The Iron Age 1923-12-13: Vol 112 Iss 24

THE IRON AGE New York, December 13, 1923 ESTABLISHED 1855 VOL. 112, No. 24 Salvaging Scrap in Cadillae Plant New Building Erected by Automobile Company at Detroit for Special Purpose of Handling Various Grades of Old Material HE Cadillac Motor Car Co., Detroit, recently estab- small pieces or short shoveling turnings, making the lished in connection with its new plant a scrap material much more compact so that it is easier and salvage department located in a separate building cheaper to handle and twice as much can be loaded in designed for this purpose and through which all iron a car. At the same time the market value of the scrap and steel and non-ferrous scrap, produced in its various is increased, for after being broken into small pieces manufacturing departments, is handled. The erection it is more suitable for use in the charging boxes of * of the salvage building reduces the cost and increases open-hearth furnaces and can also be melted in blast the efficiency of scrap handling and is a step in the furnaces. Very few blast furnaces can use long turn- company’s policy of economic production, in that scrap, ings because of their bulky character. Another advan- instead of being allowed to accumulate in the manufac- tage of the crushing process is that the small pieces j turing departments, releases valuable space in the man- of scrap are safer to handle than the bulky coils. With ufacturing building for production work. a system of conveyors, the process of handling the H The predominating feature of the scrap salvage turnings from the time they reach the crusher until F department is the installation of equipment for break- they are loaded on waiting cars is continuous. The ng up and mechanically handling long turnings, the plant has a capacity for breaking up and delivering to i yutput of which averages 15 tons per day. These pass cars 20 tons of turnings in 9 hr. tt through a crusher which breaks up the bulky coils into The scrap salvage department is located in a one ee eee . Ti ed * - ee i i - by St ag Bat- h > r ent in Si 1 ump uU ks Hauled p as E ast as It Is Accumulated Is Taken to the Scrap Salvage I epa tmen siae d rr cKs Stor e If de I d the loaded hoppers are lifted from the trucks by means of the over head crane as shown tery Tractors. sire + TaNANen te th NRL AN TEE ATLAS COREE oP NENT NEN Su egene enn nn OEE ERED SENN A 1571 v4 perenne <UCEUTE TONE H YOUN AED EDED EO PRE PENUNRRRLROG EN NND ap NUN NONE ae soer en NERD NUNN LAE OETA is ot ¢ S ee © Sars ty ht Pe bin? wr OF OT ae ' time bere : pire et | +977 oe | a eer | oh) 3 Pt ' a : ' tite 4 7 ty ie Fe shal Bip Ty RTE Eee 7? 5 os os Pt rE be » 7 " : i ‘i? : 7 ° * a : > = . a . ; « ; a | tas S qe > * . > ; ‘ . 7 a ‘ 5 - . je NEE af Laks | Eg fh) : he story and basement brick and steel building 60 x 100 ft. and 50 ft. in height to the peak of the roof and is served by a 5-ton electric traveling crane with a runway 30 ft. above the floor. Turnings are hauled to the build- ing from the various manufacturing departments in side dump trucks pulled by storage battery tractors. Usually a tractor draws two trailers each loaded with 500 lb. of turnings. Oil Is Recovered The long turnings are dumped in a pile on the con- crete floor and left there half a day to allow the oil to drain off, the oil passing through a drain in the floor to the basement. After much of the oil has been recov- ered in this manner, the turnings are removed with a magnet on the overhead crane and dropped at the side of a hopper level with the floor and are shoveled into the hopper which feeds into the crushing machine located FORM 2701 5OM SETS 2-22 OF CO COPY TO FOLLOW MATERIAL G DATE_/—. PART NAD NAME orig cee WEIGHT ey dle =< spe DEFECT DUE TO SENT TO DEFECTIVE MATERIAL RETURNED TO SUPPLIER DEFECTIVE MATERIAL NOT RETURNED TO SUPPLIER wortaeieed bee | aa ee DEFECTIVE DESIGN conn in Sept 4 47 femeemer_ | | INGE we MA Ae laaaedlash ala ” THE IRON GRAP. TR ee AGE December 13, 1923 should not be on hand for loading, the scrap is turned into another chute that discharges it into a storage }i; on the floor, and when a car is available the scrap i: shoveled from this bin through the floor onto a conveyor in the basement and is again elevated and discharged into a car. The system is so arranged that when soda chips are handled, these, instead of going through th. oil extractor, are delivered directly to the riddle. The oil from the floor drain and from the oil sepa rator passes through oil lines into a 500-gal. tank in the basement and through a wire screen strainer. Fron this tank it is pumped underground to the oil house a short distance away, filtered and placed in 500-ga! tanks, from which it is pumped back to the various manufacturing departments for use. A separate oil ex- tractor of smaller sizes than are used for the turnings is provided for removing oil from brass chips. This oil passes into a separate tank, where it is metered to keep & Ne 229823 Le it a oe oud nner When Material Is Ordered to the Scrap Department, the Inspector Fills Out in Quadruplicate a Scrap Transfer Form. One copy goes to the planning department, another to the accounting department, a third to the scrap salvage department and the fourth is retained by the inspector GMUNNEPO MEDAL UAHCSLLLALELAGY:TYOANNOT ONG | FDEDNSTRAORERERAUDONOURUGDVAEDETEREDEDGG DONOGEDEDE DT | /ONDUETEDONSDOTI: MADUERDOOERHON NCL OSOrOOOFLINUCDNEsRIED in the basement. In this crusher driven by a 40-hp. motor the long turnings are broken up into small pieces, few of these pieces being over 2 in. long. From the crusher the scrap passes over a short bucket conveyor to a bucket elevator, which carries it to near the top of the building and drops it into a steel bin of about 2 tons capacity. From this bin the scrap goes to an oil extractor in which the remaining oil is removed. After the oil is extracted by the rapid revolution of the scrap, the scrap container in the extractor is lifted out by an air hoist attached to a jib crane and the contents are dumped into a riddle. Pieces of scrap that have passed through the crusher without being broken to small enough sizes are removed from the lower end of the riddle. The