The Iron Age 1926-09-16: Vol 118 Iss 12

THE IRON AGE ESTABLISHED 1855 New York, September 16, 1926 VOL. 118, No. 12 Savings Result from Pre-Heating Castings Before Annealing and Scrap Before Melting Heated in a Toledo Steel Foundry—Sand Reclaim- ing and Ladle Drying Other Features use of electricity for annealing steel castings in an annealer of unique design, the pre-heating of the scrap before it is charged into the electric melting furnace, and the baking of cores electrically are some of the features of the practice of the Industrial Steel Casting Co., Toledo, Ohio. Recent installations in- clude both an electric an- nealing and an automat- ically controlled oil-fired annealing furnace. This company makes both car- bon steel and alloy steel castings for various com- mercial .uses, but special- izes on the lighter rail- road castings. The electric annealing furnace, which is of a new design, is of the car bottom type. It has three chambers—one for pre- heating, one for heating and a third for cooling. The three chambers are not built in a continuous line, connected end to end. Instead, the pre- heating chamber is lo- cated at the side of the cooling chamber, and there is an open arch be- tween the two so that the heat from the charge in the cooling chamber is utilized in pre-heating Heating units are pro- vided only in the heating zone.* The car bottoms have a loading area of 5 x 9 ft., and are of 5-ton ca- pacity. The cars are moved in and out of the furnace chambers by ; means of chain conveyors running underneath the com nace floor. Traveling dogs on the chain engage the cars through a slot in the floor between the rails. The chain ; . sprockets. " met ee To ‘ae cycle of operations, one being located in each zone and a fourth outside for loading and unloading. The arrangement of the fur- nace necessitates two tracks and two conveyor chains, es . in this manner was . of this type and operating f we deactibon and illustrated in Tue Ino Acs of May 4, 1922, [tse mechanical reclaiming of foundry sand, the age 1217. Bs — 759 Scrap Is Pre-hected in a Bucket in a Pit Before Being Charged into the Electric Melting Furnace, Increasing the Melting Capacity About 50 Per Cent. A bucket of pre-heated scrap is being charged into the furnace one for the pre-heating chamber and the other for the heating and cooling chambers. After pre-heating, the car passes through the back or discharge end of the pre-heating chamber a short distance to a point where the two tracks come together. Then the conveyor chain on the other track engages the car and moves it in the opposite direction to the heating chamber. This car pushes the car that is in the heating chamber on into the cooling chamber without exposure to the outside air, and the one in the cooling chamber out of the discharge end of that chamber. The car is kept in each chamber 8 hr., making a 24-hr. cycle of operations. It is stated that the castings leave the cooling cham- ber in practically a fully normalized condition. After removal, they are allowed to stand about 2 hr., when they are cool enough to be readily handled. The connected load of the furnace is 190 kw. on a 440-volt current. The temperature in the pre- heating zone is 600 to 700 deg. Fahr., und the annealing temperature in the heating zone is from 1550 to 1650 deg. Fahr. The temperature is controlled by a Leeds & Northrup two-point reg- ulating and recording potentiometer, with re- cording and controlling instruments located in a room adjoining the fur- nace. A thermocouple is located in the roof in the heating zone and is connected to the automatic control panel. Another is provided in each car, to indicate when the bottom castings are up to heat. The electric annealing furnace was built by the General Furnace Co. and the heating units and control panel were supplied by the General Electric Co. The oil-fired annealing furnace is a single-chamber car type furnace of the Tate-Jones design built by the General Furnace Co. This has a chamber 12 ft. long and 6 ft. wide and its capacity is 10 tons. The oil and ET inter 0M RARE NPN RE GRRE NE Ep 760 THE IRON AGE September 16, 1926 ee ipply to the ’ itomatically controlled by , & Northrup struments The control equip- emperature of 1550 deg. Fahr., con- . or minus 10 deg. When the g the maximum, the supply of yn but not entirely shut off. When nimum, the full fuel supply is a put on. The temperature record- ! ng ruments are located in the foyn- ! Th l-fired furnace is charged once harge is allowed to cool down to 900 I he furnace ric annealing furnace is used only when running at capacity, as it cannot be oper- nically unless there is sufficient tonnage to tinuously. The oil-fired furnace is more that it can be operated on various sized loads an be run every day regardless of the size of the ermitting good service should the customer want lelivery. When the foundry is running at ca- the oil-fired annealing furnace is held as a spare Pre-Heating the Scrap Before Melting The melting unit is a 2-ton Snyder electric furnace th a tilting-back roof. Scrap, instead of being j rged cold into the furnace, is pre-heated in a steel, rick-lined charging bucket of 3%-ton capacity. The bucke na pit, 8 ft. deep and 6 ft. in eter; then a sleeve, 12 in. in diameter, which is ection of steel pipe, is set in the center of the bucket the bucket filled with scrap. The sleeve is then ed out, leaving a hole in the center of the bucket. The Ladle Dryer of Special Design Is One of the Con- er a crane swings a combined cover and oil burner venient Features of the Plant er the top of the bucket. The flame is directed down . the bucket through the center of a sleeve on the nace is tapped in 1 hr. 45 min. The pre-heating irner. The charge is brought to a temperature of of the charge saves electric current and it is stated 1400 to 1500 deg. Fahr. in 60 to 75 min. and at an oil that it has resulted in an increase of about 50 per cent nsumption of 13 to 17 gal. in the capacity of the furnace, which was 13 to 14 After the furnace is tapped, its roof is tilted, the tons per day when the furnace was charged with cold crane picks up the charging bucket, spots it above the scrap but is now 20 tons or over. Removing the fur- furnace