The Iron Age 1922-08-10: Vol 110 Iss 6

ES] SHED 1855 HE IRON AGE New York, August 10, 1922 VOL. 110, No. 6 Steel Scrap in Cupola lron Mixtures Strength of the Product and the Percentages of Secrap- A Series of Experiments and the Results Effect on Hardness BY E. J. LOWRY* cupola cast iron by the addition of steel scrap , to the mixtures is of fundamental importance when high strength castings are under considera- In this article some of the more important characteristics of high-test irons are discussed when obtained under scientific methods of melting. As a result of the term “semi-steel,”’ the foun- dryman usually considers that any addition of steel «rap, varying from one per cent and upward, to the KNOWLEDGE of the properties bestowed on t10n. eS ee ot in Stree? SE 7 ° INCREA CENT Per Per Cent or Steer Scrap in Mix Ture Percentage Increase in Strength by Stee Additions to Two Classes of Iron Castings rr ixture will produce the strongest castings. It is not believed that the originator of this product had such a practice in mind when he placed it before the foundry world. Rather, it is felt that he had in mind a limited variation in the percentage of steel scrap to be used in obtaining the strongest iron for analysis. With this idea the term semi-steel adopted and presented to the trade. From its inception there has been more or less as to the correctness of such a name. Some rers have performed experiments to prove its others have merely stated that high-test ild be more correct. It is not within the of this paper to present arguments either against. The trade names are accepted and a vive! Was * ed ughout the discussion without any bias. 150 ‘he engineering professions, on learning that 3H Hee ap added to the strength of cast iron, be- of - peful of new applications for this material. gist, Hickman, Williams & Co. Consequently, when cast iron was ordered the engi- neer demanded a semi-steel. This caused foundry- men to jump into the manufacture of this class of metal. The movement was without preparation and knowledge. As a result a heavy loss and many exceedingly poor castings were made. This caused the manufacturer as well as the consumer to look skeptically on the increase in strength of cast iron by the addition of steel scrap. Furthermore, some foundrymen learned to contend that such addi- tions were injurious to their melt, while still others have gone to the exclusive manufacture of semi- steel castings. Limitations on the Percentage of Scrap From the foregoing, it is evident that there must be some merit in the way steel scrap is melted in the cupola. In other words, conditions in the various foundries and their methods of cupola oper- ation have a direct bearing upon the resulting product. There are limitations which must be placed on the percentage of steel scrap in the mix- ture and on the arrangement and melting practice in the cupola. These limitations are principally because of the factors of mass, time and tempera- ture. It is generally conceded that carbon by iron and steel is directly dependent absorption upon time CARBON Per Cent ToTat Mixture and temperature. Therefore, these become neces- sary elements in the melting of steel scrap in cupola charges. From the iron-carbon equilibrium diagram it is obvious that, as carbon increases in iron, the temperature of melting falls. From these phenom- — i ‘Remeeeieeeee RN i ~ ena, if the time factor is correct, the steel will ab- sorb carbon enough to bring its melting tempera- ¢ . , ture well down to the range of that of the pig iron. ey , By actual experiment in melting 100 per cent ut steel scrap charges, it was found that the absorp- d tion of carbon readily took place up to 3.00 per cent. These experiments covered various grades of carbon steel, and in each case the final carbon con- = Ay tent was within a 0.10 per cent range. ss : Factors to Be Considered yi While discussing the elements which enter into é the melting of steel scrap in the cupola, it is well ae}: to call attention to the factors which are considered ; ‘ important governors: te ie 1. Diameter of cupola, inside of lining 2. Height of cupola charging platform above bed 3. Ratio of tuyere area to melting area } 1. Size of charges. rie ». Blast pressure ' 6. Volume of blast : 7. Bed charge of coke S. Coke charges between iron charges These are given as a warning to foundrymen } who are not aware of their melting conditions, so that they may forestall their being misled in the be- Cent Re LW ILARDNESS ’ NCREASE EL O 0 10 20 30 40 50 60 Scrap iN Mixture Per Cent oF Street Scrap Additior on H Fig Inffect of Steel Iron Castings lief that they can take their original practice, add a little steel scrap and accomplish the results that follow. The diagrams as reproduced show the average results of many tests run from actual production cupolas in one of the largest foundries in the Middle a West. The time consumed by each percentage specified extended over a period of four days, 80 that the sprue was well worked in. The accumu- lated data as presented are averages of the samples from each of the four daily heats from which six tests were made. Each of the specimens were broken for strength, analyzed and microscopically examined. The bars were standard test bars and ‘ were all poured at 2300 deg. Fahr. The chemistry of 4s the iron was held as near to conformity as possible. , alas Fig. 1 shows the effects of varying percentages of steel scrap in cupola mixtures. The two lines indi- ; ; TS eate the effect on different analyses of irons. The % rg upper one represents the results obtained from a low silicon, and the lower from a high silicon iron. The base grade, or a no-steel scrap mix, has been og listed at zero and the percentage increase in O. i ey ; strength as co-ordinates. As a matter of fact, the average strengths of the base grades considered , were as follows: Strengths, Lb. per Sq. In 22,000 ,. Grades, ~ Silicon, Per Cent 0.75 *. * 1.20 29.000 1.50 33.800 33,900 se 1.65 23,000 2.10 By observing the strength chart, Fig. 1, it is seen that there is a limit to the strength obtainable by the additions of steel scrap. The highest, 40 per > cent, which gives the maximum strength, is not to THE IRON AGE August 1929 