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Dwarf Fortress => DF Modding => Topic started by: Tellemurius on January 14, 2010, 12:01:29 pm

Title: metallurgy
Post by: Tellemurius on January 14, 2010, 12:01:29 pm
ok so i know there is many modders trying to add more metals to the game but my question is:
what alloys are possible to make with dorf technology?
Title: Re: metallurgy
Post by: sunshaker on January 14, 2010, 12:11:01 pm
Anything before about 1700 looks to be fair game. After 1700 a good understand of chemistry starts and you see an explosion of knowledge (chemicals, synthetic dyes, new metals, new methods of refining, why certain refining methods will work with something and not others).
Title: Re: metallurgy
Post by: Stargrasper on January 14, 2010, 10:50:22 pm
I think Toady said 1400 was his arbitrary cutoff date for technology in DF.  You can do your own homework to see what that actually means for us as far as metallurgy is concerned.
Title: Re: metallurgy
Post by: slink on January 14, 2010, 11:07:41 pm
There are some nice comments by Tarn Adams inside the metals raw.  From those you can get some idea what is possible in his estimation.  If he feels that the metal is not capable of being refined within his timeframe, then the alloys of that metal should also not be possible.

After a while you may decide to follow your own imagination.  There are mods out there with modern metallurgy, with synthetics, and with any number of imaginary metals and alloys.   :)
Title: Re: metallurgy
Post by: Tellemurius on January 15, 2010, 11:21:22 am
well my hobbit mod needs some work done on metals. now im asking what available alloys was possible before the 1400's and see if Tolkien made a connection.
Title: Re: metallurgy
Post by: Arrkhal on January 15, 2010, 03:14:15 pm
There really aren't a whole lot of useful pre-1400 practical alloys that aren't in the game already, or that aren't variations on a theme (i.e., varying the tin content in bronze).

About the only historical and practical alloy I can think of is arsenical bronze, made from a combination of copper and arsenic.  Realgar and orpiment are arsenic ores.  Too bad poisons aren't implemented.

A lot of cultures' metalsmith gods, like Hephestus/Vulcan, are deformed, lame, and/or mad, since many early copper- and bronzesmiths would start suffering the effects of arsenic poisoning after many years.  Even if they weren't intentionally making arsenical bronze, many copper ores have arsenic in them already.

I guess you could also make certain rocks be ores of mercury, though it's not yet possible to do reactions which require a container like a vial, as mercury should.  Don't know what uses mercury amalgams would have in DF.  Lots of crazy people throughout history were dumb enough to drink it, just because shiny has to = good.

Hm, nickel is in the game.  You could add meteoric iron, which is a combination of iron and nickel.  IMO, it should make armor that's nearly as good as steel, but weapons that aren't that much better than regular iron.
Title: Re: metallurgy
Post by: Flaede on January 15, 2010, 03:29:07 pm
there's meteor iron, and the resulting stuffs from that. Didn't one of tolkien's swordities have that as a source material? I know it gets talked of a lot in various legends and whatnot.

Google sez : check out this book (http://www.springerlink.com/content/x548046w7p174500/") (or one like it) and you may have your answers.
 "Although there are 70 metallic chemical elements, only 8 (gold, copper, lead, iron, silver, tin, arsenic and mercury) were recognized and used in their metallic state before the eighteenth century CE."

That quote is apparently from a chapter on extractability vs profit, and how this has changed through the centuries. Archaeomineralogy looks interesting. Now I go to search Google with the keyword "Archaeomineralogy".
Title: Re: metallurgy
Post by: slink on January 15, 2010, 04:11:54 pm
Cinnabar is the ore of mercury that is present in DF, but mercury doesn't seem very useful in DF unless you plan on practicing dentistry.   :D

There are a few miscellaneous gold alloys that could be used for decorative items, but like the colors of bronze they are not much different except for proportions.
Title: Re: metallurgy
Post by: G-Flex on January 15, 2010, 05:09:48 pm
They could probably make some aluminum alloys, but diluting something as absurdly rare as aluminum just doesn't seem like a great idea.

The most obvious alloy that hasn't been implemented is white gold, similar to rose gold but with nickel instead of copper. I'm not sure if people actually USED it that long ago, but it's quite plausible for inclusion.
Title: Re: metallurgy
Post by: Arrkhal on January 15, 2010, 05:50:03 pm
That reminds me of something.  I believe metallic zinc was not isolated until the 18th century, but brass was known as early as 30 BC or before, and was used to make weapons and possibly armor.  So if you want historical accuracy, you should make it so that zinc cannot be extracted from the ores, but zinc ore + copper metal can be combined to make brass.

And hm, the use of metallic nickel dates back to 3,500 BC, and it was commonly mistaken for silver.  So actually, the manufacture of "meteoric" type iron from iron and nickel is quite plausible, even though I don't believe it was ever actually done in human history.  It'd also be fun to make iron meteors occur very rarely in all layers.
Title: Re: metallurgy
Post by: 0x517A5D on January 15, 2010, 07:07:33 pm
Cinnabar is the ore of mercury that is present in DF, but mercury doesn't seem very useful in DF unless you plan on practicing dentistry.   :D

Mercury can be used to make mirrors, which might be useful for the lighting arc.

Mercury is useful in extracting gold dust from ore.

Mercury fulminate.  Easy to make, powerful, high explosive.  Very dangerous to handle, forms poisonous gases on detonation, leaves poisonous residue.  Very dwarfy.  I think the alchemist should be able to make it, as it only takes metallic mercury, nitric acid, and distilled alcohol.
Title: Re: metallurgy
Post by: ein on January 16, 2010, 04:30:16 am
Mercury fulminate.  Easy to make, powerful, high explosive.  Very dangerous to handle, forms poisonous gases on detonation, leaves poisonous residue.  Very dwarfy.  I think the alchemist should be able to make it, as it only takes metallic mercury, nitric acid, and distilled alcohol.

You weren't kidding about the easy to make part.
The hardest item on that list to get is mercury and even that's easy.

Unfortunately for DF purposes:
Quote from: Wikipedia
Mercury(II) fulminate is prepared by dissolving mercury in nitric acid and adding ethanol to the solution. It was first prepared by Edward Charles Howard in 1800.
Title: Re: metallurgy
Post by: ungulateman on January 16, 2010, 05:10:39 am
They're dwarves.

The process involves alcohol.

And explosions.

I think we can bend the rules a bit here.
Title: Re: metallurgy
Post by: Arrkhal on January 16, 2010, 12:42:56 pm
Actually, all the ingredients for mercury fulminate fall into DF's arbitrary time period, even if the end result doesn't.  Nitric acid was discovered by Middle Eastern alchemists in the 8th century.  It's made from saltpeter and water, both of which are already in the game.
Title: Re: metallurgy
Post by: immolo on January 16, 2010, 01:12:08 pm
Actually, all the ingredients for mercury fulminate fall into DF's arbitrary time period, even if the end result doesn't.  Nitric acid was discovered by Middle Eastern alchemists in the 8th century.  It's made from saltpeter and water, both of which are already in the game.
And anyone with half a brain with a time machine could go back to Alexander the Great's time and invent the steam engine then. After all Heron actually had created a sort of basic steam engine. There are many example of things where you could go back and invent something if you already had the knowledge even if you only used their technology.

Not to mention it doesn't fit the setting at all. The gun and black powder were invented long before 1400 but you don't see them in the game.
Title: Re: metallurgy
Post by: Arrkhal on January 16, 2010, 01:17:20 pm
Steam engines were described a mere 400 years after Alexander the Great's rule.  No one thought they would amount to anything, but that's because they weren't dwarves.  Well, except one guy thought that steam engines could be used to forecast the weather, and he was actually probably correct, since air pressure changes the boiling point of water.

And it sounds like gunpowder is going in, in a future release, though it will be off by default in the init.
Title: Re: metallurgy
Post by: G-Flex on January 16, 2010, 02:10:09 pm
Steam engines were described a mere 400 years after Alexander the Great's rule.

