The Iron Age 1926-07-29: Vol 118 Iss 5

Notice—Y oll) willifiagja convenient summary of the week’s news on the orange-bordered editorial page. Published Weekly Vol. 118, No. 5 VAUAHAAANTANEGELOGUUUEAUUUDOUEDEDEREGOLUUENOGOOOOORROEROGONOGENOUDOONSORESOOOGOOOUOOOODOSEOREREOUAOHUUUAOUUORREEAREEOOOOOOOLOEEEEANLASNSOOOOSOOEEREDEREEREOUOOUOOOOEEEEEROAONEOOODONOOOONEEREDEREOEOONDONOOOENEEEESEREEDEOEOOODODOODEOEONDEEEOOEOOONE OOOUUEEOCEU OOOO OOODOEONONDEOROND NEW YORK, » JU L Y 29, 1926 Single Copy, 25 Cents entered as second-class matter a 18, 1879, at Post Office Six Dollars a Year in U. Ss. at New York ander the of March 3, Canada $8. 50; Foreign $12 hel KNIGHT NATIVE STEERS 13 Ib oe longer lite her Cc VERY business man will that of a finished product depends largely on They make the best belting leather; recognize this fact: the character belting leather that has the capacity for long life. > the character of the raw mate- And that’s what you, the user rials used. of power belting, are most The manufacture of Graton vitally interested in when you belt the drives in your plant. Graton & Knight leather & Knight leather belting is based on that principle. Eleven grades of hides are offered turers. to belting manufac- Only two of these are equal to the exacting specifica- tions laid down by Graton & Knight. Their per pound averages from 33 1-3‘ to 45" the most cost But they are the skillfully removed, the strong- est fibered hides that can be bought. higher. uniform, most belting is the product of a controlled process, every step of which, from the purchase of the hide to the selection of the right belt for the right drive, is governed by chemical and engineering exactness. That’s why Graton & Knight belts last longer. GRATON & KNIGHT COMPANY Worcester, Massachusetts nch Offices throughout the World GRATON & KNIGHT Standardized LEATHER BELTING LASTS LONGER The “STANDARDIZED belting, how to use Betting MANUAL” it, take care of it Send for a copy contains 170 ane of useful information abi rut and make ver the most for 101-J. your mone} $s : I cpt. THE IRON AGE Built-In Insurance Against Greater Gas Demand HEN the inevitable increased demand for gas comes, the operator of Becker Type Combination Ovens is in a favored position, for the assurance of a future supply of over 60% more coke oven gas is built into the Becker Oven. By substituting blast furnace gas or producer gas as oven fuel, this potential capacity becomes actual production. The Iron and Steel Companies buy this insur- ance in their coke plants for it is one of the most fundamental properties of the Becker Oven. It is the more valuable because no company can say when and to what extent it will need more gas. The Koppers Company Pittsburgh, Penna. Chicago, Ii. New York City wy OR EEE eC July 29, 1926 THE IRON AGE New York, July 29, 1926 ESTABLISHED 1855 VOL. 118, No. 5 The Steel Shovel—How It Is Made ical works, railroads and the various other con- sumers of shovels were confronted with the fact that there was one less standard grade of shovel and considerably fewer possible sizes from which to select. In other words, instead of four standard grades of high- carbon shovels, spades and scoops, the manufacturers now produce only three standard grades. They thus eliminate about 43 per cent of the sizes which are con- sidered unnecessary. These eliminations represent only about 7.50 per cent of the total volume of annual sales in shovels, spades and scoops. The annual output of shovels of all kinds is approximately 9,600,000 pieces. This action is the result of various meetings be- tween the shovel manufacturers and representatives of various large companies, all in conjunction with the Department of Commerce. It was originally intended to eliminate all special finishes such as polished, half-polished, etc., but, in the final analysis, this feature was not approved because these special finishes were so closely identified with the merchandizing of the line. It is recognized that special finishes represent almost entirely a merchan- dizing value, and that black shovels are considered more effective and efficient than polished shovels be- cause the polishing of a shovel necessarily wears away the outer surface of the shovel blade, reduces the gage and, consequently, the wearing qualities of the steel; also, in the case of the standard plain back or Antrim weld shovel, it results in grinding out and to some ex- tent weakening the weld. It is expected that eventually the consuming trade in general will be educated to the idea of black shovels only. Steel Handles Replacing Wooden Three standard grades of shovels were determined upon for the reason that there are but three standard grades of handles—the double X, single X, and No. 1, and, the quality of handles contributes largely to the quality of the shovel. Incidentally, the orthodox type of wood D handle is being gradually replaced by various types of pressed-steel handles used in connection with wooden stems. The manufacture of the common wood f FTER July 1, 1926, mining companies, metallurg- *Bureau of Mines, Pittsburgh. 273 Features of the Mine and Works Shovel— Types Reduced by Standardization —Larger Use of Steel Handles —Proper Way to Shovel BY M. W. VON BERNEWITZ* I) handle involves a considerable waste in ash timber, and the use of a pressed-steel handle, in cpnnection with a straight stem, results not only in the conserva- tion of our rapidly diminishing supply of ash timber, but likewise is a better and stronger handle. In general practice it is possible to produce five suitable stems from the same quantity of timber that will produce two wooden D handles, so that the selec- tion is in the ratio of 2% to 1. Almost any of the better makes of pressed-steel grips prove stronger in actual test than the orthodox wooden D handle. The eventual universal adoption of a substitute D is purely a matter of education in the trade. At the plant of Hubbard & Co., Pittsburgh, which the writer recently visited, and which has since been destroyed by fire, there has been developed what is called an indestructible pressed-steg] D handle. It is produced from 12-gage extra high-carbon steel formed hot and, under actual test, develops more strength than