The Iron Age 1917-10-11: Vol 100 Iss 15

THE | New York, October 11, 1917 ESTABLISHED 1855 — ; : te TY ~~ oer, “ry OER Bo = Se aT PR Visualizing Promises of Material Shipments Details of Scheme Followed by a Purchasing Department to Keep Active the Follow-Up Letters Regarding Belated Deliveries BY H. A. RUSSELL NDER normal conditions steel bars were shipments take much U shipped, if the orders were for regular sizes tion in a great many i and specifications, in from four to ten weeks’ check short of a certain 1 from the date of purchase. Malleable castings in evidence than ever would come along in five to eight weeks. Pig iron necessitate closer follow and coke shipments would be made as specified by plies ordered. the buyer. Furthermore, shipments when made A number of buyers use t} ‘a ick] had a happy faculty of coming through in periods to keep in touch with promises of shipment which were approximately uniform. The buyer’ chased materials. Others keep a list of the impo: knew the average number of days that a shipment tant orders before them all the time. In our pu would take from Pittsburgh to Philadelphia, or chasing department, we fill in a printed slip an from Chicago to New York. Nowadays all these. place it in one of the cardholders on the promis ‘ good old averages are obsolete. Less-than-carload board here shown. By the color we can tel = A irds « ot olored for different classes of purchased articles are put in the little pock« e dates of expected shipments. To the right are pegs for cases in which several The smaller board, shown at the right, is employed for holding tl 865 866 THE [R0N AGE October 11. 1917 whether the printed slip refers to certain groups of purchases. A yellow slip refers to general or- ders, such as belting, bolts, valves, pipe and pipe fittings, rivets, etc., also to printed matter. A blue slip covers the various items of steel such as bars, slabs, structural and special sections. A pink slip means that the items specified are either malleable or steel castings. There are four vertical lines of the cardholders on the promise board and fifteen horizontal lines, so that sixty separate orders can be listed at the one time. In the ordinary factory there will not be more than thirty to forty items that are needed more urgently than the remaining items in the order file. The average here is about thirty, al- though at times the board has been well filled. When the buyer is signing the purchase orders he can place a small x in the lower left hand cor- ner of the office copy when that particular order is one which it is necessary to follow up closely. The stenographer can then fill out one of the slips of the preper color. When the slips are written out before the copies of the order are filed there can be no possibility of the order being overlooked if the fol lowing procedure is given daily attention: Each morning, after the mail is received and the invoices covering incoming shipments are checked the buyer or his assistant consults the dif- ferent items on the promise board, making such notations on a scratch pad as will serve the pur- pose. The memorandum is then given to the stenographer and the copies of all the orders speci fied on the memorandum are laid on the buyer’s desk. The hurry-up and follow-up letters are then dictated and the buyer knows that no important order has been overlooked. The material covered by certain purchase orders may not be needed very promptly when the order is sent, but later on the situation may change. At the first indication that any item of material is needed ahead of the usual course, a slip is written out and placed on the board. When a promise of shipment is received, whether by mail, telephone or telegraph, the proper date signals are indicated on the board, on the right hand side of the item in question. It will be noted that there are two brads directly to the right of each cardholder, in the first three vertical columns. When a definite date is specified in the promise of shipment received from the seller, the first brad is used to hold the date signals, but when the promise is not definite both brads are used. For some time past the steel mills, steel and malleable foundries and others have been giving, in a number of in- stances, promises of shipment which covered a cer- tain period. As an instance we had a promise of shipment covering certain steel castings which read, “‘We will ship these castings between May 29 and June 5. Under these conditions it is necessary to indicate the minimum and maximum dates. When the purchase order covers a number of items all of which are needed promptly but which will not all be shipped at the same time, as in the in- stance of malleable castings, and it is necessary to record the promise of shipment for each item sepa- rately, then the fourth column of cardholders is used. Five minimum and maximum dates or ten definite dates may be recorded on the ten brads which are to the right of this row of cardholders. It is often necessary to order materials from a dozen or more different sources, but all of which cover items needed for one particular customer’s order. Without some definite plan to correlate these orders, the buyer may overlook some impor- tant item, or at the best it may not arrive at the factory until all the other items have been whereas this particular item should hay eer among the first to have been received. \ We place a group of orders for materials and w! re all needed for one factory order, the factory order iumber is placed on each slip and all of the slips are grouped together on the promise boa: By this method the buyer can analyze the condit euch order and their relation to each other. Son times we use the descriptive name of the other times the customer’s name, in group different purchase orders. When orders are placed for printed matter the Loard can be used not only for the purchase order tor the printed matter, but also for the necessary cuts or halftones, as sometimes the order is p! iced for catalogues or price lists before all the halftones ure received, and unless these are followed up closely there may be a delay in getting out the catalogue or price list. The date the proof was received can als be