The Iron Age 1927-04-14: Vol 119 Iss 15

THE IRON AGE New York, April 14, 1927 ESTABLISHED 1855 VOL. 119, No. Letting Foremen Teach Themselves Free Conference Method, Importance Sympathetic Leadership— The Germ Idea PONTANEOUS expressions opinion their own problems and those their fellows are diffi- cult obtain from foremen and superintendents open meeting. But this very thing the basis educational experiment now being conducted the Bridgeport Brass Co., Bridgeport, Conn., col- laboration with the Federal Board for Vocational Educa- tion, Washington, rking through State Board lucation. The experi- ment being used the State Board further ex- tension the sys- other indus- tries the State ill take root. For several weeks the course Nane Position List in the spaces below all of your specif regponsibilities ‘in your own devartment that you cen Supe rvisory sponsibilities Depertment Small Groups—Vital several intervening meetings have disposed their own grist. Programs Are Spontaneously Developed other words, the content the program not what one man, executive, group executives plan out advance being what they think foreman should know. program devel- oped the fore- men themselves and consists things which they are in- terested in, are having difficulty with and want discuss. The more experienced the group members are the better such plan will work, be- has been under amount practi- company organiza- Two meet- ngs day are eld—one from 9 Housatonie Avenue and the other main plant. Being “on company time,” attendance sense, compulsory. But the interest evoked has point where attendance would voluntary, were left the participants.. About dozen men And each group sit each meeting. through four weeks—twenty conferences. radical departure from the usual such cases the utter absence any previously planned Not only there set program for the meetings—there established topic ar- for any meeting. That remains developed meeting frequently not one topic, but will engage attention. Sometimes subject arry over from one meeting the next, even igh half-dozen meetings, not sooner threshed Then again, though topic left “in the air” meeting, may not again come until after Check-Up Foreman’s Daily Duties, Each Rated According (1) Its Demands Upon His Time and (2) Its Relative Importance His Eyes The fact that cal experience thus can directed toward solving and planning out bet- ter ways deal- ing with the prob lems discussed. planned pro- gram followed does not mean that nothing definite great importance comes from the meetings. the contrary, the things which the foremen are most in- terested and are having greatest difficulty with are the very ones which are debated. Without question this more value than consider matters remote interest and theoretical application. requires per- son lead such conferences who has been thoroughly trained promote discussions, guide them, draw points from the group, eliminate unprofitable subject matter get all participate, emphasize important points, rather important facts brought out and tabulate them clear and impressive manner the blackboard. Primarily the matter resolves itself into the form earnest discussion, guided tactful thetic leadership. The leader endeavors Keep out the discussion. simply guides the efforts 7 TSOR ule | } 7 hy 1057 those whose experience—whose intimate knowledge the subjects issue, based daily bread-and-butter contact—lends power their tongues. State Leadership Involved must understood that the work Bridgeport Connecticut for improving conditions its manufactur- ing plants. There has been established within the past two years State Trade School, located Bridgeport, and under the control the State Board Education. That this trade school close physical proximity the main plant the Bridgeport Brass Co. per- haps fortuitous. Nevertheless, there certain ele- ment cooperation between the head that school and the personnel director the Brass company connection with problems which come for solution. was the instance the State Board that George Sanders the Industrial Education Service, Federal Board for Vocational Education, Washington, was designated take charge leader the work the Brass company. Mr. Sanders has had several years experience practical shop and manufacturing em- ployment and has the same time had pedagogical training. While obviously impossible for any man familiar with all problems all forms indus- try, Mr. Sanders has familiarized himself sufficiently well with the general run such problems able lead intelligently the discussion foremen super- intendents, connection with their own work. HERE are three general methods which such problem may attacked. First the paper, lecture, method, sometimes followed discussion the subject matter presented. This method was used the Bridgeport Brass Co. its first attempts shop education, about four years ago. Second the teaching, task, method, which the usual school- room procedure followed. Third the conference method, that free discussion, without definite previous planning topic method presenta- tion. The success this method depends largely upon the personality the leader and upon his ability draw out from the men under training their frank expressions opinion wide variety topics. the most difficult the three plans carry out successfully, for requires thoroughly trained person conduct such developmental work. Experi- ence throughout the country seems indicate that, with foremen who are already the job, have been positions responsibility for from years and are doing their work fairly satisfactorily, this method far the most effective. least plan worth while investigating and trying out. following this method, Mr. Sanders has found essential let the men have their heads. they stray from the subject, sometimes pat question will bring them back the main line attack. More often, however, has found that the men themselves will return the principal topic, through some them becoming fidgety the diversion. Fundamentally most important the establishment bond confidence between the leader and the men. ‘the outset, Mr. Sanders ascertained the the men the conference. Adding the years individuals these positions, announced once that his five years industrial experi- ence would permit him tell them much about handling their jobs, where they had had collective 358 years. emphasized the point that was there simply lead them their own discussion their own problems, carried their own way, and make note the high spots, that they might have record the conclusions they had reached. 