The Iron Age 1913-05-01: Vol 91 Iss 18

Zo 4 A HE IRON AGE Established 1855 New York, May 1, 1913 Vol. 91: No. 18 Testing Room for Automobile Engines The Noteworthy Equipment of the Conti- nental Motor Mfg. Company, Detroit, for Testing without Danger of Explosions BY HARRY (¢ SPILLMAN One of the greatest troubles in automobile manufac Motor Mfg. Company, Detroit s planne these turing is the block test room. Unless the engineer has had were carefully considered and also th indling considerable experience in this line of work he will find with the utmost dispatch rence and the motor test department closed a large per- monitor roof and made strictly fireproof, not a single Experience has shown that a new motor, when first frame, with steel sash extending the full width starting to run, will usually miss fire in one of its cylinders columns. This gives a maximum amount of light TT Lh Hh a The Fireproof Test Room of the Continental Motor Mfg. Company with Its Four Rows of Testing Stands 1047 explosions and fires in this department a common occur- The buiiding is of one-story construction, havin centage of the time waiting for repairs. of lumber being used. Structural steel used for and the gas from this cylinder, which is of an explosive order to have good ventilation sash have large openings mixture, enters the exhaust line. Probably the motor next and the entire length of the monitor sash can be opened to this one is taking a rich mixture of gas from the car- by means of sash operators bureter which causes it to send a stream of flame into the A 1-ton Shaw electric crane runs the full length of the €xnaust line. This flame will ignite the mixture of the ex- test room and shipping department, the motors passing Piosive gas from the other motor and an explosion occurs, directly from the assembly floor into the test room on Ther 1ore or less lubricating oil discharged from the small assembly stands. The electric crane picks them up 8as engines, which settles in the bottom of the exhaust and places them on the test stands and also delivers them line which the explosion generally ignites. A fire in into the shipping room and assists in loading them on the ‘ test is generally disastrous, as gasoline is used trucks. mt T testing and there is more or less gasoline and oil To avoid explosions the motors exhaust into a trench On the floor. When the block test room of the Continental which has loose covered plates so that the trench deen ied Poe. 1048 inspected and cleaned at any time. These exhaust trenches run from one large trench to the center of the room, which is connected to a large exhaust fan. This exhaust fan is located in a fireproof room separated from the main room by a fire wall. The fan is a large Sirocco fan having of 40,000 cu. ft. of free air per minute at 6 oz. and is direct connected to a 50-hp. Wagner motor running at 480 r.p.m To avoid explosions an opening is left near each engine exhaust which pulls in fresh air and dilutes the exhaust from the engine. This causes the explosive mixture to become very To take care of fires in the tunnel, metal doors hinged at the top are suspended in each branch tunnel. These doors e held open by means of chains and fusible links so that in case of fire a capacity weak. they drop automatically and confine the fire to one section. All the refuse oil which collects in these trenches is drained away from the fan. A sprinkler line is installed in the main trench having standard sprinkler heads. As a further protection the ceiling of the room is equipped with a complete sprinkler system and six 2%4-in. hose lines are along the side walls In order to only have a small amount of gasoline in the building a 15-gal. tank is erected on the wall and is fed by a Bowser two-cylinder motor-driven pump direct-con- nected to a 3-hp. Wagner motor. This pump works con- tinuously, taking the gdsoline from a 1200-gal. storage tank and discharging into the small tank in the building. The small tank has an overflow returning to the storage tank. This system allows a constant head of gasoline feeding to the motors. The gasoline piping is of. brass and located below the floor line. At each motor stand is a small %-in outlet and a quick connection can be made to the car bureter by a short piece of flexible tubing. The water is circulated by means of a Union cen- trifugal pump having a capacity of 1000 gal. per minute This pump is direct connected to the * mounted on the same bed plate. water into a 1200-gal. feeding the motors. Wagner motor The pump discharges the storage tank which has a 6-in. line The water after circulating around the motor cylinders returns to a hot well where it is returned to the storage tank by means of the centrifugal pump. At each motor the water feed line is connected to the motor and return line by means of a three-way valve. The valve in the first position is closed, in the second position it connects the feed line to the motors, and in the third position it closes the feed lines and opens the return which allows the tester to drain the motor directly into the return line instead of allowing the water to run op the floor. The feed water after passing around the motor cylinders goes to the return line by means of another con- nection separate from the one controlled by the three- way valve. The water passes through a gauge glass which shows at all times if the water is circulating around the cylin- ders. This water circulating system is designed to keep the temperature of the water between 160 and 200 deg., To Avoid Explosions an Exkauster is Used to Dilute the Gases Delivered into the Loose Covered Trenches into Which the Engines Exhaust THE IRON AGE One of the Automobile Engines Mounted on Testing St and a thermostatic valve installed in the 1200-gal tank automatically opens at 200 deg. and discharg water into the feed-water heater located in the power house, where the water is fed into the boilers. As soon as the water starts to lower in the tank it is mad cold city water controlled by a float valve. This st tank also has an overflow to the hot well and a drain which makes the circulating system entirely automatic The ignition to the motors is done by means of a small motor generator outfit