The Iron Age 1925-09-24: Vol 116 Iss 13

ESTABLISHED 1855 Saving Space in THE IRON AGE New York, September 24, 1925 VOL. 116, No. 13 a Steel Foundry A Photo-Story of the Pettibone Mulliken Plant CONOMY in space, increased output and K further reduction in labor became important aims of the Pettibone Mulliken Co., Chicago, when it developed an extensive jobbing trade in steel castings in addition to its original output of rail- road specialties. Under the pressure of increased de- mands on its capacity, its steel foundry, which con- sisted of two 65-ft. bays, 243 ft. long, was extended 238 ft.., making a total length of 481 ft. Compact and convenient location of sand storage, sand handling equipment and core room was an important con- sideration, and it was decided to set aside for those depart- ments the northwest corner of the plant. Approximately 45 ft. of the western end of the north bay, adjacent to a railroad track which crosses that extremity of the building, was set aside for storage bins for new sand, coke for core ovens, clay, and outgoing rubbish. The next 70 ft. of the bay was allotted to a core room and sand mixing equipment. The Camera views, scrap. space, however, was too small for both departments, creating a problem which was finally solved by superimposing one above the other. sand bins and the heads of various elevators in connection with the sand delivering system. makers’ benches in the middle of the room are sup on steel racks, which, in turn, are handled by lift truc 795 I The small work core room is located on a floor 17 ft. 6 in. above the main foundry level. NOLADACDOUT EMAAR RSH TAN indicated on the accompanying plan drawings, permit visualization of un- usual improvements, which embrace a core room placed above the sand miz- ing department, compact arrangement for sand storage, sand handling and shaking out, and convenient placing of mold drying ovens. and cleaning equipment is featured by a large rotating screen which sepa- rates manganese steel from soft steel {LTA A mezzanine floor, 17 ft. 6 in. above the main foundry level, now carries the small work core room. On this elevation also are four core ovens for small cores, which are directly above three core ovens (on the main floor) used for larger cores. Underneath the small work core room is the equipment for cleaning, sift- ing and mixing sand. Adjacent to the sand handling depart- ment and connected with it by conveyors is a shakeout floor. In addition to the core work it is necessary in the Pettibone Mulliken plant to dry many molds of consider- able size. For that purpose a battery of five mold drying ovens was located in the middle of the foundry. Conservation of space was also employed to advantage in the melting department. Two electric furnaces are located on an elevated plat- form, with transformer equipment underneath. The general plans for the improvements were devised by the H. M. Lane Co., Detroit. The ovens for both cores and molds were furnished by Holcroft & Co., Detroit. The sand conveying machinery was built by the Link-Belt Co., Chicago, and the electric furnaces by the American Bridge Co. TUPULEUACACOARSARRDATOG ATUL S10 PUL aT taken from points Sand sifting EULA AE In the rear are core- with sand by traveling crane; the cores are dried lied ee. Some of the racks are visible at the right. EE Ea SS QUDADAUOUUA EOL. GAAMAMAA ASH AMU PRMNL LAddL THE IRON AGE September 24, 1925 MMDLOTUMTYOQSAGGREPYCGGAQNESLUOGAMAAALAULLLL LANE LSUOQOOOEONG UOC Photo-Story LAN view of entire foundry showing location of core room and sand handling department, mold drying ovens and melting equipment. The numbered arrows show where two photographs (with corresponding num- bers) were taken. Old Stee/ found'ry --- =o MOLDING Core foom, SAND STORAGE AND <-- Core Ovens BAY ~-Addition to Steel Foundry-----~~~=-~-~=---=== >| Fiasn STORAGE HANDLING Battery oF Mold Orying Ovens OURING om Stee! _. A furnaces}. e A view of the core room (below) lookinz P—toward the ovens. These are of the auxil iary air-forced blast type and are fired with coke. To save space, a battery of ovens for heavy cores was placed underneath the upper battery. The batteries are built entirely separate, each supported by its own concrete work, 7 \ A a7 “aa SS BAD ENS % 8 , “= core room on the main foundry floor level. At the right is a hydraulic ele- vator, which conveys mate- rial from the foundry up to the core room level. The cores from the upper core room may be delivered to the foundry either by over- head traveling crane or by means of the elevator and trucks on the foundry floor level. In front of the ele- vator is a certain area of the foundry devoted to the mak- ing of heavier cores and these are dried in a battery of three ovens which. are lo- cated under the four ovens situated above. The larger oven is shown at the right and the two smaller are * reached from beneath the platform at the left. This platform is connected With the general mold shake-jut system. Any molds made‘in the bay in which the core room is located may be set upon the platform and then shifted over under the other cran@ runway to the shake- out platform. 3 Looking toward the SCRAP STORAGE superimposed one above the other. both are fired from a common firebox below the foundry floor. In connection with the stack, shown at the right, a difficulty was encountered, i. e., to pass it between two crane runways. To that end it had to be flattened out. A core rack with the lift truck partially under it is visible at the right. aN f September 24, 1925 of a F oundry Herotrenaermicannetagenenaeunegt cacy tan Beneath the core room are located three -———Simpson mixers—two for facing and back- ing sand, which are shown, and another for making core sand. The mixers are equipped with skip loaders and the sand from them is taken away in boxes on lift trucks. After the THE IRON AGE boxes reach the main foundry they may continue to their destination by lift truck, or they may be handled by traveling crane. There are doors in the sand bin wall on this level so that both new and old sand are available only a few feet from the mixers. 