately one-third the strength at atmospheric temperature. For this series it averaged from 130 to 189 lbs. per square inch. Too rapid or eccentric heating up to red heat may cause such weakening of the structure or bond that the brick will break under very low pressure. Cross-breaking strength decreases as the temperature increases. Hot modulus of rupture test appears to give results, in most respects, comparable to the cold test, and for routine testing it would seem advisable to use the cold test since it can be made in much shorter time.     

THE TRANSVERSE STRENGTH OF FIRE-CLAY TILES AT FURNACE TEMPERATURES1

Commercial fire-clay tiles, were tested at furnace temperatures, for transverse strength. This was supplemented by tests of tiles of known composition made in the laboratory. Moduli of rupture obtained varied from 245.5 pounds per square inch at 1275°C, to 28.9 pounds per square inch at 1350°C but the data collected do not warrant definite conclusions.     

COLD CRUSHING STRENGTH OF FIRE BRICK1

Data on cold crushing strength in three directions, viz., flat, edge, and endwise of six brands of fire brick are given. Transverse strength data of all these brands are also given. Porosities of all the brick used in these tests were determined by the air-expansion method. The purpose of the investigation was to find whether it is possible to translate the values obtained for crushing strength of fire brick in one direction (flat) into values for the other directions (end and edge); to determine whether transverse strength data can similarly be transformed to crushing strength data and vice versa and whether porosity and crushing strength of fire brick are correlated. The data herein presented do not show the existence of any such simple mathematical relationship between the different properties of the brick. A new capping material, a mixture of sand and molten sulphur, was used for the crushing tests, and was found to be more satisfactory than the other materials commonly used for the purpose. It is recommended that in reporting crushing strength data of fire brick, the brick be tested on end.     

THE CONTROL OF BISCUIT LOSSES1

The effect of the transverse strength and the moisture content of the body on biscuit losses is discussed. A transverse strength of 280 pounds per square inch and minimum moisture content produce the best results. The analysis of the damaged ware and the brushers report gives data of great value in decreasing the biscuit losses, under given factory conditions.     

MOISTURE EXPANSION OF GLAZES AND OTHER CERAMIC FINISHES1

Research for ascertaining why some glazes are more resistant to “moisture crazing” than others revealed the fact that certain glazes expand, because of the action of water, similarly to some of the ceramic bodies t o which they are applied. Although a control of this type of expansion is very important in fitting glazes to bodies, it has not been previously considered. Its importance should be evident at once when it is considered that a large “moisture expansion” in a glaze or other finish is in many cases an indication that the glaze will not be so liable to craze when the ceramic ware or material on which it is used is exposed to moisture. This follows since the glaze and the body on which it goes and which is ordinarily very susceptible to this kind of expansion will then increase in size simultaneously and more nearly at the same rate. Such conditions lessen the tendency of the body expansion to cause tensile stresses in the glaze. In this investigation specimens of various finishes were subjected to steam at 150 pounds per square inch for an hour because it was known that this treatment of such materials produces effects similar to those caused by long exposure to weather. This artificial weathering treatment caused in lustrous glazes an average expansion of 0.004%, in mat glazes 0.011%, in vitreous slip finishes 0.005%, and in porous slip finishes 0.033%. The moisture expansion of one of the mat glazes was 30% of the average obtained for a ceramic body having an absorption of approximately 12%. This proclivity of ceramic finishes to expand by the absorption of moisture can be controlled in their manufacture.     

IMPACT AND STATIC TRANSVERSE STRENGTH OF WET PROCESS ELECTRICAL PORCELAIN1

A brief review is given of the apparatus used for determining the resistance to impact of ceramic materials, namely, apparatus of the “pile driver” type and of the pendulum type. A Charpy (pendulum) transverse impact machine of 2 ft.-lbs. maximum capacity suitable for porcelain has been built and is described. Specimens from 1/2 to 11/8 inches in diameter can be accommodated on movable supports. Data were obtained for 1/2, 3/4, 1, and 11/8 inch diameter cylinders of wet process porcelain on a 4-inch span, the average values for 1/2-inch diameter being 1.24 ft.-lbs. per sq. in., and the average value for 3/4, 1, and 11/8 inches being 1.53 ft.-lbs. per sq. in. with an average deviation from the mean of about 2.5%. Data on specimens of wet process porcelain 1/2, 3/4, 1, and 11/8 inch in diameter fractured on 4- and 5-inch spans give equivalent values for the modulus of rupture. The average of all values is 11,000 pounds per square inch.     