having a range from 6 to 12 volts [n order not to affect the voltage when another motor is started, the fields of the small generator are separately excited at 110 volts. This allows a constant voltage regardless of the load. A fuse is located at each motor in order that a short circuit will affect only one motor. Tests show that each motor uses about 3% ampere of current. Test stands are built with adjustable blocks so that the stands will hold different models of motors. A large cast- iron drain pan is under each stand to collect all the oil. These stands are all connected to a drain pipe which collects the oil which is spilled and returns it to the storage tank. The oil is carefully filtered after being used and great care is taken to have it entirely free from dirt and other foreign matter. The reclaimed oil is mixed with new oil in order to keep the quality of oil to a high standard. The entire room is illuminated by means of A flaming arc lamps, using yellow carbons. Yellow rays from a flaming arc penetrate the smoke better than any other form of artificial illumination. At each motor stan an outlet is provided for an extension cord which gives the testers a lamp at each machine. The motors are run in by belts for three or four hours before going to the test blocks. In the test room they are run in by their own power for 4 or 5 hours, and the oil pan is taken off and the bearing inspected. They are then run for 3 hours and again looked over. The night testers then take the motors and run them continuously through the night under load. The next day they are carefully torn apart and thoroughly examined and adjusted and placed on the block for final running, where they are tuned up and made ready for shipment. The test room handles this work in a very efficient manner and is designed to take care of 115 motors per day. y rage Henry R. Merton & Co., Ltd., London, take ar mistic view of the copper situation in their circular issued \pril 12. After commenting on the heavy reducti \merican copper stocks in March, they say: “The with- drawals of stocks from British and Continental ware- houses have again been on a substantial scale, that in view of the heavy purchases made for this and next month there is reason to anticipate a further consid shrinkage in the visible supplies; it is indeed quite { sible that within a few months we shall again be face face with the exceedingly small reserve stocks experience? last summer.” The Annealing of Steel Castings Extensive Investigations Showing Its Effects on Structure The Slow Cooling Process Is Best for the General Run of Castings BY EDWIN ling of steel castings is be ing more and nt. Not so long ago purc rs, and conse- ers, gave little attention his matter. A : r thorough annealing passé@ inspectors and / igs that were “red,” or whose original irance had been changed, were “annealed.” years, however, a decided change has taken has been brought about principally in two producers have sought a higher standard in and purchasers, the railroads in particular, he subject and demanded thorough anneal sult is that steel casting producers in general the subject practically and scientifically proved and enlarged their annealing and facilities, and have studied the process by microscope. Retest, te td ti ae Effect of Annealing on Structure itntine ssity for a proper heat treatment of steel cast- est be appreciated by a brief metallurgical and raphic presentation of their crystalline structure \ny steel casting when untreated is a mass of F. CONE Slow Cooling and Quick Cooling Two methods are generally used by steel foundrymen for annealing their castings. These are usually designated 1ick-cooling processes. The first as the slow-cooling and { consists in bringing the castings to a temperature just above the recalescence point, holding them at this tem- perature for a length of time sufficient to permeate them, this depending on the size of the casting, and then in allowing them to cool slowly in the closed annealer until nearly black. The second or quick cooling method is the same as the other, except that as soon as the castings are thoroughly heated throu; hey are exposed to the air by either removing the covers or drawing the car containing the castings out into the air. Strictly speaking, this last process is not annealing but air-tempering Annealing | ‘ | carries with it as part of its definition the idea of slow cooling, and this is the general acceptation of the term If the quick-cooling process becomes general there should either be a change in nomenclature to embrace both methods or specifications should designate which method be used. The relative merits of the two methods depend upon graphs About Two-thirds Original Size Taken at 87 Diameters. Nos. 1, 2 and 3 Structure of Medium, Large and Small Carbon Castings Respectively various shapes. The size and variety of these any factors—the method by which the steel is temperature at which it is poured, the rate of he size of the casting, etc. Large and small crys- ited and angular ones, are in juxtaposition utthecasting. This is vividly illustrated by means 1,2 and 3. Fig. 1 represents the structure of a ized steel casting; Fig. 2 that of a very large cast- ig. 3 the structure of a small casting. They are en hearth carbon steel and fairly representative ngs of these sizes. It is hard to realize that al present untreated steel castings. The variation largely by conditions of cooling as affected by the casting and the temperature of pouring ty of securing uniform structures and the best esults by treating a group of such structures in Same annealer is readily appreciated, though pted by a large number of steel foundries. an be but one consequence of the use of cast- green condition—a steel considerably weakened niform inter-knitting of vital parts. A casting service in that condition will probably fail one so treated that its constituent parts are united. To bring about this closer union of a to remove the resulting internal strains, steel uld be thoroughly annealed. the results to be achieved So far as the breaking up of original structure is concerned, either process is effective. Opinions differ, however, as to whether the quick-cooling process