The Iron Age 1925-05-07: Vol 115 Iss 19

THE IRON AGE New York, May 7, 1925 ESTABLISHED 1855 VOL. 115, No. 19 Correct Malleable Casting Patterns Proper Gating Saves Much in Reducing Loss of Castings—Allowing for Inevitable Shrinkage BY HAROLD A. RUSSELL* yearly on malleable castings because of the fact that the patterns are not properly made nor properly gated. A molder cannot turn out, in a day or a week, so many good castings from a poor pattern as from a correctly designed one, ‘and the same condi- tion will prevail if the pattern is not properly gated or if the gates are not properly proportioned as to feeders, etc. A correctly designed and gated pattern may have a higher initial cost than one which is made without giving much consideration to the molding cost, but the chances are that the cost is no greater. Sup- posing, however, that the cost is more, it will not amount to over a few dollars for a gate of pattcrns; and the initial excess cost, if any, is final, while the saving in the cost of the castings is continuous. “Not the First Cost, but the Upkeep” Recently the writer had a gated pattern returned from the malleable foundry because the casting cost was too high. This was an iron pattern, two pieces on *A. B. Farquhar & Co., Ltd., York, Pa M v= thousands of dollars are thrown away Fig. 1 (Left) Shows a Pattern Incorrectly Gated, as No Provision Is Made for Shrinkage, Nor to Prevent Sand from Flowing in Fig. 2 (Right) Shows Proper Gating, with Shrink Balls to Feed the Casting as It Shrinks. Sand and slag would be caught here, thus pro- tecting the cast- ings from their intrusion “perveeensenurevensannrs eeneny nant efpenaner rae ney rf EFHETERMHEREN ERNE conet unre SeseereenorseensseneEDyest tes sor :seEREeTSOEHLEEREDEDTDSESRELEOBASCREERERAET ALE ~ADET\ <9 0°RURERESESELATENPEDERD CESOODTREDSOS ES EDHERPUEERATO OEE a gate. We then made two aluminum patterns and sent them to the malleable foundry to be gated. The cost of the two patterns was $8, as we made them from the original wooden pattern which we had. The foun- dry charged $12 to gate the patterns the way they wanted them. Total cost, including expressage both ways, was less than $22. An order was placed for 300 castings from the new gate. The castings weighed 4 lb. each and the price dropped from 17c. to 12c. per pound, a saving of 5c. per pound, or a total saving of $38 on this one order, after deducting the cost of the new patterns and gate. On future orders the saving will be the full amount. Now let us consider some of the common mistakes which occur in the designing of the patterns and in the gating of these same patterns, all of which add to the cost of the malleable casting at the foundry and frequently in the machine shop, when the castings are received. We can even go a step further and include the assembling department. To follow the matter methodically it has been arranged in a series of ques- tions and answers: the questions by the writer and the 1331 1332 answers consolidated from letters received from lead- ing malleable foundries. Question 1—What are the most common mistakes in patterns, including gating for malleable castings? Answer—(A) Many of the mistakes which are reflected in patterns are the result of poor design on the part of the engineer or drafts- man. (B) In many instances complex sections are sought. without any regard to the neces- sary draft or the manner in which the iron must flow. (C) Core prints not properly drafted and core boxes not properly made to correspond to the draft on the core prints. (D) Where there are a number of patterns on a gate, patterns are frequently too far apart and not gorrectly gated. (E) Often sufficient consideration is not given to avoiding the shrinkage which always occurs and often makes the casting defective. (F) Patterns are made along the same lines as are required for iron or brass cast- ings, using the same kind of gating, shrink- ers, etc. (G) Gates not properly proportioned as to feeders, and patterns gated at the thin sec- tion instead of the heavy section, when gating at the heavy section would give best results. (H) Patterns soldered onto the gates in- stead of being pinned. (I) Patterns and gates made in a solid piece and then the gates filed down where they connect with the pattern. The patterns soon break off at that point. (J) Patterns well polished on the flat or easily “getatable” surfaces, but in other places left rough, giving results no better than ordi- nary castings. (K) Improper parting lines and arrange ment of cores. Aluminum and Brass Best Metals to Use Question 2—What is the most satisfactor) metal for patterns and for core boxes, and why? Answer (A) Aluminum and brass are th most satisfactory metals for patterns. Brass patterns are recommended up to the point where the weight of the pattern would slow up the production, except in cases where the patterns are mounted on match plates, where aluminum would be preferable. Large pat terns should be made of aluminum. (B) Aluminum is steadily growing in favor as, being light, it helps the molder and, being made with present alloys, is giving ex cellent service. (C) Aluminum patterns are somewhat more readily jarred from the gates. (D) Aluminum usually gives a smoother pattern casting and consequently the pattern maker spends less time dressing the pattern Being lighter in weight, it is more easily han dled by the molder and does not require such heavy rapping as the brass pattern. (E) Iron core boxes provide the best wear- ing material for the purpose. When iron core boxes would be too heavy, wood is preferred. Gang boxes are always preferable to singl« boxes, if quantities warrant. Question 3—Do aluminum patterns wear a long as brass? Are the gates as strong? In other words, will they stand the same average abuse as brass patterns? Answer (A) Brass patterns wear longer than aluminum. They will stand more abuse (B) Brass patterns hold onto the gates much better. (C) Aluminum patterns are much more difficult to repair than brass. (D) Where patterns are plated there seems THE IRON AGE May 7, 1925 to be little difference between aluminum and brass, as to the service received. Question 4—Is the average cost of alumi- num patterns more or less