The Iron Age 1906-03-15: Vol 77 Iss 11

THE IRON AGE P-9061 92ND WSisddory, A Review of the Hardware, Iron, Machinery and Metal Tra ®%09j0 wugiqyy Published every Thursday Morning by David Williams Co., 14-16 Park Place, New York, ' —_—— Vol. 772 No. 11. New York, Thursday, March 15, 1906. Sienic tnstel sae Tone Single Copies, 15 Ce Reading Matter Contents...... page 993 Alphabetical Index to Advertisers ‘‘ 193 Classified List of Advertisers ‘185 )) Advertising and Subscription Rates“ 192]/ Compression Shaft Couplings Manufactured by FORSTER PULLEY WORKS Cuba, N. Y. The American. Mfg. Co. Ropes and Twines Different men differ as to their favorite kind of rifle. Practically all agree, how 65 Wall Street, New York ever, on U.M.C. Cartridges. A glimpse at the interior of most any hunting shack presents these facts. A good stock of U.M.C. Cartridges, therefore, is good business. New methods and old quality in manufacture keep U.M,C. Cartridges in the lead Bristol's Patent Steel Belt Lacing _SAVES THE UNION METALLIC cant apes COMPANY, e, Belts, Money, AGENCY, BRIDGEPORT, CONN. DE READY TO APPLY FINISHED JOINT with Least Metal. 813 Broadway, .. " — First hmong, Send for Circular Q and Free Samples, THE BRISTOL CO., Waterbury, Conn. STIRLING CONSOLIDATED BOILER CO. see Page 4s Also Linen and Italian Hemp Sash Cord. asec ‘The Best in the World’’ Cleveland City eatin Gaetan. Careciend, ©. Capewell Horse Nails are Flexible enough TURNBUCEHKILEZES. to Clinch easily and so Tough that the MERRILL BROS., will not break under the severest strain AED ae. in service. BESSEMER PIG aaeowere PILLING & CRANE. Ferran reriet Capewell Horse Nail Company Trad Hartford, Conn. OUR “|= Packing of Joints will not be a source of much trouble or annoyance if you will take the precau- sy] | aes : ; : B) tion to procure the genuine at Ny 9 Tae JENHINS °96 PACHING tS Sa) It will make perfect steam joint instantly. All genuine bears Trade Mark as shown in the cut. JENKINS BROS., New York, Boston, Philadelphia, Chicago, London CALENDAR ! . suggests that you should use ce) DWGOO” GOUG ROVLEA SG cre: Drawing a stamping M. F. Roofing Tin every d THE AMERICAN TUBE & STAMPING COMPANY SEE [fF 3 ( B GEPO Ce in the year nd why. (Water and Rall Delivery) RIDGEPORT, CONN, MAGNOLIA METAL. See Best Anti-Friction Metal for all Machinerv Bearings. AMERICAN Fac-Simile of Bar. rey : SHEET & TIN PLATE yx uA imitations. COMPANY’S GNOLIA METAL CO., Owners and Sole Manufacturers, 113-116 Bank Street, We San Francisco, Mentpest, and Pittsburg. Ad on Page Is Chicago. Fisher Bidg. NEW YORK. @ manufacture al) > See ae THE IRON AGE § “ THE PLUME & ATWOOD MFé. Co,, Sooner or later Special B R A § ‘ a MANUFACTURERS OF Quality Buyers of any- thing admit @ NAME sect Sheet and Roll Brass ieaueeaneenennne COPPER na WIRE a year ago having trouble with either SHEET STEEL or TIN PLATES. Our particular finish- es of Black Sheets, like, say, Drawing, Nickel- ing, Pickled and others, have removed what seemed to be insur- mountable difficulties in many operations. So far as Tin Plates are concerned, whether Bright or Roofing, it is admitted we are ahead of the times in QUALITY although our prices are not. “Ot ayse Brothers Company GERMAN {s*==" SILVER WIRE LOW BRASS. SHEET BRONZE. SEAMLESS BRASS AND COPPER TUBING. BRAZED BRASS AND BRONZE TUBING. :: ts WATERBURY BRASS C0., WATERBURY, CONN. 99 John St., New York. Providence, R. I. Bridgeport Deaxidized Bronze & Metal a BRIDGEPORT, GONN. Automobile Castings a Specialty. High Tensile Strength. Bronze and Aluminum Alloys. Write Us. Matthiessen & Hegeler Zinc Co., LA SALLE, ILLINOIS. SMELTERS OF SPELTER AND MANUFACTURERS OF SHEET ZINC AND SULPHURIC ACID. Special Sizes of Zinc cut to order. Rolled Battery Plates, Selected Plates for Etchers’ and Lithographers’ use. Selected Sheets for Paper and Card Makers’ use. Stove and Washboard Blanks. ZINCS FOR LECLANCHE BATTERY. TU SNe GR 105-109 So.Jefferson St.: Chicago. CASTINGS Best Bronze, Babbitt Un Short Nottce rass, Bronze and # Aluminum 2 CASTINGS FOUN DERS— FINISHERS. Ww. G. ROWELL Co., Bridgeport, Conn. HENDRICKS BROTHERS ROPRIETORS OF TH Belleville Copper Rolling Mills, MANUFACTURERS OF Brazsiers’ Bolt and Sheathing COPPER, COPPER WIRE RIVETS. Importers and Dealers in ingot Copper, Block Tin, Spelter, Lead, Antimony, etc. 49 CLIFF ST., NEW YORK. Metals Brass and Aluminum For sale by David Williams Go., 14-16 Park Place, N.Y. PRINTERS’ BRASS, JEWELERS’ METAL, GERMAN SILVER AND GILDING METAL, COPPER RIVETs AND BURRS. Pins, Brass Butt Hinges, Jack Chain, Kero sene Burners, Lamps, Lamp Trimmings, &c. 29 MURRAY ST., NEW YORK. 199 LAKE ST., CHICAGO, ROLLING MILL: THOMASTON, CONN, FACTORIES: WATERBURY, CONN. SCOVILL MFG. CO. MANUFACTURERS OF BRASS, GERMAN SILVER, a - ame i. epee olt 8s and Tub Brass Shells, Gups, “Hinges, Buttons, Lamp Goo Special Brasa Goods to oon Facrorizs: WATERBURY, CONN. Drpors: NEW YORK. CHICAGO. BOSTON. Henry Souther Engineering G0. HARTFORD, GONN Consulting Chemists, Metahardicts and Analysts a Physical Testing Laboratory Expert estimony ia Court and Patent Cases. Arthur T. Rutter & Go 256 Broadway, NEW YORK. Small tubing in Brass, Copper Steel, Aluminum, German Silver, &c. Sheet Brass, Copper and Ger- man Silver. Copper, Brass and German Silver Wire. Brazed and Seamless Brass and Copper Tube. Copper and Brass Rod. WIRE. “it’s ToucH.” TROLLEY, TELEPHONE and TELEGRAPH LINES. BRIDGEPORT BRASS ~ Postal Telegraph Bldg. Broadway and Murray St., New York Light and Water. A study a3 ao and color in river, lake an By Sir paeege Pollock. 114 ee. ee Cle Mills Bridgeport, Cann Streases in Structures and the Accom- ra fer pease. Diaaras B Albert, Ee Diagra: Cloth... Cla » Modell g and Plaster Coatine. Wie h pumetes engravings and diagrams By Paul Nooncree Hasluck. 