The Iron Age 1927-07-21: Vol 120 Iss 3

RON AGE New York, July 21, 1927 ESTABLISHED 1855 Substitution Compressed Air for Steam the Operation Hammers, Presses and Shears VOL. 120, No. European Users Have Gone Far Making the Change, Re- duce Their Oper- ating Costs PROF. ERNST BLAU* EPLACEMENT steam compressed air, motive power the operation hammers, presses and shears, has been developed Europe reduce fuel expenses forging. early 1921, seven steam hammers with rams from 250 750 kilos (approximately 550 1650 and one forge press 1000 tons pressure, the works Gebriider Sulzer, G., Winterthiir, Switzerland, were operated summer means compressed air. All them are hooked live steam supply pressure seven atmospheres (approximately gage) and are operated with steam during the winter. Exhaust steam from the units during winter oper- ation utilized for heating and for maintenance the hot-water supply. The compressed air used during the summer supplied two compressors using 120 atmospheres (about 105 120 lb. gage), and sup- plying the hammers from tank capacity cubic meters (about 2650 gal.). compressor using hphr. further compresses portion the air atmospheres (about 175 lb. pressure) for the operation the press. This secondary compressor receives air compressed for the operation the hammers, supplied from the initial compressors working with interposed coolers. This delivered temperature 100 deg. (212 deg. Fahr.), which drops deg. (140 158 deg. Fahr.) the storage tank. From this drawn and preheated 200 deg. (392 deg. Fahr.), utilizing waste heat from the forge furnace, resulting *Austrian correspondent Universal Trade Press Syndicate. 131 considerable saving energy required com- pression, the resistance being reduced. Other Countries Making the Same Changes Since that time similar changes have been made many German, Scandinavian and Czechoslovakian works. Scandinavian steel works compressed air plant for supplying the tools the foundry was considerably enlarged, put the hammers and presses, formerly steam operated, compressed air footing. Two independently operated electric compressors were installed, 1000 hphr. power consumption, for each 5000 cubic meters (177,000 cu. ft.) intake from atmospheres (118 147 lb. absolute pressure). The united capacity the storage tanks 350 cubic meters (92,500 gal.). The regulation based the fact that, upon fixed maximum pressure being ob- tained the tanks, the compressor automatically shunted out commission, starting again only when the pressure the tanks drops fixed minimum limit. Some the Advantages Gained The economy effected this change motive power considerable, especially when the air com- pressed means power supplied from public utility plant. changes are necessary the ham- mers, presses shears. but necessary close the pet cocks replace with plugs, resulting immedi- ately stopping leakage losses. There reduction maintenance costs, all packing and calking materials will give five six times the length service. Furthermore, there THE Using conomy Using Air for Power 7 4 reduction, per cent, the amount lubricat- ing oil used, for steam operation the lubricating oil away. compressed air operation the piston rods are not subjected the same wear the case steam operation, they are not contact with condensation water. great advantage compressed air operation that the medium functions immediately, while the case steam operation, time lost starting, through condensation. the forge furnaces are close the hammers, presses and shears, preheating the com- pressed air practicable directly the place con- sumption. the same time, loss temperature the compressed air its way from the heater the place use will small, even pipe lines are not insulated. Limitations Heating Air The degree heating the compressed air de- pends upon the quantity and the temperature the waste gases, well the oil content the com- pressed air. When furnished cylinder compressors, compressed air has considerable oil content, that there limit the temperature which such air can heated. However, can raised considerably the employment good lubricating oils high flash point. One hundred and eighty deg. (356 deg. Fahr.) may taken the upper limit. higher tem- peratures are desired, turbine compressors are exclu- sively considered for the production the com- pressed air, these rotary compressors furnish oil-free compressed air. Even then, however, account the lubricating conditions connection with the hammers, presses and shears, there certain limit the heating. This found around 300 deg. (572 deg. Fahr.) for the com- pressed air when admitted. Ordinarily, temperature about 250 deg. (482 deg. Fahr.) should suffice. Without heating and room temperature deg. (99 deg. Fahr.), the compressed air would enter the tool absolute temperature 310 deg. with preheating, with temperature 450 and 525 deg. absolute respectively, according whether delivered cylinder turbine compressors. Air and Steam Equivalents the operation hammers 1000 kilos (about 2200 lb.) steam approximately equivalent 1000 cubic meters (about 35,300 cu. ft.) intaken air. the operation presses, however, where larger pieces are worked and the process forging consumes more time 21. 1927. The Iron Aze Pneumatically Operated Ma- chine, Rail- road Shortening Main Rods, Side Rods, Draw Bars, Rocks, Pa., the Pitts- burgh Lake Erie and where stoppages are longer, the same amount steam equivalent about 700 cubic meters (about 24,700 cu. ft.) intaken air. The Allgemeine Elektrizitats-Gesellschaft (AEG), Berlin, has conducted series experiments with smaller (and, later, also with larger) steam hammers, obtain reliable data for the basis calculating the amount compressed air required, well for ascertaining the proper type devices operated. The first trials were made with two steam hammers with rams 600 kilos (about 1325 lb.) and 275 kilos (about 608 Ib.) North Germany locomotive works. obtain experimental results fair and satis- factory character possible, the hammers were first worked with steam and then with compressed air, the same day. Identical pieces material were worked them, and the working force was not changed. Details Test Conditions the hammer with 600-kilo (1325-lb.) ram weight, axle rings with shrunk-on