Inland Steel Research Articles

Influence of Distance from Roads on Corrosion Loss in Weathering Steel Bridges

AbstractThere are numerous steel bridges worldwide, many of which are made from weathering steel. Trademarks of weathering steel, such as Corten (the United States), Atmofix (the Czech Republic), NAW‐TEN and CORSPACE (Japan), or Q345CNH (China) are commonly used. Inland steel bridges are impacted by chloride ions, primarily dispersed into the air by road traffic from de‐icing salt (NaCl) and brine solutions used in winter road maintenance, which can compromise the integrity of the bridges' load‐bearing structures. The quantity of deposited chlorides fluctuates based on the distance from the source, especially for inland bridges, where it is determined by the distance from the road. There is also a difference between the winter season and the rest of the year. The study presents in‐situ measurement data from two sites, analyzing the corrosion loss. Additionally, a regression analysis is conducted to understand the relationship between the distance from the road guide line and the corrosion loss.

Editor's Introduction

Editor's Introduction

The United Steelworkers of America's Path to Private Security: The Postwar Retiree Crisis, Politics, and Communism, 1946–1949

AbstractIn 1949 the United Steelworkers of America (USWA) successfully bargained for a pension and social insurance system, opening the door for social insurance and pension bargaining across organized labor throughout the post–World War II era. Indeed, the explosion of security bargaining after World War II facilitated the growth of America's unique but flawed public-private welfare system. Many historians have viewed labor's postwar turn to collective bargaining in a negative light and have argued that due to the weakening of labor's political power in the immediate postwar era, labor abandoned its progressive postwar vision and instead opted for a more insular, less socially oriented agenda achieved at the bargaining table. This argument still holds true, but a close inspection of the USWA's postwar work highlights a more nuanced picture. The USWA was one of the few labor unions to challenge the constitutionality of the antilabor Taft-Hartley Act (1947). The union's fight against Taft-Hartley came into conflict with the union's dire need to bring long-term security to its members, especially after many steel corporations began arbitrarily terminating steelworkers at age sixty-five in 1946. Ultimately, the issue of delivering long-term security to USWA members overshadowed the union's effort to defeat Taft-Hartley. This article focuses on the USWA's effort to bring long-term security to its members from 1946 to 1949 and looks at the postwar retiree crises in steel, the weakness of the public and private welfare systems in that era, the Inland Steel decision, the USWA's challenge to Taft-Hartley, and 1949 bargaining.

Asserting Their Voice: A Brief History of Independent Steelworker Retiree Clubs and the United Steelworkers of America, 1946 to 1990

Asserting Their VoiceA Brief History of Independent Steelworker Retiree Clubs and the United Steelworkers of America, 1946 to 1990 Henry Himes (bio) At the close of World War II, employers in the immediate postwar era worked to advance their political power at all levels of government. Business leaders developed a host of strategies to promote the virtues of free enterprise, and they vigorously pushed to reassert their “right to manage” in workplaces throughout the nation. Thus, to advance the immediate economic and long-term security needs of active workers and retirees within the new postwar order, the United Steelworkers of America (USWA), like many other Congress of Industrial Organizations (CIO) unions, came to rely heavily on their economic power as manifested through collective bargaining and labor’s right to strike, even as labor looked to strengthen its political power through organizing drives and the CIO-Political Action Committee (PAC).1 These postwar realities were at the heart of the USWA’s decision to secure pensions and social insurance through collective bargaining starting in the late 1940s, especially after the inability of labor to pressure lawmakers to pass comprehensive public healthcare as found in the World War II–era Wagner-Murray-Dingell [End Page 78] Bill.2 Moreover, the USWA’s decision to bargain for security was heavily influenced by a retiree crisis beginning in 1946. In that year, Inland Steel, and many other steel firms to include US Steel, began arbitrarily retiring steelworkers at age 65, ultimately dismissing them without a company pension or with a pension that did not provide subsistence level income. The only means of subsistence for these retirees was Social Security, which at that time had failed to keep pace with inflation, leaving many retirees in a state of poverty and reliant on their children or their extended family to make ends meet. It was within this postwar retiree crisis that we see the first efforts of retired steelworkers to organize in an attempt to better their condition. The result of their organizational efforts during World War II and the immediate postwar era were short-lived retiree organizations called “65-Clubs.” Although little documentation exists on these clubs, the sources that are available show that 65-Clubs fought against the practice of forced retirements and actively encouraged the union in its bid to bargain for security in 1949. Although the 65-Clubs supported and backed their former union, the unsettling fact remained that retired steelworkers were no longer dues-paying members of the union, and the USWA constitution did not provide any formal recognition of steelworker retiree associations. Thus, the development of independent retiree clubs such as the 65-Clubs raised some unsettling questions for both union leaders and retirees. For instance, how would union leaders represent the interests of retirees who, upon retirement, lost their rights as “industrial citizens” in the union? Would independent organizations be a threat or a liability to the union? How would retirees be represented and find a voice within the union over matters such as pensions and healthcare if they were not formally recognized? For the 65-Clubs, the issue of formal representation in the late 1940s was not yet a driving concern. The 65-Clubs advocated for stronger retirement security, which the USWA delivered to them via collective bargaining in 1949 and beyond. The issue of independent retiree organizations and formal representation within the union receded throughout the postwar “affluent era” due to a strong economy, rising living standards, contractual pensions, and healthcare—as well as various forms of public welfare protection.3 However, [End Page 79] as the economy transformed and slowed in the 1970s and 1980s, the unresolved legal relationship between retired union members and their independent organizations vis-à-vis the USWA reemerged as corporate decline and bankruptcy threatened to undermine the private security system built at the bargaining table from the mid-1940s to the early 1970s. Beginning in the 1970s, conflicts between the USWA and independent retiree clubs began to emerge; however, conflicts within industrial unions were not just confined to retirees nor the USWA. Many industrial unions in the 1960s and 1970s experienced a host of rank-and-file revolts as industrial union...