is ever required of a shovel handle. The main features of this handle are that it is made hot from high-carbon steel, is reinforced by a corrugation running reversely through the side of the handle, and the cup formation which holds the wood grip itself is partly pierced by three indentations which grip into the fiber of the wooden handle-hole, preventing it from ever turning in a man’s hand when being used. It is a substantial, well-made grip and extremely strong. The illustration shows the pressed-steel handle with wood grip and the common all-wood handle. Another feature is that the hand-hole in the steel handle is % in. wider than that of the all-wood handle. The grip has already been adopted by a great many of the leading railroads and industrial companies of the country. About 20 per cent of Hubbard & Co.’s output is now fitted with this handle, whose popularity can be estimated when it is stated that a year ago none of them were in use. Manufacture of Shovels The Hubbard plant had a daily capacity of 500 dozen shovels, spades and scoops, or 600% pieces. It em- ployed about 175 men and girls, of whom about 75 per cent were on a piece-work basis. About 80 types of 274 shovels were made in a total of 350 or more sizes and four standard grades. Hubbard & Co. operate three subsidiary plants at Alton, Ill.; Montpelier, Ind., and Aliquippa, near Pittsburgh. Making the Ore and Works Shovel The raw materials, from which shovels are produced, come in the form of sheets, gages 12, or 0.109, to 16, or 0.062, inclusive. The sheets from which the blades are produced are all high-carbon ranging from 0.70 to 0.90 per cent. The straps, which are welded to the blade in the construction of the so-called plain-back shovels, are dead-soft steel. The company also uses a large quantity of chrome-molybdenum steel for the manu- facture of its heat-treated or special-grade shovel. The ordinary plain-back shovel goes through ap- proximately 55 operations and the hollow-back type, or coal shovel design, about 24 operations. The first grade of the four standard grades is made from high-carbon, genuine crucible steel, whereas the three lower grades, or, second, third, and fourth, are made from high- carbon, open-hearth steel. Heating the Blanks: The heating furnaces use 30 to 40 gravity oil in a high-pressure system, usually operated under 30-lb. pressure; at times natural gas is used, the furnaces being equipped for both types of fuel. Depending upon the type to be made, the blanks are heated from two to five times. The two standard types of shovels might commonly be described as the ordinary dirt shovel, or welded-type shovel, and the ove or coal shovel, or hollow-back type of shovel. The major operations in the manufacture of the first type are as follows: Forming the Blade: Sheets and straps are blanked to correct size; the back strap and front strap are welded to the shovel blade, after which the blade is correctly sheared or headed, depending on the type of shovel required, square point or round point. The shovels are then shaped to give correct radius to the blade and the straps are formed and curved so as to fit the handle and take the correct radius or bend. The shovel then goes through the various finishing opera- tions. The ordinary shovel of the above type consists of three parts, the high-carbon blade, the dead-soft back strap, and the dead-soft front strap. The hollow- back type differs in that it is in one piece, all blanked from high-carbon steel. The socket into which the handle fits is an integral part of the blade itself. Fitting the Handle: As the next step consists in fitting the handle in the strap or socket of the blade, it might be stated that the thin or bottom ends of the short wooden D handle and the plain long handle are placed in a tank of hot water (about 100 lb. pressure of steam) to a depth of 4% in. After one hour they are taken out, placed in a machine and bent to the shape desired. TRe bent end is allowed to cool in a die, thus insuring that the shape is maintained. Holes are drilled in the lower part of the handle for the strap rivets, also drilled at the top for the D-handle rivets, which are now put in. Where the blades and handles are assembled, the latter are driven into the straps or sockets, riveted, and the latter are squeezed close to the handles by rolls. Polishing the Shovel: As the straps are naturally rough, they are made smooth on a series of polishing wheels. If the blades are to be polished, they are ground by means of felt wheels coated with 30, 60, and 90-mesh alundum. Handles are made smooth by a series of sand belts, 60 and 90-mesh, and finally on a wax belt. In the entire sequence of operation no one man, excepting the last, produces a finished shovel. This is then labeled according to grade and style. All of the men are adept at their work and there is no time wasted. The life of a hollow-back ore shovel is about 60 days. When worn down 2 in. it pays to get a new one. Making the Coal Shovel The coal miner uses a hollow-back shovel with 26-in. handle or a broad-point shovel with deep set sides, either plain or corrugated blade with D handle or nor- mal length. The steel in the coal shovel is lighter than that for the ore shovel and, as stated before, the shovel THE IRON AGE July 29, 1926 passes through less than half as many operations as the latter. After being sheared, the blades are stamped and shaped. The strap is pressed out during the shaping. From this point on the coal shovel is handled as the ore shovel, only that none is polished. The life of a coal shovel blade is said to be about 45 days, during which period it will handle a maximum of 450 tons. Studies of Shoveling A number of studies of shoveling (the writer ob- jects to the term “mucking,” commonly used in many Western districts) have been made, and brief reference to the findings should be of interest. F. W. Taylor’ said that the average man would question whether there is much of any science in the work of shoveling, yet this science is so elementary as to be almost self-evident. For a first-class shoveler there is a given shovel load at which he will do his best day’s work. He will do this when his average for the day is about 21 lb. Shovels