160 pages. $0.5 6 THE IRON AGE New York, Thursday, March 15, 1906. The Newton Steel Foundry Cold Saw. There is perhaps no place where a cold sawing ma- ehine is put to more severe use than in a steel foundry. Nearly its entire work is the removing of gates and risers from steel castings, and it is highly desirable that the saw blade be of great cutting capacity and that the ma- chine be conveniently manipulated in order that the work may be done economically and rapidly. A cold sawing machine particularly designed for steel foundry service and built by the Newton Machine Tool Works, Philadel- phia, Pa., is shown in the accompanying engraving. As be engaged at a time the saw blade is idle when the quick return is acting. This feature is desirable because it has been found to be best to have the saw blade still when withdrawing it from the cut, inasmuch as it is diffi- cult to clamp steel castings so that a shift or some lat- eral movement will not frequently occur after the gate or riser is cut off. In such cases were the blade with- drawn while in motion there would be a tendency, due to the changed position, to break out some of the teeth of the saw. The power feed is variable through a friction disk and shifting driver, the latter being manipulated through the handle shown near the base of the machine. It is A Motor Driven Cold Sawing Machine Built for Steel Foundry Uses by the Newton Machine Tool Works, Philadelphia, Pa. may be seen. it is of a motor driven type and uses an inserted tooth high speed saw blade. The blade in this machine is driven through powerful spur gears by a worm and worm wheel of steep lead, the wheel being of phosphor bronze and the worm of hard- ened steel and both running in oil. These parts are sup- ported from the carriage and move with the saw when feeding. The shaft carrying the worm is splined and is driven through spur gears by a 10 horse-power Crocker- Wheeler motor mounted on top of the machine. The same motor operates a quick movement for returning the saw carriage after taking a cut, the power being obtained through a belt from a pulley on the extended armature shaft to the smaller step of a pulley connected with the feeding mechanism. The larger step is belted to a pulley on the same sleeve with the gear driving the splined worm shaft and gives the cutting feeds. Both the regular drive and the quick return are transmitted through: friction clutches, both of which may be simultaneously disen- gaged so that the motor can run contimmously when neither movement is in action. As only one clutch may usually desirable to make use of this, throwing the fric- tion to its highest speed when the quick return movement is in action. The saw blade on this machine is 40 inches in diameter, and the spindle which carries it is mounted in a ram having 24 inches in and out feed. The capacity covers the cutting off of gate and risers up to 13 inches in diameter. The blade being overhung on the rear side, as viewed in the half-tone, long castings may be placed close to that side when the surplus parts are being cut off, and the ram construction is such that odd shapes of castings may be frequently handled under the ram. The machine is furnished with an independent adjustable table 4 feet wide and 6 feet long, having T slots for clamping work, which is movable at right angles to the saw blade for convenience in setting the work. In designing this tool the manufacturer has endeav- ored to give it all the power, strength and rigidity neces- sary for the satisfactory driving of the modern high speed inserted tooth saw to its full capacity, and it is believed that it will appeal to those having need of a tool of its class. Sm teeter Poss Sree ee ae tie Aaah ihn 948 The Talbot Continuous Steel Process.* BY G, A. WILSON. In the autumn of 1903 I had the pleasure of reading before this institute a paper on our practice in fixed open hearth furnaces at Britannia works, Middlesbrough, whicb I then looked upon as representing the very acme of good practice. I find, in the light of present knowl- edge, that the continuous steel process permits of the manufacture of steel more readily and more economically than I should have thought possible a short time back. On resigning my post as steel superintendent at Britannia works I took up a similar position with the Cargo Fleet Iron Company, Limited, of Middlesborough, which was then on the eve of starting the first of its 175-ton tilt- ing furnaces, as designed for the carrying out of the Talbot continuous process. Talbot Furnaces at Cargo Fleet Works, The steel plant at Cargo Fleet works at present con- sists of three large tilting furnaces, which have a nomi- nal capacity of 175 tons each but which will in reality at a pinch carry 200 tons of steel. The dimensions of the bath of these furnaces are as follows: Length between blocks, 37 feet 6 inches; width between linings, 14 feet 6 inches; depth of bath, 3 feet 10 inches to foreplate level. The furnaces are of the Wellman type and are provided with three rockers and supports, upon which the furnace rolls forward. Despite their large size they are provided with only three ports—that is, one central gas port and ‘two air ports. The ports are egg shaped in section, and this form I find to stand remarkably well. Each port is about 2 feet 3 inches across by 3 feet 3 inches high. The air chambers are 10 feet wide by 22 feet long by 17 feet 6 inches to crown of roof. The gas chambers are 8 feet wide by 22 feet long by 17 feet 6 inches to crown of roof. The air valve is 4 feet 3 inches square; gas reversing valve 3 feet 6 inches diameter ; gas supply valve 4 feet 6 inches diameter. The furnace is capable of tilting both ways and is manipulated by two hydraulic cylinders in the ordinary way. The tapping platform is attached to the frame work of the furnace and consequently moves with it— a very convenient arrangement. On the charging side the three furnaces are served by two 40-ton overhead electric traveling cranes, which are provided with 20-ton auxiliary lifts. On the tapping side the furnaces are served by two 75-ton overhead electric traveling cranes, which are also supplied with 20-ton auxiliary lifts. Features of the Plant. The lime and oxide additions are charged in by means of a Wellman charger, which runs the whole length of the staging and picks up the necessary boxes from the cars on a track running in front of the furnaces. The molten iron is run direct from the blast furnaces to a mixer of about 180 tons’ capacity. The mixer is of the ordinary Bessemer type and is kept sufficiently hot by means of four blow pipe nozzles, in which coke oven gas and air are consumed. This