Explain? And no, the aeolipile doesn't count.
Title: Re: metallurgy
Post by: Ramirez on January 16, 2010, 10:03:13 pm
My personal mods I make place the cutoff point being where heat and carbon alone cannot extract the metals from their ores. This results in things like titanium carbide (brittle and mostly useless ceramic, although can be used to make cermets) appearing, although immediately useful elemental metals don't really appear. Also adding the platinum group metals works, as they are found naturally in platinum deposits.
Title: Re: metallurgy
Post by: sunshaker on January 16, 2010, 10:28:45 pm
Cinnabar is the ore of mercury that is present in DF, but mercury doesn't seem very useful in DF unless you plan on practicing dentistry.   :D

Quote
By Arrkhal I guess you could also make certain rocks be ores of mercury, though it's not yet possible to do reactions which require a container like a vial, as mercury should.  Don't know what uses mercury amalgams would have in DF.  Lots of crazy people throughout history were dumb enough to drink it, just because shiny has to = good.

Mercury Amalgams were useful in refining metals, though it is not a pleasant process. Basically mercury will form an amalgam with most other metals (iron, tantalum, tungsten and platinum being the exception). This lets you separate a metal that forms an amalgam from ore (basically it oozes out of the crushed rock), this takes WEEKS, then you separate the mercury from the metal (I think via sulfur to form Cinnabar but I'm not sure). see http://en.wikipedia.org/wiki/Patio_process (developed in 1557 for use in silver mining, but could be used with any metal that forms an amalgam, though different additives may be needed). I think, if I'm reading wiki right that you could do something similar to separate an alloy consisting of an amalgam metal and a non-amalgam metal (say a copper-iron alloy) and recover both of them afterwards (well maybe not aluminum but it has an interesting reaction to mercury). [Edit] This allows the refining of poorer ores (say 1 to 5% instead of 40 to 60%).
Title: Re: metallurgy
Post by: Eagle0600 on January 17, 2010, 02:27:02 am
You could give any smelting involving mercury [PRODUCT:2:1:SKIN_TANNED:NO_SUBTYPE:LEATHER:NO_MATGLOSS] to give a small chance of killing the worker (and anyone in the room). If anyone else has more experience with deadly leather than me, go ahead pint out where I went wrong.
Title: Re: metallurgy
Post by: Flaede on January 17, 2010, 04:47:44 pm
You could give any smelting involving mercury [PRODUCT:2:1:SKIN_TANNED:NO_SUBTYPE:LEATHER:NO_MATGLOSS] to give a small chance of killing the worker (and anyone in the room). If anyone else has more experience with deadly leather than me, go ahead pint out where I went wrong.

It needs to have a rare chance of inducing nuttiness. (or perhaps a cumulative effect, if such can be done with the current poison system)
Title: Re: metallurgy
Post by: Eagle0600 on January 17, 2010, 09:11:52 pm
It can't. That up there was the best I could come up with. Feel free to tweak the chance and/or include it in a mod.
Title: Re: metallurgy
Post by: immolo on January 17, 2010, 10:58:27 pm
Steam engines were described a mere 400 years after Alexander the Great's rule.  No one thought they would amount to anything, but that's because they weren't dwarves.  Well, except one guy thought that steam engines could be used to forecast the weather, and he was actually probably correct, since air pressure changes the boiling point of water.
The basic sorta steam engine you are talking about was the one I mentioned Heron or Hero had created.
Title: Re: metallurgy
Post by: G-Flex on January 18, 2010, 12:38:32 am
Which wasn't a steam engine any more than a paper fan is a wind turbine.
Title: Re: metallurgy
Post by: TwilightWalker on January 18, 2010, 01:47:56 am
Which wasn't a steam engine any more than a paper fanwindmill is a wind turbine.
Fixed

In essence, it is a steam engine. As in, it uses heat and water to create mechanical energy. It's just a whole lot more inefficient and crude than a 'modern' steam engine.
Title: Re: metallurgy
Post by: G-Flex on January 18, 2010, 01:57:03 am
That's incorrect. A better analogy might be one of those silly little pinwheel things, rather than a windmill.

The aeolipile wasn't really used to do any useful work ("work" in the scientific sense); it wasn't connected to anything and, by itself, couldn't really do much except sit there spinning.

So it's like a pinwheel: It demonstrates a basic concept that can, in fact, be used as an engine, but is not any sort of useful engine itself and doesn't imply that the knowledge existed to create one.
Title: Re: metallurgy
Post by: Eagle0600 on January 18, 2010, 03:20:40 am
Yes. The deciding factor is if it implies the knowledge required to make a functional steam engine.

Also to consider: Should common dwarves really be using something that only one obscure engineer knows about and couldn't implement properly anyway?
Title: Re: metallurgy
Post by: G-Flex on January 18, 2010, 04:38:36 am
Yes. The deciding factor is if it implies the knowledge required to make a functional steam engine.

Right. I don't think there's much evidence that the people then understood the potential of it, nor did they likely have the manufacturing capability either.
Title: Re: metallurgy
Post by: Eagle0600 on January 18, 2010, 05:34:29 am
Agreed.
Title: Re: metallurgy
Post by: Arrkhal on January 18, 2010, 04:13:49 pm
Whether or not dwarves would have technology that ancient Greeks did is pretty far beyond the point.  There are definitely way better ways of deciding whether something should go into the game.  Are explosives dwarfy, or aren't they?  Is a steam engine dwarfy, or isn't it?

Also, even though the Greeks never thought of Hero's engine as anything but a curiosity, it still wouldn't have taken that much lateral thinking to have made it reasonably practical.  They knew of water wheels at least as early as 100 BC, and probably closer to 240 BC.  A stationary steam "spigot" blowing on a wheel could've easily set them on the path to a practical steam turbine engine.  Especially if they put two and two together with the Archimedes' screw and figured out that sealing the turbine in a housing increases efficiency enormously.

No one ever thought of that back then, but then none of them were dwarves either.  Jets of high pressure, lethally hot steam (heated by magma, of course) being harnessed to open doors and grind cave wheat doesn't seem that un-dwarfy to me.

More like a player-controlled megaproject, rather than a ready-built (M)achine component, but still reasonably dwarfy.
Title: Re: metallurgy
Post by: NRN_R_Sumo1 on January 18, 2010, 04:26:40 pm
Dwarves are known throughout lore and video games, and films and movies, as the type of folk who would have been the first to invent something such as a steam engine.
They are not ancient greeks, infact they are of norse mythology, so it makes little to no sense to even bother comparing them for anything other than time periods.

If the dwarves understand water wheels and pumping concepts, theres only so much time until a dwarf notices that that steam blasting off of that fresh layer of obsidian could indeed knock a dwarf clean off his feet, and then realizes it is capable of being harnessed, just like a mighty river.

We're talking about people who are mighty enough to tame dragons, people who are smart enough to forge some of the greatest weapons in lore... and the lore of dwarves have said over and over again, they are able to harness the power of steam.
Title: Re: metallurgy
Post by: G-Flex on January 18, 2010, 05:17:08 pm
Dwarves are known throughout lore and video games, and films and movies, as the type of folk who would have been the first to invent something such as a steam engine.

Being the first doesn't mean you're several hundred years ahead of the curve, and DF dwarves don't have to be identical to whatever other dwarves you're talking about anyway.

Quote
If the dwarves understand water wheels and pumping concepts, theres only so much time until a dwarf notices that that steam blasting off of that fresh layer of obsidian could indeed knock a dwarf clean off his feet, and then realizes it is capable of being harnessed, just like a mighty river.

You could say the exact same thing about real people, who invented waterwheels, screw-pumps, gearing, and complex mechanical things based on them far, far before realizing the potential of a steam engine.

Quote
We're talking about people who are mighty enough to tame dragons, people who are smart enough to forge some of the greatest weapons in lore...

"Dwarves are really really cool" isn't an excuse to give them whatever you want.

Quote
and the lore of dwarves have said over and over again, they are able to harness the power of steam.

Modern fantasy fiction is also often really bad at worldbuilding. Dwarves being able to build steam engines means they likely have a level of manufacturing capability that's inconsistent with the rest of the fictional world, and even if it's not, what "lore" are you talking about? Warcraft? Dungeons & Dragons? Some other modern fantasy that doesn't even necessarily apply here?
Title: Re: metallurgy
Post by: Eagle0600 on January 18, 2010, 08:36:16 pm
If we're going with lore from outside of DF, then kobolds would be sorcerers and masters of trap-building. They're not. That is not DF kobolds.

If we're going with lore from outside of DF, then elves would be peace-loving, intelligent, and friends to all living things. They're not. That is not DF elves.

If we're going with lore from outside of DF, then yes, dwarves would have steam engines. They don't. That is not DF dwarves.

