The Iron Age 1926-10-28: Vol 118 Iss 18

THE IRON AGE New York, October 28, 1926 ESTABLISHED 1855 VOL. 118, No. 18 Urges International Understanding Judge Gary Recommends Cooperation with Foreign Steel Interests—Queen Marie Pleads for World Amity— Institute Banquet Is Colorful Affair out other countries. . What we need in the world today is the real feeling of peace and friendship. As long as we have not that, we shal! never be able to build.” These words from the mouth of her majesty, Queen Marie of Rumania, who was guest of honor at the ban- quet of the American Iron and Steel Institute, sounded the keynote of the fall meeting of that body, which was held at the Commodore Hotel, New York, Oct. 22. Both by reason of the presence of foreign guests, which, be- sides the queen, included Dr. August Thyssen, son of the late German steelmaster of the same name, and also because of the recent formation of the European steel cartel more than usual attention was given to international problems. In addressing the opening session of the institute in the morning, President Elbert H. Gary chose as his subject, “Friendly Cooperation.” He pointed to the passing of destructive competition in the American steel industry and the progress which has been made in the direction of conciliation and cooperation, and he recommended a similar attitude of good will and friendship toward world business relations, reinforced if necessary, by international conference and open dis- cussion. With Government sanction, a fair under- standing can be reached with foreign business interests, he believes. In making this suggestion it was evident that Judge Gary had the European steel cartel in mind, although he did not specifically name it. President Gary’s remarks were,.in part, as follows: “It is appropriate to congratulate ourselves and each other on what the iron and steel industry of the United States has accomplished during the last 20 years or more in the direction of conciliation and co- operation, perfectly proper, as indicated by the later decisions of the courts and Governmental administra- tors and speakers of the highest intelligence and re- nown. Everyone present will remember the days when the steelmasters of this country were engaged in in- dustrial war; when the hand of the steelmaker was raised against his brother; when practically, in the steel business, might made right; when the Golden Rule was subordinated to the supposed pecuniary, if temporary, success of might and strength; when jeal- ousy, discord and brutal antagonism prevailed; and all this to the ultimate loss of all who were engaged in the strife. Suggests Policy of Conciliation in World Business Relations “The millenium has not arrived. We probably shall not see it in the near future, but conditions all over the world are improving. People, on the average, are grow- ing better; and they are becoming more intelligent and better educated. This makes for legitimate advance- ment, for prosperity and happiness. Adversity result- “N OWADAYS, no country really can exist with- 1191 ing from the world war and contention, has humbled the vast majority of the people and uplifted their souls. The international conferences which have been held during the last two years, including especially the one before the League of Nations, heretofore mentioned, have had a striking effect upon the minds of the people all over the world. “We have heard recently of considerable dis- cussion relating to anticipated competition be- tween the iron and steel manufacturers of the United States and their foreign competitors; but it is believed that should it become necessary an international conference would be held between all these interests, and a full, open discussion indulged in, after which a fair understanding could be reached. Of course, no agreement be- tween the different interests relating to prices could legally be entered into without the sanction of our law administrators. But if the necessity arose, it ia thought the approval of the public authorities of thie country, if they were fully informed and permitted to express opinions on the subject, might be obtained. “Conferences, open discussions and reasonable bases for maintaining peace and prosperity in business mat- ters have become popular and desirable all over the world. It is not too optimistic to assert that a plat- form of peace and prosperity could and will be adopted, and if so would be adhered to.” The Queen Has a Message HE center of interest at the banquet, which was held in the evening in the Grand Ball Room of the hotel, was the royal guest of honor. The floor of the hall was crowded with tables, at which sat 1516 mem- bers and guests. The balcony, which extends around the entire room, was filled with ladies—the wives, daughters and other feminine guests of institute mem- bers. Since the queen, with her entourage, did not enter the hall until the conclusion of the dinner, the atmosphere was charged with more than the usual amount of expéctancy. Her arrival, therefore, lent a dramatic touch to the scene. Her reception on the part of the assembled audience was cordial and prolonged, but lacked the spontaneity and warmth which was later to be hers when she delivered her address. It is perhaps not far from the mark to say that the first reaction of those present was one of curiosity—a desire to see an international figure in person, accen- tuated in this case, no doubt, because she represented an old world institution, royalty. There was somewhat more than the usual amount of ceremony and formality in the banquet arrangements and program. This was commonly accepted as reflecting a spirit of hospitality rather than obsequiousness, as an expression of esteem M4 8 cu Paria ate cage ee aaa Mth koa i) a Mien 2 i ea aes 1192 THE IRON AGE for the crowned emissary of a foreign nation rather than as a compromising of republican ideals. If there was any feeling of stiffness or embarrass- ment on the part of either guest or audience, it was quickly dissipated when the queen arose to speak. Talk- ing extemporaneously in excellent English, her native tongue, she promptly put everyone at ease. Her lan- guage was simple, unaffected, direct and to the point. Coming