Anthony G. Hopwood: Academic Iconoclast and Entrepreneur 1944–2010

A nthony Hopwood was born on May 18, 1944 in Stoke-on-Trent in England and died on May 8, 2010 in Marlow, England. He was a pioneer in behavioral accounting research. He contributed to that area with both his research and as the founding editor of Accounting, Organizations and Society (AOS), the leading behavioral accounting research journal, the reason for which he likely is best well known by scholars internationally, both in and outside of accounting. He held that position for 35 years. As Zeff (2008, 3) described it, in his remarks introducing Anthony at his Hall of Fame induction:

Mineralogical and microscopic evaluation of coarse taconite tailings from Minnesota taconite operations

Eighteen coarse taconite tailings samples were collected in 2000–2001 from five western Mesabi Range taconite (iron ore) operations located in northern Minnesota, i.e., EVTAC, Hibbing Taconite (Hibtac), USX Minntac, Ispat Inland (Minorca), and National Steel Pellet Company (NSPC), to test their physical, geological, chemical, and mineralogical properties [Zanko, L.M., Niles, H.B., Oreskovich, J.A., 2003. Properties and aggregate potential of coarse taconite tailings from five Minnesota taconite operations, Minnesota Department of Transportation, Local Road Research Board, St. Paul, MN, Report No. 2004-06 (also as Natural Resources Research Institute technical report, NRRI/TR-2003/44)]. The goal was to assemble a body of technical data that could be used to better assess the potential of using a crushed taconite mining byproduct like coarse tailings for more widespread construction aggregate purposes, primarily in roads and highways. An important part of the mineralogical assessment included X-ray diffraction (XRD) analyses and microscopic (polarized light microscopy, scanning electron microscopy, and transmission electron microscopy, i.e., PLM, SEM, and TEM, respectively) evaluation of the size and shape (morphological) characteristics of potentially respirable microscopic mineral particles and fragments. Quantitative mineralogy, based on XRD analyses, showed that the dominant mineral in all samples was quartz (55–60%), followed by much smaller amounts of iron oxides, carbonates, and silicates. Specialized microscopic analyses and testing performed by the RJ Lee Group, Monroeville, PA, on both pulverized (−200 mesh, or 0.075 mm) and as-is sample composites showed that no regulated asbestos minerals or amphibole minerals were detected in the western Mesabi Range samples. A small number (26) of non-asbestos and non-amphibole mineral cleavage fragments/mineral fibers were detected by SEM out of 1000 fields analyzed, but most were identified as minnesotaite and talc, silicate minerals common to the Biwabik Iron Formation. Amphibole minerals, absent in coarse tailings samples from the five western Mesabi Range taconite operations, were present in a single eastern Biwabik Iron Formation sample collected in 2003 for Lake County from the Cliffs Northshore operation in Silver Bay, MN. Importantly, the Superfund Method for the Determination of Releasable Asbestos in Soils and Bulk Materials [United States Environmental Protection Agency (USEPA), 1997. Superfund method for the determination of releasable asbestos in soils and bulk materials, EPA 540-R-97-028, U.S. Environmental Protection Agency, Washington], as modified by Berman and Kolk [Berman, D.W., Kolk, A.J., 2000. Modified elutriator method for the determination of asbestos in soils and bulk materials, Revision 1: Submitted to the U.S. Environmental Protection Agency, Region 8, May 23, 2000] failed to generate any protocol fibers, i.e., fibers longer than 5 μm and thinner than 0.5 μm, from either the western coarse tailings samples or the single eastern Biwabik Iron Formation sample. The combined findings suggest coarse tailings and other taconite mining byproducts should be treated with the same common sense safety and industrial hygiene approach practiced for all mineral-based materials that have the potential to generate respirable dust.