If it's going in, it's going in as a mega-project-style construction. IF.
Title: Re: metallurgy
Post by: NRN_R_Sumo1 on January 18, 2010, 09:14:02 pm
Well of course I'm not saying that it should be going against the DF lore, but incase you havent noticed, Stories Grow, Lore expands, and if Toady is planning on putting in a form of steam power, dont be complaining about it.

It's His game, and adding features to it shouldnt be shot down like they are referances to the holocaust.
Title: Re: metallurgy
Post by: G-Flex on January 18, 2010, 09:59:29 pm
If we're going with lore from outside of DF [...]

Trouble is, you have to ask yourself which lore you're using to begin with.

Gnomes could wind up being anything from little pointy-hatted guys who sit on your lawn to weird creatures in mines made out of living stone to mischievous gremlin-like creatures who build strange machinery, for example.

Pretty much all the fantasy concepts mentioned have varied so much over the decades/centuries that it's kind of foolish to prescribe very many particular concepts as "canonical" for a given creature or concept (not that I'm saying you're doing this).
Title: Re: metallurgy
Post by: Eagle0600 on January 18, 2010, 11:20:00 pm
Where has Toady said he is putting Steam engines in? He hasn't. He doesn't appear to have even mentioned them.
Title: Re: metallurgy
Post by: NRN_R_Sumo1 on January 18, 2010, 11:35:12 pm
Where has Toady said he is putting Steam engines in? He hasn't. He doesn't appear to have even mentioned them.
I never said he did, I said that if he wants to do whatever he wants to do, he is free to do so, and argueing about what should go in is pointless, as toady is the one in control.

Especially considering this topic is officially off the rails two pages ago, I think we should just end this little discussion.
Title: Re: metallurgy
Post by: Arrkhal on January 18, 2010, 11:51:02 pm
Some people really don't want poo in the game, some really don't want steam engines.

Clearly, what every fortress needs is a steam-powered sewer system which doubles as a poo cannon.

Also, I'm trying to figure out what kind of technical difficulties there'd be with making iron-nickel alloys.  One guy says the technology to make them didn't exist until the 1800's, but maybe he misspoke.  Nickel wasn't identified until the 1800's, even though it had been smelted by many different cultures as early as 3500 BC, but most of them thought that it was either the same thing as silver, or that it was some type of "white copper."

I can't really think of any reasons you couldn't just mix some nickel into a crucible of molten iron, other than the fact that the nickel would sink to the bottom if you kept the mixture molten long enough.

And nickel is already known by the dwarves in-game to be a different metal than silver and copper, so that argument won't work.  They can also smelt zinc, which is an anachronism.
Title: Re: metallurgy
Post by: G-Flex on January 19, 2010, 12:00:49 am
Where has Toady said he is putting Steam engines in? He hasn't. He doesn't appear to have even mentioned them.

He's mentioned that he isn't putting them in, and probably more than once. Even gunpowder is very much an edge-case scenario to him, in that he wants to support it but not in the game's worlds by default.
Title: Re: metallurgy
Post by: Tellemurius on January 19, 2010, 11:22:41 am
hold on here people im only talking about metallurgy not about steam engines or gunpowder though maybe later when i make the tread. dwarves in their lore should be able to use zinc in its metallic state but would need the alchemist to find uses for it. damnit i just posted a suggestion for research.
Title: Re: metallurgy
Post by: The13thRonin on January 19, 2010, 01:12:16 pm
Not to mention it doesn't fit the setting at all. The gun and black powder were invented long before 1400 but you don't see them in the game.

You might in a certain mod in the near-future :-X.

Shh, I didn't say anything ;).
Title: Re: metallurgy
Post by: Arrkhal on January 19, 2010, 02:44:02 pm
You quoted the wrong person!  I didn't say that.

I'm also still not sure if there's a valid technological/metallurgical reason that dwarves couldn't make about a 95% iron 5% nickel alloy.  Even if the metals don't mix well, it could be done in small batches with lots of stirring.
Title: Re: metallurgy
Post by: immolo on January 19, 2010, 03:55:23 pm
You quoted the wrong person!  I didn't say that.

I'm also still not sure if there's a valid technological/metallurgical reason that dwarves couldn't make about a 95% iron 5% nickel alloy.  Even if the metals don't mix well, it could be done in small batches with lots of stirring.
Please read the wikipedia articles about metallurgy. History of ferrous metallurgy is particularly helpful.
Title: Re: metallurgy
Post by: sunshaker on January 19, 2010, 04:12:05 pm
Some people really don't want poo in the game, some really don't want steam engines.

Clearly, what every fortress needs is a steam-powered sewer system which doubles as a poo cannon.

Also, I'm trying to figure out what kind of technical difficulties there'd be with making iron-nickel alloys.  One guy says the technology to make them didn't exist until the 1800's, but maybe he misspoke.  Nickel wasn't identified until the 1800's, even though it had been smelted by many different cultures as early as 3500 BC, but most of them thought that it was either the same thing as silver, or that it was some type of "white copper."

I can't really think of any reasons you couldn't just mix some nickel into a crucible of molten iron, other than the fact that the nickel would sink to the bottom if you kept the mixture molten long enough.

And nickel is already known by the dwarves in-game to be a different metal than silver and copper, so that argument won't work.  They can also smelt zinc, which is an anachronism.

I think the big thing is that they didn't have molten iron then. To get molten iron you need a blast furnace (England 1491, mainland Europe a few years earlier*). Up until that point all iron and steel refining was done via bloomeries (an example http://www.youtube.com/watch?v=gDy1jx6mLgs). Now some could argue that dwarves know a little more about metal, and some could argue that they have pig iron so they must have blast furnaces (a poorly operated bloomery will make cast iron), but you never see the option "Cast (metal) (object)" in the game, it is always forge. Further with the invention of blast furnaces iron production increases in size (in game terms you should be making 5 or 10 bars at a time instead of just one) and the process of making iron is reversed (blast furnaces make pig iron which is further refined into wrought iron and steel, you don't start with iron and work your way up).

Iron melting point 1538 °C, 2800 °F, nickel melting point 1453 °C, 2651 °F, Copper melting point 1084.62 °C, 1984.32 °F, Gold melting point 1064.18 °C, 1947.52 °F, Silver melting point 961.78 °C, 1763.2 °F.

---

* Ok yes the Chinese had them from about 500 BCE and could make cast iron tools, they couldn't make wrought iron in the blast furnace until about 200 CE.
Title: Re: metallurgy
Post by: Arrkhal on January 19, 2010, 05:28:58 pm
Quote
* Ok yes the Chinese had them from about 500 BCE and could make cast iron tools, they couldn't make wrought iron in the blast furnace until about 200 CE.

It does seem as though dwarves follow Chinese steelmaking more closely than European.  It's a combination of iron and pig iron, which is pretty similar to how some Chinese smiths made steel between about 100 BC and 100 AD (using a combination of wrought and cast iron, melted in a crucible).  And yes, as you mentioned, they had a workable blast furnace by about 200 AD.

The Indians had very advanced, glass-fluxed crucible steel at least by 200 AD, possibly as early as 300 BC.

And the dwarven use of flux definitely implies that the dwarves are making some type of crucible steel.

Also, the forge/cast semantics are pretty meaningless since it also applies to copper-based stuff.  Bronze weapons were nearly always cast, then cold-worked, but it doesn't say "cast and cold-work bronze short sword" either.

And on the semantics angle, recycled items, regardless of material, are marked for "melting," not for "forge-welding into a billet."

Magma isn't hot enough to melt iron, but Toady has said that will be addressed in the next version.

So if a complete melt and historical human ignorance of nickel are the main reasons to not have iron-nickel alloys, then the dwarves at least could logically have them.
Title: Re: metallurgy
Post by: sunshaker on January 19, 2010, 05:48:29 pm
There is probably a limit imposed a by lack of knowledge as well (mostly chemistry, alternate refining techniques, and how to extract the rare metals from ore).

One of the things I will be doing once the new version comes out is making a custom workshop called a blast furnace, then I will reorganize the metal making processes (the smelter keeps the small scale easy way, the blast furnace gets the we make 10 bars minimum at a time and do it the fast way, I might even make casting reactions for objects (casting tends to make the lowest quality objects anyways)), likely the blast furnace will be dwarves only. If I feel motivated I might make a Refinery that lets you do other methods of refining (mercury amalgam, gold cyanide leaching, acid extraction and the like).
Title: Re: metallurgy
Post by: Arrkhal on January 19, 2010, 06:30:15 pm
Quote
There is probably a limit imposed a by lack of knowledge as well (mostly chemistry, alternate refining techniques, and how to extract the rare metals from ore).