arrangement is both cheap and ef- fective and is practically doing the work which is done at some other works in large primary furnaces supplied with regenerators, valves, stacks, &c. From the mixer the partly desiliconized and desul- phurized pig iron is poured into a ladle holding some 25 tons and lifted up and carried along by means of the overhead traveling crane to the front of the furnace on the charging side. It is then tilted and the metal al- lowed to run slowly into the Talbot furnace through a short runner fixed onto the foreplate of one of the doors. The metal is tapped into a 50-ton steel ladle in the ordi- nary way by opening the tap hole and tilting the furnace as far as may be desired. It is, of course, easy to regu- late the exact quantity that should be cast at one time; and when sufficient steel has béen run into the ladle all that is necessary is to tilt the furnace back again into its original position. Arrangements are made for tapping off the slag when- ever desired; and this forms an essential point in a * From a paper read before the West of ScotJand Iron and Stee! Institute, January 19, 1906. THE IRON AGE March 15, 1906 well designed Talbot plant, as one has not only to deal with large quantities of steel but also large quantities of slag, and the days in which we could allow this to run into the pit have long passed. At Cargo Fleet slag can be cast simultaneously from doors Nos. 2 and 4 on the charging side of the furnace. The slag runs into two slag ladles, which carry about 10 tons each and which run on rails between the center stands of the furnace. The slag buggies can be run out to the casting side of the furnace to a point at which the 75-ton crane can pick them up and deal with them. The furnaces are provided with Talbot movable port ends, which are certainly very convenient. These consist of two movable cages, one at each end of the furnace, which carry the flues or uptakes connecting the chambers with the movable section of the furnaces. These are actuated by means of hydraulic cylinders and have both horizontal and vertical motions. The vertical motion is very slight, being about 3-inch rise, just to prevent fric- tion horizontally when the furnace is tilting; but when repairs have to be made to the blocks or to the uptakes from the chambers they can be drawn back to a distance of several feet from the furnace, so as to allow the brick- layers to work either at thé blocks or uptakes. The whole furnace is water cooled, there being sep- arate vertical chills for the gas and air, both on the tilting section and on the movable port ends. When the furnace is working these chills are close together. The gas producer plant which has been erected at Cargo Fleet for supplying gas to the three large tilting furnaces consists of a plant of ten Talbot mechanical gas producers. These are automatically fed, the coal being supplied from an overhead bin. As is fairly well known, these producers, which are some 10 feet in diameter, are supplied with a central shaft, provided with an arm which works in the fire. The central shaft has both a vertical and horizontal motion, the horizontal motion be- ing a slow continuous one, while the vertical motion is only used intermittently—say once every half hour or thereabouts. By these two motions the fire is kept in good condition and a very good gas produced. Each pro- ducer is capable of gasifying about 1 ton of fuel per hour. Casting is carried out at Cargo Fleet on the car system, there being no pit in front of the furnaces. The ladle, with-from 50 to 60 tons of steel, is lifted by means of the overhead crane to the requisite position over the track upon which the cars carrying the ingot molds run. The cars are pushed forward by means of hydraulic racks; the teemer stands on a platform at about the level of the top of the ingot mold. It is rarely necessary to box down any ingots. Details of Practice. Having briefly discussed the plant in which the proc- ess is carried out, let us turn for a few moments to the process itself : Briefly, we are bringing the iron from the mixer in lots of some 20 to 25 tons each, converting this into steel and casting about 50 tons of steel ingots every six hours. To bring this about, the great secret is the proper man- agement of this slag and a sufficiently decarbonized bath when the molten pig iron is run in. Our great aim is always to get a good reaction when the molten metal enters the bath; and if we fail to get this we know that the charge will be a slow one, requiring to be worked down much as an ordinary heat in the ordinary fixed fur- nace practice. On the other hand, when a good reaction is obtained (and this, with a little experience the first hand can almost always bring about), the carbon is very rapidly and energetically boiled out of the metal, and when the reaction has calmed down the bath will be found to contain not more than about .3 per cent. of carbon. Some care is required to keep the reaction under con- trol, as if too large a quantity of molten iron is added at a time it is apt to become too violent, when a good deal of slag which would be valuable in the furnace is thrown out on to the staging. With a high silicon iron or with a very gray iron the tendency is to get violent reactions; whereas with a good white basic iron there is very little to be feared on this score. March 15, 1906 Immediately after tapping, as soon as the tap hole has been closed, the requisite amount of iron oxides and lime are added to the furnace by means of the Wellman charger. While these additions are getting molten the necessary repairs to the slag line are made by the furnace hands. I may say here that we find the repairs to be considerably less on these large tilting furnaces than on the ordinary fixed basic furnaces. As soon as the oxide and lime additions are fairly incorporated in the slag the first ladle of molten iron is brought up from the mixer and cautiously added as de- scribed. When this has worked down somewhat more lime and oxides are charged in and the second ladle of metal introduced. There is always far less danger of a violent reaction with the second ladle than with the first. It is usual to run off a fair portion of the slag