I am so glad this forum is here, I can't imagine anyone figuring all this great stuff out alone!
Dan -- The whole 1505-1520-1550 thing is potentially an issue. I have no doubt that the thermocouple is indeed at the indicated temp, but that is in the upper, right-front corner of the kiln. I'm sure there's a temp gradient in there, not sure how bad. Plus, the kiln was designed by a bass-ackward right-hander, so it takes me about 5-10 secs to get the piece into the quench bucket. I thought of getting an infrared thermometer as a second temp check, but after reading their specs they're basically just a SWAG. Which is what sent me off on the magnetism versus "indicated" temp hunt.
Jake -- The 1050 was sold as "Annealed, Pickled, and Oiled." I'm no metallurgist, so I could be way wrong, but I didn't think low-alloy hypoeutectoids could be spheroidized. Anywho, I cut out the basic shape with a sabre saw, grind in geometry, and refine with file/sen, then 180-grit waterstone. The parts are then normalized no more than twice at 1600F (kiln-temp). I did not know about the descending normalize heats, makes sense in hindsight, adding that one to the list... The stuff I destructively tested had a nice gray velvet, but was much rougher than a broken tap surface.
As to kiln "air," I don't run a reducing atmosphere, to keep the protective oxide on the electric elements. So decarb could well be an issue--unprotected pieces will build up scale, or is that par for the course? I've been trying to target a temp that allows for no more than a 30sec - 1min soak. Also mix in some carbon with the satanite (very light coat for normalizing, clean and properly re-coat for quench).
My day job limits blade-work so most experiments have to happen on weekends. As data trickles in, I'll keep ya'll updated...
Brian K.