True, though trial and error played some part as well.  Hm.  Given that the dwarves do already know of nickel silver and what it is (I believe the Chinese thought that it was a certain "type" of copper, rather than a copper alloy), actually it's pretty likely they'd stumble across iron-nickel alloys at some point.  Nickel silver tarnishes much less readily than copper, brass, or bronze, so it'd be quite logical to add nickel to steel in an effort to make it stainless.

And your blast furnace idea sounds kind of similar to a mod I tried a couple months ago.  Basically, it had no-melt, and melt+flux methods for producing both iron and steel.  Bloomery and blast furnace for iron, blistering and crucible for steel.  No-melts were slower and less efficient, but melts required flux.  Ended up pretty unworkable due to the intermediate stages necessary to simulate time taken.

Hopefully the new workshop system will allow a more streamlined approach to that.
Title: Re: metallurgy
Post by: Grimlocke on January 19, 2010, 09:51:13 pm
I figured patterened steel would be worth mentioning.

It could be included in the game as a lower tech steel, one that would not be good for making armour, but better than iron for weaponsmaking. Possibly humans and goblins could be made to have them once the game allows such modding, as I think both of those not having steel is kind of weird.

Actualy if you consider dwarven steel to be one that has an irregular carbon content, then you could even consider patterened steel to be better for weaponmaking.
Title: Re: metallurgy
Post by: Eagle0600 on January 20, 2010, 01:01:38 am
Another thing to consider with any metal forging is that there are various methods of forging that get very different results. For instance, and traditional European blacksmith would hammer an object into shape and then either leave it to cool or douse it. Both of these would have the same effect: The metal crystals would contract away from each other, leaving the metal weaker than the Asian method. The Asian method was to hammer it constantly as it cooled, so that the crystals would not draw away from each other. This would make the metal very much stronger, and therefore their weapons could be thinner and sharper, and their armour less prone to bend/break.
Title: Re: metallurgy
Post by: Arrkhal on January 20, 2010, 09:55:52 am
Quote
Another thing to consider with any metal forging is that there are various methods of forging that get very different results. For instance, and traditional European blacksmith would hammer an object into shape and then either leave it to cool or douse it. Both of these would have the same effect: The metal crystals would contract away from each other, leaving the metal weaker than the Asian method. The Asian method was to hammer it constantly as it cooled, so that the crystals would not draw away from each other. This would make the metal very much stronger, and therefore their weapons could be thinner and sharper, and their armour less prone to bend/break.

Source?  That sounds rather off, like someone didn't understand the significance of work-hardening.  I guess cooling could make iron pull away from slag strands (which are the only "crystals" you'll find in wrought iron) a little, but the difference in strength would be negligible.  Asian irons tended to have less slag and more carbon to begin with, which would have far more of an effect.

Both cultures would also cold-work the material once it was cool, to harden key areas.

With bronze, it was once again the material.  Asians consistently favored very high tin bronzes compared to Europeans.  Higher tin basically resulted in a bronze with a higher failure point, but a more catastrophic failure.

If it was talking about steel, that has to be wrong.  Pounding on steel while air-cooling it is just about the dumbest thing a smith can possibly do with steel.  That sounds like the sort of thing Europeans thought Indian smiths did, around the 16th-ish century, due to Arabic misinformation.  Those guys loved telling Europeans the craziest crap about how damascus steel was made.
Title: Re: metallurgy
Post by: slink on January 20, 2010, 10:34:57 am
The word "crystals" is probably a reference to the crystalline structure of the iron itself, not to some foreign material.  I don't know what effect working has on iron and steel (which is basically also iron in the case of carbon steels), but the goal of the whole process of tempering and quenching is to leave the material in some particular crystalline state.  Apparently the goal is to heat the metal to a high enough temperature that it is all in the same crystalline form.  The speed and temperature of the subsequent cooling affects the degree and uniformity of other crystalline forms of iron in the end material.  In general, slow cooling produces a less brittle metal that does not hold an edge as well because it is also not as hard.  Cooling the metal quickly produces a material that is more brittle but which will hold an edge better.  Obviously for something like a sword, you want both qualities.  Therefore the edges of a sword are cooled more quickly then the main body of the sword, in the hopes that the result will be a sword that takes a keen edge but does not break if you smack it against something hard.
Title: Re: metallurgy
Post by: Arrkhal on January 20, 2010, 11:04:02 am
Quote
The word "crystals" is probably a reference to the crystalline structure of the iron itself, not to some foreign material.

The thing is, wrought iron shouldn't have any kind of crystalline structure other than the slag, unless it's high enough in carbon to count as a near-steel.  And in that case, you'd want to harden it like a steel, not like an iron.

For all metals, including steel without a heat treatment, pounding on it while cold work-hardens the metal.  It will generally become harder and "stronger," but also more brittle.  Most metals become rather "crumbly" if work-hardened to too great a degree, like if you bend a metal monowire back and forth repeatedly, the break won't be clean.  That's also why many older bronze swords have edges that look crumbled.  Corrosion played some part, but that's mainly repeated work-hardening and impact.

Also, pretty much every metal except steel (including iron) is annealed by heating and quenching.  I.e., if you heat copper up until it glows, then dunk it in water, it will be at its softest state.  Then you hammer on it to make it harder.

Quenching and tempering of steel, on the other hand, is basically both more and less complicated than what you think.

The crystalline structure reaches the strongest possible point at a particular temperature (which varies by alloy; for the simple steels, you heat until the steel is no longer magnetic), but a slow cooling will cause the crystals to go back to the soft state (annealing).  So a fast quench is used to keep the steel in the harder state.  Yes, you could use a slower quench (like motor oil or air cooling) to get an intermediate stage, but that results in a steel rather different from a fully hardened and tempered one.  The only steels that usually get a slow quench are the high-alloy ones, which will shatter like glass if they're water-quenched (and the appropriate cooling speed for the high-alloy ones will still result in very hard, brittle metal).

After that the metal is tempered by baking it at a moderate temperature (a modern kitchen stove can actually be used to temper some steels) for a long time, up to 12 hours in some cases.  And in modern processes, the steel may be cryo-tempered after that.

Easiest way to think of it is there are 3 different types of steel crystals; "hard," "springy," and "soft."  Obviously, for most weapons, armor, tools, etc., you want a balance between "hard" and "springy," with no soft at all.  The main role of "soft" steel is shock absorption without vibrating, like in axe heads.

Heating and then cooling very slowly (European smiths would bury blades in thick layers of wood ash, so that it would be a couple weeks or more before you could touch the steel without burning yourself) makes the steel 100% "soft."  Heating then cooling as quickly as possible (for that particular steel) makes it 100% "hard" (if done properly; a bad quench can leave some "soft" behind).  Taking a 100% "hard" object and then tempering it turns some of the "hard" into "springy;" how much depends on the temperature and time (and once again, a bad temper can turn some "hard" into "soft" instead).  Finally, in a modern smithery, a cryro-temper will turn any remaining "soft" into "springy," so a cryo temper basically will only correct flaws in the steel, it won't improve it if it was done right the first time.  Ancient smiths had to just do it right to begin with, otherwise a sword or armor would bend rather than flex back.

However, with the vast majority of metals (certainly every metal other than steel that people had prior to 1800), you can't get "springy," at all.  All you can do is try to balance "soft" with "hard," thus the dominance of steel.

And preferential hardening of the edges pretty much didn't happen at all, with a simple quench.  A self-hardened European steel sword will have an edge and spine within a couple percent of each other, hardness-wise (unlike the earlier bronze and iron swords, where the edges were work-hardened and the spine was left alone).  Differential hardening was done different ways, like the vikings put high-carbon steel at the edge, lower-carbon in the middle (given the same heat treatment and temper, the high-carbon will be harder).  The Japanese would put a thick layer of clay over the back of the sword, so that heat would escape through the clay slower during the quench.  On the Indian subcontinent, they would pour water from a pitcher over the edge of a sword rather than dunking the whole thing.

And actually, the Japanese and Indian approaches are a bit sub-optimum, since as you can guess, that means there's "soft" steel in the back of the blade, rather than "springy."  And actually, yes, permanent bending is a huge problem with Japanese katanas, despite the ridiculous hype.  Poor technique with a katana, and you can easily bend one permanently on a bad cut.  Nepali khukuris also actually do not flex and return true, their bend tolerance is very low compared to European style sword heat treatments (of course, bending a 1/2" thick khukuri is pretty hard); but in the case of the khukuri, that's probably because the "soft" steel at the spine keeps the blade from vibrating.