after the second ladle has worked down somewhat, otherwise an unduly thick slag will accumulate on the surface of the bath, and this tends to keep the heat off the metal for finishing purposes. When the bath seems about ready tests are taken and analytically examined for carbon, phosphorus and sulphur and when these are found correct the furnace is tapped. No manganese is added in the furnace, but it is all thrown into the ladle in the usual way. It is interesting to note, as showing the unoxidized state of the Talbot bath at tapping, that 25 per cent. less ferro is needed than would be required to give an equal man- ganese in steel from a fixed furnace working the usual way. Character of Steel. As showing the quality of the steel produced I give the analytical details of the first 50 casts. The steel is of excellent quality: and has been accepted by Lloyds and other surveyors for shipbuilding: Analyses of -Steel from. Talbot Furnaces. Cast. : e : Phos- Man- No. rr Carbon. Sulphur. phorus. ganese. Beers So 8 oe eet asicbdl a Ss Sek 0.25 0.034 0.032 0.420 Siw cectayvin nw pe ete ab rine cy 0.23 0:082 0.025 0.530 ae yinttp ee ee a a 0.024 0.064 0.610 Be ccc es cee cecencesvecercce 0.23 0.041 0.030 0.570 BSE See Fe oe TB. Bee ee, 0:22 0.021 0.059 0.610 Gass SiG. CMV Rite d hh tS. 0.19 0.050 0.055 0.600 Tir cc deleecwsiiessietea ts te ge O19 0.046 0.058 0.610 eas a eth ote 2 al areas 0.15 0.049 0.062 0.570 Wants svcceeecteuccatasce be ‘0.18 © 0.024 0.049 0.480 WR at Soniss HOU IRA BWIVUIA 0.22 0.044 0.037 0.478 11 Average analysis of metal 0.18 0.0387 0:034 0.570 12 direct from blast fur- 0.22 0032 0.040 0.500 13 naces for first 26 casts. 0,16 0,041 0.025 0.500 14 Phos.. .1.50 0.15 0.039 0.020 0.520 15 Sil... ... 1.25 0.15 0.039 0.049 0.540 16 Sul....0.10 to 0.15 0.15 0.035 0.037 0.520 ie ae Ae ae we Gli dee ca od 0.20 0.044 0.013 0.450 Mr a dia waren >. ooh wae acleawhawed 0.16 0.037 0.058 0.610 Be aes i666 cecawep ctv awe ee Ble 0.19 0.052 0.040 0.570 SLs Wiwbic wk hs hCle WOES 0.31 0.055 0.055 0.490 rE ae re ee weirs 0.20 0.044 0.054 0.490 Ap ale ah xs tives oben 0s eee 0.16 0.058 0.021 0.500 SE ee ee 0.1385 0.053 0.034 0.490 _ Rear ype ee 0.190 0.058 0.035 0.590 Ss £8 catch oie hee cab One 0.240 0.032 0.052 0.480 26 The mixer was put into 0.140 0.050 0.039 0.570 27 operation from cast 26. 0.150 0.050 0.039 0.570 Sil. : > Sul. Ot onthe nt 1.00 0.046 0.120 0.050 0.020 0.438 Si so Saw 'e's & @ 0.89 0.062 0.135 0.050 0.016 0.410 estes cia eee 1.12 0.046 0.240 0.0386 0.017 0.480 Shi Sis 55.25088 0.047 0.160 0.032 0.021 0.500 32... uve w. 0.745 0.044 0.160 0.046 0.040 0.520 ge 1 ae pe 0.086 0.180 0.061 0.053 0.490 Mec ertssvnws 1.30 0.062 0.170 0.057 0.060 0.490 36. .4.'. * e颥1.22 0.052 0.170 0.053 0.054 0.480 BG oo -46653 des 0.896 0.090 0.150 0.040 0.048 0.470 ila cic neiecets see 0.086 0.180 0.060 0.038 0.440 Mere cces Giska he we 0.155 0.032 0.047 0.460 es case ees 1.19 0.042 0.160 0.040 0.040 0.430 BO. ites estan 0.934 0.070 0.190 0.025 0.027 0.410 4h: ox meues 0.88 0.084 0.170 0.058 0.021 0.410 Ce aie Oe nxt a7 0.083 0.155 0.059 0.032 0.470 Ga sac etre *.1.02 0.084 0.135 0.054 0.016 0.450 Oise stea’ des 0.630 0.064 0.135 0.053 0.016 0.450 a eee 1.00 0.059 0.135 0.040 0.038 0.470 re 0.965 0.046 0.150 0.047 0.023 0.450 BE. cc cc.s ve HO 0.067 0.170 0.058 0.024 0.480 Ge baci ia cs Cote 1.23 0.082 0.150 0.055 0.030 0.553 is ndente int ee 1.17 0.096 0.220 0.049 0.050 0.500 iticndsses.s 1.09 0.063 0.220 80.050 0.039 0.480 As a rule the carbon in the steel is required fairly low, from about 0.15 to 0.20; but both higher and lower car- THE IRON AGE 949 bons can readily be obtained, more especially with very soft steel. Hitherto we have not paid very much attention to obtaining a marketable slag, having directed our atten- tion to making a good steel. The pig iron used is Cleveland forge and at times the sulphur in this is higher than could be wished. Pass- ing such iron through the mixer, however, eliminates some 30 to 50 per cent. of the sulphur, and the remainder is easily dealt with in the steel furnace. There is no doubt a mixer is a great help as an auxiliary to the steel furnace, and our experience at Cargo Fleet shows that the mixer need not be of the expensive description that has recently been adopted by several firms. I note your president in his opening address refers to the use of mixers in connection with steel making from direct metal. I entirely agree with what he says, provided the metal is run from the mixer into a large continuous steel bath, as when run in comparatively small lots into fixed furnaces there is by no means the same advantage ob- tainable. As regards the future we hope to have our third Talbot furnace working in a few weeks. A cupola plant will have to be erected to supply part of the metal and with this our output should be over 3000 tons per week. The first charge was made at Cargo Fleet on Septem- ber 4, 1905, and for the first 12 weeks there were produced 11,574 tons of ingots, or practically 1000 tons per week, with a yield of 105.7 per cent. of steel calcu- lated on the metals charged and with a speed of con- version of 8.4 minutes per ton converted. The fuel con- sumption has not been quite accurately obtained, owing to gas being used for other purposes; but a near approxi- mation brings it out at 5 ewts. per ton of steel. The ton- nage rate for labor has not yet been fixed, so that I do not propose to deal with this point; but it is obvious that as the same number of men are employed as on an ordi- nary 50-ton basic furnace which would make, say, 450 tons per week, labor must work out considerably less per ton. In my paper I have shown you that from one large tilting furnace, without expensive scrap and from com- mon molten iron, we are making by the continuous proc- ess, and with the help of the ordinary staff of furnacemen only, from 1000 to 1200 tons of steel per week, with a yield of steel up to 108 per cent. on the metals charged into the furnace, and with a fuel consumption of not more than 5 to 6 hundredweights per ton of ingots; and I would ask those of you who have charge of open hearth steel furnaces to compare this with your own practice. ————_—__~»>-—_____—— Generating sets are now manufactured