The Iron Age 1915-02-11: Vol 95 Iss 6

ssHULUHENUDNDENUEAYUETEGUUOUEOOUOUGTENUCUOOGOOOONDUODEAUEDENGOUUENONOOENURUEOLOGOGUENUEEOEGOCAUEGLENUONLUNUEAGEAOUODNNLONUEOUEODGNENAEESLULUENUGOLOOESGDSNEOOGRUENUUALEOUDOOERLEOUCOGQUONDOUOAUANENEROGEGUEQUGUUEGUENEONEAAAOCUULOOU US LEN ene nu ceLgnUeNnenrenganaegenneaneaneneegten ge see errr nccnncnnncncnncnnnnnnnnnnnnnnnnneeeeeeeeeeeeeeeeeeeeeeeeeeeeeeereeeeeee ee —EE = _ | CORDUPLARAUAAEDEDE DERI MELLEL LLL TTT MEUAUUADUSOUOUUERAROUEOOOAOEONOEOROODOEOROEOROOONOROORORD =| CUAUEALELEREODEDEGSEAEEE Ls Established 1855 New York, February 11, 1915 Vol. 95: No. 6 Labor Saving Devices in Texas Foundry Merry-Go-Round Slag Crane—Charging Machine for Cupola—Practice Followed in a Straight Floor Carwheel Plant When the plant of the Dickson Car Wheel Com-_ devices have been added, probably the most promi pany was built at Houston, Texas, in 1908, it em- nent of which are a slag crane and a charging ma bodied a number of improvements over the methods’ chine for the cupola, both of which were designed n vogue at that time. The straight floor system and erected in the company’s own shop. was employed and the floors not only had capacity The slag crane or merry-go-round, as it is for a greater number of wheels but the distance termed in the shop, employs a piece of heavy pipe between centers of the floors was also more. Prior with bearings at the top and bottom. To this pipe Consisting of a Piece of Pipe with 16 I-Beam Arms Each of Which Supports Conical Cast-Iron Pot or Saddlk e erection of this plant, the maximum distance are fastened 16 horizontal arms, made of |-beams vetween floor centers of this type, it is understood, and reinforced by rods running from the end of Was 4 ft t if} oro + he f , and the capacity of floors was 20 wheels. each arm to a casting located near the top of the plant, however, the center distance was in- pipe. On the end of each arm is hung a cast-iron to 12 ft. and the capacity of the floors was pot or ladle of conical shape, located so as to per- ught up to 25 wheels each. A number of minor mit each pot to be swung under the end of the hanges and improvements have been made since slag spout in turn to receive its load of molten indry was started and several labor saving slag. The cupola practice of the company is to per- 341 tr res j Case A Cupola Charging Machine Which Was mit the iron to run out of the slag spout before each tap, and it has been found that iron runs through slag to the bottom of the pot, even though two taps have to be made before the ladle is filled. It forms a solid mass, which is easily knocked off when the pot is dumped after cooling. The slag itself is solid and clean and contains no particles of iron except that which forms in the bottom of the ladle. The crane, which turns easily, is oper- ated by the cupola tender during the heat, a second ladle being pulled into position as soon as the one under the spout is filled. A small pneumatic hoist fastened to the wall with an iron cable running over a sheave on the ceiling is used to dump the contents of the ladles into a yard truck after cool- ing. This work is done by one man and the crane has been found a great labor saver over the method of handling slag formerly employed. The charging machine, which is worked by an air cylinder of large diameter, was designed and erected in the company’s own shop. The entire frame of the charging machine and its load is lifted by the cylinder to the desired hight, and the frame or table stops at this point. It is then slowly tipped at an angle, throwing the contents of the charging buggy into the cupola. Counterbal ance weights are employed to offset the weight of the frame, so that practically the only load on the cylinder is that of the buggy and its contents. At the time the cupola was built it was one of the largest, the inside diameter being 102 in. The blast is supplied. by a high-pressure blower and is controlled by an automatic registering pressure re corder. The entire foundry yard is laid out with a com plete system of industrial tracks so that all mate rial is brought to one central point, loaded o1 steel charging buggies before being brought to the charging platform. The charging floor is served by two 3-ton elevators, each of which has tracks on which the various charging buggies are raised to the charging floor from the ground level. There are four main tracks and turntables on the charg- ing floor, with two additional storage tracks. The metal is tapped into a 10-ton electrically-operated ladle, controlled from a stationary pulpit at the 342 THE IRON AGE February 11. |9)- esigned and Built in the Company's Shop side of the building. Overhead trackage is used t a great extent and the iron is taken from the large ladle in smaller ones by this overhead system and delivered to the molders located on the different floors. Pneumatic hoists, which have the cylinder and valves attached to the wall opposite the cupola so as to be out of the way of the dust and dirt of the foundry floors, are used to raise and lower thé ladles and the wheels. A system of rope trans- mission controls the movement of the hoist, so that the molder can stand at any point of his floor and control all the operations. After the wheel has cooled sufficiently it shaken out and is gripped on the side by tongs hanging from the hoist, the loose sand that does not fall away when the wheel is raised being knocked off with a sledge. The wheels are ther carried across the floor to the hot metal buggies, the movement of which is controlled by the same operator that regulates the movement of the ladle These buggies deliver the wheels to the pitting cranes, but prior to their being lifted from the buggies, the heads are knocked off and the coré centers knocked out. Annealing pits to the number of 120 are locate at one end of the foundry, and are spaced 52 1! on centers. They are served by four cranes which also remove the wheels after they have been thor- oughly annealed and deliver them to the cleaning department, which is located in the same relativ position to the foundry floor as an average ©@ floor bears to the road bed. After being cleaned the wheels are rolled directly into the cars for ship ment. The