Computer Modeling of Electromagnetic Fields and Fluid Flows for Edge Containment in Continuous Casting

A computer model was developed to predict eddy currents and fluid flows in molten steel. The model was verified by comparing predictions with experimental results of liquid-metal containment and fluid flow in electromagnetic (EM) edge dams (EMDs) designed at Inland Steel (Ispat Industries Ltd.) for twin-roll casting. This mathematical model can greatly shorten casting research on the use of EM fields for liquid metal containment and control. It can also optimize the existing casting processes and minimize expensive, time-consuming full-scale testing. The model was verified by comparing predictions with experimental results of liquid metal containment and fluid flow in EM edge dams designed at Inland Steel (Ispat Industries Ltd.) for twin-roll casting. Numerical simulation was performed by coupling a three-dimensional (3D) finite-element EM code (ELEKTRA) and a 3D finite-difference fluids code (CaPS-EM) to solve Maxwell’s equations, Ohm’s law, Navier-Stokes equations, and transport equations of turbulence flow in a casting process that uses EM fields. ELEKTRA is able to predict the eddy-current distribution and EM forces in complex geometry. CaPS-EM is capable of modeling fluid flows with free surfaces and dynamic rollers. The computed 3D magnetic fields and induced eddy currents in ELEKTRA are used as input to flow-field computations in CaPS-EM. Results of the numerical simulation compared well with measurements obtained from both static and dynamic tests.

Model-based control of a thermal regenerator. Part 2: control and estimation

This paper describes the model-based control and estimation techniques implemented on the hot blast stoves for the number 7 blast furnace at the Ispat Inland Steel facility in East Chicago, IN. The process model is a detailed heat transfer model of this thermal regenerator system used as part of a predictive control scheme to determine the minimum amount of fuel necessary to achieve the energy requirements. Batch nonlinear least squares estimation is used to update the predicted temperature profile and heat transfer coefficients. These estimated parameters are then used by the model-based controller to determine the minimum fuel required for the subsequent regenerative cycle.

Model-based control of a thermal regenerator. Part 1: dynamic model

This paper describes the dynamic process model and solution technique developed for the hot blast stoves used with the No. 7 blast furnace at the Ispat Inland Steel facility in East Chicago, IN, USA. A detailed, distributed parameter, heat transfer model of this thermal regenerator system is developed and verified using plant data. The model is capable of predicting accurately the temperature and energy content of the stoves during the thermal regenerative cycles. It was developed for a predictive controller that determines the minimum amount of fuel necessary to achieve the energy requirements from the system.

Self-Managed Teams in the Steel Industry: An Interview With John Selky (Part II)

The following is the final installment of a two-part interview with Mr. John Selky who was the President of I/N Tek / I/N Kote (I/N) from its inception in 1989 to his retirement in 1998. I/N was jointly financed and built (1987-1990) by U.S.-owned Inland Steel Company and Japanese-owned Nippon Steel Corporation. In 1998, Inland Steel Company sold itself and its ownership share in I/N to Ispat International, a Dutch-owned global steel conglomerate. I/N produces high quality cold rolled and coated steel coils using a computerized, state-of-the-art continuous production process. To most effectively accommodate the technology and the demands of increasingly competitive steel product markets, the work system at I/N is organized around self-managed teams made up of union employees. In our first installment, published in the previous issue of The Journal of Leadership Studies, Mr. Selky explained the development and start-up of the I/N joint venture. The highly effective I/N work system emphasizing teamwork and other work system innovations is truly remarkable considering the steel production process and the traditionally mechanistic, unionized nature of U.S. steel companies. Mr. Selky has been credited with the success of I/N's high performance work system. Although Mr. Selky's background may be found in the first installment, it is presented below for the reader's convenience.

Electromagnetic processing of liquid steel

The use of electromagnetic processing of liquid steel at Inland Steel Company is in various stages, ranging from commercial usage, with suggestions to vendors for improvements, to new application research. The status of commercially available electromagnetic stirring and electromagnetic braking are discussed. Application research of electromagnetic containment and electromagnetic throttling are also discussed. The basic theory for electromagnetic processing of liquid steel is presented.

The Improvement of Surface Quality of Continuous Rheocast Bars of Steel and High Melting Point Alloys.