1058—April 14, 1927, The Iron Age further stated that the foreman’s much trade the electrician’s the machin. ist’s. And, just these trades can analyzed their various work jobs, can the foreman’: trade divided into its three big phases: with men, dealings with materials and dealings equipment. Each these important divisions his work can analyzed into various responsibilities, each which can further analyzed, and ways and means can developed carry them out more effectively. Some the Work Done one the conferences the Bridgeport plant the group was discussing the subject sion. previous meetings they had listed one their responsibilities being that Keeping Quality Production. Some the causes for defective work had been determined the group from their own day experiences, and number ways had been worked out for dealing effectively with them, prevent defective work from being turned out the future. One the causes defective work listed was that Poor Supervision. The various members the group had told the ways which they super- vise their departments, their time distribution, etc. considerable amount discussion had taken place over the effectiveness these methods and had carried over meeting which representative THE AGE editorial department visited. blank was passed around which, after filling in, showed somewhat the form indicated Fig. This reported here mainly show the method ap- proach, and not from its having outstanding importance itself. Each foreman was asked list the specific supervisory responsibilities which came under his daily work. After these were all written down, shown the diagram, each was asked put check mark the spaces the left, opposite each item, proportion the time spent daily upon that item. The item taking the largest amount time was given rating one, while that taking the smallest time was 10. Following this, check marks were asked for the right side the diagram, indicating the items which the foreman considered the greatest importance the prosecution his work. The same scale was used here before, No. representing the greatest impor- tance and No. the least. From the case shown the diagram, which was that the foreman one depart- ment, and which the leader transferred the black- board, became apparent once that the two curves connecting various check marks were means alike. This was shown more clearly when the points and curve time spent were superposed (circles and broken lines) upon the relative importance items, shown the diagram. Discussion brought once the reasons why the two curves not look alike. the same time was brought out, after considerable talk, that probably the checking the time clock might placed position first importance. Obviously, key men for certain jobs are not work any given day, either those jobs will suffer immediate steps must taken obtain men from the employment office these particular things. Thus, the check mark for the time clock was shifted into position Three general de- ductions were made the foremen from the larity the two curves. put into condensed form the leader, and written the blackboard, these were follows: Supervisory responsibilities are not always the same; that is, one does not always require the same amount time the same type work. Some jobs supervisory responsibilities may greatest importance today and least importance tomorrow. One does not need spend great time some important responsibilities. 7 — 7 7 7 With the many responsibilities that fore- has, time must distributed some This chart and the discussion clearly that cannot plot his time distribution ake set, routine matter. The de- distribution and the reduction and defective products depend upon the thought foreman gives this re- manner. so as to ? Amplifying these items, was brought out that, really not more than one two minutes each day, each half day. was brought further that certain the important responsibili- ties have been delegated specifically the assistant foreman, someone else. This makes unneces- sary for the foreman devote more than small fraction his time something such high impor- tance that was made specific part the job another key man. Much the foreman’s time naturally has spent matters which are causing trouble the For the time being, these matters become primary importance. When the cause trouble established and correction made, may several days, longer, before that same sort matter re- quires again much the foreman’s time. Meantime, something else has developed which occupies his at- tention and which turn has solved and the proper remedy applied. greatest importance this whole work the fact that all these points were brought out the men Only occasional word adroit ques- tion the part the leader—perhaps his focusing attention upon the salient point some discussion— was needed crystallize opinion. was part his task eliminate redundancy expression; that is, the matter “down brass tacks.” This shown the summary four items above, which the original statements contained great many more moment, well known that steel rails similar rolled and forged may contain hidden flaws which ultimately spell failure, possibly with serious they can detected before the material There has recently been introduced simple piece 4pparatus which will this. The essential features shown the illustration and its action based well-tried magnetic principle which consists, slipping onto the section tested two magnetizing and two test coils, the latter being con- galvanometer. When these coils are moved the section, deflection occurs the metal but should one coil come over the other still around homogeneous section, ‘ne galvanometer needle will deflectd. The principle outlined, which both simple and re- Construction the Magnetizing Device for Test- ing Rails words than were necessary. They were the combined productions many minds which, the hands the leader, became boiled down bare essentials. Widespread Future Use the request various