small pieces pass through the riddle to a bucket elevator in the basement, which carries the scrap up near the roof and discharges it into a horizontal conveyor, which de- livers it to a chute that passes out through the side of the building and over a railroad siding, and the material is discharged through the chute into a ear. If a car COOCULEDORERRERBE DEAN UUNDDAAERONDOGETEEDEMmUPEDLONNNaDenaEoEbeNsvontecenseeD ‘ovouuenyanecuaveccagnacensovenreseevatessauenseueeneveynenensarvensenaevensunanenuanenageernrcnecsnnenerscensanmnsnesnanescaeesveneernns t1t0000) a record of the oil consumption, and is then discharged into the main tank. About 700 gal. of oil is salvaged per day. Other Grades of Scrap Sorted Various grades of scrap other than turnings are sorted in the salvage department and placed in storage bins having a capacity of a carload or more and located along one side of the building. The scrap is allowed to accumulate in these bins until there is enough of one grade to make a full carload. Above each bin is 4 chute extending out to the side of the building and over the loading track. When a car is to be loaded the ma- terial is handled to the chute with the overhead crane. Under the system adopted, handling in small lots in motor trucks is eliminated, all iron and steel scrap be- ing shipped in full carloads except portions of certain grades that the company uses in its own foundry. After the oil is extracted, brass scrap is placed in steel barrels and sold. A complete record of scrap that is ordinarily pro- duced in manufacturing operations, such as borings and rurnings Are Shoveled into a Hopper Under the Hood that Appears in the Foreground and Pass Through a Crusher in the Basement. From the crusher the broken scrap is delivered by a bucket conveyor and bucket elevator to the bin at the left ind from this it is shoveled into the oil extractor that adjoins the bi: An air hoist lifts the scrap container from the xtractor and dumps the scrap on to a riddle along the wall back of the extractor. The material reduced sufficiently in ze passes through the riddle to the basement and up the bucket elevator adjoining the wall and then is received by a horizontal conveyor that delivers it into the hopper at the corner of the building, through which it is discharged through a chute into a railroad car on a siding outside /01 AL. ;UNECOREERRDEETD OT /NAGORROOED: CFO OTERENSRERORASRRMRDOS RECTED turnings, is not kept, but forms are provided for keep- manufacturing operations. An inspector fills out ing a record of all material that is sent to the scrap sal- quadruplicate copies of a scrap transfer form for each vage department because of defects that develop during lot of material he orders scrapped. One copy of this Which Serve the Oil Extractor in the Foreground The Elevator at the Left and the Bin ee a porennestevenenerernaeer*tn SeenevunnernTneneDerUnEUED ‘Uo eU TEN een eTONeNnEdeoey en onenetnsnensenenneneuenennennenennnerscnesennsn ennneresnennenssyervreneestanne’/2!® i ie Loe Per ecm ee ee 7 ¢ ae ee oes 1574 THE IRON AGE December 13, 1923 On One Side of the Building Are Bins for Various Grades of Scrap Other than Turnings and Above Each Bin Is a Chute This scrap is handled by means of the overhead crane and a lifting magnet and is dumped through the chute into railroad cars ¢ goes to the planning department, one to the accounting department, one follows the scrap to the scrap salvage department and the fourth stays on the inspector’s book. These scrap transfer tickets show the department from Efficiency of Standardization in Germany A striking example of the efficiency of na- tional standardization as it has been developed in Ger- many is cited by Dr. A. P. Agnew, secretary of the American Engineering Standards Committee in the case of a rush order placed with German manufactur- ers for 200 locomotives for delivery to Russia. “Pro- duction of different parts was allotted to 17 different manufacturers to be produced strictly upon the plan of interchangeable parts, no one manufacturer making a complete locomotive. No serious practical difficulty was encountered in filling the order. The inspectors made a particularly striking test of the feasibility and accuracy of the plan by ordering a complete locomotive to be assembled from parts chosen at random from the parts furnished by the 17 manufacturers. It proved to be ready for service immediately after assembly with- out necessity of disassembling for readjustment.” The appearance of consulting engineering firms specializing in standardization work is an interesting development of the last few years. There are now five such firms in Germany. This work is closely connected with industrial or efficiency engineering, in which there is now great and growing interest in Germany. In general, it appears to be much more closely connected with the movement for industrial standardization than is the case in this country. The largest of these firms devotes about half of its time to standardization work, employing a staff of over 40. They have as their clients trade associations as well as individual firms. One of their clients is the trade association repre- senting the motor vehicle industry. In this work they perform many of the services that would be done by an ordinary headquarters standardization staff. Of the companies which are their clients, some main- tain their own standards bureaus, which take care of yutside which the scrap came, the part name and number, quan- tity, nature of the defect, kind of material, number of operations performed on the piece before it was scrapped, as well as supplying other data. the greater part of the detailed work, leaving to the consulting firm only the more important and difficult questions. In other cases, the consulting firm does a large amount of the detailed work. Another most interesting development is the work of consulting engineers on trade catalogs for com- panies. This is particularly significant, as it is carry- ing standardization a step farther than is usual, by introducing it into the sales organization and sales policy. In this, careful consideration is given to the question of limiting the number of types, ranges and sizes offered for sale, placing