than brass? As we know, aluminum costs more per pound, but is the extra cost offset by the difference in weight? Answer (A) As to relative cost there is not much difference in cost, as wages are the prime factor. (B) The cost of dressing an aluminum pat- tern is usually less but there is extra work required in arranging the proper brass gating. Question 5—When are iron patterns desir- able? Answer (A) Iron patterns are desirable only in cases where they are intricate, or if made of brass or aluminum would bend or spring out of shape. (B) Iron patterns are desirable where the pattern is mounted on a machine and becomes a fixed part of the molding machine and does not have to be handled or lifted, by the molder, in the molding operation. (C) Gear patterns made of iron, if the pat- terns were kept in proper condition, would give a much better and cleaner mold than if made of other materials; that is, when the teeth are cast on the gear. Proper Position for Gates Question 6—Is it best to gate to a heavy or light section of the pattern? Answer (A) Where it is not necessary to add feeders to the pattern, to take care of the shrinkage, it is desirable to do the gating on the light part of the pattern. If it is neces- sary to add feeders, the pattern should be . gated at a point where the section of metal . is heavy enough to do the feeding desired, that” is, where the section of the pattern is heavy enough so that the hot iron will feed through, to the part where the shrinkage is liable to occur. (B) Gating, in almost all cases, must be on heavy section of the pattern to take care of the feed, shrinkage, dirt, ete. Only in excep- tional cases would patterns be gated on the light section. (C) Recommend gating to the section of the pattern from which can be obtained the best flow of metal, and feeders should be ar- ranged so as to assist in keeping the metal, in the different sections of the castings, at a uni- form temperature during the cooling or freez- ing period, (D) A shrink ball is plac where ed at the point the light and heavy sections meet. This is to eliminate the shrinkage that would result from the heavy section cooling considerably slower than the light section and, therefore drawing metal from this intersection (E) Che proper place to gate a pattern de- pends entirely on its shape, but usually, where the heavy section requires feeding, it is found best to gate to this point, with sufficient feed- ers provided to eliminate any possible shrink- age that may In cases where feeders are not required, the gating is usually ov- erned by the manner in which the mrt € arrang i gate the rrea est number of ‘ , . patterns l flask S1Zé occur. Examples of P . = f Properly and Improperly Gated Patterns ‘ig. 1 illustrates a pn; i oo _ rates a pattern incorrectly gated, as no hat will ‘as been made to take care of shrinkage at will occur in ; ' i) occur in a casting of this character and, as the shrinkage yw < ould occur at w s " « é a vite g > ing, castings would not be « ital part of the cast- not be so strong as if fed Satisfactory, as they would age taken care of Fate up properly and the shetehs. there is no srevie! Also, as these patterns are gated, from flowing ; “ei made to prevent sand or slag ing into the casting when the mold is poured seein ete tiem cnacna dT ate ape May 7, 1925 Fig. 2 shows these patterns gated correctly, with proper feeders or shrink balls, which will take care of shrink- age which would otherwise develop, and these patterns are so gated as to prevent sand or slag from flowing into the castings during pouring. Fig. 3 shows a gate of eight patterns incorrectly gated, as no provision whatever is made to take care of shrinkage, which is sure to develop in a casting of this character. This gate also has outside dimensions of 10% x 13 in. Fig. 4 shows the same patterns il- lustrated in Fig. 3, except that they are gated cor- rectly, with suitable shrink balls to feed up the cast- ings so they will come entirely solid. This gate con- tains ten patterns instead of eight, and yet the patterns are so arranged that they can be used in a smaller flask than is required by the gate of eight patterns shown in Fig. 3, as the outside dimensions of this gate of ten patterns are 10 x 13 in. only. Fig. 4, in addition to illustrating the fact that patterns properly gated will give solid castings, also shows that, by having patterns properly arranged on the gate, additional pat- terns can sometimes be included on the gate without increasing the size of the flask, which enables the foundry to reduce the cost of manufacture, as a greater weight of iron is produced in every mold. This is re- flected in a lower cost to the purchaser. Fig 5 illustrates, at top, central links for a special chain and the links were proportioned as shown in the sketch. In connection with this method of gating, which proved to be improper, it was possible to have 12 pieces to the gate with one gate to the flask; where- as, gated as shown in the lower portion, there were only four pieces to the gate and two gates to the flask. This reduced the number of pieces molded to the flask, but increased the percentage of good castings received. Fig. 6 indicates A and B as the points where shrink- age would exist if the patterns were improperly gated. The average patternmaker would gate at point C. This pattern should be gated at A and B, with feeders lo- cated there to eliminate shrinkage that is sure to exist otherwise. Figs. 7 and 8 show a pattern incorrectly gated with three pieces and then correctly gated with two pieces, with feeders at both ends and shrink balls properly located. It will be noted that at times the number of pat- terns on a gate can be increased, with satisfactory results, but that at other times fewer patterns to the gate are advisable. While this latter method will re- duce the quantity of castings made, it often will in- crease the percentage of good castings from each mold. Allowing for Shrinkage Question 7—What amount of shrinkage will there be in the malleable casting when ready for shipment, that is, after being an- nealed? The outer shell of a malleable cast- ing is considerably lighter than the center: THE IRON AGE 1833 does the depth of this lighter