hoops were produced. The raw material was ingot iron block form measuring 105 110 105 mm. (about in.) and weighing 9.6 kilos each (about The blocks were worked into plates diameter 185 mm. (about in.) and mm. (about in.) thick. They were then swaged 190 mm. (7.48 in.) diameter and mm. (1.26 in.) thickness and perforated means conical mandrel diameter 115 105 mm. (4.53 4.13 in.) and completed few finishing strokes after removal from the swage. The raised seam was from (0.079 0.118 in.) wide and mm. (0.236 in.) thick and the weight the finished piece was 5.6 kilos (12.4 Average time required produce one piece and bring material for another one from the fire the hammer was min. uninterrupted operation the steam consumption the hammer was 335 kilos (about 739 lb.) hour. During the time consumed the test, 101 min., there were min. stoppage. This made equivalent 310 kilos (685 lb.) hour net steam consumption. How Compressed Air Compares the compressed air operation following, the total working time, including hauling the block from the furnace, was 4.65 min. During uninterrupted operation the hammer consumed 360 cubic meters (about 12,700 cu. ft.) intaken air hour. there was stop- page min. during the trial period min., effective air consumption 310 cubic meters (about wen f | 10,950 cu. ft.) hour shown. With steam operation there was hourly production pieces; with com- pressed air operation, 12.5 pieces. the basis equal number pieces the hourly consumption steam and compressed air were 310 kilos (about 685 lb.) and 290 cubic meters (about 10,250 cu. ft.) respectively for the 600-kilo hammer. Experiments were made under identical conditions the hammer with ram weight 275 kilos (about 608 Round rod was forged, length 155 mm. (6.10 in.) and (1.24 in.) diameter, two wedges always being worked one piece and the loops being formed swaging. The working, including taking from the fire, consumed min. per article. The steam consumption was 262 kilos (about 580 hour; the air consumption was 242 cubic meters (8550 cu. ft.) hour intaker air. Using the Steam Compress Air Electrically steam the amount 310 kilos (about 685 instead being supplied the 600-kilo hammer 2000 kw., with average actual steam consumption 5.6 kilos (about 12.4 lb.) per kwhr., possible produce kwhr. With this amount current electrically operated cylinder compressor will compress about cubic meters (about 353 cu. ft.) free air per kwhr. atmospheres absolute. This makes total 550 cubic meters (about 19,400 cu. ft.) air hour compressed atmospheres. the 600-kilo hammer requires for pneumatic operation only 290 cubic meters (about 10,250 cu. ft.) air, the sav- ing, 550—290 per cent. was thus possible means the steam turbine and the electric compressor operate also the 275-kilo hammer. Larger Hammers Similarly Tested After the tests smaller hammers, trials were made with 1200-kilo and 2000-kilo hammers. With steam operation their pressures were 10.4 and 11.4 atmospheres absolute; with compressed air operation, 8.04 and 7.43 atmospheres. the 1200- kilo hammer dump grate levers were produced, while the 2000-kilo hammer cube-shaped ingot blocks were worked into dome base angle rings. The trials gave average for the 1200-kilo hammer 732 kilos (about 1615 steam hour, against 701 cubic meters (about 24,725 cu. ft.) intaken air; for the 2000-kilo hammer, 2095 kilos (about 4714 lb.) steam hour, against 1916 cubic meters (about 67,600 cu. ft.) in- taken air hour. The 1200-kilo hammer had cylinder diameter 380 mm. (14.96 in.). steam pressure 9.42 kilos Air-Operated Flanging Ma- chine Work Locomotive Flue Sheet. The operator’s con- trols are conve- niently (Our photo- graphs are from Ingersoll Rand Co., New York) per sq. cm. (about 134 lb. per sq. in.) the active force the outset the descent approximately 7400 kilos (about 16,300 case air pressure 7.02 kilos per sq. cm. (about 100 per sq. in.), 7400+ 9.42 7.02 5500 kilos (about 12,125 The exhaust pressures the hammer, 0.59 and 0.34 atmospheres respectively, leave the change the energy actuating the pistons throughout the entire course almost pro- portional the initial pressures. Striking Time One-Third Total Accordingly, make the motive energy equal both cases, the cylinder filling must increased case pneumatic operation. Therefore the present instance, case equal steam and air pressure, the air consumption during the striking time the ham- mer should reduced about per cent (from 7400 5500). The striking time the hammer con- stituted per cent the total working time each piece. the intervening time air consumption 6.4 cubic meters (about 225 cu. ft.) minute was re- corded, corresponding air consumption 254 cubic meters (about 8950 cu. ft.) hour. Thus, during the striking time exclusively, there was consumed 447 cubic meters (about 15,800 cu. ft.) air hour (701—254 447). consideration the circumstance that, with higher pressures, leakage losses rise the extent from per cent, 614 cubic meters (about 21,700 cu. ft.) hour may considered the attainable air consumption. This case the pressure the steam and the air are equal. the case the 2000-kilo hammer the relation the pressures still more striking, 10.4 and 6.4 atmospheres. The forces above the cylinder pistons diameter 420 mm. (about 16% in.) were 11,300 kilos (25,900 and 7000 kilos (15,430 According the above, the minimum air consumption varied striking per cent. Further computation carried out before gives final result air consumption only 1560 cubic meters (about 55,000 cu. ft.) hour. Comparisons the Two Methods this manner the following comparative data have been arrived at: For hammers 600 kilos (1325 and 2000 kilos (4400 Ib.) and for steam- hydraulic presses the steam consumption for each 1000 kilos (2200 lb.) hour, while the air consumption 930, 800 and 675 cubic meters (32,800, 28,250 and 23,800 cu. ft.) hour. With 1000 kilos (2200 steam turbo-gener- ator taking 5.6 kilos (about 12.4 steam per The Iron Age, July 21, 1927—133 kwhr. will deliver 178 kwhr. energy. With this amount experience has proved that, with electric- ally operated cylinder compressor, 1800 cubic meters (about 63,550 cu. ft.) air can taken and com- pressed density atmospheres absolute, all losses having been taken into