from a country where the divine right of kings is entrenched in age-long traditions, she showed re- markable adaptability in sizing up an audience schooled in democratic principles. Under the influence of the magnetism of her personality, those present soon be- came unconscious of the glamor surrounding her royal position and became interested in her as a woman, as a leader and as a student of world problems. Speaking of her country, she called attention to its strategic importance in relation to Russia. She said: “T cannot help feeling that what I can do for my country is to make you feel that we exist, to feel that POVUUSAUTANTNALLENYONEDESAUESAONAA ANTONE NET ETA TEATT ND October 28, 199¢ quarrel. Therefore I think today we al! must forget there ever was a war. Schwab Speaks 7s queen was given an ovation at the conclusion of her address. A spontaneous demand then arose for a speech from Charles M. Schwab, who was a banquet attendant for the first time in several meetings, [t became so insistent that Mr. Schwab arose amid the acclaim of the assemblage, which obviated the necessity for the formality of an introduction. A born public speaker, he was in unusually fine form. If there were any present who were overawed by the distinguished guest, he was not among them. With conspicuous cour- tesy and gallantry, but without at any time prejudicing the dignity of his American citizenship, he gracefully extended his compliments to the queen, adroitly weay- ing his witticisms around her personality, much to her amusement and that of the entire audience. With characteristic skill in spreading the gospel of good A{YUOUNTUMNMMULOUONATTNAAUEOOERESGNOTOR UL ESR 0000 ENN SULLE ET HOREESET UA ENSTE OTA RAULT TOME TO ESOETO TET ONAN ENES ANETTA AH NESE HAMA AANA LT Business Outlook Is Favorable—Gary ‘é N basis of the volume of busi- QO ness now being secured by the United States Steel Corporation, the industry as a whole at the present time is entering new orders for ap- proximately 80 per cent of its normal capacity This, when all things are considered, should be viewed as quite satisfactory If the industry could be guaranteed continuous operations equa) to 80 per cent of capacity, it would result in fairly economical costs and reasonably profitable returns. “There appear to be no clouds on the business horizon which indicate the demand for steel products in the ageregate will be substantially re duced in the near future, although nec- essarily in a matter of this kind the perspective must be limited as to pe- riod of time. “While the earnings results for the quarter ending Sept. 30 have not yet been fully made up, we believe they will for the industry as a whole be fully as good as they were for the preceding quarter, which were quite satisfactory. OUAUNNATY ESN ELIN Mi \ HAUL you like that we should exist, DOVPOMELA NEAL NTE “The crop reports as we have them indicate the production this year will be nearly as large as in 1925, which was a bountiful year. Of course, in some particular products or in some sections of the country this may not be the case. But viewed in the aggre- gate and for the entire country, it is believed it will. And it is the general total of all which in the end influences comparative business conditions. “Money is plentiful, the amount in circulation being about $43 per capita and ample to care for all business. Collections are satisfactory, indicating the soundness of the credit situation. There is sufficient labor to meet all demands and, we think, labor should be and is entirely satisfied both with rates of pay and conditions of em- ployment “We sometimes think unfavorable statements published concerning the trend of business are either pure sur- mises or put out for ulterior purposes, political or otherwise. One thing we know positively, namely, that the ad- ministration at Washington is reason- that my coun- able and fair toward all business and all interests; and we have reason to believe that the majority in Congress will support the policies and good work the President has inaugurated from time to time and performed to the satisfaction of the people gener- ally. “So far as the question of import tariffs is concerned, we believe no legislation will be attempted, and cer- tainly none passed, which will De really harmful to the business of the country. While there will be con- tinued competition in the steel indus- try by foreign producers, we think from the statements they make there is no reason to feel they will seriously interfere with production in the United States. “On the whole there appears to be plenty of business in hand and pros- pective, and sufficient funds and credit to do it with, to maintain the very favorable volume of production at rea- sonable profit which has prevailed for the past year. Therefore, we have faith in the future.” i. GUNG try is a factor for peace, and perhaps ever so much more than you imagine, or even—I will not say that you imagine, but that you generally think of. Because you think of our position on the map you will under- stand why Rumania is an exceedingly important coun- try for Europe in general, let alone all the possibilities that lie on our ground and under our ground. Rumania is the last bulwark of civilization toward a country which is now in a state of horror.” : Emphasizes Need for World Amity Addressing herself to the subject of world relations, she emphasized the necessity for forgetting war-born hatreds and cooperating with friend and former foe alike in the work of reconstruction. At one point the speaker added a personal touch which made her plea unusually effective. Pointing to the middle of the hall, she said: “Here in this room sitting opposite me is a little nephew of mine. He is the son of my sister, who is in Germany, so that he is my German nephew (Prince Hohenlohe-Langenburg), and beside him is a very in- teresting man from Germany, Mr. Thyssen, who has come over to talk with you, and we are all friends. We were enemies once, but our quarrel was not of the kind that need remain in the world, nor was it a personal humor and good will, he brought the banquet program to a fitting close. Calls New South Child of Electric Age Another speaker whose remarks sparkled