by the B. F. Sturtevant Company, Boston, Mass., in a line of 36 sizes, ranging from 3 to 100 kw. direct connected. The vertical cross compound engines were designed to meet the rigid specifications of the United States Navy Department. which in the case of the 100-kw. demand an efficiency of 31 pounds per kilowatt hour. These engines, as well as the vertical and horizontal simple engines, are entirely inclosed, provided with forced lubrication and watershed partitions. The generators are multipolar, capable of carrying 50 per cent. momentary overload and 25 per cent. excess for two hours without sparking or undue heating. The smaller sizes of these sets are particularly adapted to service as boosters. The Northeastern Railway Company has built at its shops near Darlington, England, a number of 30-ton steel cars for hauling iron ore from the Cleveland mines. These cars are 20 feet long, 9 feet 10 inches high and 8 feet wide, and their load is considerably greater than has been carried by cars with but two axles. There are four bottom doors, composed of plating weighing 12'4 pounds per foot, the net area of the door openings being 39 square feet. The wheels have a diameter on tread of 3 feet 10 inches and the ‘wheel base is 10 feet. Including vacuum brake and all fittings the weight of these cars, each of which has a cubic capacity of 680 feet, is 12 tons 12 hundredweight. THE 950 Making a Difficult Repair Casting. An uncommon piece of repair work was recently exe- cuted by the H. W. Caldwell & Son Company, Chicago, which required the casting of a half section of an 18- foot band wheel. The whole wheel was originally made IRON AGE March 15, 1906 To cast a new half to match the old unbroken one it was necessary to use considerable care in the foundry to secure as nearly as possible the same mixture and mold it under approximately the same conditions in order that an equal diameter and circumference and the same amount of shrinkage might be obtained. sections. Fig. 2.—The Finished Wheel with the New and Old Halves United. by another foundry, but in setting it in place on the crank shaft of the engine one of the halves was acci- dentally dropped into the pit and broken. It was a planed joint wheel, such as are cast in separate halves or As there was no datum available from the original maker the first step was the analyzing of a piece of the broken casting, to determine its composition. To dupli- cate it the furnace was charged with an equivalent mix- ture and the casting was made in the ordinary way. Fig. 1 shows a view of the casting as it came from the annealing furnace. The new and old halves were then bolted together and placed on a 20-foot boring mill. The new casting was then turned down to the same diameter as the old one and a light finishing cut was taken over the entire wheel. After completing the circumferential face and edges of the rim the hub was bored and faced in the same mill. The finished wheel was then placed on balancing horses and the weight about its axis equal- ized. The finished wheel is shown in Fig. 2. Its dimen- sions were, diameter, 18 feet; face, 42 inches, and bore, 15 inches, and the total weight of the wheel 27,806 pounds. It is interesting to know that the new half proved to be only 94 pounds out of balance, being that much lighter than the old half. a Aluminum as an electric transmission line material is at a disadvantage when compared with copper in the matter of deflection from temperature variations where long spans are required. The hight of a support would thus have to be greater for an aluminum line than for copper. The strength, however, need not be so great, for the weight of the aluminum line is only 47 per cent. of that of the copper line for the same resistance, and the tension in the aluminum cables will be but from one-half to one-third as great, depending upon the temperature. Where there are bends in the line or each pole is expected to withstand unbalanced loads, due to the breaking of one or more wires, the lesser weight and tension on the aluminum cables offsets the increased hight required in the supports. At the Rombach Works, Rombach, Lorraine, gas en- gines installed by the Niirnberg for furnishing blast for Bessemer converters have been in satisfactory operation since January and are spoken of as the first gas engines employed in this way. At 90 revolutions per minute 29,- 800 cubic feet of air is delivered. March 15, 1906 Molding Sand.* BY H. E. FIELD, PITTSBURGH. A review of current literature on molding sand brings to my mind an experience some ten years ago. I then pursued a like line of research on the subject of cast iron. The results were as follows: One authority stated that silicon softened cast iron, another that silicon hard- ened cast iron; one that sulphur was the most injurious element in cast iron, another that sulphur was never present in sufficient quantity to do any harm; one that phosphorus increased shrinkage, another that phosphorus decreased shrinkage; one that manganese hardened cast iron, another that manganese softened cast iron; one that cast iron gained in carbon in passing through a cupola, and another that cast iron lost carbon in passing through a cupola. Since that time all of those apparent contradictions in regard to cast iron have been explained. A similar contradiction now exists in the literature in reference to molding sand. This is partly due to a con- fusion in terms and partly to the marked difference of opinion as to what constitutes a molding sand. I shali endeavor to explain away this confusion in terms, but it is not practical to give definite specifications for molding sand, on account of the great variety of work and the different methods of mixing sand for the same work. I wish to make it clear therefore at the beginning of this paper that I am not attempting to lay down a set of standards for the chemical or mechanical analysis of sand. The day for that may come, and when it does the sand question will be much simplified. If we would improve molding sand or reduce the cost we must have a thorough understanding of what would constitute a model molding sand. We can then intelli- gently select the materials which nature has placed at our