should be appropriate to handling a given type of material—a small shovel for iron ore and a large one for ashes. A man shoveling ore with a load of 30 lb. per shovel, and then handling rice coal, with a load on the same shovel of less than 4 lb., is not doing good work. G. T. Harley,’ efficiency engineer for the Phelps Dodge Corporation, at the Burro Mountain copper mine, Tyrone, New Mexico, said that stoping methods in which shoveling plays an important part are grad- ually being replaced by other and cheaper methods. But there will always be consider*ble shoveling done under- ground in stopes as well as in drifts, tunnels, winzes, and shafts. As it was considered that the shovelers at this mine were not producing the tonnage which they should, Mr. Harley undertook to determine how the general efficiency of the underground shoveling could be improved. As a result of the study, it was proved that the design of the shovel has a marked effect on the shoveling efficiency and, with the proper weight and size of tool, a man’s efficiency will be increased in spite of himself. A shovel weighing 5% lb. made of the best steel gives excellent service. The designs best adapted to mining work at Burro Mountain are long- and short- handle shovels, with square blade 10% by 13 in. and round-point blade 11% by 13% in., with handles 22% and 34 in. in length. The blade, of No. 15 gage steel, should hold 21 lb. of ore and have a life of not less than 1100 tons of medium hard ore when shoveled off a wooden mat or sollar. Hints to Shovelers D. J. Hauer’, efficiency engineer of Baltimore, in his “A Hundred Hints for Shovelers,”’ described and showed the style, size, and weight of shovels best suited to various tasks, and how to shovel. He said that there is skill in choosing and using shovels; proper choice and use will increase the efficiency of shovelers by a large percentage. In selecting shovels, Mr. Hauer says that the grip on D-handle shovels should not be so large that a man’s hand cannot go around it, otherwise it will tire him. For heavy work it is best to select a crucible steel shovel; for lighter work, an open-hearth shovel; and for coal, a light shovel with solid socket or hollow-back. Some attention should be paid to the lift, as the ease with which a man shovels, especially with a _ short- handle shovel, depends upon the lift. In ordering shovels it is well to state what material is to be han- dled, because the style has much to do with the effi- ciency of shoveling. The economical load for a shoveler is 21 lb., the average load for the average man; there- fore, in order to obtain this load, it is evident that dif- ferent sized shovels should be used for different mate- rials, and the bowls must be shaped and sized to suit each class of material. Men should not be expected to do good work with poor, cheap, or worn-out shovels; nor should they use them as hammers or crowbars; and, as a safety hint, a shovel should not be employed to open boxes of explosives. 1The Principles of Scientific Management, 1911, p. 64. ? Trans. Amer. Inst. Min. Eng., vol. 61, 1918, pp. 147-187. * The Contractor, March 29, 1918, pp. 135-139. Black Columns United States Exports of Black Sheets Represent American and Gray% Columns British Exports of Sheets 284,90! United Kingdom Ex- ports of Black Sheets To Japan, Total, _ ToJapan, Total, Gross Gross ca Gross Gross Year Tons Tons Year Tons Tons 1913.... 1,236 132,919 1918.... 6,863 68,152 SURG ack Seawe° “ames NE ge te ae hide 53,927 $OERisce See’) ee SOGDKGek stance. wanes MESass: °° Sinne”” Webee Seeds = stenn. Caen COR icuse sams. ° eee Seeeiads | intend “elton LOEB i cKe 53,858 163,420 BOEOe ese ea eaw 115,397 1910.... 30,338 177.408 SOiices seday 133,312 1920.... 58,723 169,243 1920.... 30,855 138,462 1921.... 127,626 193,433 1921.... 16,089 48,688 1922.... 159,092 214,916 LOeee ses 96,371 169,257 1923.... 74,757 183,748 ott. $ : ree Bs". 1923.... 172,927 284,901 1924.... 101,606 148,742 1924.... 159,099 246,756 a an en | a her) hee )h3OS ee ee cee seek Gate Japan Develops Sheet Industry Prospective Doubling of Capacity and Recent Continental Competition May Decrease American and British Sales BY GEORGE S. HERRICK N recent years, particularly since the Armistice, Japa- nese consumers have been heavy buyers of light gage black sheets. While consumers in the United States seldom use thinner than No. 28 gage, Japa- nese merchants and the extensive galvanizing indus- try that has been established in the past few years have been large consumers of Nos. 30 and 31 gage black sheets, which are generally rolled on a tin mill. Specifications for these sheets may be roughly divided into two classes: sizes and gages used by the galvanizing plants for corrugated sheets and the size used for the -plain galvanized product, which is also sold in small lots from warehouse stocks. For corru- gating, the sheets are only 30 in. wide, but are 72 in., 84 in. or 96 in. long. ‘These are generally purchased by the bundle of 224 lb., the 30 x 72-in. size being specified as 33 and occasionally 28 sheets to the bundle; the 30 x 84-in., 28 and sometimes 25 to the bundle, and the 30 x 96-in., 25 and occasionally 17 to the bundle, the number of sheets governing the gage. For use as plain, box-annealed black sheets, or plain galvanized sheets, purchases are confined to 36 x 72 in., with 13 sheets to the bundle of 107 lb. Of the large total consumed in Japan, it is conserva- tively estimated that the galvanizing plants take close to 90 per cent, most of the remaining sheets being retailed out of merchants’ stocks by the sheet. American Sheets of High Quality In the immediate post-war years the American product enjoyed the distinction of being considered by the Japanese purchasers as the highest quality and to a certain extent this reputation for quality stands today, Eagle brand, the product of the United States Steel Products Co., as a rule selling in the Japanese domestic market at slight advances in price over com- peting brands. In the past few years, however, British mills, until quite recently the only competitors for this business of mills in the United States, have estab- lished a reputation for several British brands that are today