proper emphasis in the catalog on these particular items on which the com- pany wishes to concentrate, and, in general, in featur- ing and often advertising the relation of the firm’s products to the standardization movement. More Horse Power At the National Horse Show in New York a team weighing 3575 lb. moved a load requiring 2450 Ib. trac- tive effort over a distance of 12 ft. in 6 sec. They de- veloped sufficient power to start a truck load of 32,000 Ib. on a level granite block pavement. This power would be sufficient to keep a load of 200,000 Ib. moving on such a pavement after the start had been made. This record of 2450 lb. tractive effort exceeds the 2400 Ib. record made at Ames, Iowa, last summer. E. B. Bowman, advertising manager Carborundum Co., Niagara Falls, was the guest of the New England Foundrymen’s Association at its December meeting held the 12th at the Exchange Club, Boston. Mr. Bow- man’s talk was on Niagara Falls power development, the manufacture of carborundum and the application of carborundum in grinding and foundry abrasives. Properties of Steel Containing Tellurium Experimental Heat of Cast Steel—Forging Qualities and Structure—Tellurium Present as a Telluride BY DR. G. B. WATERHOUSE AND I. N. ZAVARINE® ELLURIUM is not one of the elements used for alloying purposes with steel, and references to its use or occurrence in this capacity are extremely scarce or non-existent. The authors, therefore, welcomed an opportunity to investigate a steel containing this ele- ment, and believe a short account of the results obtained will be of general interest. Tellurium is a silver white solid with metallic luster’. In the crystalline form it is very brittle and easily powdered. There has been some dispute regarding the atomic weight, but it is commonly accepted as 127.5 (O 16). The melting point varies slightly according to different observers from 437 to 455 deg. C.,’ and is usually given as 452 deg. C. The boiling point is given as 1390 deg. C., and if air is excluded it gives a golden yellow vapor. In the presence of air it burns with a blue flame tinged will scratch glass, is rather tough and is not altered by dry air. It is formed by an exothermic reaction, and can be readily made at a low red heat. Making of the Steel The material investigated came from a 3-ton heat of steel made in the electric furnace of the Bonney- Floyd Co., Columbus, Ohio, according to their regular practice of making steel for steel castings. When about 1000 lb. of metal had been tapped into the ladle the addition of metallic tellurium was made without any stoppage of the pouring. In other words the tellurium was added to the ‘ladle when the bottom was well cov- ered with steel. The amount was 20 Ib., and the results of analysis show that about 40 per cent was retained by the metal. Throughout the pouring a whitish yellow Fig. 1—Steel Containing Tellurium, x 200 with green and gives white vapors of TeO.. The specific gravity of the crystalline varicty is 6.27. There is also an amorphous form with sp. gr. of 6.015, which changes to the crystalline variety on heating. It is closely associated with selenium and in the periodic table is placed with oxygen, sulphur and selenium. In its chemical reactions it is similar te sulphur. For much of our knowledge regarding its chemistry we are indebted to the work of Dr. Victor Lenher of the University of Wisconsin and his stu- dents.* * Tellurium is insoluble in water or hydrochloric acid, but is dissolved by nitric acid or concentrated sulphuric acid. It does not tarnish in moist air, and this property may be of commercial importance. At present the uses of the metal are very limited, and the production is small, the possible annual supply from the copper refineries being only about 125,000 Ib.’ Among the compounds the tellurides of gold have been known to metallurgists for many years, and it is of interest that a compound FeTe has been made, and its heat of formation determined. This telluride of iron *Professor of metallurgy and instructor in heat treatment, respectively, Massachusetts Institute of Technology. 1575 Same as Fig. 1 at Higher Magnification or 1000 Diameters Fig. 2 vapor was observed coming from the top of the metal and slag in the ladle, and from the stream of metal entering the molds. The tellurium was supplied by the United States Smelting, Refining & Mining Co. Properties of Annealed Castings The analysis of the steel was as follows: Per Cent Per Cent CavGel . ic acs cccmeekwi 0.24 ae 0.039 Manganese ......--+-+; 0.64 ee ‘ 0.32 Phosphorus .......--+-- 0.039 Pees kicovaxoneces O33 Two sample of the cast steel after annealing in the usual way gave the results shown below: Yield point..........+--+ 45,000 42,850 Ib. per sq. in Ultimate stress......-- 70,000 71,750 Ib. per sq. in Elongation in 2 in..... 11.5 16.0 per cent Reduction in area..... 13.5 18.5 per cent Structure of Annealed Steel These results show somewhat lower ductility than would be expected in a well-annealed steel casting with carbon 0.24 per cent, and an explanation was sought in the microstructure. Normal magnification shows the structure illustrated by Fig. 1, and the arrange- cone ne ge aa te es « a STe eet Prer, wanna =. fae = tie aha ecard a oe ok ee , aa : rns beer -_ eran ° ee nd et eee eee ee ee re Ae 0G = deci tnatbiitip ce Ry aed sree : 5 i gt err 7 SPRL 9 Riis 9 1576 THE IRON AGE ment of the pearlite is evidence of good annealing. Examination with higher magnification clearly shows the presence of a new non-metallic impurity closely as- sociated with the well-known constituent generally called manganese sulphide. This is well shown in a Fig. 3—Manganese Sulphide and a Tellurium Com- pound, x 1000 Fig. 2 taken at 1000 diameters after etching with picric acid. In the two areas near the center of the picture may be seen the dove-gray manganese sulphide, and with it is also seen the new constituent which is much lighter in color. The authors believe this constituent is due to the tellurium, and provisionally at least it can be called telluride of iron. This new constituent is also clearly shown in Fig. 3, taken at 1000 dias. Reference may be made to a previous article by Pro- fessor Arnold and one of the