with wit was Hugh Morrow, president Sloss-Sheffield Steel & Iron Co., Birmingham. The serious side of his address dealt with the “Rehabilitation of the South.” At one time, he said, the South led the country as an industrial section. Virginia mined the first coal in this country, and George Washington mined ore, which he took to 4 neighboring furnace. Alabama’s first blast furnace W45 built in 1818, one year before it was admitted to state- hood. With the invention of the cotton gin the South was diverted from industrial development to agricul- ture. By the decade ended with 1860, however, there was a revival of manufacturing activity of a diversified character. At that time the per capita wealth of the South (omitting the slaves) was nearly twice that of New England. / During the four years of the Civil War and the 10 years following it the South was economically and politically prostrated. In 1860 Alabama's public debt was $5,000,000; in 1870 it had mounted to $30,000,000. The South’s recovery has been rapid, particularly ™ recent years. Its wealth is now four times what it w* in 1900. Its expenditures for good roads are one-third aes ee as ' i October 28, 1926 of the total for the entire nation. Its agriculture has become diversified, and its manufactures now exceed those of New England. In 1923 the South spent $365,- 000,000 on education, or three and one-half times the expenditure in 1914. Described as an agrico-industrial section, the South has a unique economic position. Whereas formerly most of the foundry iron produced in the South was shipped to other sections, today 85 per cent of its output is melted in Southern foundries. Because of its unusual resources in water power and its steady development along industrial lines, the new South is referred to as the child of the electric age. Digressing from his subject, Mr. Morrow paid a tribute to the presiding officer. He said: “The domi- nant note of the American Iron and Steel Institute is character and service, as personified by Judge Gary, THE IRON AGE 1193 your president. His policy is building not only for today but for the future.” The subject of lawlessness and crime was discussed by Judge Marcus Kavanaugh, Chicago. At intervals during the banquet program Madame Alda, prima donna of the Metropolitan Opera Co., New York, sang. A feature of the convention program, which aroused as much interest as the remarks dealing with interna- tional relations, was Judge Gary’s usual message on the state of business. This is published separately elsewhere. The technical sessions, which took place during the morning and afternoon, brought out new and valuable additions to the accumulated practical and theoretical knowledge of the industry. Abstracts of papers follow: High-Manganese Pig Iron and Manganiferous Ores in Open-Hearth Practice BY A. W. SMITH HE use of manganiferous ores and pig iron in open- hearth practice is a question which has been the subject of considerable discussion in recent years. Many reasons have been advanced against the use of manganiferous pig iron in open-hearth practice, the most important of which are the following: 1—The disadvantages in the blast furnace oper- ation. 2.—The metallic loss in the open-hearth practice 3.—The increased corroding action on open-hearth basic refractories and ladle refractories. Some of the advantages obtained are the following: 1.—Elimination of sulphur 2.—Purifying action in the bath, which tends to produce a better quality steel. 3.—Saving of ferromanganese. 4.—Decreased lime charge and the saving of fluor- spar. 5.—Increased tonnage. It is our opinion that the advantages of the use of manganiferous pig iron are greater than the dis- advantages. The disadvantages are gradually being eliminated, or are proved not to have existed. The use of manganiferous ores in blast furnace mixes, which result in an iron with a content of ap- proximately 1.50 to 2 per cent manganese, we believe is of material benefit to blast furnace practice for the following reasons: 1.—The higher manganese tends to increase the rate of driving, which is due to a more fluid iron. 2.—Troubles due to high bottoms are reduced 3.—Less runner and ladle scrap is produced in the manufacture of high-manganese iron than with low- manganese iron. 4.—As a general rule, higher blast temperature can be used if the manganese of the pig is not carried too high. Lower coke consumption is obtained than In the production of lower manganese pig iron. 5.—With better furnace operations, less flue dust is produced. 6.—Owing to the affinity of manganese for sul- phur, the use of high-manganese iron will enable the open-hearth to produce steel of lower sulphur content. Some of the disadvantages in the use of manganif- erous ores in the blast furnace practice are: l.—The irregular manganese content im the ore over a period of one ore season, which as a rule results in an irregular content of manganese in the pig iron produced, inasmuch as ordinary iron ores are not classified on a manganese basis. 2.—If pig iron is produced with excessive manga- nese content, the furnace bottom is Hable to become low and frequent break-outs may occur, due to the extremely bad cutting action on the brick-work of the furnace. A study of a number of tests would indicate that there is no decrease of yield of ingots produced while using manganiferous pig iron. Within certain ranges and similar conditions, the iron oxide plus the man- ganese oxide content of the slag is more or less of a constant. The open-hearth slag formed when using high- manganese iron appears to have a greater corrosive action on the basic refractories and ladle refractories than when using the low-manganese iron. It is pos- sible to minimize this action by the proper manipula- tion of the slag while using high-manganese pig iron. The use of manganiferous pig iron enables the open-hearth to produce ingots of a lower sulphur con- tent. Given the same scrap charge, if high-manganese pig iron be substituted for low-manganese pig iron, the same sulphur content of finished ingot can be ob- tained with a 12 per cent limestone reduction. A study of over 1000 heats of open-hearth rimmed steel made to meet the deep drawing requirement, the study