consideration. Savings compressed air operation, compared with operation steam, are accordingly, the three cases cited, 1800—930 870 cubic meters (about 30,700 cu. ft.), per cent; 1800—800 1000 cubic meters (about 35,300 cu. ft.), 55.5 per cent, and 1125 cubie meters (about 39,700 cu. ft.), 62.5 per cent. Motor Drive Advantageous Electric operation compressors furthermore has advantage over operation steam the fact that the installation compressor plant for electrical operation the foundry easy and simple matter, and because compressor will accommodate itself bet- ter the variable demands that may put upon it. addition, the electrically operated compressor will benefit from the advantages improvement power production, above all reductions the price for electric power supplied, made possible the use high-pressure steam, powdered coal burning, utility generating stations. For works where current supply from hydraulic, gas Diesel engine sources, well from distant high-tension gener- ating plants, available, electricity the only motive power considered for compressor operation. Instead making the comparison between steam and air consumption for the same work terms kilogram-hours and cubic meter-hours, the volumes the two should compared under the presupposition equal degree pressure the outset, explain the apparently contradictory fact much smaller volume compressed air being adequate for the forg- ing work. two cylinders each closed above steam and air respectively are contained pressure atmospheres. The air taken the compressor has temperature deg. C., which temperature rises 100 deg. being compressed at- mospheres. understood that the temperature drops deg. rest, and that enters the cylinder this temperature. Restricting Maximum Air Temperature employing waste gases from the furnace for heating the compressed air, the regularity attack these gases does not play any figure when precau- tions have been taken that the maximum temperature attained the air will not exceed fixed point. This provided for interposing air chamber between the compressor and the hammers. There danger the compressed air being heated too strongly when air consumption for forging tem- porarily interrupted. this case may stagnate the pipe system and the heater, which continues function. therefore necessary provide by- pass that, means regulating slide, the gases may sidetracked from the heater. This slide can operated hand when required, according the tem- perature readings the smoke gases, upon bell signal. possible also provide for automatic operation the slide means contact pressure gage operating electric motor the compressed air outlet the heater. For the purpose comparison from industrial point view, more retrospective synopsis may obtained comparing the quantities air with the weight steam equal productive capacity, dif- ferent temperatures, that required, instead the percentage increase productive capacity air upon heating. 21, 1927, The Iron Age Instead 1000 kilos (2200 steam hour, the 600-kilo hammer requires 930 cubic meters (about 32,800 cu. ft.) intaken air hour, temperature 323 deg. (613 deg. Fahr.); 670 cubic meters (about 23,700 cu. ft.) hour temperature 450 deg. (842 deg. Fahr.), 580 cubic meters (about 20,500 cu. ft.) temperature 520 deg. (968 deg. Fahr.), the temperatures taken absolute; for the 2000- kilo hammer 800, 575 and 500 cubic meters hour (about 28,250, 20,300 and 17,650 cu. ft.) the same temperatures, while the case the hydraulic steam presses, 675, 485 and 420 cubic meters (about 23,800, 17,100 and 14,800 cu. ft.) hour. These figures rep- resent average values, the efficiency forge estab- lishment contingent upon many other circumstances. Vibration caused the operation the steam ham- mers transmitted the steam lines, causing the insulation loosen and fall off course time. This strongly influences the steam pressure. Furthermore, case heavy demands the steam supply the pressure drops, while with small demands the conden- sation losses will increase. The influence severe frost, also, will make itself evident similar direc- tion. There will great heat losses starting hammers after long period idleness. the case compressed air operation these disadvantages are not encountered the same extent. The kilowatt con- sumption the electrically operated compressor can measured accurately meters. Unloading Desirable When the compressed air requirements for the ham- mers and presses are regulated that the compressor and motor continue run after the demand for air over, until the pressure the storage tank drops certain permissible amount, there disadvantage. The dead running the machines represents per cent the full and oil and cooling water are not utilized for productive pur- pose. addition, there the wear and, the result the small power factor the driving motor load per cent, the consumption idle current becomes greater. overcome these disadvantages there has recently been endeavor provide the driving motor with automatic control device. this means becomes possible regulate within certain limits the pressure the supply tank. This arrangement provides for starting the compressor the driving motor when the pressure the tank supplied the compressor drops certain fixed minimum, and stopping again the pressure attains maximum limit. How the Savings Figure The saving current the installation this new system automatic control older equipments considerable, will shown the following: compressor built for air intake 1100 cubic me- ters (about 38,800 cu. ft.) hour consumes 100 kw. full load and kw. without load, and 0.35 kw. starting without load, and further, the running time with full load 5.1 hr., the duration all stoppages 5.4 hr., and finally the number daily startings 49, the consumption power, according the old methods regulation for operation with and without load, 645 kwhr.; while with the modern method regulation 527 kwhr. The saving brought about amounts daily 118 kwhr. the basis pfennigs (about 2%c.) kwhr., 3540 marks (about $842). Accordingly, the expense for the installation the new method control will paid for short time. addition, there the ad- vantage that the motor always running with good load, and accordingly working with high degree output and good