authors,‘ where a steel was described and illustrated having manganese sul- phide and sulphide of iron existing together in some- what the same way as these two sonims, using Henry Hibbard’s term for non-metallic impurities. Properties and Structure of Forged Steel It was thought advisable to see how the telluride would behave under mechanical work, and a piece of the Fig. 4—Forging Effect on Steel Containing Tellurium, x 1000 annealed casting was heated and forged under a light steam hammer, the amount of reduction being about 65 per cent. The steel ferged well, giving no evidence of red shortness. There was enough material for four December 13, 1922 short test pieces, and they were tested after the fol- lowing treatment: : No. 1—As forged. . No. 2—Heating uniformly to 1575 deg. Fahr., cooling air ‘No. 3—Heating as before, cooling slowly in furnace. No. 4—Heating as before, quenching in oil and reheating to 1100 deg. Fahr. and cooling in air. The results of the tensile tests are given below: Redn, Elon., of Yield ult. Per Area, Point Stress Cent Per Brine!! No. Treatment Lb. per Sq. In. in1lIn, Cent No 1 Ap forged ....: 59,250 83,250 17.5 38.7 179 2 Heated 1575 deg. Fahr, cooled Ge sxisarnenes 58,500 $2,500 19.5 44.5 170 Heated 1575 deg Fahr., cooled Cy ee 48,120 77,000 19.0 42.5 143 1 Heated 1575 deg. Fahr., quenched oil, drawn 1100 deg. Fahr. ... 65,000 $8,500 21.0 48.1 179 On examination with the microscope the telluride was found to have been drawn out by the forging action fully as well if not better. than the manganese sulphide, as is clearly shown in Figs. 4 and 5, both taken at 1000 diameters. Summary A careful examination of a steel containing 0.12 per cent tellurium shows the presence of a non-metallic constituent that is probably a telluride, closely asso- ciated with manganese sulphide. When the steel is forged this telluride does not break up but elongates Fig. 5—Another Example of Effect of Forging This Steel, x 1000 fully as well if not better than manganese sulphide. The steel is lower in ductility than normal materia! without the tellurium. The results would indicate that it might be well to investigate the influence of tellurium in regard to the free cutting or free machining properties of the steel, to see whether this element could be used instead of sulphur for that purpose. In conclusion the authors would express their indebtedness to Dr. G. H. Clevenger and F. S. Mulock of the United States Smelting, Re- fining & Mining Co. for the opportunity of investigat- ing this interesting material. References 1. H. A. Doerner: “Tellurium.” Reports of Investigations Bureau of Mines, Serial No. 2385, August; 1922. 2. Landolt-Bornstein, 4th Edition. 3. Victor Lenher: “Occurrence, Chemistry and Uses ° Selenium and Tellurium.” February, 1923, meeting Am. Ins! Min. and Met. Engrs. C. A. Tibbals, Jr.: “A Study of Tellu rides.” Doctor’s Thesis, Univ. of Wis., 1909. (This contains a great many references.) E. Wolesensky: “A Study of th: Metallic Tellurites.” Doctor’s Thesis, Univ. of Wis. 190° E. B. Hutchins, Jr.: “A Contribution to the Chemistry of t! Tellurates.” Doctor’s Thesis, Univ. of Wis., 1905. 4. J. O. Arnold and G. B. Waterhouse: “On the Influenc: of Sulphur and Manganese on Steel.” Journal Iron and Stee Institute, vol. 63, 1908, No. 1, p. 136. Motor-Operated Centrifugal Pumps Steel Plant Water Supply Problems—Test Data and Cost Comparisons—Definite Motor Guarantees Essential BY B. A. CORNWELL* tors in maintaining and increasing production is to operate against a total head of 165 ft. [* the steel industry, one of the most important fac- single stage double suction type with bottom suction oCnee 2 suction, the efficiency and the reliability of the water sup- ply system, which we feel should be electrically driven. Data and test results obtained are shown in the table. The motor driving this pump is designed for Centrifugal pumps are especially suited for handling a temperature rise of 40 deg. Cent. (72 deg. Fahr.) with large quantities of water quickly and in many plants this type of pump has already been adapted for supply- ing water under low heads for blast furnaces, con- densers, cooling water systems, etc. A centrifugal pump consists primarily of a water wheel revolving in a case. The water enters at the center of the wheel and is discharged from the periphery through the dis- Fle in Mil ns of Va Ms p r Day Fig. 1—Test of Allis-Chalmers Centrifugal Pump Gave Results Shown Above charge nozzles of the pump case. In this type of pump, the velocity imparted to the water by the impeller de- termines the head. We then deduce from this the fol- lowing general laws governing the action of all centrif- ugal pumps: 1. The head varies as the square of the speed. wen The quantity of water pumped varies directly as the 5 ed, 3. The power required to drive the pump varies as the cube of the speed. CCUCUUUNEGeEC HO Lana eaneuneaeconenencoeciereeeoteanentaneereneeneaneuereecsenersentenenen Test Data on Allis-Chalmers Motor-Driven Centrifugal Pump. Rated capacity, 25,000,000 gal.:; single-stage, double-suction type; suction and discharge nozzles each 24 in. diameter ; slip ring induction motor of 1000 hp., 3 phase, 25 cycle, MTT 750 r.p.m, Input to -—Efficiency—, Delivering Pump Total Head (Per Cent) (Gal.) (Hp.) (Ft.) Pump Motor 10,000,000 700 210 52.5 91.8 15,000,000 825 205 64.5 92.6 20,000,000 910 196 74.0 93.0 25,000,000 995 183 81.0 93.2 30,000,000 1030 165 84.0 93.2 centrifugal Performance and operation of typical pumps as used in steel plants can best be seen by re- ferring to the characteristic curves shown in Figs. 1 and 2, obtained from tests recently made on a 1000 hp., 6600-volt wound rotor induction motor driving a 25,- 000,000-gal. centrifugal pump. This pump is of the *Electrical engineer Carnegie Steel Co., Youngstown, Ohio. This is an a er of a paper read before the Buffalo con- vention of the Association of Iron and Steel Electrical En- gineers. 