indicated. Once a promise is noted on the board it changed, even though the day has passed that is indicated by the date signals. When shipment is not made as promised and a further promise is re ceivea, then the date signals are changed to cor respond with the new promise. When an in\ is received showing that complete shipment has bee made, the slip and corresponding date signals are removed from the board. If it is thought advisablk these slips that are taken off the board can b placed on a smaller board and kept there until the shipment is received. This has not been necessary in our case, as a written notification or a copy of the invoice, minus prices, is sent to the production department and to the foreman of the department for which the material is intended when the item is un important one. The small board, also here illustrated, is sus pended along the wall near the promise board. This smaller board holds the non-active date signals. It is 6 in. wide by 20 in. long. The promise board is 28 x 32 in. and painted a dull or flat black. The cardboard tags showing the days of the month are ’s x 1% in. and are placed on the brads when in service over the month tags, which are °% x “4 in. There is also another set of plain tags. These are *. x 114 in. and are used for several purposes. When in use they are placed underneath both of the other tags. Notations can be made on these longer tags as about 144 in. projects below the month tag Sometimes it is necessary to hold up a purchase order after it has been placed, and the word “hold” can be written on the exposed space. This prevents the possibility of the suspended condition of the order being overlooked. At other times the notation can be made that part of the order will be shipped as per the date above and the balance on the second date. This system is not only of value to the buyer, but should he be absent for any reason, almost any one in the office could obtain all necessary information regarding the status of important material orders, and also have a complete list of all material orders pertaining to each customer’s order, which informa- tion might not otherwise be so grouped that it could readily be obtained in the buyer’s absence. As we all know, quick action is often needed at unexpected moments. The war’s effect on merchant shipbuilding is to be discussed at a joint meeting of the American Society of Mechanical Engineers and the Engineers’ Club of Philadelphia in Witherspoon Hall, Philadelphia, on Oct. 23, by Homer L. Ferguson, president and general man- ager Newport News Shipbuilding & Dry Dock Co a Houses Building at Donora for American Steel & Wire Co. » EINFORCED concrete houses to the number of 100 I been built for the American Steel & Wire Co.., a, Pa. There are eight different styles, contain- four, some five and some six rooms. Of these, e being built in pairs with party walls, and the ill detached. Each house has also a bathroom ‘ull cellar. The site is about 40 miles outside of rgh and is located on a steep hill above the Mo- River. The property has been laid out into Grading was done and concrete streets with sidewalks were laid out by the American & Wire Co. concurrently with the house building, being done by the Aberthaw Construction Co., cellars were excavated with a steam shovel, i: in and some shale. The walls and floors are of {1 eoncrete. The cellar walls are 9 in. thick the walls of first and second stories 6 in. The gs were finished at the top with a reinforced ete cornice in which a gutter was formed, and on ’ the concrete ceilings a roof was built up of e framing covered with asbestos slate so that the of the exterior of the building, with the excep- the window and door frames, is fire resisting. r iildings are all equipped with gas furnaces and x ranges, wired for electric lights, and each is th both watercloset and lavatory bowl with hot id water. The outside walls are covered with The concrete is of Universal Portland cement, and, and crushed slag, mixed 1:2:5 for cellar .INCRETE HOUSING DEVELOPMENT walls and street paving and 1:2:4 for the rest of the work. Steel forms, patented by the Lambie Concrete House Corporation, were used. Thes nsist ot Y-uw hannels set up vertically and connected together wit ips and wedges passed through slotted holes in the flange At the corner of the building a 4 x 4-in. steel angle was set up and the forms lined up longitudinally by means of a steel channel used to form a belt course This not only fastened the forms of the lower floor, but was bolted into the floor reinforcement and remained in place for a support for the second story forms and was only stripped at the last when all the concrete was poured The steel wall forms also ipported the floor forms, arrangements being made by which steei channels wer bolted to the inner side of the steel wall forms upon which the floor centering :; laid Steel domes were used for floor forms. Concrete was hoisted by means of a small derrick bolted to the forms themselves and con nected with the hoisting engine which operated the mixer. The usual method was to set the forms for one story wall and floor together, and to pour continually To form, pour, and strip each story has taken about seven days Working at this rate, a house of two floors and cellar is completely concreted in three weeks, and with twelve sets of forms on the job, twelve houses are concreted in this period. The plumbing, heating, plastering, roofing and finish take about five weeks more, so that the houses are being completed at the rate of twelve in the first eight weeks and twelve every three weeks thereafter. eee ae e Ditch Dug by the Steam Shovel, Steel Forms Made Up of Charne's Are Erected for the Concrete and the Space: Between Houses Are Backfilled 867 Price Fixing by Edict or Agreement? Dangers That Result from Arbitrary Action— Importance of Controlling All Factors Entering Into Costs—Questions Which Must Be Considered BY H. recent embarkation in wholesale sociology. As he is not engaged in wholesaling or retailing or inter- ested in any way in any of the commodities whose prices have been or are to be fixed, he feels he is somewhat qualified to deal impartially with the question. This discussion is not to be construed in any manner as an attack on the Administration, but rather an en- deavor to consider facts and to prevent, if possible, a distortion of our perspective. War to-day is organized business. Ts writer views with considerable trepidation our War’s necessities are not peace necessities, consequently many things have to be done when a nation engages in war on a scale such as to-day that are not justified in normal times. 