industries Connecticut, the State Board Education has set plan whereby representatives from these industries who have been designated carry such foreman develop- ment work can trained for this purpose. pres- ent men have been appointed manufacturing concerns throughout the State attend period training for Conference Leaders, held the near future Bridgeport. These men will then back into their own plants and carry the work de- scribed this article. Initiative for this whole work rests with the Bridge- port Brass Co. Not only has been conducting, its own, series courses spread over the past four years, but asked the cooperation the official boards developing more elaborate work than had previous- been undertaken. Conferences along similar lines have taken place New York State, under the aus- pices the Division Vocational and Extension Edu- cation the State Department Education. Foreman leaders have been trained conduct plant conferences and the division has follow-up service advise with the leaders with regard special problems arising. yet too early state with confidence how much benefit will come from this system. One Brass com- pany superintendent expressed himself fully “sold” its practical utility. said that could not trace, any rate quantitatively, the improvement observed. But had noticed that the foremen seemed taking more active and more intelligent interest their work. Its leavening influence will still slower filtering through the rank and file. But the germ good idea seems lie the undertaking and its fruition will bear watching with great care. Detecting Hidden Flaws Rails Magnetizing Device, Developed Japan, Claimed Capable Locating Flaws, Fissures, Segregation and Other Defects Rolled Sections liable, has been, its application, more less con- fined laboratory work, whereas the apparatus shown intended for use mills and workshops, and the ease mills, the track. The rail, cite this par- ticular application, magnetized the magnet whose poles, and rest upon the small rollers, with but fixed air gap, between their tips and the rail. Between these poles the test coil which merely placed the rail but does not have completely surround it. horseshoe form. The magnetizing coils are connected shown suitable supply direct current, say from battery, while the test, exploring coil, connected gal- vanometer which, any marked deflection, will indi- cate the presence flaw. The truck upon which the apparatus mounted intended moved elec- trically constant rate over the rail about ft. per sec. addition the galvanometer deflection chart can arranged give diagram with deflec- tion ordinate and length rail abscissa. homogeneous rail will show slightly wavy line apart from initial disturbance commencement traverse while defect flaw shows sharp vertical break the line. Breaks less magnitude have been found indicate conditions conducive ultimate defects appearing, such local overstressing segregation, which might due the straighten- ing process which rails undergo after rolling. According Science Reports Tohoku Imperial University, Vol. XV., No. page 479, the apparatus would appear practical and well worth investiga- tion railroad engineers and The Iron Age, April 14, | 7 7 Calvanometer / 4 *\ a Slag Asset—Not Expense Blast Furnace By-Product Inherent High Value, Properly Prepared and Graded—Wide Field for Application XPANSION slag crushing companies, one instance which found the Standard Slag Youngstown, Ohio, directing attention toward blast furnace slag, its uses, preparation and possibilities. For railroad ballast has long been freely used, but much broader field, aggregate concrete road construction, yet largely untapped. The subject slag gate commercial value was thoroughly presented and discussed the winter meeting the Eastern States Blast Furnace and Coke Oven Association, held Pittsburgh March Freeman. chief engineer, Bureau Tests and Specifications, Allegheny County Department Public Works, saw reason why, with careful attention preparation, blast furnace slag might not find big market con- crete road construction. was the idea Donaldson, special agent, slag department, Carnegie Steel Co., who dis- cussed Mr. Freeman’s paper, that would necessary pay attention density and the magnesia content the blast furnace operators were find market for the slag and incidentally make valuable by-product, which would reduce the cost producing pig iron. Both speakers commented the very small proportion our slag production which finds use concrete construction, both rela- tion the amount concrete laid and the available supply blast furnace slag. Mr. Freeman placed the amount the concrete laid during 1926 100,000,000 cu. yd., which, $15 per cu. yd., would mean aggregate value $1,500,000,000. contrasted this total with 000, the value 40,000,000 tons pig iron $20 ton. Mr. Donaldson made the point that, 45,000,000 cu. yd. concrete laid east the Mississippi annually, only 2,000,000 cu. yd. made with blast furnace slag the aggregate, although, the area covered, slag freely available. Blast Furnace Slag URING 1926 approximately 170,000,000 barrels Portland cement was produced the United States, which means that about 100,000,000 cu. yd. concrete was placed this country. About per cent this concrete was used roads and equal amount poured structures. The remainder was used farms, for concrete blocks, etc. The use concrete steadily increasing and can look for- ward still Such being the case, the engineer begins concerned about ob- taining better and better aggregate mix with the improved cements being developed. seems well established that, highway con- struction, some aggregates will suffer more cracks the road than will others. Some tend form pockets, due containing soft particles, while another type aggregate sometimes fails structurally and causes the concrete disintegrate. have tests which tell something about the quality aggregates, but are still badly need more accurate tests for de- termining their durability. Concrete contractors pay little attention the quality the aggregates going into their work, but the engineers for large construction jobs are beginning pay great deal attention these things. The State highway departments are teaching the counties —the counties are teaching the townships and bor- oughs—and only matter time until such methods will adopted most contractors. The driving force back all these studies and investiga- tions the fact that large amount the concrete placed has either replaced repaired. Causes Disintegration Concrete Most the disintegration doubt due im- proper methods mixing and placing. But after have gone over the known causes for concrete failures, both roads and structures, finally come *Abstract paper Freeman, Chief Engineer, Tests and Specifications, Allegheny County ment Public Works, Eastern States Blast Furnace and Coke Oven Association Meeting, Pittsburgh, March 4. 