797 ETAIL of main floor of sand handling and Manganese Stee! tnd with Magnetic Separator Cagre FOvens core department with numbered arrows showing points where photographs taken. Views taken on the mezzanine floor are indicated by broken-line arrows Nos. 1 and 2. No. 6 was taken on the shakeout plat- form, also above the: main foundry level. 7 was taken below hoppers shown in the drawing. were No. A) 798 The —=~ment consists of an elevated platform a THE IRON September 24, 1925 wont PRoto-Story general casting shake-out arrange- The space under the front of the platform also affords protection for men passing the shake-out. little over 100 ft. long. This is a rein- Beneath the p'atform also much of the wire and forced concrete structure and the object of ele- vating it was to provide for sand handling equip- rod straightening is done. The core room is located back of the wall in the rear and is several ment underneath, without recourse to a tunnel. feet above the platform. 6— Flasks are brought to this platform and shaken out over the gratings. The sand is then taken away on a pan conveyor and put through equipment to sepa- rate lumps, rods, etc. a) “ = . re LT For sifting and cleaning, the sand is 4 ——pamed into a large rotating screen at the end of which is a manganese steel ring with a fixed magnet on the outside. The scrap in the sand is likely to contain both manganese and soft, or carbon, steel, and the two must be separated. The man- ganese steel, being non-magnetic, passes through the ring.at the end and then to the belt shown at the right. This discharge, in addition to manganese steel, consists. of core butts,and hard lumps of molding sand. When the screen is in operation a man is stationed at the belt to pick off pieces of manganese steel. The overflow then passes into the booth of an elevator shown at the right and is raised to a belt which conveys it to a rubbish bin. Any soft steel that en- ters the sieve is held against the manganese steel ring at the end by means of the seg- mental magnet and is thus lifted to near the top, where it is released and passed out through the chute shown at the front. Core rods, wires and nails are removed in this manner, also. SN li eee tees ee ef September 24, 1925 of a Foundry « IRON AGE ee . eee In addition to the core work in this plant “jt is necessary to dry many molds which are of considerable size. To accomplish this a battery of five drying ovens has been lo- cated in the middle of the plant. At one side there is a battery of four ovens served by a transfer car, as shown, and in each bay of the foundry there are three set-off tracks connecting with the system, so that cars may be filled before going into the oven and cars of baked molds may be stored at the other end. Under ordinary cir- cumstances all molding is done in the bay from which th's view was taken and the pouring is done in the further bay. The transfer car serves not only to spot the cars of molds in front of the respective ovens but also to transfer the molds from one bay to the other. In addition to work of this class it is occasionally necessary to make a very long manganese steel piece and for this purpose there was placed back of the battery of four ovens a single oven with doors at each end. One set of doors can be seen at the right projecting above the roof of the oven. In this ease the mold is made in the molding bay (in the right foreground), is run into the oven for drying and then taken out into the casting bay (at the left). To conserve working space all five ovens are fired from pits arranged beneath the foundry floor. In cornection w'th these ovens as with the battery of core ovens, the stacks had to be broad- ened out to a long thin rectangle to get them be- tween the crane girders. The melting equipment consists of Q—ws electric furnaces placed on an elevated platform underneath which the transformer equipment is located. The stock bay is behind the platform and is served by a crane which unloads the raw material into the bins and then delivers it to the charging platform. The ladles are placed in pits in front of the furnaces for filling. This view was taken from the top of a mold-drying oven and in the fore- ground may be seen one of the mold cars and one of the set-off tracks. Between these tracks and the furnaces there is a transfer truck used for returning empty flasks from the pouring bay to the molding bay, and on this car is one of the long flasks for use in the long oven referred to. ~ ometor pee Metallurgy of Iron Dryer Rolls Intricate Mechanical and Chemical Problems— How They Were Solved—Ingenious Set-Up of Mold BY J. W. BOLTON EVERAL years ago the writer was retained as S consulting metallurgist by the Black-Clawson Co., manufacturer of paper mill machinery. This firm had completed a program of mechanical standard- ization, attaining a quality of workmanship exceeding that found in most shops and, also, insuring flexibility in interchangeability of parts. For various reasons it was felt desirable to extend the improvement program into the foundry, particularly to get high grade uni- form iron and low casting losses. This end has been most happily accomplished. The experiences gained are of practical value to foundrymen. One type of casting made by this firm may be prop- erly termed a specialty—seamless dryer rolls. These are used in foudrinier machines, laundry machines and others requiring such rolls. Their function is to dry the paper or other material. They are steam heated and used in batteries of as many as 90 in paper ma- chines. The castings are up to 60 in. in diameter and 15 ft. long, 1% in. metal in the shell, as cast, and cast with seamless heads with journals cast on. The cylin- drical portion is machined all over, then ground. The slightest flaw in the finished roll is sufficient reason for rejection. Besides this, the rolls must balance within a very few pounds. When one considers that a core, set % in. off center, will throw a large roll off nearly 450 lb., and the utmost possible jiggling with machining and with manhole plates in the shop will account for only about 100 lb., the skill in molding is apparent. The set-up of the mold is ingenious. A collapsing core barrel is used and all the core removed through a small manhole in the head. The bottom and top jour- nals are chilled. (The