The Iron Age 1926-04-15: Vol 117 Iss 15

ee eee YY iC New York, April 15, 1926 ESTABLISHED 1855 VOL. 117, No 15 eld Ice Cream Cans Electrically : } : Lj a : . Longitudinal Seams Closed by Arc Welding and Bottom Attached by Resistance Welding " Savings Effected in Retinning the Cans BY ROGERS A. FISKE UTOMATIC are and resistance welders, used by operators, one a welder and the other a helper. Th the Solar-Sturgess Mfg. Co., Chicago, in the welder starts and stops the are and follows it in its process of manufacturing ice cream cans, have course along the seam, and the helper removes the fin resulted in closing the longitudinal and bottom seam shed cylinder from the machine and places in position of a can in one-fourth of the time formerly required. the next cylinder to be welded. The equipment con- This is equivalent to increasing production approxi ists of two General Electric Co. automatic are weld- mately four times. In addition, much valuable floor ers, furnished with energy from a 400-amp., constant space has been saved and worth-while economies have potential, motor generator set. Each machine uses from been made in labor and material. 70 to 75 amp. at 20 volts, and the welding is done with The old process used in making the longitudinal sean }32 in. “Armco” wire, which is purchased in bundles was to form a lap of the metal which was spot welded and fed continuously to the machines. The longitudinal at points about 2 in. apart. The seam was then sol seam of each can is 18 in. long and is welded in 30 sec., dered to make it tight. The cylindrical portion of the that is, at the rate of 180 ft. per hour. Including han can and the flanged bottom were tinned separatel) dling as well as clamping the can on and off the travel fitted together and soldered at the circumferential mechanism, a total time of 1.4 min. is consumed. Thus seam. In order to conserve ice cream cans it is cus- 48 cans an hour are made on each machine. In a 9-hr. tomary for users to return them to the factory every day this means a production of 432 longitudinal seams 18 months or two years for the purpose of having them or 432 cans. The arc welding is stopped a short dis- retinned. Bottoms held in place by a soldered joint tance from the bead at the top of the can, and gas are not secured firmly enough to withstand the process welding is used to close the seam at that point. r of retinning used at this plant, and therefore the fac From the arc welding machines the cans are con- tory found it necessary first to remove the bottom, re veyed a short distance to a grinder, which is used to tin it and the cylindrical portion separately, and then clean off the outside of the cylinder on a ring near the resolder the bottom in place. With electric welding bottom of the can. This provides a clean surface on i the can is retinned as a unit, thus saving considerable the line where the resistance welder fuses the flanged expense to the owner. bottom to the cylinder. Welding of Longitudinal Seam Is Rapid Resistance Welding Done Under Water The material used for making ice cream cans is No. The cylinder, with the bottom pressed in place, 18 gage black sheet. The cylinder material is cut to s then fitted to a tailstock or jig mounted on a Gen- size, rolled to shape and delivered to the automatic arc eral Electric Co. circular or resistance welder. The can welding machines. Each machine is manned by two |<. git. over one of the electrodes, which is a small *Western editor Tup IRoN AGE, Chicago copper disk, and is butted against a gage or stop. The 1047 a “4 a... riggs EHS ees? D 1048 Placing the Cylindrica Portte rf Ice Cream ( I é n the j Welde trod 1 ge copper disk, which is raised wered by means of air pressure under the control ‘ inually operated valve The cylinder and the nge of the bottom are securely clamped between the which are rotated slowly by an r motor The pressure between the two elec- des n be high as 1000 lb. if desired. The disks ed by means of water streams directed against it surfaces. The water is drawn by means of a motor-driven centrifugal pump from a tank at e base of the welding machine. The water is forced through the electrode-spindle bearings and finally dis- rged against the electrodes, from which it drains ' he tank. The water in the tank is cooled by through which city water is circulated. It is rent tl welding actually takes place under wate1 the cooling water for the upper electrod irround the met f the can at the point where The Resistance i . uMppe electrode, o? ne 1 . moroable > the THE IRON AGE April 15, 1926 Operation of the Are Welder Is Automatic. Welding wire is fed con- tinuously from a_ coil, shown above at the left — ST | Lae - - tie’) > welded. Moreover, the can is cool and can readily be it is being This, is is said, has no harmful effects. handled the moment it of the machine. The resistance welder is provided with three speeds: 45, 66 and 87 in. per min. The circumference of an ice cream can is about 30 in., and therefore the ma- chine is of more than ample capacity to weld in the bottoms of cans which can be longitudinally welded on the two are machines. is removed from the tailstock Produce 864 Cans Daily The daily production of ice cream cans at this plant s about 2500, and of this number 864 are electrically welded. The remainder are manufactured by the old not because the maker is not thoroughly con- the advantages of electric welding both to the consumer and the producer, but because in any radical departure of this nature it takes some time to win the confidence of the trade. This company expects that by the end of this season it will have approximately 100,- 000 electrically welded cans in use by the trade. The production of ice cream in the United States iverages 2.8 gal. per person per year, according to the Department of Agriculture, which receives statistics from manufacturers of dairy products. The total quan- ce cream consumed last year was estimated at 22,729,000 gal., compared with 285,550,000 gal. in 1924. In that year the average consumption per person was 2. 