and the bucket is let down so that its bottom nace top for charging is hard on the furnace lining, extends down a few inches into the furnace. Then the as the exposure to the air causes spalling and the lin crap is charged by tripping the bucket bottom, which ing has to be replaced every five weeks. However, the n two sections, hinged at the sides. furnace roof shows good life and has to be relined only Che pre-heated charge is melted down and the fur-_ twice a year. Drying Hand Leadles te Among the interesting features of the foundry are the facilities recently provided for drying hand ladles The ladle dryer, which was designed in the plant, is of steel and firebrick construction, 12 ft. in diameter and about 30 in. high. It has an inner and outer stee shell lined 12 in. with firebrick inside the outer shel! and lined 8 in. with firebrick outside the inner shel! These shells with their lining form the outside of the firing chamber. The dryer is divided into three com- partments and an oil burner for each compartment located outside of the outer shell, 8 in. from the floor line. The dryer is tangentially fired from these bur: ers. There are 24 portholes on the top of the dryer for that number of ladles, which are set inverted ov: the holes. The firing chambers are baffled so that 4 uniform amount of heat is carried up to each porthok The ladles are not only dried but are brought up to 4 red heat of from 1600 to 1800 deg. Fahr., this being accomplished in from 15 to 20 min. The same equip ment is also used for drying bull ladles. A rack provided above for hanging hand ladles. Drying Cores with Electricity The electric core oven is of the sliding door type built by the F. A. Coleman Co., Cleveland. The con- nected load is 45 kw. on a 440-volt current. The ribbon heating units are in the bottom of the oven and were . supplied by the Westinghouse Electric & Mfg. Co. The oven is controlled with Tycos electric contact temper ture control. The oven is set at a temperature of 41° The Classifier and Dust Arrester Equipment. The deg. Fahr., and is automatically regulated for plus and portion of the fine sand reclaimed by the classifier ig minus 5 deg. With this oven it is stated that the foun- used in making cores dry is able to use a cheaper mix and to make better September 16, 1926 THE IRON AGE The Electric An- nealing Furnace Has Three Cham- bers, One for Pre- Heating, One for Heating and a Third for Cool- ing, the Heat from the Latter Being Utilized in the Pre-Heating Chamber ar: Ne aS | Considerable Sav ing in Foundry Sand Is Effected by Mechanically Reclaiming Heap Sand. Coarse sand, discharged from the separa- tor at the left, is shoveled into the mizing machine, where new sand and bonding ma terial are added and the reclaimed sand is used for facing sand The Oil-Fired Annealing Fur - nace with Auto- matic Tempera- ture Control for Use Particularly on Small Cast- ings THE IRON AGE September 16, 192¢ beneath and a portion of this sand is used in the cor room. The dust is collected in the dust arrester this, with the portion of fine sand not used in cores, is carted to the dump. The exhaust fan reates the air suction for the system is located lean air side of the dust arrester. The reci: equipment has a capacity of 2 tons per hr. The reclaimed foundry sand is shoveled sand mixing machine, where new molding sand ing materia] are added in varying percentages After mixing, the sand goes back to the foundry r One of the important advantages claimed for the sand reclaiming process, as carried out im this plant is that there is a uniformity in the facing sand. Guess: work is avoided in determining the quality of the hea; sand and the molders always know what kind of sand they are getting. Fine sand is entirely eliminated and the sand reclaimed shows a uniform grain size under the screen test. Uniformity in the sand, it is stated, has resulted in improved quality in the castings. In addition to reducing sand cost, there is also a saving in labor, as there is less refuse sand to be hauled to the dump than before the reclaiming methods were adopted The sand reclaiming equipment was built by the W. W. Sly Mfg. Co., Cleveland. ~ @ pond What Individual Castings Cost Adopted by a British Iron Foundry in Analyzing Cost of Metal and of Molding—How Overhead Is Included { 69 ’ a be that, because of bled with burned cores. , ; , " S » Molding Sand by Reclaiming £ ld , : 4 - +omne - +» ng sanc en effected by the use of "Ty Y - re c r 7 2 fk ibe saving 18 a2v0ur ov iso u f new sand used. The re- Geom faskeaw ens The foundr; U r ia — Sana ne unary 4 } 2 g id, z a a r - urned ap sand to be reclaimed is dumped rough a grating in the floor to a hopper underneath. hopper this sand is conveyed by air through g e leading to a separator, located above » of a r o—- r of eT r rse sand . a L h —_ 1. Methods BY T. SMITH* HE subject of foundry costs is one of such general nterest and importance that, while an appreciable a f discussion and literature has cen- r rou n recent years, itis felt that no apology r ribing the methods in vogue ata large giis andry for ascertaining costs of individual g I product is mainly castings for locomo- hydraulic machinery. ring into detail, it has long been a mat- urprise to the writer, and I venture to say the plies many of the readers of THE IRON AGE, any executives will put in elaborate sys- tain their costs of machining and erection, ntl; uite content to value the output r ioundry at an average rate per 100 lb. Why st i be so, it is very difficult to follow, because f ently the cost of the castings far outweighs f any machining labor subsequently put into hem. This was the position up to some six or seven years igo at the particular foundry with which the writer is nnected, when a change was decided on. seeking a reliable method, we decided first of t ssect all our costs into three main headings: Molten r a 2. Wages spent on molding res and dressing ead charges Cost of the Metal and Molding ssing them in the order named, it was real- ed that take an all-around figure for meta] was rrect. Our output ranged from the-highest grade lers, using the best kind of pig iron with a Ww proportion of scrap metal, to other items ght was practically