castings are poured on end.) No attempt is made to remove the inner skin of the barrel of the roll as this would materially increase the Fig. 1—This 30- In. Dryer Roll Withs tood 1250 Lb. Per Sq. In. Hydraulic Pres- sure Before Bursting. Note the uniformity of metal section. The core is re- moved through the large man- hole shown. This test was conduct- ed in the presence of representatives from the Travel- er’s Indemnity Co. and the Ameri- can Laundry Ma- chine Co. possibility of steam leakage, lose the advantages of the seamless heads, and would not help in balancing. Fig. 1 shows results of a remarkable test made on one of these rolls. Metallurgically, the problem is most interesting. The metal must be strong to support the weight of the casting—14,000 lb. in the rough for the largest rolls— and particularly to resist distortion during machining. It cannot have high contraction or the roll would burst. It must be fluid to run this large area and rather small thickness. The mixture aimed at runs about 1.20 to 1.25 per cent silicon, carbon 3.40 to 3.55 per cent, manganese anywhere from 0.40 to 0.80 per cent, sulphur 0.090 to 0.120 per cent, and phosphorus 0.35 to 0.60 per cent. This produces a high grade iron for the purpose. The (,*4 Y iron castings which present a “beautiful appearance to a metallurgist” are described in this article. The securing of the proper mixture and minor changes in rig-up eliminated certain troubles which have resulted in the production of almost a perfect casting. The author is metallurgist, Niles Tool Works Co., Hamilton, Ohio. 800 wot Kel ee he Ne wie! 2 sae ee eee er ae a tan Sts 5 gth, Ib. per 6q.in Bar 0.798" from tenter of casting nr = Qo g 2 R o o o Tensile Stren ry ’ © Hardness Increases ——_-> Strength Increases September 24, 1925 26,000 Area of Cross Section in Sq. In. ig. 2—This Diagram Shows the Equivalent to Comparative Total Areas or Roughly to Cooling Rates c So 4 S U = x S Qo Mottled Iron Close Gray White Iron Section Increases ———> Fig. 3—Qualitative Diagram, Strength-Hard- ness Section ”) 9 w S 9s = Vv 3 | © ys 2 | UO = * | 5 = 5 Section Depth Increases ———> Fig. 4—Qualitative Diagram. Grain size and Diameter depth of section Table of Physical Tests Tensile No. Transverse Mod. of as Cast per Sq. In. Total Load Rupture Carbon Silicon 1.100 98 2,350 3.39 1.18 1.100 32,250 2'570 3.49 1.06 1.100 30,120 2.400 3.49 1.29 1.100 31,350 2530 3.52 1.22 Average “30,425 2,463 56,550 3.47 1.18 1.375 29,920 5,010 : 3.30 1.25 1.375 31,180 4.890 3.38 1.28 1.375 31,180 5,000 3.54 1.29 Average 30,760 4,967 58,381 3.41 1.27 1.625 31,340 8,420 3.45 1.34 1.625 29,740 7,280* 3.50 1.22 Average 30,540 7,850 55,906 3.47 1.28 2.125 25,820 —. - ~ 3.38 1.27 2.125 23,800 17,080 3.40 1.20 %.125 25.380 16.750 3.44 1.27 %.125 28,440 17,190 3.46 1.05 Average 26,110 17,670 56,273 3.42 1.20 2.625 23,200 30,650 3.34 1.29 2.625 26.400 30,200 3.46 1.22 2.625 26.640 34.000 2.50 1.17 Average 25,330 31,617 53,412 3.43 1.23 oe 8SL 8 *Modulus of rupture for round bars = —— = 30.56 ——. rD> Db» S = stress at breaking load. L = distance between supports ( = 12 in.) D = diameter. wr — 3.1416. fase rnen sens eneem renee THE IRON AGE 801 Silicon Manganese Phosphorus Fig. 5 (Right) —Routine An- alysis Sheet Showing How the Mixture Is Checked Up by Analysis and by Physical Test Total Carbon Tensile Strength eflection a os - ~ - om e -maan tn ~ finish is excellent, machinability good, and strength satisfactory. For heavier castings, lower silicon is used and for the lighest rolls silicon is raised. Phos- phorus has been run as low as 0.30 per cent, with sili- con 1.00 per cent and no bad effects noted but, with low silicon and phosphorus 0.60 per cent or above, hard rolls are encountered. Manganese 0.30 with sulphur 0.12 per cent caused no difficulties, but is fiot advised. Lower carbon in increasing contraction might cause trouble. With good coke, analyses come very uniform. Soft structure coke gives trouble. The table and Fig. 2 give results of some tests made on this metal. While interesting in themselves, these results also illustrate some fundamental principles Honennennedenesss ices comereersesnsnanennennenes see nenenenrnnnartetees and Chemical Analyses Mn S P Area 0.54 0.104 0.51 0.950 0.33 0.112 ee 0.950 es aan a 0.950 Green sand, lower 0.56 0.075 0.58 0.950 results than when dried 0.950 0.092 Ps 1.465 Dried sand , i 1.465 192 Brinell Dried sand 0.48 0.098 0.57 1.465 Dried sand 1.465 Dried sand a eo “y 2.074 Dried sand 0.69 0.077 0.56 2.074 Dried sand 2.074 Dried sand 0.114 —s 3.546 Dried sand 0.45 0.098 0.39 3.546 Dried sand 3.546 Dried sand 3.546 Dried sand 3,546 Dried sand 5.412 170 Brinell Dried sand 5.412 Dried sand 5.412 Dried sand 5.412 Dried sand caDeennensennes POnseeereseeess sarees scs6reseRSOEtT eRe RRENRROnENEDE ieReE! Meee aae IEEE EEROnETES HL APRONS mek ol a ppaapeennetiy Wenn es ‘ Metallurgy of Iron Dryer Rolls Intricate Mechanical and Chemical Problems— How They Were Solved—lIngenious Set-Up of Mold BY J. W. EVERAL years ago the writer was retained as S consulting metallurgist by the Black-Clawson Co., manufacturer of paper mill machinery. This firm had completed a program of mechanical standard- ization, attaining a quality of workmanship exceeding that found in most shops and, also, insuring flexibility in interchangeability of parts. For various reasons it was felt desirable to extend the improvement program into the foundry, particularly to get high grade uni- form iron and low casting losses. This end has been La “hy ne as 1) ob ke " Sh PWN hd » es - oh | ~ Dl 4 By BR OY m a A ON ™ te 4 " * rf eo : 4 a a ae of most happily accomplished. The experiences gained are of practical value to foundrymen. One type of casting made by this firm may be prop- erly termed a specialty—seamless dryer rolls. These are used in foudrinier machines, laundry machines and others requiring such rolls. Their function is to dry the paper or other material. They are steam heated and used in batteries of as many as 90 in paper ma- chines. The castings are up to 60 in. in diameter and 15 ft. long, 1% in. metal in the shell, as cast, and cast with seamless heads with journals cast on. The cylin- drical portion is machined all over, then