The Iron Age 1919-02-27: Vol 103 Iss 9

gSTABL! Ses foundry pra n the « bessemer The proce verters ar tions that ina da dry, and develoned dent of th Be plans au ally Urigit Dlace the a mu ment ing one ing of a) the equi: operat; the plant chair tice was be Cont Units ce versa. New York, February 27, 1}9]9 Electric Furnace in Malleable Foundry Air Furnaces Eliminated in Notable New Plant of National Malleable Castings Co., Which Will Employ the Kranz Triplex Process Br PF. kk HE new Cleveland plant of the Na- ial Malleable Castings Co. marks a step in foundry construction and numerous notable operating fea- representing radical departures in tice. It is rated as the largest foundry try and is designed for making castings by the Kranz mir turnace, triplex process which eliminates the and in which the electric furnace and nverter are used for refining purposes. s provides with the use of cupolas, con- | electric furnaces, a flexibility of opera- will permit the plant to be changed over a malleable foundry to a steel foun- The Kranz triplex process was nd patented by W. G. Kranz, vice-pres!- company. the plant’s flexibility, the equipment r construction were temporarily materi- to meet the exigencies of the war. esigned as a malleable foundry to re- pany’s old Cleveland plant and provide iter capacity, the needs of the Govern- st steel anchor chain resulted in plac- of the plant in operation for the mak- rchain. This was done before much of required for the malleable foundry d been installed. The remainder of is being equipped for. making anchor ; work was suspended after the armis rned. The manufacture of chain will indefinitely in one unit and the other v being equipped for making malleable PRENTISS casting It expected tnat ne m: dries will be ready for operation in Apt The p nt ipl ti 52 Te < venue an W hill Re | i selt Line Railroa | ! teel and rete construct I il ch I el I I | fact r l ed I I IS SO low, ecause practh ed in the construction, that 1 nsul the buildings The mai nd ducing departments fo1 tained, is al rregulari nape mately 575 x 725 ft., and pr LU acr I f I Irame Co! ! t 1 ! the A kel ! eY \ | s 35 ft mn ne I il i¢ ned ft re possible conditi ght and ver t The structure is divided int which the various department re ted Lhe accompanying drawing shows tl! t of the plant. On the west side a storage department 75 x 575 ft Adjoining the storage department about the center the melting room, 125 ft. squars and with an additior space, 50 25 in the storage b: On either melt room at right angies to tne storage department are four bavs or molding floors, each 75 x 375 ft. Thess molding floors will be know: foundries } 2, 3 and 4, and the plant is arranged for operat by units. In case business does not warrant the operation of the entire plant, one or more of the t 3 aes * ) } “7 ‘ } ‘ ‘ 4 } foundries will be run, and ated that with the exception of carrying the entire erhe f these complete ina? init f f economically as all four As stated above ne of the foundries is now used for king estes chain T he inpola eT rtment 4 ted neé y thé southwe rner the } iid y a y r the melt ing stock storage bins, the pouring platform ex tending into the storage bay. At the front of the cupolas is the annealing pot 150 ft ng and 75 ft. wide, which is served by a 10-ton electric traveling crane Between foundri« \ 2 and bevond the 1 ting department cate the re room, 125 x 175 ft with concrete fl r er this room is a basement 1 25 ft lare r the stor age of coke, firing of « ke ovel torage and 1 ing of sand, etc Adjoining the re department 537 iad ag ona eas = TES nil ll nl ln 538 : and almost in the center of the building is a four- story structure to be used for the storage of mold- ing machines, flasks, boards and various foundry supplies. This structure is built of concrete, is 75 x 125 ft. in dimensions and provides about an acre of floor space. It is enclosed only by railings around the outside and has an elevator and two stairways. Between each side of the core room and the ad joining foundry bays are aisles 25 ft. wide, which provide room for the erection of be located in other parts of the the crane runways, stacks that cannot plant because of and for other uses as may sucn be required. Above one of these aisles a mezza- nine floor, 175 x 25 ft., is at present used as a res- taurant, but later will be occupied as a girls’ core room. On the east side, at right angles to the foundries, is the department, 100 x 725 ft. The finishing and shipping bay is at th annealing e extreme eastern adjoining the annealing depart space 75 x 725 ft. he. a of side of the building ment, a pressed nd occupies a floor J } } } loading track extends this department, providing tne entire trackage for 18 cars THE IRON AGE Feb) 97 ai, L919 capacity of 12 to 15 cars, extend wall the full length of the bay, a: mai track are rows of storage bins, thos: ata at one end and those for pig ji se p toward the other end, and the coke eing an the center. The land where the st: ay is | cated was originally 16 ft. below t! esent flog level. Consequently excavating was not require i locating the bins, which extend 7 ft. above andy ft. below the present floor level. Storage capacity is provided for 20,000 to 25,000 to: ig ion and scrap, 10,000 tons of sand and 3500 ¢ ns of coke, bay is in addition to other supplies served by two 10-ton cranes, the ine Storage crane raj being 30 ft. above the floor. Pig iron and scrap arg unloaded with electric magnets which are also yga in handling the metal from the bins the cupg charging cars. All cranes are of the Pawili Harnischfeger make, and the cran throughout is limited to four different types reducing as types so that fewer spare parts have t $1Zes, ng @ &quipment and far as practical the number of be carried, Along the east side of the bins nearly on a leyg This track parallels the receiving track in a storagé ith the top of the bins and 8 ft. 6 in. above th bay on the opposite side of the foundry building foundry floor level is a platform 12 ft. wide ang The entire plant has been designed and the depart 225 ft. long, extending from beneath the charging ments are so arran _ that every successive step in platform to the melting department. Two narrow