1. In 1910 the annual consumption of ice cream gal. per person, and in 1914 1.18 gal. method, vinced of ‘ ¢ ¥ Ul =) Pal. Vas 4 Production of electric power by public utility plants United States in February is reported by the Survey at 5593 millions of kwhr. This drop from the 6117 of January and 6153 of December is only slightly greater than the decrease in length of month. \ll three months have shown daily average output greater than that of the highest previous month of Ole: AUe ICAI iny year \ patent covering the manufacture of iron sheets for porcelain enameling purposes was issued March 0 to the American Rolling Mill Co., Middletown, Ohio. Chemical Analyses of Large Ingots Facts As to Inclosures and Gases More Vital Than Strict Chemical Specifications—Melting Practice and Analysis Both Important BY J. H. HRUSKA ITHIN the past few years, the chemical and physical properties of forging, as well as rolling, steel have been thoroughly investigated and, because of this, specifications for smaller size ingots and forgings were given to steel men and to designing engineers. A review of the current technical literature on anal- yses and investigations of large ingots, however, ordi- narily fails to give any desired information. To fill this vacancy the author gives in the following tables a series of analytical determinations made from the ma terial of ingots weighing from 2 to 100 tons, above which limit individual ingots are very seldom cast or used. In carrying out this work, an effort was made te designate the importance of the relationship between chemical analyses and soundness; these being factors which should always be considered when classifying or judging certain grades of ingot iron and steel. Methods of Manufacture In modern metallurgical practice large ingots are b niaahabhahethbebdhtabinntbeedidlabiadabaiieaiedaandsediadiaces inatiiarth cottatidentiaal et ETT) Table I.—Analyses of Basic Open-Hearth Steel Ingote Weight of Chemical Analysis, Per Cent Ingot, -— - dreeatiinagnatiianntiaea Tons C Mn Si P s N Cy 0.32 0.68 0.27 0.032 0.026 0.39 0.76 0.34 0.037 0.029 0.26 0.63 0.33 0.035 0.019 0.34 0.85 0.37 0.930 0.028 0.42 0.68 0.32 0.042 0.022 0.29 0.75 0.24 0.034 0.032 10 0.36 0.73 0.25 0.039 0.033 10 0.40 060 0.223 0.029 0.024 10 0.38 0.78 0.37 0.036 0.022 20 0.20 «0.74 0.340.030 = 0.022 20 0.24 0.88 0.20 0.028 0.020 20 0.41 0.79 0.35 0.042 0.025 30 0.38 0.60 0.18 0.040 0.030 50 0.45 0.7 0.30 0.032 0.028 { 0.47 0.82 0.34 0.036 0.032 } } 0.48 0.79 0.30 0.029 0.026 ¢ { 0.34 0.74 0.36 0.038 0.028 ) 1 0.37 0.68 0.41 0.030 0.022 ( 0.42 0.7 0.27 0.039 0.030 ) 79 7.0.39 0.66 0.33 0.029 0.027 | { 0.38 0.76 0.37 0.041 0.018 ) vw 7 0.41 0.81 0.34 0022 0.0292 f 0.48 0.83 0.22 0.034 0.020 ( , 0.49 0.78 0.28 0.030 0.027 {| 0.50 0.76 0.29 0.024 0.020 . 0.34 0.62 0.17 0.026 0.021 1 2 0.49 0.68 0.41 0.012 0.018 9 74 2 0.44 0.72 0.28 0.018 0.0223 ; 5 0.38 0.65 0.32 0.024 0.022 04 ) 10 0.26 0.66 0.23 0.022 0.016 30 0.32 0.58 0.31 0.018 0.024 277 r f 0.28 0.75 0.14 0.022 0.021 0 4 0.30 0.69 0.24 028 0.024 4 Table II inalyses of Acid Ope He h © Weicht B.. Chemical Analysis, Per C Tons ¢ Mr Ss I s N 0.37 0.77 0.33 0.038 9.034 0.45 0.69 a24 0.040 0.029 0.26 0.71 0.41 0.034 00 0.20 0.76 25 0.038 03 0.51 0.62 0.28 0.027 0.05 0 0.21 0.60 0.36 0.030 0.034 1.43 0.73 0.34 0.037 0.03 0.41 0.70 0.328 0.041 0.028 28 0.72 0.22 0.035 0.019 2 94 0.38 0.&8 0.19 0.938 0.023 9 HR 0.4? 0.63 0.29 0.043 0.038 7 0.39 0.58 9.20 9.0323 0.036 >. &s 1.31 0.62 0.27 0.046 0.038 »R 0.35 0.59 0.22 0.037 0.034 0.37 0.64 0.28 0.041 0.028 9 *Metallurgist International Harvester C McCormick Works, Chicago. cast from steel made by one of the following processes: Basic open-hearth Basic electric Acid open-hearth Acid electric Basic and acid open-heart) Basic and acid electric As far as quality is concerned the best results chemically and physically—were obtained by combining the desulphurizing and dephosphorizing effects of either one of the basic processes with the better deoxidation, legasification and elimination of inclosures on an acid hearth. The use of these methods is not always applic- able due to the considerably higher melting and refin- ing expenses. Thus the greatest number of large in- gots (particularly plain carbon steel ingots) are made mostly from basic, or sometimes acid, heats. Basic Open-Hearth Ingots Without doubt the largest ingots as well as the greatest number of individual quality forgings ever produced were made from steel melted on basic lined open-hearth furnaces. It is generally agreed that the superiority of this ingot steel is due to desulphurization and dephosphorization, but it cannot be forgotten that, luring this purification, enough chance to the produced hemical constituents must be given to leave the bath as completely as possible. Impurities, solid and gas eous, cause very often a far lower grade of steel than would have been produced by melting the raw mate rials on an acid hearth, i.e., with higher sulphur and phosphorus, but without inclosures or sonims! This viewpoint should also be held in mind when looking over the analyses in Table I, in which the higher sulphur and phosphorus offers no reason for consid ering the material of a lower grade. Particularly in the manufacture of the largest sizes of ingots, where inder certain conditions two or three or even four heats have to be combined, comparatively narrow limits of chemical composition are of no importance. Various killing and pouring practices prove that exactly the ble Ill inalyses of “Refined” Open-Hearth B8teel Ingots f Che! il Analys Per Cent Ingot neintnemmammataitmmmamen Tons Cc Mn Si P 8 Ni Cr Va 2 (0.8 0.54 0.29 1.024 0.021 1.56 0.45 ‘ 0.61 0.34 0.02 0.019 2.92 0.7% 0.59 0.32 0.01 0.016 3.11 0.9% : 0.71 0.41 0.018 0.006 1.89 051 ) g 0.68 140 0.0% 0 008 2.84 0.9 ) 4 0.9 0.28 0.0% 0.01% 2.18 057 0.12 Table IV inalyses of Basic Electric Steel Inaot We ht f (hen Ar si Per Cent Ing 7 ( Mr ~ | 3 N ‘ 0.56 0.1 0018 N.012 04 { fh &s °4 9.022 }014 4” 084 ! 0.016 0 008 73 0.34 9.014 0.005 2.76 0.9 44 f 28 011 ) oF 260 07 61 71 07 0.0223 0.017 4 4? f 0.016 0.911 14.92 od4 ‘ o on 1006 0.011 l f 6? 0.16 0.014 0.018 0.01¢ 9.014 1.89 1.0% , OR 1¢ 0.2? 67 28 0.021 » O2 4 24 g4 0.29 0017 Oo 2.07 0.29 Table 1% inalyses of Acid Electric Steel Ingota We f Chemical Analysis, Per Cent To ( M Si ~ Ni ‘ » RG 0.29 0.032 0.024 1.88 0.58 42 0.77 0.31 0.029 0.026 0.28 0.71 0.24 0.034 0.019 2.16 . 