ground. The slightest flaw in the finished roll is sufficient reason for rejection. Besides this, the rolls must balance within a very few pounds. When one considers that 1 core, set % in. off center, will throw a large roll off SOOUUCOTUEONSLUDLORDEA DONG HODGEABROANNAREOOENRACOES EEO CeRSRORHERAHEEENES BOLTON nearly 450 lb., and the utmost possible jiggling with machining and with manhole plates in the shop will account for only about 100 lb., the skill in molding is apparent. The set-up of the mold is ingenious. A collapsing core barrel is used and all the core removed through a small manhole in the head. The bottom and top jour- nals are chilled. (The castings are poured on end.) No attempt is made to remove the inner skin of the barrel of the roll as this would materially increase the Fig. 1—This 30- In. Dryer Roll Withs tood 1250 Lb. Per Sq. In. Hydraulic Pres- sure Before Bursting. Note the uniformity of metal section. The core is re- moved through the large man- hole shown. This test was conduct- ed in the presence of representatives from the Travel- er’s Indemnity Co. and the Ameri- can Laundry Ma- chine Co. possibility of steam leakage, lose the advantages of the seamless heads, and would not help in balancing. Fig. 1 shows results of a remarkable test made on one of these rolls. Metallurgically, the problem is most interesting. The metal must be strong to support the weight of the casting—14,000 lb. in the rough for the largest rolls— and particularly to resist distortion during machining. It cannot have high contraction or the roll would burst. It must be fluid to run this large area and rather small thickness. The mixture aimed at runs about 1.20 to 1.25 per cent silicon, carbon 3.40 to 3.55 per cent, manganese anywhere from 0.40 to 0.80 per cent, sulphur 0.090 to 0.120 per cent, and phosphorus 0.35 to 0.60 per cent. This produces a high grade iron for the purpose. The ANOVOLUNAHLENUNADLLONEREEDUNEG: /O0EELENEOEEDODEA ED L>OONEROGOEREROONAEDONERCODEADERONONEHEOCEDODESEDENOLEGRAPROODOERDOANOEDONOBOOAOODADONO EDEN ONE SURNBDUDELAL DONNE DrOOE CORD ONNOREO ORNS pOOSRD (, BAY iron castings which present a “beautiful appearance to a metallurgist” are described in this article. The securing of the proper mixture and minor changes in rig-up eliminated certain troubles which have resulted in the production of almost a perfect casting. The author is metallurgist, Niles Tool Works Co., Hamilton, Ohio. 800 & a r 3 September 24, 1925 THE IRON AGE 801 1.60 TO “TANT c ° » > = .@ £f wo + as 0.60 }-+-+-++-+ t4 eter + se sot | PP NAL LL Se e 0.50 sell + — +—+ 3 . ren i Prey & E = rs ae 060} Sip iy tt 2 5 0.50 ew —- eo i. | } | | | - -& s | } | | o 5. 040 TTT +— —+—+- 4+ —+ + T Area of Cross Section in Sq. 1 8 | | | | | | I B : . a 0 ; q. in. & zz . Fis | he | Fig. 2—This Diagram Shows the Equivalent to Comparative Total Areas rr or Roughly to Cooling Rates Hardness Increases ———_> Strength Increases Mottled Iron Pearlitic Iron Close Gray White Iron Section Increases ———> Fig. 3—Qualitative Diagram, Strength-Hard- ness Section Grain Size Decreases ——> Section Depth Increases ———> Fig. 4—Qualitative Diagram. Grain size and depth of section Table of Physical Tests Diameter Tensile No. Transverse Mod. of . as Cast per ot In. Total Load Rupture Carbon Silicon 27,98 1.100 0 2,350 3.39 1.18 1.100 32,250 2,570 3.49 1.06 1,100 30,120 2,400 3.49 1.29 1.100 31,350 2,530 3.52 1.22 Average “30,425 2,463 5 550 3.47 1.18 1.375 29,920 5,010 ; 3.30 1.25 1.375 31,180 4,890 3.38 1.28 1.375 31,180 5,000 3.54 1.29 Average 30,760 4,967 58,381 3.41 1,27 1.625 31,340 8,420 3.45 1.34 1.625 29,740 7,280* 3.50 1.22 Average 30,540 7,850 55,906 3.47 1.28 2.125 25,820 19,460 3.38 1.27 2.125 23,800 17,080 3.40 1.20 %.125 25,380 16,750 3.44 1.27 %.125 28,440 17,190 3.46 1.05 Average 26,110 17,670 56,273 3.42 1.20 2.625 23,200 30,650 3.34 1.29 2.625 26,400 30,200 3.46 1.22 2.625 26,640 34,000 3.50 1.17 Average 25,330 31,617 53,412 3.43 1.23 sa 8SL a a *Modulus of rupture for round bars = —— = 30.56 ——. D> Dp S = stress at breaking load. L = distance between supports ( = 12 in.). D = @iameter. wr = 3.1416. nserver seaenrerneeenan, AADODENORESELENOUSDLOENDTEOOREDONONNDUDTESL DOONAAFTARELDLOL/ OLAEDDOOSODUDINETDITECERESEEDHONRRODHEREN NERD LIT I cys 004. eo conemmenrenenaneney lec cTEeuTtes hu Oo o wo fn j } A eee = re - +——_+4 +—_——_4 — — Rome — = fi i _—_+————+4 Ro | Fig. 5 (Right) g 370 TIT ] —Routine An- t | a S 350+++4 = alysis Sheet = | | 1 | | | | | Showing How © 330 Lijit Li} Lit the Mixture Is Checked Up t =, 440044777 ] eee en) TTTTTIT Ly Analysis and t senel- | r | by Physical ” a00 | | ~ | | i | Test = 3600 hil +4 +t t+ ® 1 5 7? » fp L - 3 ; “ms Pen MCeNS S54 Date finish is excellent, machinability good, and strength satisfactory. For heavier castings, lower silicon is used and for the lighest rolls silicon is raised. Phos- phorus has been run as low as 0.30 per cent, with sili- con 1.00 per cent and no bad effects noted but, with low silicon and phosphorus 0.60 per cent or above, hard rolls are encountered. Manganese 0.30 with sulphur 0.12 per cent caused no difficulties, but is fiot advised. Lower carbon in increasing contraction might cause trouble. With good coke, analyses come very uniform. Soft structure coke gives trouble. The table and Fig. 2 give results of some tests made on this metal. While interesting in themselves, these results also illustrate some fundamental principles Heperensbensredcns rer envetennveneateapenensenneds reneneneenr 44 rseres nts enenente Hone and Chemical Analyses Mn Ss P Area 0.54 0.104 0.51 0.950 0.33 0.112 ae 0.950 ae mi “or 0.950 Green sand, lower 0.56 0.075 0.58 0.950 results than when dried 0.950 0.092 ve 1.465 Dried sand aoe ; "i 1.465 192 Brinell Dried sand 0.48 0.098 0.57 1.465 ried sand 1.465 Dried sand 5 os ee 2.074 Dried sand 0.69 0.077 0.56 2.074 ed sand 2.074 Dried sand re 0.114 Se 3.546 Dried sand 0.45 0.098 0.39 3.546 Dried sand ay bist 3 3.546 Dried sand 3.546 Dried sand 3,546 Dried sand 5.412 170 Brinell Dried sand 5.412 Dried sand 5.412 Dried sand 5.412 Dried sand senenens co useePenpeynneesssuroeDeePeRROET LRUS#ODEDS OUOURE:NCERDERGRPRDFDULER SEE) D981 FEPERITTONEREDES! SENSEGDTSORSETEEEPUOPERONETENVERAUREREC W148HF—>00R04SRCHPEDEROON INTUTE TIED 802 THE IRON AGE often overlooked by engineers. These are (1) strength decreases with section size, and (2) this increase is most rapid in the central portions of the casting. The modulus of rupture decreases with slower rate of cool- ing, but the tensile test decreases even more rapidly. September 24, 1925 Diameters must be measured very accurately when cal- culating M.R., as this varies inversely with the cubed diameter. Fig. 5 is a routine analysis sheet showing how the mixture is checked up by analysis and ty physical test. Steel Castings and X-Rays How Fluoroscopic Examination May Detect Blow Holes and Slag—Possible Substitution for Radiography BY DR. ANCEL ST. JOHN LLAAUAAAAADANADATNAAEUUULASNLNAUH LATO NNNUUENAU NAL GMa tHNAE " ! 