be recommended for standard practice, as daily remelting causes this mixture of i, 4 = come sluggish after 5 to 10 days. The bes? \ oy #9 percentages to be suggested is between ° ote per cent steel scrap. This gives a good strop close-grained iron, and one which gives sa‘ -faeto» results. As an explanation of the added streny }) give, to cast iron by the addition of steel scrap Pigs and 3 are enlightening. Fig. 2 does not st» ¢tly Q here to the tests which were run showing at stee| scrap absorbed between 2.90 and 3.00 per «ent bon in the melting. This difference may be , tributed to the difference in total carbon of the pi iron and scrap used in the mix. The graphs, how. ever, do confirm the statements that steel scrap dilutes the total carbon present in the iro: Effect on Hardness The question of steel scrap tending harder the casting is amplified by Fig. 3. This increase j; hardness is appreciably felt in the wear of the cas. ing and is a noteworthy point for the consumers This increase in hardness is a result of a slightly jp. creased combined carbon content and the smaller formations of the graphitic carbon present. The microscope shows a distinctive arrangemen of carbon formation for each percentage of stee! added. There is a marked tendency to break up the large lamellar formations, causing a more even dis. tribution of the carbon throughout the section. The discussion of microscopic formations, however, j outside the scope of this paper, and the readers are therefore referred to the recent work of many of the leading investigators on the subject of cast iron, In conclusion, the facts as presented show that semi-steel or high-test irons show a marked im- provement over the regular cast irons. It is hoped that a more scientific control of the cupola wil cause a wider adoption of this practice. [ron Ore Problems in Birmingham District tript Sampling of iron ores in the Birmingham dist has been completed by the Southern experiment statior of the United States Bureau of Mines, 453 samples having been taken. These samples are being analyzed at the Birmingham and Minneapolis experiment sts tions of the bureau. A study of mine supports, particv- larly with respect to the crushing strength of ores is now under way. Several cubes have been cut fron large blocks of iron ores taken from the mines. Whe! this cube sampling is completed, crushing tests will made with a view to obtaining data on the streng! of iron pillars under compression. A detailed study ‘ the ore beds and associated formations is in progres: as a preliminary study to the support problem. Inte! esting results have been obtained in the investigation looking to improvement in the location of ores, partitl: larly with the dip compass. Steel Plant Ashland, Ky. The American Rolling Mill Co., Middletown, 0" which some time ago acquired the properties of tM Ashland Iron & Mining Co., at Ashland, Ky., 1s °°” templating extensive additions to its Ashland works, principally in connection with its finishing capacity. Proposed extensions will cost in the neighborhood $6,000,000. Reports that a $10,000,000 note issue ¥" be offered by the company in the near future appear’ on the financial pages of a number of papers last wee but officials of the company had no information to 8"* out when interviewed. Contemplated Expansion Rolling mill equipment, recently installed at ™ Wallingford Cold Rolled Steel Co., Wallingford, Cont, plant, Was been successfully tested, and is ready for P™ duction. BY GORDON FOX 3 ‘DUCTION of steel, including metallurgical! configuration of the product, involves largely ication of heat and power. Although the direct power is only about 5 per cent of the total cost duct, it is more nearly 15 per cent of the cost yperations. sheet bar, involves a total power expenditure = | } 2 ee ee } $ u -+—_——— | | E = ee * KE Ld — } ib ty ANS a : eB qr! ae A +— | l é i \ {Y 76 wn ype of Three-High Plate Mill with Mot . Drive and Flywhe : me 200 kw. hr., about half of which is required owing at the blast furnace. Due to the large tonnages involved, the cost of power reaches a consid- ible total expense. In one electrically driven plant roducing about 25,000 tons of steel per month, the rresponding electric power cost was about $40,000. Of greater importance than the direct cost of power Fig Lav« ot 10-In Cor rut ious Skelp Mill with Rough o ng Stands Gear Driven from Motor and Finishing Stands from Another. Two Belt Driven the edg mills are driven Ing the third motor from roughing the has a eparate ndirect influence of reliability and efficacy application. tric motive power is applied in the steel mill: t Directly, for rolling. for transportation and manipulation of and adjustment of machinery. q For driving accessory apparatus. In mill which is elec- equipped throughout, the power consumed 1 in general, about 60 per cent of the total, being used by auxiliary and accessory Relative usage varies. a ance er media employed in steel mills are steam, ompressed air and electricity. Prior to the f the electric motor, steam and hydrauli were extensively employed for main rolls and respectively. Most new mills are now eS 5 1 with electrically driven main rolls, and the ent steam drives are being replaced. Hydraulic ; still retained to some extent for auxiliaries. , ints of advantage, particularly for slow and 7 near motions. Hydraulic mechanisms are in- reciprocating as contrasted with high speed e obtained with motors. For linear motions, al engineer Freyn, Brassert & Co., Chicago. This a the Western Society of Engineers, won the Hunt prize for the best discussion of some phase industry, \lectric Motor Drive in Steel Industry Rolling Mill Requirements as to Power, Speed, Adjustability and Changing of Speed—Mill Layouts to Utilize Electric Power ansformation of the raw materials and mechan- A ton of steel, in the form of billet, 339 must be and perhaps several gear motors racks or cranks, reductions, introducing com- plication, cost, space and inertia factors. Hydraulic drive is well adapted to shears. It used where the market does not warrant the develop- ment of electric for revolving ladle cranes. It is also used for counter-balancing, as at main rolls and lifting tables. The principal