disposal and combine them so as to approach a standard, for I doubt if there is a founder present who can say that he has even come near to perfection in qual- ity and economy in the molding sand which he uses. We are continually told that the good molding sand of the old days can no longer be obtained and that the pres- ent supply is fast disappearing. If this is true it be- hooves us to gain a knowledge of what is necessary to make up a good molding sand, so that when nature’s sup- ply is exhausted we can prepare a satisfactory substitute from her abundant supply of constituent materials. Let us consider the composition of nature’s molding sand with this in view. Composition of Molding Sand. Molding sand is made up of two distinct and neces- sary components: First, silica in the free state, and, second, silicate of alumina. The free silica gives grain, refractoriness, porosity and low shrinkage to the sand, while the silicate of alumina furnishes bond. Free silica would be useless without the silicate of alumina, as it would not hold together. Silicate of alumina would be worthless without free silica, as it would not have sufficient porosity and would have too great a shrinkage. A confusion exists in the use of the word “silica” in re- spect to sand, which I shall endeavor to avoid by desig- nating the silica existing in the free state—quartz silica. There are several other substances present in all sand. These impurities are not at all desirable and are present from necessity rather than from choice. Quartz silica and clay in correct proportions can constitute a good mold- ing sand without the presence of any other substance. We will consider the individual characteristics of the constituents which make up a molding sand, for the cor- rect combination of these properties determines the qual ity and grade of the sand. A knowledge of the effect of the impurities allows us to determine to what extent they may be present in a given sand and still do no harm. Ingredients of Molding Sand. Quartz silica, clay, iron oxide, lime and feldspar are the principal ingredients of molding sand. Quartz Silica. —Pure quartz, or silicon dioxide, con- *From a Association Mare 5. Mr. Field is chemist of hill & Co. r read before the Pittsbur. —- By = 's ackin ™ THE IRON AGE 95! sists of 46.67 per cent. silicon and 53.33 per cent. oxygen It is very hard, fuses at a high temperature, has no cleavage and when pure is white. It is, however, gen- erally colored by some oxide of iron. Its fusibility is affected by the amount of impurities present. Quartz is the chief nonshrinkage element in molding sand. It has, however, no bonding properties. The shape of its parti- cles affects the strength of the sand, but they have no strength in themselves, as quartz is absolutely nonplastic. The size of the quartz grains determines the grade of the sand. The percentage best suited for a sand can only be determined by the kind of work for which it is used. The quartz silica should be kept as high as possible, on account of its heat resisting power, its tendency toward porosity and its low shrinkage. Bond or Clay.—The bond of a molding sand is a clay product. Pure clay or kaolinite is a hydrated silicate of alumina—that is, a silicate of alumina containing water of combination. The exact composition of pure clay is silicon dioxide, or silica, 46.4 per cent.; alumina, 39.7 per cent.; water, 13.9 per cent. It is this 13.9 per cent. of combined water which gives the plastic properties to the clay. The bond of a molding sand is not pure clay, but is generally mixed with impurities which weaken its binding power. Clay is formed by the decomposition of feldspars. These are rocks containing silicate of alumina together with silicates of the alkalies. The clay acts as a binder for the sand and holds the refractory quartz silica together. The purity and plasticity of the clay deter- mine the amount necessary to give a sand its correct bonding strength. The clay when pure is very refractory, and it is fallacy to think that because there is a large proportion of bond in a sand it is low in refractory qual- ities. A high percentage of clay in a sand destroys its porosity and causes high shrinkage and consequently cracks. A sand should be chosen with as low a clay content as is consistent with shop conditions. In foun- dries where a large percentage of old sand is used it is absolutely necessary to use a new sand containing a high percentage of bond. This is not conducive to the best results. There are, however, certain classes of work the appearance of which must be sacrificed to cheapness of material, and such conditions require that a large amount of old sand be used in the facings. When a lower pro- portion of old sand is used a new sand with less bond and consequently higher quartz silica will give a more porous facing. Feldspar.—Feldspars are silicates of alumina com- bined with silicates of the alkalies. These are generally present in small amounts in molding sand, but they should be kept as low as possible, on account of their fusibility, as they tend to flux the rest of the sand and bind it together. Ozide of Iron.—Oxide of iron is present in all molding sand, giving it its reddish color. It may be united with the bond as an impurity, or it may form a part of the quartz silica. In either case it lowers the fusing point. The iron comes into the sand either from the original rocks from which the sand was formed or from water containing iron which has trickled through the sand. Lime.