The best way to differentially harden something for maximum resistance to bending would be to temper it differenly, but that's basically impossible, even with modern manufacturing techniques.  You'd need a water bath and a line of blowtorches, or something.

Edits: clarifying the role of "soft" steel in blademaking.
Title: Re: metallurgy
Post by: sunshaker on January 20, 2010, 11:40:53 am
Arrkhal thanks for your posts, I would have said something similar but at the time I saw that first post it was well past the time I should have been in bed... It is good to see someone else that has knowledge about metal working posting about metal mods.
Title: Re: metallurgy
Post by: slink on January 20, 2010, 01:20:43 pm
Quote
The word "crystals" is probably a reference to the crystalline structure of the iron itself, not to some foreign material.

The thing is, wrought iron shouldn't have any kind of crystalline structure other than the slag, unless it's high enough in carbon to count as a near-steel.  And in that case, you'd want to harden it like a steel, not like an iron.

100% pure iron has a crystal structure.  Laymen don't think of metals that way, but chemists do.

From Cotton and Wilkinson, Advanced Inorganic Chemistry 3rd Edition, pg 858, re elemental iron (T is in degrees C):

Quote
At temperatures up to 906 the metal has a body-centered lattice.  From 906 to 1401, it is cubic close-packed, but at the latter temperature it again becomes body-centered.

Presumably this is the crystalline transformation to which metallurgists are referring when they talk about the phase diagram for steel, which is just slightly impure iron and not the result of some magical transformation of one metal into another.

Here is a pictorial description of the crystalline structure of iron.

http://www.webelements.com/iron/crystal_structure.html
Title: Re: metallurgy
Post by: sunshaker on January 20, 2010, 01:50:11 pm
Info Dump

http://en.wikipedia.org/wiki/History_of_ferrous_metallurgy
http://en.wikipedia.org/wiki/Smelting
http://en.wikipedia.org/wiki/Wrought_iron
http://en.wikipedia.org/wiki/Iron
http://en.wikipedia.org/wiki/Steel
http://en.wikipedia.org/wiki/Wootz_steel
http://en.wikipedia.org/wiki/Pattern_welding
http://en.wikipedia.org/wiki/Forging
http://en.wikipedia.org/wiki/Metalworking
http://en.wikipedia.org/wiki/Heat_treatment
Title: Re: metallurgy
Post by: Arrkhal on January 20, 2010, 01:53:31 pm
Quote
100% pure iron has a crystal structure.  Laymen don't think of metals that way, but chemists do.

Presumably this is the crystalline transformation to which metallurgists are referring when they talk about the phase diagram for steel, which is just slightly impure iron and not the result of some magical transformation of one metal into another.

I'm completely failing to see a point here.  I can only guess misunderstanding of semantics.  What I mean by "crystalline structure" is interactions between discrete micro- and nano-crystals embedded within the metal.

There's a big difference between iron itself being one big crystal (in an ideal state), and banging on it while hot "making the crystals, plural, closer together."  Work-hardening only dislocates crystalline bonds, thus making further dislocation require more effort.  It neither compresses the crystal lattice, nor does it spontaneously form a different type of lattice.  The fact that work-hardening metal turns it amorphous is kind of the reason why amorphous alloys never fatigue.

Water, it's just oxygen with a ~12.5% hydrogen impurity, right?  You can totally compare the physical and mechanical properties of oxygen and water, because hydrogen makes up such a small amount of the weight, right?

Steel production may not be "magical," but 0.60% carbon changes things a lot.

And if we're going to infodump, this is what I'd look at instead.

http://en.wikipedia.org/wiki/Cementite
http://en.wikipedia.org/wiki/Martensite
http://en.wikipedia.org/wiki/Austenite
http://en.wikipedia.org/wiki/Ferrite_(iron) (http://en.wikipedia.org/wiki/Ferrite_(iron))
http://en.wikipedia.org/wiki/Pearlite
http://en.wikipedia.org/wiki/Bainite
Title: Re: metallurgy
Post by: slink on January 20, 2010, 03:20:33 pm
Quote
100% pure iron has a crystal structure.  Laymen don't think of metals that way, but chemists do.

Presumably this is the crystalline transformation to which metallurgists are referring when they talk about the phase diagram for steel, which is just slightly impure iron and not the result of some magical transformation of one metal into another.

I'm completely failing to see a point here.  I can only guess misunderstanding of semantics.  What I mean by "crystalline structure" is interactions between discrete micro- and nano-crystals embedded within the metal.

There's a big difference between iron itself being one big crystal (in an ideal state), and banging on it while hot "making the crystals, plural, closer together."  Work-hardening only dislocates crystalline bonds, thus making further dislocation require more effort.  It neither compresses the crystal lattice, nor does it spontaneously form a different type of lattice.  The fact that work-hardening metal turns it amorphous is kind of the reason why amorphous alloys never fatigue.

Water, it's just oxygen with a ~12.5% hydrogen impurity, right?  You can totally compare the physical and mechanical properties of oxygen and water, because hydrogen makes up such a small amount of the weight, right?

No, water is not oxygen with a hydrogen impurity.  Water is a chemical compound.

Steel is not a chemical compound.

Here is a layman's explanation of amorphous versus crystalline, as regards metals.  Amorphous metals are not common, and in fact steel is not amorphous, nor is iron or copper.

http://www.mrsec.wisc.edu/Edetc/background/amorphous/amorphous.html
Title: Re: metallurgy
Post by: Arrkhal on January 20, 2010, 04:09:28 pm
You're really making too fine a distinction for most people to follow.

No, steel isn't its own chemical compound, but it's only "slightly impure iron" in the exact same sense that hydrochloric acid is "slightly impure water."

Yes, chemically, hydrochloric acid is just slightly impure water.  That doesn't change the fact that the chemical interactions change pretty significantly due to that slight impurity.  The impurity in steel is also iron carbides and secondary crystals formed around them, not just elemental carbon.

It also doesn't change the fact that "making the crystals closer together" is a pretty fallacious statement, from both a chemical and a physical point of view.

You said you don't know what effect working has on iron (and presumably also copper, brass, silver, etc., which were also all historically work-hardened).  And I did tell you what it is.

Working a crystalline metal destroys the crystal structure, making it partially amorphous; amorphous forms of metals are generally harder and brittler.  100% amorphous copper or iron would just be an ultrafine powder (probably no more than a handful of atoms per grain), so functional work-hardening will make the metal only partially amorphous, to strike some balance between malleability, hardness, and cohesion.  When the amount of amorphous metal in the mix gets too high, the metal "fatigues" and becomes brittle and crumbly, because there's an insufficient crystal matrix to hold the noncrystalline parts together.

The fancy thing about the amorphous alloys is they're already amorphous from the start, without losing cohesion.  There is no crystal structure to deform, so they do not work-harden, and do not fatigue.

And what makes steel different from iron in that respect is that iron carbides are substantially stronger and harder than amorphous iron.  Cold-working steel to any degree weakens it, while iron gets stronger up to a point.
Title: Re: metallurgy
Post by: slink on January 20, 2010, 05:30:02 pm
You're really making too fine a distinction for most people to follow.

No, steel isn't its own chemical compound, but it's only "slightly impure iron" in the exact same sense that hydrochloric acid is "slightly impure water."

Yes, chemically, hydrochloric acid is just slightly impure water.  That doesn't change the fact that the chemical interactions change pretty significantly due to that slight impurity.

It also doesn't change the fact that "making the crystals closer together" is a pretty fallacious statement, from both a chemical and a physical point of view.

You said you don't know what effect working has on iron (and presumably also copper, brass, silver, etc., which were also all historically work-hardened).  And I did tell you what it is.

Working a crystalline metal destroys the crystal structure, making it partially amorphous; amorphous forms of metals are generally harder and brittler.  100% amorphous copper or iron would just be an ultrafine powder, so functional work-hardening will make the metal only partially amorphous, to strike some balance between malleability and hardness.  When the amount of amorphous metal in the mix gets too high, the metal "fatigues" and becomes brittle and crumbly, because there's an insufficient crystal matrix to hold the noncrystalline parts together.

The fancy thing about the amorphous alloys is they're already amorphous from the start.  There is no crystal structure to deform, so they do not work-harden, and do not fatigue.