being made on the quality basis which covers freedom from surface defects, and ability of the steel to meet the physical and chemical requirements, clearly indicates that open-hearth steel of this character, made with iron of 1.50 to 2 per cent manganese content, gives the best results for steel of this nature. This study also indicated that steel made from iron which carries more than 2 per cent manganese, especially when the manganese is around 2.5 per cent, is not as satisfactory as when steel is made from iron carrying 1.50 to 2 per cent manganese. We have not as yet determined the reason for this. The residual manganese in the bath seems to bear a definite relation to the manganese in the pig iron. In the manufacture of open-hearth steels using a 45 per cent iron charge, the residual manganese in the bath, when using pig iron of 1 per cent manganese and under in the charge, averaged 0.16 per cent; while the residual manganese in the bath, when using a pig iron containing 1.50 to 2 per cent manganese, was 0.23 per cent. This residual manganese results in a saving of from 16 to 20 per cent of ferromanganese. The consumption of fluorspar was 12 per cent less on heats made with 1.50 to 2 per cent manganese iron than those made from iron of 1 per cent and under. An increase of 3.50 to 5 per cent in tonnage was ob- tained when using 1.50 to 2 per cent manganese pig iron. [The author then discusses the use of a 4 per cent manganiferous fine ore as a charged ore, a man- ganiferous lump ore as a working ore and an 18 per cent manganiferous ore as a working ore in open- hearth charges. Tables are given showing composition or ores, pig iron used and steels produced.) heats charged with 42 per cent pig iron, 58 per cent scrap, 25,000 Ib. of limestone, 2000 Ib. of 48 per cent manganiferous ore and tapped with a carbon 0.30 per cent have shown an increase of 30 to 40 cent of residual manganese compared to heats manganese ore has not been worked. The heats well and all indications pointed to a good qual In our opinion many tests must be made ces a shits! Nias athe ee mr ae Le RR Nt ER nal Bil clk 6 gay ta z el ce ee ae patie c 1194 real advantages and disadvantages of uses of man- ganiferous ores in open-hearth practice are known. We feel that exhaustive studies of slag analysis, slag conditions and slag formations must be made before any definite conclusions are drawn. As a result of our recent tests, we have decided to do more work along these lines and in doing so we hope to show that man- ganiferous ores can be used economically and bene- ficially in the open-hearth practice. Discussion Two written discussions of Mr. Smith’s paper were read; one by P. G. Wilander, superintendent of blast furnaces, Wheeling Steel Corporation, Wheeling, W. Va., and the other by M. J. DeVaney, South Works, Illinois Steel Co., South Chicago. Mr. Wilander said that the use of manganiferous ores has increased greatly during the last few years because this practice is helpful in making a better product. The practice at his plant has demonstrated that, in using high manganese pig iron, a material sav- ing of ferromanganese is immediately noted in the open-hearth department, a saving which is proportional to the manganese content in the iron. Its use also has this advantage that it tends to produce a homogeneous manganese-bearing bath of steel, whereas by adding ferromanganese the tendency is toward some segrega- tion. At his plant it has been the custom to produce iron containing 1.50 to 2 per cent manganese and in some cases from 2 to 2.25 per cent manganese, depend- ing on how much sulphur there is in the blast furnace burden and how pure the steel produced must be. In his opinion, high manganese loss in slag is not always a criterion of poor practice, as slag volume must be reckoned with. The percentage of oxide of THE IRON AGE October 28, 1926 manganese in the slag depends on such factors as hearth temperature, rate of base to silica and rate of driving. Due to manganiferous ore charged in the blast furnace burden so as to produce 2 per cent man. ganese in the iron, a blast furnace can be operated on a more acid slag and still make a low sulphur iron be. cause manganese acting as a base combines with silica, allowing lime to combine with sulphur. It is a metal. lurgical law that a metal will dissolve compounds of itself but not compounds of another metal with as much ease, therefore sulphide of manganese separates out and rises to the surface. High manganese iron will retain its fluidity much longer in ladles and mixers on account of high initial heat, thus helping to keep down scrap production. Mr. DeVaney emphasized the importance of Mr. Smith’s paper in demonstrating the value of manga- nese in open-hearth practice. The results given in his paper duplicate those at his plant, the experience ex- tending over a number of years. Mr. DeVaney in his discussion presented data covering operations of blast furnaces, open-hearth furnaces and rolling mills over a period of eight years. According to his understand- ing, high manganese pig iron represents iron contain- ing 1.75 to 2 per cent manganese and low manganese pig iron is iron containing 1 per cent manganese. The benefits realized from the use of manganese-bearing irons in open-hearth practice are: 1—Manganese is a powerful deoxidizer. 2—A more fluid slag results. 