3ut there is the ever present danger that measures may be taken as war’s necessity that on closer scrutiny and analysis may prove to be a distortion of perspec- tive due to viewing the measure in particular in the same picture with those gigantic measures that com- pose war. The armies cannot be supported in the field, financial plans cannot be worked out, or those left behind kept employed if the nation’s productive facilities are strangled or jeopardized by any short-sighted or inade- quate measures. The man is rash who will prophesy what will happen after the war. One thing is certain, however—people will have to be fed, clothed and housed, and this means employment which in turn means pro- duction, that means business which rests on commerce. In other words, somehow, some way, no matter what the state, national or international adjustments may bring, business—commerce—will be conducted in most instances at the same old stand. There is nothing in history to prove to the contrary. That being granted, we must be sane in our conception of wartime measures and keep constantly before us, not way back in the back- ground, the fact that the nation’s activities must not be hampered by half-measures—ill-conceived measures or unco-ordinated measures—lest the period of readjust- ment be made worse after the war than that necessity decrees. Must Control Cost Factors It seems axiomatic to the writer that price fixing presupposes price control of all the elements and fac- tors making up the fixed price. Suppose, for example, we consider the price of coal at the mine. That seems to have caused considerable agitation. Without going into too much detail with regard to the factors entering into the cost of a ton of coal at the mine, we can list these: (a) Labor—Productive. Labor—Non-productive. (b) Material—Productive. Material—Expense. (c) General expense. (d) Administration expense. (e) Selling expense. (f) Fixed charges. The various elements making up the main might be somewhat as follows: A—1. Skilled labor. 2. Unskilled labor. B.—1. Mine rails and auxiliary material. 2. Explosives. 8. Cables, sheaves, etc. 4. Pumping supplies, etc. There are a number of other things that have a decided bearing on the cost of production—thin vein mining vs. thick vein mining, location of vein, water conditions and the like. The manner in which the opera- factors *Gunn, Richards & Co., New York. COES” tions are financed, the character of the lease, th: of royalties, all have a decided influence on th: Some Pertinent Questions Can the Government guarantee that the wax for either skilled or unskilled labor will not adva; Can it protect the mine operators against crease in the price of mine rails, cables, cars, « plo sives, only a few of the things that enter into t rst of mining a ton of coal? Can the Government fix rates for the variou nds of mining, thin vein, thick vein, the percentage of to raw coal, etc.? Can it protect the operators from an increase in administrative expense due to high cost of living, with consequent salary increase? Can it guarantee the production per dollar of labor? It is a generally well-known fact that production in many cases has decreased while productive cost has advanced. We say, can the Government do these things? Let us say, will the Government guarantee the producer of coal, copper, pig iron, steel, flour, any of these things, the control of the major portion of those elements com- prising the cost of production? If it will, it has gone all the way and a big step forward in price fixing been taken. Some one advances the argument that the producer had to meet these conditions when supply and demand fixed the price. To a certain extent, yes; to a greater extent, no. One coal producer, for instance, might sell his product at an advance over the market because he could guarantee a certain B.t.u. content, ash content, sulphur content, percentage of moisture, etc. But un- less the price classification is very carefully drawn up, based on all the conditions it is possible to ascertain, the price fixing as at present conceived is sure to work a hardship in certain directions. Siate The Question of Priority There is still another phase of the question to con- sider—priority. This enters into some of the rate fixing plans—steel, for instance. It is the duty of every manager to keep his plant running to full capacity, if possible. A 100-ton lot of coal might probably be worth considerably more to him than the current market price, in order to keep going and fulfill his contracts. He is willing to pay a premium to get it. By price fixing he is deprived of his competitive bidding power. He pre- sents his case to a priority board. He has been fore- handed and contracted for his supplies. They have been commandeered by a railroad or by the Government. He is at bay. Does anyone believe that a priority board can pass on all the cases of this character that arise, or that it has such an adequate mechanism of stock control in its hands that it can afford the relief in the time necessary to make the relief worth while? Before we get into wholesale price fixing, let us con- sider all the available means of regulation, of aiding rather than attempting to suspend economic laws, of means for regulating excess profits. In a great many instances, excess profits will prove to be a myth and the balance on the wrong side of the sheet unless the costs of production for all classifications have been very carefully and accurately determined. It is the writer’s observation that those prices fixed by mutual agreement and understanding have give? less dissatisfaction, caused less interference and read- justment than those fixed by edict. In the case of those prices fixed by edict, it is reasonable to assume that ll the factors entering into the price were either m0 known or not carefully enough considered; and that 868 ner Eee 1917 the classification was not elastic or compre- ‘enough to meet the majority of cases that arose. mary.