the production of stings logical sequence of rage tracks are provided on this platform for haul yperations, with the material passing through the ng material to the charging floor. Cupola charg. shop in the same direction. ng cars of a special hopper type with a capa One of the interesting features of the plant 2500 lb. run on these traeks. The hoppers are an underground tunnel, 600 ft. long, that extends hinged on the front side and are discharged int from the service building, which is the works en the cupolas by raising a bale attached to the back trance, to the far side of the plant, running under side with an air hoist. Stock is weighed in the the center of the main building. This tunnel is 10 harging cars on track scales located near the ft. wide and 9 ft. high, and from it stairways con charging platform. As the capacity of each bin nect to the foundry floors and various departments s known, when the bin is emptied an accurate in- The tunnel has proved a great convenience for mer entory of the stock consumed is provided, and this going to and from work, saves time in going fron ilways serves as a check on the weights of the ma one part of the plant to another, and is also regarded terial that is taken either to the cupolas or electric as of the highest value as a safety first provision Tfurnaces. In the storage bay, a receiving track with a [he cupola platform is 75 ft. long, wide . : —— —————————————————————— d Jf 9 . \ % , § \ ; SS \ \ \ , pe GARAGE Wood | Road | —__—— Plat 1 Malleal Co t Cle UI The Kranz triplex process provides for chang!"s i da i malleabl 1 steel foundry Tae THE IRON - tied el wd —-~ wae ae i . ) io oe es a) ee ee eee to to- , g Toward the Transverse Ba n wh ( construction including the types £ t stee uhechor chair After t ce te runways shown at the 0 it gths I ead eo \ k : 9 above the floor level. It is of steel I has reinforced concrete slab floors ood blocks. One of the cranes in ised to handle the charging cars ww gage tracks and the charging er, a car haul will be installed to Loaded cars on being rging platform are placed on tracks the tracks below. Turn tables he tracks so that charging cars are the cupolas and then onto trans- In charg e car is charged at one side and side, so that the cupola charged is The design in operation of the parture from the regular foundry ipolas in general design are simi- in Bessemer steel plants, and the tice of continuous operation is fol try thy, y + service. y ith h side of the cupolas. very large thick lined cupolas. s in. in diameter and taper down to irging floor. They are lined down melting zone, having a bell-shaped thickness above the tuyeres, and about 13 in. at the base plate. gh from the bottom of 6-ft. 6-in. 6 in. in height from the charg- tapping spout. is 12 tuyeres of 6 in. diameter. It a rectangular wind box to which the under side 12 tuyere castings. re provided with peep holes directly re and cleanout holes on the under ngs. The wind box is 11 ft. 6 in. de, 9 ft. inside and 3 ft. deep. plied by two No. 514 Root positive the blast pipes being so arranged r the other may be used. The re the straight open door type used th mechanical charging and have on the lower side of the doors. —— <= =. a - ee tl inlet hk eer AGE dl —— aiealied See eel enema © 4 al fed | sill Di) ii en FR oe) BUD) h Pig I S p, Ss S iT Che capacit tnese¢ ( - f ning I the usual thickr A é ) 2 - er noul each ut WIT! itr K t } ice to 12 tons per hour eacl One cu} rating 24 hy per ad \ ipT t! ! t lire ent? f the plant, 300 tor f molten metal, which, figured on the basis of a 5 ent yi produce 150 tons of finished t per da One cupola will be kept in continuous operation ra full week and then w S re f ‘ tr er is used. In addition to the two large cupola re is a 63-in. standard foundry t I r? ‘ ing iron for annealing pots. The cu vere built by the Whiting Foundry Equipment ‘ supplied the hot metal ladles. The cupolas stand in a concrete pit 10 ft. deer in order to get a greater height from the level of the tuyeres to the charging doors Th permits ¢ the charging of } tity - Q lIAaNtItY O| a larger material in the cupolas and allows the increased charge to be heated by the cupola pit is 50 x 75 ft. ifted from the pit to a ladle car dry crane, which will also to be run into a 4-ton metal ladle car runs extends from in front of the cupolas to waste gasses from the melting zone The The ladles of metal will be with the not fr handle the slag ladle bugs on a standard gage track that serve to ’ siag department. The metal will be weighed on the vay from the cupola to the melting aepartment and again before going from the melting department t the foundry. By weighing the metal both after it comes from the cupola and after refining, a record is kept of the loss through oxidation both in the cupola and in the melting department The Kranz triplex process is designed t ver come the difficulties resulting from the presence of relatively high carbon and also in some e relatively high manganese and silicon i: usual practice, two tons of metal wil the cupola into a small ladle and conveyed to the melting room on a storage battery operated ladle car. This metal will be charged into one of the ises a iron. Ir | be tapped fror THE IRON AGE Besseme} erters and blown down to soft steel, will be used for the triplex process | the rbe nese and silicon being wholly o1 ron and the 6-ton converters for } partia I wn out While the charge is being arbon Bessemer steel for chargir c blown in thi verter, the cupola will be tapped furnaces when producing electric ste stings the ladl In the manufacture of cast steel chor contains 10 tons. This ladle of metal is then taker the cold metal is melted in the elect furnace . to the melting room, the blow in the ynverter is Four or five heats are tapped per day, the heat j finished and the 2 tons of treated metal is dumped running about 12 tons. Under norn from the converter into the ladle of cupola iron operations with the triplex process, about 15 heat Then the resultant mixture with the reduced cai vill be tapped from each furnace pet bon conte? well as reduction in the percentage of the continuous period of 24 hr. of operat manganese and silico charged into the electri The Heroult furnaces have copper tu Lor con furnace for further refinement, after which it ductors through which the cooling wate: ready to be cast. 5000 kva. transformer flows in order to n The melting room is equipped with two 2-ton low temperature in the copper tubes. It and two 6-ton side blow converters and two 15-ton that this design of conductors effected a saving af Heroult electric furnaces. The smaller converters two-thirds of the copper that would have bee! TI Storage Department Showing the Large Concrete Bins 7 ft. Above the Foundry Floor for the Storage 0! 