The Iron Age 1909-06-24: Vol 83 Iss 25

THE IRON AGE Published every Thursday Morning by David Williams Co. 14-16 Park Place, New York. Vol. 83: No. 25. New York, Thursday, June 24 1909. SP.00 a. Year, including Postage. Reading Matter Contents........ page 2042 Alphabetical Index to Advertisers ‘‘ 182 Classified List of Advertisers ° 172 Advertising and Subscription Rates “‘ 2053 REED F. BLAIR & (CO. PRICK BUILDING, PITTSBURG, PA. STANDARD CONNELLSVILLE COKE Subject: ‘‘Wise Buying is the Art of Selling” PouUNDRY . _—~PURNACS _ CRUSHED Some people will tell you that you can sell anything if it is advertised. The erigitel end enly Genuine Advertising is a great power. Yet an advertised article without selling ‘points, ‘*STILLSON WRENCH ”’ without popular appeal, can't compete with an advertised article that has an exclusive superior feature. U M C Shot Shells are Steel Lined, but no others are. Weare advertising the Steel Lining to all American Sportsmen—right to your customers, Is it safe to infer that you can sell ordinary unlined shot shells in competition with U M C Steel Lined widely advertised shot shells ? , Buy wisely! Buy U M C Steel Lined Shells to sell. ae SS is manufactured by WALWORTH MFG. CO., Bosten, U.S. A. And bears their registered Trade-Mark WRITE FOR NEW BULLETIN (4 THE UNION METALLIC CARTRIDGE CO. No. 104 y BRIDGEPORT, CONN. Agency, 315 Broadway, New York City THE BRISTOL CO, Waterbury, Conn _ WATER TUBE The Babcock & Wilcox Co., BOILERS See page 51 = Mew Yeu" “The Capewell” Horse Nail is Best Suited Cleveland City Forge and iron Co., Cleveland, 0. TrURNBU nh = a To the every day requirements of all Horse- ga ice ssn shoers and the nail which is by all odds io New York, N. ¥. most economical to use. BASIC PIG. sia on THE CAPEWELL HORSE NAIL COMPANY Pilling & Crane .. me phi Hartford, Conn., U. S. A. UFAIN "= 7 ic Ai nes Jenkins Automatic Air Valves THIADEIN AMERICA ond haa ea ahaa ah Pen a design, and take up no more room than an ordinary air cock. Besides being very simple, they are most sensitive and durable. Write for Catalog and Prices, JENKINS BROS., New York, Boston, Philadelphia, Chicago THE LUFKIN aan. _pineeon Mich., U.8.A. New London, Eng. Windsor, Can. SHEETS PET Black and Galvanized Sheets ff|“SWOHON” Gold Rolled Steel csuet n Drawing = Stamping of every description and for THE AMERICAN TUBE & STAMPING COMPANY SEE all purposes. (Water and Rail Delivery) Bripexport, Corn. PAGB 25 Tin Plate — Terne Plate MAGNOLIA reiérron METAL The Standard Babbitt of the World We manufacture everything in the MAGNOLIA METAL CO. American Sheet and Tin Plate Company Frick Building, Pittsburgh, Pa, See our ad on page 17 New York: 115 Bank St. Chicago: Fisher Building. Montreal: 31 St. Nicholas St. THE IRON AGE “FOLANSBEE — [BRASS {aco Pome ive wi, 3 WIRE Manufacturers of BLUE Sheet and Roll Brass, Wire, EVEN COLOR GER MAN SHEET | eee we aad oe STEEL SILVER (© WiRe|soting ain. nacre SHEETS Thomaston, Conn., Waterbury, Conn. Pat, Leveled Sign Brass |x-ru. —cu2t** 2%S% su anaes No Buckles, Clean Surface, IRON AGE READERS Polished or Pla or Plain Steel Stamps and Dies, Time Checks FOLLANSBEE}**" td of Pan nar SILVER pois fc Scone ater an ar Fixtures a ews oo sbur BROTH ERS a Brass, Gilding and Bronze L FOUNDED 1850 etal, Sheet, Rod an ire COMPANY | “sesscaed Geos || SOPRL SFE. 06. Manufacturers of MAKERS in Great Variety PITTSBURGH Waterbury Brass Co. : | Sheets, Rolls, Wire, and Rods. WATERBURY, CONN. 1 Cliff St., New York Providence, R. |. Bridgeport Deoxidized Bronze & Metal Co. BRIDGEPORT, CONN Phosphor and Deoxidized Henry bouther Mer Engineering G0. Brass Shells, Cups, Hinges, Buttons, Lamp Goods. Spectal Brass Goods to Order. Factories WATERBURY, CONN. Depots : NEW YORK CHICAGO BOSTON “ FOLLANSBEE POLISHED ” STEEL Bronze SHEETS Composition, Yellow Brass and Alumi- Coasliag Chemists, Met Metallurgists num Castings, large and small and Analysts. Complete Physical Testing Laboratory. Expert Testimony in Court and Patent Cases, Arthur T. Rutter & Co, 2506 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. Matthiessen & Hegeler Zinc Co. LA SALLE, ILLINOIS SMELTERS OF SPELTER AND MANUFACTURERS SHEET ZINC AND SULPHURIC ACID Special Sises of Zinc cut to order. Rolled Battery Plates. Selected Piates for Etchers’ and Lithographors use. Selected Sheets for Paper and Card Makers’ use. Stove and Washboard Blanks. ZINCS FOR LECLANCHE BATTERY GERMAN SILVER WHITE In Sheet, Wire, Rods, Tubing and Blanks. Polished wide sheets, patent levelled, for soda foun- tains, bar fixtures etc. German silver for spinning. NICKEL ANODES 2455. BRONZE, COPPER in all forms The BRIDGEPORT BRASS Co. \ THE SEYMOUR MFG. CO., Seymour, Conn. ) TS BRIDGEPORT, CONN. HENDRICKS BROTHERS rat Yn an, Doon Manufacturers of Sheetand Bar Copper, Copper Fire Box Plates poe PHOSPHIOR-BRONZE| “Search-Light”’ GAS Bicycle Lanterns Send for Circulars and Electrotypes and Staybolts, Wire and Braziers Rivets GERMAN SILVER Ingot bicmnaet ine, Slime Spelter, THe Rivensing Lead, Antimony, Bismuth, Nickel, etc. 49 CLIFF STREET ~ - NEW YORK a mang RIVERSIDE WJ THE IRON AGE New York, Thursday, June 24, 1909. Coaling Station at Guantanamo, Cuba. BY W. P. ENGELMAN, At the end of the Spanish-American War the United States Government, recognizing the urgency of a naval base in Cuban waters, acquired territory on the Guan- tanamo Bay for installing equipment to store coal from | | cI] St 4 iho oe a chutes alongside the collier into tip cars. These cars ran on a harrow gauge railroad laid on the wharf and at de- sired points over the coal storage area. <A stevedore force of 70 men was employed, and with the use of the col- lier’s derricks handled a maximum tonnage per day of 300 to 400 tons. This was a comparatively small ton- nage, entailed a high labor charge per ton of coal han- dled, and the employment of an unwieldly labor force, SINS e foitielalidtii islet aia eed Fig. 2. Genera] Views of the Coal Handling Equipment Installed for the United States Government at Guantanamo, Cuba, by the C. W. Hunt Company. colliers, and also to coal the naval vessels or fleets using the Southern waters. Near Hospital Cay a channel was dredged for water approach, a concrete wharf