section indicate the grade of the casting? In other words, would the depth of this lighter section have anything to do with the malleable quality of the casting? Answer (A) Malleable iron is known as the “black heart iron.” The main derivation undoubtedly came from the black center of properly annealed iron. The lighter surface is due to the fact that the carbon content of the surface is less than-that of the center por- tion of the casting, due to the action of the heat. If the fracture is gray or spotty, it may show defective material which annealing will LUMEN EOAURE ARAM ENDO EROELLE SLCHREEN ORES SC TL TEUELERUERE (BEDE FERDEAEE VARS LEUNG POREOEEADEUNSRUAPEDONETT 660.500 009500 8ANE FRSERT CAERER CT > .U OMT URRNED REREN MIRE PenEr Incorrect Gating im Fig. 3 (Extreme Left) Is Corrected in Fig. 4 (Center) by Providing Shrink Balls and Bet- ter Locations of Gates. At the same time, 10 pieces can be made in a space actually smaller than that previously required for eight. The same rearrangement (above) from the one below gives proper re- sults 1 ERMAN RN ONE LE HELE TEEAEDE HEDLEY FEEEUROPRMERO PY DUA DELAEERS | PAOEEDEREOG UIT HDRES EDAULMENVERAT DPC et mr4C! S664 URAL MERENENRORTEEL CE DONRE LAREN! Senos ame ome not improve. If the fracture in places looks rusty or dirty, this usually indicates shrink- age. (B) While the normal fracture of a good piece of malleable iron should show a velvety black heart, surrounded by a thin white edge which forms the outer shell of the casting, yet many very good malleable castings are pro- duced and used satisfactorily that vary from the above described fracture. (C) A fracture of malleable iron, ob- served with the naked eye, should show uni- form in color over its entire area, except the white skin immediately at the surface of the casting, which varies from a mere trace to 1/32 in. (D) Finished malleable castings should show a shrinkage of % in. to 3/16 in. per foot, depending upon shape and cross sections. CE) % im. per foot should be allowed for shrinkage on the working pattern, to get the 1334 THE IRON AGE May 7 127+0 / gate - / gate %o a flas Well Gated mmetrical about +hiy line : ya desired dimension on the annealed casting. (F) The question of shrinkage is important and very difficult to compute. It is common prac- tice to say that malleable iron shrinks % in. per foot, excepting in the case of long, slender pieces, when shrinkage may run 3/16 in. or even % in. per foot but, while that may gen- erally be the case, it is not accurate and should not be used where given limits as to dimen- sions are required. In small work, particular- ly with gated patterns, the rapping may offset the shrinkage. Patterns molded by hand may be rapped more or less, depending upon the disposition of the molder, whereas patterns WILL DISCUSS WASTE Employee Training Also to Be Considered at Washington Meeting WASHINGTON, May 5.—W. C. Dickerman, vice-presi- dent in charge of the operations of the American Car & Foundry Co., will discuss the method of this company in dealing with the problem of waste in connection with a group session of the Department of Manufacture at the thirteenth annual convention of the Chamber of Commerce of the United States, to be held in Wash- ington, May 19-22. Another aspect of the same question will be dealt with by L. A. Hartley, Director of Education of the National Founders’ Association, who will discuss em- ployee training. Discussion of methods of reducing avoidable wastes in industry will be one of the most interesting topics of the convention. The cause - for waste, 50 per cent of which has been attributed to faulty business management are manifold, covering not only materials and equipment but labor, says a state- ment by the chamber. The attention of the meeting will be focused prin- cipally upon the last phase of the problem, practical methods by which cooperation and team work on the part of the individual employee can be secured in order that daily production schedules can be attained with reasonable regularity. The subject of employee training will cover the con- servation of human resources in industry in respect to which many manufacturers have been almost as short- sighted as they have been in the conservation of mate- Lgates % “1 flash Fig. 5 (Left) Illustrates at Top a Poorly Gated Ar- rangement for Casting Chain Links. This was corrected by the layout below it, which provided proper shrinkage allowance. While fewer pieces could be cast in one flask, the proportion of good castings was increased In Fig. 6 (Upper Left) Gat- ing Should Be at A and B, Instead of the Place, C, Where the Average Molder Would Do It. Feeders lo- cated at A and B would pre- vent shrinkage strains made in vibrator frames or upon plates do not get the same amount of rapping and conse- quently the ultimate results as to dimensions of castings would not be exactly the same. In malleable iron the annealing will make quite a difference. We have taken test bars made on the same heat, annealed in the same pots and same ovens, and they have not all been exactly the same length. It would be well, therefore, for a customer who expects his work to be within a close degree of accuracy to com- municate with the foundry, to see how the patterns will be handled and what system of molding will be used. rial resources, says the statement, which adds: “It is now recognized that provision for further labor supply 1S aS Important as the development of products and markets. The floating labor supply is both inefficient and expensive. _ “How these difficulties may be overcome, how cer- ain industries are meeting the question of providing an ample and efficient producing personnel, how the de- mand for skilled workmen who are : this day of automatic and single-purpose machinery is met are some of the questions that will be discussed by representative industrialists following the two ad- dresses.” Another important subje problem of distribution. ] t necessary even in ct will relate to the general ager poles It will be dealt with in a va- ety Of aspects and progress that has been made in the direction of a solution of the distribution problem will be indicated in an address by Sidney Anderson, who was chairman of the Joint Congressional Com iesi of Agricultural Inquiry, and is now presid i a oe = penton Millers’ Federation. There will a ike : > we speakers, among them William E, Humphrey ederal Trade Commissioner, who wil] explain the commission’s new proc rocedure anc icy wi ee ec and policy with reference Se The Machinery (C] Shi Machinery ub of Chicago has 2 ‘ as elec so the. enemas year as follows: President, F i, Hae — Ring & Electric Works: vice-presi- > ae soon an Systems, Inc.; treasurer, a » eeve-Fritts Co.; secretary i eens Twist Drill Co.; assistant a np ee empe, H. F, Kempe Co. nt 4 a Ce May 7, 1925 AMERICAN ZINC INSTITUTE Annual Convention Decides to Release Statistics Earlier—Progress in Composing Differences St. Louis, May 5.