considered on a par with most of the American product. The galvanizing industry, which has grown rapidly during the past few years, aided in no small measure by an almost prohibitive tariff on galvanized sheets, is by far the largest sheet consumer. Under the new tariff schedule, effective March 29 of this year, gal- vanized sheets are dutiable at 2.85 yen per 100 kin, or, at the present rate of exchange, about $22.50 per gross ton. Black sheets until the present tariff, which is extending considerably greater protection than former tariffs to the growing sheet industry of Japan, have been dutiable for only a small amount. The pres- ent schedule imposes a duty of 0.30 to 1.10 yen per 100 kin, or from about $2.35 to $8.70 per gross ton, depending upon the thickness of the sheets. Large Number of Galvanizing Plants There are 35 or more galvanizing plants in Japan; 10 or more in the Tokio district operating a total of 26 pans; 7 or more in the Osaka district with 21 pans, and 2 in the Yokohama district with 4 pans. Among the principal factories in Japan are the following: Tokio District Tokio Galvanizing Co. Osaka Teppan (Tokio plant) Jyoto Galvanizing Co. Dog Hira-nami Kashiwa-Shokai Hinode Aento Nakayama-Noboru E. Nakayama Shoten Nakayama-Shigetaka Amagasaki-Kogyojo Toa Galvanizing Co. Inui Tessen Taisho Teppan Co. Nattori Galvanizing Factory Tokio Totan Osaka District Nippon Aento Osaka Teppan The monthly capacity of these plants in both dis- tricts is about 24,000 tons, but at this writing only about 50 per cent of the total number of pans are in operation. Even this rate is evidently considered too high, for limitation of the monthly production is being discussed as a result of the depressed market condi- tions, and as low as 30 per cent operation is consid- ered in some quarters as sufficient. This would be about 8000 tons of sheets a month. It is suggested that to obtain this curtailment all plants should dis- continue operations for about 10 days of every month. The products of the various galvanizing plants are in almost all instances marked with brand designa- tions such as Red Pigeon, Swallows, Sparrows, Butter- flies, Pheasant, Mandarin Duck, Crane, Dharma, Eagle with flag, Elephant, Horse, Lobster, Porgy, Swan, Plover, Dog, Green Tiger, Ship, Concentric circles and numerous other insignia. Until recently either British or American black sheets were used in the production of these galvanized sheets, the Japanese industry buying increasing ton- nages each year, as the industry developed and ex- panded. In 1920 the combined exports of black sheets to Japan from the United States and the United King- dom totaled 84,578 gross tons; in 1921, 143,715 tons; in 1922, 215,463 tons; in 1923, 247,684 tons, and in 1924, 260,705 tons. It is noteworthy, as the accom- panying chart shows, that, while there was a steady increase in the total consumption of black sheets over this period, the exports of the United States declined as the British exports increased, and those of Britain declined when American shipments became greater. The exports of 1924 possibly marked the high point in the combined sheet exports of the two countries, for 1925 shows a total of only 125,669 tons, and with de- velopments in the Japanese sheet producing industry, 275 276 and the recent appearance of Continental competition, the high total of 1924 may not again be equaled. Both the galvanizing plants and the merchant buy- ers of sheets generally buy certain brands or the prod- uct of certain mills which rank high in their estima- tion. In the case of purchases of sheets from mills in the United States there will sometimes be prefer- ence for the product of the United States Steel Prod- ucts Co., or the Bethlehem Steel Co., the Youngstown Sheet & Tube Co., or the Wheeling Steel Co. Numer- ous British mills are reported among the sellers to Japan, and practically all their products are brand Analyses of German, British and Japanese Sheets (Results of Tests in Japan) Maker, Location ie Mn Phos Ss Si Ca. Gelsenkirchen Bergwerks A. G., Germany 0.08 0.40 0.04 0.04 “WwW Gilbertson & Co., ER oe wis fk cee 0.09 0.42 0.18 0.09 “Re at Imperial Steel Works, {5 0.10 0.40 0.04 0.04 0.14 0.35 Yawata, Japan -oer 19.18 0.50 Se ae aie vas Kawasakai Dockyard Co.,§ 0.08 0.34 0.51 0.28 0.13 0.12 Kobe, Japan ..... ; 10.10 06.36 0.60 0.31 0.85 0.14 Osaka Sheet & Plate Mfg. {0.08 0.40 0.45 0.03 0.01 Co. (Tokuyama factory) / 0.14 0.42 0.60 0.04 trace *Comet brand. marked. An accompanying list includes the most popular British brands and the names of the manu- facturers or distributers. Rolling Capacity Stimulated in Japan The increasing demand from the Japanese galvan- izing industry and other users in Japan has stimu- lated the development of a domestic rolling capacity, which is beginning to assume sizable proportions. For some time the Imperial Steel Works, Kiushiu, has been rolling light gage black sheets, but its capacity for this product is only about 10,000 tons a year. The Osaka Sheet & Plate Mfg. Co. operates a sheet mill at Tokuyama with a capacity of close to 10,000 tons, but the lightest gage that has been profitably produced is No. 28, so that it is not a serious competitor for the thin gage sheet business of the Japanese market. About a year ago, however, the Kawasakai Dock- yard Co., at Kobe, began to increase its small sheet capacity by the purchase of rolling mill equipment in the United States, placing orders with such makers as Mackintosh, Hemphill & Co., Pittsburgh, and the National Roll & Foundry Co., Avonmore, Pa. Today the Kawasakai dockyard claims an annual capacity of about 35,000 tons of thin gage sheets and, with the com- pletion of present installations some time in July, the total output of this one company, it is claimed, will be close to 95,000 tons a year. Thus far the Japanese industry faces one rather serious obstacle, the high cost of production. Belgian and German Sheets Tested In the meantime, although the Japanese have been developing a domestic sheet industry, there has been considerable activity in seeking new sources of supply abroad, and tests have been made on sheets of foreign manufacture other than American or British. Several months ago a trial shipment