on piling built, having a frontage of 340 ft. and a depth of 70 ft., and a coal stor- age basin prepared of 68,000 sq. ft. on the coral reefs in the rear of the wharf. For immediate need a temporary coal handling and storing equipment was installed. The coal was unloaded by the collier’s steam-operated swinging derricks, hoist- ing coal from three hatches and dumping the coal over difficult to maintain, owing to the remoteness of the sta- tion from any labor center. In consequence of these dis- advantages, as soon as additional appropriations were available, steps were taken to install a modern, high speed coaling station to transfer coal from colliers to the storage area and from this storage area to the naval vessels, Various plants of this character were investigated, including the one of the Delaware & Hudson Railroad at Delanson, N. Y., which was installed in 1907 by the Cc. W. Hunt Company, West New Brighton, New York, 1988 THE IRON AGE June 24, 1909 Fig. 3.—The 140-Hp. Two-Cylinder, Four-Drum, Balanced Main Hoisting Engine. Fig. 4.—The 60-Hp. Single-Drum, Direct-Geared, Boom Hoisting Engine. Fig. 5.—The 60-Hp. Single-Drum, Double-Cylinder, Reversible Gear Trolley Engine. where 3000 tons of coal is handled per day with one ma- chine, and it was decided to install a similar equipment at Guantanamo. The operating machinery of this plant, of which Figs. 1 and 2 give general views, consists of the following: A 125-hp. boiler to generate steam for the engines, in- cluding one directly connected to a 35-kw. electric genera- tor, furnishing current for moving the tower trucks and lighting the plant; a 140-hp. main hoisting engine, two- cylinder, four-drum, balanced type, to operate the hoist- ing ropes (Fig. 3) ; a 60-hp. boom hoisting engine, single- drum, direct-geared type, with friction clutch and band brake to raise and lower the boom when it is desired to move the tower from one vessel hatch to the other, which is also provided with a separate winch head for hoist- ing the coal required for the boiler (Fig. 4); a 60-hp. trolley engine, single-drum, double-cylinder, reversible- gear type to run the trolley in and out over the boom (Fig. 5); a four-wheel boom truck complete with deflect- ing sheaves mounted on steel frames for conveying the grab bucket in and out over the boom; a 214-ton capacity steam shovel or grab bucket (Fig. 6) ; a full set of hoist- ing and traversing ropes of length to traverse the entire length of the bridge and provide extra wraps on the en- gine drums and to operate the grab bucket at any point from the underside of bridge to 30 ft. below water level, or through a vertical hight of 80 ft., and approximately 300 ft. along the bridge; two 25-hp. electric motors for moving the tower over the storage area; and the neces- sary track and equipment for a runway 3490 ft. along the storage area. The operating machinery is mounted on a structural steel frame or bridge, the underside of which is 52 ft. above mean low water level, spanning the storage area, with a distance center to center of tracks of 261 ft. This bridge is supported by four structural steel legs, each mounted on a universal truck for moving the tower lengthwise over the storage area. The tower is propelled by direct-current series motors, geared to the driving wheels of the truck, one motor on the forward truck for each track. These motors are operated from one con- Fig. 6.—The 214-Ton Grab Bucket Entering the Hold of a Vessel. June 24, 1909 troller in the operating room of the tower, and a con- stant speed motor is used at the land end and a variable speed motor at the water end so that the bridge may be kept in alignment. The coal handling machinery is operated by steam power, because it was considered that reliability of op- eration in emergencies, economy of maintenance and easy regulation of operating speed are in its favor. The op- erating machinery is housed at a central point and re- quires two operators, one to control the lowering, filling and raising of the.2%4-ton grab bucket, the other to control the running in and out of the trolley truck over the boom and the discharging of the bucket over the storage area. Fig. 1 shows the 40-ft. projecting boom placed in a_ hori- zontal plane over the vessel, while Fig. 2 shows the boom raised to permit the moving of the bridge from one ves- sel hatch to another. As indicated, this boom is hinged so that it may be raised to clear any obstructions, such as the masts or funnels of the vessel. As will be seen from Figs. 3, 4 and 5, the engines are all of the Hunt heavy duty type, massive in construc- tion and especially designed for heavy continuous duty, insuring durability in service, economy of steam and low maintenance cost. The grab bucket or shovel, Fig. 6, is of special construction, in that it is symmetrical as re- gards its center of gravity, thus avoiding the usual chaf- ing and wear on the operating rope; the reach of the scoops is adjustable, so that the bucket will operate with equal facility on various grades of coal, and the bucket has exceptionally great closing power, stiffness and strength. The illustration shows the shovel, with the scoops opened, just at the point of entering the open hatchway of the vessel. The usual dimensions of this hatchway are 10 by 12 ft. After an eight-hour continuous test November 25, 1908, in which the plant developed a capacity of 100 per cent. over and above that guaranteed by ahe builder, it was officially accepted by the Naval Bureau. The machinery has been in continuous operation since and with com- plete success, reducing the labor force at the plant from 70 men, as in the first installation, to two engineers and a fireman, besides working to a capacity which could not be approached by the previous system. The speed of the plant is best appreciated when it is stated that the bucket enters the narrow hatchway, is automatically closed, loading itself with 2% tons of coal, hoisted a vertical hight of 50 to 70 ft., transferred along the boom and across the storage area a distance of 110 to 300 ft., automatically dumped and returned to the hatchway in from 40 to 45 sec. eS The Economic Position of the Electric Steel Furnace. At the