Formation and Strength of Magnesia Whiskers

The formation of single-crystal magnesia whiskers during the compressive deformation of single crystals at room temperatures is described. These whiskers can have strengths of the order of millions of pounds per square inch. They are formed during fracture as a result of the discontinuous propagation of cracks which are mechanically relieving internal stresses resulting from plastic flow     

THE EFFECT OF MECHANICAL PRESSURE ON THE IMBIBITIONAL AND DRYING PROPERTIES OF SOME CERAMIC CLAYS,I*

A number of ceramic clays in the plastic condition were held between water-permeable pistons under mechanical pressure of from 200 to 20,000 pounds per square inch in contact with water at atmospheric pressure until equilibrium was reached; the water in the pistons was removed by compressed air, the pressure released. and the moisture content, density, drying shrinkage, and other properties of the clays determined. In every case, the moisture content and drying shrinkage decreased with increasing pressure and with some clays at high pressures expansion occurred on drying. Rather complete data are given for a number of clays and their theoretical and practical significance is discussed.     

THE RESISTANCE OF SINGLE CLAY BODIES TO THE ACTION OF STEAM1

Twelve whiteware bodies were made, consisting of 51.41%, clay, 10.69% North Carolina feldspar, and 37.9% flint, one clay being used in each body. Twelve clays were studied. The specimens made from these bodies were fired in the regular tunnel bisque kiln to cone 9, glazed on one side, and fired to cone 4 in the glost kiln. The trial pieces were then subjected to the autoclave test, with the steam at a pressure of 100 pounds per square inch, maintained for a period of 3 hours. Of three American ball clays none was found to have caused crazing. In the case of four domestic kaolin bodies, one crazed in part, two were noncrazing, and one shivered. Of five imported kaolins, one of the bodies was noncrazing. While lower absorptions bring about a craze-resisting condition, it was shown that of two single clay bodies with practically the same absorption, one may resist the steam action and one may not. The structure of the clay is an important factor in this connection.     

Experimental Study of Fracture of Glass:I, The Fracture Process

A concept of fracture is developed from experimental data. Fractures are found to originate at flaws or cracks of finite size, most of which are at the surface. The mechanism is one of crack propagation which begins when the local stress at the crack exceeds a minimum value. The rate of propagation increases with crack growth until a critical stress is reached at the crack tip which coincides with a limiting crack velocity. This limiting condition is identified with the boundary of the mirror surface of the fracture. From calculations to be presented in Part 11, the critical stress is estimated to be several million pounds per square inch.     

METHODS FOR TESTING CRAZING OF GLAZES CAUSED BY INCREASES IN SIZE OF CERAMIC BODIES1

Investigations to determine the causes of a type of crazing which develops on certain glazed ceramic wares, some time after firing, revealed the fact that in many cases such crazing is caused by an expansion of the body. This is probably due to the combination of water with the body, while the glaze remains practically constant in size. A body may be tested for this type of crazing by placing the glazed specimens in an autoclave and subjecting them to a steam pressure of 150 to 175 pounds per square inch for one hour. Bodies showing the least tendency to develop this type of crazing are those which have a low porosity, are not very soluble in sulphuric acid, and have a low ignition loss above 110°C.     