6&2 0.27 9.0328 9.031 2.18 1.14 47 58 0.19 0.026 0.028 2.68 0.47 swe — nina sac one 1050 THE IRON AGE analyse f ladle tests give widely dif- nd different chemical compositions give i pn! eY é The pro ] this state- ind in the daily experience of every i (J H i | T ver tne } I l I é ites ne use rder t produce iarge On thi ntrary, acid steel, e hearth almost fre rtunity to pro- ‘ which would arise or manulacture tself. In Table hearth steel for larg O H h St ] d process is the combinatio1 acid processes. Steels made by this e usually of the highest grade and the field fulness covers almost as much area as that r the war industry and specia The analyse dicated in Table III do not ff ‘ riority of the steel they repre- e particular photomicrographs of all these well as those previously mentioned, should ludex rove the truth of this remark he microstructure, however, does } present paper and was Ble S Ingot With e last 10 years, the steadily increasing electric furnace aused indire« tly the pro rger quality ngots weighing from 2 to 10 more tor 4 lar the chemical ar iyisis of basic electric concerned, up t } resent time the electric e! been mort I ced for melting I illo. e¢ sed in the manufacture Crane Facilitates Construction of Exposi- tion Building \ crane which is credited with playing a prominent in the rapid completion of the Palace of Agricul- ure, which is one of the four major buildings that will use the Sesquicentennial Exposition at Philadelphia, here illustrated. The building is 500 ft. wide and 1 f. (Y . mL, iid . os Gliaeeiiel 00 ft. long. The contract was awarded to the Austin Co., Cleveland, last fall and the building completed on irc! ] Uhe crane, named the Blue Goose, was employed in ng the structural steel and in handling other ma- of carbon steels only in cases where quality was the guiding requirement. Examples of the chemical composition of various ingot steels melted on a basic lined electric furnace will be found in Table IV. With the exception of Examples Nos. 1 and 2, all steel was made on arc furnaces. Acid Electric Steel Ingots Larger quantities of ingot steel are very seldom manufactured on an acid-lined electric furnace hearth. The acid furnace, however, is frequently used as in the combination with basic lined furnaces, the steel being desulphurized and dephosphorized either on basic open- hearth or basic electric furnaces and then transferred to the acid-lined furnace. Slag, sonims and gases are given opportunity to float to the top of the bath, mak- ing the steel much cleaner, tougher and _ stronger. Examples of the chemical composition of larger ingots used for the automobile and war industry will be found in Table V. C onctusio? In the manufacture of large ingots, exceptionally trict specifications of chemical composition proved to be positively only of a theoretical value, if not useless, account of the increased effect of segregation on indness and pouring practice in general. The require- ment of a clean steel, i.e., without slag or other non- metallic inclosures or impurities (sonims, refractories, etc.), as well as a quiet molten metal cast at a proper speed and temperature, should be more closely con- trolled than final analyses (except ladle tests). On the contrary, determinations of chemical analyses of inclosures, or the composition and quantity of occluded and absorbed gases, will be of a greater value and im portance for the future improvement of the manufac- ture of ingots than just a few “points” of carbon or a ittle more manganese. This statement does not mean to eliminate chemical analyses; the correct opinion of a steel quality, however, can be obtained only by taking both factors—analysis and melting or pouring practice into proper consideration. terials. It is a Brownhoist No. 2 gas engine creepe truck crane with a 40-ft. main boom. A special feature is the @5-ft. gooseneck extension to the main boom, which was designed by Brownhoist and Austin engi- neers to facilitate the placing of roof lumber and othe: light material on top of a building four stories ir height. The capacity of the main boom is 10 tons at 12-ft. boom radius. The gooseneck extension has a capacity of 1000 lb. The machine is operated by one man and is used for bucket, hook or magnet work and for driving piles. It is painted blue, the standard colot for all Austin equipment. The gooseneck extension, also painted blue, suggested the name of “Blue Goose.” The 25-Ft. Gooseneck Ex- tension Per- mitted the Placing of Material on Top of a Build- ing Four Sto- ries High. The machine was used effective- ly in building the Palace of Agriculture, which is one of the four ma je r build- ings that will house the Ses- gq uicentennial Ex position April 15, 1926 cS ot atl ath. ew Electric Blooming Mill Drive Installed in Record Time at Donner Plant—Net Shut-Down Only 13% Days—Motor on Site of Old Engine APID installation of the new elect mill drive put in operation last July by the D ner Steel Co., Inc., Buffalo, stands out as a ur omplishment. The new drive replaces the 48 x 60 j imple, twin-cylinder Macintosh-Hemphill engine f nerly used in driving the 36-in. blooming mill. T} gine has been in service since 1906 and was operated n-condensing, by steam furnished in part from a bat ery of coal-fired boilers in one boiler house and ist furnace gas-fired boilers in another boiler hou Since the blooming mill in this plant is most esser il in the production of alloy and special steels mad: customers’ specifications, it was important that lange be made with a minimum shutdow \ ft arefully planning every step, and immediately upon ceipt of the last car with electrical equipment from he factory, the mill was shut down on July 2, the old lrive removed and the mill again put in operation th the new drive in its place on July 20. The tims om the last ingot with steam to the first ingot with ectricity was just 18% days, (about 13% working as the time spanned the July 4 shutdown.) New Building Needed The engine was typically located in one end of a ean-to building known as No. 1 Power House, which adjacent to the blooming mill building and houses lso the hydraulic pumps, boiler feed-water pumps, cumulators, air compressors