plant has a daily capacity of 400 wheels and is divided into 16 floors, each having provisi0! for 26 chills. The main building, which is of whit brick and steel construction, measures 135 x 264 ft. In common with all the other buildings, it 54° a terra cotta tile roof and practically continuous rows of high windows on all four sides. The cupo room, 30 x 72 ft., adjoins the plant at the center of one side. The core department is housed i” ‘ separate building, measuring 36 x 100 ft., and connected with the foundry by industrial tracks Core and sand storage sheds adjoin the core bu Id t 1- February 11, 1915 g i the sand is unloaded directly into the stor- we m, thus eliminating extra handling. The als npressors, blowers, etc., are motor driven, housed in a power house measuring 40 x ey Heating and Ventilating Factories From a committee report presented before a recent meeting in New York of the American So- ety of Heating and Ventilating Engineers by f. L. Hogan, chairman, the following notes have been taken: The industrial building of to-day is heated by one of three methods: direct steam; direct hot water; or by forced circulation of air which is heated by heaters, supplied by steam or hot water and centrally located. The greater num- her are heated by direct steam because it can be installed by any steam fitter and frequently the superintendent with his millwright and other help can do the work. They know more about this sys- tem than any other and are not keen for methods they do not fully understand. In certain lines of industry where moisture from some drying process or otherwise, must be absorbed by the air within, the blower or hot- = ALN i, ‘ ce (Oe | ak ‘ ak | ‘ Ce Se .. ‘ ‘ h- “a oe } ¥ ¢ - ‘ -—T s? ‘8 , : ‘ 1 " i ' ‘ 4 ‘ i P rt fw 21-4 oo ee ees Natural Air Currents When Heating Method Mini Draftiness by Keeping Exposed Surfaces Warn ast system is most efficient because by means it the moisture is removed by the circulation { the air that heats the building. Also in build- ngs where smoke or gases must be removed, the torced circulation is desirable. In order to study the movement of air currents is assume a building as illustrated in Fig. 1. ‘his could be used as a foundry, machine shop, arshop, structural steel plant or forge. The side walls are of concrete blocks and glass set in steel sash; the frame work is of steel, the floor f concrete; the roof of reinforced concrete with mposition roofing cover. The natural air cur- rents in the structure would be as indicated by mall arrows in the illustration. This movement s caused by the difference in temperature of the ir within; that coming in contact with the cold monitors and outside wall becomes cooler heavier, and consequently falls. The warmer ontact with the floor rises and circulation set up tending to equalize the inside and out- e temperature. "rom a heating standpoint we are interested strata covering the lower 8 ft. of the interior; nust be kept comfortable and fairly uniform. be accomplished by creating currents in pper portion of the building so that no cold il reach the floor, taking care of the out- alls by radiant heat from radiators placed ind out from the walls, or below and on or e walls, and taking care of the lower strata by heat from the hot strata above. This | is practically keeping the exposed surface structure warm so that there will be no cold ts in the working portion. a THE IRON AGE 343 In structures of this kind where the peak of the roof is 40 or 50 ft. above the floor and a working temperature of 65 deg. near the floor is maintained, the temperature near the peak will be approximately 90 deg. While it is apparent that by keeping the exposed surface warm or keep ing a lay er of warm air next to it, that the inside of the structure will be warm, nevertheless, it would seem as though it would be better to keep the working strata warm and do so in such a wa) as to prevent the cold currents from entering this strata. This would reduce the temperature of the air in proximity to the cold exposed surface and decrease the heat loss from the building. In order to produce results like this it would be necessary to continually mix hot air with the air in the working strata in order to maintain a working temperature. In this system the hotter portion of the building is the lower, and the radiant heat is up and toward the exposed sur- faces. Air mixes or diffuses very rapidly and sufficient air must be circulated in the lower working strata to maintain a uniform temperature Such a system is what is aimed at with hot blast and what is frequently obtained. It is surprising how well and with what a little heating surface and consequent small steam consumption one can = St ae «x i >} <T rl >. 1 > > = Fhe a a> in A rash: filly = APS ‘ veh ; f . - OF — an e s * - . » 7 iny ° “ . ‘ Werks ¥ ‘ - ‘ a is 4,7 r ; boy 29, , — ' »o 4 . ’ Ga wy 2 Dep IR z 2/5 Fig rt \ f ts Whe Hot A I A Worki st heat a building in this way. A distributing sys- tem which would approximate these results is in dicated in Fig. 2. Frequently it is attempted to heat a structure like this with a hot blast system by simply having outlets in the mains and no drop pipes. In this case it would be necessary to direct air toward the outside walls and downward at various angles in order to produce a distribution and the heating would revert to a condition where one would have to warm or produce a layer of warm air next to the exposed surfaces and in this it would be the same as a direct radiation system. The exposure in this case would be larger and the usual method of figuring would not suffice. One feature of hot-blast heating that is par- ticularly apparent to us is that most contractors do not have the confidence in their ability to make the installation a success that they do with direct radiation. As a result, very often direct radiation is resorted to where a fan system would be more satisfactory and economical. We think this is due possibly to the feeling in general that a fan sys- tem is more or less guesswork. Nothing is further from the truth, for the science of hot-blast heat ing has been developed until absolute results can be guaranteed by the leading concerns. The Delaware Foundry & Machine