—Lime is sometimes present in molding sand. It makes the sand fusible and liable to crack and crumble in the mold. It may come from the water which has aided in the decomposition of the rocks during the forma- tion of the sand. Analysis of Molding Sand, The ultimate analysis of a good molding sand will give results within the following limits: Per cent. NN ia Sm da v's ol NMA UDA N eo etd Cee Oesie da aes 75 to 85 PE nti thin «tee aed oud Vedled oad ane} dice 7 told CSS 480.4246 eR OR Ae een te ee Rea ee aa Kee aeeds 2 DT Pe cae Ciddu ddcdduddtencaveseuans center 0.5 Ge OE RI NNO cacdwusevadescnadwisutddidaswatewaws 6 The total percentage of iron oxide, lime and alkalies or the total fluxing agencies should not ordinarily exceed 7 per cent. in one sample. In a high grade molding sand used for heavy work they should not exceed 5 to 6 per cent. A sand analyzed by the rational method should give a quartz silica of from 60 to 70 per cent., a clay substance of from 20 to 30 per cent., with a feldspar below 10 per cent. If the iron was determined separately and sub- tracted from the clay substance with which it is included by this method we should have a fair indication of the properties of a molding sand, as far as its refractoriness is concerned. The strength is so dependent upon the purity and condition of the clay that it cannot be accu- rately gauged by any analysis. Two molding sands, one a so-called strong sand and the other a rather sharp sand, both of which would be classed as a No. 4, give the following results by ultimate and rational analysis: Sharp Molding Sand. Ultimate analysis. Rational analysis. Per cent. Per cent. BOGE. sskdend See SORE: TR. 5 bce bb ecedeeacssovnd 67.85 Alumina...... 9.30 Clay j including iron oxide..... 22.03 Iron oxide.... 4.53 substance / excluding iron oxide.....17.50 EE 6 Swed eke es 66d a5 945R6 2 10.12 Strong Molding Sand. Ultimate analysis. Rational analysis. Per cent. Per cent, RING. 5.600008 Tee DON Wea cscicccicvsveeesswek 64.66 Alumina...... 9.26 Clay 4 including iron oxide..... 28.06 Iron oxide.... 5.56 substance ( excluding iron oxide.....24.50 eT err Te er Tere yee rt 7.28 Refractoriness, The impurities which impregnate a molding sand greatly reduce its refractoriness. The sodium and po- tassium salts in the form of feldspars and mica are constituents of all clays to a greater or less extent and consequently form a part of all molding sands. These alkalies, fusing at a low temperature, may bind the rest of the substances into a hard mass. Iron oxide also in- ‘creases the fusibility, as does lime, which is occasionally present. This latter is most harmful when present as a carbonate, as a gas would be given off at a high heat which would prove detrimental to the mold. The size of the grain of a sand may affect its refractoriness. Sev- eral experts on clays have demonstrated that under certain conditions the fusing point of the clay is deter- mined by the size of the grain. It is probable that this holds good in regard to a molding sand, the larger grained sand having a higher fusing point. : Porosity. Some sands are naturally porous, while others are very impervious to gas and moisture. The porosity of a sand determines the amount of venting necessary. Some sands must be vented very freely for all grades of work, while with others the use of a vent rod is hardly neces- sary. There are four factors which determine porosity: First, the proportion of quartz silica to the bond; second, the size of the quartz silica particles; third, the shape of the quartz silica particles ; fourth, the condition of the bond. Generally speaking, the higher the proportion of the quartz silica the greater will be the porosity of the sand. The larger the quartz particles the more porous will the sand be. It will be apparent, however, that the size is limited, from the fact that a sand cannot be too coarse and still give a finish to the casting. The particles should therefore be kept as large as possible and still produce the desired effect as to finish. The porosity is also affected by the shape of the quartz silica particles. Irregular crystalline structures with sharp edges and cor- ners will leave greater spaces between the particles than will regular shaped particles with smooth surfaces, which are apt to fit closely together and thus prevent a free passage of gas or air. The less the proportion of bond used, and still have sufficient binding power in the sand, the greater will be the porosity. It follows therefore that the stronger the bond the less the quantity necessary to produce the same results, consequently the sand having the strongest bond requires the lowest percentage of bond. The tendency of clay to bake together and destroy the porosity of the sand and its tendency to crack, due to excessive shrinkage when drying, render the presence of a large amount of clay bond objectionable. It is very necessary that a sand be chosen with a low percentage of strong bond rather than a large percentage of weak bond. Strength. The strength of a molding sand determines its adapta- bility for different kinds of work. Some castings may be 952 THE IRON AGE March 15, 1906 made with sand having comparatively little strength, while for others a strong sand is absolutely necessary. The amount of strength necessary is somewhat dependent upon shop practice. 'The methods of molding, running. venting and mixing of the sand must all be considered in determining the proper strength of a sand for a given class of work. The practice of using flour, molasses or clay wash in mixing up facing, together with the pro- portion of coal dust and old sand used, is also an im- portant factor to be considered in the choice of a sand. In foundries where nailing is generally resorted to a weaker sand may be used than where nails are not used. A good mechanical mixer which intimately surrounds each particle of old sand with particles of new sand, rather than putting the old and new sand together in chunks, also permits the use of a sharper sand. Where flour or molasses is used or where the proportion of old sand to new sand is comparatively small the use of a sharp sand is possible. The strength of a sand depends upon three conditions : First, the proportion of bond; second, the strength of the bond, and, third, the shape of the quartz silica particles. Size of Grain. The grade of a molding sand is determined by its grain. ‘The finer grained sands are used for the lighter work. Sands are graded and sold by numbers, based upon the size of the grain. A sand should be as fine grained as possible and still satisfactorily fill the other requirements of a molding sand. This is due to the fact that the finer grained sand will give a better surface to the casting. The grain of the sand is determined largely by the grain of the orig- inal rock from which the sand was formed. The fineness of the sand is obtained quantitatively by the use of a series of