3— The sulphur is lowered in the steel by 12 to 15 per cent. 4—The residual manganese in the bath runs as high as 0.23 to 0.25 per cent from the use of high-manga- nese iron and from 0.12 to 0.15 per cent from the use of low-manganese iron. 5—The saving of ferromanga- nese amounts to 2 Ib. per ton of ingots. Welding of Iron and Steel BY COMFORT A. ADAMS ONE of the methods of fusion welding described below (excepting forge welding) is more than two generations old, and practically all of the significant applications have been made within the last genera- tion, most of them within the past decade. These newer methods have ceased to be a tool for repair work alone, however valuable they may be in that field, and now constitute one of the greatest modern labor-saving devices employed in regular production. Few of those not in actual contact with these applications realize either their magnitude and importance or the rate at which they are increasing. The author’s object in writing this paper is to pre- sent a brief description of the several processes of welding, their advantages, limitations and fields of use- fulness, with particular reference to the welding of iron and steel. Except where otherwise specified, mild steel will be assumed. No attempt will be made to Colo. mining engineer. plants. discuss the deeper metallurgical phases of the problem as the writer is not a metallurgist. [The author’s paper, which covers 71 printed pages, is a thorough discussion in outline of nearly every phase of this important art. It is divided into two principal parts: Description and discussion of methods, with the second part dealing with the applications of welding. ] In describing the various methods, Mr. Adams takes up each one separately, covering the processes and some of their applications. His treatment is also some- what historical. Some of the various kinds of welding discussed are forged welding, electric resistance weld- ing, butt welding, seam welding, spot welding, the !at- ter being gone into quite thoroughly. In discussing tube welding, the author states that several hundred thousand feet of steel tubing are made every day by the resistance welding of the edges of strip steel rolled Us 200A] eNeUneneen catered TRH NNENON MNO AOA EEO a Me: SMITH was educated in the grade and high schools at Pueblo, Colo., and at the Colorado School of Mines, Golden, He was graduated from the latter institution in 1914 as a He had some experience as a chemist with the Colorado Fuel & Iron Co. He started with the Youngstown Sheet & Tube Co. in 1914 as a metallurgical inspector. Since then he has occupied successively positions as assistant foreman of the rolling mills, assistant superintendent of the open-hearth, and assistant su- perintendent of the blast furnace and steel department. At present he is works superintendent of the Campbell, Struthers and Hubbard MA RNR ee Me A a aaa — ; October 28, 1926 suuuns3 ANANDA TPT a2 4400YE AA. / R. ADAMS, who has been Lawrence professor of engineering at Harvard University since 1911, is a director of the American Bureau of Welding, New York. During the war he was appointed by the President as a member of the general engineering committee o/ the Council of National Defense of which he was later made chair- man. During the war he was active in the application of welding to shipbuilding. He was also largely responsible for the organization of the American Engineering Standards Committee. He is credited with numerous inventions in the engineering field and has been active in consulting work. He is a member of several of the leading foreign and American engineering societies. THE IRON AGE la RIBS ON TATA ROM Ti AE ll ih SAR ah 2 414) ACAD ERNE NTS EULA RL ANMBT eR MMME AURA AUER GaMONRSSUUTARELA 001°." RRPRMNRAD ORT RP MRRP ORNS MRE RENTER PP ee up to form a tube. A single machine will take the flat surface and shape and weld it at a rate of from 60 to 150 ft. per min. Several divisions of the electric arc welding method are discussed, including the use of coated electrodes. The quality both of arc welds and resistance welds are treated in the paper. The subject of oxyacetylene welding, this portion of the paper being prepared by S. W. Miller, of the Amer- ican Welding Society, is thoroughly gone into with sev- eral examples of applications of the method. The por- tion of the paper devoted to thermit welding is written by J. H. Deppeler. Several pages are devoted to welding engineering and this subject is discussed under the following heads: Design, material, apparatus, welding operators, tech- nique of welding, inspection and testing. In the second part of the paper, devoted to applica- tions of welding, the author gives a summary in sev- eral important fields, such as shipbuilding, pipes, tanks and pressure vessels, structural steel, the automobile industry, railroads and rail joints. Each one of these is taken up in order and their advantages as well as some of the more recent products of the application of welding in those fields are discussed and fully illus- trated. Considerable space is devoted to welding in the structural field. The application in this field is as yet of negligible magnitude, says the author, the few ap- plications and tests already made indicating that it has enormous possibilities. Some of the applications in this field from the earliest time to the present are dis- cussed and individual installations are quite fully gone into. The application in foregin countries is also touched upon. The author states that the American Bridge Co. will shortly erect a five-story frame build- ing for the Westinghouse Electric & Mfg. Co. involving about 700 tons of steel in which electric welding will be used exclusively in the fabrication and erecting operation. . After giving an outline of the proposed investiga- tion which will shortly be undertaken by the American Bureau of Welding with the cooperation of the Ameri- can Institute of Steel Construction, the investigation being conducted to secure fundamental information needed by designers and contractors in connection with the use of welding in large steel structures, the author devotes a few paragraphs to a discussion of welding versus riveting in steel structures, which follow:] It may be of interest at this point to make a brief statement of the advantages and disadvantages of welding for steel structures as far as it is possible from present knowledge. 