Company, Veta ware, Ohio, has completed its organization by the elec tion of C. C. Steadman, president; F. M. Bauereis, vice-president; H. M. Bing, treasurer; and Robert Greer secretary and manager. The company expects to have its new foundry ready for operation in about a month. tt a bs > a ~~ AO OP ee ee eae Se oe preter ens a So ee = “¢ Jive Seletes hes aaa « aa — SN, serie tama 8 - - Locating an Executive in the Factory Employing Telephones and Extension Sig- nal Bells Instead of Messengers to Find Men Frequently Absent from Their Desks BY H. A. The methods formerly used in locating Mr. Jones or Mr. Smith by messengers, hurrying from one department to another, interrupting workmen and often not finding the party wanted until the need of his presence had passed, have become prac- tically back numbers. To those who have become accustomed to the newer methods, the former seems as antiquated as the stage coach or the horse cars. Every day more and more factories, mills and de- partment stores are taking a big step forward by installing telephone switchboards, in charge of com- petent operators of either sex. These phones are usually located in the various department offices, Car E.Gas ALLEY Stable E. GayAtLey Machine | TI Shop /Office “ Ti; Foneman's Office (/2F7) Stock Room (2°FI) RUSSELL*- ioceniteiideitescesiediimas cate at any moment of the day. To each of these gi was given a separate signal, such as two rings- three rings, four rings, then for the others, two-two, three-two and four-two. These signals are easily remembered and a larger number than we use cap be readily handled by the operator and easily dis- tinguished from each other in the factory. Within a very short time the operator will learn how to give clear, distinct signals. When the operator calls any shop-phone from which an extension line runs, the bell at the phone and those on the exten- sion line ring simultaneously. If the party wanted is not close to the phone the extension bells wil! hop Extension = OH—> nter re sf + is ee Y N. Courr AtLey Founalry Foreman's Office ‘ 2 B22, “ Engine Dept 1 ngine Ve B 4; % 722 1 9 P T T24(Sheet lronShop) 472, £ Engine Dept Too! R, Foréman's Pfhice ila “Stock Room Diagram of a Factory Showing the Arrangement of Telephones and Signal Bells Employed in a Large Manufacturing P| [Tc Locate Men Who Are Net Always at Their Desks. in the Drawing the First-Floor Partitions Are Indicated by Dott Lines and Those on the Second Floor by Solid Lines. The Numbers Are Those of the Extension Lines from the Teleph Switchboard and Correspond to the Instruments Respectively, Jacks Thereon, the Prefixes B and T Being Used To Denote Signal Bells and Telephone While the Small Inferior Numeral Following Designates the Floor on Which the Bell or Telephone is Located but there are usually certain strategic points be- tween departments, where the phones may be placed to advantage. The location of all phones should be determined in consultation with the repre- sentative of the telephone company. About a year ago we installed a switchboard controlling 17 factory department telephones and 7 in the main office, or 24 in all. We, however, went a little further than this. From the majority of the factory department telephones we ran extension wires to signal bells. On the majority of these extension lines we only required one bell, but on one line we have two and on another line three sig- nal bells. The distances that these bells are lo- cated from their respective phones vary from 20 to 100 ft. We found that there were six men in the office and works whom it might be necessary to lo- *A. B. Farquhar Company, York, Pa. attract his attention, within a radius varying fron 20 ft. in a boiler shop to several hundred feet 1 other departments. When the noise is extreme, 4s in a boiler shop, a signal light can be used if dt sired. When a single ring is given at any of the phones the person nearest to the phone should answer, but when any of the specific calls are given only the person whose signal is given should answer. B) insisting that this rule be followed there is abs0- lutely no time wasted, by a number of people 10 various departments answering calls that are 1) tended for only one particular party. To enumerate all of the various time saving plans that have come up would make an extended list, but a few of these may be of assistance to others. Office men can be located in the various departments for long distance calls, which can often be answered from the neares- 344 February 11, 1915 hus saving the time required to come to the d return and doing away with the possibil- eping others from proceeding with the mat- ter and also. Salesmen can be located and sum- » the office to meet customers. Notices of can be sent out by the operator. When eetings may occur only once in a month, the can be of valuable service, in seeing that who is to be present receives the notice in For one series of our shop meetings the nd ials are notified not only shortly before the hour, but the day before also. This gives chance to have their questions or sugges- ns thought out and not only increases the value neeting, but shortens the length of time re- iired. Foremen can send to or receive informa- n from each other, from their own department or er they may be at the time. The operator ites the party, then notifies the caller and thus saves the time of both, or the operator can take a memorandum of the message, transmit it at the npportunity and then transmit the answer if required. Remember that the more the oper- s to do, the more time is being saved by lepartment heads. signal system has worked out splendidly. As our operator can locate individuals in less i minute. In fact, the signal can be sent over le plant, which covers four city blocks, in a minute. There are several concerns e an electrical call system that rings all ultaneously. We have found, however, that ir operator has not had the slightest trouble in ng the separate calls. Before the operator ves at the end of the day two of the phones are ected with the telephone exchange and these t disconnected until the operator returns in rning. One of the phones so connected per- the factory watchman being in close touch he city