Harrisburg meeting of the Engineers’ Society of Pennsylvania on June 10 P. McNiven Bennie, Fitz- gerald & Bennie, Niagara Falls, N. Y., presented a paper on the “Relation of Electric Furnaces to Siderurgy.” The paper reviews much of the ground covered at the recent meeting of the American Electrochemical Society. It is interesting, however, to present Mr. Bennie’s con- clusions as to the economic position of the electric steel furnace as follows: First, as to high grade steel, the electric furnace is rapidly becoming a serious competitor of the crucible method, for the simple reason that it is less expensive. Against. a high cost of labor, crucible renewals and the fact that steel must be melted in small units, we have a lower labor cost, small cost for refractories, and the pos- sibility of handling several tons of metal] of uniform com- position, Second, as to steel for structural and rail purposes, the electric furnace is so far only asking recognition as a useful adjunct to existing apparatus, for doing ad- ditional refining or treatment in an economical and ex- peditious manner. Not a rival, but an ally, in the gen- eral siderurgical scheme, Third, for steel castings the electric furnace cannot compete with open hearth castings, but for a grade some- what better, where additional refining would be required, THE IRON AGE 1989 the electric furnace has decided advantages. For cast- ings of crucible quality the electric furnace methods will give satisfactory results at less cost than crucibles. In addition, for heavy castings the larger quantity of metal which can be treated as a unit is of much impor- tance. It is undoubtedly a fact, to which all who have seen an electric steel furnace in operation will bear witness, that higher temperatures are at the command of the metallurgist than heretofore. Generally speaking, re- fining operations can be carried on more rapidly and thoroughly with higher tentperatures. Whether any sub- stantial good is accomplished by additional refining, we shall have to leave to the steel makers, when they shall have come to agreement among themselves as to that point. I heard it said recently by a metallurgical engi- neer that product with just as good analysis could be made in any ordinary furnace as in the electric furnace. The truth of this contention is granted, but not the im- plied conclusion that analysis is the whole story. Given a choice between two steels, of identical price and an- alysis, one of which is known to be the product of the crucible process and the other of the open hearth process, would any engineer hesitate? As to the electric furnace, if it can produce an im- provement in quality, worth more than the increased cost,.its future is assured. All electric steel furnaces work under basic conditions, even those used for tool steels. It has been found in Germany, for example, that steel is improved by simply putting it into an in- duction furnace, leaving it there for an hour or two, without attempting any refining by slags, meanwhile supplying only sufficient energy to maintain the tempera- ture. It is believed that this gives dissolved gases an easy opportunity to escape. Finally, the following im- provements may be looked for: Electrodes of larger size and quality that will reduce the present consumption per ton. 7 Refractory materials superior to those now in use, and . probably themselves the product of electric furnaces, such ‘ as fused alumina and other refractory oxides. In elec- tric furnaces where an are is present there is consider- able vapor formed by volatilization of silicon, calcium, calcium oxide and even iron itself, which vapors are very active chemically, attacking the walls and roofs of the furnace. The destruction of the roof in electric fur- naces is probably due as much to these vapors as to the high temperatures. Increase in size and capacity of furnaces. Keller can now build furnaces for treating molten steel with a capacity of 10 to 12 tons. Robert Turnbull, Dr. Her- oult’s engineer, is confident that 15-ton furnaces present no difficulties whatever. For the first time electric furnace steel] was reported in the German returns of production for 1908. The amount was 20,000 tons. When it is considered that electric furnaces charged with molten metal are good for 10 heats daily it will be seen that with a total daily eapacity of from 190 to 150 tons of steel the electric furnace may fairly be said to have emerged from the metallurgical nursery. Dt ci incall cities M. Schiffer, who makes a specialty of breaking up and removing salamanders from blast furnaces, has taken offices at 9140 Commercial avenue, Chicago. By the application of methods devised by him he undertakes to prevent personal accidents and damages to property which often happens in the execution of this work. The safe removal of a 400-ton salamander from No. 7 blast furnace in the South Works of the Dlinois Steel Com- pany was recently accomplished under his direction. A Washington dispatch says that the removal of the Curtis turbines from the Southern Pacific liner Creole, which has been laid up at New York for some time, will not cause any change in the specifications of the new battleship North Dakota, which call for its equipment with the same type of engines. It is stated that the machinery of the Creole was among the first turned out of the Curtis type and that important improvements have been made meantime. 1990 A Lodge &*#Shipley Lathe for Auto- mobile Hubs. A lathe built by the Lodge & Shipley Machine Tool Company, Cincinnati, Ohio, for the rapid machining of automobile hubs is shown in Fig. 1. Two of the fea- tures that contribute most to the high producing capacity were directly at hand in the company’s patent head which facilitates changes of spindle speeds according to the requirements, and the turret on the bed which, in connection with the tool in the compound rest, permits THE IRON AGE June 24, 1909 turned to on one piece, after the carriage had encoun- tered the first longitudinal stop, the turning tool would be set for the second diameter by bringing the corre- sponding compound rest stop into position, and the handle at the bottom left side of the apron would be raised to pass over the first stop, after which it would automat- ically fall into position to encounter the second, and sO On. The lathe is a Lodge & Shipley 18 in. x 8 ft. patent head quick change gear engine lathe, with turret on the bed, which automatically revolves and is provided with power feed. The parts which this lathe is adapted to Fig. 1—An 18-In. by 8-Ft. Patent Head, Quick Change, Gear Lathe, with Turret, Built by the Lodge & Shipley Machine Too] Company and Particularly Adapted for Turning Automobile Hubs. Fig. 2.