and other power hous¢ juipment. This building, being narrow and served by rather low 10-ton electric overhead traveling crane, vas found entirely inadequate for the purpose of hous- ng the new drive. It, therefore, became necessary to rect a new building of ample size, with adequate crane facilities, to serve the needs of the reversing moto ind auxiliaries, in place of a portion of the existing in-to over the engine. Construction of the new building carried with it ertain difficulties not ordinarily encountered in worl this nature. Operation of the mill, before the final shut-down, could not be interrupted, in spite of the fre- juent occasions for interference with construction The large steam separator, together with steam piping ind exhaust piping serving the engine, as well as ac- imulators, hydraulic pumps and electrical apparatus n and near the engine room and used in conjunction vith the mill, had to be moved, to clear the site for foundations and walls of the new building. Approximately 7 ft. wider than the power house lean-to, the east wall of the new building fell outside f the existing building. Foundation for this wall, on account of having to carry also the crane runway ‘olumns, had to be piled. Oak piles were driven to re- fusal by a pile driver specially designed to drive them n the limited space between the existing power house nuilding and an adjacent brick boiler house stack While excavation and concrete work for the east vall were in progtess the end wall of the old power LEMMA ELTSAAAAETEORNUARENDEDAETT ONION ELT VETTE TNT TaN NTT e DU n¢ { rether with roof and east W ill in the f the engine, were removed to cieat indation and end wall of the new build- ng, and for the switchboard basement, which extends ss the south end. Meanwhile, the brick wali sepa rating th looming mill building from No. 1 power house was removed in five bays opposite the engine, to expose the steel work of the mill building and to per mit later the erection of a new partition wall, forming al the west wall of the new drive room Steelwork Erected Under Difficulties After the ist and ith wall concrete foundatior were in place, the erection of the steel work for the new building was started. Column extensions were added to the mill building columns for supporting the west ends of the drive building roof trusses, about 5 ft. above the eaves of the mill building. The east columns and roof trusses of the new building were then placed by use of a hand car on a track supported on the roof of the lean-to, and raised by a portable gin pole, also sup- ported from the same roof. Sufficient space was not available to erect the steel work from the ground by using ordinary erecting equipment. The roof of the new building was then placed, which, with the excep tion of brick walls, virtually completed erection of the new structure over the top of the old building. Two more bays of the old power house building, beginning at the south end, were then taken down. The mill building columns were reinforced on the drive side, and the new crane girders for the crane, to serve the new drive, were erected in two bays. A 75-ton open- hearth pit crane, overhauled and converted into a single-hook crane to serve the motor-drive building, was next placed on the runway in the two south bays A fourth bay of the old building was taken down, which permitted erection of a third bay of the new crane run way girders. This procedure was carried on until the entire old building had been removed and the complete new runway erected. The engine was, in this manner, times covered by either the 75-ton crane of the new building or the 10-ton crane of the old power house, or both, if needed in the bay between them. Tearing down the old building and subsequent erec- tion of new members were done under cover of the roof of the new building, while the engine was operating on regular mill schedule. Use was made of the new roof trusses for fastening rigging used in dismantling and erection. Following this, the laying of brick for the east and south walls was started and erection of the switchboard gallery, followed by erecting switchboards and connecting wiring. Meanwhile, foundations for the north wall of the drive room were put in and the con- crete work for the underground air ducts completed as far as possible. ‘ all at all New work up to this point was carried on around and over the top of the engine while operating, without a single shutdown except for the regular Sunday stops IME is one of the most mporta t ele word “delay” on the tally sheet is as nent n the operation of a steel mull. The red rag to the superintendent. For that , reason the story of how quickly a big replacement job can be done makes worth-while reading. Tearing out a heavy, cumbersome engine, blasting out its foundations, putting new foundations and motor drive in the self-same location—all within 134% working days _is a feat done last summer in Buffalo Donner Steel Co., tells how it was done. In thi article A. L. Foell. chief engineer 1051 1052 [he construction wor vas carried on under more or ess difficult conditions. The engine, being badly out valance, put in vibration everything around it to an xtent rec iring stopping certain parts of the work at né I nore than extraordinary bracing of forms nerete, scaffolds and various members of the ng under constructior There were no switching near the te to f tate handling materials. A mited amount of ice across the end of the building d r i ible, in which construction rK ¢ { irriea I E ! iration Wv made for the final shutdown, that the change to the electrical drive could be made the shortest possible time 4 temporary construc- evated on a trestle across the north end of he d uilding, between the engine foundation and vall, was placed a few days before the mill wn, so that it could be quickly connected rary spur track, also placed at the same the n rom a track in the mold yard. r} tra was placed across over the mill tables while ( \ it dow The trestle was provided, to THE IRON AGE April 15, 1926 make the north end of the engine foundation accessibl for dynamiting. A Leyner concrete drill sharpener and Ja a tempering furnace were installed temporarily near the site, to keep the