And what makes steel different from iron in that respect is that iron carbides are substantially stronger and harder than amorphous iron.  Cold-working steel to any degree weakens it, while iron gets stronger up to a point.

Hydrochloric acid, another chemical compound, is not impure water.  An aqueous solution of HCl, however, has properties more or less resembling the two materials in the mixture according to the proportions in which they are present.  Aqueous hydrocholoric acid is not some magical substance with new properties unknown to either water or HCl.  At least not unless you mix them in your kitchen while drinking Guiness just before calling the news media.   :D

Steel is not iron carbide.  Steel is iron with carbon impurities present within the iron crystal structure.  This does change the properties, however it does not make the iron into some other metal with properties contrary to all other metals worked by mankind.

If steel loses a valued property by a treatment which causes iron to gain that valued property "up to a point", might that not mean that the material called steel has already been given the optimal amount of that treatment as a matter of course in making the material?  This as opposed to steel being a magically reversed metal quite different from iron?

The entire field of metallurgy is riddled with contradictory and confusing terminology, partly due to attempts to keep trade secrets and partly because the people who originally discovered the processes did so before chemistry had become more than a quest to convert lead into gold. 

I have no doubt that professional metallurgists have a decent understanding of what happens with each metal and why it happens, while professional metalworkers know how to make things happen without understanding why it works.  I don't expect to find any of this information clearly stated on the Wiki, which consists of entries made by anyone who happens by.  Some of what I have read there is complete nonsense.
Title: Re: metallurgy
Post by: Arrkhal on January 20, 2010, 07:19:17 pm
Quote
If steel loses a valued property by a treatment which causes iron to gain that valued property "up to a point", might that not mean that the material called steel has already been given the optimal amount of that treatment as a matter of course in making the material?

Frankly, no, that's not how it works.  You're trying to understand structural chemistry from, apparently, a mixture of an aqueous inorganic chemistry background, and complete ignorance of the gross physical properties of metal as well.  No offense, but you're failing miserably.

You're just going to ignore or intentionally misinterpret any scientific data I may throw at you, so you're on your own to find your own citations, or to remain argumentatively ignorant if you'd rather do that.

I have to wonder just what kind of strength difference this person thinks there is between wrought iron (or the misnamed "low-carbon steel" which isn't really a steel at all) and high-carbon steel.

Is it really that unprecedented in solution chemistry that 0.6% by weight of an impurity will fundamentally change the properties of a solution?
Title: Re: metallurgy
Post by: G-Flex on January 20, 2010, 07:53:41 pm
Sometimes in unusual ways, too; it's not rare for an alloy to have a melting point higher or lower than the melting points of all the constituent metals.
Title: Re: metallurgy
Post by: Arrkhal on January 20, 2010, 11:01:54 pm
Quote
Sometimes in unusual ways, too; it's not rare for an alloy to have a melting point higher or lower than the melting points of all the constituent metals.

That's a really minor difference, though, when you compare how much magic carbon adds to iron. (note: I'm not talking about you at all, G-Flex)

Steel actually is pretty unique in multiple ways.  But I suppose certain peoples' brains are broken by that fact.

I don't even want to know how inorganic solution chemists react to carbon nanotubes or buckyballs.  Or kevlar.  Or spider web.  Or aluminum chloride.
Title: Re: metallurgy
Post by: slink on January 21, 2010, 01:25:46 pm
Frankly, no, that's not how it works.  You're trying to understand structural chemistry from, apparently, a mixture of an aqueous inorganic chemistry background, and complete ignorance of the gross physical properties of metal as well.  No offense, but you're failing miserably.

You're just going to ignore or intentionally misinterpret any scientific data I may throw at you, so you're on your own to find your own citations, or to remain argumentatively ignorant if you'd rather do that.

I have to wonder just what kind of strength difference this person thinks there is between wrought iron (or the misnamed "low-carbon steel" which isn't really a steel at all) and high-carbon steel.

Is it really that unprecedented in solution chemistry that 0.6% by weight of an impurity will fundamentally change the properties of a solution?

That's a really minor difference, though, when you compare how much magic carbon adds to iron. (note: I'm not talking about you at all, G-Flex)

Steel actually is pretty unique in multiple ways.  But I suppose certain peoples' brains are broken by that fact.

I don't even want to know how inorganic solution chemists react to carbon nanotubes or buckyballs.  Or kevlar.  Or spider web.  Or aluminum chloride.

My background includes a doctorate in physical and organic chemistry as well as years of chemical research experience in various industries.  The advanced inorganic chemistry was just a course requirement along the way.  The course was specifically on the elements in their elemental forms, as well as in their most common inorganic compounds, which last time I checked included bulk metals.  I've been trying to be kind to you, but it has been evident for our entire discussion that your understanding of chemistry, both theoretical and practical, is perhaps secondary school level, if that.  I don't expect you to be able to produce any scientific citations.  I was willing to credit you with some working knowledge of metalworking, but if you need to bolster your position with personal insults then I have to conclude that the information on the Wiki does indeed represent the depth of your knowledge.
Title: Re: metallurgy
Post by: Arrkhal on January 21, 2010, 02:16:53 pm
It's amazing how people with (claimed) degrees can be so incredibly ignorant of things outside their specialties, but oh, well.  Frankly, your understanding of metallurgy and the interactions between alloying elements made me seriously think you were still in chem 101, at first.  That's the approximate understanding level that your conclusions show, anyway.

Once again, you're on your own to find "better" sources (meaning ones written by people who club you over the head with their degrees).  I've explained how steel actually works, in incredibly basic terms.  If you don't believe it because it doesn't match your incredibly rudimentary understanding of elemental metals, tough cookies.

I'm willing to bet you won't bother to look, because you know you'll be proven wrong.

I'm just going to add this to my list of "Things Arrkhal has been told by other PhDs" and call it a day.

Spoiler (click to show/hide)

http://www.feine-klingen.de/PDFs/verhoeven.pdf

This is from an actual accredited metallurgist and bladesmith, and pretty clearly and simply explains the distinct molecular differences between iron and steel.  It even starts out by describing the ways in which iron and steel actually are similar, and how low-carbon steels work (which actually are just iron with a slight carbon impurity), before transitioning into the high-carbon, hardenable steels.  It's obvious your education was only equivalent to the first handful of chapters there.

Ferrite and austenite are common between iron and high-carbon steel.  Cementite, otherwise known as iron carbide is not.  Unhardened steel or iron contains no iron carbide.  Work-hardened steel or iron contains no iron carbide.  Heat treated high carbon steel does.  It's really impossible to make it any simpler than that.
Title: Re: metallurgy
Post by: NRN_R_Sumo1 on January 21, 2010, 03:41:58 pm
You are both acting like children.
stop it.
play nice.
Title: Re: metallurgy
Post by: slink on January 21, 2010, 09:18:10 pm
It's amazing how people with (claimed) degrees can be so incredibly ignorant of things outside their specialties, but oh, well.  Frankly, your understanding of metallurgy and the interactions between alloying elements made me seriously think you were still in chem 101, at first.  That's the approximate understanding level that your conclusions show, anyway.

Once again, you're on your own to find "better" sources (meaning ones written by people who club you over the head with their degrees).  I've explained how steel actually works, in incredibly basic terms.  If you don't believe it because it doesn't match your incredibly rudimentary understanding of elemental metals, tough cookies.

I'm willing to bet you won't bother to look, because you know you'll be proven wrong.

I'm just going to add this to my list of "Things Arrkhal has been told by other PhDs" and call it a day.

Spoiler (click to show/hide)

http://www.feine-klingen.de/PDFs/verhoeven.pdf

This is from an actual accredited metallurgist and bladesmith, and pretty clearly and simply explains the distinct molecular differences between iron and steel.  It even starts out by describing the ways in which iron and steel actually are similar, and how low-carbon steels work (which actually are just iron with a slight carbon impurity), before transitioning into the high-carbon, hardenable steels.  It's obvious your education was only equivalent to the first handful of chapters there.

Ferrite and austenite are common between iron and high-carbon steel.  Cementite, otherwise known as iron carbide is not.  Unhardened steel or iron contains no iron carbide.  Work-hardened steel or iron contains no iron carbide.  Heat treated high carbon steel does.  It's really impossible to make it any simpler than that.