of Belgian-made open- hearth light gage black sheets was tested in Japan. The product was apparently found satisfactory, but Lake Superior Mining Institute Will Go to Milwaukee The twenty-fifth annual meeting of the Lake Supe- rior Mining Institute will be held on the Gogebic iron range Wednesday, Sept. 8, with headquarters at Iron- wood, Mich., and the day will be spent in visiting the mines. A business session will be held in the evening, at which papers will be presented. After the meeting the party will take train for Milwaukee, arriving Thurs- THE IRON AGE July 29, 1926 these” sheets were only 30 x 72 in., the smallest size used for corrugating. A few months ago, however, the Gelsenkirchen Bergwerks A. G., Diisseldorf, Ger- many, shipped a trial tonnage of open-hearth steel sheets, made to Japanese specifications (36 x 72 in., 13 to the bundle of 107 lb.), and upon tests they were reported comparable in quality to the best British brands. The accompanying table shows the chemical analysis made of the Gelsenkirchen sheets compared with the British-made Comet brand and the products of the Imperial Steel Works, Kawasakai Dockyard Co., and Tokuyama factory. Finishing Mills Being Developed As a modern industrial nation, Japan has made tremendous strides during the past 15 to 20 years. The development of a sheet rolling industry is only a small part of the ambitious program being carried out in the Japanese steel industry. During the past few years wire-drawing plants have been growing in number and size, so that Japan has become a heavy buyer of wire rods in the world market and a smaller consumer of foreign wire and wire products. British Brands of Black Sheets Sold in Japan Brand Maker Comet W. Gilbertson & Co., Ltd., Pontardawe, Glamorgan, Wales Raven Grovesend Steel & Tinplate Co., Ltd., Gorseinen, Glamorgan, Wales Koto ] Upper Forest & Worcester Steel & Tin- Morestead Special plate Works, Ltd., Morriston, Glamor- gan, Wales Eclipse } Frederick Braby & Co., Ltd., London Flexum | Phoenix Baldwins, Ltd., London E. V Ebbw Vale Steel, Iron & Coal Co., Ltd., Ebbw Vale, Monmouthshire Fan ) Partridge, Jones & John Paton, Ltd., Dolphin 45 Newport, Mon. Harvest H. B. Barnard & Sons, London A. J. Co — Jones & Co. (merchants), Lon- don Sunflower surnell & Co., Ltd., Ellesmere Port, near Birkenhead Samson Melyn Tinplate Co., Ltd., Neath, Gla- morgan Staley Crown John Summers & Sons, Ltd., Stalybridge Marksman ¥ Bowesfield Steel Co., Ltd., Stockton-on- William Tell Tees Pr. Dt Dorman, Long & Co., Ltd., Middles- D: L. { brough, England Globe John Lysaght, Ltd., Bristol Dobbin Brunner, Mond & Co., Winnington, Northwich, exporters Stag Wellfield Galvanizing Co., Ltd., Llanelly Lily Richard Thomas & Co., Swansea Lily Crown Miller, Gibb & Co., Liverpool, exporters A few months ago it was authoritatively stated that the Imperial Steel Works would soon be in a position to supply the rail requirements of Japanese railroads for sections up to 80 lb. and part of the requirements for 90 lb. and heavier. On April 10 the Steel Manu- facturing Encouragement Act, providing for a subsidy on molten iron. produced from ore for immediate steel production, was made effective. In addition, the act exempts such producers for a period of 15 years from business profit taxes and import duties on equipment. A drastic duty on copper is developing the native cop- per mining industry. Gradually, from a large importer of finished prod- ucts, Japan is apparently slowly working into the posi- tion of an importer of semi-finished and raw products for conversion in its own finishing mills. day morning, Sept. 9. Visits will be made to the plants of tle Allis-Chalmets Mfg. Co., the Bucyrus Co., the Cutler-Hammer Co., A. O. Smith, Worden-Allen Co. and others. The closing meeting will be held at Mil- waukee in the evening, after which the members will be free to return home as they may desire. E. W. Hopkins, Ironwood, is president of the institute, and A. J. Yungbluth, Ishpeming, Mich., is secretary. To his capable handling of the affairs of the institute for more than 25 years much of its success is due. President (at Right) Award- ing Prize to Boy Scout Participant in Children’s First-Aid Contest at Bethlehem Meet School Girls (at Left), in Safety by the Bethlehem Corporation, Work Out First- Aid Problem at Annual Meet Grace Trained Steel Making Accident Prevention Popular Employees of Bethlehem Steel Corporation Compete at First-Aid Meet for Cash Prizes oe and mine rescue teams made up of more than 200 employees from all units of the Bethlehem Steel Corporation’s steel plants and mines competed in the annual First-Aid Meet at Bethlehem, Pa., on June 26. To stimulate employee interest in first-aid and accident prevention work, the corporatién awarded almost $4,000 in cash prizes to the winners of the preliminary and final meets. In addition, silver trophies are awarded to the winning steel plant and mine teams for the best work in their respective fields. The trophies are held for one year and until the next an- nual meet. These annual first-aid meets represent the final step in the graduation of 1200 employees trained in safety work each year at the steel plants and mines of the corporation. More than 7000 Bethlehem workers have now been trained in first-aid methods and, in addition, similar instruction has been given also to several thousand boys and girls in the districts where the cor- poration maintains operating units. In a message to the participants in the meet, Presi- dent Eugene G. Grace said: Bethlehem Steel Corporation endeavors to working conditions safe in its plants tific study most accidents for- merly accepted as inevitable are now prevented. By even greater thoughtfulness and caution on the part of all employees such accidents as now occur can be largely eliminated. Thus, acci- dent prevention in Bethlehem plants becomes a matter of vig- ilance and education. In addition to bringing about proficiency in the care of in- jured workers, first-aid instruc- tion helps maintain the interest of all employees in safe work- ing practices. make Through scien- Teams Show High Average of Skill The Johnstown Cambria plant team won first place, with an almost perfect average