—Detail of the. Lathe as Equipped several operations without resetting of work and tools. Two new features that do away with the necessity of measuring and calipering in the execution of duplicate work are the positive stops for the longitudinal feed and the diameter gauge to limit the cross travel of the com- pound rest, so that the tool will turn exact diameters. The adjustable stops of the longitudinal feed may be seen in both illustrations on the bar, secured fo the bed under the carriage apron. The diameter stops are mount- ed in the slots of the rotable barrel, shown in Fig. 2, on the carriage to the right of the compound rest. Any one may be placed in operating position by turning the knob at the front. If two or more shoulders were to be for the Second Set of Operations on Hubs. work upon, as shown in the illustrations, are front and rear automobile hubs of malleable iron. The hubs shown on the floor in Fig. 1 are front hubs, 544 in. long, 5% in. diameter across the flange and 2% in. diameter on the smaller end, which is threaded. The rear hubs are siniilar, the main differences being that the rear hub is faced on both ends, finished more completely on the outside, and has a ball race at one end only. On this style of hub there are two sets of operations, for the first of which the lathe is provided with special reamers and boring jigs, and a 15-in. combination chuck, such as shown in Fig. 1, and for the second, drivers, special arbors for holding the hubs in their bore and See June 24, 1909 thus insuring a true piece of work, and the turret tool equipment, shown in Fig. 2, comprise the equipment. In machining the front hub for the first operation the hub is held with the flange against the jaws of the chuck, as shown in Fig. 1. The turret operations com- prise boring a straight hole through the hub with a four-lip drill, boring the seat of the ball cup and ream- ing this seat. While these turret operations are being carried on, the tool on the compound rest faces the end, thus completing the first operations. Holes in the flanges are drilled before the second operations. For the second operations the front hub is mounted upon an expanding straight mandrel, carried in the hole in the lathe spindle, as illustrated in Fig. 2. The drive is from a pin, fitted into «a drilled hole in the flange. The turret operations comprise boring the seat for the ball cup and reaming this seat, for which the correct depth is positively obtained. While the turret tools are at these operations, the tool in the compound rest is facing the flange. The barrel of the hub is also turned and the various diameters are positively obtained by the diameter gauge. The thread is then cut with a die, thus completing the machine work for the front hub. The rear hub for the first operations is held with its flange against the jaws of the chuck. The turret op- erations are boring and reaming the seat for the ball cup and facing the seat for the dust washer. While these turret operations are in progress the compound tool faces the brake pan on the flange and turns the flange diameter; all diameters and lengths are ob- tained from the positive stops. Holes in the flanges are drilled before the second operations. For the second operations the rear hub is mounted upon a straight arbor, which is located in the hole of the lathe spindle, and the hub is driven by a pin through a drilled hole in the flange. The hub is additionally Supported by a bar carried in one of the turret holes, which allows faster cutting, and gives truer work. All operations are performed by the tool in the compound rest, comprising facing the end, facing the flange and turning the barrel. —————_- ——————_—— Ontario’s Sheet and Tin Plate Enterprise. Toronto, June 21, 1909.—An agreement has been reached by the Sheet Steel Corporation, Morrisburg, Ont., and the municipal corporation of that village. The Sheet Steel Corporation purchased the assets and rights of the Canada Tin Plate & Sheet Steel Company of Morris- burg, which after starting its plant encountered a number of difficulties, chiefly the lack of tariff protection and lack of working capital. The municipality of Morris- burg made large outlays to secure the industry. It ob- tained power rights from the Dominion government and erected a power plant. involving an ultimate expense of $80,000. The Sheet Steel Corporation, with William Mc- Comb at its head, started up the plant and is now em- ploying 150 men. The output of the galvanizing depart- ment is sold ahead to October. New capital has been provided to the amount of $100,000. The company has agreed with the municipality to operate for two years a four hot mill plant employing 200 men and for an addi- tional two years a six hot mill plant employing 250 men. The village leases the power plant to the corporation for 386 years and assigns it the water rights secured from the Dominion government. The company is also to have the right to put up elec- tric lines on the street and to operate trolley cars for the transportation of freight between the mill and the wharf. The village is to pay the company $30,000, while the latter undertakes to settle the claim of the power plant contractor. The village waives two-thirds of the general taxes against the mill property. i Outing of Rhode Island and Massachusetts Metal Trades..