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12method for manufacturing wrought iron grew and many manufacturing plants were builtthrough out the United States.In the United States an industrial revolution occurred during the middle of the 19 thcentury. Evidence of this can be seen in the development of new production processes,more industries being built, further development of the assembly line, growth of cities,and a decrease in the agricultural work force. The United States would later experiencethe civil war, which meant that much iron was needed for the war and for rebuilding afterthe war. During this time of industrialization and growth, wrought iron was used quiteextensively through out the country as well as in the construction industry.Many iron companies through out the region started manufacturing standardizedshapes and sizes of iron to be used for construction purposes. Each iron company had aset of standardized shapes that were produced only by that company. The companieswould print compilations of what they produced and from these booklets iron productscould be purchased. The American Institute of Steel Construction (1953) compiled manyof these standard shapes from larger companies throughout the country from the years1873 to 1952. Some of these companies included Carnegie Brothers & Company,Limited, The Passaic Rolling Mill Company, and the Phoenix Iron Company.In addition to producing standardized shapes for building construction, many ofthe iron manufacturers designed and produced bridges. One popular bridge company wasthe Wrought Iron Bridge Company of Canton Ohio. This company designed, patented,manufactured and constructed bridges. Most of the bridge companies publishedpamphlets describing the different types of bridges they built and their uses. For example,Figure 2.4 shows the front cover of a pamphlet published by the Wrought Iron BridgeCompany. Many cities, counties and even farmers simply ordered bridges from bridgecompanies by using their pamphlets. This phenomenon lead to the existence of numerouswrought iron bridges through out the United States.
13Since there was such a demand for wrought iron in the late 19 th century, manymechanical processes were invented to increase the production and quality of wroughtiron. These mechanical processes were needed to increase production capacity andreduce the amount of labor dependence that existed in the previous processes. Many newfurnaces were introduced, but none were very successful in their attempts.Concurrent with the attempts to improve the mechanical manufacture of wroughtiron, Henry Bessemer developed a new process for making steel, which was introducedaround 1855. Before this, the methods for making steel were very complex and tedious,therefore making steel was rare and more expensive to use for any sort of buildingpurposes. These processes are known as the cementation and crucible processes.Developed many years before-hand, these steel-making processes involved the additionof carbon to iron by soaking iron in carbon and letting it set over time, or meltingwrought iron and mixing it with a carbonaceous material (Stoughton, 1934).The basic concept of the Bessemer process depends on the successful rapidoxidation of the impurities (Si, Mn and C) by keeping the iron ore in a fluid molten bathwith extreme heat, thus forcing the slag to separate from the steel by floatation (Johnson1928). This was done by subjecting molten pig iron to a superheated pressured blast forabout twelve to fifteen minutes. Figure 2.5 depicts a picture of a Bessemer Converterduring one of these blasts. After oxidizing all the impurities out of the molten iron, analuminum and manganese alloy carrying several percent carbon was added. Theintroduction of this alloy resulted in the addition of carbon to the molten iron, making itsteel. Then the molten steel is poured and solidified into ingots and castings which arethen rolled into shapes (Johnson, 1928).The original Bessemer process created a brittle steel that was not useful. Then in1856 Robert Mushet discovered that by adding a compound containing manganese andiron to the molten iron in Bessemer’s process, the resulting steel could be made moreductile and have superior strength (Fisher, 1963). Bessemer and Mushet received many
Page 1 and 2: Purdue UniversityPurdue e-PubsJTRP
Page 3: 1. Report No. 2. Government Accessi
Page 6 and 7: epairing a bent wrought iron tensio
Page 8 and 9: vPageCHAPTER 3TEST PROCEDURES FOR M
Page 10 and 11: ixLIST OF FIGURESFigurePageFigure 1
Page 12 and 13: xiFigurePageFigure 3.30 Top View of
Page 14 and 15: xiiiFigurePageFigure 5.12 Typical T
Page 16 and 17: xvAppendix FigurePageFigure D.7 Ini
Page 18 and 19: viiiAppendix TablePageTable A.5 Det
Page 20 and 21: iiiThe authors would also like to t
Page 22 and 23: 2but also what material properties
Page 24 and 25: 4microstructure of the metal. The c
Page 26 and 27: 62. LITERATURE SEARCHBefore experim
Page 28 and 29: 8imperfections, the performance of
Page 30 and 31: 10wrought iron. Adding the slag aft
Page 34 and 35: 14patents for their process and tra
Page 36 and 37: 16This method of testing of structu
Page 38 and 39: 18plot of this percent elongation d
Page 40 and 41: 20significant variation in the perc
Page 42 and 43: 22The practice of restoring histori
Page 44 and 45: 24Elleby, Wallace W. Sanders, F. Wa
Page 46 and 47: 26From all the surveys that were di
Page 48 and 49: 28Table 2.1 Average Ultimate Streng
Page 50 and 51: 30Figure 2.3 Wrought Iron “Sponge
Page 52 and 53: 32Histogram of Kirkaldy Wrought Iro
Page 54 and 55: 34Percent Occurance in Range - %45.