14, 1927, The Age Road-Building Material* against the fact that, some these jobs, after every attenton was paid the details construction, the work was unsatisfactory. chairman sub-committee the American Society for Testing Materials the “Conditions fecting the Durability Concrete,” attention has been called many millions dollars worth con- crete which becoming unsatisfactory, and other which have been total failures. Some these failures were undoubtedly due the use unsound gate and great effort being put forth devise suitable tests determine this quality. These failures, found throughout the length and breadth the try, are most common the colder sections. Gravel and Limestone Aggregates Around Pittsburgh have available gravel dredged from the rivers, limestone shipped from adjoining counties and blast furnace hard slag produced the district. Gravel produced large necessary dredge about two tons gravel obtain one ton sand. This makes gravel than would otherwise be. Gravel specifications rather indefinite quality requirements. lar stress is-laid the grading and Allegheny requires the abrasion loss not exceed per Gravel coming from variable source liable lack uniformity quality the individual mat and sometimes grading. Crushed gravel uniform than run-of-bank dredged gravel. ticular advantage possessed gravel ability. easier place gravel mass-construction than any other engineer always has difficulty obtaining product. Limestone obtained directly from the ledges and test the material for abrasion ness. The limestone further subject test believed indicate its ability resist the freezing and thawing. This soundness test important, and the toe the . the + igate = ame- som a 7 7 7 7 7 necessary reject the output entire the stone unsound. Where such will gradually rot away and This unsoundness can detected and testing the source, but handled bad will result. satisfactory aggregate, particularly highway construction, rests Slag for Use Concrete Abou ago several slag producing compa- nies inaugurated series tests determine the various particularly slag. Ag- were from widely separated ranite from Georgia, trap-rock from Penn- local gravel, and blast furnace hard slag from several furnaces. These tests definitely indicated that the crushing strength slag concrete equal that made other material. But the tests were made laboratory cylinders, and refer only the com- trength the conerete. They might not necessarily apply thin slab like the section must resist flexure and abrasion. need more information along these lines. series tests being inaugurated make careful study this property possessed gravel, stone and slag con- pressive road. wt emb tests started years ago, samples steel edded specimens; the end years rusting had taken opinion not need worry about rusting being caused the use slag rete any more than any other aggregate. were Uniform Quality Prime Essential Slag ordinarily produced lacks the uniformity iality obtained from limestone. For that reason the average engineer prefers limestone over any other material for road construction. some lo- gravel cheap that the engineer cannot refuse use it, and good, uniform gravel produce good concrete. But had aggregate made under quality specification, Portland cement now being the engineer would feel some hope producing crete for The future holds great possibilities for the devel- Blast Furnace Slag dispose blast furnace slag with the least possible cost the producer, how prepare is ft 1j land, has been the concern blast furnace expens for many years. Pig iron now produced United States annually about 40,000,000 tons. approximate estimate the amount slag produced annually 20,000,000 tons. must taken away from the furnaces maintain operations. Its removal and dis- constitute important item the cost when and the slag quality improved that engineering requirements and specifications par with other aggregates. market not im- available for all the blast furnace But when properly produced, wider field for its use aggregate cement and bituminous the lighter makes the finest railroad ‘ne United States east the Mississippi River annually placed approximately 45,000,000 cu. this amount only some 2,000,000 made with blast furnace slag the aggre- ‘withstanding the fact that this area slag within easy shipping distance from the fur- the usefulness slag for ballast and bitu- roads, traffic bound roads offer prom- Donaldson, special agent Slag De- arnegie Steel Co., Pittsburgh. opment manufactured aggregate from blast furnace slag. sure, will have control the flux stones, produce slag which will not disintegrate with age. will necessary use care making the slag, that will not contain foreign matter, such brick and other rubbish. Slag now produced makes satisfactory concrete, but will necessary improve its general characteristics greatly, have demand par with gravel and stone. The average engineer strenuously objects placing light— so-called “honey-comb”—slag into his concrete. The use slag will retarded until this light material has been eliminated. One thing which has made slag desirable this district the fact that the producers have used care grading. Engineers particularly desire material comply with specifications grading, and some will overlook the light material the slag well graded. have built some satisfactory roads with blast fur- nace hard slag. were possible obtain slag having the same uniform quality limestone, would doubt readily obtain the same following among con- crete producers limestone, particularly for road con- struction, where the highest type aggregate