1. A saving of steel by the elimination of many overlaps, brackets and angle connections, and possibly by the reduction of sections 2. In some cases, such as that of lateral wind bracing, this elimination simplifies the architectural treatment of exterior and interior finish 3. The elimination of the noise of riveting 4. The elimination of layout and punching of rivet holes, as well as of the rivets themselves On the other hand, the large scale use of welding will doubtless develop difficulties and disadvantages not now foreseen, although many of these have already been met and overcome. One of these difficulties relates to tolerances as to length, camber, etc. For example, beams are now ordered % in. “short” with a plus or minus tolerance of % in. In a welded structure, these large tolerances would be objection- able, as they would require either an excessive amount of weld metal to fill up the joints, or the use of brackets and angle connecting pieces, the elimination of which constitutes one of the savings of the welding process. The exact widths of web plates and the absence of considerable camber are not always of importance in riveted girders but are of considerable importance in the case of welding. Conclusions The establishment of welding as a dependable in- dustrial tool has opened up a new era as to economies and other gains which may be effected in fabrication. Experience has shown what are the most important factors that enter into the making of successful welds. Among these are skilled workmanship, supervision, in- spection, proper welding wire and base material, de- sign, proper technique, and suitable apparatus. With each of these under intelligent control, a uniform and dependable product will be assured. Discussion In discussing Professor Adams’ paper, J. D. Wright, General Electric Co., Schenectady, N. Y., said, in part: Electric welding has already become a manufactur- ing process of great importance, and its use by the in- dustries is being rapidly extended. The development of automatic welding has been one of the important factors contributing to this increase. Automatic weld- ing is most applicable to quantity production work where the seam is either straight or circular in form. The use of electric welded plates instead of iron or steel castings in the construction of oil circuit break- ers, transformers, and generator and motor frames has resulted in a material decrease in the gost of manu- facture. From several years of experience in making oil tight joints and seams such as are required on transformer work we have found that are welding is about 15 per cent cheaper than riveting. In a paper on Modern Steam Power Stations by Cc. W. E. Clarke and D. L. Galusha, presented at the May meeting of this institute, mention was made of water-cooled walls for pulverized fuel furnaces. The side wall construction consisted of water tubes to which flat longitudinal fins are welded, the fins com- pletely filling the gap between the tubes and forming with the tubes a complete metal wall. The welding of the fins to the tubes is interesting because of the length of the weld and the fact that two automatic welders are working simultaneously on the same machine. The fins, which are about 2 in. wide and 3/16 in. in thickness, are welded to diametrically opposite sides of the 4-in. nit Ge nibs ataeeas 1196 tubes, which vary in length up to 30 ft. Four welds are necessary to complete the job, it requiring two to hold each fin in place. The welding is done at a rate of about 1 ft. per min., and two arcs are used so that one seam on each fin is welded in one passage of the travel carriage. The machine on which the work is done con- sists of a bed about 30 ft. long, grooved so that the tube to be welded fits in tightly at about half its diam- eter. The fins are then laid in position along the sides of the tube, and the whole locked in place by an in- genious set of clamps controlled by compressed air. These clamps are so placed that the fin is pressed tightly against the sides of the tube at the point to be welded, and also prevented from moving vertically. The two welding heads are mounted on the same car- riage, which carries them the length of the tube, de- positing metal at the same rate on both sides of the tube. When the end is reached, the carriage stops, the clamps are released by a single movement of the con- trol lever, the tube is turned over and again clamped, and the two other seams welded on the return trip of the carriage. One of the principal reasons for the success of the automatic welder in this particular case is the rapid and even deposition of metal on both sides of the tube simultaneously. With hand welding, for example, it would be practically impossible to synchronize the rate of travel and the amount of metal deposited by two operators working on both sides of the tube at once, and even if it were, the cost would be prohibitive. If a welder were working alone, by the time he had welded the fin on one side, the contractive effect of the cooling weld would warp the tube so badly that it would be im- possible to weld the other fin into place. With the automatic welder working on both sides of the tube at the same time, the contractive effect is completely neu- tralized, and the tube remains straight. One of the most interesting of recent developments is that process which has been called atomic hydrogen are welding. One of the great features of the atomic process is the prevention of oxidization of the weld which as a result is extremely ductile and strong. Ap- proximately 30 to 40 cu. ft. per hour of hydrogen at THE IRON AGE October 28, 1996 2 to 3 lb. gage pressure are consumed by th. average size torch used in our laboratory. Most of the experi. mental welding work has been-on alloy steels, such as chromium steel, containing up to 35 per cent chromium nickel steel up to 85 per cent nickel content, molybde. num steel up to 20 per cent molybdenum content, man- ganese steel up to 12% per cent manganese content and many others. The results attained indicate that welds can be made by the atomic process which cannot be made by any other known means. It is not expected that this process, when placed on the market, will sy- persede the present method of are welding, but it should greatly broaden the field of electric welding ap- plications. A. M. Candy, Westinghouse Electric & Mfg. Co. East Pittsburgh, Pa., described the series of tests of welded specimens conducted by his company and the test buildings it has erected to demonstrate the possi- bilities of the electric arc welding process of joining structural steel members. The first building con- structed is a small one, 40 x 60 ft. and 50 ft. high. It cost $3,000, whereas it is estimated that if it had been riveted the cost would have been $5,000. A second building, 70 x 220 ft., and 80 ft. high, with five stories and a