—If prices are to be fixed, they should be - agreement and not by edict. Care should be o insure proper classification. Costs, if not ade- known for any given classification, should be y determined. Every effort should be made to the elements comprising the cost of production. -onsideration should be given to the necessity visability of fixing the price. Great Increase in Exports of Explosives VASHINGTON, Oct. 9.—A phenomenal movement in ports of explosives is recorded in an exhibit pre- by the Bureau of Foreign and Domestic Com- showing the shipments of cartridges, dynamite, wder and other explosives since Jan. 1, 1913, to d of the fiscal year which closed on June 30 last. exhibit covers the entire period of the European | registers a percentage increase that is believed without a rival in the exports of any other single of American products. e total exports of explosives of all kinds for the lar year 1913, which include the first five months the war, amounted to $5,252,077, made up of cart- $3,015,399; dynamite, $1,498,222; gunpowder 1000, and unspecified articles, $651,601. The beginning of 1915 was signalized by a tremend- «pansion in the exports of all classes of explosives the exception of dynamite. Shipments of cartridges to $25,408,079, gunpowder to $66,922,807, and all explosives, including loaded shells and shrapnel, 5,129,957, making an aggregate for the class of 58,969,893. But huge as these totals were, they were ar exceeded in 1916, when the aggregate of the class early 300 per cent, every item in the list sharing the gain, which, however, was most notable in the ise of gunpowder and all other explosives. The grand of the exports for 1916 was $717,144,649, divided follows: Cartridges, $56,996,854; dynamite, $4,510,- 197; gunpowder, $263,790,851, and all other explosives, $391,846,747. That the exports of these articles for 1917 will far ed the enormous figures for 1916 is clearly fore- shadowed in the statistics for the first six months end- r June 30, last. The four classes for the first half aggregated $414,523,991, or at the rate of nearly $850,000,000 for the calendar twelvemonth. Exports of dges totaled $33,311,945, dynamite $2,132,487, powder $169,409,614, and all other explosives $209,- 975. Every class with the exception of dynamite a very substantial proportionate gain over 1916 Asks for Central Control WASHINGTON, Oct. 10—A petition from business to Government asking for the creation of a central con- f all Government purchases has been filed by the er of Commerce of the United States. While asking directly for the creation of a Department Munitions, such a department was suggested in this iment published to-day by the national chamber. petition was the substance of a report drafted by al committee of the chamber of which Waddill ings of New York is chairman. ich an appeal as this is not new to the present nistration at Washington. President Wilson un- tedly has been told before what business desires ne has undoubtedly given some thought to the sug- that the control be centralized. There are, ermore, indications that the President is work- ng to such an end. The appeal of the Chamber mmerce of the United States therefore comes most opportune moment. Pocahontas Pig Iron Corporation, Roanoke, Va., cen organized to operate the Graham, Va., furnace. ompany plans for improvements to cost about v0, and expects to blow in the latter part of Octo- with daily capacity of about 150 tons. John B. rnsey & Co., engineers, Roanoke, will operate the organization. THE IRON AGE 86a Small Squirrel Cage Induction Motor Squirrel cage induction motors ranging in size from 4% to 3 hp. have been developed by the Crocker-Wheeler Co., Ampere, N. J. The motors, which are designed for operation at a constant speed on 60-cycle polyphase circuits, have an imteresting scheme of ventilation Use is made of the projections of a number of rotor bars for a short distance at each end of the rotor core to serve as fans. The inside of each of the bearing shields has a pressed steel guide that separates the incoming from the outgoing air, thus enabling air to be drawn into the motor at each end through openings near the shaft and forced by the fan action of the pro jecting ends of the rotor bars against the stator wind ing, around the ends, and finally out through the holes near the outer periphery of the shield. The bearings have sheet metal caps at the ends and self-closing oil well covers to exclude dust and dirt. The oil grooves in the bearings keep a film of oil between shaft and bearings, no matter what the direc- tion of the belt pull. To provide an accurate belt ten sion adjustment, slotted feet cast integral with the Extending Some of the Rotor Bar a Short Distance beyond the Ends of the Rotor Core Is Relied Upon to Provide Ventilation in a New Squirrel Cage Induction Motor stator frame are employed. The stator windings are insulated by placing the coils in insulated slots and the complete core and winding are impregnated with a special varnish to render them immune to moisture and acid fumes. After removal from the impregnating tank, the core and coils are baked and then again dipped in the varnish and baked. The Iron Age in a Permanent Home The United Publishers Corporation, New York, pub lisher of THE IRON AGE, has purchased the building largely occupied by it at 239-243 West Thirty-Ninth Street, through the acquisition of a majority of the stock ownership of the building. The first floor is occu pied by the Times Square Station of the New York Post Office; three floors and the basement are occupied by the Federal Printing Co., which is the printing de partment of the United Publishers Corporation; four other floors are occupied by the publishing offices of the United Publishers Corporation, and the purchase thus guarantees to this publishing business a permanent home under desired conditions and surroundings. The building, which has eleven stories and a basement, and measures 194 ft. 6 in. in frontage and 90 ft. in depth, is located within easy access