must used. Only One Yard Fifty Made from Slag the 100,000,000 cu. yd. concrete placed this country last year, presume that less than per cent was made with blast furnace slag. would estimate that more than one-third this concrete was placed within shipping distance blast furnace slag, that there should opportunity for considerable ex- pansion the production blast furnace hard slag by-product, and not waste product. Under the conditions which would produce the max- imum use blast furnace slag for concrete gates, manufactured aggregate would had with known chemical composition. would durable under the action the elements, material free from organic matter, one which has splendid surface for bonding the mortar and one which crushed uniform grading, free from dust. will producers blast furnace slag see that future de- velopments tend toward uniformity and durability. By-Product Value* ising outlet. The latter are constructed counties and townships doing small amount grading and placing upon the road concrete size slag mixed with per cent slag sand, These roads are rolled and scarified alternately for about three weeks, until uniform set has taken place. This type offers good road approximately $5,000 mile, which boon poorer communities unable have costlier type highway. Magnesia Content Important Unfortunately, many producers have the idea that all blast furnace slag should suitable for the market after passing through the crushing and screening plant. Such not the case. Slags from blast furnaces using limestone containing least per cent magnesia are suitable for the market present. But when limestone such produced the Mahoning and Shenango Valleys and points east Pittsburgh, well some limestone from the Lake regions, used, without the addition stone bring the magnesia content per cent, the slag slakes down the dump pit. Slag aggregate concrete came into use about 1895 the eastern part Pennsylvania and Johnstown. came into more general use, particu- larly blast furnaces and steel plants, between 1903 and 1906 the Pittsburgh district, Pottsville, Read- ing and Lebanon, Pa.; Youngstown, Cleveland and Lorain, Ohio; Mayville, Wis., Chicago, and later Gary, Ind. one another these plants has been used concrete about every type construc- tion for which concrete can and light The Age, April 14, 4 times foun quarry be stone 18 use jisint cause Gist: must De pl Limestone ! 7 | 7 7 ry he an an 7 n eS ise +h é 7 | ne 7 . | posit as producir to ire pr an gra ay tr he va. ne rm gat es. ave ] mis 1e- 7 — mass foundations, including those blast furnaces, coke ovens, stacks (several which were 290 ft. high), water tanks, dams, sewage treatment plants. First Tentative Specifications About ten years ago the first effort toward estab- lishing tentative standard specifications for blast furnace slag was made the American Society for Testing Materials, the United States Bureau Stand- ards, the United States Bureau Public Roads, the American Society Civil Engineers, and the American Railway Engineers’ Association. Recognition all these societies has been obtained for under certain definite specifications, one which that the weight crushed slag shall not less than per cu. ft. While some States specifications vary slightly, slag when submitted the abrasion test, compared with allowable loss stone per cent. These requirements were made the societies favor slag, due the fact that has more angular fracture than stone, leaving thin, sharp edges, which. when submitted the abrasion test, show much higher loss than limestone. But when placed con- crete slag uniform density has shown, under the wear tests the United States Bureau Public Roads, good resistance wear the best gates. Slag Ballast Material Due the presence considerable amount honeycomb slag, has not been considered desira- ble railroad engineers for ballast trap rock hard limestone. The common complaint that breaks under the action the tamping pick much larger extent than good limestone. But field offers such wide possibilities for the use blast fur- nace slag railroad ballast. During 1926 railroads New York, Ohio, Pennsylvania, Kentucky and West Virginia used total over 1,000,000 tons crushed and screened blast furnace slag for ballast, and 275,000 tons the Alabama district. The Southern roads territory adjacent Birmingham used also total 1,720,000 tons rough bank slag for sub-ballast pur- poses. Even with this, however, the slag used for ballast 1926 was almost negligible when compared with the amount stone and gravel used for ballasting the large trunk line railroads, the greatest source whose income hauling raw materials into the furnaces and finished materials away from them. grade blast furnace slag were produced comparable that lime- stone, the railroads could not well refrain from using ballast material within reasonable shipping distances from points production, provided, course. the prices are not above those for limestone. American Electrochemists Arranging Western Excursion departure from the usual custom the American Electrochemical Society has been decided upon for the fall meeting this year. will take the form ex- cursion through the Northwest, visiting industrial centers interest majority the members. The trip will last for little over two weeks, starting from Chicago Sept. and returning Sept. 20. special train will provided, leaving Chicago the evening Monday, Sept. and observation and club cars, in- cluding maid and valet service and all possible conveni- ences, will included. The first stop will made Minneapolis, where Dr. Mann and his local committee will conduct the party through the School Mines and the United States Bureau Mines. The next stop will Butte and Anaconda, Mont., and other western locali- ties, view mines, ore dressing, smelting and refining plants and laboratories. Spokane, the latest power developments and various industries will in- 1062—April 14, The Age The Carnegie Steel Co. made of eXpe ments several years ago determine what material could obtained more pid and cooling the molten slag than mplis the large slag dump. The slag resulting dense, weighing over 100 per cu. compared depositing the dump. This material Was ap. proved the railroads for ballast. However, various