factor efficiency. } { 4 q | Tack-Welding Two Panels and Lookouts fully years Europe and America have been and “fazed” the problem housing shortage. London, Berlin, Paris, New York, Phil- adelphia and others have been grappling with housing congestion. this has been added the complication high cost living, for all which solution sought the steel frame house. The problem the steel house should problem all, tithe the will-to-do were given that goes daily into the solution the minor problems the steel industry and the building world. Steel Industry Fails Take Lead The complete answer lies failure the part those most vitally affected—namely, the steel inter- ests—to grasp the complexity, magnitude, economics and psychology the problem, their non-support those “outsiders” who attempt its solution, and not setting intensive research their own place the steel frame house its rightful and eventual place before the architectural, building, financial and home- owning world. Since the steel framed house eco- nomic certainty when the steel house problem solved one way another, this will also prove the nearest solution housing shortage. General Problems Modern Housing Before mere opinions are expressed necessary analyze some basic facts, principles and conditions which today govern homes and housing: cannot questioned that large factor the present high cost living the great indirect tax imposed the staggering fire losses over $2,000,- 000 per day due bad construction, combustible con- struction and defective heating. author has been engaged engineering practice for some thirty years, the last ten which has devoted almost en- tirely research the steel framed house. graduation from Hobart College, Geneva, Y., collaborated with Prof. Carpenter, Cornell University, the prepara- tion the latter’s first edition “Heating and Ventilating Buildings.” During the war was research and experimental engineer for two the Harriman shipyards, and that capacity designed 9000-ton electrically welded and electrically powered this time was instrumental bringing about the creation the welding committee the Emergency Fleet Corporation, later merged into the American Welding Society. now with the Research Engineering Corporation, steam freighter. New York. Shortly after his Steel-Framed Dwelling Electrically Welded Stucco Combined with Steel Meet Prob- lems Non-Combustible House Construc- tion—All Joints Tack-W elded Job JAMES DUDLEY Conclusion: The “Dwellings Tomorrow” must not only steel-framed but incombustible well. Housing lumber which has been adequately cured longer commercially obtainable save excessive costs. This results faulty construction due shrinking, warping, etc., wherever used. Conclusion: the “Dwellings Tomorrow” ce- mentitious equivalent sheathing must used re- place wood even when framed steel. Settlement foundation walls has become common that even engineer-builders skill and repute claim this inevitable. Even the “Dwellings Tomorrow” are steel-framed and incombustible, small advance have been made unless foundations are made absolutely settlement proof, thereby insuring against cracking. Damp and wet cellars are today common, even high grade communities, that “bone-dry” conditions are rarely secured. Every ounce the “Dwellings Tomorrow” must imprisoned for life least “bone-dry,” not hermetically sealed, foundations. walls and roof wreckage from corrosion itable. meet demands cost reduction, exterior sheathings should stucco, which outcompetes all other sidings save shingles clapboards. However, the all too frequent cracking stucco, due lack permanent rigidity framing and lathing, however built, today compels repairs, rapid depreciation and warranted criticism even perfect stucco. Conclusion: the “Dwellings Tomorrow” the steel-framing must permanently and rigidly joined against yielding from weather conditions settlement. the mad scramble for cheap houses, the vast The Iron Age, July 21, d | | majority not only lack adequate heat insulation but are not even tight against wind penetration. Conclusion: The “Dwellings Tomorrow,” com- posed they inevitably must steel, stucco and glass, all having the highest rate heat conductivity, must perforce have the entire exterior envelope excep- tionally well sheathed with some adequate and perma- nent insulation invite warranted condemnation the score physical discomfort and excessive fuel bills. The many sudden and widely distributed hous- ing disasters, due violent windstorms throughout the country, demonstrate fundamental weakness pres- ent methods making framing joints. Conclusion: The steel-framing the “Dwellings Tomorrow” can scarcely too well tied together for safety and permanence. The only absolutely depend- able jointure either riveted welded one, and the use even cold rivets, let alone clips bolts, does not and cannot produce rigid jointures under field condi- tions. aftermath World War conditions home- seekers now demand some semblance architectural beauty even the expense essentials, regardless whether this wise not. The “Dwellings Tomorrow,” which embody steel framing with incombustible sheathing in- side and out, become popular and within the buy- ing reach the public, must incorporate such sys- tem construction, technique building and sequence plan condition, regardless merits, demerits costs. Further, such system must meet occupants’ needs and desires such would met any exist- ing system. short, must permit the use omis- sion every detail structurally desirable. deep rooted and far-reaching are prevailing methods installation conduits for plumbing, light- ing, bells, ventilation, radio and heating, that hollow walls, floors and partitions are today practically uni- versally necessary and demanded. Conclusion: the “Dwellings Tomorrow” walls, floors, partitions and roofs must hollow and de- signed and framed permit ready installation and concealment all types conduits now used. 10. true today that union labor can, and many sections absolutely does, dominate the house- building field. Conclusion: the “Dwellings Tomorrow” are based steel framing, whatever the design, merits costs, union labor must won the “sweet reasonableness” its own self interest, new in- dustrial war the hurt all concerned. 