disadvan- of. hydraulic drive piping expense, incon- venient control, low efficiency, high maintenance costs, freezing and danger from leakage about molten metal. Compressed air is used to a limited extent for minor inear motions and for riveting and chipping. One of the principal advantages of electric power the mill the fact that it permits tralized generation. The power plant, equipped with efficient turbine generators, occupies a minimum of space and may be located to its best ad- provided with screws, is equipment, as lages are n steel lies in cen- condensing vantage, yet not conflicting with mill layout. Waste heat from blast furnaces may be utilized effectively and completely. The diversity factor between mill de- mands results in a relatively good load factor on the power house and boiler plant. Duplication of boiler capacity and operating thus minimized. Power can be generated to best advantage on a quan- tity scale in a central plant. Electric power can be easily and economically trans- forces Is & 5 d Shear 2000 Mp. Rovahing oe 2000 Hp Finishin Drive mitted in quantity Protection of the distribution ‘ means is readily afforded. Duplicate feeders, loop sys- ’ tems or inter-connection may be employed. Faults are quickly isolated. There are no stand-by power losses at point of application; moving machinery may be readily supplied. The ease of metering electric power permits a ready check on rolling conditions. It permits rolling at maximum safe rates and assists to economies. The possibilities of purchased electric power are attractive in many instances, either as a main or sup- plementary source or as a stand-by, particularly for plants in which waste heat is not available. The in- vestment may thus be minimized. Probably the prin- cipal deterrent to the more general use of purchased power for steel mills is the experience of lack of re- liability. The steel mill power plant compares in re- liability and continuity with the central station and enjoys the advantage of contiguity. Transmission interruptions are still of too frequent occurrence with of ee ead ni Ge = oe Se are Ss y iret L : 1 ‘ay ’ j . : ; . { : ‘ > > © « : 340 some utilities. Power interruptions at a steel mill are always and sometimes almost disastrous in their consequences. Interruptions from an _ outside source are particularly inconvenient because of their indefinite duration. Probably the greatest advantages of electric drive are derived at the motors. Their compact form, light weight and wide range of characteristics permits their effective application to all classes of main and aux- lllary apparatus. Their ease and flexibility of control as to speed, torque, direction of rotation and braking are of préeminent advantage. Their ready subdivision into units as desired assists in simplifying the drives. Their reliability is evidenced by the fact that, in most mills, the electrical delays are few and usually of short serious THE IRON AGE rolls in each successive stand must revolve f; August 16 those in the preceding stand by an amount cient to account for the elongation, and thus As the delivery speed of is approximately the same as the periphera] the rolls, the intake speed varies in proporti: or minimize looping. draft. Thus, for a 30 per cent intake speed is to exit speed as 70 is to 100. varies some with different sections. Some control is possible by adjusting the in each stand. stands to skew the sides, and also to e¢ The driven. stands metal, so lear the in eac as h to scale. group through gearing or belt to the drive. a type of continuous mill. Continuous mills are widely used both for r work reduction it 4 T) Guides are commonly inserted Mills of t! are often divided into groups of stands, usu: roughing and finishing, each group being se; Fig. are ») i] 1929 and for producing the simpler shapes. At Gar installed a continuous blooming mill having stands. This principle is widely used for billet. sk sheet bar, strip, merchant and rod mills. Th: advantages of the continuous mill are large product with little labor and rapid reduction with littl between The rolls are of short consequently may be of relatively small diameter. T} type of mill requires relatively low power per unit output, due both to the high temperature of working and to the small roll diameters. The simple reversing mill comprises a single tw The lower roll is fixed in el 1S passes. lengt} involve relatively low inspection and The overall economy from coal duration. They maintenance charges. ile to the work is comparable or superior to that of Motors involve no stand-by losses, Their and other drive media. and may be started and stopped on short notice. and minimizes mill wear high stand of rolls. uniform torque speed a4 ~ . ~_ . a . * . . . a . : ? ‘ > . & -”“ '. 2 Fe 4 % . ot sa breakage. Automatic control, with current limiting Tin. 4. Betaian - aes and protective features, safeguards both the drive and : z the mill and minimizes dependence upon the operator One Motor to Drive ‘ ; Electric drives for main rolls are available, having Roughing Stand, WI) ‘ - a wide range of characteristics. The general type of eile Alas dad ) drive selected depends primarily upon the type of mill < 4 3 and its requirements. There are now installed in the Five F hing Stands it L United States and Canada more than 600 main roll Tande motors. These represent a variety of mill ar- 7 y angements which do not permit of distinct "ay, 9 assificatior There are, however, some pre —— e < ——— > } ominating features which render possible a 5 Z eral classification of mills from the motor drive view a - nt. Such a classification will be here attempted and e y the principal features of the various mill types briefly 2 sed, hiefly as they reiate to drive cor lerations. " a 1 J Classification of Rolling Mills ean ry or } = Many mills comprise essentially one or more stands yy 1 TE Ga hensl trains of rolls which revolve continuously in one + ecti Three-high stands are commonly used, ir = which the metal is passed forward between the two 1, ver rolls and returned between the two upper rolls. 