—The tendency of the miner and smelter of zinc to compose whatever differences that may have arisen between them and to work for the good of the industry as a whole was emphasized at the seventh annual convention of the American Zinc Institute, which was held at Hotel Statler, St. Louis, April 27 and 28. The outstanding feature was a dis- cussion of “The Miner’s Viewpoint,” by Eugene H. Wolff, past president of the institute. and “The Smelter’s Viewpoint,” by Leland E. Wemple, president Illinois Zine Co. Stewart A. Trench, C. S. Trench & Co., New York, who followed, attempted to reconcile the two viewpoints in a discussion of “The Zinc Busi- ness.” “The Story of Fire Clay Refractories,” a subject of increasing importance in the zine industry, was dis- cussed for the first time before the institute by L. M. Richard, consulting engineer and economic geologist. Other papers were read on “Electrothermic Zinc Smelting,” by Robert Lepsoe, consulting metallurgical engineer, Consolidated Mining & Smelting Co. of Canada; “Zine Coating,” by C. S. Trewin, technical department, New Jersey Zinc Co.; “Milling Practices in Tri-State District,” by Frank E. Weeks, Velie Mines Co., and “General Conditions,” by Adolph Boldt, of the Chamber of Commerce of the United States. The institute decided to release its statistics for publication immediately upon their issuance, instead of holding them five days for publication release. They will be released on the tenth of each month. In the discussion of the advertising campaign, it was brought out that some of the more conservative members of the institute felt that the relatively small resources of zinc ore should not be exhausted through a campaign for the larger uses of zinc, while the less THE IRON AGE 1335 conservative thought that there should be no fear along this line. It was decided to continue seeking sub- scriptions until July 1 to complete the campaign fund of $100,000. The institute continued the financial plan for its general purposes which has been in effect for the last three or four years, which includes the subscription of 5c. a ton on slab zinc, 2%c. on 50 per cent con- centrates and 1%c. on less than 50 per cent concen- trates. The number of directors was increased from 21 to 24, the new directors being Charles A. H. deSaules, president United States Zinc Co.; James F. Robertson, Commerce Mining & Royalty Co., and L. E. Wemple. The directors elected these officers: President, A. P. Cobb, vice-president of the New Jersey Zinc Co., New York; first vice-president, A. E. Bendelari, vice-president Eagle-Picher Lead Co., Chicago, who is the retiring president; second vice-president, Jesse G. Starr, Quinton Spelter Co., Joplin, Mo.; third vice-president, John A. McCarthy, Anaconda Copper Mining Co. New York; treasurer, Howard I. Young, American Zinc, Lead & Smelt- ing Co., Mascot, Tenn., and secretary, Stephen 8. Tuthill, New York. Mr. Tuthill has been secretary of the institute since it was organized under his direction in 1918. It started with 20 members, while it now has 206, representing virtually 100 per cent of those engaged in the mining, smelting and rolling of zinc. More than 100 members attended the convention, the largest in the history of the organization. The institute had as its guests the senior class of 15 of the Missouri School of Mines at Rolla, who at- tended all of the sessions, including the round table discussion led by Dr. Dorsey A. Lyon, acting director United States Bureau of Mines. Mr. Bendelari was toastmaster at the banquet held at Hotel Statler on Monday evening, April 27. The principal speaker was James Schermerhorn, former publisher of the Detroit Times, and talks were made by Richard Jenkins of Galena, Ill.; E. M. Johnson of Henrietta, Okla., and S. A. Trench. A BINOCULAR MAGNIFIER New Instrument to Relieve Machinists’ Eye Strain In certain industries where visual examination is necessarily employed by mechanics and machinists at lathes and at other tools in order to gage the progress of precision work, eye strain and fatigue often result from the smallness of the product to be examined. To correct this difficulty a new instrument, known as the “binocular stereo magnifier,” has been put on the mar- ket recently by E. Leitz, 60 East 10th Street, New York. It is claimed that, by the use of this new in- strument, the minutest parts can be inspected and technical details controlled, as well as the smallest units adjusted to their relative position in an accurate and reliable manner. The new instrument is described as producing a stereoscopic image which shows the object under ex- amination in plastic relief, sharper and clearer than by the naked eye. It is suggested that the use of this instrument may eliminate some of the large losses in production, and that there will be a diminution in the constant falling off in efficiency and quality of produc- tion, due to poor vision. The new magnifier is furnished for use with a variety of different stands to suit each particular re- quirement and, since the prism body can readily be in- terchanged with any stand offered, a saving in cost of installation will always prevail. It is pointed out that when using the binocular magnifier the object is re- produced in its actual orientation, or, in other words, in the identical position as seen with the naked eye. It resembles a pair of prism binoculars, arranged on a stand as shown in the illustration, each tube being rotated on its axis, permitting an adjustment