of both the New York Central and Pennsylvania Railroad terminals and is three blocks from Times Square. Steel Company’s Celebration The Taylor-Wharton Steel & Iron Co., High Bridge, N. J., is arranging to celebrate Oct. 13, its 175th an- niversary and also the twenty-fifth anniversary of the production of manganese steel. An industrial parade will be held in the morning, and games and sports for employees in the afternoon. A community clambake will be held at Riverside Park in the evening, followed by dancing. The Pedersen Bros. Mfg. Co., Bridgeport, Conn., has been dissolved. The business will be continued by Julius Pedersen under the name of J. Pedersen Ma- chine Co. nie ott American Electrochemists’ General Meeting Papers and Discussions on Electric Pig Lron from Scrap, Corrosio1 Problems and ARDLY a meeting of the American Electroch tant message to the steel industry. The th week, Oct. 3 to 6, was no exception. The ov H relating to topics of vital consequence to industrial progress and the prosecution of the war, ; Matters relating to the electric furnace, particularly in were discussed in a profitable manner. Melting Brass 1 of Steel, Pickling Steel Electrically emical Society is held that does not bear som: irty-second general meeting, held in Pittsbu: er 325 attendants listened to many importan: D « sv low phosphorus pig iron from scrap; the corrosion of iron and steel, especially copper-bearinyg the electric melting of brass; the progress in electrochemical analysis, and chemical war supplies were among the topics. Th on Thursday and Friday mornings, the afternoons a symposium on ¢ e sessions devoted to papers and discussions wer being devoted to excursions to large industrial ; laboratories and research institutions in which Pittsburgh abounds. HE address of welcome on Thursday morning was one that elicited much approbation. It was given by John A. Brashear, president John A. Brashear Co., Pittsburgh, who was introduced by the chairman, Dr. Colin G. Finck, president of the society, as one of Pittsburgh’s famous scientists. After calling attention to the city’s advantages as a convention town and re- citing in a most unique and interesting way his asso- ciation with S. P. Langley, with Westinghouse and with as many as 180 celebrated scientists in his 77 years of experience, Mr. Brashear closed with the statement that we know not what is yet to come in scientific and other progress as a result of the world war. Electric Pig Iron from Ore and Scrap Steel One of the most interesting papers of the convention, from the practical steel standpoint, was “Electric Pig Iron in War Times,” by Robert Turnbull, Turnbull Elec- tro Metals Co., St. Catharines, Ontario, Canada. Mr. Turnbull presented an abstract of his paper. It printed nearly in full in this issue. The author dis- cusses the commercial possibilities of the manufacture of low phosphorus pig iron from steel scrap in an electric furnace with particular reference to post-war conditions and the reasons why electric pig iron direct from ore is not being made now in North America, although the profits appear attractive. The addition of steel scrap to blast furnaces and electric pig iron furnaces is also touched upon as a procedure which is now profitable. Supplementing his presentation, Mr. Turnbull called attention to the analyses of his product of pig iron from scrap, pointing out that the average of the analyses given in the paper showed the sulphur to be 0.028 per cent and the phosphorus 0.030 per cent. For the last 15 days of September he said the average had been 0.019 per cent sulphur and 0.030 per cent phos- phorus. Speaking of the inability to raise the total carbon above 3 per cent in the iron, Mr. Turnbull said that attempts to reach 3.50 per cent had resulted in nearly complete destruction of the roof. The load factor in making iron had been 68, including five shut- downs. Dr. John A. Mathews, president Halecomb Steel Co., Syracuse, N. Y., after being called upon to open the discussion, said that he had had no experience in mak- ing: pig iron from scrap in an electric furnace, but desired to know the economical reasons for putting steel scrap back into pig iron instead of directly into refined steel. is Canada’s Shortage of Low Phosphorus Iron I Mr. Turnbull’s reply was that in Canada there is a decided shortage of low phosphorus pig iron to supply the 20 or more acid open-hearth furnaces in that country of 15 to 25 tons capacity each; that it is almost im- possible to get high-grade ores from the United States, and that now no pig iron is available from the States. There is therefore no other way to get such iron except to make it in this way. He made also the sur- prising statement that 5000 tons per month of steel borings and turnings are now being exported Canada to the United States for use in regu furnace charges. Another answer to Dr. query was that there is good money in it. Edwin F. Cone, associate editor, THE IRON Acs expressed his interest in this subject and commented on the value of Mr. Turnbull’s paper. He related that he had been shown very recently some physical tests a number of bars of cast iron made by a company producing both pig iron and iron castings by this proc ess. The bars were 1 x 1 in. and several had been tested at Columbia University. The average results showed a tensile strength of about 45,000 lb. per sq. in. wit! rupture at about 72,000 lb. per sq. in.