reasons, especially the cramped surrounding one two the plants which ex. periments were made, production tities not been possible. shed Was extremely ne Nag The slag produced the latter point has usual possibilities, especially for railroad ballast. weighing slightly over 100 per cu. ft. very dense, with absorption less than per cent and abrasion loss averaging about per cent, pared with allowable stone abrasion loss per cent. This shows clearly that, the ordinary furnace practices today, slag having cent more magnesia commercially possible. Manufactured Product, Slag Quality Under Control Mr. Freeman stated that there was approximately 100,000,000 cu. yd. concrete placed during 1926 the United States. Approximately per cent, 000,000 cu. yd., was made blast furnace slag. course much the yardage concrete was beyond the shipping distance blast furnace slag. However, the territory within easy shipping distance, which 45,000,000 cu. yd. concrete was placed, only 2,000,000 cu. yd. was made with blast furnace slag. Assuming that all such slag produced 1926 had entered into concrete, there still would have remained approximately 25,000,000 cu. yd. concrete made with stone and gravel. Blast furnace slag not the only mineral aggre- gate feel the tightening specifications. Many engineers are deeply concerned where they will find materials with which produce permanent con- crete. Recently eminent concrete authority said that blast furnace slag, properly made and prepared, more nearly approaches the ideal than any the natural mineral aggregates, because anufac- tured material and can controlled, which not the case with natural mineral aggregates. producers realize that slag valuable product and not waste material, will naturally re- ceive more care and attention its handling. Stated another way, the producer can prevailed improve production methods, slag possibilities may readily capitalized. spected. The Snoqualmie Falls power development Seattle, Wash., will one the interesting Just out Seattle stop will made inspect Cascade tunnel, the longest America, now nearing completion. From Seattle the Northern Pacific Railway provide boat trip Vancouver and return. east again, the Great Falls power development and electrolytic zine plant will visited. There will side trip Trail, C., view what probably the most complete metallurgical plant the Technical sessions will held Omaha, Neb., Keokuk, Iowa, the party returning Chicago Sept. 20. One day side trips are planned into and Glacier national parks. The ladies wil! pecially entertained the local committees the vari- ous towns visited. The Northern Pacific has the entire cost the trip $182, including mea Members with guests who desire participate trip may communicate with the secretary the ciety, Dr. Colin Fink, Columbia University, York. | 7 = Manganese Lost Basic Slags Nearly 280,000 Tons the Metal Wasted Last Year from Open-Hearth Slags—How the Calcu- lation Made—Recovery Advocated DR. war period 1914 1918 stimulated interest the quantity, composition, and proper use the reserves manganese ores this country. Most the manganese used the steel industry the form ferromanganese. Our reserves manganese ores from which this alloy can made are limited. The total reserves ore suitable for manufacture ferro- manganese are equivalent approximately 600,000 tons the alloy, and our yearly requirements are ap- proximately 350,000 tons. therefore, the ut- most importance conserve the limited resources against the possibility cessation importations and bend every effort solve the metallurgical prob- lems involved the utilization such domestic sources manganese which might rendered avail- able for the manufacture ferromanganese. Low-grade manganiferous iron ores are the most important the other sources manganese which may converted into ferromanganese. These ores are being studied the North Central Experiment Station the United States Bureau Mines. Another source, which ever increasing, the manganese the open- hearth slags. With the present day use high-manganese iron for the open-hearth, the manganese content open- hearth slags has considerably over that ten years ago. 1917, Cone (a) estimated that the average MnO content basic open-hearth slags was per cent, but present this approximately 8.0 8.5 per cent, the increase being due primarily the high-manganese pig iron. This figure has been acuteness the manganese situation during the lined follows: the writer’s personal knowledge the practice number steel plants, average MnO content 8.0 8.5 per cent has been observed. From large number plants where data slag composition are not available, Equilibrium Manganese, Carbon and Transactions, and E., vol. 73, 1926, in HERTY, but where data manganese content the pig iron, and limestone charged into the open-hearth furnaces, are available, the manganese content the slag may readily For the pur- pose calculation the following assumptions are made: (1) Per cent manganese in pig iron.......... — (2) Per cent manganese scrap.......... 0.40 (3) Per cent pig iron 45.00 (4) Per cent FeO finishing slags.............18.00 (5) Per cent limestone 8.00 (6) Pounds dolomite used per ton steel..... 45.00 Using charge 100,000 lb. for ease calculation, the manganese entering the charge is: The slag weight calculated from the lime charged, assuming that the limestone contains 52.0 per cent CaO, the dolomite 54.0 per cent CaO, and the final slag 42.0 per cent Lb. CaO dolomite........ 