1 MUTT f posed author of this paper, who is a consulting physicist in New York and who is one of the authorities on X-ray crystallography and radiography in general, be- eves that he has hit upon a method of examining castings which will prove of prac- tical value to steel foundries. If blow holes and sonims can be detected in valuable ca stings before machining, a long step in advance will have been taken. The desired end depends on further research. The article discusses the foundation of the work. LiLUTETN ANNES [ the Atlantic City convention of the American A Society for Testing Materials in June, 1925, the committee on metallography submitted a com- prehensive report on X-ray testing. This report and the discussion thereof by V. T. Malcolm and others should be read by all who are interested in the appli- cation of X-ray methods to industrial problems. In his own diseussion of the report the writer stated his belief that for many types of castings it would be pos- sible to substitute fluoroscopic screen examination for radiography, thereby reducing materially the cost of X-ray inspection. This belief was based upon the Fig. 1—A Radiograph of the “Synthetic Specimen” Plus 83 Additional Sheets of Iron Making a Total Thickness MAMMAL AMAA ALU early results of an extended investigation of this ques- tion which had just been instituted. In the course of this investigation quantitative data will be secured on the size of the smallest cavity which can be detected by trained and by untrained observers in various thicknesses of the metals commonly used in castings, and the relation of these cavities to the sizes of cavities which can be permitted in the type of casting under consideration. The investigation will extend over a considerable period of time and will re quire the cooperation of makers and users of castings. The results will be published from time to time as they of 100 Sheets or 1.4 In. EAS me Se on ea ger ree ——— seas Tit Dit ne alana Sa TE ere Sen 5 et ae ee lh eee September 24, 1925 THE IRON AGE 803 Fig. 3—In This Radiograph the “Synthetic Specimen” Was About 2 In. from the Film With Extra Sheets Between are secured. The present article describes preliminary work in the determination of the size of detectable cavities in steel, The facilities used in this investigation have been provided by the Wappler Electric Co. of Long Island City, N. Y. The X-ray equipment consists of a power plant capable of generating an effective voltage of 200,000 corresponding to a maximum voltage of 300,000 such as is required for satisfactory radiography of three inches of steel, a water cooled X-ray tube of the Coolidge type capable of carrying a current of 30 milli- amperes, the necessary apparatus for circulating and cooling the water, a lead-covered drum surrounding the tube which permits the X-rays to escape only through predetermined openings before which the specimens are placed, a blowing equipment for circulating air through the drum, a portable dark-room booth, and the necessary control devices. The walls of the dark-room booth were of Beaver board and had a negligible ab- sorption for X-rays. During a part of the investigation the specimens being exam‘ned were set up between an aluminum win- dow in the lead drum and the wall of the booth, manip- ulation of the specimen being made by the assistant who operated the controls. This was found to be in- convenient and the booth was placed w'th the wall in ‘ontaet with pre window, the specimen being set up on @*stand within the booth. In this way the observer could manipulate thejspecimen at will without leaving the da¥k-room. In both’ cases a simple arrangement of auxiliary lead shields was effective in preventing the escape of secondary radiation. The customary type of barium platino-cyanide fluorescent. screen was used formdetecting the X-rays. Most of “the. ébservations were made with a screen covered with four sheets of %-in. lead glass to absorb the rays and protect the observer. These were not cemented together and so caused much destruction of detail throveh multiple. reflection. This disadvan- tageous condition was intentional as it was desired to get the data under as poor cond'tions as might be met in actual practice. Some observations were made using a periscopic arrangement of mirrors and a reading glass of rather low power, and a few were made with a 2-in. lens and but one sheet of lead glass. The specimeng examined were made by piling to- gether numerous sheets of transformer iron 0.014 in. thick. Seventeen such sheets were drilled in a system- atic manner and bolted together to form a “synthetic specimen.” The appearance of this specimen is de- picted in Fig. 1, which is a radiograph of the specimen plus 83 additional sheets of the iron, making a total thickness of 100 sheets, or 1.4 in. Each vertical column of spots represents a series of holes dr'lled through the same number of sheets of the specimen, column 1 Fig. 2—Focal Spot From Which the X- Rays Proceed being through onc sheet, column 2 through two sheets, column 3 through three sheets and so forth. The drills used were Nos. 1. 