11. Never before has the heating homes heen great factor the housing field. The fact cannot controverted that the majority homes are not even adequately heated. “Dwellings Tomorrow” necessarily are based the Conclusion: 136—July 21, 1927, The Iron Age lathing applied rapid heat conducting building materials use today, namely, steel and stucco, adequate and economical heating major factor the problem. This holds true also regardless insulation and fuel employed, since one failure steel house give ample winter warming greater cost than for its wood counter- part will heralded the four corners the country. 12. practical impossibility for any man say accurately what even given house-design will cost, unless computed experienced builder, figur- ing from exact plans and specifications and for given location, time limit, season, etc. Nevertheless the home seeker who may build buy but once life- time does not, and cannot, know this and all too often influenced snap judgment high pressure salesmanship. The result that today the vast ma- jority dwellings are effect made-to-order struc- tures instead being manufactured known unit cost basis. Conclusion: The “Dwellings made steel and stucco adequately insulated and economi- cally warmed, must and can reduced manufac- turing unit cost basis, provided these are built mul- tiples. Otherwise designing costs, labor and materials supervision, etc., the newer method, unless written off for promotion purposes, must suffer serious cost handicap regardless design system employed. This mathematical certainty provable advance construction. “Weldcrete” Follows Technique Wood-framed House The particular construction devised the author and offered him least one solution the steel- house problem illustrated the accompanying photo- graphs the first embodiment thereof, which has re- cently been completed Teaneck, J., for George Hitchcock, realtor. order disabuse the minds all investigators the very outset any likeness technique concrete houses, however built how- ever meritorious, the author defines and describes this system “Weldcrete” combining the “weld” from welding with the from concrete. The welded skeleton steel framing wholly carries all loads, static dynamic, while the cement the stucco serves sheathing only. Disregarding footings and foundations, this Weld- crete system follows architecturally and structurally, broadly and even detail, the technique wood- framed houses. other words, for each sill, plate, stud, joist, strut, lookout, rafter, ridge, head, jamb, sill, even trim, member wood, there steel counter- part. All are assembled essentially the same se- quence followed any conventional wood-framed house. While the practice almost universal space wood studs, joists and rafters 16-in. centers, this neither necessary nor desirable all Weldcrete steel constructions. With given house design and method inside and outside sheathing may prove more effi- | | cient and economical shrink such steel frame spac- Standard Metal Lumber Channels Although technically feasible employ the lightest standard structural steel shapes for fram- ing members, calculation and actual experience demon- strate that, least under present steel market condi- tions, standard “metal-lumber” channels, such have been the market for many years, have the fewest limitations for use Weldcrete houses framing channels, approximately 1/16-in. thickness, any dwelling may completely constructed from. these alone, the four-room bungalow the multi-family six- story walk-up tenement. matter mere clerical routine take off bill materials all required framing members cut square and exact the dimensions demanded the specific plans and specifications the dwelling erected. This cutting can done nominal cost either the mill, the warehouse even the building site, all without single perforation punch drill. All the steel framing members for the demonstra- tion house shown the accompanying photographs were ordered thus from the mill. evident that this technique permits the widest latitude and flexibility the translation the conventional wood framing any architectural plan into steel-framed counter- parts. Gaged the demonstration house here shown, the entire steel framing, composed 4-in. channel studs and rafters and 6-in. channel joists, for any usual detached dwelling, totals less than lb. per cu. ft. structure. passing interest note that neither this demonstration nor any other dwell- ing employing this technique necessary make use single structural item which not general use today. Electric Tack-welds Used Entirely There are seven more less distinct types welding which engineers can rious metals into machine structure. These are blacksmith welds, oxy-acetylene mit welds, electric butt-welds, electric spot-welds, elec- tric fillet-welds and electric tack-welds, the latter being effect merely fillet welds reduced the smallest practicable linear and volumetric limits. the Weld- crete technique only electric tack welds are necessary desirable, save unusual and infrequent cases. The Weldcrete system calls for overhead weld- ing, nor are the jointures dependent the shearing strength the welds. Tack-welds chiefly duplicate the function the carpenter’s nails wood framing. Each such weld requires but fraction minute make, with negligible weight added metal and consump- tion electric current which The strength the tack-welds proved the fact that cold chisel, machinist’s hammer and plenty muscular energy are necessary break joint whgn once made. How System Meets Essentials House Construction The methods followed this Weldcrete demonstra- tion followed other examples can best shown meeting the author’s own “Twelve Essentials the Steel Incombustibility secured flooring, which should and can art-colored cement; inside trim, which — + should and can drawn metal; doors, drawn metal with art-designed, unburnable panels, and steel- casement windows. Wood boarding for rough flooring, and*rough roof sheathing, both anchored directly the metal lumber framing “expansion should and can made rigid and fire-safe, art-colored cement fin- ished flooring and color-blended roof shingles, remain unchanged throughout the life the building. Settlement except the building whole im- possible, due its