drills in good condition. Lumnit« cement was procured to expedite the foundation work Tearing Out and Rebuilding « The engine with its auxiliaries and steam piping weighing nearly 1,000,000 lb., was dismantled and re- moved completely in 22% hr. after shutting dow Drilling and dynamiting of the engine foundation fo: new foundations for the motor-generator set and the r versing motor was started simultaneously. The motor- generator set was placed across the south end of the engine foundation, sufficiently far away from the re- versing motor to permit concentration on its founda- tion, so as to permit its completion earlier than that for the reversing motor. Erection of the motor-generator set was started seven days after shutting down. This was followed by completing the concrete work, mostly poured with Lum nite cement, for the exciter set, slip regulator, conduit At Left Is the New Motor- Generator Set with the Main Mill Motor in Background. Below is the old engine which was taken out; the shaft con- nection at right, leading to the blooming mill still farther to right (not shown) is in the same the motor drive shaft shown, in upper through the wall into the mill building. Another view of this electric drive location as view, passing appeared on page 59 of our Jan. 7 issue ey tain sn fa ile) ~ eee se ~ tila April 15, 1926 tunnel between switchboard basement and motor-ger erator set, and for the bus-bar cellar between motor generator set and reversing motor. the reversing motor was next completed. mitted starting erection of the reversing motor 12 day ifter shutting down. The wiring, together with settir THE IRON The foundation fo This per- o i ip of auxiliaries, was carried along as rapidly as pos sible, to permit turning over and adjusting the main inits as far ahead of starting as possible. In preparing the foundation for the reversing mot: 7 the engine foundation was dynamited out to a depth of t about 11 ft. Structural beams were anchored at th elevation, into the remaining existing foundation below by six of the engine foundation bolts, which we shortened for this purpose. These extend into tt « t existing concrete to a further depth of about 10 ft Fight of the motor anchor bolts, not including the fo Approach | Above Is the General Layout of the New Driving Units, in Thew Rela tion to the Blooming Mi n the Next Building. the way the neu motor-roon str At right is show) ture was built up, over the old power house. The new crane run- i way is & ft. higher than the old a? the span about 5 ft. greate Al AGE 1053 principal bolts at the drive and thrust bearing end, were secured to these beams for bolting down the motor. lhe four bolts at the drive end bearing were anchored ijown through the new concrete into the old engine foundation below and fastened in the tunnels of the old foundation at a depth of about 20 ft. below the motor Dase., New concrete for both foundations was poured of Portland cement up to about 15 in. of the top and fin- shed with Lumnite cement concrete. sufficiently hard surface to permit erection of equipment in the shortest possible time after pouring Erection of the mrotor- generator set and reversing motor was started about The aim was to Otain a of concrete was ( ompleted ) 26 hr. after their respective foundations were poured During the shutdown the mill machinery was com- pletely erhauled, including certain changes in the rol: ’ esp stp oy staat hy hy hy yy fet sty de. Purout Blooming Mill ; Build ng je Power House Ne 4 * i r) Sh 44 = 1 S4 = wa = 8 ) ~ 5 S s > Motor -Drive cy Pp 90°F" 1054 stand to permit the use of larger blooming rolls and new universal spindles between pinions and mill. The pinion housing was machine altered for new pinions of arger diameter, and equipped with new bearings de- ened for lubrication by splash from the pinion teeth. [he pinion teeth, bearings and universal ends of lead nd mill spindles are lubricated by oil from the bath pinion housing, into which the pinion teeth dip. A new operator’s pulpit was erected in place of the used with the steam drive. This pulpit, of ‘late and structural steel construction, is entirely in- Steel sash with clear wire glass incloses three des, with bullet glass extending across entire front, to give a full view of mill to the opera- ves and at the same time offer protection from flying e. The pulpit is ventilated by washed air from the ers -prool plate New Equipment sing motor consists of a single-unit shunt- d machine operating on 750 volts d.c. current, hav- peed range of 0 to 120 r.p.m. in both directions ing a momentary torque capacity of 1,050,000 ft. Its continuous capacity, based on 50 deg. Cent. perature rise, is 4000 hp. It is direct connected to pinion housing of the mill through a universal lead ndle. The motor is semi-inclosed and is ventilated washed air. [The motor-generator set consists of two 1800 kw., leg. Cent. rating 750-volt d.c. shunt-wound genera- y a 3000 hp., 50 deg. Cent. synchronous speed, 2200-volt, 3-phase ip ring induction motor. A ven by 10-ton flywheel mounted between the induction motor and one of the tors, while the other generator is direct con- nected to the motor on the These units plate and are all opposite end. upported on a common base ’ ed for the purpose of forced ventilation by { air, with provision for self ventilation when n for the d.c. generators and the reversing irnished by a 100-kw. motor-generator set ng at 750 r.p.m. Three 75-kva. single-phase trans- vith 115-volt taps for starting are used in fe WI he 300-volt current to 230 volts for the auxiliaric \ liquid slip regulator is r automatically regulating the amount of re- ‘ I ne econdary circuit of the induction motor, n exchange of energy between motor and } regulator arranged for use in start- he set and for dissipating the slip energy. furnished by two air washers each of 30,000 cu. ft. of air per min. Nor- her furnishes air for the reversing motor, le t her is used in ventilating the motor and erators of the motor-generator set. Inter-connect- lu leading from these washers permit the normally on the motor-generator set to ven- reversing motor, in case of trouble with the ans ‘ I 1 Capacity Phosphorus in Wrought Iron by Different Puddling Processes