of the interpupillary distance of the observer’s eyes. The prism bodies are equipped with eyepieces which slide into tubular mounts, allowing one to correct any differ- ences of vision between the observer’s eyes. The instrument permits a magnification from 3.5 to 30 diameters, which is claimed sufficient for practically Using the Binocular Stereo Magnifier for Eye Strain Relief all calibrations and control work on finished or semi- finished products. The working distance from the ob- jectives’ prism body to the specimen varies up to 6 in. and is dependent upon the magnification used. One can readily cover an object up to 2 in. in diameter with low-powered eyepieces whereas, using the higher eye- pieces, the field of view is slightly decreased but is con- siderably larger. od ie Se oo ae itt to ace ot a) eT cacedemeie eon are porate 1336 THE IRON AGE Industrial Type Speed Transformer A spur-gear speed transformer designated as its “industrial type” and intended for general industrial work where speed transformer units are operated under continuous or heavy service conditions has been brought out by the Hill Clutch Machine & Foundry Co., Cleveland. All gears have cut teeth of 20-deg. involute form, the teeth being short in length and thick in cross section to assure strength. Both the high and low speed shafts are supported in the central housing in double bronze bearings, and provision is made for Speed Transformer for Conveyor and Other Drives ordinary thrust conditions. The high and low speed shafts are in identical axle alinement, the action being positive and both shafts revolve in the same direction. The gears are easily accessible as the cap at both ends can be removed conveniently. Continuous splash system of lubrication is employed, a metal disk on the high-speed shaft automatically lubricating all the gears and bearings. The unit is inclosed in a dust proof leak proof case, The transformer is made in seven sizes. Each size has a number which bears a fixed relation to the diameter of tthe low-speed shaft, the number also in- dicating the horsepower the low-speed shaft is capa- ble of transmitting safely at 100 r.p.m. The trans- former is offered for use in connection with conveyor drives, steel plants, smelters, pulp and paper mills, refineries, cement mills, brick plants and other plants where a speed changing device is required. Fire Resistance of Reinforced Concrete Columns Reinforced concrete columns subjected to fire tests when carrying regular working loads form the subject of a 76-page publication of the Bureau of Standards, designated as technologic paper No. 272. Copies may be obtained at 25c. each from the Superintendent of Documents, Government Printing Office, Washington. One of the strong features of reinforced concrete has been the fact that the cement and aggregate form- ing the concrete, and the steel forming the reinforcing, have almost identically the same coefficients of expan- sion when subjected to varying temperatures. This fact has preserved the bond between the two and pre- vented the rupture whieh otherwise must have occurred in millions of cases. Under conditions of fire, how- ever, where the exterior is subjected to a temperature far exceeding that which penetrates to the interior of a column or other member, this similarity of expansion does not prevail, with the result that concrete spalls off, leaving the steel exposed. Under this condition the steel rapidly softens from the application of intense heat, with resultant collapse or partial collapse of the column or wall or building. In the present tests it was demonstrated that con- crete columns require the protection of independent heat insulating materials just as steel columns do, al- though they will resist failure longer than bare steel columns. Light metallic reinforcement in the pro- tective concrete may be used, the reinforcement being in the shape of expanded metal or similar materia! This prevents the heavy spalling which would expos: the interior or main reinforcement, and thus protects the latter. In case aggregates of the non-spalling class are used, the protective expanded metal member is unnecessary. Failure of any such member depends upon both the intensity of the fire to which it is subjected and the duration of the subjection. A table is given show- ing the period of resistance, in hours, of various types of column structures made up with various forms of steel reinforcing and further protection. The re- sistance varies from 1% hr. in the case of the most poorly protected specimens tested to 6 hr. in the cases of six of the specimens, these being the ones best de- signed and most adequately protected against heat. Arc Welder for Railroad Shops A portable electric arc welding machine of large capacity and designed especially for use in railroad shops, has been brought out by the Lincoln Electric Co., Cleveland. It is a 300-amp. machine and is fur- nished for any voltage. The stable-arc is employed. The arrangement of the machine may be noted from the illustration. It is mounted on a riveted structural steel frame only 21-in. wide so’ that it can be moved through narrow aisles. Its weight is close to the floor to eliminate danger of the truck tipping over and at the back of the frame there is an extension to protect the welding unit. The wheels are 12 in. in diameter and are all steel, being made of disks to which the rims are welded. The wheels are mounted on roller The Machine May Be Taken Through Narrow Aisles bearings. The ine j s. > machine is adapt f i adapted for welding locomo- om frames, cross-head guides, truck sides, main driv- ing — Journal boxes, brake levers coupler hafts and other parts. It is stated that it will put on 7 to 10 lb. of meta] = : ae etal per hour In building up cross-head guides and from 4 to 5 ft. of firebox se: welded per hour. The machine | a on =e starter, convenient hooks for the cable push button trolled truck handle and a water a as See con- when dropped down affords os oo! cover which weather. Its weight js 1800 Ih protection from the sienna Harry D. Carson drawn from Miller. ganized Carson, and Don A. Marsh Carson & Co. Marshall & Co. all have with- E Inc., and have or- » Inc., with offices in