fire department, police headquarters, One of the essential details is to keep the regular r or a competent substitute at the switch- at all times during the working hours. By ng so the very purpose for which the switch- was installed, namely, to save the time of whom the minutes count, will be defeated. perator should have other work, that is, work vill not take her away from the switchboard, s circular work, addressing, card index or ther work, which can be dropped instantly sumed later without losing the thread of con- secutive thought. A desk can be placed at right ingles to the switchboard and by means of a re- chair the operator can swing from one desk e other without moving the chair or arising ery factory there are certain bells that are > or less constant use, such as elevator bells. re, the extension bells should, as far as have a different tone or sound from the factory bells. Signal bells should be placed from electric motors as may be consistent heir location value. The hum of the motor seems to strike the same keynote as the | either absorbs the bell sound or drowns same trouble has also been found when the ere placed too close to the circular saws in dworking department. In one or two loca- was necessary to construct sound proof the boiler shop being one of these. Tongued ooved boards were used, double thickness, iilding paper between. The door should fit p Inside there should be a drop light, also ir telephone and memorandum pad. The THE IRON AGE 845 desk type of phone seems to answer all purposes very well, although the wall type will be installed if desired. A small size outline map of the various build- ings and departments, showing the location of tele- phones and extension bells, would prove to be a big help to a new operator, especially if the operator is a girl, as the chances are small of her actually be- coming acquainted with the physical layout of the factory and the relation of one department to an other. A map similar to the diagram shown would be sufficient. Changes can, of course, be made or additional equipment added from time to time, if the need arises after the system has been in oper ation for a period. Referring to the diagram it will be noticed that the three signal bells branching from telephone No. 20 are not all on the same floor, two are on the second floor and one on the first or ground floor Telephone No. 18 is on the third floor of the ware house, while the signal bell is on the second floor. Several considerable areas not covered by the tele phones or signal bells will be seen. These are out side of the usual traffic routes and are mostly for storage. Consequently there is very little noise and the bells on the other phones will send their signal through these spaces. A special call for the factory fire department can be added to the signal list if desired. We have found an emergency call list of considerable value. This includes local fire department, a list of doctors, police headquarters, ambulance, etc. sy having this list typewritten and in plain view of the oper ator many valuable minutes are saved at times when they count most. Scrap Workmen’s Compensation in New York The National Association of Waste Material Deal ers, 170 Summer street, Boston, Mass., has issued a statement regarding the work of its Compensation In- surance Investigating Committee, which is in part as follows: The New York State Insurance Department com- bined dealing in junk, scrap iron and scrap metal under one rate of $13.28. The recommendations of the com mittee to the department were that this classification be divided, due to the fact of a greater difference in the method of handling scrap metal than of handling scrap iron, and the hazard in each one of these trades differed. After considerable correspondence the recom mendations were granted, and the new classification was made called “Metal Scrap Dealers,” covering firms engaged in collecting, smelting, refining and shipping metals, whose rate of insurance is to be $3.24 per $100 payroll. metal business are now assessed at $2.20. Firms en- gaged in the handling of both scrap iron and metals are still to be continued under the junk or scrap iron rate of $13.28. The department maintains that the handling of scrap iron is very hazardous and that records show that the rate of $13.28 is equitable. Records also show that the men engaged in scrap metals are sometimes used in the scrap iron department. Con- cerns dealing in rags, paper stock, scrap iron and metals, that is, general junk dealers, can secure a division of their payroll, so that their rag sorters and handlers can come under the rate of old rags at $6.48 and those that handle scrap iron under the junk or scrap iron rate of $13.28, but this division can only be secured by personal application to the New York State Insurance Department, and dealers must show an abso- lute division of employees. Drivers and helpers engaged in the scrap A special meeting of the American Society of Mechanical Engineers will be held in San Francisco in September. This is in addition to the regular spring meeting, which will be held at Buffalo in June. " » ie 3, ae See EGET at BS BRE SE 5 ERE a GEE RS Mme Ts a2 - te FG. ¢ - 7 Sound Steel Ingots and Rails’ Comparison of Ingots Poured by the Hadfield and American Methods and the Rails Rolled from Each BY G. K. BURGESS AND SIR ROBERT HADFIELD It was thought by Director Stratton, of the United States Bureau of Standards, and ourselves to be of sufficient interest and importance to com- pare the properties of rails rolled in one mill ac- cording to American practice, from several types of ingot of substantially the same chemical composi- tion but cast by several processes; and to compare in considerable detail the properties of an ingot Figs. 1 and 2—Split Hadfield (Left) and Split American In- got, Showing Location of Drillings and Condition of the In- terior manufactured by the Hadfield special-feeding proc- ess and one of the usual type for rolling into rails. We are greatly indebted to F. W. Wood, presi- dent of the Maryland Steel Company, who made this investigation possible by kindly placing his rail mill at our disposal; and he and his associates at Spar- rows Point did