7 ae ip, ete. To the platform on which material is conveyed to the charging floor, charging cars of the hopp ! | f e overhead cranes THE IRON AGE o41 bus bar arrangement been the construction of the furnaces dard Heéroult design. The trans- ' fl i Ip} en ted in substations back of the fur- irst bay, a ning and n n the age pper section of the cables, 30 in num- ent to a round bar 8 in. in diameter 200 lb. per lineal foot. The furnace rs. 6 in. in diameter, and the graphite The foundry flo a in diameter. Tilting is ac rated by concrete division walls, ft. higl or-driven tilting gears. Sm: and 10 in. thick, extending between the iilding ns are provided near the electric olumns. Wit 1 these low | furnace supplies. The melting part of the building is left « enclosed, is served by a 20-ton crane’ distribution of light and the ixiliary, the crane runway being 30 Alongside of the division walls, molders’ stalls 1 ir. The chemical laboratory is lo- ft. wide, will be built in the malleable department neighborhood of the melting depart- providing each molder a floor space x 35 ft ore room. Molding machines will > install required reated in Two Electric Furnaces of t Type, O f ¢ kw. H gf H Furnace for Drawing, a Quenching being L Bet wee Two Unit used for drawing the shot of chai he furnaces, tw aha th FP AEF CDI OE BEE we = vs Bg Me, i it ree 542 Each unit will accommodate 70 molders per turn. Hot metal will be taken from the melting room in 6-ton ladles, carried along the hot metal track that runs between the foundry bays and the storage bay, and taken by a crane from the ladle car to the unit in which it is needed. Here it will be poured into bull ladles for distribution around the foundry. Sand from the sand mixing department will be delivered to the molding floors in a similar manner. The core oven equipment includes two batteries of double-end ovens, five ovens in each battery, 5 ft. wide, 15 ft. long and 7 ft. wide inside. Each chamber accommodates two core racks, which will be handled in and out of the ovens on elevating platform storage battery trucks. The ovens are either coke or oil fired from the basement. The oven doors are 1% in. thick and are made of two plates with an insulation between of powdered kiesel-guhr. The gases from the ovens are taken from the top by a brick flue which is connected to the stack by breaching. The chimney is 4 ft. in di- View From the Switchboard End of the Power Plant Show tl Rear the Heaters and Cir ameter and 75 ft. high. A monorail extends in a straight line from the storage bay through the core room for bringing in sand, coke, etc., these being jumped through openings in the floor to the base- ment. The castings, after being shaken from the molds will be carried by crane to the end of the bay adjoining the annealing department. Along the foundry side of the annealing department, each foundry will have a battery of 20 and 28-in. x 56- in. tumbling barrels driven in groups of eight each. These will be used for hard rolling. By having these separate hard rolling units for each foundry the transferring of castings from one foundry to another is entirely eliminated. There are two batteries, each of three annealing ovens, at one end of the annealing room and two ovens at the opposite end where the space is partly occupied at present by heating furnaces. The plan, however, provides space for seven ovens at each end on one side and five ovens facing these on the oppo- site side, making 12 annealing ovens at each end with a common system of flues and connected with THE IRON ng the Electri ulating AGE Feb one chimney, 7 ft. 6 in. in diamet height. The annealing ovens are and 25 ft. deep inside, and each 40 tons of castings of an average walls, roofs and doors are insulat 41% in. of Sil-O-Cel brick. Each four burners fed with powdered will be charged with steam and Sufficient space is left back of tl final operations of soft rolling, gr blasting. From here the finished . to the storage and shipping bay adj The manufacture of electrit ste in the first foundry floor necessitaté stalls tion of some equipment specially required for 4 / work. The method of making this chain y scribed in a paper prepared by Chester K. Brooks assistant manager of the foundry, and presente, , the last annual meeting of the American 8 Testing Materials and published in THE Iron Ag July 4, 1918. Toward the front of the first }; are located five standard core ovens for mal il Equipment, One Air Compress Pump for the Heating System =. large cores or one-half lug sections used in the molt ing of steel chain. The chain links after being cas in sand molds are rolled in Sly tumbling barre's and these pre-cast links are made into continuous lengths 90 ft. long or a shot of chain by molding and casting links connecting the pre-cast ' Chain is made in only one size, 21% in. in d After the shot of chain is cast, it is rolled in tery of 48 x 60-in. and 36 x 60-in. Sly tumbune barrels located at the lower end of the bay, chain is then ground on four swinging frame 2 ers located at the end of the bay on one side annealing room. After being ground, the chain is heat a set of 900-kw. electric heat treating furnaces the Baily type, built by the Electric Furnace \" and having a capacity of 50 tons per da) The a includes two furnaces and a quenching t ; chain is subjected to a high temperature in te * furnace for hardening, then quenched in wate!, = then tempered in the second furnace. The furnacs 1 ‘ng encnine are 28 ft. long and 15 ft. wide, and the quenc® + J in ate Treaveu y )] —_—___—_—_—_" 919 two units is 10 x 40 ft., the set taken for entering the furnaces, pace approximately 175 ft. in vat