—The Rhode Island Branch of the National Meta! Trades Association entertained the members of the Boston and Worcester branches at an outing on Narra- THE IRON AGE 1991 gansett Bay Thursday, June 17. <A typical Rhode Island shore dinner at Fields Point was enjoyed and later a steamer took the large party to Rocky Point, where a ball game between the Rhode Island and Massachusetts members resulted in a victory for the hosts by a sub- stantial margin. The day was concluded by a sail around the bay in the early evening, supper being served on the boat. The officers of the Rhode Island Branch, to whom a large part of the success of the outing was due, are E. A. Beaman, Beaman & Smith Company, presi- dent; Henry D. Sharpe, Brown & Sharpe Mfg. Company, vice-president; J. G. Aldrich, New England Butt Com- pany, treasurer; J. A. Holland, secretary; and executive committee composed of E. C. Bliss, E. C. Bliss Mfg. Company; C. E. Davis, American Locomotive Company ; L. W. Downes, D. & W. Fuse Company, and H. L. Scott, Henry L. Scott & Co. The booklet containing the pro- gramme had many jests and much useful information concerning Narragansett Bay and its surroundings. —_—~-o—_———_ Canada’s Mineral Production. Toronro, June 19, 1909.—The mineral production of Canada in the calendar year 1908, according to the prelim- inary report of the Dominion Department of Mines, was of the total value of $87,323,849, as compared with $86,- 842,765 in 1907. Of the 1908 aggregate $41,655,936 is credited to the metailic group, the remainder being the value of the nonmetallic group. The items under the metallic head are as follows: Oe A Ore er eee eee Te eee $8,500,885 a ee ee ne eee ee 9,559,274 Pig iron from Canadian ore.......eeeeeeseeees 1,664,302 ER ETE CTP EEC E CE eT OL eC 1,920,487 BE Ca euhis doks ode we oaks Ce Veda wee 66% Cbues 8,231,538 CN asintctadhé. oxen yeas ees ewe. kon et hes 112,253 Ne cn ck ek os deme eee AA Os hee ke ames 11,667,197 Iron and Steel Production and Bounties, Besides the pig iron made from Canadian ore, as in- dicated above, there was an output of 531,415 tons, valued at $6,446,892, of Canadian pig iron made from imported ore. The total shipments of iron ores from Canadian mines amounted to only 203,490 tons, valued at the mine at $486,857, as compared with 312,496 tons, valued at $666,941 in 1907. The greater part of the ore came from the Helen mine in Michipicoten, delivered at the Midland and Hamilton furnaces. The 16 furnaces at work in the year consumed less domestic ore than they did in 1907. Their total pig iron product in 1907 was 651,962 tons. Of last year’s pig iron output 6709 tons were produced with charcoal as fuel. Steel ingots and castings aggregating 588,763 tons, valued at $9,233,602, were produced in 1908, as com- pared with 706,982 tons, valued at $15,612,590 in 1907 The production for the two years is shown in the follow- ing table in gross tons: Ingots: 1907. 1908. Open hearth (basic).............. 459,240 443,442 pe PR Pe ee eee ey eee 225,989 135,557 Castings: Open hearth (acid and basic....... 20,602 9,051 Ce ss a5 ia S Man ot hss 1,151 713 The bounties paid on iron and steel during the two years were as follows: 1907. 1908. Pig iron from Canadian ore...... $201,421.47 $213,458.34 Pig iron from imported ore...... 591,583.80 569,166.93 WE WEES Ciba eaeeteestoewease 1,099,873.37 917,876.63 BRaeE WETS: LOUD. ccinaccccccceeces 412,417.26 297,778.68 ERS... i geen obs dk wr eee $2,305,295.90 $1,998,283.58 The estimated silver production of the country in 1908 was 22,070,212 0z., as compared with 12,779,799 oz. in 1907. Though the quantity produced last year was 72 per cent. greater than in 1907 the money value was only 40 per cent. greater, owing to the lower prices pre- vailing in 1908. More than 87 per cent. of the total output came from Ontario mines. In the nonmetallic group the minerals running into the largest aggregate value are the following: Coal, $24,381,842; cement, .$3,781,371; asbestos, $2,484,768. 0.. 4.) 0.d. IRON AGE June 24, 1909 ARC WELDING.” BY C. B. AUEL.T 1992 THE Though@pis paper has for its title “ Arc Welding,” it may nots miss to describe very briefly several other process electric welding, and thus give a better idea of the particular field of application for arc welding. There are four distinct processes of electric welding, known respectively as the Thomson, the Zerener, the La Grange-Hoho and the Benardos, from the persons who either originated or had most to do with developing them. In the Thomson, or, as it is sometimes called, the in- candescent or resistance method, the metals to be welded are clamped to the terminals of an electric circuit and carefully butted together. When the circuit is completed current flows through the abutting metals, heating them to fusion, when they are automatically forced together, thus uniting perfectly. The resulting joint is always ac- companied by a shoulder or fin, which, however, is easily removed, usually by a hand file, though sometimes an au- tomatic hammer or roll is employed. The apparatus, one form of which is shown in Fig. 1, consists of a transform- er, in size from 1 to 100 kw. or more, depending upon the class of work to be done. The primary of the transformer may be designed for operation at any one of the usual voltages and frequencies, the secondary being arranged to give a very large current at a very low voltage and being further provided with terminals in the shape of heavy clamps, sometimes water cooled, in which are secured the metals to be welded. Variation of output is obtained by switches or a choke coil in the primary circuit. The method just described is used for a variety of purposes, such as uniting wires, rods or bars of similar or even of dissimilar metals, making tires and cylinders, putting heads on bolt and screw bodies, joining rails, &c. In the Zerener or electric blowpipe process an arc is sprung between two carbons and caused by an electro magnet to impinge upon the metals to be welded. The Fig. 1.—Using the Thomson or Incandescent Electric Welding Apparatus. metals are thus brought to a state of fusion at the point of contact with the arc. The apparatus employed, Fig. 2 (taken from Glaser’s Annalen), is much like certain types of direct current flaming arc lamps, the carbons approaching each other at an angle, and further resem- bling them in being provided with a magnet for blowing the arc downward, shaping it, however, into more or less * Presented before the Mechanical Section of the Engineers’ Society of Western Pennsylvania, April 6, and published in the May, 1909. Proceedings. + Manager of Railway and Control Department, Westinghouse Electric & Mfg. Company, East Pittsburgh, Pa. of a pencil point instead of spreading it out as is done in the lamps. The work to be welded is so placed that the are may be directed upon it, the blowpipe being moved by hand either toward, away from or parallel to the work, as occasion makes necessary. Owing to the general construction of the apparatus, which does not Fig. 2.