the only consideration. ate the factors influencing the metal cost rade of pig iron 2 f pig iron to scrayz ntry we are paying at the present time SOc. to $1.30 per 100 lb. for pig iron, this latter ng the best close-grained material as used for hy- irau! ‘ylinders, designed to stand the heaviest pres- sures. Similarly, according to the type of casting and ecification, our ratio of pig iron to scrap put into the la may vary from 75 down to 20 per cent. At one period it was proposed also to take into con- sideration the effect of material used for headers on the costs but, after investigation, it was decided that the effect was not such as to warrant the additional complication and expense that would be entailed. In the first place we make use of what is known 4s the cupola sheet, a replica of which is shown in Fig. 1, and on which are recorded the weight and descrip- tion both of the metal melted and of the fuel used Under the heading of molten metal cost, however, there are other items of expenditure, such as the men’s time for charging and tapping the cupola, unloading pig iron and scrap and breaking it up ready for use, re- pairs to the cupola, cleaning and daubing the ladles, cost of power for the blower, etc. Standard order numbers are allocated to each of these items and against which all expenditure is booked. With a view to debiting each grade of casting with its correct cost, the output is divided into three grades, A, B and C, the deciding factors being the grade and rice of pig iron and the relative proportions of pig d scrap used in its manufacture. The precise clas- sification of any individual casting is made by the foundry superintendent and, accordingly, in making up the molten metal cost, a division is made into the three headings as shown by Fig. 2. This gives a representa- tive cost of metal during a recent month for the vary- ing grades of castings. For identification purposes, the pattern number of each casting is prefixed by one of the three letters, A, B or C, indicating the grade and type of metal from which it is to be made. It is to be noted that, in using any figure for out- put, it is of course understood that this refers to good astings only, any defective ones being put back into the cupola for remelting. Their weight will be ex- cluded in the second melt, since it will already have been taken care of in the previous charge. We have thus the cost of the metal for each type of casting up to the stage of pouring into the mold, and our next question is the wages spent on molding, core-making and dressing. For these operations piecework prices are fixed by the superintendent and thus become a definite charge against the particular castings to which they refer. Incidentally each workman, on commencing a new job, nr r an an cas September 16, 1926 given a card on which are full details as to the iantity required, pattern number, piecework price, , and on which is booked the actual time spent on it. ’n completion of the job, the cards are returned to the tice, first, for his wages to be made up and, secondly, r the details to be entered in the cost records. Overhead Charges Overhead charges may be considered as the whole f the remaining expenses pertaining to the running | IRON FOUNDRY DAILY CONSUMPTION a ice ce Fig. 1 (Above) — Replica of the Cupola Sheet Fig.2 (At Right) —Molten Metal Cost Sheet for Three Grades of Castings [DIRECT WAGES | pace ma S a | tons | # | $ | @ | A Go | 3/%0 | /6f0 | 676 B Ir orn | C IPP | gor Patr.No. 86! Fig. 4 (At Right) —Details of Cost for Individual Castings, a Bed Plate Being Used as an Example ME a QUAN. |WEIGHT| ‘Coe heoupine | CORES Tos % | $ of the foundry. Our practice is to total them up each month and divide the sum arrived at by the gross num- ber of hours worked by the men, booking their time directly against productive work. This gives a rate per hour which we debit against each job according to the time spent on it. We consider that the time a job takes in the foundry is the fairest basis of charg- ing overhead, since the majority of the items, such as taxes, insurance, heating, supervision, etc., are fairly constant week by week and appear to us to have little comparison to the weight of the output. | In the months during which the amounts shown in Fig. 2 were expended, our overhead charges amounted to $4,772 and the total number of hours worked, booked on the men’s cards against their various jobs, equaled 13,635 hr. We therefore debited the sum of 35c. per hr. against each job according to the time spent on it This figure is of course watched closely and minor THE IRON AGE 763 IRON FOUNDRY ACCOUNT FOR MONTH ENDING _ - --. --- adjustments are made from time to time, but we are satisfied that it helps us to get a truer cost than any other means we have yet hit upon. The writer has purposely refrained from a dis- cussion of the general subject of overhead expenses since, first, every foundry owner knows perfectly well of what they consist, and, secondly, so much has been written from an academic and non-practical point of view that the mind tends to become befogged with what is, after all, a relatively simple question. Gross Cost of Each Grade Apart from making up individual costs, a summary of the gross cost of the total output in each grade is made up each month along the lines indicated by Fig. 3. The individual costs are made up along similar lines and the details in Fig. 4, relating to a bedplate for an electric lighting plant, may be of interest. The procedure adopted in quoting for new work is first to estimate the weight. From previous records it is ascertained whether similar castings have been MONTH ENDING “OENERA S9f | 3/F0\, 14.76 1§3 \/447 | 427 43? |\PRT is Fig. 3 (At Left) —(jross Cost of the Total Output of Each Grade for a Month RHEAD| TOTAL {cost PER ICHARGES| COST | 100LB. IRON FOUNDRY COST RECORD Dre. AZ384 pescription Bed Clay CHARGES) COST | _—— (MOLTE DIRECT WAGES |_| bvenneal TC wi lee TAL es TOTAL | RH TOTAL COST made, and, if so, the wages cost is noted and the price built up with the aid of the current costs and charges. Alternatively the requirement is submitted to the foun- dry superintendent, who decides the grade and fixes the piecework