—exceeding by at least 100 per cent the values of ordinary cupola gray iron castings. Mr. Cone asked Mr. Turnbull what had been his experience along this line and also whether he had made any better record than 700 kw-hr. per ton on the electric consumption, for he had been told that it was possible to produce iron by this process with a consumption of 300 to 500 kw-hr., doubting, however, the former figure. Mr. Turnbull, in his reply, stated that steelmakers using his iron had found no difference in the quality of steel produced in the open-hearth and that he had no record of tests of the iron itself as cast. It was a fact, however, that the pigs were much tougher than ordinary low phosphorus iron and harder to break, rendering it necessary to be careful in making the pig beds and the connections between each pig. As to cur- rent consumption, his measurements recorded in the paper covered a period and were taken on the peak. He believed it possible, however, to make iron on 4 consumption of 500 kw-hr. per ton on integrated power In further reference to Doctor Mathews’ remarks, Mr. Turnbull said that Canadian steelmakers were als very reluctant to change their acid to basic open- hearth bottoms as a solution to the problem of scarcity of pig iron. This would involve great expense and loss in time. Mat The Combined Carbon and Electrode Consumption Asked by Mr. Cone as to the content of combined carbon in his product, the author said that it averaged about 1.60 per cent when the total carbon was 2.70 pe! cent, leaving only 1.10 per cent carbon present 45 graphite. In response to a question from F. A. J. Fitz Gerald, FitzGerald Laboratories, Niagara Falls, N. Xe as to electrode consumption in this process, Mr. Turn- bull stated that it averaged 45 to 46 lb. per ton of iron produced. H. E. Randall, the Shawinigan Water & Power Co., Montreal, Canada, said that he knew © one plant that had been started for making cast 10! by this process so as to get a quick return on money. Corrosion and Copper Bearing Steel Nearly every meeting of the society is featured 5Y a discussion in some form or another of the corrosi0® problem. The subject was presented by papers touching on several phases of the question: The corrosion ” 870 the atmosphere, the corrosion of metals by acids sion due to certain conditions in electrolytic or plating. familiar topic of copper bearing steel and the problem was brought out by a paper by O. rev of the C. F. Burgess Laboratories, Madison, entitled “The Corrosion of Fence Wire.” At- by the fact that much of the barb fence ertain Western districts, made years ago, is good condition, while wire now made corrodes tes away rapidly, Mr. Storey started an investi- as to the cause. Much to his surprise the found that, in fences where one strand had d and the one alongside it had not, the analysis d in the latter the presence of copper. He ex- | specimens. The paper will be reviewed later ue IRON AGE, but a brief abstract is to the effect definitely established that the durabilit of wire is due to the presence of copper or ot crease the corrosion of stee¢ ind decre e the corrosion in the early steel and wrought iror came r-bearing ore of the eastern United States rted re The proportion of copper steel made N th port- opper vire Op I is blé as t day steel usually contain d there- des rapidly rdinary at- eric conditions rrodes more inder condi- favoring rapid of iron, i ice versa, iron des more slowly onditions fa- rapid corro- life of fence dependent q iality of galvanizing er 11, 1917 THE IRON AGE 871 say that copper is a panacea Che results of the autho having been called to his attention, he went to Wiscon sin and obtained samples of the old barb wire which he analyzed with the same results. He exhibited an array of these samples. He called attention to the fact that sheet steels all corrode in the first 10 to 12 months, but that the copper-bearing ones in all cases slow up at this point, being covered with an apparently vitreous, dense protective coating, while all others cor tinue to waste away. Dr. Finck said that he had had samples of coppe steel sheets that had stood many corroding atmospheres except those at the sea coast, where the salt-laden at e mosphere had been deleterious Mr. Buck reit ated his old contention that his own observations were to the effect that in a salt brine solution all such sheets cor roded, while in the atmosphere of the sea coast the copper bearing metal stood up Prof. Joseph W. Richards, Lehigh University, South Bethlehem, Pa., and secretary of the society, called attention to the fact that in barb wire there existed the possibility of electrolysis between adjoining wire the twisted strands; that this was especially possible if one wire was harder than another. The questior > would straight wire corrode at the same rate Pickling Steel and Its Problems Problems cor nected with the pickling of steel were given some attention. The sub ject was brought up by a _ paper, “Electrolytic Pick ling Process and Its Effect on the Physical Proper ties of Metals,” by J. Coulson, physi ‘al chemist, West inghouse’ Electric & Mfg. Co., East Pittsburgh, Pa. It was presented by the author A brief abstract of the paper is as follows: or steel Since the gal- The Largest Electric Steel Furnace Operating in the World It is a 20-to To determine the ng is usually Heroult furnace from which as high as 27 to 30 tons has been tapped \ embrittling effect life of the party of over 200 electrochemists witnessed the pouring of a heat from this absorbed hvdr da aaicaedl Ms furnace on Saturday at the Duquesne plant of the Carnegie Steel Ce : reg iepends prin- upon steel pict the iron different which should be highly resistant to corrosion ples of spring teel wire were pickled mically by simy N.¢ ler . ‘ = dipping in acid, also by electr« tic pickling, using then . N. Speller, metallurgical engineer, National Tube oorpoaes or a a2 el iden” Kaaekan, ‘sak ihc «ees advised caution in drawing conclusions regarding wires, the same sand-blaste: nd the thr ts treated s complex problem. He recognized the value of described, showed the che y cleaned and t thodically pper in steel as a resistor of atmospheric corrosion, cleaned to be very brittle, while the anodica ned had water pipe a different condition obtains. In the the strength of the origi ples ir tests were also le of such steel pipe, after two or three years’ ™#de with drill-rod steel, hot-rolled Mi Rm NG Cole-Teree , no matter what the copper content, detrimental ; - : ' a . elongation nd re ction of re l i ft on always results, but on the outside the copper , r ist aaWiicaaagis ; - : * metal always presented a better appearance which t 1 wit , other steels. The outside is subjected to atmos corrosion, while on the inside there is a large e of water. Dr. Carl Hering, consulting electrical engineer, James Aston, Pittsburgh, claimed that the paper nts to the complexity of the whole problem, and d caution as to jumping to conclusions. He re- i the fact that we have three