does not leave certain internal strains in some sections of the castings which the slow cooling prevents. This would be especially true of cast- ings of uneven section. The writer has known, in the case of castings made from the same pattern, of frequent failures of some of them. A partial investigation showed that those that had failed had been annealed or heat- treated by the quick-cooling method, whereas no case was found of failures of any of those annealed in the other way. These castings were of uneven thickness and the failures took place in the heavy sections. It is highly probable that in the case of castings of thin and fairly uniform section the quick-cooling process is entirely satis- factory in every particular, and of course much more ex- peditious. The fuel used, whether coal, gas or oil, is a matter of local management and availability. Types of Annealing Furnace The design of the furnace is a very important matter and depends upon the kind of castings to be treated Small castings are often annealed in a small or car annealer and large ones in a so-called pit annealer. In the latter the best results are obtained by locating the source 1049 4 \ Shs. 1050 THE IRON AGE May 1, 190 of heat on one side instead of the ends, thereby insuring A careful examination of this table an even heat distribution. In any event, small castings following: should not be annealed with large ones. It is the practice 1. Slow annealing increases the tensile stre: in many foundries not only to anneal large and small original steel. castings together, but to do this in a large annealer approximating 34 ft. long by 8 to Io ft. wide and 5 to 6 ft. deep. The great objection to this procedure is not so much in the mixing of large and small castings, though this is bad enough, but in the fact that it is usually impos- sible to obtain uniform temperatures throughout such a 1 large annealer, whether the source of heat is at the side 2. Quick annealing materially raises the tens over the slow annealing, with a corresponding ductility. 3. In almost every case the elastic ratio is « either heat treatment, but more particularly cooling process, the exceptions being account other adequate causes. The prevailing conception that annealing a st “softens” the st@@fand so lowers its tensil: proved erroneous by these static tests and others. It :s als@#established by many practical repeated annealings, with slow-cooling, raise s the tensile strength with a corresponding decreas tility—a fact little appreciated by the average { The following actual tests from slow cooling trate this: or ends. Careful tests of such an annealer, both micro scopic and thermal, made by the writer, showed wide variations of temperature in different locations and de cided fluctuations in physical results. This was especially true of castings located near the source of heat and thus frequently over-heated. Regulation and uniformity of temperature are essential to the best results. It would seem that the time is not far away when progressive foundrymen must adopt means whereby castings of similar lesign and section can be heat-treated in furnaces prop- erly suited to the size of the castings. Elong. Reduction ye Tensile Elas. in2in of area Effect on Physical Properties str., lb. limit, lb. percent percent | g ; . peel ; : Unannealed.. 70,000 36,000 22.0 30.9 ¥, There is another point of view from which the two Annealed P once ... 75,000 39,000 27.0 4. methods of heat treatment should be regarded, and that is ,a,pecjed’”’ at —_ ; bi the effect on the physical results. If the object to be three times 81,000 43,000 21.5 32.5 irreg. Photomicrographs About Two-thirds Original Size Taken at 87 Diameters. No. 4, Unannealed Carbon Steel; No. 5, Same, S \ 6, Same, Quick-cooled attained is the production ol the Dest Static results then Nickel Steel Castings the quick-cooling method is the most effective. By far the best tests are obtained in almost every case where this The same marked improvement in the tensile method is used. This is best illustrated by actual results and relative ductility is noted from the following collected by the writer in his practical experience and the case of nickel steel castings, but there does t shown in Tables 1, 2 and 3. Carbon, nickel and vanadium to occur the decided change for the better in the el steel castings are compared. The tests were made on fatio, the maximum having been reached in coupons of uniform size and conditions of pouring, so cooling method; if anything there is a decreas: that the investigation could be as reliable and at the rati same time as practical as possible. The terms “green,” Taste 2.—Nickel Stee 6 2] 77? “asick” clonat 1e . nditions of the - slow” and qui kde signate the three co ant n ey i Eloag. Reduction steel, “green” representing the untreated and “slow” and \rensil Ries, india. of ares “quick” the two treated conditions. lest str., 1b. limit, Ib. percent percent F: Taste 1.—Carbon Stee! 17 *Greer 100,000 52,520 13 16.16 8 +Slow 101.010 63,630 19 4 : Elong. R« tu u 19 $Quick - 107,000 67,000 20.5 37.20 Tensile Ellas. 2 it per 108,00 65,000 17.0 32.5 Test tr., I imit, er cent ercent | tur cent 7 i 5 a 66,000 18.0 34.10 : : me 000 36.5 aaa ~% ' es ae 2 Slow .. 108.000 70.000 18.5 36.60 3 + 91500 42. 5 34 oan S316 3° Quick 114,200 65,900 15.0 25.82 ing 4 0 ; 0.31 a 115,000 70,000 17.0 29.20 ang 5 8, 26.5 40.3 reg 3.84 Slow ‘ 99.000 67,000 21.5 45.4 6 69,5 36.000 30 43.4 ut 51.80 26 Quick ... 99,480 66,660 20.0 40.3 ing 7 sos See 38.000 27.5 4] 6 cup 52.00 . 161,000 60,000 19.5 30.9 an 8 Green .... 69,47 41,000 ] eran 6900 9: ee. aes 0s Sow 40,000 U +3.4 2 ¢ 4.8 oem a - . 10 Quick .... 77,090 44,500 25.5 8.8 , Cur 57.80 Fig. 7. tFig. 8. tFig. 9. 11 Green .... 78,000 38,000 24 27.5 4 gran. 48.73 os —_—_— Analyses 2 Slow ..... 80,370 41,380 4.0 37.0 irreg 51.61 — - N é , »0 nea 13 Quick .... 85.500 48,00 25.0 372 Yeup 56.10 Carbon Man 14. Green 72,000 42,500 26.0 30.9 irreg. 59.0 per cent per cent 1S Slow ..... 75,300 40,61 2¢ 42.3 cup 53.8 N tk Baie Ps 0.35 0.70 16 Quick 79,000 45,500 43.4 1% cur 57.6 N eo ere ee ccnce 0.70 ———- N Ree éaeea ate cee 0.65 *Fig. 4. tFig. 5. tFig. ¢ Analyses———— s 7 7 Carbon Moanin Oiiloen Vanadium Steel Castings er cent pe cent per cent No, 1 steel ..