An investigation recently completed by H. S. n and Samuel taw- Epstein of the Bureau of Standards its purpose the study of the effect of phos- one of the ever-present impurities in wrought ron, upon properties of the finished iron as made by different puddling tecently, mechanical puddling processes have been advocated and used to a considerable extent to replace the time-honored hand-puddling method, on account of the high labor costs of the latter. Very little has been published on the properties of the wrought iron made by these newer processes, phorus, processes. Phosphorus in wrought iron is usually regarded with some concern since it embrittles the iron or makes it “cold short.” The phosphorus is contained in both the iron matrix and the slag threads to which the wrought iron owes its characteristic “fiber.” Only the phos- THE IRON AGE April 15, 1926 other unit. Washers, fans and pumps, located in No. 1 power house, just outside of the motor drive room, are arranged to take in outside air or to recirculate air from the motor room, or both, as desired. The starting controls for motors driving the fans and pumps ar: interlocked with the main starting control on the larg: units, so that the latter cannot be put into operatior without forced ventilation. The bearings on the reversing motor and motor- generator set are ring oiled, supplemented by a grav- ity oil circulating system to insure ample and fres} oil at all times. The flywheel and reversing moto bearings are arranged and piped for water cooling, i: case of emergency. Switchboards and equipment are placed across thé south end of the motor drive room. The low-voltag: starting, contactor and instrument panels for the re versing equipment, together with automatic switch- boards for the mill auxiliary motors, are on the mair motor-drive room floor. The high-tension oil switche: are placed on one end of a gallery over the switch boards. The d.c. resistance, mounted on racks, is placed on the other end of this gallery. The 75-kva single-phase transformers and a series transformer ar placed in a cellar under the switchboard, as a protectior against fire in case of the loss of one of these. es Operates with Fewer Men Operation of the reversing motor is entirely the hands of the roller through a manually con trolled master placed in the pulpit. This mas ter, together with a _ single similar master co: trolling the approach and delivery tables on thé mill, is so placed as to enable him to operate the mil! and tables with his right hand. Another similar mas- ter conveniently placed gives him control of the screw down with his left hand. The manipulator is hand operated from the pulpit by another operator. This arrangement allows the operatives freedom in operat ing the mill in either a standing or sitting position and makes possible the operation with two men, where for- merly three were necessary. The equipment has anestimated monthly capactiy ir rolling 21%4-in. square ingots into 4 in. x 4 in., 5%4-in. x 5% in. and 9 in. x 9 in. blooms of 35,000, 50,000 and 62,000 tons respectively. The complete electrical equipment was furnishe and erected, including wiring, by the General Electri Co. The new universal spindles, pinions and bloom roll were furnished by the Mesta Machine Co., Pittsburgh Structural steel for the building was furnished and erected by the Lackawanna Steel Construction Co., Buf falo. The necessary piling was driven by the Great Lakes Dredge & Dock Co., Buffalo. All other work including rearranging of equipment, dismantling of en gine, foundations, brickwork and miscellaneous work including engineering, was executed by the Donner or ganization. phorus in the iron matrix, however, affects the proper- ties of the metal. Mechanical puddling appears to b¢ more effective in reducing the phosphorus content to a lower figure than is hand puddling. Experiments wer carried out on wrought iron made by each of the tw methods on a “split” heat of pig iron, the two parts of the heat being refined by the two processes, hand and mechanical puddling, respectively. For certain purposes, such as drill pipe for which a “stiff” materia! is needed, a certain percentage of phosphorus in the iron is desirable. The amount, in such a case, is usual- ly considerably higher than that in good quality bar iron, for which the total phosphorus ought not to ex- ceed 0.15 per cent but slightly. The investigation was not extensive enough to war- rant any sweeping conclusion concerning all the merits of wrought iron made by the two processes. However, nothing was noted which would show that wrought iron made by hand puddling cannot be equaled by mechan- ical puddling if properly carried out. Centrifugal Pipe from Sand Molds How the “Sand-Spun” or “Mono-Cast” Product Is Made in a New Plant—Details Covering the Molds, the Sand and the Finished Product ONO-CAST is the trade name for the cast iron pipe made centrifugally in refractory-lined molds by the American Cast Iron Pipe Co., Birmingham. In this article the subject is dealt with under two heads: First, raw materials; second, equipment fot converting these into a finished product. Raw Materials The ordinary grades of pig iron available in the Birmingham District are used and as there are no risers or gates, the amount of return scrap is nominal. Standard by-product coke is the melting medium, with modern cupola practice used in converting the iron to the fluid state. The weighed charges of carefully selected iron are introduced into the cupolas by a mechanical charging machine and the operation of the cupola is controlled by recording pressure gages, vol ime gages and pyrometers. In the production of the refractory molds, which are the basis of the centrifugal process, red loam molding sand from the Montgomery, Ala., district is used as a base and to this is added a sufficient amount of washed silica sand to produce a molding sand of the prope specifications. This sand is carefully checked for the amount of bond, permeability, moisture and grain size The chief bond of the molding sand comes from th: red loam, but yellow field clay, fire clay, or glutrin may be used to give additional bond to the sand in the green state. The sand, when rammed in the