15 full load for 24 hr. and a temperature rise of 55 deg. Cent. (99 deg. Fahr.) with 25 per cent overload for 2 hr. immediately following a full load run of 24 hr. As can be seen from these curves, with the discharge valve closed the efficiency is zero, since no useful work is being done. The horsepower required under this condition is consumed in friction and dissipates itself as heat, with the result that an electrically driven pump of this type cannot be operated with its discharge valve closed for more than 15 or 20 min. without over- heating. As soon as the discharge valve is opened, the capacity increases as the efficiency increases, until it reaches a maximum of 30,000,000 gal. per day at an efficiency of 84 per cent. This particular pump has been in operation since 1918 and the results shown by Cc} ~~. An T a ARK ! l | ! ! f I ! ! ! ! ! j 4 ! I ! ! if ! J — Fig. 2—Curves for 1000-Hp. 6600-Volt Motor Driv- ing a 25,000,000-Gal. Centrifugal Pump. Maximum efficiency lies between 600 and 800 hp. output this test indicate that it is still capable of delivering the same capacity as obtained five years ago and that this capacity is in excess of the guaranteed capacity. Influence of Variation in Frequency In making tests on a.c. motor driven pumps, we often find that there are certain changes in the a.c. motor characteristics due to changes in the frequency and voltage of the generating station. When there is a change from normal conditions there will be a loss in efficiency unless there is a corresponding change in the other variables to restore the original values. For instance, a drop in frequency means increased density of the field with lower efficiency and increased heating. If, however, there is a corresponding drop in voltage at the same time, the motor will operate under normal density, but with decrease in output proportional to the 77 ». = = so * aos - " ~ ~— oor maw . =org v meaner . i aan " 3 - . ' Selita ita iin a atcha Tatar etet tt " * OB ce aa " a thee D —_ ~ » - “~ " ‘ " , nabinnoen = Sayer, Phe ry he pte SP thee m7 bia - ‘ by »,* is 4 » i= 7 S. tJ ra s > “ae . : ei 7 . * : . ’ ° : -, 1 ' ihe : , e « . , jay ’ . > - - . 2 : - ; “~ * \- 4 . a a er > ; * ‘ . ~~ . . * 7 “ i .? * ’ 1 * 5 . > : 1578 THE IRON AGE decrease in the speed, which lowers with the frequency. In comparing installation and other costs, assuming 1000 hp., and the turbine-driven installations with starters, condensers and auxiliaries, the author used a figure of $15,400 for an induction motor driving pump unit. With the synchronous motor, the figure was $15,- 800. With the steam turbine-driven pumping unit, the figure was $38,000. Buildings, wiring and piping were not included. Operating cost for 30,000,000 gal. per day at 165 ft. head is given for the steam turbine-driven pump at 0,288c. per 1000 gal. By the motor-operated centrifugal pump, the figure is given as 0.238c. per 1000 gal. Better Efficiency and Lower Costs Investigations have shown that, in every case of the many instances where steam pumping equipments have been entirely replaced by electric driven pumping out- fits, the efficiency and the operating costs have been greatly improved. A large number of steam driven city water pumping stations have been electrified, with the principal idea of getting better efficiency and more reliable service at less cost. However, in connection with the electrically driven pumping stations, steam driven pumps in many cases are necessary to insure a continuous supply of water in case of failure of the electric power. It is generally conceded that, where electric power is available, there is no satisfactory comparison be- tween the electric motor and gas or steam engine drive for centrifugal pumps. The first cost and cost of main- tenance and attendance are considerably less; the sim- plicity and the reliability much superior and the power Board to Facilitate Time Study Work The time-study board illustrated, which is the in- vention of T. R. Hough and is intended to facilitate the work of time study observers, has been placed on the market by the Stein & Ellbogen Co., 31 North State Street, Chicago. In addition to providing a convenient writing sur- Time Study Board with the left hand and the board held The watch may be operated as shown face for holding the time study record blank, the board holds the watch in such position that the latter may be operated with the left hand as shown, the board resting on the left arm and leaving the right hand entirely free for recording the figures. The lock holder for the watch holds the watch securely in the position most convenient for operation and "protects the watch against breakage. The inclination of the December 13, 1923 cost ranges from 25 to 50 per cent less, as has bee: demonstrated from tests. Discussion G. H. Cramer spoke particularly of a hard pump problem in the case of quenching cars of coke at th: by-product ovens. A tank of 10,000 gal. capacity wa emptied and had to be refilled on a 3-second cycle. Thi was particularly hard on the starting equipment fo: the pump. By using motors for this purpose, enough was saved in maintenance and repairs in a single yea) to pay for the installation of the motors. For this service, a Westinghouse engineer stated that self starting, synchronous motors, designed for high speed and operating with thermostatic control, would be very useful. R. G. Nye, Buffalo Steam Pump Co., pointed out that the difference between a motor designed for 50 deg. temperature rise and one designed for 40 deg. was a minor consideration, provided a definite guarantee was obtained as to what the motor would stand. It was brought out that the 40 deg. motors were definitely de signed for an overload of 25 per cent maintained for 2 hr. without exceeding the temperature rating. When the temperature figure was raised to 50 deg., in most cases this was not accompanied by any definite guar antee as to overload capacity, either in percentage o1 time. Consequently, the condition became less satis- factory than before. It does not matter to the pump manufacturer which standard prevails, provided the definite overload capacity goes with the temperature standard. Without this guarantee it frequently be comes necessary to instal the next larger size motor. watch is intended to facilitate accurate reading and to prevent glare on the face of the watch. The movable clip permits shifting the record blank on the board, clip it at either the top or at the side, and always have it in the position