mezzanine floor, is being erected at the com- pany’s Sharon Works. Its cost is expected to total $250,000. A test of the building will be made in De- cember when one floor will be subjected to twice its estimated load in service. The designs used in the test specimens and in the buildings were based on the use of welding and in almost every case the joints provided could not have been riveted. James H. Critchett, Linde Air Products Co., New York, emphasized the necessity for the application of engineering principles in welding. He mentioned a railroad repair shop in which the welders are relieved of all responsibility for the design of a given weld and the kind of welding to be employed. In this shop also welders are given periodical tests. In speaking of oxy- acetylene welding, he said that the atmosphere created by the torch permits the welding of many materials, such as brass and alloy steel, which are not now weld- able by other commercial processes. Action of Sulphur in Basic Open-Hearth Practice BY A. N. DIEHL HIS paper} is presented with the desire that it be considered in connection with one read by the author before the institute in May, 1926, and will be confined principally to the action of sulphur in basic open- hearth steel practice. As mentioned in the previous paper, the object of this experimentation and research on the part of the company was to develop a more com- plete knowledge of reactions and element balances, as an assistance to the further study of the metallurgy of steel making, especially directed to the elimination of objectionable metalloids. The tests were made for the most part at the Duquesne Works of the Carnegie Steel Co., but, in addition, data from other plants of the same company have been included. Some repetition of data given in the previous paper is necessary, but this has been unavoidable in order to clearly outline the practice under discussion. In order to show the effect of the different elemen- tary factors and materials as they are involved and their relation to sulphur characteristics, each is taken up separately. It is the aim to give not only the data pertaining to practice, but such allied tests and deduc- tions which may be of interest to the industry. The principal elements comprising an open-hearth charge are pig iron, scrap, ore, limestone, dolomite, fuel, slag and refractories. [The author, in the paper of 37 printed pages, dis- cusses in detail the influence of these various parts of +Supplements a paper presented May 21, 1926, under the title of “Data Relating to Basic Open-Hearth Stee] Practice.” [Tur TRON AcE, May 27.] The detailed data presented in the previous paper should be considered in connection with the present study of the action of sulphur. the charge. The influence of the pig iron and scrap is first taken up, followed by a consideration of the effect of fuel on the sulphur content, different kinds of fuel being considered, particularly bituminous coal. Limestone is next taken up, attention being given to its sulphur content and the percentage of sulphur en- tering the steel. Mr. Diehl then discusses the influence of iron ore and refractories. An important section of the paper is that devoted to the influence of manganese, gases and temperature, particularly the effect of re sidual manganese on the sulphur content of the steel. Of prime importance is the discussion of the effect of the slag. In this, tables are given of the distribution of sulphur between the slag and the metal as well as of the sulphur distribution in the ladle. The paper is well illustrated with graphs and with tables of analyses. ] Summary and Conclusions It may be well to summarize the more important features outlined, and draw such conclusions as they may indicate. The most assured method of producing low sul- phur basic open-hearth steel, is to use materials containing a minimum quantity of that element Pig iron and scrap should be kept as low in sulphur as possible. This is subject of course to the other materials entering into the operation, as well as the specifications which have to be met. Gas free from sulphur is preferable, but in the use of by-product or producer gas it should be extremely important that the gas be burned October 28, 1926 UTTAR Wa LA eee THE IRON AGE 1197 BPR. SUMMARIES in SR IE TRL R. DIEHL was graduated from the Pennsylvania State College in 1898, and entered the employ of the Carnegie Steel Co. in 1899 as a chemist at the Duquesne works. He was transferred to the blast furnace department after seven months and was made assistant blast furnace superintendent at the same plant six months later. In October, 1901, he was made superintendent of that department, i” which capacity he served until October, 1915, when he assumed the position of assistant general superintendent of the Duquesne works and of the blast furnaces. He was appointed assistant to the operat- ing vice-president a year and one-hal/ later, with headquarte re at the general offices in Pittsburgh. president, which position he still holds, (MBA! {A CAAUUNAUUAAGAATNOMNNTLL 2 YUOPNORSUAD AAA AA ATARRO SAAS RAAT, sate so as to oxidize the hydrogen sulphide before com- ing in contact with the metal or scrap. Slag conditions are of primary importance, especially where higher sulphur materials are used, and every care should be taken in operation to obtain correct analyses and weights of mate- rial entering the charge, also the ore and flux should be carefully calculated, wherever possible. The slag should be oxidizing and basic, as with an acid or non-oxidizing slag calcium sulphate may be reduced, and sulphur revert to the metal bath. The slag should be sufficiently fluid to effect a proper interchange between the metallic and non-metallic baths, to enable the reactions to take place freely. In operations requiring a run-off slag, this material should be removed to the greatest extent possible so that the final slag may be utilized to the best advantage. Care should be taken to prevent resulphuriza- tion due to a change of slag composition from contamination with loam, sand, or any other for- eign material in the runners or ladles. The tests given are for conditions of operation as described. As all localities