-++seeeeeeeeereeees 0.27 0.66 0.294 A study of the table below shows that in the cas Na TO ees ee & She ~~ eae 1.70 0.245 ‘ . . . ‘ ‘ sre t No. 6 steel 23 0.67 0.292 vanadium steel castings quite different conclusions 4 No. MERE 1k OGke who's SE 0.2 7 292 + aid No. 8 steel .....--.+seeeees --- 0.24 0.64 0.264 be drawn from those noted for carbon steel and ™ eh: BE EE nsec eweces kk See ar. 0.62 0.282 o are WO. 14 Steed 2c escccinesccevccsees 0.27 0.67 0.289 steel castings: 1913 THE IRON AGE [051 / , I : Vanadium S p Elong. Re ensile Elas in 2 in f area r., Ib. limit, Ib. percent per ce Fra 84.500 39,000 18.5 25.8 g ‘ 85.01 48.500 21.0 37.2 [ 7 a: R31 ) 53.000 21 34.1 ; 78,125 45,625 21.62 32.65 rreg : 88,00 61,000 12.50 15.36 bad 71,25 44,500 28.50 46.35 6 83,700 54,800 20.00 30 rreg 74,625 44,375 24.00 60 irre 86,500 55,000 19.00 4 ) reg é 70,25 45,000 2 5 27 70 50.700 al i g 70 0 44,000 46.80 4 : . 0 60,00 24.10 irre ) 5 14.80 gr ) 4 ( 37.20 r g Q ) 50.500 an & l, 2 g. 1] thig ( Manga Ss V if t per cent zo 0.66 2 ).22 59 0 18 0.22 0-¢ { 0.23 0.69 é 0.24 0.60 f 0.21 57 62 0.26 0.49 g3 juick cooling of vanadium steel castings, carried ler the same condidons and at the same time witl n and nickel steels, produces: 9 ea A Tw is Or ial S ~ { : 6 ‘ n tensile strengtl é ed increase in elastic rat e rising lessening of ductility. ising decrease in reduced area licating the reliability of these important conclu uld be stated that the tests were made a) t th many of the carbon steel tests discussed in a ; 1 t ng, and also that a microscopical examination pat ‘ . ' i rostruc i aimost a pertect heat treatment and a microstruc- ZS n better than in the carbon tests n should also be called to the peculiar fact t im steel castings possess a considerably higher ten- trength and brittleness in the green or natural stat n steel, nickel steel or any other description o ting. The necessity for careful and thorough heat is all the greater in the case of vanadium li 1 ten to regoing discussion with table shou fact that if the end to be attained by an r heat treatment is the best physical results, the cooling or air tempering should y 4 xcept in the case of vanadium steel castings Heating Before Annealing $ point it is proper to mention briefly a matter been more or less discussed among metallurgists, cial reference to steel castings. It is claimed by it the best physical results can only be obtained iting the metal to a high temperature—about 2000 3 F.—followed by sudden cooling and then by proper ling. The object of this is to destroy the large lline structure, known as ingotism, which results a slow cooling in the sand, this being more pro- ed the greater the bulk of the metal. It also results a high initial pouring temperature. In the case >A LD NER RRs ot pee g } tin | I ! l I iaree CaStiNes 1d us mn xenerai, S$ A 14 ‘ ' ' s racticabie, even e resuits snoul Sta r suits r t] ir\ eth« ds I 4 re exct t enough for all practical rpos ! | instance of the results of a trial of this pr ‘ } cs he Same I! tal is given be \ 1 : & dé s t is ca ‘ ' P } j V 7 ‘ Ss " R é S Ss +i Ang I ed the W g | I I ~ t ul imp | nt t s—t S \ 1 i followed treatment of the san tal ic] ling process Che improvement ; nown in t microstructure, the 1 ré ta lg smaller ' Metallographic Results Che etallog ts ject are inter sting The nev e ¢ ct f the ooling of f ee ‘ el tron ul above ul ence { products 1 very ne micros wherea ‘ vy cool lg causes a ructur terme betwee ind the . ‘ | ‘ +} green state I raet Ss! ay tnis nti in the . " ‘ \ eale S ) led ‘ ns der t T Vv ‘ if re re | ‘ ( | rigs | ink [ : \ I 1icl led t : . : steel istings These f ' : ; rest Im ia S 1 go rept t ‘ : ' } ‘ . , ‘ ’ ’ tructures t { 5S al ) lab i lical d e it ' eabk » the effect the 1 iy y ‘ : ‘ ferrit compre tals Ir re wn ¢ "1 ystal f na ' The trie are ft res 77 t ' labl Spt tt uld to the ror ne t condit I i at " har rie4 . j nate 1} many : le I ed by t writer trongly rest les the tu f ordin ' n e¢ castings annealed the sh ling pr ess This can be apprec ited | ' comparison with Fig. 5 The microstructure of the slowly-cooled spe en i i haracteristic, differing decidedly from either f the ther types It will also be noticed that the microstructure resulting from t almost ideal, though the physical result Annealing Temperatures The question of the temperature at which steel cast ings should be heat treated is am important one. The oretically there are definite limits, such as 1562 deg. F to 1654 deg. F. for ordinary 0.20 per cent. to 0.30 per cent. carbon castings, and possibly other limits for nickel, vanadium, et But in actual practice it is found that ach i ag a 1052 arbitrary figures cannot be followed The size f the annealer, the location and type of pyrometer and other factors cause this i instance, to insure satisfactory structures and fractures from all parts of an annealer of large dimensions | with a thermo-couple pyrometer located in a hole or holes in the walls, it is found necessary cause the chart to register not less than 17co deg | nor more than 1800 deg. | With such practice inspe tors have been presented with fractures a1 physical tests that have proved entirely acceptabl: An interesting effect of annealing peratures on the physical results of steel castings phase of the caused by annealing at low temperatures or temperat t nperatures just under the recalescence point. Ey this is meant ings that may be subjected to a temperature around 1450 deg. Ff. t so deg. F. fr the annealer or from the fact their particular location in that the desired annealing was not reached This f temperature reters oniv to ste¢ castil ot moderate carbon contents, or up to 0.2% ¢ ; , , oy : ‘ cent t has been found that many of the best physica ; . . results, as regards ductility in irticular, ha resul trol! such conditions as ar¢ indi ited by the 1 m n static results Elong Reduct Tensile Elastic in 2 in. of area str., lt limit, Ib. per cent. per —HFra -e 7,501 33,000 33.5 egula wavy 64,500 35,000 33.5 + regular, wavy 68,000 40,000 29.0 0.