erection unitary slab rein- forced concrete covering 100 per cent the excavated house area. Bone-dry cellars are secured waterproof com- pounds integrally incorporated the reinforced con- crete foundation and walls with waterproof cement finished inner faces. Exterior sheathing secured rigidly anchoring ribbed metal lathing the unyielding, welded, metal- lumber studs and then incasing these three-coat, waterproofed, art-colored and art-textured Portland ce- ment stucco, preferably “shot” suitable “gun” speciaily devised therefor. Insulation all interior faces roof and exterior walls secured any one number the modern wall-boards having low thermal conductivity which are anchored the metal lumber framing expansion nailing. The Underwriters’ (inside) “one-hour fire- proof rating” secured finish coat fireproof plaster applied the wall boards with without tex- turing and decorations. Tornado and earthquake insurance secured the action the thousands interlocked tack-welds which anchor the hundreds frame members into one homo- geneous structure distributing all such dynamic loads, from ridge foundation, throughout the framing whole instead any one section. Architectural treatment subject limitations prevailing styles individual interpretation there- of, owing the flexibility the technique con- struction. Architectural plans the simplest the most ornate character, whether for tiny cottage elaborate mansion, can executed with fidelity and with precision scarcely obtainable with any other known system building. Since the combining welded-steel skeleton with reinforced stucco sheath- ing lays restrictions upon the designer, may even boldly and confidently essay new styles form, color and texture. Hollow walls, partitions and roof are integral part and are secured with greater ease and less ultimate weight and cost than with other systems which are based solid counterparts. Further, nothing pre- vents the use solid panels, for closets, etc., space limitations demand cost can lowered. Union labor has critically investigated this building system and wholeheartedly cooperated executing its first demonstration embodiment, finding casus belli hidden therein. Costs such welded steel and stucco homes can brought down the irreducible minimum wood costs just soon they are built sufficiently large numbers permit modern engineering and manufac- turing methods substituted for the obsolescent, hand-made, retail attempts which now prevail. These welded-steel and stucco “Dwellings Tomorrow” show annual savings sufficient amortize their costs less than years. 3 Framework Completed With Outside Veneer Being Applied;—the Finished House The Iron Age, July 21, 1927—137 4 » Bridge Between Science and Industry How Secure Coordination Between Scientific and Industrial Research—Confusion Use Metric Terms—Elab- orate Apparatus Not Necessary DR. WILLIAM BLUM break down those false distinctions between “pure” and “applied” science that have frequently hin- dered the progress each field, must admit that there are still two fields, however vaguely they may defined. very doubtful whether, even such distinction could eliminated, the result would advantageous. The types mind, the educational prerequisites, the environments, and even the physical equipments required the one hand for the establish- ing new and fundamental principles science, and the other hand for their adaptation and applica- tion industry, are usually different that sel- dom that both types can found the work one individual even small group. ESPITE the numerous efforts recent years Correlation and Coordination Required order, however, that each group may function properly, and contribute its share the welfare humanity, there must correlation and coordination their activities. Without frequent and fruitful con- tacts with the new developments pure science, in- dustry would soon degenerate into era empiri- cism. One the best means for bringing about the de- sired contacts through technical organizations such the Electrochemical Society, devoted, our consti- tution states, “the advancement the theory and practice electrochemistry.” with full appre- ciation the great value our papers and discussions industrial electrochemical processes that venture the suggestion that need greater leavening papers the fundamental principles electrochem- istry and allied subjects. indisputable fact that the average indus- trial electrochemist does not have the time, facilities, or, has been out college years more, the mental point view unearth and assimilate himself, from the increasing mass new facts and theories the physical sciences, those parts which may aid the solution his practical problems. the other hand the basic investigator, encouraged so, could many cases explain simply and concisely the scope and conclusions his researches, and thus facilitate the application such principles indus- tries which may have but scant knowledge. “Interpreters” Suggested order correlate science and industry better, may not necessary bring the actual workers each closer together, provided there are those who will serve “liaison officers,” interpreters, and will es- tablish close contacts with each group, and endeavor fit together the needs one and the results the other. that activity, which broad sense cov- ered the term “industrial research,” that would especially call attention. some degree every success- ful industrial process includes three steps, even though these may not have occurred the chronological order indicated: 1.—It involves certain general principles which some cases have been clearly defined and have led this application, while many other instances such principles have either been long known and their ap- plication overlooked, they have not yet been recog- nized defined, though they are being unconsciously applied. Part the presidential address the annual spring meeting the American Electrochemical Society Phila- delphia April. The author was retiring president and with the United States Bureau of Standards, Washington. 21, 1927, The Iron Age relation such principles the require- ments any industry determined, and the probable conditions for their favorable application are predicted. 3.