7 —_— ['wo or more such stands are often connected in train, oe Re eel that is, with all roll axes 11 common vertical plane nd with the drive shafts in series, so to speak The tion, while the upper roll may be raised and lowe! st simple merchant mills are of this type. The last by a screw acting against a hydraulic balancing nd in this mill is commonly two-l gh, as the piece de These rolls are driven through spindles f asses through it in one d re tion or ind bette pair of pinions, which, in turn, are driven by the eng sh can be obtained than in a three-high m where or motor through a flexible coupling. The met he center roll serves double duty passed alternately .forward and back betwee! Some billet mills comprise two or more three-hig! rolls, which are reversed for each pass. ! stands, arranged either in train or in tandem Ra are located in front and rear of the mill. ind structural mills vary in layout, but commonly 1 Electrically driven blooming mills are almost ide ree-high trains and tandem sets, w operat sively of the reversing type. In these mills n ontinuously in one direction and largely at fixe aligning guards are located above the tables g peeds the piece into the proper pass of the main Sheared plate is generally rolled on three-high m manipulating device serves to edge the piece W f the Lautl type, the principle of which is shown sired, so that it may be reduced in two dime! Fig The upp r and lower rolls are driven, while The general arrangement of such a mill is WI the intermediate roll is rotated solely by friction fron Fig. 3. The principal application of the simple r* the roll which backs it up Both the upper and the ng mill is for roughing ingots. A _ reversing intermediate rolls may be raised and lowered. Tilting mill has been installed at the Mark Plant of st tables are provided in front and rear of the mills, and & Tube Co. of America. two such stands may be used in tandem The universal mill is a reversing mill « . So-called continuous mills comprise a number of two-high stand of horizontal rolls, and, 1! id two-high stands arranged tandem, so that the metal one or two sets of vertical rolls located at the side le in + is ifl Lan sequence. The passes in a straight line through the s All direction. rolls revolve continuously in one the mill ahead of and/or behind the horizon The vertical rolls, which work on the edges ot t ne ved in and out, are driven through gear- main pinions. Universal mills are em- velv for rolling slabs and universal plate. ; used for some structural shapes. r rsing mill enjoys a number of important r breaking down ingots. It is flexible slabs and blooms of various dimensions _as ordered, without changing rolls. Due e of lifting or tilting tables, the interval tween passes for manipulating and return- mav be made short. The steel may be veen the rolls slowly, permitting of heavy Be it shock and avoiding slippage. The speed ‘ ; can be adapted to the length ‘ The draft is under the con- i nerator and can be varied ; steels or for a cold piece, . asses may be employed as de- - = ; to the absence of lifting ta- } fj ersing mill as a whole is me- mpler than the three-high rh the electric drive equip- a) 2) —=——_27} A tna — 5 éeteo* 1430554 o coe > -ueere oo ae omplex, experience has shown that de trical sources are less frequent and usu is than mechanical delays, so that add mplexity is warranted by mechanica Hill Steel Co. is installed a reversing roughing plates, which are finished i: en Y of the Lauth type. It has been found ng mill is preferable to a three-high particularly as to the short interva In rolling sheared plate it Is neces slab 90 deg. after it has been rolled first passes. It is easier to turn th i tables of the reversing mill than of the three-high mill. Moreover, sary to square the piece accurately o1 as it can be run against the mai: juared before the latter are acce ece entered. It has been suggested ee-high plate miil with a motor without a reversing motor, which could en passes when desired, but suc} nstalied mbine the various types of star the simpler combinations is tl mill. The single roughing stand of igh; the finishing mill contains high stands in trair The piece, roughed down by several passes l g and then entered into the finish- from one pass to the next through Fig 4 shows the general arrange- f Belgian mill. The advantage of he fact that the roughing stand is speed than the finishing train. A 1922 THE IRON AGE 341 low speed is suitable for roughing work, as the rolls bite better on the heavy drafts and difficulty in en- tering the billet is avoided. Moreover, the finishing stands may be driven at a higher speed, as they are less compromised by the roughing stand requirements. As several passes are made in the roughing stand of a Belgian mill, this is a limiting factor in produc- tion. One development of the Belgian mill is the com- bination mill which comprises a roughing mill hav- ing several two-high stands in tandem, on the con- tinuous principle. This is followed by two or three peahyu : atg ; t ee it oat ‘ ’ parate groups of three-high stands in train, each group being separately driven at a different speed Repeaters are used, at least in part, for guiding the piece from stand to stand. Fig. 5 shows the genera arrangement of a combination mill. The continuous roughing group is able to maintain production to fill the finishing mills. The operation of the looping stands at different speeds reduces the length of loops between stands and thus avoids excessive cooling. It maintains the larger sections longer, both due to lower roughing speeds and by permitting more reduction in + ; he later passes. It permits each group to operate at ts most suitable speed and prevents restriction of the peed of the finishing rolls, which should be as higt as possible. The cross country mill, Fig. 6, is a combinatio1 made up of several stands or trains in tandem, but eparated so that the material leaves one before en- tering another. The piece is carried between stands by live roll tables or transfers To avoid excessive ength of mill the piece may take a Zigzag course, reversing its general directior f travel in passing through the various sets. This arrangement of mill usually permits rolling the steel in both directions, which improves its quality. The individual groups or sets may be driven separately or by gear, belt or rope, from a common source The cross country mill is ised to roll products not we adapted, due to size r shape, for continuous or loop mill rolling A sheet mi consist f two stands of two-high pair being used f pal or roughing, the other for finishing The rolls revolve continuously in one dire« tion at slow speed. The sheet bars are passed between tne rolis Dy tne roller and returned over the top roll by the catcher. The lower ro s at a fixed elevation and driven. The upper 1 revolves solely by friction Irom tne ower roll or the steel and is fed up and down by screws. Several pairs of stands are com- monly connected in train and driven by a single motor. (To be concluded) ui or icles eernnneeteeneniiiin meen ene ne — —_ ‘ , ry eT "NY 16 : } Be fa 3 :. ‘ é , ; . 