Friday, June 29, 2018

Ingot Train

Normally, an ingot train would run inside a mill between the teeming facility in the open hearth building, the mill's yard tracks to let the steel cool, and the stripper in a rolling mill. [PracticalMachinist] Now ingots are obsolete because of continuous casting. The special heavy duty flatcars that carried the ingot molds were called ingot buggies.

United States Steel Corporation posted
This ThrowbackThursday we're climbing aboard the USS Express! Check out this image of ingot molds in transit from our Gary Works in Gary, Indiana.
Seymour Long: Unique trucks on those cars there. What kind are they?
EJ Jaquay: Seymour Long Don't know for sure but I guess standard wheels with AP bearings on special bolsters. The heavy covers over them are likely there to protect the wheels from teeming splashes.
James Torgeson shared

Graham Whitfield posted
Cast of Rimming ingots leaving the Teeming Bay on route to the Stripper Bay. Great bunch of guys on the Locos, the Drivers and Shunters serviced the Teeming landings, Mould Bay, Stripper Bay and Soaking Pits.
British Steel Llanwern 1978.
[The are some interesting comments about life in a steel mill.]

Michael Riha posted two photos with the comment: "Been awhile since I posted, so William O'Neal Stringer's post about the ingot train inspires these shots from one of my first trips to Calumet Ave on the lakefront...long before CN or even the casino."
Steven Suhs I recall handling one of these had 2 300’s. Was interesting to hold the speed at 15 mph when loaded when the 300’s did not have speedometers.
Chuck Olen Olejniczak I worked at US Steel South Works where we filled those molds with molten steel from the #4 Electric Furnace shop. They were sent to Gary Works to be stripped and rolled at the plate mill as our plate mill was closed in the early 80's.
William O'Neal StringerWilliam and 2 others manage the membership, moderators, settings, and posts for Friends of The EJ&E RR. Yes, but the steel had different qualities. They made plenty of regular steel at Gary Works.
[What we are looking at is really the molds holding the ingots. A machine called the stripper will lift a mold by the round lugs near the top and then a hydraulic plunger will shove the ingot out.]

1

2


PracticalMachinist
[There are no lugs at the top. How do they strip the mold?]

Chuck Roth posted
In front of the caboose is a steel ingot load.
Joe Usselman 95th street

Here we can see why they were called buggies. It looks like just two molds per car 2-axle car.
TheNewMikeFan21
O Guage
TrainWorldCity
[Another model. Since ingot trains normally stayed in a mill, there won't be too many railfan photos of them.]
ChestOfBooks
[I can't tell how many axles this buggy had.]
TrixTrains
[The ratio of one mold per two axles is rather common.]
The buggies were also used to carry trays holding scrap metal that were used to charge open hearth furnaces.
U.S. Steel Gary Works, April 19, 1912
One of the photos posted by Michael Mora about the lighthouses at the mouth of the Calumet River
[Note the cut of ingot cars in the middle of the photo. We are looking at the south side of U.S. Steel South Works.]
Ingot stripper in Homestead, PA  I could not find a date for this photo. The steel mill is not only gone, the brown land has been redeveloped.




John W. Coke shared his post of two photos with the comment: "Lehigh Heavy Forge Corporation, Hot ingot transport car. Photo by Barbara Ryan, Horseshoe Curve, October 2004."
Richard Middlekauff It is used to transport hot steel billets. We used to see them regularly thru Harrisburg from Steelton, hauling billets to Lehigh Heavy Forge. We had a Conrail engineer explain that there was a 16 hour window from when the billet hit the floor of the car to delivery at the forge. They would pull four or five of the cars up from Steelton to the Harrisburg yard. They hustled to connect them to the front of an eastbound stack train and take off.
Patrick Carroll I would assume that it was around 1600*-1800* Fahrenheit
Jason Kliewerhttp://www.rrpicturearchives.net/rsPicture.aspx?id=308787
Noe Gutierrez LHFX 37000 is a former Bethlehem (BFIX) car. It's a "hot ingot car"   https://lionelllc.wordpress.com/tag/flat-cars/     Four 3-axle Buckeye trucks enables the car to have a rated capacity of 744,500 pounds, or just over 372 tons.
1

