STEEL IDENTIFICATION THROUGH SPARK OBSERVATION By Raymond Tyler

STEEL IDENTIFICATION THROUGH SPARK OBSERVATION By: Raymond Tyler Dalke Dr. Jan Brink Mr. Mark Weller

Introduction • Steel Manufacturing Open Hearth Furnace • Basic Oxygen Furnace • Electric Arc Furnace • • Steel Categories Killed • Semi-Killed • Rimmed • Capped • • History of Spark Testing • 1909 -1970’s

Why Spark Testing? • • • Cost Availability Ease of Use

0 198. 07 216. 22 233. 87 251. 00 267. 60 283. 66 299. 17 315. 70 331. 91 347. 52 362. 49 376. 83 390. 53 413. 23 435. 13 456. 20 476. 43 495. 86 514. 88 535. 66 555. 57 574. 60 592. 72 609. 89 627. 00 645. 68 663. 44 680. 21 695. 93 710. 56 725. 54 741. 91 757. 27 771. 62 784. 92 797. 15 819. 40 849. 83 878. 90 906. 59 932. 89 957. 78 Counts Spectrometer 1018 Plain Carbon Steel 250 200 259. 79 Fe 150 1018 50 589. 07 Wavelength (nm)

Methods of Spark Testing • Grinding Wheel • • Prototypes Compressed Air 1015 Plain Carbon Steel

Apparatus • Baldor 8 inch Bench Grinder • • • ¾ Hsp 3600 RPM 2. 4 Amp Serial# G 8 -165 -11 Coarse grit Al 2 O 3 grinding wheel Medium grit Al 2 O 3 grinding wheel

Medium Grit Abandoned • 1 1015 plain carbon steel 2 3

Apparatus • Mounting Arm 2”x 2” box tubing • One- 5/16”-18 x 1 ¼” machine screw • One- 5/16”-18 x 2” bolt •

Apparatus • Current Backboard 2 – black poster boards • Inch scale • • Future Backboard 2”x 2” pine studs (frame) • 40”x 45” black background ¼” paneling • Inch scale •

Mounting Apparatus • • • Remove eye shields, tool rest, and guards Utilized the existing bolt holes Loctite®!!!

Specimens Tested • Plain Carbon Steel • • • Alloy Steels • • O 1 D 2 Stainless Steels • • 1215 4140 4340 Tool Steel • • • 1015 1018 1045 1075 1095 17 -4 303 316 Others • Gray Cast Iron

Procedure • • • • Observe Safety! Mount Specimen Turn on grinder Prepare camera and turn off lights Swing mounting arm into grinding position Stand back roughly 4 foot and take six pictures Return mounting arm to non-grinding position Turn light on and align pattern density card Take two readings, a 10 second and 30 second blast on separate cards Turn grinder off Measure the force applied to grinding wheel Record measurements Upload photos using Image J software and record data

Data Measured • • • Rockwell Hardness Brinell Hardness Spark Length Projected Angle of Extremes

Image J Projected Angle Spark Length Angle of Extremes

Results Spark Testing • • • Average Force 3. 3 Newtons =. 74 lbs Average projected angle -58. 35° from the positive x-axis Measured RPM 3575 Type of Steel HRC Brinell Spark Length (in. ) Angle of Extremes (°) 1015 55. 67 560 44. 82 17. 36 1018 50. 67 475 35. 93 27. 08 1045 61. 00 670 38. 83 34. 48 1075 83. 00 N/A 30. 96 27. 62 1095 86. 67 N/A 24. 73 25. 94 1215 57. 33 601 40. 13 27. 86 4140 60. 33 653 33. 98 27. 01 4340 53. 33 530 37. 41 32. 25 O 1 61. 67 670 28. 24 26. 12 D 2 58. 00 620 14. 26 16. 72 17 -4 Stainless 79. 33 N/A 22. 86 30. 32 304 Stainless 75. 33 N/A 12. 51 25. 26 316 Stainless 78. 00 N/A 22. 13 25. 79 Gray Cast Iron 58. 67 620 5. 24 11. 64

Pattern Density Cards

Spark Detail 1015 Plain Carbon Steel 1095 Plain Carbon Steel

Comparison Chart

Further Research • • • Lab Experiments Thermal Imaging Pneumatic Fixture

References • • • American Society of Metals (1978). Metals Handbook: Properties and selection: Irons and Steels. (Ninth Edition). Library of Congress Cataloging in Publication Data. United States of America De. Garmo, E. P. , Black, J. T. , Kohser, R. A. , and Klamecki, B. E. (2003). Materials and Processes in Manufacturing. (Ninth Edition) Hamilton Printing. United States of America Stookey, D. and Dargan, N. (1967). Spark Testing Training Manual Tschorn, G. (1963). Spark Atlas of Steels. The Macmillan Company. New York Azzouz, S. , Brink, J. , and Weller, J. M. (2011). Material Science Lab Manual www. steel. org www. matweb. com asm. matweb. com www. azom. com

Special Thanks • • • Dr. Magaly Rincón-Zachary Dr. Jan Brink Mr. Mark Weller Dr. Jonathan Price Dr. Rebecca Dodge UGROW

Questions?