—The Zerener or Electric Blowpipe Apparatus. lend itself to the carrying of large currents, and to the difficulty in properly regulating the arc, the process is confined to a rather narrow range of small work of the rougher kind, such as the welding of small castings and wrought iron plates. In the La Grange-Hoho process, otherwise known as the water pail forge, Fig. 3, the metals to be welded or forged are fastened to the negative terminal of an elec- tric circuit, the positive terminal being placed in a wooden tank containing a suitable solution. Upon com- pleting the circuit by inserting in the solution the metals to be welded or forged, they are rapidly brought to the proper temperature, when they are then withdrawn and welded together or forged to shape in the customary man- ner. The process is adapted to small and simple work, preferably of wrought iron, and such as can be readily manipulated by hand. It may be mentioned in passing that all three of these processes are used for soldering as well as for welding, it being simply a matter of applying less heat. In the Benardos or are welding process, Fig. 4, the metal to be welded forms one terminal of a direct cur- rent circuit, a carbon electrode the other. By touching the carbon to the metal and instantly withdrawing it a certain distance an are is sprung between the terminals. Through the medium of the arc, which has a temperature June 24, 1909 between 3500 and 4000 degrees C., the metal may be either entirely melted away, molded into a different shape or fused to another piece of metal as desired.’ A complete outfit for arc welding consists of a direct cur- rent supply with its controlling apparatus, a stock of carbon electrodes of various diameters, fireclay, or car- bon blocks for molding the metal, a flux, and material for filling purposes. Owing to the intense glare of the are the work must be done in an inclosure in order not to interfere with other work in the immediate vicinity. The operator, too, must be thoroughly protected over the entire person. It is not sufficient, as with oxy-acetylene welding, simply to shield the eyes with a pair of colored glasses. Ex- posure to the direct rays of the arc produces an irrita- tion of the skin quite similar to sunburn, the skin redden- ing and subsequently peeling, being accompanied by a stinging or burning sensation over the area of the ex- posed surface; but with, however, no more serious con- sequences. For this reason a covering either of canvas or stove pipe and fitted with a projecting window of thick colored glass is usually worn over the head, while the hands and wrists are protected by gauntleted gloves of buck or pig skin. In making the window for the hood it is advisable to use two pieces of glass, one of red and one of blue, or one of red and one of green, as the com- bination is more satisfactory than a single color. Both the canvas and stove pipe are open to objection, the for- mer on account of the lack of ventilation, the latter owing to the possibility of touching the carbon electrode %, Fig. 3.—The La Grange-Hoho Water Pail Forge. to it in a moment of carelessness and thus receiving a shock. Care should be taken to have the window of the hood project a litle, as the glass will, in time, be- come quite hot, and if too close to the eyes will inflame them. If preferred, a wooden shield properly fitted with glass and which is held in the hand may be used; but it, too, has an objection in that it requires the constant use of one hand. The necessary direct current may be obtained either from a 100-volt independently driven dynamo, from a similar public supply circuit, or from a battery operated in conjunction with a dynamo or other supply circuit; or current may even be obtained from a higher voltage sup- ply, if this is the only kind available, though the last is very wasteful and can be recommended only where the work to be done is so infrequent as not to warrant one of the other methods being employed. In general, the supply should be of not less than 75 to 100 kw. The dynamo may be shunt or compound wound, preferably the latter, and if direct connected a flexible coupling should be used to prevent burning out of the armature. The circuit for the control of the current may be ar- ranged in either of two ways. The first of these is shown diagrammatically in Fig. 5. One leg of the cir- suit leads from the switchboard through a circuit breaker to the main rheostat, which consists of two water bar- rels. These are provided with pulleys and counter- weights, by means of which the distance between the terminal plates may be varied and the resistance in the circuit increased or decreased accordingly. From the rheostat the circuit is continued to a metal table which forms the positive terminal. The metal to be welded may be laid upon this table, especially if it has a flat, THE IRON AGE 1993 Fig. 4.—Using the Benardos or Are Welding Apparatus. smooth surface and is not too large; otherwise it will be found more convenient to fasten the cable from the rheo- stat directly to it. The other leg of the circuit leads from the switchboard through a single pole switch to the carbon electrode. While water barrels, Fig. 6, serve as rheostats fairly well, the objections to them are that when the plant is worked very hard the water will oc- casionally boil over, necessitating a stoppage of the work to allow the water to cool; further, the bands on the barrels rust away, thus requiring new barrels every few months. Grid rheostats are therefore frequently used instead. They are provided with several switches by which the resistance may be graduated. A second arrangement of circuit is shown in Fig. 7. It differs from the first in having a relay which operates to cut out a part, or even the whole, of the main rheostat as soon as the circuit is completed. Where the cost of current is an appreciable factor, this is a convenient ar- rangement, as the loss through the main rheostat may be reduced or eliminated. One kind of electrode, illustrated by Fig, 8, consists of an insulated metallic handle provided with a properly clamped carbon, which forms the negative terminal of SHUNT FIELD WITH RHEOSTAT cee eC + CARBON — oer ELECTRODE —>{ f b ‘ ] + [ =- a | / \ CASTING ~ a TO BE WELDED GENERATOR Circuit BREAKER 7 AMMETER § r™ aos © wrTar TABLE WATER <i Fig. 5.