everything possible to make the ex- periment a success, including the execution of sev- eral of the tests and analyses. CLASSIFICATION AND MANUFACTURE OF INGOTS Of the ingots used in this investigation, eight were made in Sheffield and furnished by Sir Robert Hadfield, and one was made and furnished by an American steel company, as a comparison ingot, and was supposed to represent the usual type of ingot from which rails are made. *From a paper to be read at the New York meeting of the American Institute of Mining Engineers, February 15, and published jn the February Bulletin of the Society, 346 The characteristics of the ingots are given jy Table 1. Ingots 1, 2, 3 and 4 were cast large eng up and fed by the Hadfield method in the usya) manner with charcoal and blast continued unti! the molten steel had set on the top of the head, varying from 20 to 40 min. To ingots 1, 2 and 4 was added 0.1 per cent. aluminum, and to the nickel-chrome ingot, No. 3, 0.125 per cent. For sake of compari- son, there were also included two ingots, Nos. 8 ang 9, cast with the small end up and fed by the Had. field process; three ingots not fed, two of piping steel, Nos. 6 and 10, and one of rising or “unsound” steel, No. 7. The Hadfield ingot No. 1 and the American comparison ingot, No. 10, were cut up for examination as to segregation, blowholes and pip. ing, while the others were rolled into rails. It was expected that ingots Nos. 2, 3 and 4 would give rails Table 1.— ‘lassificttion of Ingots Size, Wat., Method of Type of CHEMICAL ANALYsis No. in. Ib. casting ‘steel C Mn 8 ) 1 18 5,964 Hadfield, large end up. Ordinary rail steel. 0.59 0.97 0.041 0.031 0.21 2 18 6,006 Hadfield, large end up. Ordinary rail steel. 0.55 0.96 0.043 0.029 0.12 3 18 5,900 Hadfield, large end up. Nickel-chromium steel. 0.25 0.38 Ni3.70 Cr 147 0.19 { 18 5,850 Hadfield, large end up. Ordinary rail steel. 0.56 0.92 S 0.040 P 0.035 0.19 18 5,200 Ordinary, small end up. Ordinary rail steel which pipes, not fed. 0.56 0.94 0.060 0.05102 7 18 5,100 Ordinary, small end up Ordinary rail steel of rising or boil- ing nature, not fed. 0.57 0.95 0.080 0.04502 8 18 5,700 Hadfield, small end up. Ordinary rail steel. 0.58 0.96 0.070 0.051 0.2 9 18 5,700 Hadfield, small end up. Ordinary rail steel. 0.59 0.96 0.054 0.0400. 10 #19 American, ordi- nary manner, small end up. Ordinary rail steel. 0.46 0.94 0.05 of a uniform quality throughout nearly the whole length of the ingot, and that No. 1, which was selected by chance from the specially fed ingots cast large end up, would show a uniform, sound structure throughout. Previous experience has shown that ingots of the type of Nos. 8 and 9, cast by the Had- field process with small end up, would be expected to be less satisfactory than the Hadfield type rep- resented by Nos. 2, 3 and 4, cast with large end up. The former sometimes show a tendency to develop 4 pipe at the lower end. Ingot No. 6 would be eX: pected to show piping and segregation, and No. | segregation and unsoundness; for both of these ir gots a much greater waste would be expected than for the specially fed ingots. EXAMINATION OF INGOTS At the Pittsburgh laboratory of the Bureau © Standards two of the ingots were sawed in halves —Hadfield No. 1, of the specially fed type cast large end up, and the comparison ingot, No. 10, from 42 American mill. Figs. 1 and 2 are photographs © the two ingots showing the location of drillings and a comparison of their interiors. In Figs. 3, 4 and 5 respectively, are shown the segregation of carbon, phosphorus and sulphur for each of the ingots. 4 similar survey was also made for manganese, With February 11, 1915 lerable segregation of this element in either [it is evident that there is freedom from ble segregation over 95 per cent. or more of THE IRON AGE 34, misunderstanding of instructions and unfamiliarity with this type of ingot, the top bloom crops of the first two rolled, specially fed Hadfield ingots Nos. Table 2. Rolling and Inspect 5 « 4 - ) at S hr. 9 min 8 hr. 40 min 8 hr. 55 m nit air 10 br. 45 mix g mill 1 min. 40 sex 1 min. 40 sec 2s 4) sex 40 sex rature of ingot in blo ming 1,100 1,115 1.110 11 5 14 1,125 mill to hot saw 3 min. 50 sec 4 min. 10 sec min. 23 sec 4 ee 0 sec min. 22 sex ture first rail bar at hot saw 950 deg 960 deg 970 deg 70 de g NO 980 deg rature second rail bar at hot 945 deg 900! deg 150 deg M5 de 165 deg per cent. of ingot 4.2 5.& 7.8 12.9 43 s, per cent 7.2 7.4 9.7 14 ‘ 5.3 er cent* 1.3 2.7 1.9 2 2.5 got available for rails 91.5 sv.9 S84 82.4 ) s ”» 2 tage of firsts 77.2 77.1 s2.5 4 5, 5 mnds8 22.8 22.9 47 , i ts s rap® 0 0 0 ‘7 78 Special feed, la " \r ar ‘ ‘ oming tc saw. *Has been corrected as explained : we ¢ all are reheated 5T wo rails, ( and D, from middle of ingot were s:rapped for mechanica . ‘ : Hadfield ingot, which is also entirely free from y or blowholes. The comparison ingot, if rolled to rails, should have about a 50 per cent. discard. MANUFACTURE OF RAILS [he ingots were charged into the soaking pits, which had been allowed to cool considerably on Sun- lay evening and rolled Monday, April 13, 1914, at 8 into 100-lb. P. S. section rails, the seven ngots being interpolated among other ingots. In the Maryland mill the rolling from ingot to finished rail is a continuous process without reheating of the looms. In Table 2 are shown some of the char- acteristics of the rolling. Apparently through a 15 AS HADFIELD HADFIELD nd 5 phur in Percentages. The Left-hand Pair Shows the © i the Right-hand Pair the Sulphur Comparison. The Was 59 In., and of th —Diagram Sections of Hadfield and American Ingots Showing Segregatior 2 and 3, were excessive, at least double what was necessary to carry the blooms through the rail mill. The other Hadfield and comparison ingots were sheared as instructed. The A rail was made the short rail, usually 6 to 10 ft. long, to be examined as to soundness. The drop-test specimen was cut next the bottom of this short A rail, a 13-in. specimen for tensile tests from the head of the C rail, and 3-in. pieces for chemical, metallographic, and hard- ness tests from the heads of the A, B and C rails. TESTS OF RAILS The hardness tests, with the exception of those on rails with a pipe or seam (from ingots Nos. 6, Comparison of Carbon, Phosphor- arbon Comparison; the Central Pair, the Phosphorus Com- Height of the Hadfield Ingot it Which Drillings Were Made e American, 63 l SS ee = = “3, + ce ae . oe 348 THE iRON AGE February 11, 19); O and M, positions of samples for chemical analysis. 