most convenient. The board includes an envelope for the storage of schedules of standard speeds and feeds and other work- ing data. With reasonable treatment it is said that the woodwork will not warp. Wages of Foundry Employees in Ohio Third-quarter wages of employees in 134 foundries reporting to the Ohio State Foundrymen’s Association compare with those in the July report as follows: An increase per hr. for common labor of 0.028c., for pat tern makers, 0.102c.; for core makers, 0.001c.; a de- crease for brass molders of 0.020c. and for iron mold- ers, 0.045c. The total of employees represented in the October report is 8163, living in 59 communities. It was revealed in a recent survey made by the National Industrial Conference Board that American labor is receiving higher “real” wages today than at any time since 1913, not excepting the peak period of 1920. This may be attributed in part at least to the decline in cost of living, which in the survey made last July was 20.8 per cent below the peak prices of 1920. Germany's Foreign Trade in Steel Germany’s exports of steel in August are reported by Stahl und Eisen to have been 132,789 metric tons, making the total to Sept. 1, this year, 1,241,052 tons as compared with 1,645,104 tons for the same 8 months last year. Imports were 221,112 tons in August, which brings the total to Sept. 1, this year, to 1,339,085 tons, compared with 1,424,483 tons to Sept. 1, 1922. The H. P. Smith Co., Westfield, Mass., manufac- turer of radiators and boilers, has awarded an increase approximating 10 per cent in wages of molders. The day wage scale is now $7.20, contrasted with $6.60 and extras which brought the total up to about $7 the past year. Piecework molders will receive a corresponding increase in pay. The company employs 300 molders, and plans to increase this number early next year. Present Status of Pressed Metal Industry History of Industry and Causes in Proportion to Possibilities Retarding Expansion Application of Engineering to Sales a Basic Factor metal industry, through the development of the function of engineering as applied to the sale of pressed metal products, was presented in a paper under the title of “Pressed Metal Engineering: Principles and Examples,” by Douglas P. Cook. presi- dent Boston Pressed Metal Co., Worcester, at the machine shop practice session of the annual meeting of the American Society of Mechanical Engineers, held Dec. 6, in New York. Mr. Cook’s paper dealt more particularly with the problems of the so-called jobbing pressed metal indus- try. The fundamental causes and supplementary con- ditions affecting the status of the industry and handi- capping the adoption of a policy of sales expansion into relatively undeveloped fields were vividly outlined. The importance of the engineering function and the key position of the sales engineer in extending the market for the products of the industry were emphati- cally brought out. In addition, Mr. Cook’s paper was felt to present to those not in the industry a forceful sales talk on the possibilities of economies in the em- ployment of pressed metal parts to their own devices. At the outset it was pointed out that there was no mechanical field of equivalent scope and importance that so much needs and will so richly repay unsparing critical analysis of its present status and conditions as what has come to be known as the pressed meta! industry. A METHOD for the stabilization of the pressed Some Producing Groups Classified “Broadly speaking,” said Mr. Cook, “a thorough study of the application of press processes would cover three general producing groups, the so-called jobbing industry, comprising those plants that manufacture special pressed metal parts to order; the several dis- tinct groups that have gradually evolved as a result of intense specialization of the press process, and the seattered field of independent manufacturers of other than purely press products, who often devise and employ the most unusual and striking exemplifications of the procsss. In addition there is the collateral field of pressed metal equipment, the field of raw material, the detailed study of technical methods of production in the industry itself, tool and machine design, and the collateral processes of annealing, heat-treating, ma- chining and finishing. This, it was stated, is the general scope of the field of “pressed-metal engineer- ing,” a term not yet in general use, and a field that even today lies almost unexplored. ee Of these producing groups, the so-called “jobbing pressed metal industry was said to be made up of about 75 major plants and about 300 minor ones, if all be included who solicit press work whatever their principal line, with an annual volume of probably 40 to 50 million dollars. It is legitimate therefore, he said, to call this a major industry, for such it ranks in the importance of its service even though, because of its peculiar character, it is difficult, to determine its exact membership or annual turnover, with accuracy. A major claim to interest in the pressed metal process was pointed out to lie in its wide diversity of application, with the result that no individual or particular group can be said to be abreast of its progress. The flexibility of application of the process. which has pervaded hundreds of industries in countless forms, while exceedingly valuable to industry at large, was emphasized as containing both —— disadvantages to the jobbing industry. The See rapid growth of the industry was stressed, this — being said to be also uneven and almost uncontrolled. “It was left primarily to the jobbing industry alone,” sald Mr. Cook, “unaided by the usual benefits of organ- ization or by the cooperation of collateral interests, to discover new fields and applications for the process, new outlets and markets for its products. It is the comparative failure of the industry as a whole adequately to solve this problem that has caused several existing conditions that must be remedied be- fore the industry can fully come into its own.” Decentralized Growth of Industry Unfavorable A fundamental cause contributing “to what might almost be termed the lethargy of the industry in seeking to extend and stabilize its