of 99.5 in the working of four first- aid problems that furnished the basis of the competition. This victory was won by the narrow margin of half a point over the Bethlehem plant team, which scored 99 per cent. The Leba- non and Coatesville teams were a close third and fourth, respec- tively. and Prepares to Mine Rescue Team Member Dons Gas Mask Enter Poisoned Atmos- phere of “Mine Gallery” on the Field at Bethlehem’s Annual First-Aid Meet 277 The contests were held in the open on Lehigh Field, like an athletic meet. Teams were ranged in a circle in the center of the field and judges watched closely the working out of each problem. The problems ranged from simple administration of first aid, in a case of minor injury, to treatment of compound fractures and rescue and resuscitation of imprisoned mine workers. Typical Field Problems A typical first aid problem given to the mines divi- sion at the meet was described to the competing teams as follows: A man is found in a mine on his back, uncon- scious, his lips and ear lobes are blue, no indication of pulse or preathing and his pupils are dilated. The miner’s left arm is rigid at the shoulder; the elbow stands off at a distance of 2 in. from his body; the shoulder appears flat and swollen and thére’f?s a marked depression beneath the point of the shoulder: the head of the bone under the arm pit is found in an abnormal position. The ends of bone can be seen on right leg 4 in. below knee; the right leg is shorter than the left and out of line from normal position. Treat. The teams were allowed 2 min. to read the problem 10 min. to work it out. Another problem, for which the working time was 5 min., involved demonstration of three methods of rescuing a man found unconscious and his body in contact with a live elec- tric wire. After rescuing, the team was called upon to treat the “patient” for burns and shock and to demonstrate arti- ficial respiration for 2 min. Apart from the first-aid work, other problems involved temporarily sealing off a fire in the main drift of a mine, rein- forcing a loose and dangerous roof and overcoming the various obstacles that confront rescuers in a mine disaster. and Gallery Made to Simulate Mine For the purpose of conduct- ing the mine rescue contest, a wooden gallery 144 ft. in length was constructed on the field, to represent the interior of a mine. As the teams worked out their problems, formaldehyde fumes 278 were generated inside the gallery, to bring about the condition of gas or after-damp which usually de- velops in a mine disaster. The work of the various teams could be observed by the judges through win- dows placed around the side of the gallery. All team members in this contest had had experi- ence in mine exploration and rescue work at a number of mine explosions and fires during the past two years, both in Pennsylvania and West Virginia. Apparatus used by the teams was that approved by the United States Bureau of Mines for mine rescue work and fire fighting and for use in any irrespirable atmosphere. Course in First Aid The first-aid meet is a valuable means of stimulat- ing employee enthusiasm for safety work. However, the meet must have a substantial background of pre- vious educational activity. The first-aid course which Bethlehem gives each year to hundreds of its employees covers a period of four months and consists of two hours of training per week on the company’s time. One hour is spent with a regular instructor and the Blower for Producer-Gas Machines The Morgan Construction Co., Worcester, Mass., developed and put into service, under the supervision of the late Charles W. Lummis, a new type of blower specially adapted to the work of injecting the proper proportion of air and steam into gas producers, with- out the usual roaring noise and without moving parts. Blast Distributing ~ Valve ~~ SN Cross for Distributino ' Gy Pass Steam e hAdjust Blast Valve Under Hood Morgan Blower for Producer-Gas Machines Has No Moving Parts and Is Termed Noiseless THE IRON AGE July 29, 1926 other is used for rehearsal under the supervision of an experienced fellow employee—a permanent safety committeeman who has previously taken the course. Each shop has one of these committeemen designated to keep a watchful eye upon his fellow workers and to spread among them the gospel of accident prevention. As the committeeman is one of the “boys,” he can appeal to the men from their own point of view. The Bethlehem employee’s safety education is two- fold, consisting of first aid and accident prevention instruction. He is trained to rescue men from danger, to give artificial respiration, treat shock, apply tour- niquets, bind up wounds and splint broken bones. In- struction is based on literature circulated by the Fed- eral Bureau of Mines and other first aid authorities. Before bandage and splint work is taught, a simplified but thorough course in anatomy and physiology is given. Through the medium of pictures, charts and the human subject, the instruction is made as practical as possible. Simple names take the place of medical terms and a sharp line is drawn between real first aid and the doctor’s work. The blower is based on a new principle discovered during experimentation, namely that when steam is discharged through a number of very small orifices directly into a Venturi tube, without the use of gath- ering cones, these small streams propel twice the vol- ume of air which can be propelled by the same amount of steam against the highest resistance in a gas pro- ducer by means of a single steam jet blower of the Koerting type, and does this efficient work in compar- ative silence. Normally this new type is found not to use sufficient steam to inject the air required to make good gas. The remainder of the steam is supplied through a bypass pipe to a cross at the top of the blower, as indicated in the accompanying drawing. This bypass is con- trolled by a brass key shown on the left of the cut, which is made separate, to be held by the gas fore- man and thus to prevent irresponsible tampering with the adjustment. By these means, it is emphasized, the minimum quantity of steam is used because the amount is not governed by the needs of the blower. Steam equal to 20 