prices at which it shall be made. From this information the total estimated cost is arrived at, as well as a quotation. With reference to patterns, in the normal course, the whole of the cost of the pattern shop is charged against the foundry and included in the overhead charges. Exceptions are occasionally made in the case of orders requiring intricate and expensive patterns, a separate cost being recorded and spread over the number of castings ordered. In conclusion, the methods outlined herein have proved quite satisfactory in service and, as a result, we are able to submit quotations with a much greater degree of reliance than hitherto. + vemeres ; ; . | & ij i ean ee ede a RE aa nh BT SWOT aye MEPL. PAY ee COM REIN Re AIRBIN HE O te cated) mmwetle. -~ Alloy Iron Made Electrically Castings Containing Nickel and Chromium Have Unusual Properties—Longer Life of Alloy Iron Ingot Molds NI he most interesting fields for future metal- () irgical development is in gray iron castings nade in electric furnaces. Rapid progress in sections of the country is being made in this with some highly important results. In a small indry in Western Pennsylvania, a group of zealous orkers is gradually developing a line of electric gray castings which possess many features of interest. Primarily engaged in making ingot molds on a arge scale for many of the leading steel-making com- panies of the country, the president and directors of the Vulean Mold & Iron Co., at Latrobe, Pa., leased a small foundry near their principal plant, with a view to developing some line of iron castings. The plant had been used for making pipe fittings. After canvassing the field, it was decided to install an elec- tric furnace for producing special products in gray ron. The regular product of the company is ingot molds designed chiefly for the manufacture of high-grade soft steels, alloy steels, and tool steels, which consist of both split molds and solid molds of the latest type. During some research work on various grades of cast iron to determine their suitability for ingot molds, alloy cast iron was made in a crucible, melted in a resistance type electric furnace. The unusual properties of this iron were at once noted and it was decided to go ahead with an experimental study of this material. It did not take long to determine that there was a consider- able field for this type of product which led to the easing of the nearby foundry, mentioned above. The foundry was remodeled and a considerable amount of new equipment was added which included traveling crane and monorail systems, modern molding and core-making machinery, and other equipment de- signed for the production of these special castings from one pound to one ton in weight. The most important addition, of course, was the installation of a %-ton Moore electric furnace, particularly designed for melt- ing cast iron and having a complete automatic control system. A cupola is available, also, for making equip- ment for the No. 1 plant and other ordinary gray iron products. Some of the Special Castings Made The electric furnace has a capacity of 10 tons of alloy cast iron and the cupola about 20 tons of gray iron castings per day. This plant now produces all of the split ingot molds which the company manufac- tures, made of both cupola iron and alloy cast iron. The chief aim, however, is the development of electric furnace alloy cast iron and already a large number of castings have been placed on the market. These include die blocks, hammer dies, automobile parts such as pistons, cylinder blocks, special molds for the glass industry, heat-resisting iron for furnaces and ovens, and wear-resisting castings such as pipe balls and piercing points. In all cases where comparative re- sults were obtained, this alloy iron has proved itself superior to the ordinary cupola iron. The experience of the company in reaching out into this field has been an interesting one. The first small castings which were made were the horns for loud speakers for a prominent maker of radio apparatus. These are, of course, thin-walled castings. Unusual success was at once attained, the surprising feature being that they were made from Bessemer iron, elec- trically melted. Thus, the theory that high phos- phorus is essential to the pouring of thin sections was exploded. It is understood that this is the first time that such castings had been made from Bessemer i: Incidental to the production of these castings was the use of a special apparatus by which the cores for t} horns were made by blowing sand into a core box Another casting of special interest being made fro: electrically melted and treated Bessemer iron a small air-cooled cylinder of specially thin section Many hundreds of these are being successfully pro- duced. A feature is their particular soundness, de: sity and close-grained structure with ready machin- ability. Alloys Change the Structure The company has had some interesting experien in making alloy castings by this process. Various per- centages of chromium and nickel, either alone or in combination, have been incorporated in certain cast- ings, and their marked properties have made them desirable. As is well known, the presence of these alloying metals in gray iron decidedly changes the structure of the iron, imparting both increased strength and hardness, and yet rendering the machin- ability better, if anything. In the manufacture of this alloy iron, the Vulcan Mold & Iron Co. has found it highly advisable to use an electric furnace. A large recovery of the alloys is made possible by this method, due to the high tem- peratures and to the absence of oxidation. It was also found that control of composition could be made surer and that, when the proper analysis for a given casting was found, it could be readily duplicated. The very desirable condition of low sulphur content is also attained. Alloy iron of very low carbon content, almost on the border line between iron and steel, has been made with comparative ease. Melting takes place in the usual manner, the charge generally con- sisting of pig iron and steel scrap, the alloys being added just before tapping the heat. A number of unusual properties have been produced by varying the amount