--Diagram of One Manner of Connecting an Are W-iding Circuit. the circuit. The carbon used will vary from 4 to 1% in. in diameter by 6 to 12 ih. long. It should be hard and solid (not cored), and in burning away should leave a rounded end instead of a pencil point. The carbon is clamped about midway simply to reduce the resistance somewhat. In another kind of electrode a button is provided which, when pressed, brings into action two solenoids; these in turn closing the main circuit, but keeping it closed only as long as the button is pressed down by the finger. The advantage of this feature is that short cir- | i i | i 1994 THE IRON AGE cuits are guarded against in case the electrode is acci- dentally dropped or carelessly set down. In preparing for a weld, Fig. 9, emphasis is laid upon the necessity of making the piece to be welded the posi- tive terminal, so that the current will flow to instead of from the carbon electrode. Should the direction of flow be reversed, carbon will more readily enter the piece being welded, thus producing a very hard weld and one difficult, if not impossible, to machine. The plates in the water barrels are next placed at what is deemed to be the correct distance apart to give the necessary resist- ance; or, if grid rheostats are used, the same result is accomplished by adjusting the switches, each of which cuts into or out of the circuit a certain number of grids. The circuit breaker and the single pole switch are then closed, after which the operator places himself in posi- tion, with the carbon electrode in one hand and having within reach of the other the flux and the material to be used as filler. He next pulls the hood down over his head, touches the carbon electrode to the piece to be welded and instantly withdraws it to a distance of 2 in. or more. The arc thus produced is allowed to play upon the piece, being given a rotary motion by the hand, until Fig. 6.—Water Barrel Rheostats and the Benardos Electrode. the metal commences to boil. Should the are cause trouble by frequently going out, or if, om the other hand, it prove too intense, the resistance in the circuit must be altered accordingly. The rotary motion enables a con- siderable area of the surface of the metal in the vicinity of the weld to be heated, thus preventing it from cooling too rapidly, with the consequent danger of cracking or producing a hard weld. When the fusing temperature is reached, the filler and the flux are put into the boiling metal, a little at a time, the are meanwhile being con- tinued until the weld is completed. Hammering of the weld during the process of cooling will be found advan- tageous as giving the metal a closer grain. It is advis- able, whenever possible, to make the weld during one con- tinuous application of the arc. Not only will the weld thus be made more quickly, but there will be no tendency for scale to form and so assist in causing a hard weld. When, however, it is necessary to make several applica- tions of the arc, care should be taken to remove the scale by brushing with a stiff wire brush. It is equally neces- sary to have the metal quite clean before commencing a weld; this may be accomplished by chipping, or the piece may be tilted and the arc applied until the dirt or slag has melted and run off by gravity. June 24, 1909 SHUNT FIELD WITH RHEOSTAT ¥ J AK SERIES RESISTANCE GENERATOR ra . —s SWITCH ae | r | CIRCUIT BREAKER Th | SERIES AMMETER RELAY ? VOLTMETER— CARBON ELECTRODE METAL TO BE WELDED > ( w oe ee Fig. 7.—Diagram of Another Manner of Connecting an Are Welding Circuit. In the welding of wrought iron or steel, the filling material may be soft iron rod, punched iron scrap or broken bits of steel castings. A very good flux consists of a mixture of 15 to 25 per cent. of red oxide of iron (Fe,0,) and 85 to 75 per cent. of borax (Na,Bo,0, + 5H,0O). Any carbon which may have been introduced into the weld unites with the oxygen in the flux to form CO, gas, leaving behind soft iron. Should, however, this CO, gas not be wholly removed, it will cause sponginess in the metal. The borax simply assists in preventing oxidation by spreading over the weld and keeping out the air. When building on a lug, a mold is made of fireclay or carbon blocks in order to give the metal the desired shape. Fig. 10 shows a cast steel bearing cap, before and after being provided with a lug and the way in which the mold is prepared. In welding cast or malleable iron, the metal must be slowly preheated to a cherry red, the weld being made while in this condition, and the piece then allowed to cool equally slowly. The same flux as for wrought iron or steel, and filling material of soft iron rod, punched iron, copper or special cast iron may be used. For small work it is preferable to have a gas furnace, opening from the top, and if possible to make the weld without removing the casting from the furnace. For large work a tem- porary furnace may be built entirely around the casting. ports being provided which at the proper time can be un- covered and through which the carbon electrodes can be inserted and the welding done. When welding a brass or zinc casting, the piece must be supported in such manner that it will not lose its shape, and borax should be used as a flux to reduce oxidation. ; Welds made in iron or steel by the electric are are sometimes found to be extremely hard. Where there is no machining to be done this feature is of little mo- ment, and occasionally may even prove of advantage. Where, however, machining is required a hard weld is a serious matter, and, while annealing may be resorted to, remaking the weld will usually be found preferable. It may be taken for granted that when a hard weld is encountered it is due to failure to observe one or more of the several precautions already outlined. It is interesting to compare the strength of fire welded with arc welded iron and steel bars. In a paper by Samuel MacCarthy on “ Steel Plates, Pipes and Fittings, and Benardos Are Welding in Connection Therewith,” read before the Institution of Mechanical Engineers, Eng- land, the results of a series of tests were given which are reproduced in Table 1. The bars were all scarf welded, Fig 8.