EFFECTS OF AUTOCLAVE TREATMENTS ON CERAMIC BODIES AND CLAYS1

It has been found that porous ceramic bodies increase in volume and weight due to an autoclave treatment in which the ware is subjected to steam at a pressure of 150 pounds per square inch. The change is rapid at first but decreases as the time of treatment is increased. Typical American and English china clays also increase in volume but ball clays when fired to the same temperature as the china clays do not increase in volume. The effect of prolonged drying treatments after the autoclave treatment is also studied. Data given indicate that the changes in volume are not necessarily caused by rehydration of the clay within the body. Bodies containing clay, feldspar, and flint show a greater increase in volume than do the pure clay constituents. It is shown that the composition is a more important factor than absorption in determining the reaction of ceramic products to the autoclave treatments.     

OUTLINE OF REFRACTORY REQUIREMENTS FOR THE IRON AND STEEL INDUSTRY1

One of the greatest obstacles to the development of better refractories for the iron and steel industry has been the failure of the iron and steel men to give refractory manufacturers accurate detailed analysis of chemical, physical and thermal conditions to which the refractories are to be subjected. This paper summarizes briefly some of the conditions to be encountered in the major processes. Blast furnace refractories may be divided according to requirements as follows: Hearth and Bosh brick should withstand the scouring action of molten iron and acid slag at temperatures around 1800°C. Inwall brick should be impervious to hot, reducing gases, should resist the sand blast action of the from particles of ore carried by the gas, should have a low coefficient of thermal expansion and should possess sufficient compressive strength to support the weight of the upper part of the furnace. Top brick should be as dense and resistant to abrasion as possible. Downcomer, Dustcatcher and Gas Line brick should be dense and resist sand blast action of gas heavily laden by particles of charge. Hot Blast Main and Bustle Pipe brick should be of low heat conductivity. Hot Blast Stove brick should not vitrify at 900°C, should have maximum capacity for absorbing and giving off heat, and be of high compressive strength. The by-product coke oven is becoming a big factor in the refractory fields and has major requirements as follows: Canals and Ovens require brick of high thermal conductivity which will resist sudden changes in temperature and will not be affected by reducing gases at high temperatures. Checker brick should have great capacity for absorbing heat. Bessemer converters require brick resistant to slag at temperatures from 1600° to 1700°C, the nature of the slag being determined by whether the process is acid or basic. Requirements for open hearth furnaces are as follows: Roof brick (both acid and basic furnaces) must not only be capable of maintaining an arch but should withstand as much as possible the action of iron oxides at temperatures of 1800°C. Checker brick (both acid and basic furnaces) should possess a maximum capacity for absorbing and giving off heat, and a minimum chemical affinity for oxides from charge. Ports (both acid and basic) must withstand the action of slag splashes, also direct action of flame. The hearth of the furnace consists of several courses of brick (acid or basic depending on the process) upon which is built the hearth proper by means of many layers of crushed refractory of the same nature. This crushed material must frit together at high temperatures without excessive softening.     

SILLIMANITE KILN REFRACTORIES MADE FROM AN ANDALUSITE BASE1

Some andalusite refractories are high in transverse strength. Bars 12 inches long, 2 inches wide, and 1/2 inch thick tested across an 11-inch span supported a 45-pound load with 13/32-inch sag at cone 16^1/4 and a 1/2-pound load at cone 34 down with 1/16-inch sag. A standard 9-inch brick tested under a load of 50 pounds per square inch at 1525°C showed no deformation. They are relatively constant in volume, are not affected by kiln gases, and tend to improve rather than to deteriorate under continued heating owing to the formation of an increased amount of mullite. Andalusite saggers used at cone 12 are estimated to have stood 180 cycles and are still in good condition. Saggers in continuous use at cone 16^1/4 have an estimated average age of 1^1/2 years and many are four years old. The andalusite lining of a periodic kiln being fired regularly at 3000 to 3200°F is still serviceable after 110 firings. Cars built of andalusite refractories have given five years of continuous service in tunnel kilns operating at cone 16^1/4, whereas cars built of fireclay refractories were unfit for use after three to four months. Side walls, damper boxes, expansion sleeves, and flame shields of Dressler tunnel kilns operating at cone 16^1/4 have proved satisfactory.     

