This is a common problem with the brands mentioned in the tropics. It is called lead bloom. The article Jonathan referenced is fairly exhaustive but not conclusive. They do say it seems to be a reaction with acid in the environment, perhaps tannin in the wood, the finish, the air. At any rate it's a good read and they put a lot of time and effort into it.
The article claims that impurities in the lead are not the problem, however, it is not uncommon at all to find pianos in which one size of lead has the problem and different sizes right next to them do not, so...
Trimming the lead in place with a hacksaw blade is a temporary solution. Many people advocate using some type of sealant as mentioned above, it is logical. However I have encountered many leads that are "blooming" from the inside out, if this is a chemical reaction as opposed to some sort of oxidation then sealing isn't going to help. So I don't advocate it. Perhaps in places where the effect isn't too aggressive, perhaps sealing will slow it down, I don't know. But here in Hawai'i it can be really aggressive and I honestly don't think it helps. Here are some pictures I posted last year of a worst case scenario:
http://my.ptg.org/communities/community-home/digestviewer/viewthread?GroupId=43&MessageKey=3daa5cea-f4b7-4d09-b8b9-f8ba5e9e9899&CommunityKey=6265a40b-9fd2-4152-a628-bd7c7d770cbf&tab=digestviewerYou can see in last image there that the contamination is through and through. I've also run into a Knight vertical in which almost all the keys were shattered to the point the keys were broken in two. Of course this can happen to the leads in the damper back-action too and they are much more fragile than key sticks.
As you can see, I know much more about this than I'd like to.
The white powder if really fine, finer than chalk dust so there's bound to be some floating around in the shop if you have to deal with a whole set of keys with as many as, what, 2-300 leads on a grand? I use a rod in my drill press to push them out for replacement, or a forstner bit to trim them as mentioned. The holes on Sohmer verticals, which seem to have this problem universally on their later models, do not go all the way through the key so they a) can push a big chip into the neighboring key and b) can't be simply pressed out.
I have been concerned about dust that I have surely inhaled to the point of getting a blood test last year. It came out negative but to tell you the truth, that only made me suspicious of the test. At least it's not in my blood I guess.
One last thing in a long post. I have run into some new Asian pianos, Young Chang I think, in which the key weights didn't look like lead. I've also heard from a someone in tech services at Yamaha that they "think" Yamaha is using something else in the their hybrid grands but not yet in the acoustic pianos. I don't believe that Steinway doesn't know about this, it's extremely common in their pianos in the tropics, but I can understand why they wouldn't want to address a lead problem in this day and age. Perhaps some manufacturers are working to get ahead of the problem at least in the future.
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Steven Rosenthal
Honolulu HI
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Original Message:
Sent: 05-08-2018 09:26
From: Patrick Baron
Subject: key lead expansion
I'm looking for commiseration and advice. I'd only encountered this problem once in my 25 years in NYC, and that was a piano that had just arrived by ship from South America. When I recently ordered key weights from Steinway, I asked about the problem and Chad Frye (?) said he'd never heard of such a thing. I've encountered it on Steinways, Yamahas, Knights and other brands.
The leads are corroding, turning into a whitish powder, and in the process expanding. In the worst cases, they split the key. Here in the Virgin Islands (land of salt air and high humidity) it seems to be a fairly common problem, leading to keys locking up as the lead weights begin to interfere with the adjacent keys. I've tried various coatings in an effort to slow the progress of corrosion, but it seems as if, once begun, it's impossible to halt.
Questions: Are the weights pure lead or some alloy?
What is the proper name of the powdery substance that results?
Is that substance more or less reactive/potentially harmful than the unscathed lead?
Is there a coating specifically intended for lead? (I've tried a "High Performance" acrylic metal lacquer)
Does the corrosion creep from one lead to another, propagating across the keyboard? (This is an important question bearing on how thoroughly one must clean the keys before installing new leads.)
Thanks in advance for any light you can shed on this. Any chemists out there?