so-called anti-corro- aterials: Wrought iron, in which he believed the ayS an important part; ingot iron, with its and the copper bearing steels. Unfortunately, Mr. Storey does not tell us the value of pure such fence wire, though he does say that wrought taining no copper had a measure of protection. ‘annot say in his opinion that any one of the three tions to the corrosion problem is correct. ). M. Suck, metallurgist, American Sheet & Tin Co., Pittsburgh, said that Mr. Storey does not | ‘OY t Philadelphia, in opening a brief discussion, said that he regarded the results offered by Mr. Coulson as doing an injustice to cathodic pickling. It might be bad for hard steel, but he deemed it beneficial for other steels and not fair to condemn cathodic pickling because of unfavorable conclusions from using hard steel Dr. Joseph W. Richards called the generalization from the experiments altogether too broad, mentioned the fact that only carbon steels were tested, and recommended that the title be modified accordingly. Another paper along similar lines was “The Pre- vention of Brittleness in Electroplated Steel Springs.” It was presented in abstract by the author, T, S. Fuller, research laboratory, General Electric Co., Schenec- 872 tady, N. Y. The paper may be outlined as follows: The literature of ing brittleness, perimental work he the relations of hydrogen to iron, caus- reviewed In the author's ex- tested the breaking strength of untreated springs, then tested similar ones electrically copper plated, pickled in sulphuric acid and tinned by dipping in molten tin and then copper plated. The pickling makes them brittle, also copper plating, but tin dipping per plating is found to prevent embrittlement The facts are all absorption by the steel of atomic or erated at the cathode is the cause steel springs in the plating bath This embrittlement may be prevented by first dipping the springs in a bath of molten tin. which is may be used as a is extensively seven before cop- entirely. in accord with the assumption that the hydrogen lib- embrittlement of nascent of the The tin forms a coating on impermeable to Rosin flux in the tin dipping. The springs may be sand-blasted, but must not be pickled in acid. the steel atomic hydrogen. Steel springs may in molten tin at be dipped ture of 260 to 300 deg. C. with a tempera- yuut appreciably changing their mechanical properties Comment on the author’s results was to the effect that the brittleness described was due to the solution and its character rather than to any other cause, and it was suggested that free cyanide might have been present. Electric Melting of Brass Two interesting papers were offered relating to brass and copper. T. F. Baily, president Electric Fur- nace Co. of America, Cleveland, presented an abstract of his paper, “Resistance Type Furnace for Melting 3rass.” The author gives more recent results of the commercial operation of his furnace which was de- scribed in THE IRON AGE, Feb. 1, 1917. He gives run- ning tests of this furnace melting brass and bronze with mechanical tests of the cartridge brass produced and numerous analyses showing the uniformity of the metal at the beginning and end of the cast, The elec- trical power required shows favorable comparison, he claims, with melting costs when using crucible or open- flame melting furnaces, the average being 450 kw-hr. per net ton of bearing bronze (495 per metric ton), and 311 kw-hr, per net ton of cartridge brass (342 per metric ton). H. W. Gillett, U. S. Bureau of Mines, in discussing the paper, claimed that Mr. Baily thinks always in terms of 24-hr. operation and both overestimates and underestimates his results. His averages need further explanation, he thought. Table 1 of the paper does not show that the furnace was kept hot at night. The speaker was glad to see the relation in this table be- tween the percentage of loss by chemical analysis and that by weight. Mr. Baily in explanation stated that for continuous operation the current consumption would be about 400 kw-hr., but on 10-hr. operation, about 550 kw.-hr. Deoxidation of Copper for Castings “Copper Castings for Electrical Use,” by G. F. Comstock, metallographist, Titanium Alloy Mfg. Co., Niagara Falls, N. Y., was abstracted by Professor Richards. This was the only paper of the 26 on the program not preprinted. In brief, Mr. Comstock re- called the fact that sound copper castings are hard to obtain and that the problem of superior deoxidation was now a subject of experiment at his company’s plant. He had found silicon a good deoxidizer if used in the presence of careful melting, and his company had been able to make good sound castings poured in sand. The metal, however, is soft and weak and not easy to harden. Professor Richards, by way of comment, said that the use of silicon as a deoxidizer of copper was not new and that unless the author had some new way of using it, the paper did not present any additional light on the subject. A member of the society testified that the use of boron, in his experience, makes the conduc- tivity better, the boron being used as a suboxide and also as boron carbide successfully. Testimony was also offered to the effect that two-tenths to three- tenths of 1 per cent of magnesium as a deoxidizer gave good results. THE IRON AGE October | 1917 Resistance Furnace for Heating Stee! A resistance furnace for heating steel to ‘orgin, temperatures was discussed in a paper, “A Ry ene Furnace,” by Frank Thornton, Jr. Other app! ations of such a furnace include the heat treating stec parts; hardening dies and tools, tempering divs ay, tools; annealing steel, brass, copper and othe: s heating copper, brass and other metals for ling: melting copper and brass; firing ceramics and firing enameled ware. The paper discusses the heating of furnaces by resistors placed inside the furnace, ejtho, on the hearth of the furnace or on a shelf around the walls. The scope of operations suitable to such fy,. naces is mentioned and the nature of the resistor material, its purity and its electrical characteristics are discussed at length. Experiments were made to determine the suitability of various materials, and best results were obtained with silicon carbide blocks, bricks