Puddling (metallurgy)

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Schematic drawing of a puddling furnace
Puddling was an Industrial Revolution means of making iron and steel. In the original puddling technique, molten iron in a reverberatory furnace was stirred with rods, which were consumed in the process. Later, it was also used to produce a good-quality steel with the correct amount of carbon; this was a highly skilled art, but both high-carbon and low-carbon steels were successfully produced on a small scale, particularly for swords and other weapons.
Contents
1 History
2 Process
3 Puddling furnace
4 Impact
5 Precursor in China
6 See also
7 References
7.1 Bibliography
7.2 Notes
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History
Puddling was the first true industrial process to make steel from pig iron. A primitive version of the process was known in China already in the 3rd century. The pig iron tapped off the blast furnace was puddled with iron bars, bringing it into it contact with oxygen in the air and burning off any surplus carbon.
In Europe, the process was one of several that were developed in the second half of the 18th century for producing bar iron from pig iron without the use of charcoal. It was invented by Henry Cort at Fontley in Hampshire in 178384 and patented in 1784. A superficially similar (but probably less effective) process was patented the previous year by Peter Onions. Cort's process consisted of stirring molten pig iron in a reverberatory furnace in an oxidising atmosphere, thus decarburising it. When the iron 'came to nature', that is, to a pasty consistency, it was gathered into a puddled ball, shingled, and rolled (as described above). This application of the rolling mill was also Cort's invention.
Unfortunately, Cort's process (as patented) only worked for white cast iron, not grey cast iron, which was the usual feedstock for forges of the period. This problem was resolved probably at Merthyr Tydfil by combining puddling with one element of a slightly earlier process. This involved another kind of hearth known as a 'refinery' or 'running out fire'.[1] The pig iron was melted in this and run out into a trough. The slag separated, and floated on the molten iron, and was removed by lowering a dam at the end of the trough. The effect of this process was to desiliconise the metal, leaving a white brittle metal, known as 'finers metal'. This was the ideal material to charge to the puddling furnace. This version of the process was known as 'dry puddling' and continued in use in some places as late as 1890.
The alternative to refining gray iron was known as 'wet puddling', also known as 'boiling' or 'pig boiling'. This was invented by a puddler called Joseph Hall at Tipton. He began adding scrap iron to the charge. Later he tried adding iron scale (in effect, rust). The result was spectacular in that the furnace boiled violently. This was in fact a chemical reaction between the oxidised iron in the scale and the carbon dissolved in the pig iron. Again to his surprise, the resultant puddle ball produced good iron. Hall subsequently became a partner in establishing the Bloomfield ironworks at Tipton in 1830, the firm becoming Bradley, Barrows and Hall from 1834. This is the version of the process most commonly used in the mid to late 19th century. Wet puddling had the advantage that it was much more efficient than dry puddling (or any earlier process). The best yield of iron achievable from dry puddling is a ton of iron from 1.3 tons of pig iron, but the yield from wet puddling was close to 1.0.
The production of mild steel in the puddling furnace was only achieved in about 1850 in Westphalia in Germany and was patented in Great Britain on behalf of Lohage, Bremme and Lehrkind. It only worked with pig iron made from certain kinds of ore. The cast iron had to be melted quickly and the slag to be rich in manganese. When the metal came to nature, it had to be removed quickly and shingled before further carburisation occurred. The process was taken up at the Low Moor Ironworks at Bradford in Yorkshire (England) in 1851 and in the Loire valley in France in 1855. It was widely used.
The puddling process began to be displaced with the introduction of the Bessemer process, which produced steel, which could then be converted into wrought iron using the Aston process for a fraction of the cost and time. For comparison, an average size charge for a puddling furnace was 800900lbs (360410kg)[2] while a Bessemer converter charge was 15 short tons (13,600kg). The puddling process could not be scaled up, being limited by the amount that the puddler could handle. It could only be expanded by building more furnaces.
Process

Exterior view of a single puddling furnace. A. Damper; B. Work door
The process begins by preparing the puddling furnace; this involves bringing the furnace to a low temperature and then...(and so on) To get More information , you can visit some products about scrapbook supplies storage, shoe repair machine, . The FRONT BUMPER FOR HYUNDAI ACCENT products should be show more here!