the co rest Building, Philadelphia. Th wit conduct a general business in nig ron’ aaa coal. Pig iron, coke and i. May 7, 1925 : : i a F —s Tae eee Methods of Welding Inspection Practice of Various Industries in Testing Skill of Operators Reviewed at Welding Society’s Annual Meeting—New Officers Elected the methods followed by various industries in inspecting welds and testing and checking the skill of welding operators was an outstanding feature of the annual meeting of the American Welding So- ciety, held April 22, 23 and 24 at the Engineering So- cieties Building, New York. The meeting as a whole was well attended. New officers were elected, A. G. Oehler, Railway Age, 30 Church Street, New York, being the new president. George Bird, Bird-Potts Co., Atlanta, Ga., was elected to serve as vice-president, Southern division, and C. H. Smith, Linde Air Products Co., San Francisco, was elected vice-president, Pacific Coast division. Directors at large are James Burke, Burke Electric Co., Erie, Pa.; J. W. Meadowcroft, Edward G. Budd Mfg. Co., Philadelphia; S. W. Miller, Union Carbide & Carbon Laboratories, Long Island City, N. Y.; and H. A. Woofter, Thomson Electric Welding Co., Lynn, Mass. Dr. C. A. Adams, professor of engineering, Har- vard Engineering School, Cambridge, Mass., continues as president and W. Spraragen as secretary of the American Bureau of Welding, which is the research de- partment of the American Welding Society. Dr. H. L. Whittemore, Bureau of Standards, Washington, and A. D. Risteen, director of research, Travelers Insur- ance Co., were elected directors of the welding bureau. Progress reports were made at several committee meetings. The electric arc welding committee, headed by H. M. Hobart, General Electric Co., Schenectady, is making a comprehensive investigation to determine certain fundamentals of electric arc welding, such as the effect of various currents, angles of bevel, number of layers of deposited metal, and size of electrode. Test results were analyzed at a meeting of the committee. A sub-committee is carrying out tests on the are weld- ing of non-ferrous metals. The resistance welding com- mittee, of which H. A. Woofter, Thomson Electric Welding Co., Lynn, Mass., is chairman, discussed the welding of special metals and it is hoped to gather con- siderable data on spot welding. The committee on specifications for iron and steel to be welded, headed by W. J. Beck, American Rolling Mill Co., Middletown, Ohio, have a definite program of investigation, upon which it will report later. An educational committee has been formed with E. H. Ewertz, general manager Bethlehem Shipbuild- ing Corporation, Moore plant, Elizabeth, N. J., as chairman. This committee will work up fundamental data for the training of electric arc and gas welding operators. An inspection trip to the Bayway plant of the Standard Oil Co. of New Jersey was well attended. The company’s shops were visited and the application of welding in the construction of pressure vessels was inspected, as well as the welded joints on lines and headers that replaced the fittings formerly used. \ TECHNICAL session devoted to a symposium on Many Papers at Technical Session More than 25 papers were prepared for presenta- tion at the technical session. Most of the papers were brief, and several were preprinted. In a paper on “Standardization in Welding,” W. Spraragen, secretary of the American Bureau of Weld- ing, expressed belief that too much responsibility has been placed upon the welder, and that the engineer has dodged his responsibility in the matter of design, tech- nique to be employed and selection of materials. When these problems are worked out, he said, the welder is called upon only to manipulate the torch or electrode to do a particular job and after a little training can 1337 be depended upon to do the work with less variation in quality than is found in riveting, providing there is a proper inspecting and supervisory force. In discussing the testing of welds and welded prod- ucts it was said that the testing is different for every industry. In some ca hydrostatic pressure can be applied and in others, blows of a hammer, soap solu- tion, oil penetration and’ reduction of air pressure were said to be useful. In the majority of tases, however, tests of this sort are neither possible nor desirable. Where all of the variables, except the actual deposit of the metal, have been determined by competent engi- neers, the quality of the product will be known in ad- vance. The skill of the operator can be tested and checked for the particular job at suitable intervals. Suitable inspection service, it was emphasized, should be given careful attention. The inspection service should, it was stated, include checking whether all requirements preparatory to the welding have been fulfilled; whether suitable mate- rials are being used; and include the method of depos- iting the metal. It should also be ascertained whether the correct current or size of torch tip is being used, whether the manipulation of the torch or electrode is satisfactory and whether the parts to be welded are free from foreign matter. Finally it should be known whether the proper penetration and fusion are being obtained. In some cases it might be desirable to have the welder stamp his number on the job, and in others the inspecting force might test specimens of the work to destruction. The expertness of the operator in depositing the metal for the particular job can in most cases, it was stated, be determined only by physical tests to destruc- tion of specimens of his work. ' Meetings Helpful in Maintaining Quality Inspection was held as an important factor in get- ting uniformly good welds by Jonathan Wolfe, assist- ant superintendent of track and roadway, Chicago Sur- face Lines, in a paper on the methods employed by his company in the carbon are welding of rail joints. By frequent inspection and by discussion at the welding meetings, the knowledge and skill of the operators is being increased. The welds are inspected by the su- perintendent of welding and by the foreman, the latter also laying out the work and making daily reports of the work done. The welding meetings are attended by all division