or rods. Satisfactory running with temperatures uy to 1200 deg. C. was obtained. New Metal for Thermocouples A paper of interest to those connected with heat- treating problems was “Calorized Iron as an Element for Thermocouples,” by O. L. Kowalke, professor of chemical engineering, University of Wisconsin. The author compares the thermo-electromotive force of couples of “calorized” iron-constantan with that of “uncalorized” iron-constantan. A sample of calorized iron wire from the General Electric Co. gave the same thermo-electric potentials as uncalorized iron, up t 1000 deg. C., on repeated calibrations. A sample from the Brown Instrument Co. gave slightly different poten- tials until after it had been heat treated at 800 deg C., after which it gave similar results to the other calorized wire. The author concludes that a heavy wire, lightly calorized, gives as constant results as uncalorized iron, and has a much longer life. Dr. C. G. Finck, in discussing the paper, called at- tention to the fact that the author presents a cheap thermocouple that is reliable and easily replaced. W. E. Ruder, research department General Electric Co., Schenectady, N. Y., felt indebted to the author for his results. New Way to Analyze High-Grade Ferrosilicon Two papers of direct bearing on chemical analytical problems were presented. One was: “A Method for the Commercial Analysis of Ferrosilicon,” by Russell E Lowe, chemist, the FitzGerald Laboratories, Niagara Falls, N. Y. It is recognized that the analysis of high- grade ferrosilicon presents many difficulties and some of these are cleared up by the author. An abstract is as follows: The method of position of the involves the decom- means of nitric and hydrofiuori icids, and the determination of those elements that are gen- erally called for in for the 50 namely, manganese, phosphorus, and silicon. In the sulphur and phosphorus determination a is presented for the necessary removal of the last traces of Fuorine without the use of sulphuric acid The method, as given, has all of the accuracy of the olde! fusion methods while at the same time it is easier to handle and saves platinum. Some remarks are appended upon the probable volatiliza- tion of phosphorus from samples of ferrosilicon kept 19 years in screw-topped glass jars procedure described alloy by specifications alloy sulphur, per cent iron, aluminum method more T. D. Yensen, in calling attention to the fact that carbon was not mentioned, asked the author whether it is possible to determine carbon in ferrosilicon with- out burning the silicon; direct combustion does not get all the carbon. Mr. Lowe replied that the maximum carbon in 50 per cent ferrosilicon was 0.20 per cent and that he had found it impossible to get the carbon by direct ignition. Mixing the alloy with red lead was possible but disagreeable and not very accurate. “An Improved Electro-Analysis Apparatus” was explained by J. L. Jones, metallurgist Westinghouse Electric & Mfg. Co., East Pittsburgh, Pa., the appa- ratus itself being exhibited and operated. It is a & and 10-unit electrically-stirred electrolytic apparatus er 11, 1917 tantitative chemical analyses, particularly in rrous alloys. The electrodes and beakers are nd stirring is done by revolving tungsten rods. analysis receives its own current, graded by a tat from 0.5 to 6 amperes. The volume of non- is work in many large laboratories is now so that this special type, used by the Westinghouse ny, seems to fill the need adequately. electric Status of the Norwegian Iron Industry Norwegian iron industry was authoritatively ed, especially from the electric standpoint, by mn Styri, metallurgist Hussey-Binns Steel Co., eroi, Pa., in a paper, “The Electric Furnace in the opment of the Norwegian Iron Industry.” This opment is briefly reviewed, followed by a detailed int of the introduction of electric steel furnaces electric pig-iron furnaces. The effect of present yrmal war conditions on the expansion and future industry is discussed and the commercial rela- regarding supply of ore, fuel and steel scrap are -borated. The development of casting, rolling, and manufacturing plants is outlined; also the condi- s controlling the present investment of capital in industries. Regret is expressed that the govern- t is favoring non-electric plants, while private capi- is more inclined to the development of electric iods. More extended attention will be given to this ater 1ssue. Che Society and the Naval Consulting Board The society’s share in the work of the Naval Con- ting Board was reported upon by two members who given most of their time the past summer to this portant field. Lawrence Addicks, consulting engi- - neer, New York, has been the board’s chairman of the mmittee on special problems in connection with the bmarine board. Prof. Joseph W. Richards’ duties have been concerned with dealing with all manner of iggestions offered the board from every quarter. It as impossible for obvious reasons to go into details, it it was emphasized that every suggestion and prob- , whether apparently of weight or not, was given consideartion and some of the results arrived at id been of deep significance. The society’s board of directors reported a recom- endation that the next meeting be held in the South. also announced that $2,000 had been appropriated r purchasing Liberty bonds. \ member of the society who has attended all of 32 meetings since the founding in 1902 said that s one excelled every other in point of entertainment perfection of management, especially as to plant sitations, which were a feature. Thursday afternoon least 200 members and guests boarded a special ‘in and were taken to the American Zine & Chemical plant at Langeloth, Pa., where the manufacture inc and sulphurie acid was inspected. The re- earch laboratory of the American Sheet & Tin Plate at Pittsburgh and the new laboratory of the ingstown Sheet & Tube Co. were also visited. The World’s Largest Electric Steel Furnace "he excursion, which wound up the convention, was Saturday, when a special train took over 200 to the nts of the Westinghouse Electric & Mfg. Co., the tional Tube Co. at McKeesport and the steel depart- ent of the Carnegie Steel Co. at Duquesne. Here the