44.5 Ib. Slag weight From the relation between manganese the metal and manganese oxide and iron oxide the slag, (Per cent slag) 2.3 for tapping (Per cent metal) (Per cent FeO slag) temperatures The ratio: Per cent MnO slag Per cent metal whence Per cent slag Per cent metal Knowing the slag and metal weights and the total pounds manganese, the calculation the manganese the metal and the slag is: Let x — Ib. manganese in the slag 940 —- x = Ib. manganese in the metal 100 x 12,500 (940 (100) 100,000 EXT week Cleveland unusually important meeting the general manganese problem held under the auspices the Ohio section the American Institute Mining and Metallurgical Engineers, the Hotel Cleveland, Cleveland. One the problems considered the conser- vation This article discusses loss manganese going every day large scale. The author physical chemist the Pittsburgh Station the United States Bureau Mines. The article was written especially for THE IRON AGE with the ap- the causes and cure for steel, well man- ganese and other problems. The Iron Age, April 14, 7 7 7 0.42 estimated two independent methods which are out- 2.2, 7 : ) ~~ q af \ é 3 whence manganese the slag and 940—760 180 lb. manganese the metal. Residual per Per cent manganese the 12,500 7.85 per cent MnO. This very close check against the figures given for MnO previously, and safe assume 8.0 per cent MnO (6.2 per cent Mn) the average content finishing slags. The total amount basic steel produced 1926 was approximately 37,500,000 tons. The slag weight for basic furnace will average approximately per cent the weight steel, and the total weight slag was therefore 4,500,000 tons, containing 6.2 per cent manganese. The manganese these slags was 279,000 tons. small amount this 279,000 tons going back into the blast furnace raise the manganese content the pig iron, but the greater portion undoubtedly being dumped. addition finishing slags, “flush” are importance that they contain greater both iron and manganese than finishing the blast furnace but their tonnage pared with finishing slags. the present time are essentially manganese into the pig iron the use manganese ores, using the manganese for when com phur elimination, slag conditioning, and smal] ferromanganese, and then sending the greater part the manganese the slag heap. Recovery the manganese from these either proper use the blast furnace, their utilization raw material the manufacture spiegel ferromanganese, must come our reserves manganese ore decrease. Research methods working these slags should not put off until the manganese situation becomes pressing, because there will undoubtedly technical difficulties ull them the most efficient and economic manner. Alita Method Assembling Caterpillar Treads Features Use Motor-Driven Socket Wrench for Uniform Setting Bolts—Foot Pedal Control GEIGER RACK making the Caterpillar Tractor Co. plant San Leandro, Cal., the basis straight line production. one can see the growth from one small unfinished drop-forged link in. com- pleted track ft. long. The link, after seven opera- tions six single-purpose machines, where rights and lefts are handled together, enters rotary automati- cally controlled electric furnace, leaving which given differential quench. Provision being made for the link, after heating, drop into special holder and automatically receive the differential quench through the medium small motor, gear set, pneumatic clutch and the appropriate contacts for solenoid-operated power switches. After draw the links are assembled, with the 3 _ \ \ \ 14, 1927, The Iron Age track spools and pins, special 80-ton press, after which the shoes are attached the completed track, conveyed trolley, shown Fig. the point application the main assembly floor. Worthy note, for assembling the track shoe, motor-driven socket wrench (shown Fig. which, through the medium pneumatic friction clutch, will slip predetermined torsional stress and released entirely, for passing from bolt bolt, foot action the operator, shown the arrow This mech- anism assures uniform setting the shoe and also constitutes physical test each bolt and nut seen the air hose that supplies compressed air the pneumatic friction cluteh. ~ Fig. (at Left) Shows the Air Hose Supplying Compressed Air the Pneumatic Friction Clutch, While the Motor Which Drives the Socket Wrench. The lower part the wrench, gages the bolt and sets predeter- mined and uniform tension. Foot lever used shifting from bolt bolt Fig. (at Top) the Shoes Are Being Attached the Track | t = 4 — NDUSTRIAL research laboratories are usually thought non-productive units industry. That is, their value based, not upon tangible earn- ing capacity but upon their contributions toward im- proved methods and practices the field which they serve. From this viewpoint well established research department, meeting all the requirements the in- dustry which part, would seem have reached its highest development. Cases however, where research leads the opening new commercial fields and then pos- sible that research department may made pro- ductive branch subsidiary its parent organiza- tion. may continue carry its investigative work and the same time enter the commercial field, thereby opening the way carry its own charges operation and maintenance and also add the earn- ing capacity the organization which part. This has been the history the Chrobaltic Tool the original purpose which was the scientific investigation materials for present requirements well new metals for use the engineering field. possibilities more extended use industry alloy castings were such that was decided sep- arate the research department from its parent organ- and make separate unit, which would carry metallurgical investigations alloys and de- velop market for its produets. This move led the organization the Chrobaltic Co. with headquar- ters and plants Michigan City, Ind. Research work now going Michigan City directed toward widening the field for the use alloy castings, particularly where they may substituted forgings. the present time production con- special and heat-resisting alloys and electrical resistance The main foundry brick and steel building which well equipped with The metal Research Promotes Alloy Demand How Laboratory Has Increased Variety Prod- uct—Making and Testing Heat-Resisting Alloys Made Electrically trode type electric furnace made William Swin- dell Brothers, Pittsburgh. Electric current pur- chased from the Northern Indiana Public Service Co. Incoming voltage 6600 and this stepped down 350 volts, for use the furnace, means air- cooled Westinghouse transformer. The average charge for the highest type alloy per cent nickel, per cent chromium and per cent other ingredients, consisting largely scrap produced the foundry. The scray first charged and then the nickel and chromium are added. Before pouring, the metal slagged and deoxidized. Special means are employed obtain accuracy melting and pouring temperatures. The freezing curves such alloys drop more rapidly than