7 4 , . > i 5 e Improvements in Heroult Electric Furnace a % aS . .. o : ¥ n . ‘sg T » - « Copper Pipes Carrying Cooling Water Used Instead of ‘ " T Copper Busses—Transformer Room Under- - ° ia sath the Charging Floor . YT \ HERE has been recently installed and placed in’ there is a mast made of structural mate: operation a 7-ton Heroult electric furnace at the support the electrode cranes. It was found plant of the International Nickel Co. at Hunting- to carry the conductors over the top of thes « ton, W. Va. Although this furnace embodies the usual order to avoid proximity to iron parts with | features of this type of furnace as manufactured by the quent reactance. This also involved having ove) American Bridge Co., the design is a new one and there flexible cables. In the present design the ma ’ are certain modifications or improvements which are inated and the electrode cranes supported f: 7 shown in the accompanying illustrations. ie : : : as = F ee : gi 1 I'ransformer Room Under the Platform Che furnace is used for melting and refining Monel i: metal, which is cast into ingots for subsequent forging .The relatively small copper pipe conductors can }y and rolling. It has a basic lining and desulphurization brought very close to each other, which makes and deoxidation are carried on under a basic slag, as_ sible to have longer leads and at the same time hay The Large Picture Shows 7 y e New Type of Heroult ot ; leectric Furnace with the ; Li te 3 rs Leading p from th ba . : } ransforme room, Situ Jf” , £ 4 ed Under the Platforn i iv Mhie entrance to it is : roug the door just below the four men, The lustration just under the the transiormet . m itself 7 shows the fur- ace while in operation 4 on Monel metal, The ab f the usual large ount ) smoke and considered a Lleature Legs Sen - ead 3 “ “a ‘ is customary with steel. Practically all heats tapped ' 7 up to the present time have been as low as 0.005 per ’ : +t cent sulphur. - Copper Pipes as Conductors Instead of using built-up copper busses the electric current is conducted to the electrodes by means of cop- a per pipes. The pipes also serve to carry water to the nae electrode holders and to the electrode coolers. For acd electrical reasons, a hollow circular section is the best them extend beneath the floor. The necessary me one for conducting oe current, and as the cop- room for the passage of cranes is reduced and no ex per is water-cooled, only about one-third as much cop-_ ible cables or other obstruction surround the _ , per is required as when using busses. This is particu- the transformer room being beneath the floor. *™ tof larly true when the busses have to be carried over a arrangement makes it more convenient to have ~ F . hot furnace. All designers of electric furnaces have trode supporting mechanism attached to the tune” had to contend with the difficulties arising from re- either at the back opposite to the pouring spout © ; el actance in furnaces of a large enough size so that the’ the left or right hand side. In the present casé¢ : electric current required was considerable; for instance, mechanism is placed on the left hand side. =, where the amperes exceeded 7000. The trouble due to The transformers are 1800 k.v.a. water-coo! ed, Ut! reactance is accentuated by having long conductors’ eral Electric transformers. The cooling water om spread far apart and where the electric conductors passthrough the transformer and then through the co ce near or between iron parts. pipe conductors, thence to the electrode holders, thro i 2 In most of the familiar types of electric furnaces a flexible connection and back to the electrode cole tM ieee fog 4u 10, 1922 operating voltage is 100, although taps are | give higher voltages in case the voltage on sion line should be below normal. In order rges on the line and obtain steady operation, ieht advisable not to have the power factor . 0.90 and additional external reactance was nd is of the type furnished by the General mpany, as shown in one of the illustrations. ndrical form of shell was adopted in pref- the dished or bowl shaped bottom, on ac- : structural strength. These furnaces were pped about a hinge on line with the pouring the furnace was provided with counter- In the rocker type of furnace the usual type rolling on a plain surface requires the cylin- ; i] to stand too high above the foundation. In nt design, both the casting on which the fur- and the rocker are curved. By thus dividing Rocky Mountain Industrial Relations Con- ference rhe second annual conference on human relations ry, under the management of the industrial le ent of the Young Men’s Christian Association, wa i at Association Camp, Estes Park, Col., July »8 29 and 30. The sessions were attended by several .4 persons, mostly business men and manufac- ture! from Colorado, Utah, Wyoming, Nebraska, Kansas. Oklahoma, Texas and Montana, with a scat- ‘tering of visitors from Eastern states. Program and veneral arrangements were in the hands of A. Bruce Minear, international industrial Y. M. C. A. secretary n the Rocky Mountain region. The purpose of the conference was to discuss sub- iects connected with relations of employer, employee and consumer. Addresses, most of them given by men prominent in industrial management, covered various phases of these relations. Besides the prepared talks, there were general discussions in which different pojmts of view were advanced and experiences exchanged. The industrial relations conference grew out of a small week-end meeting of business men held in con- nection with the Y. M. C. A. schools at Estes Park in the summer of 1921. At this meeting it was suggested that a more widely attended conference be held in 1922, ind that a foreman’s course be conducted at one of the Y. M. C. A. schools. Both suggestions were carried it through co-operation between the Y. M. C. A. in- lustrial department and interested business men of the Rocky Mountain district. The program of the conference follows: Progress in Recent Years in Human Relations in In- | H. Weitzel, Pueblo, Col., general manager Fuel & Iron Co, Three-fold Responsibility of Management to the Industry,”’ W. C. Coleman, Wichita, Kan., presi- in Lamp Co Industrial Future,’’ J. Merle Davis, Tokio dustrial secretary Y.