treating operations, the chain ir sections about 20 ft. long and pass through the furnaces at a ire attached to hooks and the chain the furnaces by electric operated winch drawing the chain into the then into the quenching tank, and . ng it into the second furnace and floor for cooling. After heat treat- tested by means of two 3000-lb. testing machines and a 700,000-lb. testing machine. ipply comes to one unloading hopper 4] 1 of the plant near the end of the After being discharged into the he track, it is taken by an apron ed to one of two elevators. One levator f a 16-in. screw conveyor which car- the boiler room bunkers. The other ilar storage bin of 250-ton capacity mn conn with the coal pulverizing equipment. n the pulverizer house is a Manitowoc coal dryer, he necessary conveyor and elevating equipment, and wo R impact pulverizers of the high type. rom a ( e collector on the annealing building _12-in. screw conveyors carry the pulverized | to storage bins over the annealing furnaces. The pulverizers have a capacity of 3 to 7 tons each, lepending on the fineness of the pulverized fuel. The boiler house and power plant at the south iof the foundry occupy a brick and steel building, 25 ft., and 40 ft. high. Electric current is by the Cleveland Electric Illuminating Co., ivered to the power house at 11,000 volts n three cables, each with a capacity of 3500 kw. he current distributed through a high-tension 37 ft. long and 18 ft. high, to the etric melting furnaces, heat-treating furnaces, ito a bank of transformers in the power room supply current to two 300-kw. rotary con- that furnish direct current at 230 volts to rcuit for the operation of cranes, and ink furnishing alternating current at take care of the blowing and cleaning 1 other power requirements, and also ng circuit. The work’s distribution lirect and alternating current and for ong and 7% ft. high. The board is nd wired that current used in every separate operation in the works can order to take care of any accounting juired. The power lines throughout carried in underground conduits. essor equipment located in the power Ingersoll-Rand compressor with a 800 cu. ft. of free air per min. at 30 en by a 150-hp. synchronous motor ork and a high-pressure compres- ft. capacity, direct connected to a [he compressor furnishes air for vibrators, and for fuel oil ing the core ovens and drying the cs +1 ; witennoarg . il ru, r nec lines, 4 de of the power house next to the heaters and circulating pumps for heating system which takes care of The boiler room is equipped with 340-hp. water tube boilers that sup- g system. The boilers are equipped stokers which are coal fired from ers. The ashes are ejected from the 8-in. steam ash conveyor to a pit out- THE IRON AGE 543 are loaded cars and used for filling purposes The heating system takes care of approximaté 150,000 sq. ft. of radiation, or sufficient to heat 4 average-sized residences In the main building the radiation is made up of pipe coils composed « l45-in. pipe, and in this building alone there approximately 50 miles of this one size pipe The machine and carpenter sho} ecupy a tw story building, 75 x 120 ft., between the pot four dry and the power house, the machine shop being on the first floor and the car ter shop on the second floor. Lubricating oils are kept in a building 28 x 30 ft. located in an open court between tl machine shop and main building The pattern shop occupies a three-story bu ing, 60 x 150 ft., on the first floor of which are the shop operating and engineering department offices and pattern storage department. The second floor is used for the making of anchor chain and mall able patterns. O) hi tern shop and the general pa ttern } yr) Tor Tf é Sharon and Melrose Park works and an exhibit room. soth the second and third floors have st foundries for making white metal and brass t ings for metal patterns is a stairway and elevator at each end of the building, which has a monitor roof. The first floor has a wood block floor and floors of this type used in some other de partments where they are found desirable. The nealing department and shipping departments will both have wood block floors. The service building, a three-story ture, 50 x 90 ft., through which plant by means of the the time lobby, is designed primarily f vice of the employees, and contains the d locker rooms, and final finis] ing brick struc the men enter the underground tunnel from r the ser ispensary shower lavatories, baths and drying room on the first floor. locker room and separate room for foremen, with lockers, showers and lava tory and toilet facilities on the second floor. The entire third floor will be the men, furnishing them providing a room for meetings. A office building, which has not yet adjoin the service building. More than the usual] attention was given to the toilet facilities. are provided in the foundries and various partments, and equipment and fixtures of modern and sanitary type stands for the hot and cold spray heads. used for a club ttractive roon for quarters and iarge general been built, will T are used The are white enamel supplied thr men troughs, and ] a+ - wate! ugh yoose-neck Simon-Carves Ltd., Manchester, England, whose Ne - \ York office, 2 Rector Street, is in charge of W. E. She ley, American representative, has received an order for the coke ovens, coal ind coKe-! nal ne plar ‘ also a sulphuric acid plant, which will be erected ‘onnection with the blast furnace plant to be built India by the Indian Ir & Steel Co., Ltd., as n tioned in THE IRON AGE | ver mon-Carves, |] is the pioneer of t y-product coke industry in Eng land and still is the largest lilder of that class of equipment the United Kingdo It was the first t erecta prod t t in Ind nd the ne ment ; above ne seventl attery t e erected by that company in India The plant of the Reznor Mfg. | Mercer, Pa manufacturer of the Reznor gas heaters, has been put in operation, after being closed for about repairs and extensions. More machinery an were added, as well as a large stock-room pany sold over 100,000 gas heaters during the 1918 season, a number of these being purchased by the Gov ernment for its plant at Nitro, W. Va a month for 1 floor spac« The com ; th i ray in } SA ll tc i owe —vitie.. 