sieves. Of these, 100, 80, 60, 40 and 20 mesh are used. A weighed amount of the dried sand is placed in the 100-mesh sieve, which is shaken for a definite time, say, one minute. The siftings are carefully weighed and the weight recorded. The 80, 60, 40 and 20 mesh sieves are used in the same way. These separate weigh- ings are multiplied by the number of the mesh of the sieve. There is a certain loss due to dust flying, &c., which is found by subtracting the total of the weights obtained from the original weight. This loss is multiplied by the average mesh of the sieves, which is 60. The sum of the products of the weights obtained by the number of the sieves divided by 100 constitutes what is known as the degree of fineness of the sand. This method is quite unsatisfactory in many ways, as all sands of the same degree of fineness do not have the same physical effects when used as a molding sand. This is due to the fact that the proportion of sand which passes through each sieve has an important bearing upon the quality of the sand. A sand whose particles are all small but of uni- form size will give better results than one with a com- bination of large and small grains which might be of the same degree of fineness when judged by the standard sieves. It is never advisable to judge of the fineness of a sand by its appearance, for a comparatively few large particles will give the whole sand the appearance of being coarse, while in reality it may be very fine when judged by the standard sieves. Conclusion, We have looked at molding sand from two viewpoints: First, as a study of the materials which go to make up a molding sand, and, second, as a study of the properties which are necessary and most desirable in a molding sand. A thorough understanding of the principles considered should aid us in intelligently selecting the best sand for our individual use. Let me remind you that what proves to be a good sand in one foundry may prove just the opposite under the differing conditions of another. It is with this fact strongly in mind that I give you general information rather than specific data which might apply to one set of conditions, Any future improvement in the quality of molding sand will come from an intelligent interpreta- tion of the principles which we have studied to-night. March 15, 1906 Producer Gas in Portland Cement Manufacture. In the making of Portland cement the most important step is the burning of the crushed raw material to expel moisture and volatile matter and give the material an affinity for water, upon which its cementing properties depend. The calcining or burning process yields a fused product known as Portland cement clinker, which after being ground and sifted forms the finished cement, ready for the market. For the burning a very high tempera- ture is required, which is generally obtained by the com- bustion of finely powdered coal with air under pressure. Now a new system has been introduced by William Swin- dell & Brothers, German National Bank Building, Pitts- burgh, Pa., in which producer gas is used as the fuel in place of the powdered coal. It dispenses with an ex- tensive power plant equipment for pulverizing and dry- oe HOG LL <4 Ox as ¥ S SYS a r ‘ OW = o manistaslede —— ne Va Mibddddbibcnncccca nts 5 eee Vly seeer tee coeecs us i PEt THE IRON AGE 953 The lower view is a vertical section on the line B—B of the upper view, showing the gas producer, com- bustion burner and a part of the kiln near the outlet end. This view also shows the handling facilities. The ma- terial as it is discharged from the rotary kiln is passed through a chute to a cement car, in which it is trans- ferred to the cement mills. At the left may be seen the ear floor over which the coal is brought to the top of the producer. The consumed content of the producer is re- moved at the bottom through a water seal, as in the standard Swindell apparatus. An advantage of this system is that any low grade of coal can be used, while the best grades, free from sul- phur, are now required when powdered coal is burned directly, and the ring” being eliminated, the troubles associated with it are avoided. As no ash enters the kilns the product is reasonably considered to views. “ nose =< A ——— ———$—$$<— w/ ——— | OTTO, Zila 7} — Plan and Elevation Sections of a Swindell Gas Producer in Connection with a Portland Cement Rotary Kiln. ing the coal and also claims a large saving in operating expense. The system has already been applied to six rotary kilns at the plant of the Diamond Portland Cement Com- pany, Middle Branch, Ohio, the first kiln being installed one year ago. These kilns are 6 feet in diameter by 60 feet long. On tests made the output has been 240 barrels of 380 pounds to the barrel in 24 hours on a fuel con- sumption of 110 pounds of coal per barrel. The system employs a Swindell gas producer of special design for preheating the air as well as supply- ing the gas, which is connected with the kiln, as shown in the accompanying line drawings. The upper view is a plan and horizontal section on the line A—A of the lower view, taken through the gas and air flues of the combustion burner up to the entrance to the kiln. Only a small part of one end of the kiln may be seen in both be of better quality. Other strong points of the new system, mentioned by the builders, are simplicity in oper- ation, increased output, a saving in fuel and labor and applicability to present kilns at a moderate cost. The builders announce the receipt of a contract from the Art Portland Cement Company for the installation of this system in its new plant at Kimmel, Ind., and a number of Michigan and Lehigh Valley companies con- template adopting it. — OS An organization is stated to have been formed in Rochester, N. Y., under the name of the International Congress of Inventors, to endeavor to secure reforms in patent laws and freedom from “unlawful exactions.” George F. Gallagher has been elected president. Mem- bers will be divided into two classes, separating those who have taken out patents from those who have not. 954 Development of Large Gas Engines. Under the title “The Prime Mover of the Future” c. E. Sargent presented a paper before the December ineeting of the Wes