GLASS CONTAINERS1

For centuries glass bottles have been recognized as superior containers. At present over 4000 different sizes and shapes are being made and the industry is in a state of rapid extension. Glass containers possess the advantage of being sanitary and permitting the contents to be seen. Recently the laboratory of the Glass Container Association has tested 180 lots of beverage bottles. Some of the better types, or those approaching the champagne style, were found to withstand an end crushing pressure of from 8000 to 12000 pounds, a transverse pressure of from 800 to 1800 pounds, a hydrostatic pressure of from 400 to 1600 pounds, and an impact of a fifty-pound hammer falling from 2 to 6 feet. Similar tests are in progress on other types of containers and on the closures employed. Troubles due to alkalinity are of rare occurrence.     

Forsterite refractory brick produced by talc and magnesite from Thailand

This research focuses on refractory material synthesized from precursors of talc and magnesite in Thailand. They were mixed at a molar ratio of 1:5 with mechanical activation at 5 h and calcined at 1300 °C for 1 h to create forsterite. The resulting forsterite crystals were round with less than 1-μm particle size. Synthetic forsterite refractory was formed into refractory bricks and studied at various sintering temperatures of 1200, 1300, and 1400 °C with a dwell time of 2 h. The characteristics and properties of refractory samples were tested in physical properties, cold crushing strength, thermal conductivity, thermal shock, and corrosion resistance from various substances. The results showed that increasing the sintering temperature increases the physical properties and cold crushing strength values. Also, the sintering temperature increases will increase thermal conductivity. The best condition of forsterite refractory brick sintering was 1400 °C for 2 h (FB-14), which showed the following desirable properties: firing shrinkage of 18%, bulk density of 3.03 g/cm³, the apparent density of 3.26 g/cm³, both apparent porous and water absorption values of zero, and cold crushing strength of 72.18 MPa. The FB-14 brick has excellent resistance to corrosion and penetration from lead silicate frit and copper slag. There was minor weight loss from the corrosion of the chemical solutions used in sodium hexametaphosphate production, whereby weight loss will begin on the 18^th cycle. Consequently, the FB-14 brick can be used for blast furnace walls to slow down corrosion, which will allow the blast furnace to have a longer life cycle.     

Durability of Deaired Brick

The applicability to deaired brick of the durability gradings in the current American Society for Testing Materials Specifications C 62 and C 216 was questioned because of the lack of data on the properties and weathering resistance of de-aired brick. The production of 14 plants producing deaired brick was accordingly sampled, and determinations were made on representative subsamples of such properties as transverse and compressive strength, water absorptions by 24-hr, cold immersion and by 5-hr, boiling, and the derived saturation coefficients. Representative subsamples were also subjected to the action of weather in the exposure test plot maintained at the National Bureau of Standards and relations between measured properties and the effect of weathering for five years were considered. The effect of lamination and other types of nonhomo-geneity on weathering was also noted. It was concluded that the current specifications apply to both deaired and nondeaired brick.     

RELATION OF CRUSHING STRENGTH OF SILICA BRICK AT VARIOUS TEMPERATURES TO OTHER PHYSICAL PROPERTIES*

The failure at elevated temperatures under constant load for silica brick is reported using the Iupuy load test apparatus. The crushing strength at 1500°F, 1800°F. 2100°F, and 2400°F is recorded, as well as the crushing strength at room temperature. The size of test piece utilized normally was 1 by 1 by 2′/2 inches. A definite relationship is shown to exist between the strength at room temperature and that at elevated temperatures. The effect of variation in lime content, bats content, and fluxes is also reported. Data were obtained on brick made from three different quartzites. Additional physical data are reported to give information concerning the properties of the brick tested.     