market.” was said to be “in reality—inherent in the peculiar empirical and individualistic method by which the industry reached its present stage.” Other important causes given were the contemporaneous growth of the auto- motive industry, and the effect of the war on the industry. “Tracing from early stages the actual growth of the mechanical knowledge, which developed, without concentration or orderly dissemination,” said Mr. Cook “we find that when a few original companies had accumulated knowledge and facility in handling the new process, practical mechanics, tool makers and foremen split off to form new companies. In these the same process would be repeated, slowly acquiring a store of practical knowledge that would in turn be split off and conveyed to another center of growth. Each remaining company continued on its way, increas- ing its own store of knowledge and experience, while the new companies, as rapidly as they were formed, entered new fields and developed new practices, based on their original accumulation of knowledge. “Actually, of course, the operation of this simile was controlled and regulated to a degree by the normal interchange and adjustments of every-day business, but the deduction is inescapable that owing to this particular method of development there was a constant tendency toward the partitioning of new knowledge of the developing art, which resulted in a constant decentralizing of important, even indispensable, in- formation. “As a natural result of this tendency, the compara- tive progress of the various specialty companies was uneven and unbalanced. Some rapidly placed them- selves in position to perform original redevelopment or redesigning work and to handle various unique prob- lems of economical, interchangeable, quantity produc- tion, while some could not, and did not even pretend to achieve any one of these things.” It was also pointed out as worthy of note that the individuals forming new centers of growth were in many cases the practical or administrative mechanics of the relinquished organization, men untrained in the field of management, accounting, production control, and the modern principles of selling so that the growth of the new companies was sometimes slow and difficult until the necessary managing and sales experience had been accumulated or finally provided for by the addi- tion of that type of personnel, after which rapid and comparatively safe progress became possible. Another check on general growth was said to be that here and there able and efficient companies had pioneered into a new field, established themselves there- in with a standard production and withdrew from the jobbing or specialty group, thereafter abandoning orig- inal or development work, except as it contributed alone to their own particular field of production. In addition to these main inherent tendencies result- 1579 a a= apn wv > | acai rm rs ee OY Seapeyerss “ey ° sree ae a a ee ee A AEs te. ae? or " “ - pape " " St deta nee ee mt | ne q . D par oreaeeeeeaete retin ee en t ‘ = et ese “A cedienemeeprgrrosenryy as aa Sting ia fet Ta GEMINI PE sense * eos Ero 1580 ing in uneven and retarded progress, the confusion was still worse, it was said, because the effective growth of the industry has occurred mainly within the last 15 years, a period of intense effort resulting in a tremen- dous burst of redevelopment of processes, methods and equipment, occasioned by the demands of automotive design and production. The automotive industry, it was stated, absorbed an important proportion of the free and constantly expanding press capacity of the country and supplied in return the principal impetus for the rapid growth of methods and equipment. The effect upon both industries was said to be practically revolutionary. The pressed metal industry opened sud- denly to the automotive engineer a limitless field, still but half explored. “Upon the smaller pressed metal industry, the effect was still more impressive and important. The intense pressure of the automotive demand tended to prevent the creation or growth of any self consciousness and resulting cooperative spirit in the industry as such. It was too intensely occupied with its efforts to meet the immediate and broadening situation, with the inevitable result that its attention was almost exclusively centered upon the customer industry whose demands were most immediate and insistent, with only occasional and spas- modiec efforts to apply to the needs of all other indus- tries the knowledge and ability produced by having served the one to the full extent of its insistent de- mand.” Influence of War Period “The war effort of the industry, a fascinating study in itself,” said Mr. Cook, “only exaggerated and inten- sified these conditions, and the receding wave of its exigent demands lent force to the already logical pres- sure and economic certainty that the industry must now accept its opportunity to broaden its fields and mar- kets by intensive effort into industries comparativly undeveloped.” It was given as his belief that if all potential cus- tomer industries had been assisted in their development proportionately to the automotive there would today be little difficulty for a jobbing industry double the size of the present to support itself. The same assertion would hold good, he said, if, in the near future, pressed metal might be introduced into all other possible cus- tomer industries in the same proportion of feasible ap- plication as it has into the automotive industry today. “The road from the pressed metal industry to the automotive plant and back is broad and well traveled,” said Mr. Cook. “Relatively the approaches to hundreds of other potential customer industries are but vague and unbroken foot paths. In this condition lies not only the great present opportunity of the industry, but a coming demand for a new type of highly trained engi- neer to do an indispensable work.” Supplementary Conditions Handicap Expansion Supplementary to the major causes of the failure to expand the possibilities of the industry there are, he said, a number of general conditions that affect its status and seriously handicap its efforts to adopt the logical and seemingly imperative policy