1-8, positions of hardness tests. Fig. 6 Rail Section Showing Locations of Samples 8, 9), show a high value of hardness numeral for position 5, Fig. 6, in the A rail. Otherwise the hardness is quite uniform over the sections, and from one rail to another, except, of course, for the nickel-chromium, No. 3. The results obtained by the Maryland Steel Com- pany for the drop tests are shown in Table 3; of in- spection in Table 2 and physical tests in Table 4. The O and M analyses for all the elements and for the A, B and C rails will be given later in a complete paper. For all the Hadfield ingots cast large end up the rail macrostructure is very uniform even over the web for the front end of an A rail. Rails from both the Hadfield ingots cast small end up show a very different macrostructure from the first group. It is interesting to note that the pipe of ingot No. 6 cast in the ordinary way is not accompanied by any con- siderable segregation. This pipe extends well into the C rail even after a top bloom discard of 13 per cent., confirming the characteristics of the split com- parison piping ingot No. 10. From the several tables of tests and from metal- lographic examination it is found that the percent- age of ingot available for sound rails of uniform homogeneous structure is 91, 90 and 88 respectively for the specially fed ingots cast large end up, Nos. 2, 3 and 4, as compared with much less percentages of sound ingot metal usually available. GENERAL CONCLUSIONS In all, nine ingots were used in this investiga- tion; eight furnished by Sir Robert Hadfield, all but one of which had approximately the same chemical composition. ) st R 100-Ib. P. S. seetion; 3-ft. supy ts; Ww ht of tup, 2.000 Ib.: fa 15 Ingot Per ELONGATION ON BASE No. Blow set Istin. 2ndim. 3rdin. 4thin. 5th in. 6th in. Total 9 First 7% 0.03 0.04 0.05 0.05 0.04 0.08 6.24 3 First 0.8 0.08 0.04 0 05 0.05 0.04 0.03 §. 24 4 First 1.1 0.02 0.04 0.05 0.05 0.04 0.02 6.22 6 First, pipe at 1.0 0.02 0.03 0.04 0.04 0.03 0.02 6.18 fracture 7 First 1.0 0.02 0.03 0.04 0.04 0.04 0.03 6.20 Second 1.9 0.038 0.04 0.0 0.06 0.06 0.06 6.31 8 First, pipe at 1.0 0.02 0.04 0.05 0.05 0.03 0.03 6.22 fracture. 9 First 10 0.072 0 02 05 0.05 0.04 0.03 6.21 The examination of the split ingots shows th great superiority of casting large end up : ; ing by the Hadfield special process, such ingot being physically sound and uniform throughoyt ona practically free from chemical segregation L Teed. aig Table 4.—Results of Tensile Tests Cut from Center of Head Yield point!, Ultimate Elongation, Ingot lb. per strength, lb. per cent. Reduction No sq. in. per sq. in. in 8 in of area > 98 , 700 177 ,300 9.75 27.3 100 sil} 2 69, 100 119, 600 14.00 25.2 10 silk 69,000 118, 600 12.00 26.0 10 silk 6 69 , 300 119,300 14.00 27.3 10 silk 7 67,000 120, 600 11.75 23.6 10 silk 8 69 , 000 119, 600 12.00 20.4 10 silk 9 68, 000 119,000 1.75 20.4 10 silk ‘Yield point found by use of dividers and running the machine bac} was found where there was a permanent stretch The examination of the rails shows that for 4 gots cast by the Hadfield process, those cast jarg, end up will give rails of uniform quality free frop flaws of all kinds; those cast small end up may show a soft region in the web of the A rail but are o.herwise sound. Those cast in the ordinary map- ner from piping or otherwise unsound steel may or may not give sound rails, depending upon the con- dition of the steel. In addition to the certainty of producing all sound rails by the special-feeding process from in- go-s cast large end up, there is a great saving in metal and a consequent increase in percentage of sound ingot available for rails—in these experi- ments an average of 90 per cent. for ingots Nos. 2, 3, 4, as compared with about 50 per cent. for the piping ingot and an uncertain amount from the rising type. The usual physical and chemical tests do not appear to give an adequate measure of the quality of rails. For example, the results of the tensile and drop tests and chemical analyses would not separate the sound from all the unsound rails here examined. The question may be asked, is it not worth while to use, in the manufacture of rails, only sound steel which is cast and rolled in such a manner as to make practically every rail a sound and safe one? We believe this can be done without excessive cost. Matthiessen & Hegeler Improvements The Matthiessen & Hegeler Zinc Company, 1a Salle, Ill, will start another furnace within a few days, which will give the plant a total equipment 0 over 6000 retorts. The first unit of a ribbon mill wi! also be started in 30 days, as the melting and re- heating furnaces for it will be completed by that time. The company also recently authorized a 50 per cent. extension to its rolling mill, to consist of one pair 0! roughing and four pairs of finishing rolls and acces sories, the building to cover about 23,000 sq. ft., and to be of the same construction as the present rolling mi! building. The method of driving the rolls has not ye' been decided, but the practice of steel mills and 21 mills, both in this country and abroad, is being car fully investigated before letting the contract for the machinery. A contract for a complete overhead crane and monorail system for the rolling mill was let som time ago, and this should be in operation before April 1. The Matthiessen & Hegeler Zinc Company has also under consideration plans for a fireproof building ‘ accommodate the machine shop, blacksmith shop, ™" shop, carpenter and box shop, car repair shop, and store, contracts for which will probably be let in the near future. Following this will be the installation of a complete and modern equipment for handling and storing hard coal screenings. pruary 11, 1915 Test of New Stoker and Boiler Baffle 1al meeting of the mechanical section of the Society of Western Pennsylvania was held in the Oliver Building, Pittsburgh, on Feb- J. A. McCulloch, engineer of the