flask, faced with ordinary pipe foundry facing, made fron nut coke which has been pulverized to the consistency flour. This is the common material used as pipe mold facing and comes in the form of a semi-tempered material. The sand used for making the socket cores which form the middle of the bell of the pipe, is a ver fine grained washed silica sand, such as ised making oil cores for radiator castings. This sand mixed with linseed oil, which is the binder Tar is the only other material used and tl bought on a specification governing content of moisture and free carbon. It is pumped from larg tank cars in which it is delivered into storage tank and removed from these to the dipping vat is re ] lired. Making the Refractory Molds The equipment required for the operat Mono-cast centrifugal pipe foundry consists of the following: Mono-cast pipe is of unit construction, that is, one pipe to the flask. The flask, which is made of cast iron, is machined on all points so as to make possible to do rapid work. It is necessary to ram 1e sand mold perfectly concentric with the spinning surfaces of the flask. As shown in the plan ef the new plant, there are -way ramming stations at the positions designated as No. 1. The empty flasks come down the run as indi- cated at No. 2 and are received on a tilting table in the run which delivers them into the vertical position on the ramming stations as shown at No. 3. The flasks are handled three at a time and these two ram- ming stations are used to alternate the work so that, while they are ramming @n one station, they are com- pleting the rest of the work and making the change on the other station. + \ 1 r I Once the flasks are in the vertical position and properly located on the ramming tools, the three pat terns are lowered into the flasks. These patterns are handled from above by a stationary pattern hoist. The pneumatic ramming machines are then moved into po- ition by mechanical means from above and lowered into the individual flasks. The sand delivery chutes are placed into position and the ramming operation proceeds throughout the length of the mold, which is about 16 ft. long. The time consumed in ramming is bout 1-% min. The patterns are drawn, three at a time, from the Ids, the molds are lifted off of the ramming steels by a hydraulic lift and the blacking is applied to the face of the molds while in a vertical position. They are then returned to the horizontal position by the il able and are ready to move forward on the flask run, as indicated at No. 4. The flasks then pro eed to No. 5 where they are picked up by an overhead 6 and delivered to the casting machines at No. 7. In this operation the flasks are handled two at i time by the special device attached to the crane Casting the Pipe [The top half of the Mono-cast pipe casting machine hown at No. 8, is elevated to sufficient height to illow the flask to roll in sidewise. The machine i then closed, the motor is attached to the flask by a juickly detachable clutch and the proper amount of iron is placed in the pouring ladle, as shown at No. 9, DIET et) to the preside ney in 1924. RAT eer 1 my Wi Wi HEN the process of making cast iron pipe centrifugally in a refractory mold was first announced, it was known as sand spun pipe. The first announce- ments appeared in THE IRON AGE, June 5, 1924, where a preliminary description of the process was given, and in some editorial comment on the development in its issue of March 20, 1924. which have taken place since then, resulting in the perfection of the process and the building of a large plant at the works of the American Cast Iron Pipe Co., Birmingham. The process is named the “Mono-cast” process. The inventor of the process is W. D. Moore, president of the American Cast Iron Pipe Co. He has been closely connecte d with the foundry business since 1908 and has been president of the company for the past two years. He was born at Hannibal, Mo., April 17, 1882, and was educated in the public schools at Galion, Ohio, being graduated from the high school there in 1900. In 1908 he became connected with the present company as an engineer, advancing from that position This article is a description of the developments t= April 15, 1926 1056 AGE THE IRON iM Fig. 1(b) Photomicrographs of Comparative Struct edge (c); and Fig. 2 (a, b and c) shows t/ The chill on the outside (sections a) the mono-cast but the graphite formati: is not so coarse and has not the tendency t ‘cast. The inside (c) shows the chilling eff shows no tendency a three-way machine built on a rather abrupt incline. The flasks are placed on a tilting table and tilted to the incline in which position they are held while the sand is being removed from the mold. The flasks, with the pipe in them, are returned to the horizontal position by the tilting table and the pipe puller No. 15 removes Bie tte) the pipe from the flasks three at a time and deposits them on the run at No. 16. In this run there is a which immediately conveys the pipe into a conveyol Cast Pipe: Fig. 1 shows mono-cast structurs e large ladle o1 iil trolley No. 10. The cooling oven at No. 17. hin then inclined to the proper angle with bs Aa : . ence to the horizontal and the pouring operation Cooling and Cleaning Imm¢ tely the metal is poured in the mold, This cooling oven is equipped with a slow-moving t spinning and the iron is placed on the wall conveyor which gradually rolls the pipe through the nd he er¢ tk rm of a tube until it is suffi oven, where it is kept under temperature control for er i4 t hape when the machine i approximately 40 min., and until it has reduced in hut temperature to at least 500 deg. Fahr., at which time The ld, with a finished pipe in it, is rolled on ready to be removed from the cooling oven and hroug e machine takes the position shown at’ enter the cleaning department as shown at No. 18. N From tl on it is moved to No. 12 where When the pipe is cleaned it passes to station N: the end trimmings are removed from the flask and the 19, where it is picked up by a small hoist, and passes t sand removed from the bell end of the pips to station No. 20, where it is lowered into a bath of takes place within 10 min., including the y nning operation 7 flask, with the