of sales expan- sion into relatively undeveloped industries. Among the handicaps cited was the lack of popular or general recognition of the large contribution made by the industry to modern civilization, resulting in ab- sence of consumer interest and support. Another was the failure of the industry to develop engineering stand- ards or to publish adequate technical information for the assistance and guidance of possible customers. It was stated that to a great extent the industry has been content to sit back and await customer inquiries, The losses caused by acceptances of customers’ engineer- ing were outlined, and in this connection Mr. Cook said: “Not informed as to all the possibilities of the situa- tion, the customer may request quotations on some crude original design, which perhaps may take but a fraction of the advantages of design or function that would have been disclosed by proper analysis and ex- pert consultation. Such inquiries also often contain the theoretical and useless specifications of tolerance the attainment of which adds unnecessarily to produc. tion costs and the large total of actual loss entailed by THE IRON AGE December 13, 19232 the lack of proper sales engineering investigation, |, such cases, too, the time and expense of preparing esti mates and quotations is wasted. “The time is here when the alert manufacturer wi! call as freely and promptly upon his pressed metal en gineer to consult on problems of design and construc tion as for years he has called upon other branches oi the engineering profession. Also the day is here when fewer companies care to quote blindly to a blueprint calling for limits of 0.0005 in. variation, nor on designs whose functions or specifications or use they have littl or no knowledge. Separating Engineering and Production Functions “The expansion of sales engineering in the industry will in time remedy another and related handicap, th lack of definition and separation of the functions of engineering and of production. Originally there was no acknowledgment of the necessity of any engineering. A sample or sketch was submitted to the ‘practical’ man of the organization, who proceeded to make it. The usual customer regards the purchasing of pressed metal parts purely as a matter of competitive selection on a basis of price or first cost. If he knew the real facts, he would realize that apart from first cost there is great difference in the engineering service that he may receive, and that his selection should be guided by that fact and by the scrutiny of ultimate cost and economy.” That the work of the pressed metal sales engineer is not only to be recognized but will be de- manded and willingly remunerated by the customer as the primary essential to successful production was a belief expressed. The question of ownership and removability of tools was also said to be a handicap. On this Mr. Cook stated: “It is demonstrable to a fair-minded customer that in paying a preliminary ‘tool charge’ or ‘tool ex- pense’ or ‘cost of tools’ he is not thereby purchasing a physical asset, removable or transferable to his order. He is in effect purchasing primarily a service covering not alone the physical construction of the tools, but also the necessary preliminary work involved in re- design and redevelopment and the actual designing of the tools; and that his payment of such a charge is but his proper contribution for the services and toward the maintenance of an organization competent to perform the specialized character of work required.” Another hindrance to extensive redevelopment work mentioned was the difficulty of protecting exceptionally successful redevelopments, many of which represent nothing patentable either in process or result, but which nevertheless represent distinct and often valu- able improvements over current practice. Advocates Individual and Cooperative Research That the greatest rewards of the next decade will accrue to those that develop with greatest intensity the waiting field of redevelopment, was emphasized, and it was pointed out that there has begun in the in- dustry an intensive search for articles and parts that can be advantageously redeveloped. This work, it was indicated, will probably be carried on both cooperatively and individually by separate companies. It was brought out that a group in the industry, the Pressed Metal Trade Extension Council, has been supporting for some months a modest campaign of national advertising, aimed to draw out suggestions for possible redesign. The early results of this were said to have elicited hun- dreds of suggestions. Similar search by individual com- panies is already routine daily work, but on the whole it 1s spasmodic. Both the cooperative and individual research should be reinforced, said Mr. Cook, by per- sistent advertising, publishing specific economies ob- — and emphasizing possibilities of further appli- cation, Establishment of engineering standards for the in- dustry was regarded as imperative, and also making available scientific investigation of qualities of mate- rials most suitable for specific operations and results. Publicity to stimulate a broad consumer interest and demand was also emphasized as necessary. HUUUTOUUCHEACoOveveennenneneenevevnerea ts eoneneroryseeneveencesnentennoenenevssneneenrentan (Concluded on page 1625) Strip Mill Designed for Ease of Control Arrangement of Thirteen Stands in Two Parallel Rows and Completeness of Motor Drive Are Features in mills of ‘its class, a new 20-16-in. strip mill recently has been completed and placed in opera- by the West Leechburg Steel Co., Leechburg, Pa. neans not only that the company can now boast of nill second to none in the country in point of effi- ‘y and capacity but, as it supplements 12-in. and n. units, it also means that the range of sizes pro- iced by the company is widened. Hitherto, this company has not done much in the wider material, which finds heavy use by the automo- tive industry for underframes, brake drums and fenders; new mill permits it to enter that field. The mill lesigned to roll strips varying from about 18 in. to 6 in. in width and % in. and lighter in thickness, in either coils or cut lengths. As the 9 in. mill rolls mate- ria