National ny, was elected chairman; Edward D. Le- Philadelphia Company, vice-chairman, and rt, Karl Nibecker and D. A. Polhemus were : ectors. John A. Hunter, steam engineer of \ an Sheet & Tin Plate Company, read a pa- BENJAMIN F. AFFLECK The New nd the Retiring Presidents of ‘Tests on a New Type of Chain Grate Stoker | New Method of Baffling Stirling Boilers.” I» his pa- Hunter stated that there had recentlyybeen in- it the Vandergrift works of the Ameriean Sheet Plate Company, a combination of a compara- type of chain grate stokers and of Stirling th a new method of baffling. The installation of seven class M-22 Stirling boilers nominally 600 hp., containing 6032 sq. ft. of water heat- g surface and 396 sq. ft. of superheating surface. An lual unlined steel stack 72 in. in diameter and 150 gh above the breeching produces the draft. Each provided with one type L Green Engineering stoker, 10 ft. 6 in. wide by 12 ft. long, con- 126 sq. ft. of chain surface. The boilers are with soot blowers having stationary and ro- les. The water back designed by the Babcock W « Company has two separate water boxes p!aced tly over the other and each is connected to drum and front steam drum, insuring’ positive to each box. tests were undertaken primarily to determine arantees made by the Green Engineering Com- the stokers could be met. These guarantees combined efficiency of boiler and grate of 74 vhen the boiler was operated between 125 and nt. of rated capacity, and also an overload of 100 per cent. The tests were conducted ac- to the code of the American Society of Me- Engineers. Mr. Hunter presented a table, that efficiencies of from 67.7 to 79.8 per cent. ‘ities of between 74 and 195 per cent. of the ere obtained. sten before the war was selling for about 67c. It now commands about $1.35 per Ib. for im- nédiate shipment. tl THE IRON AGE 349 E. M. HAGAR RESIGNED Benjamin F. Affleck now President of the Uni- versal Portland Cement Company Edward M. Hagar resigned and Benjamin F. Affleck was appointed president and chairman of the Universal Portland Cement Company at a meeting of the board of directors held at Chicago, February 3 Mr. Hagar retires to assume the presidency of a new EDWARD M. HAGAR . } }* ’ ersa or cs company which he is forming acquire a chain of Portland cement plants serving a large part of the United States. His office and those of the new com pany will continue to be at 208 South LaSalle street, Chicago. Mr. Hagar has been at the head of the Universal Portland Cement Company since its organization in 1900 and under his direction its business has grown with conspicuous success from a production of 32,000 bbl. in 1900 to a present plant capacity of 13,000,000 bbl. annually. For several years the Universal Port land Cement Company, a subsidiary of the United States Steel Corporation, has been the largest shipper of Port land cement in the world. Mr. Hagar was for two years president of the Association of American Port land Cement Manufacturers and was the organizer of the Cement Products Exhibition Company, which has held annual industrial exhibitions since 1907. A gradu ate of the Massachusetts Institute of Technology in 1893 and of Cornell Univer ity i L894, Mr. Hagar organized and conducted the business of Edward M. Hagar & Co., manufacturers’ representatives in machinery lines in Chicago, prior to his with the cement industry Mr. Affleck’s connection with the cement industry has been exclusively with the Universal Portland Cement Company, of which he has been general connection manager of sales since it organiZatior The Sharon Foundry Company, Sharon, Pa., held its annual meeting recently and re-elected officers for 1915 as follows: W. W. Shilling, president; Thomas Kennedy, secretary and treasurer; directors, W. W. Shilling, Thomas Kennedy, Harry Forker, J. P. Whitla, W. L. Wallis, George L. Collord, Joseph Riddell, J. E. Wood and Robert Mcintyre. RD ee =. 350 THE IRON AGE A 1000-Ton Hydraulic Forcing Press The Treadwell Engineering Company, Easton, Pa., has recently completed what is believed to be one of the largest hydraulic forcing presses ever built in this country. It was especially designed February 11, 19); New Suspended Tool with Flexible Shas, The Stow Mfg. Company, Binghamton, ° recently brought out two new types of flex tools. One of these, which is that illustr direct-connected drilling, buffing and grin an 5 Gs + } ‘ 4 sna! 18 A Recently Completed Hydraulic Forcing Press Capable of Exerting a Pressure of 1000 Tons for the Cuban-American Sugar Company for fore- ing sugar mill rolls off and on their shafts in its machine shops at Chaparra, Cuba. The press has a normal rating of 1000 tons, but is equipped with a gauge for recording pressures up to double that amount. The plunger is 20 in. in diameter, is packed with outside leather cuffs, and has_ three forcing speeds of 20.2, 0.4 and 0.6 in. per min. A triplex oil pump, driven by a 5-hp. motor with independent plunger control constitutes the pumping outfit. The valves for the pump are located in a _ separate block from the plunger, and are connected to the plunger cham- bers by seamless copper tubes. This arrangement enables the three plungers to be controlled by a single lever arranged so as to operate one, two or all three plungers and thus provide the required variation in the forcing speed. The gauge has a separate check which is relied upon to prevent damage to the recording hands when returning to zero after the pressure in the plunger cylinder is relieved. The pressure lines are made of seam- less copper tubes, and have a pressure safety valve and a by-pass valve for returning the oil from the press cylinder to the oil storage tank located in the base. The tension bars, which measure 5 x 15 in. in section, are 30 ft. long, and were especially rolled for this press. The guayule rubber industry has been revived on a considerable scale in the Torreon district of Mexico. It is authoritatively stated that since November 1, 1914, this product to the value of more than $300,000 has entered the United States through E! Paso and Eagle Pass. Several of the guayule rubber factories are now in full operation and many men are now employed on the different ranches in the