¢ irregular, wavy Photomicrographs About Two-thirds Original Size Taken at 87 Diameters. THE IRON AGE May 1, A striking characteristic of the fracture of su is that they all have a “wavy” or corrugated surface point of fracture—always a positive evidence of It will be found that such tests are lo strength than the same steel properly though the ductility will be considerably better due to the easy slipping of the crystals on each The metallographic results of these thermal cor present interesting phenomena, at least from a | : view of beauty. Under the microscope this under : medium carbon steel presents a beautiful and inte: structure showing the steel in its transition stage fr annealing tensile purely laminated to the cellular structure. In fact possible to secure as many different and variegated as there are possible points to observe. An inspecti Figs. 13, 14 and 15 will illustrate this fully. These facts, however, do not apply to higher car steel nor to nickel or vanadium steel castings. Such un heating in these cases results in very poor physical which are often ondition. Therefore, the necessity for careful and ough heat treatment of all grades of perative Of equal importance is the effect of too high temper : tures in the annealing furnace. The results of this lessening of the ductility of the steel, especially if c quickly far inferior to those from an untr steel castings is Slow cooling from an excessive temperature te: to correct some of the bad effects, so far as static result Nos. 10, 11 and 12, Vanadium Steel; Nos. 13, 14 and 15, Under \nrealed Carbon Steel; Nos. 16, 17 and 18, Over-annealed Carbon Steel 1913 THE IRON AGE but the resulting crystals are large and \ uccompanying physical tests will illustrat ar and tests Elon Reduction biec las n tf area ‘i : pe per cent ns 44.000 21.0 42.8 eg wats 36,000 25.0 39.4 : ; 41,006 20.5 40.3 ar ; responding crystalline structures of the al : wn respectively in Figs. 16, 17 and 18, none ( {1 safe structure. The first two are slow ontt a too high temperature and the last one, Fis effect of quick cooling under the same Tests with Larger Sections ect has thus far been discussed largely fro “* Dra n experiments made with regulation test cou 2 D ] ; ; ; Dr: annealed attached to or detached fro 4 Ss So far as they go these are reliable and rep But in order to test these facts on a larger methods of heat treatment were carried out o1 $ Side, steel of larger dimensions. Bars 5% x6™% enter i ng and all of the same composition were used tR ed in the green or natural condition; another a d at about 1700 deg. F. by the slow-coolin: third was placed in the same locality in the ler, and after proper soaking it was removed The ir for quick cooling. Each of these bars was’ green steel are illu physically and microscopically as follows ferio crographs About Two-thirds Original Size Taken at 87 Diameters. Nos. 20, 21 and 22 Various Structures of Unannealed Various Structures of Quick-cooled Carbon Bar <4 and 25, Various Structures of Slow-cooled; Nos. 26, 27 and 238, 1054 traction of the metal on cooling renders the interior of the larger sections of steel castings less dense. Slow Annealing Section: The tests resulting from this examination are found in Table 5, the numerals having the same signification as previously. TABLE 5 Elong. Reduction Tensile Elastic in2in. of area Test str.,lb. limit, Ib. per cent. per cent. Fracture 1 *Drag, corner . 74,000 41,000 26. 40.3 irreg. 2 Drag, center . 75,000 42,000 24.0 30.9 Mer. flaw 3 Drag, corner .. 75,000 38,000 26.0 40.3 irreg. 4 Side, middle .. 74,500 41,500 24.0 30.9 irreg. 5 Ccpe, corner -» 75,000 40,500 26.5 43.4 irreg. 6 Cope, center . 76,000 41,500 20.0 24.1 irreg. 7 Cope, corner .. 76,000 eeee ee 24.0 40.3 % cup 8 Side, middle : 76,000 cabeca 21.0 29.2 irreg. S Center oskasnsexks 57,000 eas 6.0 15.3 irreg., flaw 10 ¢+Left center, drag.. 75,000 dnewe 19.0 20.6 irreg, 11 Right center, cope. 73,900 wae 16.0 22.4 ang. 12 tRight center, drag. 74,000 _........ 16.5 18.8 M%er., flaw 13 Left center, cope.. 73,000 14.5 18.8 %er.,flaw *Fig. 23. Fig. 24. YFig. 25. In the tests in Table 5 the general average is better than in those from the green section. The same difference obtains between the center and the other bars. The outside - 8’ Fig. 19 portions, Nos. 1 to 8, show a uniformity that is very de- sirable. The general effect of the annealing has been to improve all sections, internal strains being removed, duc- tility improved, and tensile strength increased. Quick Annealing Section: A static examination of this has resulted in the tests compiled in Table 6, the numerals referring to the same parts as in the two previous tables. TABLE 6 Elong. Reduction Tensile Elastic in2in. of area Test str., lb, limit, lb.-per cent. per cent. Fracture 1 *Drag, corner ..... 78,000 38,000 26.0 41.9 irreg. 2 Drag, center ..... 77,000 42,500 23.5 32.5 irreg, 3 Drag, corner ..... 79,500 50,000 24.0 41.9 cup 4 Side, middle ..... 78,000 48,000 23.5 27.5 irreg § Cope, corner ..... 80,000 45,500 25.5 44 6 cup 6 Cope, center ..... 78,000 43,000 23.5 35.7 rreg, 7 Cope, corner ..... 55,000 47,500 Flawed bar ... Es 8 Side, middle ..... 80,000 51,500 21.0 2 irreg. D FUCMIEr... cactacscee 77,000 52,000 15.5 20.6 poor 10 Left center, drag.. 77,500 43,000 19.0 18.8 poor 11 Right center, cope. 77,000 43,000 14.0 18.8 % gran. 12 Right center, drag. 79,000 48,000 16.5 18.8 gran., flaw 13 tLeft center, cope.. 78,000 44,000 11.0 18.8 irreg. “Fig. 26. Fig. 27. tFig. 28. The effect of this method of annealing is the same on a large section of metal as on test coupons, i.e., the tensile strength is appreciably increased and the elastic ratio considerably augmented without loss of ducility but rather with an increase. The outside bars, 1 to 8, are the best, and the inside ones show some improvement in their average over the corresponding ones of the other sections. Of particular interest is the fact that in each case the corner bars are superior to the other outside bars. Microscopical Examination All of the 39 physical tests in the three foregoing tables were examined under the microscope, but only a few of them were photographed. A discussion of these follows: Green Section: 20 and 21 reveal the micro- structure of the outside and center of this section, the former being fairly uniform in its lattice formation and typical, and the latter being