those cast iron and therefore the range temperatures must have special attention. Pyrometers are used show temperatures the furnace, but before the metal poured hand check test made. About per cent the molds are made the floor, although three molding machines are available and are used when economical so. The core- box type molds are made iron flasks which are moved transfer cars 2-ton electric hoist mounted I-beam bridge. The loaded cars are pushed into oil-fired ovens where the molds are baked for hr. Once mold baked, left the oven until time for used. this way there little possibility its absorbing moisture from the air. Facing sand not used but the surfaces the mold are washed close some the voids the sand. The cores are the ventilated type. Gates are cut off means band saw. Four Types Alloys Produced Four types heat-resisting alloys are now being made. These alloy castings can cut means Per Cent the Molds Are Made the Floor. They are the type and are dried oil-fired ovens. The Swindell electric furnace shown above The Age, April 14, 7 7 N sc 7 7 7 4 gas flame and they can welded either the elec- tric arc gas method. The castings are rust-resist- ing and are machinable. They are ordinarily made four grades, each meet specific thermal require- ment. Roughly these are for temperatures above 2000 deg. Fahr., from 1650 1950 deg., temperatures below 1650 deg. and for low temperature work. 650-lb., single-phase Snyder furnace located separate foundry building which equipped for the manufacture small alloy castings. Among the products cast that department are variety oil burner castings and resistance grids that are used electrical control devices. The specific resistance one the alloys the same that cast iron and, shorted, the alloy grid will not spark, thereby mak- ing desirable for use electric mine locomotives. How the Alloys Are Tested one section the industrial laboratory are sev- eral oil-fired furnaces where heat-resisting alloys are tested. Burner pots, such are commonly used domestic oil-heating appliances, and now undergoing extensive tests. Careful attention given the de- 4 and sign the pot. then cast from alloy metal placed furnace special construction with pyrometer controls and relays. The complete unit then tested. The oil flame lighted and the temperature the casting brought rapidly the maximum temperature developed the burner unit. Then the flame suddenly cut off and blast cold air directed the pot, the oil being MB matically turned when the temperature the pot reaches pre-determined point. This heating and cooling cycle continued, with periodic examinations, until the casting that under observation fails. The recording instruments furnish graphic record the temperatures employed and the number times that the unit was operated. care- ful study the development stresses and the havior the metal under actual working conditions leads alterations the design the pot and changes the content the alloy. This plan aims determine the correctness designs and appropriate- ness materials for certain definite functions, and establishes values for products anticipation their manufacture large way. Iron Made About Years Ago Chain, Uncovered Kentucky Landslide, Unusually Well Preserved— Character the Wrought Iron and Cast Iron Revealed Analyses and Structure HAIN, composed links wrought iron and struts cast iron, was defensive weapon used 1861 the confederate army its efforts hold the Mississippi River against the aggressive movements Gen. Grant. Sixty feet chain mile long used was uncovered recently landslide Co- lumbus, Ky. was attached anchor, the shaft which ft. length with each arm ft. long. For years this chain has been buried depth ft. the east bank the Mississippi River. The bars used for the construction the links were about in. diameter. The spread the center each link in. and the overall length in. The average weight link, complete with cast iron strut, lb. Cast one side each strut are the S.” and the opposite side “W. Macrophotograph Chain Link Taken from the Mississippi River After Having Been Macrostructure Transverse Section the Old Chain Links Links. 100 1066—April 14, 1927, The Iron Age Y.” thus giving the clew that the chain originally belonged the Federal Government and that either was seized with Government stores the opening the war that was later captured and used more less effectively the confederates prevent pass- age Federal gunboats the Mississippi River. Analysis the links shows them contain: Per Cent 0.06 0.185 Slag and oxides........... 2.50 Microscopic examination discloses typical wrought iron structure. The metal contains large amount slag and the grains ferrite are equi-axed. Crystal- lization not regular and deep etched transverse There 1861 Since One f — — 7 7 7 7 i 4 4 : 7 - — = — | t section shows the lamellar structure wrought cro The links are well preserved and only super- fic ially yrroded. The analysis strut shows the following com- weition * posi Per Cent 3.69 0.64 0.536 Sulphur 0.072 1.21 Microscopic examination classifies this gray casting and, the opinion chemists, this mate- rial has resisted corrosion because the mechanical the high percentage carbon. The truts contain plates graphite, large amount pearlitic carbon and phosphide eutectic. number blow ho les, 4 “uo. ranging size from 1/16 in. diam- eter, were found all the castings that were examined. Analysis the clay which the chain was buried showed contain: Per Cent 75.30 12.51 Calcium oxide 0.90 Magnesium oxide ........ 0.94 Loss ignition ......... 3.20 Indications are that there was nothing contained the clay serve unusual protector for the chain. The theory has been advanced that the low percen- Structure Existing Strut Taken from One the Links. 100 tage manganese and carbon the link and the high percentage manganese, phosphorus and sulphur the strut are not responsible for retarding corrosion, but that the well preserved condition the samples due the fact that they were buried, protection having been afforded the strut because its high con- tent carbon and silicon. The links are believed have been protected the slag fibers the wrought iron. More Tons Per Blast Furnace Per Day Average Production Pig Iron Pittsburgh District Increases P