Thank you very much for that excellent reference document.  I consider that to be a reputable source of information and I will read through it.  I can even forgive the source of the link!   :D
Title: Re: metallurgy
Post by: sunshaker on January 21, 2010, 09:36:27 pm
Thank you very much for that excellent reference document.  I consider that to be a reputable source of information and I will read through it.  I can even forgive the source of the link!   :D

So let me see if I understand this correctly, you continued this argument because you don't view wiki as a valid source of information? Even if the people giving you the wiki links are familiar with the material in question through schooling and careers and can vouch for it being mostly or completely right?
Title: Re: metallurgy
Post by: guale on January 21, 2010, 11:20:37 pm
Am I the only one that has noticed how derailed this thread has become?
Title: Re: metallurgy
Post by: NRN_R_Sumo1 on January 22, 2010, 12:38:19 am
Am I the only one that has noticed how derailed this thread has become?
I noticed that two pages ago, and by making this comment we derail it even further. :D
Title: Re: metallurgy
Post by: Arrkhal on January 22, 2010, 09:12:25 am
Quote
So let me see if I understand this correctly, you continued this argument because you don't view wiki as a valid source of information? Even if the people giving you the wiki links are familiar with the material in question through schooling and careers and can vouch for it being mostly or completely right?

Precisely.  That's why I had to look so long and hard for a good cite.  Wikipedia doesn't say anything that disagrees with it, but it's a more "scholarly" source.  Also, I checked Encyclopedia Britannica, and holy crap those guys are smoking crack!  The EB article says the purpose of heat treating steel is to prevent carbide formation!

Anyway, I'm also suspecting a lack of very common metallurgical knowledge, namely:

1. Low-carbon/mild steels and high-carbon steels are in no way comparable in how they can be heat-hardened (the intermediate medium-carbon steels are much more rarely seen, and do show the transition between low-carbon and high-carbon properties).
2. Low-carbon/mild steels can be strengthened by a maximum of about 50% via heat-treating and 100% via work-hardenening, whereas high-carbon steels can be strengthened about fivefold to tenfold by heat treatment.
3. Low-carbon/mild steels were invented in the early 20th century (maybe late 19th?) as a low-cost alternative to wrought iron, so any discussion of low-carbon/mild steel whatsoever is irrelevant to DF.
4. Low-carbon/mild steels cover nearly the exact same range of carbon content that's present in wrought iron; 0.01% to 0.29% for low-carbon/mild steels, 0.01% to 0.25% for wrought iron.  That actually is one of those commercial steel industry obfuscations; either "mild steel" is a misnomer, or "wrought iron" is.
5. Low-carbon/mild steels are not intended to be used in very high-stress applications like weapons, hand tools, armor, etc., thus their inclusion in a discussion on DF weaponsmithing is doubly irrelevant.
6. Low-carbon/mild steels are actually slightly weaker than wrought iron, even given the same manufacturing techniques, due to their lack of silaceous slag.  Low-carbon/mild steels also corrode faster, for the same reason.  For the same carbon content, low-carbon/mild steel will be equally as hardenable as wrought iron, only lacking slag strands.

That's about the only thing I can possibly think of.  Slink was talking about low-carbon/mild steel, not high-carbon steel, and was ignorant of all of the above.  I guess that might make sense, as low-carbon/mild steel is a more "common" material (it's what steel building frames and cars are made of), and thus more likely to be covered by a basic class.  IIRC, even 300-level physics doesn't cover high-carbon steel, though 400-level physics does (as will any 200-level structural or material engineering class).  Even so, the above 6 facts are relatively common knowledge.

But that's my best guess, anyway.
Title: Re: metallurgy
Post by: slink on January 22, 2010, 10:45:52 am
Thank you very much for that excellent reference document.  I consider that to be a reputable source of information and I will read through it.  I can even forgive the source of the link!   :D

So let me see if I understand this correctly, you continued this argument because you don't view wiki as a valid source of information? Even if the people giving you the wiki links are familiar with the material in question through schooling and careers and can vouch for it being mostly or completely right?

I continued to dispute statements which I considered to be inaccurate, whatever the source. However, I do consider this document more reliable than a secondhand retelling of a body of online information maintained by the general public.

The pdf document is a digitilized book written by an American author with decades of experience in both the theoretical and the practical aspects of metallurgy.  It is posted on a German smithing website, which is within the author's intent.  The book explains in very clear terms how the the crystalline structure of iron is affected by the carbon impurites which are present in the material known to metalworkers as steel.  I found it very informative.  I feel that it contradicts nothing of what I said.  It did add substantially to my understanding both of the jargon used by metalworkers, and of the scientific origins of the meetalworking of iron and its alloys.  I recommend the document to anyone who has come to the subject from a scientific background and has been struggling with the maze of trade secrets and layman's explanations available online.  I understand that the author intended the book to work in the opposite direction, ie to explain to the crasftsman the science behind the craft.  As a Rosetta stone, it works both ways.  :)
Title: Re: metallurgy
Post by: Arrkhal on January 22, 2010, 12:33:36 pm
Simplest possible explanation of cold-working I could find.

http://physics.pdx.edu/~pmoeck/phy381/coldworking.pdf

If you still can't understand how cold-working of iron and heat-treating of steel are distinct, then...
Title: Re: metallurgy
Post by: sunshaker on January 22, 2010, 09:44:53 pm
Quote
4. Low-carbon/mild steels cover nearly the exact same range of carbon content that's present in wrought iron; 0.01% to 0.29% for low-carbon/mild steels, 0.01% to 0.25% for wrought iron.  That actually is one of those commercial steel industry obfuscations; either "mild steel" is a misnomer, or "wrought iron" is.

My overtired, overworked brain is saying that Wrought Iron contains up to 3% glass slag as a side effect of the manufacturing process  (which gives it the wood fiber appearance and different working properties from mild steel, it feels totally different from mild steel when you forge it) but I can't find a citation for that. Incidentally this slag posses problems for modern welding processes (forge welding works fine, oxy-acetylene works ok, but mig and trig have problems, some kind of reaction between the slag, gas and wire, again overtired, overworked brain lacks a cite but suggests one of the metal working forums or maybe usenet (actually given the age of the memory it is usenet)).
Title: Re: metallurgy
Post by: Arrkhal on January 23, 2010, 01:51:24 pm
Yuppers, exactly.  You might have missed #6.

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6. Low-carbon/mild steels are actually slightly weaker than wrought iron, even given the same manufacturing techniques, due to their lack of silaceous slag.  Low-carbon/mild steels also corrode faster, for the same reason.  For the same carbon content, low-carbon/mild steel will be equally as hardenable as wrought iron, only lacking slag strands.

Also, IIRC, the slag makes wrought iron excellent for forge welding, as the glass strands make it self-fluxing.

I would guess that any kind of arc welding would have the problem that it would heat the material unevenly, as glass is an insulator and iron is a conductor.  I forget the currents involved (ridiculously high, I know that), but if they're high enough to blast through glass, then arc welding probably boils the slag strands away at the weld point, which would definitely be very problematic.

But yeah, my main point is that in "chemical" terms, the difference between "steel" and "iron" is the inclusion of carbon.  But in metallurgical terms, "iron" is actually "steel" with silicon oxide in the mix.  That's pretty crazy.  3% is a small enough alloying element that wrought iron would be more properly called something like "siliceous mild steel" (I've been spelling that wrong for awhile!).  Or, mild steel could be "mildly carboniferous iron."

From an historical perspective, anyway, the difference between "iron" and "steel" is heat treatability.
Title: Re: metallurgy
Post by: Tellemurius on January 25, 2010, 11:57:27 am
Am I the only one that has noticed how derailed this thread has become?
already declared that 2 pages ago. at least the conversation has return to metals. searching around the internet i discovered Damascus steel. now the process for production is a pain in the ass plus testing for true products produced few but the results was a tough flexible steel that is able to hold its blade and cut though other metals without damage.
Title: Re: metallurgy
Post by: sunshaker on January 25, 2010, 01:13:45 pm
searching around the internet i discovered Damascus steel. now the process for production is a pain in the ass plus testing for true products produced few but the results was a tough flexible steel that is able to hold its blade and cut though other metals without damage.

Real Damascus or False Damascus (Pattern) Steel people are claiming is Damascus? If the production of the steel involves crucibles and the word Wootz shows up then it is the real stuff, if the process involves welding different steels together than it is the fake pattern stuff.

Cutting through other metals without damage is nothing special, many of the harder metals will cut the softer ones with ease: bronze will cut gold or copper or tin, hardened steel will cut soft (annealed) steel (yes even if the hardened steel is mid-grade 0.6% carbon and the annealed steel is tool grade 0.95% carbon, it just won't do it for very long).
Title: Re: metallurgy
Post by: Tellemurius on January 25, 2010, 02:01:07 pm
searching around the internet i discovered Damascus steel. now the process for production is a pain in the ass plus testing for true products produced few but the results was a tough flexible steel that is able to hold its blade and cut though other metals without damage.