states of Coahuila and Zacatecas cutting the guayule shrub. Plans are on foot for the extensive exploitation of the guayule shrub lands of the upper Rio Grande border region of Texas. The American Shipbuilding Company has placed a contract with the Great Lakes Dredge & Dry Dock Com- pany for the construction of a new dry dock 700 ft. long and 102 ft. wide at its South Chicago yard. Work will be started at once, it being planned to have the dock completed by September 15. The present dock at South Chicago is 564 ft. long and 70 ft. wide, not being large enough to accommodate the large ore boats. chine that is suspended from the ceiling, while the other is a general utility tool supported on a pedes tal. Both of the tools take their power from the nearest electric light socket and are supplied with motors for use on either alternating or direct cur- rent circuits at potentials of 110 or 220 volts. The special advantage claimed for the suspended type of tool, which can have the point of suspension changed and the counterweight adjusted, is that no bench or floor room is required. The pedestal type of tool is designed for die sinking, drilling, buffing, A Suspended Type of Direct-Connected Tool for D : ng Bufting and Grinding Equipped with a Flexible 5 grinding and driving screws. The speed of opera tion of the suspended and pedestal tools are 540" and 400 to 7000 r.p.m., respectively. The plant of the Mesker Bros. Iron Company, St Louis, has been put on 24-hour shift to fill a large °™ der for field cooking ranges for the commissary depa!’ ment of a European government whose name is 00 divulged. The contract calls for the construction within 200 days of 2000 steel ranges mounted on wheels. Ft Febr V 1k, 1915 »ACKING INGOT MOLDS A New Device to Do Away with Present Awk- ward Methods BY SIDNEY K. EASTWOOD wcompanying sketch shows in detail the i tion of a device for use in placing the as- ail packing around the tile in the bottom of ecu ingot molds. The usual way of doing this - to drop the packing into the mold and then work + in place with a flat bar. The packer shown uses this same method but in addition has means for olacing the packing in the mold and steering it into piace. ~ It consists essentially of a wooden cylinder, a, tyrned to a size a little smaller than the top of the tile and with a point on the lower end which fits in the hole in the tile. This cylinder, which has a | iron washer attached to its lower end, is fastened to an iron rod, b, which is long enough to reach about a foot above the top of the mold. A piece of flat stock, d, an eighth of an inch thick and about 3 in. longer than the cylin- der is bent as is shown in the illustration and is fastened at its upper end to another flat which has a hole drilled in it so that it will pass over the rod in the cylinder. This part of the packer is then fastened to another iron rod, c, as shown. This rod has a strap riveted to it which will reach around the other rod and serve as a guide to the motion of the packer iron d and pre- vent its cutting into the wood of the cylinder. for Packing In. hen the whole is as- t Molds sembled, several rubber washers are slipped on the central rod above the cylinder to control the wnward motion of the packer iron. lo use this packer, the packer iron is drawn up- y its handle and a piece of packing which has twisted into a ring is slipped on to the cylin- lhe whole device is then lowered into the mold it the point of the cylinder fits in the hole in tile. The packing is then worked off the end ‘ the cylinder and on to the tile by the packer iron. packing is then pushed into place and forced by the use of the packing iron, which is worked same manner as the iron bar is used in the thod. The advantages of this packer over | style way of using a bar are that no light is essary to locate the tile, no time is lost in locat- packing after it is dropped into the mold, packing can be forced into place much er t ‘he iron, steel and by-product coke industry of the States the consumption of sulphuric acid is esti- to be 200,000 tons annually, out of a total annual tion of 3,250,000 tons. The fertilizer industry 100,000 tons of acid; the petroleum industry tons and the explosive manufacturers 150,000 THE. IRON AGE 351 An Improved Form of Belt Shifting Pole To eliminate the accidents that are likely to happen when an operator climbs a ladder to put on or take off a belt by hand, various forms of belt shifting poles have been devised. The Ready Tool Company, Bridgeport, Conn., has developed one that is an improvement on the type in which a single pin is placed in one side of the stick near the end. The device consists of one piece that is designed to be bolted to the regulation pole. A swivel fork Using a Recently Developed Belt Shifting Pole To Replace a Belt on a Pulley The Device Proper Is Shown in the Smal Insert supporting three rollers forms the essential por tion of the shifting device and is held in place by a wing nut. Two of the rollers are tapered, which is relied upon to do away with any possibility of the hook getting caught and the pole being torn from the operator’s hand and thrown across the room, and also to eliminate any chance of the belt binding. The use of the pole is brought out in the accompanying illustration, while the arrangement of the rollers is shown in the small insert cut. Since two of the rolls are tapered, it is pointed out that after the belt is placed in the fork the tendency is for it to slide on the pulley and for the forks in their turn to slide away. Large Continuous-Service Induction Motors For continuous service, such as driving pumps, blow- ers, compressors, hoists and other machinery requiring heavy torque at starting, the Westinghouse Electric & Mfg. Company, East Pittsburgh, Pa., has placed on the market a line of large slip-ring induction motors. The bearings are dustproof and rest on three machined seats in accordance with standard steel mill practice, and the bearing shell may be removed and replaced without tak- ing off the lower half of the bearing bracket. The increased antimony demand is reported to have resulted in the reopening of the mines at Lake George, York County, New Brunswick, which were worked many ye