sand and pipe in it, now passes tripping machine as shown at No. 13, which is tar and is held in this bath a sufficient length of time to take a proper coating. The bath itself is under tem- perature and chemical control. The pipe then passes to No. 21 where they are permitted to drain free of A Mono-Cast Centrifugal Machine for Making 16-Ft. Pipe. The upper half lifts ip and the flasi containing the It is in the position which it assumes when revolving. re fractory-lined mold rolls into the machine in a horizontal position ‘Set each! ee a. of Mono-Cast Centrifugal Pipe and it outer edge (a) middle (b) and inner orm a continuous network as in the sand April 15, 1926 THE IRON AGE 1057 Sa nd ‘ ime relative positions in a sand cast pipe. ich deeper on the sand cast pipe than on the middle (sections b) of the mono-cast f the core in Fig. 2 while the mono-cast hange in this section surplus tar and then pass to No. 22, where tinue to cool. They then pass to station N¢ they are lowered to the pipe run again ar to the hydraulic testing press No. 24. Gas | not coated but after being tested in press No pass to press 25 where they may be given an ai of 25 pounds air pressure under water. Fron they pass to station No. 26, where they are and the individual weight marked on the outside and ,, “re ees ; a inside of each pipe. From here they pass to N 7 one: nae: is accumulated a : re moved fr m the where they are picked up by a monorail hoist, or ee eee sons Se hing CN 7 a. At No 4 here truck, and distributed on the load ne vard a . s a shake ] sand storage bin for the opposite half shed product. of the shop and this serves in the same way as No. iat ‘a ‘te 14: both are located at the center line of the shop The Empty Flasks Underneath these bins thers a reciprocating sand From station No. 13 the empty flasks p eed dow! nveyor operating from the bins to No. 31. This the run to No. 28 and then to transfer car N 9 and onveyor takes the sand from the bins No. 14 and No are taken across, as shown by the arrow, to flask ru 0 at a predetermined rate, which controlled by slide No. 2, and then proceed through the ramming tatior alve ind the stroke of the reciprocator As the sand again in their regular turn. mes from these bins into the reciprocator it is almost In this shop are two units which operate entiré f not entirely free of moisture, and at a temperature independent of each other, except that they have th f approximately 125 deg. Fahr As it is moved along same sand handling and preparing machinet ind the by the reciprocator between stations No. 14 and No same source of iron supply. », clear water is added, which is the first addition to . bring it back to molding temper Sand Regeneration At station No. 32 is the make up and in a bin which The tempering and regenerating of the sand start equipped with an automatic feeding device operated at station No. 14 which is the dry storage bin wher by the stroke of the reciprocating conveyor. This feed Mono-Cast Centrifugal Pipe Split Endways to Test for Uniformity of Section, Inclusions, Blow Holes, etc. 1058 THE IRON AGE adjustable so that with each stroke of the conveyor ne can introduce a definite quantity of make-up sand. In this way a uniform distribution of the new make-up and into the total body of sand is effected. As the d continues to move from No. 32 to No. 31, by ' the conveyor, it is thoroughly mixed and ad- | water is added, if required At No. 31 the sand is ivered by the reciprocating nveyor to a belt conveyor which is running at an ngle of about 30 deg., and which elevates the sand m the basement of the shop to a point above the rking floor | into a duplex paddk er at No. 33. In passing through this mixer, the thoroughly mulled and, if any additional water h, or any other material is to be added, it this station, so that as the sand leaves this ++ . : ; vel and delivers there are no more additions to be made, except ] tior wate make up any error in may be f 1 f is delivered from the end f the paddl er at No. 34 onto a belt conveyor which is operating an angle of approximately 30 deg. This belt elevates ind to station No. 35, where it is discharged off end of the belt onto a vibrating screen whic} 1 aerates the sand and delivers it onto another nveyor which 1 yperating at an angle of a} 30 deg., and the lower end of this belt r is approximately 6 ft. above the shop floor This belt works from No. 35 to No. 36 and f the inclination, station No. 36 is well uy tl rd floor of t shop \ } i carried from No. 35 to No. 36, t re taker nd a check is made for moisture ind bor I aqad nt this the screer d ron ’ Keep tne grain s 4 t [ I or nere lipment f tne il ! lld the te indicate tl I nd rur 1g le } ming through the mixers No. 33 and N + t ivold ever having it too wet as it comes ont ( ‘ t N As the sand arrives at N 6 it passes onto an I brating screen which further mixes and aerates nd breaks up any accumulation of moisture as result of applying water to it on the belt. The sand then drops into a circular revolving bin, No. 37, where thers a nominal storage of tempe red sand. The bottom of this bin is equipped with an auto matic feeding device so sand ean be delivered to cross belts No. 38 and No. 39 simultaneously or separately. From station No. 38 to No. 40 there is an inclined belt iveyor elevating the sand from the bottom of bin Ne. 37 up into a chute which delivers it to bins 41 ind 42 As the sand travels from No. 38 to No. 40 n the belt it is again sampled and tests run for mois ture Th belt is als equipped with water facilities so as to add moisture if found necessary. Sand bins No. 41 and No. 42 are of the revolving type with automatic feed at the bottom. These bins ire located immediately over the ramming station as wn in the plan, and it is from these bins that the ammers take the sand and deliver it into the flasks is required during the ramming operation. [The raw materials, such as sand, facing, clay, etc., required in the operation of this plant are stored in he basement of the shop, as noted at No. 44. At No. 45 there is a pair of vertical skip hoists which handle 1 half vard bucket from the basement floor of thi b ilding up through the first floor and delivers their charges into the Simpson mix