—Detail of the Benardos Electrode for Are Welding. at at 5 NTN ee a Be June 24, 1909 THE IRON AGE 1995 Table 1.—Main Results of Tests of Fire-Welded Compared with Electric-Welded Bars, Ultimate tensile strength per square inch. Brand and size. F = Fire-Welded. E = Electric-Welded. = Brand. Inches. -——Tons.——, Low ae ae, SF 20.3 a MOPEDS ATOR so 6 nin 0 i. 6c BS 2x */6 \E ge 211i Lew a? i oxs jF 21.5 Pe JOWMOOP ITOD... . eee sree seve X */i16 1B a 21.8 Netherton best iron......... 2x\%4 ; : ee 20.1 Park 9 SF 20.9 oe i: ee ee 2x% LE ae 223 Sark i = {,F 20.4 re ig) ge errr xlg LE Pp 21.0 Average of electric-welded bars = 1,766 nine — ae — —-— = 118.5 per cent. Average of fire-welded bars = 1,490 the scarf ranging from 144 to 1% in, It will be seen that there is a difference of about 184 per cent. in favor of the are welded bars, and it is of further interest to observe that the strengths of the welds range from 73.6 to 92 per cent. of that of the original material. Besides the welding of metals the Benardos or are welding process may sometimes be employed with advan- tage along quite different lines, as, for example, in cutting away surplus metal, also in removing sink heads from castings, Fig. 11; or for boring holes in wrought iron and steel] plates, Fig. 12; for flanging pipes, for opening the tap hole in furnaces, &c. In Fig. 13 is shown a casting which was received from the foundry without the strut supporting the bearing bracket. This was supplied by welding on a heavy wrought iron support. To give exact data as to the time required for mak- ing welds, the current consumption, size of welds, &c., is from the nature of the work almost impossible. Tables 2, 3 and 4 will, however, afford some idea of these items and are given as approximations only. Table 2.—-Benardos Process, Filling Drilled Hole in Awle Cap. Volts Volts across across are includ- Line volts Amperes. rheostat. ing carbon. L2G (ONG GEES ov wiccicavae ee ae oe SS ee ee ee 38 63 SO Eine c tes} 00s Vie een 500 36 65 kc hoc nee es kw nle sae e 550 39 61 bs g-0's 0.9.0 a 8h ewe i eens 600 42 53 DUS 60 cs ska eee eek 650 44 51 OF x 0:0 65k ROS le Re Riets sas 650 45 50 LOR. 56's. See ee et es ob 600 42 58 Size of hole = 1% in. -in diameter by 2 in. deep. Size of car- bon = 1% x6in. Time = 56 sec. Table 8,—Benardos Process, Removing Sink Head from Aale Cap. Volts Volts across across are includ- Line volts. Amperes. rheostat. ing carbon. 120 (open CHRCWIE) 6... cscccnctc oa a ae OB. «cic hice hind Oia agli cnelte¥s 600 34 62 PB. os ceed Rape oo reel waaeen 650 30 67 WOR i ikke Sb cee akeereiasrees 600 31 67 BO 5 oh Me ER eS le he soe Chee ee 850 (kick) 30 64 TOR Ts Ohne tad Cine Oe ss cw es 850 30 71 IDG vie devnwadns ates cake ee 850 (kick) 35 63 Cross section of sink head = 24%, x 6 in. Size of carbon = 1% x 6in. Time = 4 min. 45 sec. Table 4.—Benardos Process, Burring Hole in Wrought Iron Plate. Volts Volts across across are includ- Line velts. Amperes. rheostat, ing carbon. 120 (open circult)........cee at xe . Ciesso'. os wavendst wha eee 430 23 72 BR as eV da ee R Rae ones 400 22 81 ER 6d 0.5 6b odd ek US ain boise 870 20 86 OO cece has cee Cea es a6 4 4 1,000 (kick) 24 60 OF Sa Se aed aes hte 1,000 (kick) 35 63 Size of hole = 1% in. in diameter by 1% in. deep. Size of carbon = 14% x 6 in. Time = 3 min. 30 sec. (includes 45 sec. for reversing plate). The query has doubtless arisen in the minds of many among you as to how arc welding compares with the oxy- acetylene process. The two processes would seem to be complementary rather than antagonistic, arc welding hay- ing as its particular field heavier and, if it may be so called without misinterpretation, rougher work, while the oxy-acetylene process is more adapted to small work, castings, shafts and sheet metals, including the cutting of thin sheets, the close regulation of the flame permitting a delicacy of manipulation impossible with the are. Contraction of area at fracture. Extension Ratio of Figure Cc in 10 in. weld to solid. of merit, -—Fer cent. -—Per cent.— -—Per cent.— Tx¢ 15.2 on 7.3 eas 77.9 a ate 308 rae ‘gua 17.3 ai 7.3 ji 81.1 care 365 22.3 Te 11.3 48 90.7 oad 479 aaa ha 20.7 ae 9.7 exh 91.8 “as 451 10.1 a ae 3.4 ee 84.4 ine 185 oe a ales 10.8 oon 4.5 ale 92.0 at § 217 9.3 ae 1.9 ated 69.1 ene 194 ean fue 18.4 on i 3.8 an 73.6 shat 410 15.9 a 8.1 ~~ 82.3 oe 324 a a 15.4 eo% 7.3 one 86.4 as 323 1,490 1,766 Discussion, C. PrrtLe: A motor generator set giving a low voltage source of supply should by all means be used. As a rule 220 or 110 volts are used, which is very inefficient, and not enough current is available at 220 or 110 volts from the ordinary industrial plant to do good work. Nothing to my mind has kept arc welding back so much as trying to operate with too little current. "Mr. Auel’s tables show from 350 to 400 up to 1000 amperes, and this is the range of current necessary to meet all conditions. Very little welding work can be done with a machine that will not give 600 amperes with safety. Are welders are being used mostly in steel foundries, but several are used in other plants and for work which is unusual. For instance, one user is making the side seam and putting heads into hot water boilers and low pressure steam boilers. He is putting these on the mar- ket and guaranteeing them. There was one case of cut- ting material by the electric arc, in which about 30 slag pots had been made, which would not clear the ground by about 4% in. It was found to be partly due to a mistake in the drawing and partly to the sag of the mold, which made the bottom of the pot too thi