THE MAKING OF DOLOMITE BRICK AND A STUDY OF THEIR PROPERTIES1

This investigation deals with the making and the properties of dolomite brick. A thorough review of the literature shows that there are many improvements possible in the making of dolomite brick and some of the principal faults are pointed out. In this investigation it was shown that 200-mesh dolomite mixtures of a composition 9–0–6M (9% Fe₂O₃–0% Al₂O₃–6% SiO₂–85% dolomite); 6–3–6M (6% Fe₂O₃–3% Al₂)₃–6% SiO₂–85% dolomite); and 2–4–4M (2% Fe₂O³–4% Al₂O₃–4% SiO₂–90% dolomite) can, if calcined to cone 20 down, be made into better brick than any previously described. The advantages of this higher fired material are (1) it has been more completely shrunk than that fired at lower temperatures and therefore does not shrink as much when refired in the form of brick, (2) in the use of aqueous binders less trouble is encountered due to slaking than with the lower fired material. In a continuation of the binder studies a thorough investigation was made of molasses, tar, epsom salts, water and carbonated water. No conditions were found where water, carbonated water, bindex or epsom salts, could be satisfactorily used. Using 20-mesh (2–4–4M) calcine and 15 and 20% of molasses as a binder it was found that the brick always squatted considerably at about cone 15 down. This was shown to be inherent in the material itself and not due to a migration of any part of the material or a softening of the molasses. The most successful brick were made using 20-mesh D9-0-6M composition (9% Fe₂O₃–0% Al₂O₃–6% SiO₂–85% dolomite 200-mesh calcined to cone 20 down), plus 13% of a one to three dextrin-water mixture as binder, and 20-mesh S6–3–6M (6% Fe₂O₃–3% Al₂O₃–6% SiO₂–85% dolomite 200-mesh calcined to cone 20 down), plus 12% of a 5% solution of sodium silicate and in each case fired to cones 16 to 18 down. These brick are dense, well shaped and refractory. Cone fusion temperatures of calcines 9–0–6M, 6–3–6M and 2–4–4M were made in an especially constructed oxyacetylene furnace. The results of the tests show that the above compositions have cone fusion temperatures above cone 40 (2010°C) down. In connection with this work it was also shown that an electric induction furnace, where graphite is used as the resistor, is not reliable for cone fusion tests due to the strong reducing atmosphere. In a load test on brick D9–0–6M and S6–3–6M it was found that when they are heated to 1350°C and held at 1350°C for one hour under a load of twenty-five pounds per square inch they show only a small compression. Brick D9–0–6M shows a compression of 3% while S6–3–6M shows a compression of 0.9% neither brick showing any tendency to crack or squat. In a spalling test these brick (D9–0–6M and S6–3–6M) were shown to possess the characteristic fault of magnesite in that they do not withstand sudden heat change without spalling. On heating one hour a t 1350°C and then exposing to room temperature they crack badly. The use of less flux was unsuccessful as the material thus prepared shows strong hydration which is fatal in that it causes the material to disintegrate. Dolomite compositions 9-0-6M, 6-3-6M and 2 4 4-M, flux violently with silica and fire brick but are inactive toward magnesia and chrome brick. It is, however, possible to burn the dolomite on fire clay brick if a thick layer of magnesia brick grog is used. Since it is necessary to grind the dead-burned dolomite before it can be made up into brick i t is necessary to know the relative tendency toward slaking of the various size particles. It was found that the finer the calcined dolomite is ground the more rapidly the slaking takes place and that it is in some cases very appreciable for 20-mesh material as used in making brick.     

改性石墨对镁碳砖性能的影响

为了提高钢包渣线镁碳砖的使用寿命,将0~1%质量分数的改性石墨引入到钢包渣线用镁碳砖中,研究了其加入量对镁碳砖体积密度、显气孔率、常温耐压强度、热膨胀率和抗渣性的影响,并采用偏光显微镜分析了试样的显微结构。结果表明:引入少量改性石墨对镁碳砖的致密度略有负面影响,但改性石墨在高温下产生的体积膨胀能弥补砖的基质收缩和砖与砖之间的缝隙,从而提高镁碳砖的抗渣性;当改性石墨加入质量分数为0.8%时,镁碳砖中骨料与基质的缝隙最小,抗渣性最好。