~M. C. A. Training of Men from the Industrial Standpoint,’ ert, Denver, manager Swift & Co idence and Goodwill,"’ W. L. Petrikin Denver Great Western Sugar Co. Public and Industrial Relations,’”” B. B. Brooks former governor of Wyoming 1 Program of Health and Recreation in Industry,’’ Dr Kallenberg, Chicago he Rev. David G. Latshaw, New York. Stian Spirit in Industry,” T. W. Currie, pro of Texas head nool for foremen and other business execu- ) flex ‘ted in connection with the industrial rela- race rence, covered a course of five days, July This ee isive, with intensive instruction in the fol- e ele wine eral subjects: nace, ership, by Fred O. Kelley, Lincoln, Neb or of tary of the Y. M. C. A. -o th H tory and Economics, by E. S. Cowdrick i engineer Con- inization, by T. E. Barker, Denver, general , nver Rock Drill Mfg. Co. passe the Mount as applied to industry, by coppe versity of Texas. roug? to the four classes, there was a daily eooie! THE IRON AGE 343 the curvature between the two castings the advantage of the rocker type is obtained without having the center of gravity above the rolling center. The furnace tilts backward as well as forward. The arms carrying the electrodes have been brought in at an angle, for the purpose of placing the electrodes as close as possible to each other and to the center of the furnace. This is important in furnaces of high power, to avoid burning the furnace lining, especially where the basic process is used. The electrodes are actuated by winches and motors attached to the fur- nace. The General Electric Co. regulator is used. The tilting mechanism consists of two gear wheels on the same shaft, with connecting rods attached to the fur- nace. The tilting motor is of 15 horsepower. Although the rated capacity of this furnace is 7 net tons, on account of the weight and compactness of Monel metal, heats of 9 tons are being tapped. open forum, led by one of the students, in which sub- jects of direct interest to industrial executives were thrown open to general discussion. More than forty foremen, superintendents and others were enrolled. It is planned to make the school for executives and the conference on human relations in industry an an- nual event, and preliminary arrangements for the 1923 meetings already are under way. Trend of Wages Over the Depression Figures of the National Industrial Conference Board for wages covering the period from July, 1914, to January, 1922, show average hourly and weekly earnings, average hours of employment and the ratio obtained by comparing money wages with cost of living. The figures are based on 26 major industries, 3800 industrial establishments and more than 1,000,000 wage earners. As shown in our table, the average hourly earnings of all wage earners were 98 per cent higher at the end of December, 1921, than in July, 1914. The drop be- tween December, 1920, and December, 1921, was 22.4 per cent. Common labor was 92 per cent higher in December, 1921, than in 1914, but 27.1 per cent lower than in September, 1920. Skilled labor was 98 per cent higher than in 1914, but 20.7 per cent lower than in September, 1920. Because .of shorter working weeks, the ‘average weekly earnings of all wage earners was only 80 per cent higher than in July, 1914, but was 25 per cent lower than in July, 1920. Similarly, common labor was 74 per cent higher than in 1914 and 30.2 per cent lower than in August, 1920. Skilled labor was 80 per cent above the 1914 level and 23.8 per cent below July and August, 1920. Real wages, meaning the purchasing power of the money wages received, were 11 per cent higher at the beginning of this year than in 1914. In other words, the standard of living had increased to that extent, this resulting from the fact that wages were 80.2 per cent higher and living cost 62.3 per cent higher than in 1914, the excess of wages accounting for the in- creased real wage or purchasing power. The highest point of real wages during the entire period under survey was reached in October, 1920, with 21 per cent greater real wages than in 1914. July, 1914 Peak, 1920 Dec., 1921 Hourly earnings All wage earners 24.3¢ a 62.1 48.2¢ Common labor 20.7 b 54.6 39.8 Skilled labor, male 28.0 b 70. 65.5 Women ‘ iis 15.6 ‘ 41.7 34.7 Weekly earnings All wage earners $12.36 d $29.69 $22.27 Common tabor 10.89 e 27.14 18.95 Skilled labor, male 14.19 d 33.64 25.66 Women 7.82 c 18.79 15.76 Hours per wee k Average nominal 55.1 ce 50.7 49.8 Plant activity ; 3.8 ec 49.8 47.2 Per wage earner.. 51.0 ce 48.5 46.2 Index number Wages, weekly.... 100 d 240.0 180.2 Cost of living..... 100 d 204.5 162.3 teal wages... 