non-uniform. Fig. 22 shows the section near the center and here a still different struc- ture is found, the presence of slag, oxides and manganese sulphide being clearly shown. Slow Annealing Section: Figs. 23 and 24 show the crystalline structure of the outside and center of this condition of the same metal. The almost exact sim- ilarity of the two structures reveals how uniform is Figs. THE IRON AGE May |, | J IQI3 the condition of the metal from this treat: more striking is the thoroughness of this meth n tt it shows that it is possible to permeate and transfor, completely large sections and remove all strains exhibits a portion of the metal near the cent trating how the presence of slag, oxide or n sulphide disarranges the best structures and rend a good heat treatment. Quick Annealing Section: Figs. 26 and 27 crystalline condition of the outside and the center tively of this section that has been quickly annealed Whi}. the structure is similar to that obtained from test pon the resulting crystals are larger and by far much les uniform than those resulting from the other pri annealing. Such structures must insure a weaknes metal that is never obtained from the other proces less the annealing has been imperfect. Fig. 28, located near the center, shows how the presence of slag, oxides and manganese sulphide distorts the crystalline arrangem and weakens the steel. A chemical examination of a cross section of the gree bar proved the absence of any appreciable segregat anes Wear Ss the elements in a steel casting of this size. The anal of this steel was as follows: Carbon CWO ROSCOE KORTHOHHEOSEHK SR DOOC HOSS EOEE OEESO 0.27 DOMMES. (cake ve cawes siebe cuseaue eaves bhee Gabe 0.67 DOE, haba 62 00h ce baeed ek bate ease se wees 0.289 t BOE co ckvned ssp evcnpeead babi betes denen senha 0.042 | TOME ccccacwdecccciee cheek saeeoeneCanbennel 0.031 { en This is the average composition of acid open-hearth steel castings. The three sets of tests, discussed in the foregoing, reveal the physical and microscopical condition of each and show how uniform or non-uniform each is in cer- tain parts. In the green condition the non-uniformity is ver) marked, the presence of the large crystals affecting static properties unfavorably and the strains therefr causing weaknesses of marked intensity. They reveal the actual condition existing on the outside of any steel cast- ing of moderate size. The larger the casting the more marked is this internal weakness, which emphasizes the importance of a proper heat treatment. The effect of the slow-cooling process has been t remove all strains and render the whole metal as uniform as possible except where affected by variation in density or impurities. No heat treatment can rectify this. Phys- ically this process has produced uniform static results an microscopically the metal has been transformed into condition of almost regular crystallization even to center, showing the removal of all strains. The quick annealing process has produced a condition of static uniformity, with the increased beneficial char- acteristics of greater strength and ductility. But it probable that this apparent uniformity is only partl reliable, for the crystalline condition is non-uniform and the presence of more or less internal strains is doubtless crystals. Importance of Heat Treatment The preceding presentation of the subject demon- strates how important is some heat treatment of stee! castings. All castings should be annealed. This article is a plea for the slow-cooling process as best adapted to the general run of steel castings to produce a thoroughly reliable metal of enduring properties under all ordinary conditions. Superior static qualities, as evidenced by results from test coupons, are not the first consideration. For these sections of metal the quick-cooling method is safely applicable and an increased strength is obtained, but to so treat locomotive engine frames, wheel centers and other castings of varied thickness would result in 4 sacrifice of internal strength for better physical results with the probability of ultimate failure of the castings ™ service. Other methods of heat treatment are undef investigation, and one standard railroad is conducting extensive experiments on the heat treatment of its ste¢! cast locomotive frames. It is reported that large deposits of copper, coal ané iron and manganese ores have been discovered about 15° miles from Calcutta, India, in the Dalthum district. ed 1913 THE IRON AGE 10 Friedrich Changeable Open Hearth Port nstruction and use of the Friedrich changeable veloped at the Julienhitte in Germany, was de- detail in The Iron Age of August 25, I91I0, p. some extremely good operating results were ir issue of December 5, 1912, p. 1312. Engineer vives still further results in an article in Stahl for March 13, 1913. By the use of these ports ds described in the preceding articles the repair e Julienhiitte have been reduced by about 40 per y10 they were only 24.7c (1.04m) ; in IQII, 27.8c and from January to July, 1912, 25.4c (1.07m) ton of good ingots. were 384 working days from August I, I9II, 31, 1912, during which time the plant was run possible. There are six 40 to 45-ton furnaces 150-ton mixer at the Julienhitte, and the pig iron- ss is used almost exclusively. It should be borne that no open-hearth plant can be run in Germany ind that the Friedrich port can be installed in 6 hr. on Sunday morning, the furnace being 1in on Monday. During these 384 days, which <4 * 6= 2304 furnace days, there were four days only four furnaces were working, 187 days on ve were working, and 193 on which all six were ition. This gives a total of 2109 furnace days, so ring this long period of 15 months only 8.46 per ‘ the total furnace days were needed for repairs. In rds, the plant was used on the average to 91% nt. of its capacity. The previous articles gave the able steady and high daily tonnage outputs per up to June 15, 1912, and these results were main- | up to October 31, 1912. economic importance of these results is clear with the old construction a six-furnace plant is neces- » insure four furnaces being constantly at work and furnaces part of the time, the Julienhiitte plant during four-fifths of