per cent of the weight of coal is found sufficient to gasify high grade coals, although this ratio increases with the fusibility of the ash. The blower is specially designed for use with the Morgan producer-gas machine and means are intor- porated with it for controlling the amount of blast which can be discharged at the center of the fire, con- sisting of a valve under the hood at the top of blast arms. When this valve is closed all the air is com- pelled to pass through the hollow arms of the pro- ducer-gas machine into the large blast ring which sup- ports the brick lining, but if the fire tends to run cool in the center a small opening of the valve serves to correct that tendency. It is locked permanently in position once the proper adjustment is made to suit the coal. The air inlet plate is also permanently locked in the full open position, needing no adjustment. It is provided only to prevent ingress of air when the pro- ducer is shut down. The maximum capacity of the producer-gas ma- chine is ordinarily reached with a steam pressure of 30 to 40 lb. per sq. in. The blower is now supplied as standard equipment on the Morgan producer-gas ma- chines. An A BC description of how steel is made has been printed by the “land Steel Co., Chicago, largely for distribution among the children of its employees. The idea in mind was that children of thousands of steel workers are almost wholly without information as to the exact nature of the work which goes on in the mills where their fathers or brothers are employed. The description of steel-making processes, which is in non- technical terms, was prepared by Walter C. Carroll, vice-president of the company, and copies of the book- let publication will be sent to any person or group who may be interested. Course in Foundry Studies Indianapolis High School Prepares Students to Enter Foundries—Short Course for General Student OR those boys who are willing to doff their white collars and get their hands dirty in an effort to learn the practical as well as the theoretical in foundry practice, Indianapolis Arsenal Technical High School, a part of the public school system of Indiana- polis, has provided a small foundry in which modern methods are taught. Two alternatives are offered the students. If they wish to prepare for advanced training in college, or to acquaint themselves with the general metal-working field, they may elect a two-year course in “Metal Crafts,” six weeks of which are devoted to instruction in foundry work. If, on the other hand, financial ne- cessity or dislike for further academic studies makes them impatient to become skilled foundrymen as rap- idly as possible, they can choose a vocational foundry course extending over a period of two years. In either case, the sequence of study is much the same, except that the longer course gives students an opportunity to become thoroughly versed in foundry practice, whereas the shorter term imparts only a_ surface knowledge. In the foundry, which is 50 x 60 ft. in area, there is equipment for approximately 30 boys. It consists of a small cupola, individual molding benches, tumbling barrel, traveling crane, flasks, hand tools, two core ovens and three furnaces for non-ferrous metals. A heat is poured about every two or three weeks, al- though non-ferrous castings are made almost daily. While no castings for commercial use are produced, a number of articles of value to the public schools are manufactured by students of advanced ability. For example, clamps for lathe rests, bevel gears, stoker fennenvennnnenionencnsennensnnnansnnensrsoonsnsansessousennienn’ Through Doing Jobs Assigned to Them. ONeLOPONSONASSRONADDLNNOGNENSUNANDDONALEROEROOEESEOOALOOEOROOUREUOONNOEAEDONEDOLACEOUNEEOOLSELONGREDOAGOUOEONEOAHOOOERODEERIN en esoNsaoeRnoNENSgONOOEOESDONenOOORNOEFERNORY links, stoker shoes, stoker hooks and anvils are sup- plied by this school foundry. Method of Instruction Students gain a knowledge of foundry art through hearing shop talks and observing demonstrations by an instructor, and through executing jobs or projects assigned them. In the latter case, the student is re- quired first to prepare an analysis ef the job. The mimeographed sheet contains a number of headings corresponding to the operations on that particular job, and he must explain how to go about the work. As an illustration, the sheets on which the boy is to ana- lyze “making a mold,” have the following divisions: position of pattern on the follow board, condition of sand, facing sand, ramming the drag, venting the drag, making the joint, parting materials and methods of using, placing gates and risers, gaggers and soldiers, ramming the cope, venting the cope, getting a lift, use of water in swabbing, rapping and drawing the pattern, finishing the mold, cutting gates and risers, facing dust, cores, closing, clamping and weighting, pouring, shaking out, and final remarks. Before beginning the work of executing a job, the boy is given “operation sheets” detailing the procedure to be followed. These sheets also give information about the tools, equipment, materials, metal analysis, material cost, labor cost, type of mold, type of sand, etc. For example, in making a grooved block in a simple two-part mold, the “operation sheets” are of much assistance. They tell him that he must have these tools: a shovel, a No. 8 riddle, bellows, brush, rammers, “Yankee” slick, heart and spoon slick, trowel, - Knowledge of the Foundry Art Is Obtained by the Students Through Shop Talks and Demonstrations and In executing a job, the student follows “operation sheets,” which out- line the process, step by step GLLseHeneUHeNnnENNNNEERONANANONEHDONEEDENEEDAONDOOERONONDUNEELONELENOOEDIGEUDLONEDDOREOOUEOLANODTOSEDTONEEOENRODERREDOOED ONE LOUEDUDOROODEREOOEREL DOG EIT NODOEDOGUSOEONOO TT OED NUCOROOACEONTRHONEDN "279 AT VANERELEEAAUUODDEANODOLERDOOOORERARODOEGEOODO REL HOORERRUDOOOORNDONDLENEDOO I ONNEDOURESOOODORERIOOREREDOGCSSORARODOEROROODODEOR EDO OOED IDOLE NNN TE SET ONTT OY OETVERT OT HaNTOnesNOETOOnONOOgODD 280 SHENEDEDYAEDEOON FEOASLANOLI LEESON EEUREDAOBRDHOS GI CUEDDESRDLEEDLENLEDUGEOL DORE UONGDURGEROURDDOOHOOD ONDE ONCE DOE ERENED ENED HOU nr pEEN: THE IRON AGE July 29, 1926 