10, 20, 30, 40 and 50. In the original negative the spots in column 1 and a No. 60 hole 2a iter ar NE nos “ otal Me oe - arma A: arn atte tne test Son el A pip RE IEE hoe a2 spe cs lain al 5 laa ninsouunel : os 7 rs i : en ih er eas phn a oe, ty sae 4 , * ’ — " ; a : 7 aoe ate em Di 5 Dawe i 804 THE IRON AGE through one sheet at the bottom of column 16 can just be observed, while the spots in column 2 are plainly discernible. The tube used was originally developed for the so- called “Deep Therapy” medical treatment. Though able to carry 30 milliamperes continuously it was oper- ated at only 10 milliamperes so that the results might be comparable with those obtainable with other less powerful tubes. The focal spot from which the X-rays proceed was very broad, as shown in Fig. 2, which is a picture made by X-rays passing through a fine hole in a lead shield midway between the target and the film so that the image is natural size. The effect of the breadth of the focal spot is not noticeable in Fig. 1, for the “synthetic srecimen” was only about % in. from the film, with the extra sheets of iron between and the tube. In Fig. 3, however, the effect is marked. Here the “synthetic specimen” was about 2 in. from the film with the extra sheets between the two. In making the negative for Fig. 3 columns 1 and 2 were unfortunately screened off. It is probable that the smallest hole in column 1 would not have been observable. The fluoroscopic tests were made on samples rang- ing in thickness from 20 sheets (0.28 in.) to 100 sheets (1.4 in.) under the least favorable conditions, that is, with the screen covered with four sheets of lead glass, the unaided eye could always pick out the column for which the holes were through only one-tenth the total thickness, and for the greater thicknesses could pick out holes having a diameter as small as the same amount. For lesser thicknesses there was some diffi- culty in picking out the correspondmgly small holes. When but one sheet of lead glass covered the screen and a 2-in. lens was used to aid the eye a No. 30 hole through six sheets in a total of 100, and a No. 40 hole through two sheets in a total of 50, were observed. Recording Temperature of the Iron at a Cupola Spout Probably one of the most interesting papers pre- pared for presentation at the iron sessions of the Syra- use meeting of the American Foundrymen’s Associa- tion, Oct. 5 to 9, will be the paper on “Continuous Iron Temperatures Recording,” to be presented by H. W. Dietert and W. M. Myler, of the United States Radia- tor Corporation of Detroit. After trying out the many various ways of determining iron temperature, the foundries of this corporation have developed a method whereby iron temperatures are practically controlled. After using various methods of direct reading without success, a method of recording the temperatures of the gases above the iron stream has been worked out which gives a practical control which agrees with the best observation of experienced foundrymen. The method used is fully explained and illustrated in the paper by these two engineers. Brass Association Prepares Catalog A new official catalog was considered at a meeting of the National Association of Brass Manufacturers held at Hotel Hollenden, Cleveland, Sept. 8 to 10. The book will be arranged according to the kind of goods that are installed in a building—first, taking what are commonly known as roughing-in goods or unfinished products, used in the basement, such as ground-key, compression stop and drains, sill and sediment faucets, brass fittings and ferrules; then, sink and tray faucets, lavatory fixtures and nickel-plated goods of a variety of kinds used in up-to-date plumbing. The convention also approved an illustrated booklet showing the right and wrong ways of handling and installing plumbing brass goods. This will be distributed among master plumbers purely as educational matter. It will also be supplied by members of the association among their jobbing trade and customers to aid in disseminating information regarding the proper use and installation of plumbers’ brass goods. September 24, 1925 When the lead glass was omitted and the protection of the observer was secured by viewing the screen in a mirror with the aid of a reading glass a No. 30 hole through four sheets in a total of 50 was readily ob- served. Under these circumstances the No. 40 hole through four sheets and the larger holes through three sheets were occasionally discerned, but they must be classified as difficult to detect. With an arrangement of two mirrors and the reading glass the No. 30 hole through five sheets was readily observed but the No. 40 hole and the holes through fewer sheets were again difficult to detect. These results show that under the conditions of the tests, which correspond to the most unfavorable condi- tions that would be met in actual practice, isolated de- fects having a diameter as small as 1/10th the thick- ness of the part examined can be detected without diffi- culty. Any improvements in technique, such as better screens, better arrangements for viewing the screen, use of tubes having a smaller focal spot, would all tend to increase the ability to discern smaller cavities. Any accumulation of cavities, such as constitutes porosity, pipe, sand holes or slag inclusions, would correspond to superposed holes through several layers, or holes of larger cross-section, or both, and would so be more readily detected. It is not within the scope of the present paper to say whether or no all cavities smaller than those which can be discerned in this way can be tolerated in cast- ings. That can only be determined by the appropriate coordination of X-ray and mechanical tests. But when it is considered that a cavity 1/10 in. in diameter in a member 1 in. sq. represents a deficiency of but one per cent in the material supposed to be present in the plane through the cavity, it is believed that many types of castings may have tolerance limits and dimen- sions permitting fluoroscopic X-ray inspection. American standards, as well as the nomenclature of the association, are being adopted in Canada, accord- ing to a communication from §S. J. Frame, secretary Brass Goods Manufacturers’ Council of Canada, which was read at the meeting. An associate membership in the Arbitration Founda- tion, Inc., New York, was ordered. The annual meeting of the association will be held in New York, Dec. 9 and 10. Cost of Manufacturing Discussed Discussing “The Cost of Manufacturing” in United Effort, the house organ of the