Real Damascus or False Damascus (Pattern) Steel people are claiming is Damascus? If the production of the steel involves crucibles and the word Wootz shows up then it is the real stuff, if the process involves welding different steels together than it is the fake pattern stuff.

Cutting through other metals without damage is nothing special, many of the harder metals will cut the softer ones with ease: bronze will cut gold or copper or tin, hardened steel will cut soft (annealed) steel (yes even if the hardened steel is mid-grade 0.6% carbon and the annealed steel is tool grade 0.95% carbon, it just won't do it for very long).
well im talking about the real stuff. whet was special about this type of stell that it can cut though other metal AND keep a blade for a long time due to carbides and carbon nanotubes in the steel. now of course the 1400's they didn't know what was nanotubes but they were present.
Title: Re: metallurgy
Post by: Arrkhal on January 25, 2010, 06:36:16 pm
That's still not a very big deal.  Most armor was made out of much poorer steel than swords, or even of wrought iron.

Carbon nanotubes are found in plain old wood ash and soot and smoke, so it's quite likely they're present in all metals that are heated in close proximity to a charcoal fire.

The vast majority of info about wootz steel, just like katanas, is pure fabrication.  Wootz was a good steel for its time, but accounts were very exaggerated.  Tests have shown that, by modern standards, real wootz is slightly weaker than a modern tool steel (which is an incredible feat given the technology used to make it).

Wootz was also dependent on very specific ores that could only be found around parts of the Indian subcontinent.  When those ores ran out and they had to use normal iron ore, wootz could no longer be made.

It would be good if, in a future version, there can be regional differences like htat, though.  One area's hematite makes a superior steel, another place's marble gives a bonus to statues, etc.

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hardened steel will cut soft (annealed) steel (yes even if the hardened steel is mid-grade 0.6% carbon and the annealed steel is tool grade 0.95% carbon, it just won't do it for very long).

Actually, a hardened 0.60% carbon steel will cut annealed steel of nearly any carbon content (as long as it's not one of those crazy new high-alloy things) for a very long time.  That's what machining often is. ;) (well, okay, most high speed steels are 0.80% carbon or higher, and cobalt alloys work even better, but you get the idea). Yes, the modern fancy ceramic coatings help, but that just means replacing the bit every month instead of every week.
Title: Re: metallurgy
Post by: sunshaker on January 25, 2010, 09:36:05 pm
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hardened steel will cut soft (annealed) steel (yes even if the hardened steel is mid-grade 0.6% carbon and the annealed steel is tool grade 0.95% carbon, it just won't do it for very long).

Actually, a hardened 0.60% carbon steel will cut annealed steel of nearly any carbon content (as long as it's not one of those crazy new high-alloy things) for a very long time.  That's what machining often is. ;) (well, okay, most high speed steels are 0.80% carbon or higher, and cobalt alloys work even better, but you get the idea). Yes, the modern fancy ceramic coatings help, but that just means replacing the bit every month instead of every week.

HHS (High Speed Steel) will cut metal at about 3 times the Speed and Feed as High Carbon Steel (hence the name), Coated Carbide will cut metal about 5 times the Speed and Feed as HHS. At work the Coated Carbide inserts have a designated tool life of 300* pieces (and we hit 300 pieces over 95% of the time, sometimes they can be pushed a bit, maybe 10%), it takes us about 5 hours to do 300 parts. We are a 24/7 factory this means we replace Coated Carbide inserts about 30 times a week per machine. The drills and reamers we use are also Coated Carbide and they have scheduled a tool life of about 1200 holes (again 5 to 6 hours, 4 or 6 holes/part) and again you can push them a bit (about 10%), again this is about 30 times a week per machine. They are sent out for re-sharpening and re-coating, I have no idea how many times they can be re-sharpened (I'll have to ask).

You might have a cutting tool last weeks or a month if you were a low-volume shop, but they don't last that long for our high volume CNC factory.
Title: Re: metallurgy
Post by: Ramirez on January 26, 2010, 07:25:45 pm
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Posted by: Arrkhal
The vast majority of info about wootz steel, just like katanas, is pure fabrication.

While it is true that most of the stories about katanas are exaggerated beyond mortal comparison, they did quite a good job considering the poor quality of their ores. The folding to create fine, alternating layers of high and low carbon steels is both an early example of composite construction (it's too macroscopic to be considered an alloy) and more importantly for this thread, easily doable by dwarves. Just a simple steel + pig iron = 2x folded steel.

For the topic of the ores of wootz steels, would it not be possible to create several different hematites with some of them giving different types of iron (possibly even percentage chances of different irons)? It would let you create different irons with different levels of impurities (low-grade sulphur-rich ores, or high-grade nickel-trace ores, for example).
Title: Re: metallurgy
Post by: sunshaker on January 26, 2010, 09:39:26 pm
For the topic of the ores of wootz steels, would it not be possible to create several different hematites with some of them giving different types of iron (possibly even percentage chances of different irons)? It would let you create different irons with different levels of impurities (low-grade sulphur-rich ores, or high-grade nickel-trace ores, for example).

Yes you can do that. Either you need to make a bunch of different iron ore types (nickel_iron, sulfur_iron, vanadium_iron, etc) and assign them to different minerals, or you need to make a bunch of different minerals and make a reaction for each of them.
Title: Re: metallurgy
Post by: Arrkhal on January 27, 2010, 10:28:03 am
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You might have a cutting tool last weeks or a month if you were a low-volume shop, but they don't last that long for our high volume CNC factory.

Only CNC I've experience with was for prototyping only, so very low volume indeed.  Actually, 300 in a month sounds about right.

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Quote
While it is true that most of the stories about katanas are exaggerated beyond mortal comparison, they did quite a good job considering the poor quality of their ores. The folding to create fine, alternating layers of high and low carbon steels is both an early example of composite construction (it's too macroscopic to be considered an alloy) and more importantly for this thread, easily doable by dwarves. Just a simple steel + pig iron = 2x folded steel.

Early Japanese metallurgy is quite a bit different from the katana specifically, though.  The Vikings folded different alloys together centuries before the Japanese did, for the same reasons (very low quality ore).

The layers also were not alternating high/low carbon.  Forge-folding will actually equalize carbon content between different alloys.  Other alloying elements are not as mobile as carbon, though, and end up stuck in their layers, which is why folded steel can be etched to show the layers.  But the carbon content of the whole thing will be homogenous, if it's folded into more than about, oh... 30-50 layers?

Also, pig iron has the [BRITTLE] tag for a reason.  Even heated to what would be forging temperature for steel, it will break rather than bend.  Given the carbon content, you'd also end up with very brittle steel, even if successful.

What would actually be a bit closer to the reasoning behind folding metals together, for the Vikings and the Japanese at least, would be 1 iron + 1 steel = 2 very slightly weaker steel.  I.e., if you don't have enough "premium" steel to make an entire blade out of (or to arm an entire army with), you can fold it together with inferior steel to end up with something entirely adequate, but not quite as good as the "premium" metal you started with.  And that actually could be a very valid approach in some games, where steel is just too hard to mass produce (though I hope the dependence on flux is removed).

It would also be possible to accidentally produce a batch of overly-brittle steel, then forge-fold that together with the overly-soft steel you accidentally made last week, and get "regular" steel.  But that's probably well outside the scope of DF.  I would hate having to micromanage what properties each individual bar of steel had!

I think a better way would probably be to just have ores and metal bars have quality mods.  A good furnace operator can increase the quality of the bar over that of the ore by a bit.  And a good quality bar will produce a very slight boost to the quality mod of the resulting item.  Different quality bars can be forge-folded together to produce intermediate quality bars (shifted towards the quality of the better one by skill of the blacksmith).  Add a couple special rules for folding iron and steel together (like that a ☼iron bar☼ is equal to a no-quality steel bar), and you're done.
Title: Re: metallurgy
Post by: Andeerz on April 19, 2010, 11:12:01 pm
Arrkhal, I don't know if you have done it already as I haven't searched yet, but those kick-ass suggestions regarding regional variations in ore qualities and the like would make an awesome addition to the suggestions forum, and would have my vote if it made it to the eternal suggestions board.  :3  You, sir, are awesome.