Page 56 and 57: 3660Combined Wrought Iron BarsTensi
Page 58 and 59: 38The Bell Ford Bridge consisted of
Page 60 and 61: 40Two. These samples were taken fro
Page 62 and 63: 42specimens were of constant cross
Page 64 and 65: 44Along with rectangular tensile co
Page 66 and 67: 46After the initial test loading wa
Page 68 and 69: 483.6 Fatigue TestingTo develop a b
Page 70 and 71: 50The final specimen category consi
Page 72 and 73: 52This analysis was completed using
Page 74 and 75: 54After the initial test was comple
Page 76 and 77: 56completed, but before the surface
Page 78 and 79: 58readings, load cell readings and
Page 80 and 81: 60Figure 3.3 Donated Eyebars 4 and
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62Figure 3.7 Heated Areas in Blue o
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64Figure 3.11 Detail Used in Groove
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66900080007000y = 27.153xR 2 = 0.99
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68Figure 3.19 Charpy Impact Testing
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70Figure 3.23 Eyebar Connection in
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72Figure 3.27 Eyebar A After Filler
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74Figure 3.31 Side View of Finished
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76Figure 3.35 Front View of Eyebar
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78strength from the existence of pe
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80The carbon content present in the
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82value may not be very accurate bu
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84strengths was found to be 29,940
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86wrought iron bars were investigat
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88stresses are induced. These perma
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90toughness the material. The test
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92From the finite element analysis,
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94Table 4.1 Chemical Analysis of Ey
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96Table 4.3 Tensile Coupon Test Res
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98Table 4.5 Charpy Impact Test Resu
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100Table 4.7 Comparison of Strain G
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102Figure 4.1 Typical Micrograph of
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104Figure 4.5 Fracture Surface of D
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106Comparison of Tensile Strengthfo
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108Combined Wrought Iron Bar Histor
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110Figure 4.17 Macrograph of Weld u
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112Figure 4.21 Cleavage Fracture of
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Figure 4.25 Elongation of Hole in E
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116signs on or near the bridge that
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118testing of historic wrought iron
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120so that they would act in symmet
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122The reasons for the differences
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124The second corrosion pattern mod
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126Keating (1984) stated that the s
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128charcoal fire until it is red ho
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130Figure 5.3 Picture of Bottom Cho
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132Figure 5.7 Using Force After Usi
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134Figure 5.11 Reassembling a Pin C
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1366. SUMMARY, CONCLUSIONS AND IMPL
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138rectangular in shape. These eyeb
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140were joined together with a full
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1424. The Charpy impact energy of t
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144connections are unsymmetrical, i
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146LIST OF REFERENCESAASHTO (1998).
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148Hodgkinson, Eaton (1840). Experi
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150Appendix A. Data Collected From
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152Table A.1 Wrought Iron Bar Tensi
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154Table A.1 (continued) Wrought Ir
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156Table A.2 (continued) Wrought Ir
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158Table A.3 Wrought Iron Angle Ten
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160Table A.4 (continued) Summary of
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162Table A.4 (continued) Summary of
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164Table A.5 (continued) Detailed I
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184Table A.7 Tensile Strength Data
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186Table B.1 Example Historic Wroug
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188DepartmentofTransportationIf you
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190CountyIf your organizationdoes m
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192County 16: County bridge inspect
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194State 13: Included in original d
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196Figure C.1 Diagrams Showing Loca
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198Figure C.3 Heating of Eyebar fro
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200Figure C.7 Double V Butt Joint u
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202Figure C. 11 Welded Tensile Coup
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204Figure C.15 Tensile Coupon from
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206Figure C.19 Cooling Bath with Su
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208Figure C.23 Side View of Eyebar
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210Figure C.27 Eyebar End Connectio
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212Appendix D. Welding Procedure fo
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214D.2 Filler Weld for Eyebar Conne
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216Figure D.1 Weld Joint Detail Use
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Figure D.5 Completed Weld Before Su
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220Figure D.7 Initial Pass Pattern
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