HONEEONnOREEnennErenenDennnenennnnerneveasereesenseareneraneeneensereneenennenapoeDenversenecsennessnenereeseenesseenesgnes A Two-Year Course in Foundry Practice Is Open to Students at the Indianapolis Arsenal Technical High School. In another course, ‘metal crafts,” six weeks is devoted to foundry work. The foundry is 50 by 60 ft. in area, and there is equipment for about 30 boys en cenennsennanennneennceenenesnes strike, gate stick, drawspike, rapping bar, gate cutter, sponge and vent wire. One roll-over board, one bot- tom board and a 12 x 12-in. snap flask are essential equipment. In materials he must have molding sand, facing dust, parting sand and water. The time allot- ted for the operation is 15 min., while the labor cost is placed at 8c. The following metal analysis is given: 2.40 per cent 0.60 per cent 0.08 per cent 0.50 per cent Silicon Manganese Sulphur Phosphorus To guide the student intelligently in carrying out this project, the following detailed procedure is out- lined: Ram the drag or nowel 1. Place roll-over board 2. Place pattern on the board 3. Place drag on the board 4. Riddle sand on the pattern 5. Tuck sand against straight sides of pattern 6. Fill drag with heap sand. 7. Pean ram sand against the inside of the drag 8 sjutt ram the drag 9. Strike off surplus sand 10. Bed bottom board 11. Roll over the drag. 12. Remove roll-over board. » the joint 1. Rap lightly on pattern with trowel handle 2. Smooth joint of mold with trowel 3. Sprinkle parting sand 4. Blow parting sand from pattern Ram the cope. Place the gate stick. "lace cope half of flask Riddle sand on the joint Tuck sand around the gate stick Fill cope with heap sand Pean ram the cope Butt ram the cope Finish top of mold and form the sprue 1. Strike surplus sand from the cope 2. Draw gate stick 3. Taper top of gate to a funnel shape and pack the sand firmly with the fingers Get a lift. 1. Jolt the mold 2. Rap the drag 3. Separate the cope from the drag by lifting 4. Place the cope on the pattern board, with the face side up. Finish the mold. 1. Fillet sharp edge of sprue. 2. Make necessary repairs to the cope. 3. Blow all loose sand from both cope and drag. 4. Sponge around the pattern. 5. Rap and draw the pattern. 6. Slick the joint. 7. Cut the gate and finish by firmly with the fingers. Do any necessary patching Clean mold by use of bellows and slicks. “IA Se wire packing the sand HOneneneONESEDENeDsenHOGANnEGNEREeNEnesnsereneenenneeLenNAEnEAETONHLNCNHOEEELUNOROENEONEREOONOLUNOSEOEESEOONANOORFOOESESONONOSEOIORE 10. Apply facing dust 11. Blow surplus dust from the mold 12. Replace cope on the drag 13. Remove snap flask from the mold Place the mold on the floor, jacket, weight and pour Sprinkle loose sand on the floor. 2. Place mold on the floor with a rubbing, twisting motion, so that the mold will settle to a solid bearing 3. Jacket. 4. Weight 5. Pour with medium hot metal, keeping the gate flooded Shaking out (Castings must remain in the sand for at least 15 min.) Short Course Outlined The outline of the six-weeks’ foundry course is reproduced below. Emphasis is placed upon the fact that this is not a hard and fast curriculum, but that it is being changed constantly, as experience demands the modification of certain parts or the inclusion of new material. Indeed, it is the best the instructors yet have arrived at, but should not be taken as a per- fect model. FOUNDING Comparison with other metal-working methods General attitude toward the foundry trades Modern methods. Skill required in foundry trades Small part played by machinery. The art of founding depends upon the hand, eye and mind for results Foundry equipment. Up-to-dateness. Absence of mechanical paraphernalia Modern production methods Demonstration No. 1- MAKING AND POURING A MOLD MOLDING SAND. Composition. Sources of supply Artificial or “milled”? sand Various grades Shop Talk No. 2 TEMPERING SAND. Wetting. Cutting Sulphur Use and care of shovels. Job. No. 1— TEMPERING SAND. Shop Talk No. 3— GREEN SAND MOLDING. 3ench tools and their uses. Two-part bench molds. Roll-over method. Demonstration No. 2— MAKING A MOLD OF A GROOVED BLOCK. Job No. 2— SIMPLE TWO-PART MOLD, GROOVED BLOCK. July 29, 1926 THE IRON AGE 281 Job No. 3— Job No. 27— TWO-PART MOLD, SINGLE BRACKET. MOLD WITH RISER. Job No. 4— ; Bar bells. TWO-PART MOLD, DOUBLE BRACKET. Job No. 28— Job No. 5— MOLD WITH RISER. TWO-PART MOLD REQUIRING FILLETS TO Vise castings. BE MADE. Shop Talk No. 9— Large bracket. MOLDS HAVING MORE THAN TWO PARTS. Job No. 6— Job No. 29— TWO-PART MOLD Rocker arm. Shop Talk No. 4— MOLDS WITH GREEN POCKETS. Job No. 7— MOLDS WITH GREEN SAND CORE. Square washers. Job No. 8— MOLD WITH GREEN SAND CORE. Oblong washers. Job N No. 9— MOLD WITH GREEN SAND POCKETS Surface plates Shop Talk No. 5— DRY SAND CORES. USES. Advantages and disadvantages When necessary. Materials used in making Methods of making. Job No. 10— MAKING DRY SAND CORES Job No. 11— MOLD WITH DRY SAND CORE. Pipe union. Job No. 12— MOLD WITH DRY ‘SAND CORE. Elbow. SAND CORES AND Job No. 13— MOLD WITH DRY SAND CORE. T-pipe. Job No. 14— MOLD WITH IRREGULAR JOINT. Cylinder. (Depressed joint.) Job No. 15— MOLD WITH IRREGULAR JOINT. Cylinder. (Straight joint.) Job No. 16— MOLD WITH IRREGULAR JOINT. Cylinder. (Arched joint.) Shop Talk No. 6—- Explanations and demonstrations of the ADVAN- TAGES AND DISADVANTAGES OF EACH a ae ae OF IRREGULAR JOINT. Job No. 17— MOLD WITH IRREGULAR JOINT. Yoke. Job No. 18— MOLD WITH IRREGULAR JOINT. Bracket with lugs. Job No. 19— MOLD WITH IRREGULAR JOINT. Rocker arm with lugs. Job No. 20— MOLD WITH IRREGULAR JOINT. Blank gear. Shop Talk No. 7— BEDDING-IN METHOD OF MOLDING. Why this method is sometimes necessary More skill required than in the roll-over method Job No. 21— MOLD MADE BY BEDDING-IN PROCESS. Grooved block. Job No, 22— BEDDING-IN MOLDING. Grooved block and cylinder, Job No. 23— BEDDING-IN MOLDING. T-bracket. Job No. 24— BEDDING-IN MOLDING. Stove leg. Shop Talk No, 8— SHRINKAGE AND USE OF RISERS Job No, 25— MOLD WITH RISER Anvil. Job No. 26— MOLD WITH RISER Put shot. Sheet Sales and Shipments for Six Months Sheet steel manufacturers representing approxi- mately 75 per cent of the country’s capacity sold 1,- 474,585 net tons, produced 1,775,1