A new continuous rheocasting process for steels and high temperature alloys has been developed by Inland Steel incorporating a dual chamber casting machine utilizing separate electromagnetic stirrers around each chamber. Initial casts on the rheocaster were plagued by breakouts and very rough as-cast surface morphology. The mechanism for solidification and formation of cast surface morphologies on as-rheocast bars has been determined and verified by comparing predicted surface morphologies to actual surface morphologies. The mechanism was then used to develop new withdrawal patterns to eliminate sticker breakouts and obtain good surface quality.

5520718 Steelmaking degassing method: Keilman Leonard M; Flanagan William F;Bradley James E; Balajee Shankverm, Crown Point, United States assigned to Inland Steel Company

5520718 Steelmaking degassing method: Keilman Leonard M; Flanagan William F;Bradley James E; Balajee Shankverm, Crown Point, United States assigned to Inland Steel Company

EM of mechanical plated Ti and tin coating on steel

Mechanical alloying, originally developed as a means to produce oxide dispersion strengthened alloys, has since been adopted for producing a wide variety of materials such as solid solution alloys, metal matrix composites, intermetallics, nanocrystalline and amorphous materials. It has also demonstrated as an efficient method for alloying gaseous elements by solid-gas reaction. Interest in using metal and metalloid nitrides as coating materials has been increased considerably in the past few years because of their special properties including extreme hardness, high temperature stability, high corrosion and wear resistance, and excellent conductivity. A new coating technique through the marriage of mechanical plating and nitriding has recently been developed in this laboratory. This paper presents an electron microscopic study of mechanically plated Ti and TiN coating.Commercially produced (Johnson Matthey, Inc.) fine-grained (325 mesh, or 44 μm) Ti (99%) powders were used as the starting coating material. Interstitial-free steel sheet (provided by Inland Steel) were cut to a size of 1.5 cm × 1.5 cm as the substrate.

The Development of a Continuous Rheocaster for Ferrous and High Melting Point Alloys.

A new continuous rheocasting process for steels and high temperature alloys has been developed by Inland Steel incorporating a dual chamber casting machine utilizing separate electromagnetic stirrers around each chamber. The caster parameters were varied in a series of experiments to determine the optimum combination to provide a fine degenerate dendrite size, small peripheral dendritic zone, and minimum percent dendricity. The optimized process produces a degenerate dendrite size of about 80 microns with a peripheral dendritic zone about 1.5 mm thick and no dendricity. A series of casts was made of 12 different steel and high temperature alloys to determine the capability of the Inland Steel rheocaster to provide a satisfactory rheocast structure on various alloys. The rheocaster produced an acceptable rheocast structure for all alloys cast. Comparison of the cast structure of the Inland Steel rheocast material to conventional continuous cast material has shown that highly alloyed materials can be cast using rheocasting and provide a fine, homogeneous, and unsegregated cast structure. This is not the case for conventional continuous casting processes available currently.

Saarstahl AG v. United States: Inland Steel Bar Co. v. United States

Saarstahl AG v. United States: Inland Steel Bar Co. v. United States

LEDLOY 4140

Abstract LEDLOY 4140 is a lead and/or tellurized chromium-molybdenum alloy steel having free cutting characteristics. It is recommended for gears, shafts, fasteners and similar machinery parts. This datasheet provides information on composition, physical properties, elasticity, and tensile properties as well as fracture toughness and fatigue. It also includes information on forming, heat treating, machining, and joining. Filing Code: SA-212. Producer or source: Inland Steel Company. Originally published as Incut 4140, June 1967, revised August 1994.

LEDLOY-AX

Abstract LEDLOY-AX is a lead and tellurium-bearing steel, having superior free-machining characteristics. It is recommended for screw machine products, fasteners, hardware, etc. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties as well as fracture toughness and fatigue. It also includes information on forming, heat treating, machining, and joining. Filing Code: SA-227. Producer or source: Inland Steel Company. Originally published June 1968, revised July 1994.

LEDLOY-A

Abstract LEDLOY-A is a leaded, low-carbon free-machining steel recommended for high production automatic screw machine products. This datasheet provides information on composition, physical properties, and elasticity. It also includes information on forming, heat treating, machining, and joining. Filing Code: SA-176. Producer or source: Inland Steel Company. Originally published April 1965, revised June 1994.

Strategic planning: The engine of change

Inland Steel Industries is a $3.5 billion corporation with two main businesses. The Inland Materials Distribution Group (IMDG) is essentially a combination of a metals “hardware store” for small machine shops and small users of steel, and a vehicle to provide customers with materials management services—just‐in‐time inventory and initial processing, for example. The IMDG contributes about $1.5 billion in sales annually. The other business is the Inland Steel Co., which focuses on manufacturing.