Document zdXvZQXM2qrmKx8GmMvB435Y6

I ' JUnR^MUWlUX RUCUKUI MID EHGIREERIMG CENTER KVi- 3-<r-b> mo Date July 15, 1966 *r Title: SILICATED SUPEREX RJENACE BLOCK FROM REPUBLIC STEEL CORPORATION AT GADSDEN, ALABAMA - Cause of Failure Requested by: K. F. Greene Request No. IID 2031 JM CONFIDENTIAL. N o t /i Aeral distribution o r "publication. Assistance was requested In determining cause of failure of SUPEREX after two years service at the Sevlndell Dressier annealing furnace In Gadsden, Alabama. The MgO value of the complaint sample was found to be appreciably lower than a standard sample of SUPEREX and a sample from their Lee Wilson furnace, which was.In service for ten years. This was confirmed spectrographlcally. From X-ray analysis. It is suspected that the complaint sample was subjected to higher teuqieratures than specified. It appears that more high temperature reaction products and penetration to greater depth In the complaint sample were formed in two years than in a serviceable sample, Lee Wilson, formed after ten years. Material Submitted Laboratory Index No. Description PLAINTIFF'S EXHIBIT K-1524 A93-69-I A93-69-2 A93-69-3 Complaint SUPEREX from SevlndellDressier annealing furnace. Standard SUPEREX from Waukegan. SUPEREX from Lee Wilson furnace. Methods of Analysis Conventional silicate procedures were used to determine the components. Calcluun and magnesium were determined by EDTA titration. Samples were also examined by X-ray and spectrographic techniques. Results of Analysis Chemical (on Ignited basis) sio2 RoOo CaO MgO Sevlndell-Dressier 82.3 11.5 1.8 3.6 Standard 81.1 10.9 1.1* 5.7 Lee Wilson 81.7 10.5 1.7 5-^ Ignition Loss at 1800F Basic magnesium carbonate (MBC) 0.76 8A 5.2 13.3 0.62 12.6 These values are based on the total MgO content. The values are probably high by about one per cent because the MgO content of other constituents in SUPEREX was not considered In the calculation. Notebook No. 3^33, FP 21-22; 3366, p 1^3; 3379, P 39 File 1*32 JOHNS-MAHVILLE RESEARCH AND ENGINEERIN6 CENTER fcvvi- 1^0 Report No. 431*502 J Date May 20, 1970 TITLE: FLAKING OF "SUPEREX" M, COMPLAINT REPORT NO. 70-RI-71-10 Requested by: Sales Service Request IN-985 (Complete) SUMMARY It was reported that flaking at the surface of "SUPEREX" M in "aluminum soaking pits" of the Kaiser Aluminum Company in Trentvood, Washington, vas contributing to an abnormal amount of dust which caused problems when the ingots were rolled into sheets. The furnaces were built by Swindell-Dressler Corp. Since "SUPEREX" M has been used successfully in this type of service for many years, excessive compressive stresses parallel to the 12 x 36 in. face of the block in these furnaces was considered to be a possible source of the unusual flaking or delamination. Although most of the flaking in the form of approximately 1/8 to l/l by 6 by 6 in pieces occurred in the 3 in. intermediate layer of "SUPEREX" M, 2 in. thick blocks were used in this investigation because 3 in. blocks were not readily available from stock at Waukegan. Pieces of "SUPEREX" M were crushed by application of the load on the smaller faces and the nature of the failure was observed. Application of the load on a lA or 1/2 in. key stock on the edge of the piece resulted only in local failure, but when the load wa applied to the entire surface of the smaller face of blocks which had been dried, heate on one face at 1000F or subjected to 1000F for 2U hr in a soaking heat, the results suggested that this type of compressive stress could have contributed to the separation of laminar pieces from the s\irface. Contents: Summary, Appendix I (Table), Appendix II (Photographs) JM CONFIDENTIAL. Not fo r gen itlrib u iio it or republicallon. i. . i .. J) Reported by:. Is cc: M. W. Burleson, DH (S) H. E. Konrad, DH C. E. Ernst, DH D. B. Wingerter, DH Mvl Pit J. A. McCague, Waukegan C. H. Jensen, Waukegan A. G. Sinclair, Tor Off L. M. Adamson, Tor Off Notebook No. U039, pp 50-51 H. Shimanowitz F. L. Pundsack (S)*tT." A. McKinney L. R. Blair (S) J. 0. Collins J. E. Neal S. E. Wooley K. L. Kinder (2) Library (2) File: W. K. Hesse Chrono File: 1*31 JDHNS-MANVILLE RESEARCH AND ENBINEERING CENTER Q^ Repo. io. 1*32-321* Date June 19, 1970 Title: HARBISON-WALKER HARD FACED BLOCK - PROPERTIES COMPARED WITH "SUPEREX" SG Requested bjr: SSR No. IN-967 (complete) SUMMARY The Harbison-Walker Hard Faced Block was composed of about 3/1* in. of a high density mineral fiber sheet bonded with starch and clay. This was laminated to a conventional mineral fiber insulating block. The organic binder provided excellent strength and hardness until the organic binder was removed on exposure to heat. The hard face was then found to be seriously impaired as indicated by easy indentation with thumb pressure and extremely low resistance to abrasion. "SUPEREX", the hot face side of "SUPEREX" SG, by contrast shows only slight reduction in hardness and resistance to abrasion after exposure to service temperatures. It must be concluded that in service the hard face of the Harbison-Walker block may be eroded by compressive forces and vibration resulting in exposure of the mineral fiber insulating block to temperatures which would cause excessive shrinkage. By contrast, if the compressible backing of "SUPEREX" SG should become damaged, the "SUPEREX" the major portion of the block, facing the heat would in no way be endan gered. Contents: Summary, Discussion, Appendix I, and Appendix II. JM CONFIDENTIAL. N o t fo r gen Unbutton or republicatton. Reported by: K. F. Greene Mineral Fibers and Aerospace Specialties Section Jw cc: L. D. Sorrentino, DH Int'l M. W. Burleson, DH (S) H. E. Konrad, DH C. E. Ernst, DH S. A. Tompkins, DH (S) D. B. Wingerter, DH Mvl Pit W. L. Stafford, Casale A. G. Sinclair, Tor Off L. M. Adamson, Tor Off F. L. Pundsack ((S) J. A. McKinney L. R. Blair (S) W. C. Streib R. H. Neisel J. 0. Collins M. E. Binkley K. F. Greene K. L. Kinder (2) Library (2) File: W. K. Hesse Chrono Reference: Research Report No. 435-Int-1121 l*32-Int-7^7 Notebook No. U017, pp 17-20 File 1*32