of alloys together with changes in the percentages of the ordinary constituents of cast iron. In castings of very small sections, it is possible to produce an iron having a dense, close-grained struc- ture, pearlitic in character, which can be machined readily at a much higher Brinell hardness than 's possible with ordinary gray iron. This is done by the elimination of hard spots, chilled corners, and by hav- ing the graphite more evenly distributed and in 4 more finely divided state. Castings of large sections have been made with only a slight variation in hard- ness from outside to center and machinable at norma! speeds with Brinell hardnesses of over 300. These castings are very strong, tough, and resistant to wear. Where high strength is desirable, castings have been made with tensile strength on a standard A.S.T.M. test bar of over 40,000 Ib. per sq. in., and a transverse strength of 4550 Ib. Practical experiments on heat-resisting alloy cast iron made with high percentages of alloys have shown a freedom from excessive oxidation at high tempera- tures. An experiment conducted under similar cai ditions of temperature and time on pieces of alloy irom and ordinary cupola iron showed an oxidation loss of 2 per cent on the alloy iron and 30 per cent on the cupola iron. Various customers in various fields are trying ov‘ these types with satisfaction and success. There 4P- pears to be a large demand for such castings, especially when made under the conditions obtaining in an elec- trie furnace, because of the uniformity in control of the analysis, and the better recovery and thorough 764 September 16, 1926 THE IRON AGE 765 Structures of Typical Alloy Iron Castings PTOTOMICROGRAPES Represent Metal Etched in 4 Per Cent Nitric Acid and Taken at 150 Diam eters. From left to right they are: Alloy iron die blocks, hammer dies, etc., machineable at Brinell 302; tensile strength 38.750 Ib. per sq. in. Alloy iron pistons and cylinders, rapidly machineable at Brineil 196. Heat-resisting alloy iron for furnaces, ovens, ete. hard. mixing of the alloys with the iron, made possible by the higher temperatures. Ingot Molds of Alloy Iron The company has had some interesting experience with the production of split ingot molds made of electric furnace gray iron, both plain and alloy. A number of these was made and sent to a few regular ustomers without their being informed of the different character of the metal. A canvass of the field, after 1 reasonable time, resulted in many expressioris of ap- proval of the decidedly improved character and life of certain molds in use. It developed that these special Shortcomings of Technical Education Much difference of opinion appears in some of the preliminary reports of the Society for the Promotion of Engineering Education, in connection with its in- vestigation of the present status of its field. The statement is made that we have concentrated most of our facilities in colleges designed primarily to fit men for planning, investigatory and advisory service of professional grade. Craftsmanship, trade training, ap- prenticeship and foreman training are provided for but meagerly. Training for the lesser technical periieate not permanently attractive for college men, is a inadequate. For the operating type of activity littk istincti ining is given. w altigtietion ef seas at the weakest end of the scale is taking place. The whole situation peeaaines the integrity of the engineering degree and over code the colleges with men for whom their distinctive type of training is inappropriate. What Is Needed Now Most immediate of the needs of the moment is to provide for large numbers of young men a briefer, more practical, more intensive training than that of an engineering college. It must be a training broader than that of a trade school and quite distinct from that of an academic junior college. Of the two types of young men to be provided for in such schools, one already is employed in industry but is desirous of giv- ing a limited time to intensive training, to facilitate his progress in chosen lines of activity. The other is the ndary school graduate who does not desire an sieall theoretical preparation, but seeks to enter the | | Wear-resisting alloy iron, strong and ones were superior to the ordinary cupola made product. From this brief recital of the experience of one company, just entering this field, it is evident that the surface has only been scratched. The refining possibilities of the electric furnace is one factor in producing better castings, the high temperature pos- sible for thin sections is another. Then the radically different metal obtainable, under the foregoing favor- able conditions, by the addition of alloys, is the basis for the prophecy that the gray iron industry, because of the uses to which its product may be put, may undergo decided changes in the next few years, industrial field through its junior technical or super- visory service and work his way up. Graduates of a small group of technical institutions now doing excellent work in this field are able to enter active life at a fairly early age. They have assured earning power, with ample time for thorough grounding in experience, and with willingness to accept the regime and environment of operating organiza- tions. They rise to positions of considerable responsi- bility and in some cases achieve distinguished success, though more often in the operating field than on the professional side. Topics to Be Strengthened General consensus of opinion was had in a question- naire, to the effect that economics is the most useful of the cultural subjects not now adequately covered. Much evidence points to the conclusion that neither the type nor the extent of economic training in engi- neering curricula is commensurate with the vital im- portance of the economic phases of engineering work. Only after being out of college for several years does the graduate acquire sufficient familiarity with eco- nomic thought to be able to make use of it. Specific instruction in administration and management prob- lems is regarded as highly desirable, whereas foreign languages as such are considered of comparatively smal! value to the engineering student. A convention