the year works more days with six than with ve furnaces. While it is usually estimated that a furnace vill operate 250 out of the 300 working days in the year, is seen from the results above that at the Julienhiitte a e is in operation for 274.6 days; that is, 10 per cent This means a Io per cent. increased output, or that lesigning new plants where the amount of output de ; limited for any reason, one or more furnaces, with accompanying buildings, machinery, etc., can be | the changeable port is used. om pte ccematte, The British Shipbuilding Trade yd’s Register, issued in April, indicates 94,000 tons nerchant shipping in course of construction in the s yards in the United Kingdom than was the case months ago. The promise of the future, however, mewhat in doubt. With recent advance in wages shipbuilding yards and the increased cost of ma- the prices quoted by builders for new shipping had to be greatly increased. A contributive cause high costs also mentioned is increased charges due to legislation. There is accordingly much more hesi- in placing orders, and Engineering of London says that feeling in shipping circles is that until the prices ne steadier there will not be many new ships put nstruction. The increase shown in Lloyd’s returns to the bringing into evidence of work which was some time ago at more favorable terms than are oted. work in hand on March 31 was as follows: Mer- ships, 2,063,694 tons; warships in dock yards, 132,190 home warships in private yards, 273,421 tons; for- warships, 150,700 tons; total, 2,620,005 tons. The ate is 153,065 tons more than it was three months ind 278,638 tons more than six months ago New Zealand Government has taken up the ques- the establishment of an iron and steel plant to up iron ore deposits at Parapara and Omakaka. The cals of a London syndicate were considered unsatis- ry by the committee representing the House of Repre- tives of New Zealand and the advisability of the rnment developing the industry as a state enterprise ng considered. ow wn A Metal Culvert Curving and Forming Machine The Niagara Machine & Tool Works, 630 Northland avenue, Buffalo, N. Y., has recently brought out a forming and curving machine for corrugated metal. The machine will handle work as heavy as No. 10 gauge standard galvanized sheets for the manufacture of culverts, sewers, etc., and will not only curve the sheet to the proper form, but will also re-shape the ends at the same time to make the dif ferent sections interlocking. Herewith is a view of machine High-carbon steel forgings are employed for the rolls, A New Curving and For ting Machine for Corrugated Material which are made in one piece, with the exception of the forming collars on the ends, which are removable. The two front rolls, as well as the rear one, are all driven The pinions and connecting gears are made of steel. with teeth cut from the solid. The position of the lower front end of the rear roll can be varied vertically by a hand wheel at the left side of the machine, while the upper front roll can be raised by a lever on the right side to remove the formed cylinders. The machine is double back geared and the motion is controlled by a hand lever operating a friction elutch. The external diameter of the rolls is 7%4 in. and the weight of the machine is 4500 Ib The Baltimore Advertising Convention The Associated Advertising Clubs of America will hold an international convention of advertising men and busi ness men interested in the extension of trade through publicity in Baltimore, Md., the week of June 8 to 13 This will be the ninth annual convention of a body which has affiliations in Canada and England and desires to ex- tend its connection to all countries in the world. It will be attended by delegates and business men, including im- porters and exporters, from all parts of this continent and from many European countries. The indications are that the attendance will approximate 10,000. It will be the first world-wide convention in the interest of advertising ever held. <A special invitation to attend has been ex- tended by the Department of State of this country, through our consular offices, to advertising clubs, commercial bodies, publications and business concerns and agencies throughout the world. The Advertising Club of Baltimore, whose executive offices are at 1 North Calvert street, has for some time been actively engaged in the work of creating interest in the convention. President Edward J. Shay of this club some time ago appointed a press and publicity committee, comprising representatives of Baltimore publications and business interests, which has been doing excellent work in spreading news with regard to the development of prepara- tions for taking care of the convention. The chairman of this committee is Alfred I. Hart, editor of the Old Bay Line Magazine Another record in the production of large ingots has been recently established by Cammell, Laird & Co., Léd., Sheffield, England. The ingot, which was intended for special Admiralty requirements, weighed 150 tons. Its length was 23% ft. and it measured 8o in. across the flats at the large end Es = Seer maine, = Pak ae ee ee 1056 THE IRON AGE May 1, 191 New Oscillating Steel Ball Burnishing Barrel ism for fastening it in the desired position. locked in a straight horizontal position by tl For burnishing metal pieces longer than 16 in., the ; : ; j : ment of a lug which is cast on the side of Abbott Ball Company, Hartford, Conn., has brought out , 1: 4: St ee ee : proper, with a slot in the sliding lock member a new type of burnishing barrel It is designated bv the e . possible to lock the barrel at angles of 5, Io with the yoke, the locking being accomplished gagement of teeth in the cpposite end of the sli with corresponding teeth in the outside end of thx bearing on the barrel. The possibility of lo barrel at different angles for running, it is p gives more or less of an oscillating motion t tents, the angle in any particular case being d y the character of the work to be finished. When the locking mechanism is disengaged, can be swung in an upright position to load ar turned over on the main bearing for dumping tents, as shown. The barrel is octagonal in shaps inside dimensions