naturally have different materials and specifications to deal with, each must solve its own particular problem. The data given aim principally to outline the action of sulphur under the conditions prevailing at the time of the tests, as well as to point out fundamental reactions which are uni- versal irrespective of location. It is the desire of those who assisted in the collec- tion and compilation of these data, that the information may serve to stimulate further efforts on the part of the industry to simplify basic open-hearth operations, and also to encourage in others a further and increas- His appointment as operating vice- vas made in 1925 SPRATT “STEED PO PTTL BREA 3 RMT ST A, ing zeal in the field of research to produce an even bet- ter quality of product with the materials available. Discussion This paper was discussed in writing by W. A. Max- well, Inland Steel Co., Indiana Harbor, Ind., and by F. S. Slocum, Jones & Laughlin Steel Co., Pittsburgh. Both discussions were presented by the authors. Mr. Maxwell said that the one great value of Mr. Diehl’s paper was that the data in it are based upon actual practice. He thought, however, that a further study of the effect of sulphur in blooming and rolling mill practice would be of considerable benefit. Mr. Diehl’s conclusion, that an increase of sulphur in the pig iron means an increase of sulphur in the steel, was borne out by his own experience and also that the amount of silicon in the pig iron has a marked influ- ence on the quantity of sulphur in the steel. The author’s conclusions as to the amount of sulphur dué to fuels are correct and have been proved by experience at the Inland Steel Co. Mr. Maxwell in his written discussion includes tables which illustrate these facts. He said that he agreed in all the conclusions of the author, adding that in his opinion the use of lime is a distinct benefit in the elimination of sulphur. Mr. Slocum testified that, where coal is used as fuel, the screening of it is of decided benefit toward the low ering of sulphur. He also stated that pig iron of high manganese content should be used to eliminate sulphur as well as to reduce oxidation and also his experience had demonstrated that the deep bath in a tilting fur- nace will remove sulphur faster than a shallow bath in a stationary furnace. He felt that it was expedient for all to cooperate in lowering sulphur for the benefit of consumers. Plate Mills—Recent Developments and Tendencies BY F. M. GILLIES ae are that the production of sheared and universal plate will be in excess of 4,300,000 tons in the current year, which will be the heaviest production ever turned out. Since the war 24,096,231 tons of sheared and universal plate have been pro- duced as against 20,205,211 tons of shapes, 18,337,547 tons of wire rods and 17,283,658 tons of rails; this, too, in a period when plates have been generally sup- posed not to be in great demand. Since the war the consuming trade, according to average annual price lists, has spent over a billion and a quarter dollars for plates. This indicates that the plate trade is of no small dimensions and that it is deserving of much thought in method and means of producing better quality at lower cost. This idea of better quality at less cost in a business spending an average of $178,- 000,000 annually has developed improvements and will continue to develop them as long as there is need for them. The advance in roll turning, brought about by the introduction of the plate roll grinder, has been a greater benefit to the rolling than anything recently developed in this end of the manufacture. The grind- ing machine does extremely accurate work and does it quickly, and entirely eliminates the necessity to depend on roll turners, who vary greatly in ability. Mill conditions are made more standard because of this mechanical method, for the grinding machine will produce the same result on each roll, while irregu- larities are often produced on the surface of rolls turned in a lathe. These irregularities make the mills very difficult to operate. Accurately tapered rolls, always a difficult thing to produce in a lathe, can be produced in a grinder with ease on a very flexible basis. The grinder has the advantage of being able to taper a roll in a short period of an hour or two to meet a special condition of wear. One well-known manufacturer has installed a ma- ee cn te ee Sey ee a si fae “ “ e Ath 5 5 SNS Amis ei wns Se i feat an a eee eee ee Se eee me r ey See een 1198 THE IRON AGE chine for the laying out of plates. This may be the start of development along this line, but it still is quite inflexible and too slow for mills producing plates at a high rate per hour. The idea is substantial and it would be natural to deduce that good results would evolve. The most recent promising appearing shearing de- velopment is the Ennis table, invented by L. Ennis, of Dorman Long & Co., in England. His patent is a table which appears much like a section of the ordi- nary roller table, but mounted on wheels and operated on rails. The plate, after being end sheared, is de- livered on to this table and transferred to the side shears by means of a double series of live rolls divided in the middle, capable of independent operation. Hence they may be operated in unison and in the same direction of rotation, or those on one side of the table may be rotated at a slower speed than those on the opposite side or even in the reverse direction, so as to secure a drag or slewing action to the plate, and in this way permit the operator to bring the plate on the table into position for shearing. In addition to the rollers there is a series of electro- magnets, capable of being traversed across the table so as to hold the plate at any desired point. The faces of the magnets are just below the level of the top of the rolls, and each magnet can be made free to revolve in its own bearings and be caused to act inde- pendently of the other magnets. Of the 24,096,231 tons of plate produced since the war, 7,562,788 tons have been rolled on universal mills. This, in comparison with the country’s universal plate- producing capacity, shows the universal mills to have been more steadily employed than the sheared