The Iron Age 1927-09-22: Vol 120 Iss 12

New York, September 22, 1927 ESTABLISHED 1855 AGE VOL. 120, No. Sky-View Budd All-Steel Automobile Body Plant Philadelphia; Midvale Steel Co. Central Background; Atwater-Kent Radios are Built Two-Story Buildings Steel Required Automobile Bodies Special Qualities Sheets More Successfully Obtained Showing Steel Manufacturers Exact Require- ments Than Buying Strict Specifications expands into new fields found the plant the Edward Budd Mfg. Co., Philadelphia. Just years ago small group men who believed the superiority the all-steel automobile body started business; the first bodies were made somewhat like custom bodies would made today—with large ex- penditure labor and relatively small amount equipment. the intervening years, thanks inten- sive development special machines and labor-saving equipment, the Philadelphia plant has grown until its present capacity the order one million complete bodies per year and additional capacity exists plants Detroit, England and Berlin. Advantages Sheet Metal The reasons for steel automobile body are much like those for steel railroad coaches, but for some dozen years they were known considered principally the technicians the automotive industry; more lately the buying public has become acquainted with them. From the users’ standpoint: welded all-steel body effect jointless, single piece; the various parts not rub, nor develop squeaks leaks. long lived and consequently gives the car higher trade-in value. Strong, slender door posts and window frames give in- creased vision. Most important all, safer—in the event accident, the body does not crush catch fire. Finally its gross weight less than the composite body, thus reducing operating expenses, prin- cipally for tires. interesting example how the use sheet metal From the manufacturers’ standpoint the advantages all-steel are equally apparent. Steel better building material than wood, because much stronger and stiffer equal section, and the material can more easily shaped into economical forms and sections resist the imposed load. Permanent joints steel may made without the mortising operations necessary wood, which remove portions one member where the material needed most. Steel more uniform quality and not pronouncedly weak across the grain, wood, and unaffected weather changes. therefore lends itself more readily standardized quantity production interchangeable units, thus speeding the time completion and reducing the amount material process. all-steel body can baked with impunity for de-greasing, enamelling other finishing operations, something which may done only the most moderate extent with wooden skeleton, covered with sheet metal. Despite the impression which may exist that steel vould refractory material bend and mold into the rounded forms demanded fashion, experience proves well adapted for this purpose. permits much latitude the body design, and requires less bulk for the required strength, thus giving greater vision and more roomy interiors. For these reasons the all-steel body has been used the extent that (according the Budd company’s figures) one out every three passenger automobiles made 1926 had all-steel bodies, number leading 779 4 AR DOOR GLASS OPENING REAR QUARTER OPENING QUARTER WINDOW GRASS OPENING Cross Sections Posts All-Steel Sedan Bodies, Com pared the Sections Composite Construction, Shown Phantom manufacturers using them extensively America, Eng- land, France and Germany. Not only has this development consumed important tonnages sheet steel, but has also influenced the design composite bodies the end that greater and greater amount steel going into those types, until today has almost enough for self-supporting tructure. Steel Bought “Understanding” essential factor the success the all-steel the ability secure sheet steel having the combined properties high surface finish and good drawing qualities. degree these two are antago- nistic. The best and smoothest surface necessary take the mirror-like enamelled lacquered finish de- manded the motorist acquired cold rolling the finishing passes. This, however, causes work hardening the sheet, reducing its ductility and its ability take further deformation the stamping presses. balance these two opposing factors distinc ively steel-making problem, and has been process solution since the beginning the all-steel body years back. That reasonably good ion has been effected is evidenced by Hollow Steel Broke Solid Squares Steel OK. Circles Indicate Steels Whose Elongations were 25.0% ach Plot Average Three Tests Percent Elongation Gage Length Transverse Direction Rolling Percent Gage Length 780—September 22, 1927, The Iron Age the fact that the Edward Budd Mfg. Co.’s Philadel- phia plant absorbs sheet steel the rate 165,000 tons per year when working capacity. Body stock bought them “understanding” rather than “specification.” Budd’s metallurgical staff has always insisted that the best way develop better steel for its purposes take the steel makers into its confidence, show them exactly what the steel expected do, point out clearly any feature new die design body finish which probably puts new demand the metal, and then ask the steel makers deliver sheets for that purpose unhampered any chemical physical specification. That does not mean that Budd engineers not have pretty definite ideas what chemical analysis and what ductility and thickness tolerances would best for their purpose. Experience has shown them that sheet should about 0.04 in. thick avoid drawing out too thin the corners, filed too thin finishing operations, well have enough body resist dents normal handling. This tendency toward standardization one thick- ness, which the steel makers are able deliver within close tolerances, has simplified the construction and operation dies, jigs and welding machines, and the accountine and routing material process, thus resulting economies which offset any savings Hollow Squares: Broke Circles indicate Steels Each Average Three Tests Percent Elongation Gage Length Transverse Direction Rolling. nN Parallel Direction Rolling. Studies Deep Drawing Stock. Three long strips were cut from each sheet parallel direction rolling and three right angles. These were gaged and in. and tested tension. Elongations measured the in. gage length plotted large dia- gram; elongations measured over in. plotted the small diagram ‘ ! Legend o a," o o weight expected from using thinner sheets un- important places. Elongation the Criterion for Successful Stamping Steel Furthermore, study number successful and unsuccessful heats has shown* that trouble forming never experienced when the sheets have elongations determined test strips better than either the following limits: Elongation 2-in. gage length: With rolling, per cent and across rolling, per cent. Elongation gage length: With rolling, per cent and across rolling, per cent. average six samples from each sheet. Normal Grain Size Box-Annealed Sheet. Magnification 100 diameters Grain Size Obtained When Condi- tions Are Such Cause Exaggerated Grain Growth. Such sheets liable crack- ing first subsequent draw certain stamping does give trouble, and test the sheet metal shows ductility uniformly equal better than those figures, the trouble looked for the dies press shop practice. However, stamping develops undue number rejects new lot steel, and that steel test gives ductility below the limits noted, when measured either the 2-in. gage length the 8-in. gage length, then the steel maker notified that the “bug” his material. Thus the Budd company’s unwritten steel specification used appraise their own manufacturing practice, rather than determine the steel company’s operations. Winlock and Kelley. the Budd company, discussed this matter before the 1927 convention, American Society for Steel Treating, paper entitled “Testing Auto- mobile Body Sheet Such purchasing method has several advantages. puts the responsibility producing steel for particular purpose the shoulders the steel maker, rather than his customer. procures special grade sheet known the trade “extra deep draw- ing,” commanding premium, but not expensive would definite chemical and physical specifi- cations would have met. Furthermore, avoids the necessity close sampling receipt. Inspection for surface finish made the mill. