The Iron Age 1927-03-31: Vol 119 Iss 13

| 1 ne oO “u 7 2 4 M \ | | ESTABLISHED 1642 cage first source for the buyer doubt.... The regular source for the buyer who knows. Ryerson Steel-Service plants are located Chicago, Milwaukee, St. Louis, Cincin- nati, Detroit, Cleveland, Buffalo, Boston, New York. 2—March 31, 1927, THE IRON AGE 7 | i y THEIRO ACE New York, March 31, 1927 ESTABLISHED 1855 VOL. 119, No. Fashioning Steel into Naval United States Navy Operates America’s Greatest Ordnance Supply Source Close National Capitol—Massive Machinery Employed GEORGE Capitol Washington, city far separated from ordinary industrial plants, one the finest gun factories the world. This establishment converts ordnance steel into naval armament ranging from one- pounders the gigantic 16-in. 50-caliber pieces. not only manufactures, but also keeps perfect repair, all the guns now used the United States Navy. Whenever big little guns require re-rifling repair, the vessel visits some stipulated drydock navy yard. The guns are lifted from their steel-shod mounts and are freighted the Washington Navy Yard, the Potomac, either water rail. This mammoth plant, housed massive building con- and steel, 572 ft. long, 243 ft. wide and 135 ft. high, equipped with the finest gun-making tools. The peace-time complement about 2500 men in- creased many 10,000 employees during war emergency. Among the outstanding equipment are lathes which range from 120 204 ft. length and swing from 102 120 in. These lathes are driven electric motors, some reaching 100 hp. One them has extraordinary feed screw which in. diameter and 202 ft. long. Two huge rifling machines are adapted for handling the heaviest rifles ever manufac- tured. Other and smaller equipment designed for making secondary-battery guns. Seven electric cranes include trio which the maximum burden reaches 380 tons. The largest guns which are handled (16-inch) weigh 286,135 each. short distance from the United States Five the 14-In. Naval Guns, One Which Appears Top Page, Mounted Railroad Trucks, Were Action Against the Germans Before the Armistice. They were the most powerful weapons used land any the combatants. *4639 Montgomery Avenue, Bethesda, Md. 915 DACY* Most the the gun repairs present consist re-rifling jobs fitting the weapons with new liners. remarkable shrinkage pit used for this work. This huge concrete chamber was built ex- actly “reverse English” style the methods con- struction commonly followed. Unstable soil conditions demanded that the pit built from the top downward, instead orthodox fashion, from the bottom up- ward. Instead excavating the 100-ft. pit, walling with supporting timbers and then laying the concret« walls, sections were cast the surface units ft. thick and ft. high. The first section was placed di- rectly below the surface. After the concrete had hard- ened, this unit wall was undermined and lowered and another similar section was placed above it. This process was continued until finally monolithic walls 100 ft. high and ft. thick had been sunk into place the borders the shrinkage pit. The bottom, also concrete, was made ft. thick. The shrinkage pit divided into ten compartments, each ft. square and ft. deep. There elec- trically operated elevating table each gun pit, which can regulated accommodate armament all sizes from 3-in. the heavy 16-in. guns. One the most powerful cranes the factory employed lift and raise the heaviest guns and out this pit. This crane, which has clear lift ft. above the gun shop floor, responds delicate control. Method Relining Heavy Guns UNS relined are heated electricity for 800 deg. This heat exposure produces maximum ex- pansion the fine quality ordnance The rifled liner then swung into position over the gun pit crane power and exactly the right time lowered into the hot steel jacket the gun. large hydraulic jack then locked into place over the mouth the gun hold the liner position during the shrinkage process. the steel jacket cools, grips the liner with great tenacity. This business of-re-lining these naval guns—great and small—is truly marvelous the mathematical accuracy which obtains. The fit usually snug that minute fractions measurement, small one two thousandths inch, are dealt with. The toler- ance errors are small that they seem entirely in- significant the layman. the gun-makers, reliable accuracy the greatest importance for, without it, gun liners valued $15,000 $25,000 each may ruined. There are four complete electrical furnaces this gun shrinkage pit. Each furnace consists circular sections from in. high, which are quite similar the forms used building concrete silo. This arrangement facilitates building the furnace accom- modate any size style gun. The furnace—a monster cylinder steel—insulates and incases the gun which re-lined. Electrical coils distribute the heat and maintain the temperature uniform all parts the furnace during the gun-expanding period. Observers keep tab the furnace temperatures, during the operations, means special heat regis- tering gages. Never before engineering history has such large electrical furnace been used. the four furnaces the Washington Navy Yard were operated full capacity the same time, sufficient power light city 100,000 people would required. Firing tests these naval guns are conducted alongside the Potomac River the Dahlgren proving ground, after the essential ordnance repairs have been 4 Aluminum-Bronze Ingot Weighing 15,000 Lb. This said have been the largest its kind ever cast the United States. was used ordnance manu- facturing the Washington Navy Yard 916—March 31, 1927, The Iron Age on > Inserting Completed Liner Big Gun the Shrinking Pit. This view shows clearly the mas- sive character building required carry 380-ton cranes made. The guns are transported barge Dahl- gren, where they are mounted and tested for range and firing accuracy under wide variety conditions. the firing tests are satisfactory, the guns eventually are returned their respective ships and mounted for sea service. Guns which not come speci- fications the range are returned the ordnance factory for additional work. Recovering Much By-Product Metal involved manufacturing new guns are both interesting and intricate. The Washington Navy Yard operates steel and brass foundry where rough forgings used armanent production are made from by-product materials, machine shop trimmings, cartridge cases and obsolete gun mounts, which are classified scrap. Instead selling these waste materials the junkman, they are made over into ordnance steel non-ferrous metals, the case may be. During the last fiscal year, 3,952,722 forg- ings for naval ordnance were made this plant. Both carbon steel and the various alloy steels such nickel steel, chrome nickel and chrome-vanadium are produced. The steel and iron forgings which are made range weight from one ounce tons, while bronze castings heavy tons are produced. One million pounds ordnance steel, 700,000 Ib. cast iron and 733,186 lb. brass castings were made the Government mills last year. Large steam-hydraulic presses are features the Navy Yard forge shop. One 2000-ton forging press which weighs 1,000,000 lb. required freight cars deliver this machine when was purchased. The press and its foundation were installed total cost $200,000. When active service, shaping and molding hot metal, this press under efficient con- q Preparing Bore Naval Gun, Pre- liminary Re- lining it. The boring tool ap- pears The sturdy de- sign the steady rests for the gun shown com- parison with the man trol telegrapher’s key. livers blow 4,000,000 recent achievement this forge shop was the production 15,000-lb. bronze-aluminum alloy forgings coverings for submarine guns. They protect the ordnance against salt water corrosion and are said the largest forgings ever made such alloy material. Three catapults airplane launching de- vices weighing 20,000 lb. each were completed lately, the form rough forgings. Large ordnance rings, some which are ft. diameter and weigh tons more, are manufactured inexpensive and efficient system forging originated and perfected the United States Navy. These rings are not welded nor fused together acetylene electrical processes. They are made from solid cast steel, which shaped, slotted, curved, cut and molded form the completed rings clever and unique system. The descending die de- One the Massive Gun Lathes Turning Heavy Gun Liner. Building New Guns gun forgings, when delivered the gun factory, are turned and bored finished dimen- sions and then are heated the shrinkage pits. The big and little guns are made simple building-up process. large heated forging cylindrical shape lowered over smaller (cold) one and then shrunk into permanent place. Then another, yet larger, cylin- der steel encircles the others and, when the hot metal cools ordinary temperatures, contracts and grips, under enormous pressure, the forging upon which shrunk. modern naval gun consists ten twelve forgings assembled this way. One these 8-in. guns weighs tons when com- pleted and fires 260-lb. projectile. 12-in. gun 56-ton masterpiece steel and workmanship and throws shell weighing 870 lb. The gigantic 16-in. gun belches forth steel projectile weighing 2100 Ib. The man central tool fixture shows its size. The lead screw foreground supported ingenious fixture which permits the tools pass The Iron Age, March 31, 1927—917 i The 14-in. naval guns made Washington and used France during the World War were the most powerful armament either the allied the Teuton armies. The maximum range these guns was 52,- 000 yards (not quite miles). monumental trans- portation problem, however, was associated with moving them over the foreign railroads. French engineers first refused transport America’s “big Berthas,” and was not until the German long-range guns threatened Paris that this mighty armament was loaded aboard special railroad mounts. Bridges shook and shivered until the heavy trainload had passed and curves, not built handle such material, were negotiated. The foreign locomo- tives snorted and puffed climbing the grades. these American guns weighed tons and its shell had muzzle velocity 2800 ft. per sec. Ten years before the Civil War, the Washington Navy Yard was responsible for the conversion smooth-bore guns into rifled armament, while also engineered the substitution cylindrical and pointed projectiles for the historic round shot which previously had been used. From then now, this gun factory has been writing ordnance history. Many efficient re- forms design have been achieved here. Peaceful Work, Also During peace-time, the outstanding manufacturing facilities the Washington Navy Yard are harnessed assist the other Government departments supply- ing such materials mail boxes for the Post Office Department [See THE IRON AGE Nov. 11, 1923, page 1369], money plates for the United States Treasury, repairs for airplanes and similar accessories. All this work done under competitive contracts. The Navy Yard bids for the jobs the same way commercial concerns. The Government policy award contracts the lowest reliable and responsible bidders. The national ordnance factory, hence, wins much spare- time work wholly merit. Electricity Industrial Heating Heat-Treating Departments Need Improving—Forging Fur- naces Have Faults—Advantages Melting Gray Iron and Brass Electrically the course comparatively few years, the in- dustrial electric heating load the United States has grown from almost negligible figure until present excess 3,000,000,000 kwhr. annually. This number kilowatt hours may visualized more readily considered that, give this service, there would required power plant capable carry- ing load 375,000 kw. continuously for hr. per day and for 365 days. effort provide plant executives with information the latest developments the application electric heat manufacturing processes, conference that subject was held Purdue University, Lafayette, Ind., March 23, and 25. addressing the conference, Nelson, power engineer Indianapolis Power Light Co., Indianapolis, Ind., pointed out that the rapid growth the heating load could taken true indication that electric heat producing economical results for industry. reference the advantages electric heat said that made determine the heating capacity and consequent cost are based the kilowatt hour, which incidentally the unit service paid for. kilowatt hour produces definite amount heat— 3412 consumed and expended the form heat. Neither the company that produces and sells electric energy, nor the consumer, can vary the heat content the kilowatt hour. The heat produced per electric unit independent atmospheric conditions and since that heat not the result combustion, the atmospheric conditions the furnace are neutral. these advantages must added the ability apply electric heat capacity the desired point, and also the ease with which temperature can con- trolled.” Tests indicate that japanning and drying ovens may operated satisfactorily changing the air times per hour, but explained Jordan, super- intendent pyrometer department Studebaker Corpora- tion, South Bend, Ind., better provide changes per hour and assure safe and satisfactory working conditions. “The necessity for improved heat-treating methods the result demand for lighter sections and cor- respondingly lower factors safety,” said Davis, metallurgist Warner Gear Co., Muncie, Ind., paper, the title which was “Heat-Treating Furnaces and Methods.” “Today many heat-treating departments otherwise modernly equipped organizations,” said, 918—March 31, 1927, The Iron Age “are shamefully neglected units. into many plants and, after admiring various phases fabricating efficiency, visit the heat-treating department. place smoke and grime, dirt floors, men operating ineffi- ciently and laboriously, badly constructed furnaces, fuel wastage and poor pyrometric equipment. Why does such condition exist? Why will management balk paying $5,000 for modern furnace but will spend readily for machine which will increase its production per cent one part. not dollar saved the heat-treating department good dollar saved the machining lines? Sometimes be- lieve because the heat-treating department lacks champions. Many factory executives have risen responsibility from the shop, and with their thought and energy always concentrated upon the mechanical problems production, they have failed fully realize the possibilities which lie dormant improving heat- treating operations. Why does cost 9c. 12c. per carburize? can done for 6c. per Ib. The in- stallation modern annealing furnace one plant eliminated the labor nine men, saved $500 per month the gas consumption and reduced furnace repairs $2,400 per year. Under-Fired and Over-Fired Furnaces “Under-fired furnaces should always used for annealing alloy and high-carbon steels. Over-fired furnaces will not produce uniform temperatures the furnace the very principle over-firing. realize, making this statement, that many over-fired furnace installations may found different plants, but those have investigated all have the same common defects— cold floors, flame impinging the work, hot and cold areas and general lack uniformity. Under-fired furnaces provide hot hearth, hot side walls and hot arch and uniform heat radiance. Most annealing fur- naces are gas oil-fired, but many the newer instal- lations are using electric elements. Electric heat ideal for nearly all annealing operations. The chief objection the high initial cost. “In heating steel for hardening tempering, four methods are common practice: Heating immer- sion some liquid molten medium; direct radia- tion the heat the work; conveying the heat directly the work flame combustion blast; and transferring the heat air blast previously heated. heat-treating can used for all ranges | temperatures from 250 deg. Fahr. The temperatures from 250 deg. Fahr. 1250 deg. Fahr. may re- garded the annealing drawing ranges; oil nitrites are suitable 600 deg. Fahr.; saltpeter from 600 1000 deg. Fahr.; and lead above 1000 deg. Fahr. For drawing the temper, oil nitrites are the best mediums and should employed preference air-drawing furnaces. good drawing oil can purchased for around per gallon. price for drawing salts does not seem excessive until one considers that the salt used molten and gallon molten nitrite salt costs from $1.50 $2.50. Electric heating oil- drawing furnaces are preferable gas oil for they reduce the fire hazard and practically eliminate it, the electric units are sheathed and the units are not exposed oil vapors. With additional electrical con- trol, temperatures can held within limit deg. and such furnaces can placed progressive pro- duction lines. “For hardening immersion, lead and cyanide mixtures are the most common mediums use. Lead not suitable for temperatures above 1600 deg. Fahr., due rapid oxidation the lead. For temperatures between 1600 deg. Fahr. and 1800 deg. Fahr., barium chloride, which melts about 1500 deg. Fahr., should used slight decarburization the surface not detrimental. Immersion methods above 1800 deg. Fahr. far have not met with great degree success, due the inability produce pots which will give satis- factory life, and the difficulty designing furnaces with ample heat capacity. Cyanides produce the clean- est work any the molten mediums. Cyanides are solvents for oxides and, except for gray cyanide stain, the work comes out cyanide clean enters. not recommend electric heating for cyanide immersion hardening, for several reasons. First, the operating costs are excessive; second, the installation costs are too high compared with gas and oil furnaces; and last, danger always exists burning out the unit accidental spillage cyanide, for molten salts are conductors and will produce short the elements. Electric High Temperatures “For heat-treating operations between 1400 deg. Fahr. 1600 deg. Fahr. the electric furnace comes within its widest field usefulness, for the radiation principle heat transfer most effective within these ranges. With electric elements for heating and elec- trical control, any desired temperatures can regu- lated with fine exactitude. Electric control may regarded the micrometer heat-treating and absolutely necessary for uniform hardening. “Since electrical heat shows economy only where not wasted, but held within the furnace insulating mediums, very doubtful that electrically fired car- burizing furnaces present design will show any econ- omy the fuel alone considered. But for exact tem- peratures, vital thing carburizing, the electric fuel superior. Furthermore, the fuel represents only about per cent the process cost. Pots and lids make per cent the cost, carburizer per cent, furnace depreciation per cent, and labor per cent.” Forge Furnaces Need Improvements Mr. Davis was emphatic his statements regarding the improvements that are needed the design and operation forge furnaces. “Raising the steel very high temperature,” said, “decarburizes it, in- creases the grain size, and weakens the inter-crystalline cement. Forging decreases the grain size again and mitigates portion the evil. much work done forging, the trouble minimized; little work, the grain size remains large. billet heated 2100 deg. Fahr., and finished 1600 deg. Fahr., good forging can expected. billet heated 2350 deg. and finished 2000 deg. Fahr., poor forg- ing will result. The effect high forging tempera- tures ruinous steel quality. Over-heated forgings are sluggish thermal changes. They not anneal readily, not harden satisfactorily, are weak im- pact, and show dry, coarse fracture. have seen bars pulled from forge furnaces for upsetting which actually fell apart from their own weight. Gray Iron Melted Electrically That manufacturers electric furnaces are turning their attention the production gray iron castings was indicated paper entitled, “Melting Gray Iron the Electric Furnace.” This paper was read Bromer for Wallis, president Pittsburgh Electric Furnace Corporation, Pittsburgh. After re- viewing briefly the development electric melting fur- naces, the author presented the following comparative cost figures: Electric furnace: 800 foundry returns $22.95 per gross ton 400 lb. heavy cast scrap $22.95 per gross ton 800 cast iron borings $17.07 per gross ton Electrode and refractory cost.... $1.28 Ferroalloys and coke added..... 1.50 Cupola practice: 1000 pig iron $28.68 per gross ton 1000 heavy cast scrap $22.95 per gross ton 335 lb. coke $10 per net ton... 1.68 Attention was called this paper the fact that comparative costs were usually unfavorable the electric furnace because its product has been placed quality basis. was contended that the electric fur- nace can make high-grade castings from all-scrap charge. Further advantages the electric furnace are: Control product during the melt, close tem- perature regulation, finely divided carbon content the product, and the absence sulphur pick-up. The author pointed several installations where single electric furnace run alternately gray iron and steel. One precaution necessary, however, changing from iron steel. Mill scale ore should used prepare the bottom order avoid excess carbon the first charge steel. Melting Brass Electric Furnaces That the saving metallic losses alone will usually justify the installation electric furnaces brass foundries was pointed out paper “Melting Brass the Electric Furnace,” Crosby, presi- dent Detroit Electric Furnace Co., Detroit. The metal- lic loss fuel-fired furnaces often runs high per cent, whereas the electric furnace the loss need not exceed per cent over extended periods, said the author. Improved quality product further advantage the electric furnace, this being shown not alone the first inspection the foundry, but rejections resulting from defects disclosed after much machine work has been performed various parts. “The rapid melting brass,” said Mr. Crosby, “cuts down the absorption deleterious materials. 1918, 2000-lb. furnace was rated 300 kw. and six seven heats were poured per turn. Present practice calls for furnace 250 lb. capacity, which uses 150 kw. and melts charge min. ton brass melted the use 275 290 kwhr. The disadvan- tage the electric furnace the matter fuel cost gradually being eliminated. The charge for electric energy has not changed materially the last few years, whereas the price oil has risen from 3c. 8c. per gal. Electric currents 1%c. 2c. per kw. cheaper than oil 8c. per gal., gas 55c. per 1000 cu. ft. More than 25,000 employees the General Electric Co. hold bonds amounting approximately $22,500,000 the company’s Employees Securities Corporation. The average holding $903 per person increase over 1925, while the number bondholders represents increase per cent over the previous year. The Iron Age, March 31, 1927—919 Recuperators for the pen-Hearth Suggestion for Recovering Part Waste Heat Now Going Stacks—Less Fuel and More Steel Claimed Possible—Carborundum Used Construction ossibility using recuperators for open- ting men and engineers for several hav erviewed are divided into two classes: First, those who have waste heat boilers ilizing waste heat; second, those who have waste heat boilers and prefer return all the waste heat the furnace, possible, making closed cycle. the case one large company, the claim made that the use electricity for driving mills and machin- ery gradually reducing the usefulness waste heat boilers, making the regenerator the recuperator the only alternative. the recuperator principle looked upon with favor many instances, general discussion the subject seems justified for the benefits that may accrue from engineering standpoint. have not applied the recuperator design ques- tion open-hearth furnace. have, however, made installation which the temperatures are quite similar open-hearth requirements. Heat That Goes the Stack The quantity heat lost the stack open- hearth furnace, operating under average good condi- tions, without waste heat boiler, considerable. The average temperature these gases furnaces representative plant approximately 1400 deg. Fahr. the case 100-ton capacity furnace making heat every ten hours, and gasifying 600 Ib. coal per ton steel tapped, the possible avoidable loss fuel per annum, (300 working days), the stack 4320 tons coal. reduction temperature gases from 1400 The author identified with the refractory division the Carborundum Co., Perth Amboy, 920—March 31, The Iron Age FITCH 700 deg. Fahr. when entering the stack would equivalent saving per cent the fired = ad $5.50 per ton coal gasified, for coal deliver ered and $1.50 for gasification, the savings would per year. present practice, the temperature air going the furnaces varies greatly. 960,19 This must cause loss Plan perative Revers- ing Pit Furnace, Which stalled the Fitch System peration Air time making heat. this temperature differ- ence can modified and hour can deducted from the time making heat, the results would increase production. This value, added per cent fuel saving, would make substantial total Practically all furnaces service were built with gas and air regenerator each end the furnace. The checker volume each probably averages on! cu. ft. per ton metal tapped. number plants, where furnaces were built with checker volume accepted good proportion, the hearth has since been enlarged. the checker volume could not increased, the ratio checker volume per ton steel tapped has some small plants, furnaces have low cv. ft. checker space per ton steel tapped. these cases, the stack temperature obviously high. change the construction existing furnaces for the economy would obviously ticable. build new furnace with the present type regenerator, sufficient capacity return all the desired waste heat the furnace, would undoubt- ciency regenerators service the present time recognized and understood engineers. The use fuels high calorific intensity have one esign changed operating conditions far furnace desig |! P «x a > - - fi} 7 Charging Platform Hot Gas Elevation Open-Hearth Furnace Which Has Been Added Recuperator concerned. Furnaces fired with coke-oven gas, tar and fuel oil not require preheating the gas. The preheating air only economically necessary. In- deed, number operators have expressed the opinion that not necessary preheat producer gas where can delivered the furnace parts 1200 deg. Fahr. Where fuels are adopted that not require pre- heating both gas and air, checkers may used for air only, thus substantially increasing the heating surface and temperature air. Even under this condition, the total heating surface would not sufficient many cases give the desired economical results. This last condition the particular problem interested and for which the following comments are intended. The use recuperator, combination with regenerators, shown the illustrations. The recu- perator added the present furnace without any change other than flue connections for reversing valves. There sufficient space between regenerators all fur- naces that have studied for recuperator the re- quired size. With the checker and recuperator combination the temperature the air entering the checkers from the recuperator would practically constant 1000 deg. Fahr. reversal the checker temperature the end question would maximum. This would decrease proportion the decrease temperature air going the furnace and until the economical heat transfer limit had been reached when the next reversal takes place. With 1000 deg. Fahr. air entering the checkers the variation the temperature the checkers, and consequently the air passing through, would greatly minimized over air entering the checkers from the atmosphere direct. Advaritageous results the tem- perature the furnace are apparent. The use screen checker chamber before the recuperator desirable for the purpose removing the oxides and dust, thus cleaning the gases before they reach the first pass the tubes. The tubes not f x 7 4 a 7. Pyrometer deteriorate any temperature found practice this kind. Although several shapes may used, the tubular form very efficient for the flow gases recuperators. This type construction used the recuperator under discussion. How the Recuperator Built The tubes, made silicon carbide, are treated, protecting them from oxidation. This type tube permits the maximum rate heat transfer per square foot heating surface per degree and hour. are made one piece. There are joints the tube surface exposed the direct action the furnace gases, hence the possibility leakage reduced the minimum. The tube ends are effectively sealed cementing. The tubes are installed after the tube ter- minal are The tube terminal walls are special shapes made fireclay, and designed facil- itate the removal tubes. This construction affords chamber compartment between tube banks large enough admit man for tube inspection and removal necessary. “Core busters,” shown one illustration, are employed compel the air pass contact with the wall the tube. The “core busters” consist solid cylinders made fire clay. Legs are fitted for center- ing them the tubes. “Core busters” are used all the tubes. They are made three sections each in. long. The center section made uniform diam- eter, while the end pieces are pointed facilitate the flow air into and out the tubes. The recuperator heating surface, illustrated the open-hearth furnace, approximately 7500 sq. ft., 111 sq. ft. per 1,000,000 B.t.u. fired per hr. This re- quirement based the gas from 500 13,500 B.t.u. coal entering the furnace per ton steel poured, Carbotrax Carbotrax Core Buster General Details the Fitch Carbofraz Recuperator The Iron Age, March 31, 1927—921 Heated a = ‘ = 4 ; g 3 7 7 7 7 7 Cc with temperature furnace gases entering the recu- perator 140 deg. Fahr. and reduced 700 deg. Fahr. the stack. loss heat equal 100 lb. coal estimated for gasification coal. This recuperator capacity based what being done with recuper- ators now service. The amount heating surface the total unit, regenerators and recuperator, estimated equiv- alent the cubical capacity regenerator stand- ard cross section area and 122 ft. length. The dif- ference capacity the present standard regener- ator and the proposed combination explained the difference the kind and thickness the materials used the design the recuperator. How the Recuperator Functions Referring one illustration, the furnace gases enter the recuperator “A,” and pass one direction— around the tubes—to the The furnace gases pass the tubes vertical column, thus utilizing all the heating surface the tubular members. The air for combustion passes through the tubes entering combustion air flows continuously one direction through tubes. After passing through the tubes the air reversed from one end the furnace the other alternately required. Two these recuperators were installed double chamber car type kiln for the manufacture face brick the Summerville, Pa., plant the Hanley Ceramics Co., about year ago. Each half the kiln has its recuperator, which located about 150 ft. from the discharge end. The recuperators were designed for natural gas fuel and deliver the waste gases dryer about 500 deg. Fahr. matter fact, the recuperators the Hanley plant were designed for fur- nace gases entering the first pass the recuperator 2000 deg. Fahr., whereas this temperature has not exceeded 1400 deg. Fahr. approximately. interesting and important factor the oper- ation these recuperators that practically leak- age has been discovered between the passageways for furnace gases and combustion air, recuperators that have been service practically one year. This un- doubtedly due the fact that the coefficient expan- sion silicon carbide only slightly below that fire brick; that the change volume with change temperature this practice almost negligible. There not much difference opinion among oper- ators the advisability using gases under pres- sure the operation recuperator, the design will permit. Production the all important item. have furnace that can put operation quickly, and not dependent upon stack draft, advantage that looked upon with favor. applying recuperator the open-hearth fur- nace, expected higher furnace gas temperatures than 1400 deg. Fahr. will met with eventually, and after the true value the recuperator known. the case higher temperatures, the rate heat trans- fer will much greater than found 1400 deg. Fahr. However, this advantage, that more work can done per square foot heating perature that may expected not carbide above 4000 deg. Fahr. There are transformations any temperature below tion. Certainly not any temperature found practice this kind. the event tube becoming the age air would small percentage the total and would mingle with the stack gases. pro} ability would not perceptible, and the leak undiscovered until inspection period. necessary present practice repair furnace walls and roof well clean checkers periodically, ample time would provided for inspection tubes, and the life recuperator could prolonged indefinitely. Dust Possible Limitation applying recuperator principle this design open-hearth furnace for the manufacture the only limitation appears the quantity, temper- ature and nature dust that may deposited the tubes. With 1400 deg. Fahr. temperature furnace gases entering the recuperator, the temperature the walls the lower tubes will not exceed 1150 deg. Fahr. the first pass and average several hundred de- grees for the recuperator, therefore, well below the temperature the plastic state dust, and conse- quently this may removed the use soot blowers the case boiler practice. This method has proved effective where pulverized coal used fuel boiler plants modern design, and using coal comparatively high ash contents—600 Ib. ash per hour projected into the fire box quite common this practice. per cent this ash precipitated the tubes and settings, 120 would removed peri- odically. open-hearth furnace fired with coke-oven gas and boiler fired with equal value fuel the form pulverized coal, per unit time, not exactly comparative case, due the difference nature the non-combustible substances found the flue gases. However, the quantity only considered, the dust the case the boiler many times that found the open-hearth furnace, and comparative. The temperature the furnace gases the first pass tubes would about 1400 deg. Fahr. average first explained, 1100 1200 deg. below the minimum corrosion temperature referred to; one justified concluding that serious reaction would not result due use silicon carbide the manufacture tubes. basis 0.259 deposit per 100 cu. ft. gases and 6000 Ib. coal gasified per hour and all the gases combustion passing out the stack 1400 deg. Fahr. present practice, there would dust deposited per hour the recuperator tubes all stopped there. Undoubtedly, smaller percent- age actually deposited and this removed blowing intervals, almost negligible quantity compared with the results boiler practice using pulverized coal fuel. Steel and Power Exhibition Toronto Canada’s first steel and power show will held the new Varsity Arena Toronto Aug. 31, Sept. and simultaneously with the long established Canadian National Exhibition. The steel and power show backed the Montreal and Toronto chapters the American Society for Steel Treating; Canada Council, Toronto Council and Hamilton Council the Universal Craftsmen’s Council Engineers; Toronto and Hamilton organizations and the Dominion execu- tive the Engineers’ Mutual Benefit Fund, and the Toronto branch the American Electroplaters’ So- ciety. Many the exhibits will operation. They will feature the use metal working, heat treating, materials handling, welding, power generating, refrig- erating, ventilating and electrical equipment. Exhibits 922—March 31, 1927, The Iron Age will made high-speed carbon and alloy steels, bearings, refractory and heat insulating materials, packing, water treatments, and power and lubricating oils. Technical sessions are appointed for the three days and papers are scheduled heat treatment, ma- chine shop and power plant practice, high-speed corrosion resistance, coal pulverizing, materials dling, welding, heating and ventilation. The chairman, Bradshaw, 153 University Toronto, reports that per cent the available bition space now taken. pamphlet “The Evolution Overhead Ac- counting” has been issued the Department facture the Chamber Commerce the States, Washington. McCullough, the Chamber’s department manufacture, send copy any executive requesting it. 7 7 7 7 7 q 7 a Rolls Wide Range Products’ Mill Wisconsin Steel Works Equipped Pro- duce Universal Plates, Structural Shapes, Rounds, Squares and Flats ROGERS list steel products that can rolled the new No. mill the Wisconsin Steel Works, South Chicago, reminds one number pages taken from warehouse catalog. buyer’s re- may call for 13-in, channels, 2-in. the sections are rolled the No. mill. order may made that calls for universal plates, in. squares and forging flats, in. in. in., all which rolled the No. is, fact, “mill many trades.” was designed occupy limited space and roll wide range products possible with the least capital expenditure consistent with the tion high-grade equipment. The operators the mill look upon one that will keep invested capital working near top speed all the time. not planned gage production the day, week even the month, but the year. other words, pro- duction over the period year, not records estab- lished during short periods, that shows true economy and profit. The owners believe that mill universal acter product and installed with relatively small outlay money can operated more uniform rate, year and year out, than can group mills making the same range products. This installation } FISKE light structural mill, and 24-in. bar mill for rounds, squares and flats. The No. mill extends north and south for dis- tance 745 ft. the south end terminates billet storage dock, the opposite side which stands electrically driven blooming mill that was completed the fall 1925. The new mill adjacent mer- chant mill No. which turn stands next mill No. buildings Nos. and terminate the north end newly constructed shipping building, which 100 418 ft. Standard-gage tracks and load- ing docks are provided the east and west ends the shipping room, and the entire floor space, portion which occupied two shears for the No. mill, served two double-trolley overhead electric travel- ing cranes. Electrical Units Provide Wide Latitude Operation The main electrical units, all which were fur- nished the Westinghouse Electric Mfg. Co., East Pittsburgh, Pa., are five number. Included fly- wheel motor-generator set, consisting two 3000-kw. direct-current generators driven 2200-volt 3-phase 60-cycle motor, which rated 6500 hp. One gen erator feeds 3100-hp. reversing motor, the universal mill and the stand rolls. The second generator supplies power three 2000-hp. ad- justable-speed motors, ‘which drive stands Nos. 4 3 4 q Tp « The No. Stand, Which 27-In. Reversing Roughing Mill, Driven from the Same Shaft the Uni- versal Mill (Shown Right). Crane lugs are provided the No. stand that can removed and section floor can then placed over its foundation The Iron Age, March 31, 7 7 & 4 7 4 a 7 Th 4 A | Bul The Flywheel Motor-Generator Set (Above) Designed with Two Generators. One drives the 3100-hp. reversing motor and the other provides current for the motors stands inclusive (At Right) Aiken Cooling Bed Serves the Uni- versal Plate Mill. Two cooling beds are provided for sections that are finished No. stand. single line roller tables delivers the product shears, which are located the ship- ping building. The mill building 745 ft. long The Universal Mill (Below) May Used Break-Down for Heavy Sections. The vertical rolls may moved back provide clearance, and the housing designed for the in- sertion large-collared 924—March 31, 1927, The Iron Age Shear. Combination Plate Straightener i} | —— — —. - grouped follows: Nos. motor, Nos. stand, the third motor. The main motor drives are controlled the Ward- Leonard system. The control the reversing motor the universal mill that modern electrically driven, reversing blooming mills. The five 24-in. non-reversing rolls have speed range from zero maximum 200 r.p.m. reason their being driven separate generator, which provided with the Ward-Leonard system motor con- trol. The slow speeds are advantage when rolling large rounds, and the high speeds are necessary when making thin flats. addition these units there 1000-kw. motor-generator set that supplies 250-volt direct current the auxiliary motors and cranes throughout the mill. Two heating furnaces for billets and slabs have been installed, and space has been provided for third unit, should required the future. Each fur- nace, which ft. wide ft. long inside, equipped with fuel-burning devices that may fired with either coke oven gas oil. The furnaces were built Alex. Laughlin Co., Pittsburgh. Two finishin stand, which can used finishing stand for universal plates. Finished plates are passed Aiken edge-straightener hot The universal mill may also used conjunction with the No. stand break-down for large beam sections, may used for the first passes for plates varying width from in. in., which are finished the 24-in. mill with vertical edging rolls place. heavier tonnage narrow plates can pro- duced unit time when using the 24-in. mill than when finishing the universal mill. One advantage that strongly favor the use the No. mill that can full operation the pro- duction universal plates during periods when necessary change rolls make repairs stands The No. stand two-high reversing roughing mill, the rolls which are connected spindles and couplings with the rolls the mill. other words, both these stands are driven common motor. Special crane lugs are provided the No. stand that can removed the overhead crane when rolls are being changed the universal mill. No. not operation, the coup- Flywheel Motor Generator Future 200,000-gal. tanks are used for the storage fuel oil, which handled steam-operated pumps through return system piping. The furnace dampers are electric motors. the charging ends the furnaces billets are placed skids 15-tom magnet crane, furnished the Morgan Engineering Co., Alliance, Ohio. The pushers are electrically operated and are paired that two parallel lines billets may fed through each furnace the same time. heated billet pushed from furnace falls the furnace table and delivered hydraulically operated dividing This table extends beyond the shear trans- fer that delivers billets the approach table stand No. which two-high 30-in. universal plate mill with rolls. The housings this mill are special design that allows the vertical moved they will besin the clear when the mill used break-down stand for beam and other The maximum clearance obtainable 59% 47-in. window provided the housing that rolls with large collars may used. The No. universal, mill may serve any one several purposes. may used for the universal plates widths ranging from about in. this case the finished product moves down the run-out table from the No. stand and transferred the approach table the No. lings between and No. can broken. such ase No. either remain idle, can removed and section floor placed over its foundation. The run-out table from No, feeds the rolls No. which 24-in. two-high stand far ite practical operation The housing No. however, designed three-high, but single- pass mill and only the two top rolls are used for sec- tion reduction. The bottom roll means which the lower roll stand No. driven. The product, having been given one pass No. kicked down the approach table No. which 24-in. two-high stand. The top roll No. driven through the middle roll No. The 2000-hp. motor that drives stands Nos. and has adjustable speed 230 460 r.p.m. After having been given reduction No. tlie section travels slightly inclined approath table, passes through, the case plates, 18-in. vertical-edging set and delivered stand No. which 24-in. two-high mill. The section kicked down from the run-out table No. the approach table No. which 24-in. three-high stand. The two last-named stands are line and, like Nos. and are driven 230 460-r.p.m. 2000-hp. motor. The drive between Nos. and similar that be- tween Nos. and except that this the two lower rolls the stand nearest the motor (No. are The Iron Age, March 31, | | 4 used for reduction area. The top roll No. dummy acting only means for driving the top roll No. The lower roll No. driven the middle roll No. Vertical Edging Sets Provided for Finishing Flats The section, upon leaving No. travels in- clined table 24-in. finishing stand, which vertical edging set which used when thin flats plates are being rolled. The finishing stand also driven 2000-hp. 230 460-r.p.m. motor. Two hot serving the 24-in. mill are each wide. ve yy gem ft. The groups drives, the arrangeme nea tic tables are outgrowths, some measure, the neces- ity conserve space. The edging sets ahead The Furnaces Are Equipped with Oil and Each edger driven 175-hp. 350 900-r.p.m. motor. The three 24-in. mill drives and the two edging sets are controlled from one pulpit. should noted that transfers have been pro- vided that all approach and run-out tables are right angles the axes the mill rolls, thus avoiding the diagonal tables cross-country mills with three- high stands rolls. Further, the run-out tables from Nos. and are the same level, thus bringing the three hot beds the same grade and permitting the use single delivery table the shears. This table extends along the east side the hot beds and feeds through angle and flat straighteners, which are portable and may replaced section Beyond the straighteners transfer, which feeds either side parallel roller tables, each which delivers shear. The straighteners are driven 175-hp. 350 900-r.p.m. motor, and each shear powered 80-hp. 400 motor. The shear gages are motor-operated, and each piece cut kicked off the table into cradle that stands 926—March 31, 1927, The Iron Age ment mills, the location transfers and the various levels approach and are equipped with adjustable rolls. cale platform. When cradle load recorded and overhead crane inished product storage railroad car: The contract for all the mill machiner, job was placed with the United Engineerin Foundry Co., Pittsburgh. That company later sublet the ing the universal mill and the second stand rolls, together with their tables, the Mac Hemphill Co., Pittsburgh. The tables, starting the approach No. and including the delivery No. are driven mill-type motors designed Seale washed from under all rolls and three pits, from which removed bucket at- tached one the mill cranes. The roll shop equipped with 30-in. 14-ft. grinder and five turning lathes. The Morgan Engineering Co. furnished the main Gas Burners. The dampers are motor-operated mill crane, which equipped with 60-ton main hook and 15-ton auxiliary hook. 15-ton roll-shop two 10-ton double-trolley cranes the shipping room and 15-ton roll-storage crane were supplied the Cleveland Crane Engineering Co., Wickliffe, Ohio. The mill lubricating system was installed Bowser Co., Inc., Fort Wayne, Ind. Three separate oil filtering units are provided. One unit furnishes oil the gears and the bearings the universal and the second unit distributes oil the three sets gears and bearings and also the gears and their bearings stands Nos. clusive. third system serves the bearings the 3100-hp. motor and the flywheel motor-generator set. The oil used both the universal mill and the re- duction gears and pinions heavy and will cold weather. All oil lines, both and from the various units and bearings are heated with low sure steam pipes incased the insulation covering oil pipes. Each receiving tank, filter and pressure tank provided with heating coils. net +a le Nine & Lands NOS. 0 finishing hot-rolled round steel bars was either cold drawing turning and polishing. the use these processes many tons bars all sizes have been finished yearly low cost. With the development the centerless grinder, recent years, has been found possible finish round steel bars high-carbon and high-speed steel accuracy previously regarded impossible, the same time, removing any surface defects and decar- burized skin, which might result from the process cold drawing the bars. Many tons high-chrome stainless steel bars, which are later forged turned into various shapes, are ground annually for the sole purpose inspecting the soundness the bar. This inspection sure and rapid, and value the manufacturer stainless steel that saves transportation costs and retains satisfied customers keeping the defective material his own plant. The customer, turn, saves money the elimination labor formerly wasted work- defective bars. nuraber years, the only practical methods Basic Principles Centerless Method The first installations centerless grinders were for finishing cold drawn bars high-speed and other alloy steels. The steel generally hot rolled, pickled, given one pass through the cold drawing die, annealed and accurately straightened before going the grind- ing machine. very essential that these bars straight, and the larger the diameter the bar, the straighter must be, because the small bars have degree flexibility not found the stock larger centerless grinder not straight, and must straight the very end. Cincinnati Grinders, Inc., Cincinnati. rangement the Grinding and Regulating Wheels May Regulating Noted From Dia- gram the Left Fig. (at right) —Bar Grinding Em- ployed the No. Machine 4 Round Bars Finished Centerless Grinding Surface Defects Removed and Bars Ground True Size Within 0.0005 In.—Use Process Extended 4-In. Diameter Stock CASTER* Although the functioning the centerless grinder generally known, brief review the principles operation should help better understanding the following outline its application round steel bars. There grinding wheel mounted fixed housi