044 THE IRON AGE NEW RECORD FOR EXPORTS January Makes Remarkable Showing—More War Restrictions Removed W ASHINGTON Feb. 25 Despite rest? ind embargoes, to say nothing of shipping difl ] i and he demora ition of foreign mark J ary export yf the U1 ited é broke i ¢ l Stat ‘Ss com piled by the Bureau of Fore on and Domesti Com merce reveal the fact that the value ot tl January exports reached a figure never before touched by any monthly figure in the history of America ommerec: The total exports for that month were $623,000 000 imainst $566,000.000 for December, 1918 ‘ nerease of $57.000.000—and an increase € £118.000.000 over the January, 1918, figures, which tot ed $505,000,000,. Only twice before have the monthly export figures reach the $600.000 000 mark n Januarv and December. 1917 During the seven months of the fiscal year ending with January, 1919, the exports totaled $ 15,000,000 against $3,450,000,000 for the corresponding period of the previous vear I aiu ot ti Jar l npor \ 7 O00 000 rease of only $2,000,000 over the December figur« und a drop of $21.000,000 from the Janua 1918, total of $?34,000,000 For the even month period, the tota imports are $1,698,000,000 against $1,634,000,000 for the ime period of last year The January excess of exports over imports also broke all records It was $410.000.000 almost the equivalent of our total favorable trade balance of the ast normal year—1914—which aggregated only $470, YUU UUU Removing War Restrictions The most important removal of war restrictions 01 yur commerce during the last week was the announce the War Trade Bo it trad sumed with that portion of the Rhine provinces of Germany included within the ment by ird that trade has been re area of military occupa tion by the American and Allied armies. The definite unnouncement of the methods of procedure by which exports to and imports from this territory will be governed has not been made. In the meantime. how announcement by the board, persons d in trade with that territory, may com municate with the War Trade Board here. As the territory thus opened up includes some of the most important industrial centers of the former German Empire, it promises to be a big item in our ever, SayS an Siring to engage ommercial development, especially as it is likely that iccess to this territory may be provided direct through the mouth of the Rhine in Holland, instead of by the roundabout course through France. Trade with the former German colonies also ha been re-opened. The latter authorization says a stat ment by the War Trade Board, permits all persons in the United States, subject to the rules and regulation »f the board, to trade and to communicate with persor residing in colonies which were owned or controlled by Gern any oO! Aug ] 1914 TI extensive author 1 on includes the areas in Africa known as German East Africa, German Southwest Africa, and Kamerun. It ilso includes Kiauchau in Asia and the Bismaz Arch Marshall Islands and German Samoa in the Pacific. Ir ypening a these colonies to the resumption of trade tT > ] 1 ] 1 } the War Trade Board declared that applications hers f+ . xsl] } fo rahliv en? ia rod f ] + “+ aiter Wil € TavorabDly co aered for iicenses to expo! r to imt a commodities ft ind from such ter Tor t Despite the program to re-op the occupied po tions of Germar y, there 1s stlil a hiten in the questiol of renewing full commercial relations with the Grand Duchy of Luxembourg, although commercial com munications are being permitted. The Australian government has revoked the ban on the importation of certain articles of tinplate and goods packed in tinplate containers. Market for Iron Pipe The Far Eastern Division of the Bureau of Foreign and Domestic Commerce has prepared an interesting Febr I report on the possibilities of estab market for iron pipe from the United § " “There is perhaps one considerat veighs all others,” says the report, market for iron pipe in the Far East entire absence of modern sewerage densely populated countries of the Far China, have for years depended upor turn of the night soil to the land to terioration and for this reason our m ewage disposal are not likely to be ially as the cities obtain a revenue f; f this waste material who in turn sell , in the neighboring districts. “Waterworks and gas works on however, are now established in the ec] Orient and the demand for iron pips ; . poses is likely to increase. There w general use of gas in the Orient that United States, however, because of the Japan and the tendency to adopt el and China for lighting purposes. Ther ery great demand in Japan for boil purpose of fitting out marine boilers ar recent growth of manufacturing and boilers in industry. The Nippon Kokka n the manufacture of iron pipe. There is a growing market in the Dut for iron pipe and here the comparative pean population, 125,000, is constantly dema: : modern drainage and sewerage facilities ‘ considerations regarding night soil do not where the tropical soil is not in need of ’ methods of agriculture, crop rotation ame is true of India and the English h extensive work in introducing modern sanita th The Temporary Loss of British Trade When the British government announced that the import restrictions which had been lifted after the armistice were to be resumed March 1 an inquiry was begun by the American Manufacturers’ Export Asso ‘lation to determine what effect this would the export situation. The result of thi summarized in a statement issued by George Ed Smith, president of the association and pr: f the Royal Typewriter Co. “The American manufacturer,” he sa that England is under the necessity of read domestic affairs. it is true that this r will work considerable hardship on Amer which have a large investment in Great Br which cannot supply their English branches w for some time to come. On the other ha not mean that the American manufacturer m don his English branches, because we aré : within six months or at most a year Eng more resume importation upon normal lines. Priot to the war we were England’s best custo! Excluding the raw materials the United States to Great Britain, the factured exports from us to England and ind to us were approximately the same M\ English markets and England needs Am cets, and it is not likely that England wv delay longer than necessary the resu mutually beneficial trade. “Realizing that he himself may need 5] ires to assist his own business back tions, the American manufacturer is 1 riticism of the temporary measures w! may adopt. On the other hand, he has be Sir Henry Babington Smith, the acting missioner for Great Britain to the United every effort should be made by Great Brit all necessary adjustments as easy as is po the circumstances for the other friendly nat by these readjustments. “Under the circumstances there is but for the American exporter to do while he from England by these temporary import res! he should not be idle.” was ours. St.tie, Dynamic and Notch Toughness’ Value of the Charpy Test in Determining Ability of Steel to Resist Rupture Under Notch Conditions—Its Use in Europe BY DR. SAMUEL L. HOYT eel that appears to have received the ture is ¢ es har angle ration, at least in this count1 riginal notcl Cer ' ‘ ey or tho h is due, possibly, to our regard ire self healing, of which lead n example lalitative property or, at any rate, in the opposite manner, since the notch becom ré els ductility. We have erroneously rounded with distortior In the iV a it l r to judging the toughness of a f high notch t 3 yr in the tensile or similar test affected by a notch thay e wit] y not ‘ w presented in the present paper point that ) ‘ as <e hardness of tensile strength in independent property and of Notch Effect in ngineering Practice require in so far as th 1 r} ie al a deter nations If sucl { ) tice has ‘ rat ' ' Yr ¢ necessary to vise ¢€ er 2 es itt tion bv nve f iring or valuating toughness : e : . heer y } I ‘ ‘ ! pact test (the Charpy test) is the notch effs ca ‘ ant ] y } Law } ‘ ogica f hat has so far bee : . . . auced \ e 1¢ ry f ! ; etir f purpose. It is further advanced, : = aid : ; : and at other time may e ul tentionally introdu phasis, that we have two kinds of : : : ; , : ; Dv faulty or areless workma hit f these. the te with and, accordingly, they will be oS ‘ . s the more reprehens é re fieult t¢ ently. . ; guard against Another equally important p ‘oc . _ +. : , lay oP 4 +» ‘ . . Materials Classified as to Toughness necessity of considering ne ire a desirability of heat treatment a i meal of ove | ee! defined omew hat as follows: ing or counteracting the effect of the notch hose that offer considerable re A certain railroad company was |} n¢ troul nent de formation but Ww hich, once sucn splice nar fa ] ire wt ich fron the re rac ; \ een overcome, may be deformed plasti possible to connect with roadbed nditior T Vy the expenditure of considerable parts of the faile 1 } irs howed that the y iteria “ her words, tough materials may be de- well up to the quality required by the specificatior aS ally but they absorb a considerable’ that no basis for criticisn ma nm that score the process. This kind of toughness’ [ft contained 0.34 per cent ind 0.018 per cent toughness when the rate of loading phosphorus; it had an elong: n of 35 pe ent or r dynamic toughness when the rate 92 jn. (50.8 mm.): a tensile streneth of 65.200 (99574 atively rapid, as in impact testing, ke.): and a vield point of 33000 Ib. (14,968 kg.). Or t the strain distribution is essentially making a microscopic examination. the stee] showed static toughness does not imply considerable > oy J a > or dynamic toughness In fact, Stattian structure is may be seen from Fig ] may be equal to, greater than, or Furthermore, the pearlite wa f the familiar lamellar tougl ness, thus dividing materials type that haracteristic of i vwoled ste I} This is well shown by numerous de 1 developed from tl examinat vas that t t ra ind the splice bars forn 2 not 1 tnat tne structure of the bar was ich that it lid not alway Notch Toughness B adequately resist the notch effect produced every me it a stress applied to a bar that a car passed over the ra t (repe ' re in cross-sect on along its length The solution of this pr len non-uniform strain distribution at recting or imp? ng the ruct r ss-section. If the change in cros to which end a series of heat-treatment t rm of a nick ora groove, the strains aucted By , t g th ir t pe , nick multiply and are much greater deg. C. for * r. and quenching ruct strain over the cross-sectior Such ecured that w I Any : hangs cross-section, is here re mount of free ferrite rhe t h, and the non-uniform strain dis reased to 92,000 (41,750 , notch effect. The ability of a material to 45,000 per s n. (20,411 t ses when in the notched condition is was decrease ( ent A cl r notch toughness. ture is reproduce , ; ee fect is well illustrated every time a mall piece of a failed splice se bar to break it off at any particular laboratory lhe o1 i irse Wid yw by the hand produces strains at ture 1s repia ed by necw rt h well in excess of the resistance of which is sorbite posed 1 hence produces the fracture. A nal pearlite and 1 t a unnotched bar would merely bend pared to 1 W u ; is it is that a bar, even though made |! d to highly 1 tant to t teh eff naterial, if notched, may behave as the adopt e-Ure uw Vas ¢ I te nown that the severity of the notch some tr : lr :, is the angle of the notch decreases rms, tallied while in neav} rhting - ar the notch effect increases in most made by a we hown auton . , fracture starts, because the angle of company and suspicion rested at lr pon the t drivers, particularly as the material was known to pass esented at the February meeting of the all specificat on It contained 0.485 per ent rpor Mining Engineer New ¥ Feb. 18 had an elongation of 27.1 per cent in % in., a reduc ot . M inneapetio “Minn. " — tion in area of 45.6 per cent, a tensile strength of ae ellneena er cerca 546 THE IRON AGE Febr 27 igs. 1 and 2—Original Structure of the Splice Bar, 65 and 425 Diameters Respectively 77,500 lb. (85,153 kg.), and a yield point of 39,900 lb. (17,690 kg.). An examination of the axle (not heat- treated) showed that the taper had been cut by a rough- ing tool in such a way as to leave the notch indicated in Fig. 5. Knowing the danger of the presence of such a notch if the steel were in a poor physical condition, a microscopical examination was made; this showed the condition represented in Figs. 6 and 7. Here again the presence of a relatively large amount of excess ferrite will be noted. The result of a simple oil quench of a part of the failed axle is shown by Fig. 8. While the free ferrite has been largely eliminated and sorbite has been substituted for pearlite, an even better heat treatment would be to quench the axle in water, to en- tirely prevent the segregation of ferrite, and to reheat to produce sorbite and the requisite mechanical prop- erties. fests for Toughness It has been customary to test materials by various static and dynamic tests and to judge from the strength and ductility whether the quality of the material is sufficiently high to warrant its use regardless of the jesign of the part, its relationship to other parts, or possible defects due to faulty workmanship. One of the bjects of the present paper is to show that, in case the material is to be used in the notched condition, the usual tests are unable to differentiate clearly between materials that will probably stand up and those that are likely to fail. This means that it is necessary to sup plement the ordinary tests with a test on notched bars In order properly to define what is meant by tough ness, it was necessary to distinguish between conditions of uniform and of non-uniform strain distribution. Likewise in testing the toughness of materials thx same distinction must be made, a point that, due to more or less general disregard, is somewhat strongly emphasized here. A qualitative test for toughness quite commonly used is the nick and fracture test for fiber. This test is useful to a certain extent, but it should have no more place in scientific testing of materials than an ordinary scratch test for hardness. The reduction of area in the tensile tests is very frequently looked at with an idea of sizing up the toughness of the material It is more correctly a measure of ductility and becomes a measure of static toughness only in a limited sense, inasmuch as it is the ability to deform and not the resistance to such deformation that is determined. The area of the stress-strain diagram may be taken as a measure of the static toughness. Such measurements show, for example, that the toughness of annealed carbon steels increases with the carbon content up to about 0.30 per cent C. This figure. combined possibly with the resistance to impact, should be very useful in case the strain distribution of the finished part is essen- tially uniform. The value obtained by dividing the tensile strength by the proportional limit and multiplying by the elonga- tion (Martens) may be very useful in certain cases; for example, in bringing out the toughness of pure copper. The value of this determination is also limited, as it does not include the resistance with which a material opposes permanent deformation. All of these ts values are of undoubted importance terpreted, but none would bring out the materials in the foregoing exam) to their apparent indication of strengt they would be directly misleading. The recognition of the peculiar w: materials when in the notched conditi development of the impact test on n supplement to the customary static a) and for the express purpose of testi toughness. In its present form the of systematic experiments extending or more by Barba, Frémont, Charpy, A which culminated in the reports of Char national Association for Testing Mate 1912 and of Ehrensberger to the Gern Testing Materials in 1909. The accumu dence over this period made possible th: of a standard test so that now it can be that the notched-bar test, or in particu test, is capable of supplying informat toughness that the tensile test gives perfect, and often in a directly misleading, manner test shows the great danger of angular sudden changes in cross-section, particularly material of low notch toughness is used : In the report of Ehrensberger, result three classes of materials were given: Forged steels, forged special steels, and cast carbon These three classes of materials can be com; means of the figures shown in Table 1, wi from the report. Table 1 Notch Toughness of Three Class: f It * o, Shee ‘ oc x of = = 2 Rua A aa & I ED CAI N STEELS t 0 2: & ) 2¢ 64 16 } Q t l 36.100 Zt ) i0 1) 4 «"¢ ) ‘ ) 1? O00 24.5 70 ae ] 4( 00 26.4 60 4.7 F 13 ) 13,000 12 t & H KE CHROMI I 200 2 70 $2.1 1 ( 10 800 l 62 ae ] 118.200 ] 3 H 19.3 ‘ ) t > 1 8.3 CAS STEEI ( Of 2.9 l 7 ° ngat i gage length equ A few comparisons may serve to bring out thé of the Charpy test for toughness. Tests 1 that the notched-bar test bring out the lack of ness (or at least notch toughness) of test bar was forged too hot, although no evidence of given by the tensile test. Tests 1 and 25 show plainly that the toughness cannot be entirely from the reduction of area or elongation; test Figs. 3 and 4—Structure of Splice Bar After Heat [r 65 and 565 Diameters Respectively eatl - eb ; 919 THE IRON AGE 547 eb! the two, but test bar 25 possesses index of their probable behavior. If these points were ’ toughness. Test 10 shows how far’ considered, the purchaser would certainly insist that fi es can come from indicating lack his materials show a high degree of notch toughness it ie e probable cause all cases where they are to be used in ¢ the true char- —— ——________, the notched condition al is brought out Ch Se : t cone OM. Summary ’ ‘the carbon steels WU), Undoubtedly the occurrence of a teels reveals a su- 7 the notch effect in machines and en- i itter that is not as ‘ gineering structures is much more it by the tensile | common than is generally recognized. tests indicate that “= — ———==_ This is generally due to the design . ve greater tensile Fie. 5—Notch Steel Axle M of the structure but may be caused ' ame ductility but by a Roughing Tot by faulty workmanship. Even a : . rhness of the latter hasty examination of such machines id out by the notched-bar test. The as locomotives, automobiles, stationary gas engines, ’ the cast-steel specimens show that steam engines, etc., reveals an amazingly large number e excellent elongation and reduction of notches and in many such cases the material com- thus apparently ductile, but be quite posing the parts should have a high degree of notch x when tested in the notched condi- toughness to insure against failur ; steel behaves the same as a piece of The logical test for such materials and the only one capable of yielding reliable results is the notched : ort of 1909, an interesting case was. bar test. This test should supplement the usual tensile 2 the notched-bar test can give infor- or hardness tests and its results used as an index of steel that is in no wise suggested the resistance of the material to the notch effect Fir Two Photom grapt Represent the Original Structure fa Re Ax f I meter TI us ne repres he structure after oil quenching, the mag tion being tests, either static or dynamic. The A factor of safety is generally used in the design with two steels A and B, really the of parts of machines requiring the material to have lifferent conditions of heat treatment, a certain strength combined with a certain amount of ductility. These properties are written into the speci fications and the material is inspected on such a basis py yn A Steel in Two Dif Neither the factor of safety nor the usual properties ( offer a guarantee against failure in cases similar to those discussed hers It is for this reason that the Jy Se cause of many failures remains a mystery when test J . a e& S = bars taken from the broken parts are found to pass all : ; gos v3 s9¢ ly specifications. The Charpy test would undoubtedly ; Et =e = = show a low impact value, due either to faulty heat - mon, Lo E s treatment, in case the parts were heat-treated, or to f 79 9 44 lack of proper heat treatment. e 2. Not even the resistance to frac- y a weight falling from a height of 0 m.) as given in the next to the last ss tes the excessive brittleness of steel B. ture at once showed that B is in a ndit than A. These figures could most indefinitely and have been well A lecade. w no longer be any doubt that there is which is of great technical importance, ‘sured and in many cases not even indi- tensile test. In spite of this un- Charpy test, which is now extensively Is given but little attention in this uld seem to be due to lack of familiar- ‘ users of steel with the facts that in mber of cases materials are used in a n, whether intentionally or otherwise, o used the tensile test offers no reliable ion isual The utilization of the tar and gas in by oven operation has been shown in an interesting way by the Koppers Co., Pittsburgh The company has pre- pared in chart form as a wall hanger, a reproduction in product coke colors of an apple tree which has produced a large amount of fruit. Each of the apples is named for some product obtainable from coal, and the main branches and subdivisions are al named so that one may get ' the iso path in at a glance through which the particular derivative copy of the chart : to the Koppers Co. the by products recovery obtained. A can undoubtedly be had by applying The file manufacturers of France to the number of 42 have formed a society, according to L’Usine. Dec 5, 1918, with an office at 60 rue de Miromesnil, Paris. Eugene Wolff is director, and the functions of the so- ciety are principally to see that the tool steels neces- sary in the production of files be apportioned justly and as liberally as supplies can be obtained. b ee 548 THE IRON AGE Feb Y= SCREW THREAD COMMISSION House of Representatives Passes Bill to Extend Its Life for One Year WASHINGTON, Feb. 25.—The House of Representa ives has passed a bill to extend the life of the Na tional Screw Thread Commission for one year after its statutory expiration, March 21, 1919. The action was taken on a favorable report by the Committee on Coinage, Weights and Measures, which found that the commission is seriously hampered by the fact that four months have been taken up 1 jata and that the big work of the commission is still ahead of it. So far no opposition to the bill has man fested itself in the Senate. Dr. S. W. Stratton, Director of the Bureau of Stand- ards, is chairman of the commission He testified before the committee concerning the importance of the work which the commission is doing. It has held s meetings attended by 29 representatives of the Army ] ; +a | . and Navy and 108 manufacturers, as well as repre sentatives of the British Mir istry of Munitior and the French High Commission Before making a final re por ne comn sion belleve tnat an inter? nal co! fers W r I essary oO |} V1IGdE pasis fo irbdl trar\ recommendations. ly the meantime, Directo. Stratton declared the commissio1 preparing tenta e reports on standards for the following: terminol pr) nape ¢ thread, system of coarse screws, syste f ne screws, §s m or sma scre el or pipe nread vst of ! e couplings, syste! f instrumer scre nda svsten of mea liremeé t I | test Director Stratton a le red it the commis as found 1) T} t tnere Ss! taco on tel no y mon he sel ind manu turers ¢ rews; (2) that thers le e de it ! ! ( rom t ecognized standard ha I nre j he Se rey nanufactured in the United State (3) that there onsiderable deviation In many resp n the accepted standard of pitch for screws n tured in this cour y; (4) that there is not a standard whereby the accu racy t WOT ? ? h p n t ] | (5) th +t thers j not a standard method of me iring and testine fo accuracy; (6) that there are numerous special screw ised which are only slightly different it just suffi ie! lifferent to prevent interchangeability; (7) that there a desire among manufacturers of the United States for an international standard; (8) that an inter national standard is an absolute necessity if the present shipping and foreign trade program is to be successf (9) the above conditions have seriously interfered wit} the naval and military operations during the war, a1 for many vears have constituted a serious hindrance to -OMmmerce. “The importance of international standardizatior ie jeclared Dr. Stratton, “is not recognized as it appears to us it should be. The ships we are now building. and which will enter foreign ports where the United Stat flag has never before been seen, will carry into our ‘ompetitors’ markets the produce of our factories, and it is therefore imperative that the screwed parts of our products interchange with the screwed parts furnished Dy our competitors To