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Crucible steel is a steelmaking process that involves melting materials in small foundry crucibles for carburizing or decarburizing. The process produces high-quality steel with specific characteristics. It is one of the oldest documented methods of making steel and is still used for specialized applications. The process involves heating crucibles to white heat, loading them with raw materials, and leaving them for several hours until the materials have dissolved. The steel is then poured into ingot moulds. The process has largely been replaced by cheaper, high capacity processes such as Bessemer ovens.
The term crucible steel can be somewhat misleading as it does not refer to a particular steel product but rather to a specific steelmaking process. The crucible steel process involves melting materials such as wrought iron, cast iron, and blister steel in small foundry crucibles for carburizing or decarburizing. During these processes, carbon is diffused or removed from the stock to produce optimum metallurgical qualities in the finished product. After melting, the crucible is removed from the furnace and the steel is poured into ingot moulds. The crucible steel process is one of the oldest documented methods of making steel, and although it has been replaced with more efficient methods, it is still used to produce small quantities of high quality materials for specialized applications.
Steel is a combination of iron and small amounts of carbon. Combinations like these are known as alloys with additives, in this case carbon, which enhance the quality of the base material and impart specific characteristics to the final product. Steel, for example, is harder than wrought iron, less brittle than cast iron, and has better wear and corrosion resistance qualities than both. Steel can be produced in a variety of ways, most of which involve smelting iron stock in the presence of a carbon source. This process causes small amounts of carbon to diffuse into the molten iron with typical final carbon concentrations ranging from 0.2% to 2.1% depending on the intended use of the alloy.
One of the oldest forms of steel making is the crucible steel process; the earliest reliable records of crucible steels are medieval Islamic records from about 1050. The basic principle of crucible steel is centered around melting metal stock in vessels or containers made of various refractory materials small enough to be handled by one or two people. The containers or crucibles are charged with various metals including wrought iron, cast iron or blister steel and fired in special furnaces to melt the charge. Low carbon materials such as wrought iron are supplemented with a carbon source such as coal which carburizes or infuses the melt with carbon. Conversely, stock materials with carbon contents too high for general steel production are decarburized; this is typically done by exposing the molten material to a source of oxygen.
The process generally begins with heating the crucibles to white heat in a coke or gas oven, at which point they are removed from the heat source, loaded with raw materials, and returned to the oven. They are then left for several hours until the raw materials have completely dissolved. The crucibles are then removed from the furnace, any impurities on the surface of the molten steel are skimmed off, and the steel is poured into ingot moulds. This process is time consuming and expensive and has largely been replaced by cheaper, high capacity processes such as Bessemer ovens. However, the high quality of crucible steel has meant that the process is still used to produce small quantities of steel for specialized niche markets.
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