United Engineering & Foundry Co., Pittsburgh, F. C. Biggert, Jr., tells of the harmful misunderstandings which sometimes arise in industry due to the mistaken idea of some poorly in- formed people that profit is the difference between the cost of wages and material and the selling price of the product. He takes up one by one the various items in the cost of a product, including such well known factors as repairs to tools and equipment, purchase of tools, lubricants and supplies, taxes and depreciation. He goes into a detailed discussion of the “direct labor hour” and the work that shoulda be charged to it. Most of Mr. Biggert’s article is based on conditions as he has found them in the machine shop of the United Engineering & Foundry Co. His article began in the July issue and is concluded in the Augyst issue. The Weirton Steel Co. has been granted a Federal permit to build a river loading terminal at its plant at Weirton, W. Va. The new terminal will include a 200-ft. loading dock and a 400-ft. unloading dock. Three ice breakers will be installed at the plant. It will be necessary to dredge approximately 36,000 cu. yd. of material from the harbor at that point to install the docks. These docks and harbor facilities will enable the company to handle coal from its mines above Brownsville, Pa., to the coke plant by river and river shipments of steel. es ata) es al RIAD Cl De» iced th Ss New Records by Steel Treaters Technical Program of High Merit and Splendid Attend- ance at Seventh Anniversary of American Society for Steel Treating—Largest Steel Exposition OTH technically and as an exhibition the annual gathering of American steel treaters this year set a new mark. It has definitely become one of the leading events in the year’s history of the steel industry—eagerly looked forward to by metallurgists, steel treaters and steel equipment makers. All past records were easily eclipsed in the quality of the program, in the attendance of leading metal- lurgists, steel men, and others, in the size and success of the exposition and in other respects. It was the seventh annual convention and national steel exposition of the American Society for Steel Treating which met in Cleveland last week, Sept. 14 to 18. Praise and admiration for the smoothness with which this really large undertaking passed off was heard on all sides. Registration of members, exhibitors and guests is officially reported as 5420. Of these 1912 were members, which is about 58 per cent of the total membership members were present or 40 per cent of the total. a new record. At Boston last year 1210 The Technical Papers and Discussions ROM a technical standpoint the convention was one of the highest in quality ever conducted by steel men in this country. The ten sessions, held mornings and afternoons each day in the ballrooms at the Hotel Cleveland and the Hollenden Hotel, respectively, were distinguished by an unusually large attendance and a keen interest in each session, even up to the last one. Seldom did the number present fall below 250 and at one session the attendance was at least 500. Men of prominence occupied the chair at each session and leading metallurgists read papers or partici- pated in the discussions. For the first time preprints of the papers were available for distribu- tion, some of them having been distributed earlier by mail. By the time the sessions were opened about 75 per cent were in printed form. It is possible in the following columns to give only a brief account of the leading subjects brought out and discussed in the 35 papers on the program. Session on Steel-Making Processes N innovation in the usual program at these conven- tions was a session devoted to steel-making pro- cesses. The introduction of papers on this subject is sig- nificant. It is generally taken to mean the first step in a wider field of endeavor for the society—other subjects besides steel treating. The fact that the attendance— close to 500—was the largest of any, attests to the in- terest displayed by members and to the probable suc- cess of future attempts. Dr. John A. Mathews pre- sided. Proportion of Heat-Treated Steel: The program was introduced by a brief paper by C. J. Stark, editor Iron Trade Review, Cleveland, on the “Proportion of Heat-Treated Steel to Total Production.” The speaker stated that the steel industry is passing through a transition period in which quality steel is now more the aim than quantity. Significant of this trend is the recent decision of the United States Steel Corporation to build a large alloy steel mill at Chicago. Citing the automobile industry as the largest user of heat-treated steels, he gave figures for 1924 that showed for every ‘1600 tons of rolled steel consumed by that industry 1000 tons was heat treated. While the railroads are the largest consumers of steel, they are the poorest users of heat-treated material. In his opinion 3,000,- 000 to 3,500,000 tons of steel is heat treated each year. The Acid Open-Hearth: The “Acid Open-Hearth Steel Melting Practice” was discussed by Radclyffe Furness, superintendent of melting and forging de- partments, Midvale Co., Nicetown, Philadelphia, one of the leading authorities on open-hearth melting. ‘The characteristics of the process as well as the reactions and the composition of the slags were fully treated. The details of charge, melting and pouring temperature and the making of additions were discussed. Reasons for the superiority of acid over basic steel were also given with emphasis on the importance of the proper “conditioning” of both, stating that this has a great influence on the defects which may appear in the fin- ished product. Discussion: A written discussion by Walter H. 805 White, of the Naval Gun Factory, Washington, was read by Jerome Strauss, of the same organization. Recalling the fact that much high grade acid open- hearth steel has been made at Midvale, Mr. White claimed that the superiority of acid steel was not due to a silica bottom and to slag reactions altogether but that the use of high-grade scrap was a large factor. Much high grade basic steel, both plain carbon and alloy, is being made due to more scientific melting which is being standardized. The Basic Open-Hearth: The