are 12x30 in., the latter length. It is lined with hard maple and opens at loosening four nuts on swing bolts, as indicat: Rehabilitation of a Flooded Foundry Quick Rising from Ohio Floods of the Niles Tool Works A N rype Osc g Burnis I V\ S B Are Used The floods in the Central West are now a istory, except with those manufacturing concert builder as its oscillating barrel and can be filled almost en- were most affected. However, the work of cleanin; tirely with the pieces to be finished, the steel for doing getting plants into operation was accomplished in a wor the work, the soap chips and water bei1 ided as usual derfully short space of time It is pointed out that by the method of fillir the worl In the case of the Niles Tool Works Compa has no chance to turn on end or move in the barrel as it chine shop, at Hamilton, Ohio, water over 12 ft. in dept! would in one having a smaller diameter and only partially passed through the shop, leaving behind several incl lied. The builder states that small work, running up t mud. While the company was handicapped on account o! a few inches, can be finished more satisfactorily in its a shortage of labor, work was commenced immediatel; regular burnishing barrels, one of which was illustrated in to get everything into shape and within two weeks’ tin The Iron Age, February 29, 1912. The reason for bring Superintendent Siebold had part of the shop in oper ing out the new type of barrel was to allow pieces, such tion. This is especially quick action, when the damag: as sash rods, etc., to be finished by the burnishing process to the central power plant is taken into consideration As will be noticed from the accompanying illustration Che large foundry building, situated across the street the barrel itself is held in trunnions in a yoke, the sides but on lower ground, had more than 15 ft. depth of water of which are made of channel irons. The barrel can be’ with the resultant damage from deposits of mud and locked at an angle with the sides of the yoke by a cast- débris of all kinds. Fig. 1 shows the foundry the d iron locking piece sliding in the yoke and having mechan-_ after the flood, and Fig. 2 indicates the quick results ac a -. genaiw it rks Foundry Immediately After the 15 Ft. of Water Subsided 1913 i mw a Fig. 2—Main Bay of hed under direction of Foundry Superintendent : in five days’ cleaning-up work. Both the machine ind foundry were operating up to 60 per cent. o! n April 15. President James K. Cullen belongs the credit f a ting the plan which was adopted by other manu = turers of paying skilled labor full time when engaged eaning up work. Although many men were not able idvantage of this offer, as they wer htening out their own homes, the idea had a stimu effect on those who were able to work outside, and responsible for the engaged in results ac irge degree 15s A Water Power Head of 5412 Feet he utilization of a water power head of 5000 ft. has en considered impracticable in technical circles. M her, civil engineer, Lausanne, after whose plans many power projects with a comparatively high head have developed, has made it his aim, as a member of the f administration of the iris to convert into electric energy the water power Lake Fully, near Martigny, in Canton Wallis, Switzer with a head higher than has hitherto been used 5412 ft. The execution of this scheme has been upon, the orders for the materials d and the work has been commenced lhe most interesting question in connection pment arose when deciding in what manner the pip: uld be constructed to withstand a pressure of 2425 sq. in. at the lower end. A satisfactory as well as The pipe line, having a length l Société d’Electro-Chimie I necessar\ with this le solution was found ut 234 miles, 11/16 in. and 23% in. and thicknesses of 15/64 in. t 2 in. The pipes of the upper section will be of the 4 lapwelded type and those of the lower part will | drawn from a consists of pipes with inside diameters ve less. The seamless pipes, which are ngot, can be made up to the largest diameters e turbines for 15,000 hp. will be built by Piccard, & Co., Geneva, Switzerland, while the pipe line is in the hands of Thyssen & Co. wil at Muelheim-Ruhr, Germany, extensive steel, plate works as well as a water gas welding plant for ipes. At Thyssen & Co.’s works a great many pip¢ for water power plants have been constructed constructior Niles Tool Works Foundry, SI THE IRON AGE wing the Result of | A Large ‘ \ new larg line of a res Boston, Mas iF handle worl ] inges i rom the largest wa illustr ] S1Z¢ in wel, The leverag the eu r < 25 t 1 pressurt tons, it stated, is thus easily able. When the lever in the position shown in the ac- companying en- graving, the rack or ram can be easily moved up o down by the hand wheel. The knee is operated by a crank, as shown, which revolves al screw by a pair of itre gears This screw runs in nut in tl base and the design such } if the knee in be low- ered t its ex- treme position without the screw reaching the floor, making it nus possible to place the p utting the floor for the to the frame by two studs nd locked so that the kne« f the els at screw is tightening t t knee Size of Crank-Operated Arbor Press a thet o_o wy a> Mae de : + es Ce ee Three Years of Accident Prevention Results of Efforts to Eliminate Accidents to Employees by the Eastman Kodak Com- pany—Some of the Safeguards in Operation The results obtained vent Eastman ke perience presented herewith show the successful Statist! by the continuous campaign waged to pre to employees in the five factories of th ompany in Rochester, N. \ a strong justification of the accidents dak ( Phe cx works’ committec The Iron . lge illustrations o! to which reference was made in Also reproduced oI satety October 24, 1912. are several of the devices to which attention had not previously been given, used in accident prevention in the factories of the « pany. As will be seen from the table giving the number of accidents occurring in each of the five factories in the years 1910, I91I and 1912, their number has been cut down materially when the greatly increased number ot workers is taken into consideration, there having been 1823 more employees in 1912 than in 1910. In 1910 with th