—The feasibility economic large scale oper- ations investigated, and operating conditions are defined. these the first step involves fundamental research, the second industrial research, and the third engineering. the following attempt point out some the factors involved industrial research, most the illustrations have been drawn from the field electro- deposition, with which most familiar. One ad- vantage this selection that have made most the mistakes which call attention, and can thus speak from first-hand knowledge. Metric Terms Confused with Others One who engaged industrial research soon finds that must all too literally serve “interpreter” the terms and expressions used science and in- dustry. excusable, and not surprising, long the common system weights and measures most largely used industry, that the workmen and the foremen should employ them their tasks. But may well question whether the average works chemist, even the professional consultants who laboriously (and hope conscientiously) teach their students the advantages the metric system, not lose their con- victions too easily when they leave the college walls. hold brief for the metric system industry and have only respect for the chemist who translates the results his laboratory tests into terms that the layman the plant can use. But the laboratory, where the chemist reigns supreme, and where all his measurements weight and volume are necessity conducted metric units, just why should cut sample sheet metal in. for corrosion test? really believes that the metric system too cum- bersome inconvenient, why does not set pharmaceutical weights and use vessels graduated fluid ounces and fractions? Why Use Hybrid Units Not being psychologist, cannot even suggest reason, valid otherwise, for the frequent use chemists hybrid units, such milligrams per square inch, for the supposed benefit the foreman work- man. The obstinacy with which such hybrid units are retained laboratory reports and even submitted manuscripts may well remind one the best known our common hybrids! Another, only slightly less obvious conflict between the usages science and industry, the expression concentrations. Here again, long ordinary units are employed the plant, such expressions “ounces per gallon” are perfectly definite and justifi- able, even though the laboratory results are obtained grams per liter. But when the chemist talks about “ten per cent solution,” does anyone (including often himself) know whether means ten grams the salt one hundred grams solution, one hundred cubic centimeters solution, one hundred cubic centimeters water? You may consider that the above examples, which could mutiplied many fold, represent trivial illustra- tions, and have little practical significance. Nevertheless venture the suggestion that just such minor lapses these are largely responsible for the gap between science and industry. Another quality, especially needed and often lacking industrial research, sense proportion. the | | ai ‘4 determination fundamental constants nature, generally desirable obtain the highest possible accu- racy, which demands precision each factor com- mensurate with its probable effect upon the final result. such work the result itself the goal, and effort should spared attain the highest accuracy. industrial research, however, the justification for any given study its possible probable utility for given purpose. The precision sought any such work must therefore bear relation the problem whole, though not necessarily limited present re- quirements. Need Elaborate Apparatus Fallacy One the most common fallacies industrial re- search the assumption that elaborate apparatus for reproducing the plant conditions semi-commercial scale must always provided. Thus often hear the statement that certain result may true for beaker experiments, but does not apply large-scale conditions.” Any such conclusion, warranted, simply evi- dence that one more variables the plant are dif- ferent from those the laboratory experiment. reasonable and highly important make preliminary observations existing large-scale processes order determine what factors are involved and which de- serve investigation, either from the standpoint im- proving existing method developing competi- tive method. predecessor, Dr. Becket, has admirably pointed out his presidential address last year, engineering cost estimates should play important part the selection subject for extended industrial research engineering development. this discussion the conditions surrounding in- dustrial research, have considered chiefly the me- chanics the operations, rather than the scientific principles methods pursued. Obviously these depend much upon the nature the problem and the state knowledge that particular field that few sound generalizations can made. One the most difficult decisions make any such investigation whether study closely the current processes order determine their limitations and possibilities, whether far afield the search for radically new principles procedures. There much said favor each course, and expediency often the deter- mining factor. The first the safe course, sure yield results some definite value. How Radical Improvements Will Come All research involves uncertainty and risk, other- wise there would real problem. only through study related even apparently unrelated fields science and industry that radical improvements are likely made. here that the greatest respon- sibility and opportunity the “industrial researcher” are involved. The ideal investigator this type (who course does not exist) should broadly educated, should least acquainted not familiar with all recent developments both science and industry, and should have the uncanny knack making good guess which the innumerable possibilities for prog- ress most promising. Just present are having wave iconoclasm literature, science and society whole. read the “Private Life Helen learn that the famous “Microbe Hunters” were human beings and not demi-gods; the layman penetrating into the mys- teries science and realizing that the scientist superman, but simply painstaking, patient student the laws nature. the extent that this attitude the public re- moves the mysticism from science, and makes the scien- tist himself more