basic open-hearth process was dealt with in a paper “Basic Open-Hearth Steel” by Edward Whitworth, Bourne-Fuiler Co., Cleveland. Mr. Whitworth treated the subject under three heads: History, furnace design and practice for high carbon forging steels. For the latter he advocated the use in a 100-ton heat, of about 10 per cent of lime, 60 per cent scrap and the remainder pig iron with cold or a hot metal. About two-thirds of a pound of alumi- num per ton of steel should be used and when poured from the ladle, a scull of about 1500 to 2000 Ib. should be left. Most additions should be made in the furnaces. Discussion: In reply to a question as to the cause of laminations, Mr. Furness stated that it would be difficult to determine all causes. Some of them might be blow holes, included slag, crystal slips, etc., but in any case acid steel is more free from these causes than basic. Delta and Gamma Iron: Dr. Zay Jeffries introduced at this point an interesting problem. It being pretty well established that delta steel exists as a body- centered space lattice formation, he asked whether any melters present had noticed the contraction and ex- pansion of steel as it cools from the liquid to the solid state. At 1400 deg. C. the steel changes to a face- centered cubic lattice, gaining in density. At 900 deg. C. it goes back again to the body-centered cubic lattice. The shrinkage observable is particularly marked at these points in steel from zero to 0.55 per cent carbon. In other words, what is the amount of contraction as the metal passes from the delta to the gamma iron? Mr. Furness replied that he had observed some phe- nomena which tallied in a measure with these facts. 806 M iit tt uit MUA AUAMUDAALUNA CATA Hi UNL UU THE IRON AGE September 24, 1925 UAC0ULLSMMNDUDEDNUASISGLUULES90 SOGGADU FY OCRANAA LALOR ESA AHO ELEPHANT RTH NMSA ARES LU Chairmen of Four of the Sessions DR. J. A. MATHEWS DR. G. K. BURGESS Kl Steel”: This was the title of a paper by F. T. Sisco, metallurgist air service, War De- partment, McCcok Field, Dayton, Ohio, delivered in abstract by Jerome Strauss in the absence of the author. Two principal advantages of this process are claimed: Extreme flexibility and high quality steels produced in tonnage lots. Oxidizing conditions can be closely controlled either with complete oxidation, with partial oxidation or without oxidation. Under average “Blectric Furnace Features of the Technical Meetings Symposiums on Hardness and on Metallurgical Education. Important additions to the Literature on Tool Steels and Fatigue of Metals. New Information on the Metallurgy of Magnetism. Two New Devices for Measuring Hardness. The Dilatometric Method of Heat Treatment and What It Means. conditions, melting with partial oxidation is productive of the highest grade steel. The author discusses these various phases in considerable detail. Deoxidation and desulphurization are gone into fully as well as the procedure in completing the heat. Discussion: Several electric steel experts discussed this paper. Charles McKnight, research department, International Nickel Co., New York, spoke of degasifi- cation as being sometimes overshadowed by deoxida- tion and as not being thoroughly understood. M. A. Grossman, metallurgist United Alloy Steel Corporation, Canton, Ohio, discussed the point brought out by Mr. Sisco as to the reactions between silicon and carbon, stating’ that sili¢éon promotes the solubility of carbon monoxide in steel. The addition of ferrosilicon at the end of the heat Was commended. Dr. B. Egebergy Hale comb Steel Co., Syracuse, N. Y., diseassed’ an 0.80 per cent carbon steel and a chrome-nickel steel made under both partial and complete oxidation conditions. Jerome Strauss, metallurgist, Naval Gun Fagtory, Washing- ton, emphasized the fact that the character of the scrap and oxidation are important, calling attention to the importance of the reactions whith take place on the furnace bottom as well as with the slag. Symposium on Hardness A symposium on hardness has been a regular fea- The ture of recent conventions of the steel treaters. DR. ALBERT SAUVEUR PROF. BRADLEY STOUGHTON AULA LAUALUSNALAEUUUUUAUROSAE STAN CLMIUOUD AULA A one this year was exceptionally good and one of the features of the technical sessions. Three new machines for determining hardness were described in considerable detail during the symposium, thus providing more work for those investigators who are laboring to co-relate the results of the machines now commonly used. Dr. Albert Sauveur, Harvard University, has devised one called the “Durometer.” It employs the idea used by some manufacturers of ball bearings—namely, to compare the rebound of a ball from a hardened surface. In the durometer, a standard ball is dropped a known distance, striking the surface to be tested, which has previously been mounted at an angle of 45 deg. to the vertical. The distance forward which the ball travels before striking some horizontal carbon paper is a measure of its hard- ness. O. W. Boston, University of Michigan, also de- scribed two English machines exhibited at the Wembley Exposition. Both of these use the Brinell indentation principle, but are so designed that the rate of loading is automatically controlled, as is also the time at full load. One of them, the Vickers, uses a blunt four- sided pyramid instead of a ball; the impression on the tested surface is therefore a square. By adjusting a microscope slit to compass exactly the diagonal of this square, the Brinell hardness may be read directly on a graduated head. The machine is built like a stout punch, very rugged and strong. Lack of portability was mentioned as likely to counteract the advantages of easily and accurately estimating the diagonal of the square impression. A comparative study of Brinell and Rockwell hard- ness numbers was presented by R. C. Brumfield, Cooper Union,” New York. Using several alloy steels, heat treated in various ways, he secured the following rela- tions: Brinell Number = K + (K, — Ro) = K + (K, — Re)? where Rp and Re are the Rockwell numbers when using the ball and the cone, respectively. He found that the impression ‘made by the 1/16-in. ball in material 100 hard was stbstantially a 1/16-in. sp