and show of road builders will be held in Chicago, Jan. 10-14, inclusive, 1927. Charles M. Upham, Raleigh, N. C., is business director. SPH Bnd Creates Supply of Skilled Labor Chicago Foundry Conducts Apprenticeship Course in Molding. Pattern-Making and Tool-Making—Both Class Room Instruction and Shop Training Provided BY ROGERS A. FISKE* share of our skilled workers The ORMERLY a larg« fam. from the industrial centers of Europe. war and, later, restriction of immigration cut ort this supply, and in the meantime our industries ive continued to expand and the demand for skilled abor has grown from year to year. The manufac- turer who, in 1914, had in his employ highly skilled and loyal workers fortunate if he still has many them in his shoy These men, however, are grow- old, and the time is fast approaching when age | strike them dow: These were among the considerations which brought apprenticeship training forcibly to the attention of the Pettibone Mulliken Co., 140 South Dearborn Street, Chicago, manufacturer of frogs, switches and crossing material, and operator of a manganese steel foundry Fat 1924 tudent training course was put into peration, following a thorough study of other courses The purpose then, as it is today, was to create a source of skilled labor. The training course is directly under the supervision of G. E. Berg- strom, employment and personnel manager. A. M. Cor- nell, works manager, has general supervision over the course, and E. W. Powell, chief engineer for the com- pany, plays an active part in its operation. : The course is conducted independently of the public school system, mainly for the reason that none of the Chicago manual training schools is located in the neighborhood of the plant. Although a high school education is not a prerequisite for admission to the course, it is considered highly desirable. In fact, every effort is made to bring to the attention of high school students the fact that the training course is available to those boys who are mechanically inclined. This is accomplished by visits paid to the various high schools in the city by Mr. Bergstrom, at which time he ad- dresses the boys and points out to them the advan- tages of further education and training by a company which offers them an opportunity to learn a trade. Invitations are extended to high school students to visit ; Two Foundry Apprentices in Their Second Year Preparing a Floor Mold for a Commercial Casting 766 September 16, 1926 the plant, and many do so. Another source of recruits is the sons and relatives of men who are already em- ployed in the shop, No Effort Made to “Sell” Course Application for enrollment in the student training course must be made in person, and the applicant must be not less than 17 years of age. He must also be The Apprentice Shown Above, Who Has Com- pleted One and a Half Years of His Course, Is Able to Make Practically Any Pattern Required in the Foundry A Definite Sched- ule of Work Is Established for Each Type of Machine to Which the Apprentice Is Assigned - able to prove to the company’s satisfaction that he is honest, of good behavior, physically sound and good moral character. A boy, upon making application, is examined to obtain a general idea of his turn of mind. He is then taken into the shop, where the various phases of the work are explained to him. In many cases parents or guardians accompany the boys. No effort is made to “sell” the course. In fact, just the opposite is true; in the foundry it is pointed out that the work is dirty and often strenuous. During his first visit to the shop the prospective student’s attitude is closely watched, and if, after further questioning, he still shows interest in the course, he is placed on probationary work for a period of from three to six months. If he has shown the proper attitude toward his work and the ability to make progress in it, the stu- dent may, at the end of three months, together with his parents or guardian, execute a student mechanic’s course agreement with the Pettibone Mulliken Co. For students who are slow in grasping the fundamentals of the course the probationary period may be extended to six months. ; Upon entering the course the student is given a physical examination, and this is repeated at intervals THE IRON AGE in accordance with the rules which govern the other men in the shop. The student is always started in the department for which he expresses a preference. The agreement, which must be signed by the stu- dent at the end of his probationary period, may be seen by him at any time upon his request. This, although in reality a contract, binds only the company, inasmuch as the attitude has been taken that if at any time a student becomes dissatisfied, it is better to let him with- draw and leave the service rather than to make any effort to force him to discharge his obligation. The agreement, which is signed by the works management, the student and his parents or guardian, states that the student accepts the offer of the company to afford him the opportunity to learn a trade. The student, in turn, promises to promote the interests of his em- ployer during his period of apprenticeship. He also agrees to pursue the prescribed course of instruction and to do a reasonable amount of home study. The employer promises adequately to train and instruct him in the principal operations of his chosen trade and also to pay him wages specified under the terms of apprenticeship, which are attached to the contract. The agreement is in force during the number of years required for the course, including the probationary period of from three to six months. It also specifically states the number of hours the apprentice must work, not including the time devoted to home study. Students Required to Make Up Lost Time The terms of apprenticeship recognize that time may be lost by the apprentice as a result of serious illness or a decrease in working hours or entire sus- pension of work dictated by the state of business, At the discretion of the employer, the student may be required to make up any part of, or all, lost time before being permitted to enter the next stage of training. Good deportment, attention and earnest effort are demanded of the