2
Mikl Lussier commented on John's share
From their site :
<<Lehigh Heavy Forge has earned the elite status of Forgemaster.
Starting with ingots up to 285 tons, our 10,000 ton open die hydraulic press produces the largest forgings in the western hemisphere with ship weights exceeding 166 tons. In addition we also operate a 3,000 ton open die hydraulic press for work roll forgings, billets and smaller forgings of various configurations with ship weights starting at 10 tons.>>
[So the continuous caster has not made all ingots obsolete. Only those ingots that would be rolled. Since rolling mills are used to make beams, plates, rolled sheets, bars and wire, rails, etc., I imagine most steel is no longer initially cast as ingots.]

 
William O'Neal Stringer commented on his posting about a train order mixup between Kirk and South Works
William O'Neal Stringer commented on his posting about a train order mixup between Kirk and South Works
Al Wszolek One per car. Rocked side to side, think the soeed limit was 10 mph. Also a time limit on loaded ones to the stripper on Gary mill.The "J"had two divisions in Gary. Kirk Yard, and Gary Mill Yard. Mill yard switchmen were only allowed to perform service in that mill. KIRK yard was a where trains were assembled for going to the many connections that the J had. At one time it connected with every carrier that went into the Chicago swiching district .also out of KYD yard transfers handled cars into and out of Gary mill, plus local connections with many other carriers and other industries, and also transfer service to and from USS South Chicago. I hired in 1968,At that time we had about 50 regular assignments, plus extras put on as needed. Five men on a crew, foreman two helpers ,engineer and fireman, when I retired in 2003 ,a hogger and two ground was normal.


Bill Parkinson posted
Some ingot action at the No.1 open hearth back in the 1970's AIS works Port Kembla.
How do you define an ingot? For us in a remelt plant in Pgh, it was about the size of a household water heater, a little longer
Anybody?
In the Open Hearth days at U S Steel in Youngstown, Ohio our most common ingot size was 19" x 22". For us a heat would be about 42 ingots. We made a lot of bar stock that was rolled at the McDonald Mill, now McDonald Steel. We also poured ingots for blooms that would go to the 40" Hot Strip in McDonald. We had 2 Blooming Mills, one was a 40", the other was a 43". The biggest ingots that we poured were 26" × 43".
So, billet size is measured on the end of the bar. Under 36 square inches is a billet over 36" it is a bloom.
Our 43" mill would take a reheated ingot, roll it down to a bloom, then advance it without reheating to finish rolls where it was slit and rolled down to 4×4", 2×6", 2×8", and 2×2" size.
So, I have seen casters that cast bars, but you can make bars from larger ingots.
The smallest ingot moulds were probably for pipe rounds.
Just a note of clarification, the 19"×22" size was the actual ingot size at the top of the mould. The moulds were about 7 feet tall.
I remember stringing those ingot molds onto rail cars for the next heats! Then they’d go to stripper mill then to the soaking pits to be reheated for the old slab mill then on to the hot strip furnaces and turned into coils, and to the cold mill if finished.... Ford Rouge Plant Dearborn, MI🇺🇸 (from ‘74 to ‘16) a lot of changes and closures now.

Robert Ries posted three photos.
Vincent Daniel shared
1

2

3

Robert Ries posted two photos.
Vincent Daniel shared
Seen one splash over on auto’s look like a bomb.
1

2


Bob O'Neal posted sixteen photos with the comment:
HOMESTEAD STEEL WORKS - 1950
INGOT OPERATIONS:
A URR switcher brings an empty INGOT MOLD train into Open Hearth No.4. The overhead crane slowly swings the huge POURING LADLE of molten steel at 3500F to a position above the cars. The foreman in the pouring crane housing will supervise the pouring of ingots, directing the ladle's bottom stopper to open. After the train of ingots is filled, they will be taken out to cool, then, stripped of their molds in the STRIPPER SHED, the ingots are sent to the SOAKING PITS to be reheated to 2000F for the ROLLING MILL.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16


No comments:

Post a Comment