superintendents, welding foreman and operators, and at some of these meetings samples of welds, test pieces, etc., are shown, and methods are dis- cussed. Instructions are issued covering future work and by means of the meetings the operators are brought in touch with each others’ work. Helpers in each gang are trained by working under the supervision of a welding operator, and metallic process welders are advanced after serving an apprenticeship under the carbon operator. The skill of the operators is checked by the inspection of welding done by them and their work and also by the service record of the joints made by them, each operator being required to stamp an identification letter on the joint he makes. Rail joint welding was discussed also in a paper by H. M. Stewart, superintendent of maintenance, Boston Elevated Railway. Before men are assigned to regular joint welding they are instructed in the care and oper- ation of welding machines and make up test joints under the direction of instructors. These test joints Pewee cre nee sy eeee wtene tT one (AOE OTN aCNNRE ORLA Nene ES CORE (Concluded on page 1389) wim Cane yim ath sae Peete ON ARAN TARE A aR RE ONT ME nt a Se dee ae oe ae eee oom Sey eee weer wes 4 - Si ea rear arse PRED yates Bh Sel iene ght 1338 THE IRON AGE Heavy-Duty Universal Milling Attachment A universal milling attachment known as the No. 5 Hevy-Du-T, has been added to the line of the Por- ter-Cable Machine Co., Syracuse, N. Y. It is designed for making heavier cuts than possible with similar attachments previously marketed by the company and is recommended for irregular and intricate work requiring end mills up to 1'%-in. in diameter. Like the No. 4 model, the new attachment is gear driven, but the ratio being only 1 to 1 there are fewer gears. “The reversing mechanism is not employed and the gears run in oil, which is stressed as assuring silent operation. When equipped with a boring head the device may be used to bore fixtures and drill jigs at any angle. It may be attached to any standard overhanging-arm milling machine and is driven by a taper arbor of suitable size for insertion in the spin- dle of the machine. The outer end of the frame of the device is secured to the overhanging arm by an adjust- able clamp, as shown, and ease of mounting or remov ing the device is a feature. The drive arbor, inter mediate shaft and gears of the attachment are of chrome-nickel steel and run in S. R. B. ball-bearing and Norma-Hoffman roller bearings. The spindle is pack hardened and runs in adjustable bronze bear- ings. A split draw-in collet for 1%-in. shank end mills may be furnished. The weight of the attachment is 45 |b. Medium and Light Duty Friction Clutch Few parts and accessibility are features of the Lemley model F friction clutch illustrated, which is a recent addition to the line of the W. A. Jones Foundry & Machine Co., 4401 West Roosevelt Road, Chicago. The principle of operation is simple and special tools are not required to adjust or disassemble the device. Uniform pressure on the friction surfaces at all times is claimed. The two toggles are adjusted at the same time by means of one split ring. Free floating friction rings of fiber or asbestos brake-lining material are employed. The device is furnished as sleeve clutches, cut-off couplings, or bolted to the arms of pulleys, gears or sheaves. Scavenger Valve Prevents Compressor Explosions A new type of scavenger valve for air receivers in compressed air plants was described by William F. Parish and William B. Smith-Whaley, of Parish & Tewksbury, engineers, 17 East Forty-second Street, New York, before the metropolitan section of the pe- troleum division of the American Society for Mechan- ical Engineers, April 9. It is generally conceded that air receiver and line explosions are caused by explosive mixtures due to air and the lubricating oil, but the trouble cannot be prevented through a control of the character of the lubricant, as such explosions are found to occur with either high or low flash point oils. These explosions will not occur, however, if air and oil vapors are prevented from forming combustible gases. Pockets and traps in the air line also can be guarded against. As regards the receiver, means may be introduced for constantly scavenging the tank and thus preventing the accumulation of vapors. In the method described, which has been in use about seven years, a scavenging valve is employed, the air entering and leaving the receiver through the same opening. The mechanism of the valve allows the pressure to open a passage for the compressed air to the top of the tank. The outlet opening has fitted to it a length of pipe that goes to within a few millimeters of the bottom of the tank. Any air flowing from the pump or compressor to the air system, therefore, has to pass from the top of the tank entirely to the bottom before it can leave. This serves to sweep all vapors and gases from the receiver and keep it full of air with only a minute amount of oil and vapors that do not have a chance to collect and stratify. A valve of the type described is shortly to be placed on the market for use on air receivers. Cutter Clearance Gage A gage intended to aid in grinding the correct angle of clearance in milling cutters, and which may be used for right and left-hand mills, is here illustrated. . The body, which is of V-shane and holds the gage }| eae cutters and for end locates the cutter lade 1? . ; . fe In correct rels center line of the cutter, Al] sonihana aall = oe hardened and ground. Two rage blad a furni hed “ > £ » ¢ e - ; ” . : with each gage and cutters from ',-in. up t "8-in i diameter and of any width may be m ae a : ‘say Ve Measure In using the gage, the insid surfac oe > : are brought in contact with +) t ae . oe the gage blade is dropped wr... : as shown, and ee cutter is the er olved ao a bring the face of the ; se aah ae 1 Ontact with the he or? Vv a 7 Saison at nn weuny angle of hemes in nh will correspond with the angle of th = — = being marketed by the Brows & Meenas Mfg. Co., Providence, and jg ; i oo is designated as the No, 1e ( Th 1, 41 ne May 7, 1925 | eo arene ee Seen eee ne Following Up Purchase Orders International Petroleum