human, contributing the prog- ress humanity. But over-emphasizes the “ma- chinery” research, and ignores the spirit research, whether pure applied science, substituting the husk for the kernel. Industrial research should have goal beyond the salary the investigator the dividends the em- ployer. should strive serve also the worker the plant, make his lot safer and happier; and aid the general public through economies and improvements quality that contribute the welfare humanity. What Thomas Browne said the medical sciences, his quaint “Religio Medici,” just appropriate the application science industry: “No one should approach the temple science with the soul money-changer.” Master Brand Galvanized Sheets Unpopular Jobbers Object Carrying Duplicate Stocks; Fabricators Demand Flex- ible Coatings and Buyers Cheap Article American Zinc Institute, contained the text address given before the spring meeting the institute Patterson, secretary the Sheet Steel Trade Extension Committee, bearing upon the problems galvanized coatings sheet steel. noted that while the greatest lost market lies gal- vanized sheets, this classification comprises only about one-fourth the production the contributing members his organization, and consequently can get only its share attention. Sales galvanized sheets are about stationary, whereas production other kinds sheets have been the increase. reach the field building construction, Mr. Pat- terson’s committee has prepared accurate specifications for cornices and circulated them among architects and builders. has also started movement for the paint- ing eaves troughs and downspouts the inside be- fore marketing, reduce corrosion from water drip. The idea that galvanized roof needs regular painting being promoted, and studies have been undertaken develop paint which will adhere new galvan- ized sheets. Preparation standards for sheet metal farm buildings has also been undertaken response This program, together with publicity directed toward the farm and household field, represents new effort. the past two years the program the Sheet Steel Trade Extension Committee was based the last issue ZN, the periodical issued the the belief that the sheet metal contractor the key man the industry, whereas Mr. Patterson now feels that the contractor primarily mechanic, and will hopeless task make him better merchant. THE AGE for May and 14, 1925, project market “Master Brand” sheets was favorably re- ported. They were stamped individually, con- sist exclusively prime sheets galvanized gage and thicker, and rigidly inspected for thick- ness zinc coating, which was the maximum possible carried without cracking and peeling during normal forming and fabricating operations. Mr. Patterson now feels that this project has not brought the anticipated success. “The one measure which expected most effective reestablishing galvanized sheets the con- fidence the public, namely the Master Brand, had been put through only far making agreements with our manufacturers for the use the brand, and writing specifications for all gages galvanized sheets,” said Mr. Patterson. “But the jobbers offered much opposition carrying the Master Brand sheets with their heavier coatings, addition the commercial sheets, that, reflecting their objections back through the sales departments the steel com- panies the managers, there resulted cessation all activity toward the production these Master Brand sheets. “The objection the jobbers was based the The Iron Age, July 21, 1927—139 | 4 proved facts; first, that the use which the sheets their warehouse was put never known advance the jobber and most generally not the customer who buys the bundled sheets; second, the light coatings now use will generally stand most the operations bending and forming which sheets are put, but for some operations even these coatings are too heavy and peel flake off. “There tendency for these operations be- come too difficult for the galvanizing withstand, not only because the bends being made more care- lessly, but also because the employment auto- matic machinery which makes these bends very much more quickly, thus giving insufficient time for the flow metal occur. The jobbers having the moment little consumer demand for heavier coated sheets, and the certain knowledge that the heavier coated sheets would not satisfactory for many purposes under present ideals design and manufacture, made very pronounced opposition the grounds self- interest against the greatly increased stocks which they would have carry they stocked the Master Brand sheets. Modified Field for Master Brand “The consequence this decided sales opposition was that the Master Brand sheet with all the adver- tising that has been done already, and with the continuous references which still make it, will either have dropped completely will have promoted modified form. “We know from our market analyses that there are dry sections the country where the very lightest coating and thinnest steel sheets last for many years roofing without rusting out, but there are other and more numerous sections where sheets not last satis- factorily with their present coatings. Nevertheless, the great bulk the demand for roofing sheets the present time for exceedingly cheap sheets, and sell these people the idea quality bound slow and expensive undertaking, even though very necessary one. One fact importance this con- nection that the agricultural field, which con- stitutes very large percentage the total use such sheets for roofing purposes, over per cent the farms this country are worked tenant farm- ers. Therefore very special type advertising will have devised which will reach the owners these tenant farms. “In the meantime, however, practical measure importance the sheet steel manufacturers and means holding and recovering considerable part the market for the covering steep pitched roofs, wish see the Master Brand applied two forms roofing, namely, corrugated and V-crimp roofing, neither which usually receive, once they have been formed, any severe quick bending their later joining application. “In 1926 corrugated and V-crimp roofing took about per cent the total production galvanized sheets and amounted about 300,000 tons.” Mr. Patterson exp