100 f 121.0 111.0 i——-December b—-September ‘ June d—July. e August f—October; July showed 117 ; € * : ; : ’ , é i : : ‘ ; ’ ; : ‘ : ’ ; - f ‘ : } ; ; “ ré : 4 : _ é : 2 7 ¢ 7 oa, Mew alletapeemeee eet oa THE IRON AGE Core Box for Making Sash-W eight Cores A patented combinati®n core box for use in connec- tion with end-drawn sash weight flasks, and which together form a special system of making sash weights, is being offered by the*De Ved Brothers, Inc., Balti- more. This system is ffitended to permit the produc- tion of sash weights in large tonnage at very low cost, with a smooth eye and plainly marked. The core produced by the box is in the form of a plug adapted to close the top of the sand mold in which the weight is cast, forming the eye which receives the sash cord, and incidentally forming the entire top of the weight. The core box is made up of two side members piv- oted to open and close in a tongwise manner. These members are pivoted to a base as shown in the illus- tration. Holes or pockets are formed by registering cavities in the opposed members, the two cavities form- ing cylindrical opening when the members are swung closed. A center detachable bar, located parallel to the axis of the swinging members, extends through the pockets and forms the eyes in the respective plugs. To shape the core to form the top ends of the weights the base member is provided with upright pro- jections spaced to correspond with the pockets. One projection closes and forms the bottom of the pocket when the swinging members of the core box are brought together, bringing the corresponding semi-circular cav- ities together to complete the formation of the pockets. These projections are also used to support the number plate. In the system as a whole, which the company is ready to lease to interested parties, what are called end-drawn flasks are used. These are 4 ft. long, 4 ft. wide and 18 in. high and contain 120 sash weights to the flask, or from 800 to 1000 lb. of iron. It is claimed that one laborer can put up 10 to 12 of these flasks per day, making 8000 to 12,000 lb. of sash weights and that experienced molders are not necessary to perform this molding, common labor being said to be adequate for the process. With the combination core box described it is claimed that the cores for the flasks can be made by a boy at the rate of 500 per hr. It is figured that the cost of molding and of making the cores is one dollar per ton, the flasks now up, ready for the hot iron. A very cheap grade of melting scrap and also very low grade of scrap such as roofing tin, sheet metal clip- pings, etc., can be used in this system. The company recommends the system to all foun- dries to be worked in with other general foundry work, it being emphasized that this system permits a foundry to produce sash weights for local requirements at a saving in freight and handling expense and permits of quick delivery to nearby consumers. August 1(, 1999 Electric Alloy-Atlas Crucible Mey.,; President L. J. Campbell of the Electric A Si, Co., Youngstown, Ohio, announces*®Rat the per of this property with the Atlas Crucihle Stee] ur kirk, N. Y., is virtually completed. Consumn n of the consolidation may be expected very s states. Mr. Campbell will be chairman of and chief executive officer, located at Dunk T, unify management, leading directors of th Alloy company have been added to the board of Atlas Crucible Steel Co., including James A. Can; Thomas J. Bray, W. A. Thomas and L. J. Camph As far as possible the properties will b¢ erate as a single unit until the merger details ar: T completed, in order to get the advantages of operating 4m {fT Core I Making S&S Weight | Top and em tions ar¢ above. 17 drawn fi placing are economies which will thereby be effected. A tempora! working arrangement, with Mr. Campbell in chargt therefore in effect until legal consummation of merger is completed. Permits were issued in Chicago in July for 1)# buildings, fronting 33,075 ft. and involving a total cos" of $16,214,300 as against 754 permits for struct fronting 21,403 ft. and costing $14,004,650 in July, 192] an increase of 390 permits, 11,671 ft. of frontage #! $2,209,650 in cost. The figures, however, show 4 crease as compared with June, 1922, of 275 perm! 8744 ft. of frontage and $10,362,550. Figures [0! first seven months of 1922, showing 7569 permits, - 960 ft. of frontage and a cost of $127,716,610, greatly in excess of the records for the same ™ in previous years as far back as and including 19%! The United Coke & Coal Co., seller of foundry, *% nace and domestic coke and coal, has moved its offices from 2013 to 814 Fisher Building, Chicago. on Acid Electric Furnace Practice’ Basic Scrap and How to Charge It—Making a New Bottom —When to Tap and How to Pour—Alloy Addi- tions in the Furnace BY CHARLES WELLMAN FRANCIS practice is the most universally used in the ent day foundry for the manufacture of + castings. This fact was probably due the recent world war conditions which ibout a great scarcity of Austrian magnesite intry, magnesite being the best of all basi and has caused the development of our rican product to such an extent that we have ssely approached the qualities of the Old iterial which we at one time thought could not d. Again, production was the first word in can steel industry during this period, and tice is the fastest and most economical when physical and chemical specifications only are As a result, one great difficulty has arisen 1y tend to swing us back more generally to eration, namely, that our scrap as a product icid-lined furnace has gradually become more n quality, due to no refining. Also during this iction period, competition has become much which will tend to the manufacture of finer grades of steel. Basic Scrap for Acid Furnaces \s has been mentioned in one of the previous arti the writer has found it advisable to use a good isic scrap for charging the acid furnace. This scrap d be of a light, quick melting, shoveling type, and ive body enough to prevent the electrodes from penetrating it and striking the furnace bottom. p prevent the latter occurring, the foundry scrap n of the charge, which usually makes up 40 to ent of the melt, is first placed on the bottom of furnace with the purchased scrap on top, taking prevent the piling of the scrap against the side ind banks as much as possible. 