Co.’s System Recognizes That Getting Goods Is Important Part of the Transaction almost as important as placing the business,” said Byron C. Kitchen, assistant purchasing agent of the International Petroleum Co., Ltd., Toronto, Ont. “A buyer may drive a good bargain, and save money on a purchase, but unless the order is delivered within the time specified it may mean an ultimate loss to his firm. In buying, as in other things, it is results that count.” Many men are adept at making good _ purchases, and can obtain concessions that their less favored associates cannot get; but few, with- out the aid of a Dear Sirs: és | FOLLOW-UP system for purchase orders is good follow-up Please furyish information o y using space below for reply. This form must be returned if letter is written in reply giving particulars requested. system for their purchase orders, 1 When was order shipped? are able to get 9 good deliveries of For following up purchase orders when deliveries seem un- certain, a printed letter-size sheet is used with a list of ques- tions introduced as shown immediately below. the . purchasing 2 If not shipped, when will you ship? } When will you ship balance due on above order? A printed blank is mailed out. On this are listed a number of questions, and the clerk indicates at the top of the form the questions that he desires to have an- swered. In this case it would be questions No. 1 or No. 2, “When was order shipped,” or “If not shipped, when will you ship?” Then the clerk makes another entry in his diary, say on April 7, which allows time for a reply. If the papers have not been received by that date, or a good explanation received, another form is mailed out indi- eating questions No. 4 or No, 22. In the case of very urgent orders agent may retain Subject . a copy of the order and urge delivery with personal let- ters. However, the form letter has been found suc- cessful. An execu- comply with requests indicated the material they 4 This is second request for information regarding shipment of tive of a large have ordered. The above order. Please give: immediate attention manufacturing Imperial Oil Re- 5 Render invoices in triplicate concern with fineries, Ltd., of 6 Send Customs invoices in triplicate, two of which must be which Imperial Oil which the Interna- yaa r invoices in septuplicat Refineries, Ltd., . ‘ ende yoices se cate . tional Petroleum 8 Send packing lists in quintuplicate. does a large busi- Co., Ltd., is a sub- 9 Show on invoices or packing lists, gross, net and tare weights nese said to the sidiary, has in pounds and kilograms writer: evolved in the 10 Show package markings on invoice “When we see general purchas- 11 Show customs declaration in Spanish (as given on order) on one of the follow- ing department invoices, up letters come in after years of ex- 12 Send Bill of Lading or Express Receipt to this office. we know that it perimentation a 13. Show separate piece for each item means business : 14 Should not price read. vary efficient os nd 15 Unable to locate on order the......item on your invoice. and make haste to tem of tracing or- 1B"@ive Gérréct’ order number. deliver their order, ders. 17 We passed invoice dated .. amount... covering this or give them a Including the material. Explain attached plausible reason purchasing agent 18 Render. separate invoice for each consignment. for not making and his assistant there are nine buyers, and a total staff of 30 em- ployees. This de- partment must provide for all of the needs of six refineries, 14 central marketing stations and all of the small stations in Canada, as well as two refineries, three drilling fields, and marketing stations in the South American countries of Chile, Colombia, Peru and Ecuador. When an order is sent out, an exact copy of it is given to one of the clerks whose sole duty is to follow up orders. On the bottom of this order is noted by the buyer the date on which delivery of the goods should be obtained. If there is no particular importance for quick delivery, the clerk makes an entry in a monthly diary on a date a day or two following that on which the goods should be shipped. Say, for example, an order is given to a firm in Montreal for some oil cans to be delivered to Winnipeg on April 1. Allowing time for the documents to come through the mail from Montreal, the clerk makes his entry in his book for April 3. If upon lobking over the entries for that date he finds that documents have not been received and that apparently shipment has not been made, he sets in motion the tracing system. 21 Your invoice of Please advise. 23 Remarks :— 19 You have. not deducted freight allowance. 20 Give invoice reference on attached expense bill. being held pending receipt of expense bill. 22 Have not received reply to my letter of......on above subject 1339 delivery.” From the many other questions printed on the form it can be seen that it has other uses than to hasten shipment. It is far less costly and more simple than to dictate a separate letter for each order, and to judge from the attitude of the firm mentioned above, the results are just as satisfactory. Revolving distributors of the McKee type will be in- stalled by the Carnegie Steel Co. on Carrie blast fur- naces Nos. 1 and 2 at. the Homestead Works. The order for the distributors has been placed with Arthur G. MeKee & Co., engineers and contractors, Cleveland, who will also furnish three double hopper larry cars each of 300 cu. ft. capacity for use with the Carrie furnace storage bin system which is being reconstructed and provided with bin bottoms of the Baker type. The Yolande Coal & Coke Co. announce develop- ments to begin at once on coal lands at Connellsville, in the lower part of Jefferson County, Ala., a big shaft to be opened and the Blue Creek coking coal to be mined, $300,000 to be expended on the development. 1340 THE IRON AGE Heavy Lathe with Special Attachments for Turning Crankshafts A 48-in. heavy lathe with special attachments for turning both single throw or multi-throw crankshafts has been designed recently by the Niles-Bement-Pond Co., 111 Broadway, New York. The machine is claimed to reduce the time required for setting and machining such shafts and to assure greater accuracy. T