student, and his work dar- ing each division or “period” of the course must be up to the company’s standard. The agreement also provides that the student shall be subject to shop rules in force at the time of commencing the apprenticeship and to any additional regulations which may be adopted from time to time. A student may be discharged from the company’s employ for unsatisfactory work, incom- petency, improper conduct within or without the shop, social disease, indifference to shop rules and regula- tions, or insubordination. A student who has been suspended on account of business conditions has the option of resuming train- 768 ing before any additional students are enrolled, but to obtain this preference he must report at once when notified by the company that a vacancy exists. Such tools as are required by the student for his personal use in his chosen trade are supplied by the company at cost. On the company’s regular pay days the stu- dent receives wages for the actual hours of service, including time spent in the classroom. His wages are computed on an established basis for the training which is subject to any general wage adjust- ment during the apprenticeship period. urse, Apprentices Are Given Vacations [he students have the right to terminate the agree- with the company for personal reasons. When due proof of such reasons is submitted, the company will furnish a statement cancelling the contract with- it stigma to the student. At the completion of the course a cash bonus of $100 is paid to the student, in iddition to his regular wages, as a reward for the faithful discharge of his obligations. All students who, during their respective terms, have been in the ervice of the company for a period of one year are entitled to a vacation of one week with pay accord- ing to the period rate. A student is allowed 14 days’ leave per annum for sickness. Should the student be absent for a longer period, he must serve the additional time before he is permitted to enter his next period. In the event that a student is transferred from a day- rate department to one on a piece-work basis, he is paid the full piece-rate schedule accorded to other employees doing the same class of work. He is guar- anteed, however, a minimum wage equal to the hourly rate set for the period in which he was engaged at the time of the transfer. Three Courses Are Now Available The present apprenticeship training program em- braces three courses, one of three years for student molders, one of four years for student pattern-makers and another of four years for student tool-makers. Plans are now under way to add a course in black- smithing and forging. The course in molding is sched- uled as follows: Clerical work 3 weeks Making small cores 12 weeks Making large cores 12 weeks Machine molding 3 weeks Bench molding 12 weeks Electric furnace department 6 weeks Annealing and cleaning 4 weeks Dry floor : 8 weeks Helping molde: 6 weeks Floor molding 44 weeks Manganese department 3 weeks Floor molding, gray iron department ; 29 weeks Lectures, mechanical drawing and math- ematics 10 weeks Vacation 3 weeks The pattern-makers’ course is as follows: Helping: shellacking, stripping and turn ing core prints and small patterns 14 weeks Core room work 4 weeks Foundry floor work 23 weeks Pattern-making ; 113 weeks Metal pattern-making 8 weeks Mathematics, mechanical drawing and lectures . ; ae tate 12 weeks WOE gure + 00s 6k%s 0c nen cde 4 weeks The tool-makers’ course is scheduled as follows: Tool crib, hack saw and band saw. 6 weeks Switch stand drill press 8 weeks Tool room drill press 4 weeks Lathes oe . 26 weeks Boring mill a are re 23 weeks Drilling machine 21 weeks aes, ee 12 weeks Planer ; > ode REA bb Oh ode cee bee 21 weeks py eee. eae 9 weeks OT a re 8 weeks Manganese-grinding . 10 weeks Bench and floor work....... 26 weeks Planers in rail shop 4 weeks a ee Ar ee ee 6 weeks Wen OR COTIMR. 5 ooo cckcccvcesse 8S weeks Mathematics, mechanical drawing and SOGEOD acc chetackes — he's a 12 weeks Vacation ox 4 weeks Those who planned the courses did not forget the value of lectures and instruction in mechanical draw- ing and mathematics while the student is learning his trade. Classes are held three hours each week, one hour being devoted to mechanical drawing, one hour to mathematics and one hour to lectures. Standard text books are used. THE IRON AGE September 16, 192¢ The instruction in mathematics and mechan drawing is under the supervision of the enginee: department. The mathematics does not go be, ordinary shop trigonometry, mensuration and gg: etry. The primary purpose of the mechanical drawi course is to give the boys a clear understanding blue print reading. It is not intended to make draf men of the students. The lectures are given pri: pally by the foremen of departments in which apprentices are working. In the lectures, which mig better be described as “talks,” the foremen explain practical solutions to shop problems and point ov ways in which the students can improve the qualit, and quantity of their work. Compensation of Students Changes Every Six Months The rate of compensation for students is shown i: the following tabulation: Student Pattern-Maker Student and Student Molders Tool-Makers First period of six months.... 40c.perhr. 25c. per hi Second period of six months.. 45c. perhr. 30c. per hi Third period of six months... 50c.perhr. 35c. per hr Fourth period of six months.. Fifth period of six months... 624c. perhr. 45c. per hr Sixth period of six months... 70c.perhr. 50c. per hr Seventh period of six months............ 55c. per hr Eighth period of six months............. 60c. per hr When the student enters a department he is put directly under the supervision of the man in charge. who is responsible for his safety and progress in the department and is also expected to make an effort to guide his personal habits. At stated intervals lectures are given to the students on general business methods, particular attention being given to the organization of the Pettibone Mulliken Co. and the standards it has set for the quality of its products. All through the apprenticeship course the employment and personne! manager keeps in touch with the parents or guardians of the boys by making personal calls at their homes Consequently he is able, in most cases, to keep a close check upon the boys when they are absent from the shop or the class room. 55c. perhr. 40c. per hr Make Inspection Trips to Other Plants Visits to other manufacturing plants are arranged so that the students will not become narrow as a result of knowing only the practices in the shop in which they are receiving their training. Within a given time after an inspection trip each student is required t prepare a written report on what he has seen and learned. This is graded, and the student advised of his standing. Throughout the course, weekly reports on class room and shop work are sent to the parents or guardians. No effort is made to stimulate compe- tition by posting grades so that the students may know the standing of others taking the course. At the completion of his course the student is given a diploma. This is neatly engraved on a good grade of parchment, worthy of display and in keeping with the graduate’s warranted pride in what he has achieved. The diplomas are signed by the foreman of the depart- ment in which the student has been an apprentice, and also by the works manager, the chief engineer and the employment and personnel manager. It has been found that some boys who take a course have had previous experience, and it has been the prac- tice in the past to give them credit for work which they have already done, thereby reducing the period of apprenticeship. Although this practice seems un- avoidable in some instances, it is not favored by the management. Obviously every boy entering the course cannot be- come a department foreman or a works manager. The students who are fitted for higher positions are quick- ly recognized, and their progress is watched closely. The other boys are carefully supervised with the idea of developing them into first-class mechanics of the type that can be relied upon for accuracy, quality of workmanship and a long period of faithful service to the company. With this latter point in mind, it is sometimes found necessary to extend the training RED LEE es reea renee ser eee neeRtneNNE )YoUrety pewannenrenerete ty: (Concluded on page 823) aa ed Foundrymen to Meet in Detroit Many Exhibitors at Annual Meeting of American Foundrymen’s Association, Sept. 27 to Oct. 1. International Congress a Feature in itself, but this year the prestige will be enhanced by the convening at the same time of many foundrymen and metallurgists from several European countries. The thirtieth annual convention and exhibition of the American Foundrymen’s Association and the second international foundrymen’s congress will meet simultaneously in Detroit the week of Sept. 27. Preparations are nearly completed for an event which promises to be unique and epochal in American foundry history. A technical program of 24 sessions, covering every field of foundry activity, has been pre- pared. At many of these, some of the prominent foreign metallurgists will present papers and discuss topics. The American contributions to the program will fully sustain the reputation of former occasions. The exhibition, always a feature each year, will be the largest ever held. In the spacious buildings of the State Fair Grounds adequate space will be available. On the following pages will be found a list of the exhibitors and what they will offer. A new departure is the reproduction of photographs of many of the representatives of the leading companies. The technical program was published in THE IRON AGE, July 15. , LARGE convention and exhibition of American foundrymen is always an important event Exhibitors at Foundrymen’s Convention, Products They Are Showing and Representatives Attending ApVANCE Miru.ine Co Chicago Booth 19 i 1 Core binder and cores Represented by: A. W. Hicks and D. T. MeGrory ApamMs Co., Dubuque, Iowa. Booths 423 and 425. 10 in. x 32 in. Adams jolt squeezer, 16 A\Gnew Evecrric WELoInc Co., Inc, Milford in x 42 in. Adams jolt squeezer (shown for the Mich Electric welding apparatus and equip first time), Adams pneumatic sand riddle, Adams ment cherry snap flasks, Adams steel jackets miscellaneous equipment Represented by Aim Repvucrion Sates Co., New York. Booths Lester Demkier and W. J. Spensiey 224 and 226. Airco 99.5 per cent pure oxygen, kk Ree Preeti KEMPNER Philadelphia Vice-President Equipment Co. Mishawaka, < L. MUNN Vice-President Arcade Mfg. Co. THE IRON Air etylene in cylinders, Airco-Davis- welding and cutting torches, regu- Airco-Davis-Bournonville No. oxyacetylene machine cut- Airco-Davis-Bournonville demonstrations Represented by: advertising department ; C. D'W district manager; Fred Bowers, LeRoy Edwards, industrial L. P. Naylor, | supplies, liagraph for > operation), ve discharge manifold ste el and castings. Alstyne Detroit Cummings and sales engineering department ; tive AJA ELECTROTHERMIC Trenton, Booth 127 800-lb ta meiting turnace CORPORATION, non-ferrous metal (shown for the first time) and 175-lb., 30-lb. and 15-lb. ferrous or non- ferrous metal melting furnaces tepresented by G. H. Clamer, president: E. F. Northrup, president and technical adviser; Dudley Willeox, secretary and treasurer AJAx Meta Co., Philadelphia. Booths 123-126 \jax brass and bronze ingot metals and castings, mode therefrom Ajax Bull Bearing alloy, Ajax- Wyatt electric furnace Represented by: G. H Clamer, president and general manager; W. J. Coane, vice-president and sales manager; Frank M. Willeson, New England and New York State ep! ntative Zeno D. Barns, Ohio and Michi- in State representative; Henry Gieseke and W ul Adams, representatives of Ajax-Wyatt u i Ss ALBANY SAN & Suppity Co Albany, N. Y. Booths 44 and 4¢ Jersey fire sand, French sand (brass), Jersey fire clay, Windsor Locks sand, dry blast sand, sea coal facing, core compound ind foundry supplies ALLEN AIR TURBINE VENTILATOR Co., Detroit. Exhausting equipment produced from copper and standard equipment in regular and special] finishes. Represented by: Perry F. Kimball, president and general manager; L. P. Halleck, engineer Hugh T. Wreaks and C. B. Brown, salesmen ALLOYS & Propucts, Inc., New York Booth 19%. Special alloys and novelties Represented by Gilbert T,. Mason; John A. F