'here is a double reason for piling the scrap in the f the furnace as much as possible and conse- keeping it off the banks and side walls unnec- First, when it is piled in a heap in the center furnace it will be the melting zone of the elec- which tends to enhance quick melting. Second, 1mount of unnecessary labor is done away with this scrap clings to the side walls and banks be pulled into the bath when the furnace is Of course, some of this work always has to be natter how carefully the furnace is charged, advisable to eliminate hot and heavy work possible. It is important to emphasize here ite of melting is solely dependent on the man- h the furnace is charged and how the cur- ed. the charge is entirely melted a test is taken for a fracture reading by the melter; one the test piece is then drilled and sent to the for analysis. According to the result of the ie necessary amount of ferroalloys is added the metal is hot enough to pour. No slag idded during the acid electric furnace heat, ties in the scrap, together with the wash- tr f July 27, p. 201, the author discussed tric furnace and in the issue of Aug. 3, Pp. 27% res of electric foundry design and equip- 92 ings from the banks and side walls, form sufficient slag. Often an acid heat will melt practically free of slag, but from the time the charge is entirely melted until the heat is ready to be tapped, the slag will accu mulate rapidly. An acid heat should be tapped when the slag bubbles and becomes puffy, which is often termed a “dry” slag. When the heat is tapped the furnace is ready for fettling or repairing. This work depends entirely on the condition of the furnace bottom and banks, and requires considerable experience to be done properly. Ground ganister is used and sometimes it is mixed with silica sand, depending on the conditions of the furnace. This material is usually wet thoroughly, be- cause the wet mixture can be more accurately thrown from a shovel to the desired point in the furnace. Also because the wet mass will tling material when thrown from the shovel. Inexpe- not spread as will dry fet rience in doing this work is usually illustrated by the building up of the furnace bottom or the rapid disap- pearance of the banks, caused by using too much bot tom mixture or not enough, respectively. Great cart must be taken in repairing a “hole” which is sometimes left in the banks or bottom after a heat is tapped. In doing this the same methods are employed as are used in open-hearth furnace practice. If the hole is smal! the hot metal which stays pocketed therein can gener ally be balled on the end of a cold rabble or hook and pulled out. If the hole is larger the use of a little silica sand will help the operation considerably. After making bottom, as the above operation is commonly termed by steel melters, it is advisable to close the furnace doors and let stand for a few minutes, as the intense heat of the furnace will cause the new repairs to set into place, and consequently it will not be so easily displaced by charging the foundry scrap. Burning in a New Bottom surning in a new furnace bottom is one of the most important features in any type of furnace practice. Methods used in the electric furnace differ consider ably from those used in open-hearth furnace work. Ground ganister, silica “grits,” silica sand and fire clay are used in the proper proportion to form a some what plastic mixture, and the entire bottom is put in place in one operation with the use of a foundry air rammer, and smoothed off to the desired contour. The bottom should then be dried thoroughly with a wood fire from 24 to 48 hr., after which the furnace is dumped to remove the ashes and a bed of coke is dis- tributed evenly over the bottom. The electrodes are lowered and the power turned on as low as possible. Four to six hours of burning, with the power on and off intermittently, is often sufficient to give the bottom the necessary baking, prior to charging the furnace. The furnace will gradually become hotter under these conditions, and it will be found advisable to leave the power on for shorter periods. After the furnace has been well heated it will be found that these periods during which the power is shut off will give as good results as those during which the power is on, provided the furnace doors are kept closed and sealed, for the new furnace will be getting - » #3 a Pp q "4 : . a *? : 3 : 5 } ty : 4 | 3 * . *. ” » a? aS * . oo the desired soaking. It is surprising how quickly the empty furnace will be heated; consequently great care must be exercised not to carry this work on too quickly or a “dripping” of the roof and side walls will take place, greatly diminishing the life of the refractories. Tapping and Pouring The remaining phase of this problem which the author wishes to discuss briefly is the tapping and pouring of an acid heat. Considerable controversy arises at times whether to use bottom-pour or lip-pour ladles. For acid heats of three tons capacity or smaller, the lip-pour ladle will be far more economical in the long run because, aside from being much easier to handle, they will last for six to eight heats without being relined other than knocking off large particles of slag and repairing the lip. On the other hand, the bottom-pour ladle for small heats produces consider- able distress in a small shop, due to the delays experi- enced in “setting stopper,” to say nothing of the prob- ability of losing a large part of the molten metal in the furnace pit. Just as much care must be exercised in setting the stopper in a small ladle as must be em- ployed in an 80-ton open-hearth ladle. All the metal should be tapped into a big ladle at once so that the furnace can be given the proper care immediately, instead of being “shanked” from the fur- nace, as is often done with the smaller size furnaces. Considerable electric power is also saved by getting Large Hydraulic Flanging Press A hydraulic flanging press, the total weight of which is 42 tons, and capable of exerting a maximum pressure of 435 tons, is shown in the accompanying il- lustration. It was built recent- ly by the Hy- draulic Press Mfg. Co., Mount Gilead, Ohio, for the Merchants Dispatch Trans- portation Co., Rochester, N. Y., and is used for flanging the plates for Mur- phy car ends. The machine will flange cold steel 5/16 in. thick and 10 ft. long. It has a stroke of 24 in., and the maxi- mum distance be- tween platens, daylight space, is 36 in. The two rams are 20 in. in size and located as shown. Two 5% in. aux- iliary cylinders are used for returning the platen. pet-type H-P-M high-pressure trols the movements of the press, the valve being manipulated by one hand lever. The cylinders, platens, housings and other parts of the machine are of cast steel and in connecting up the press H-P-M hydraulic valves and fittings were used. This equipment is said to be the largest tha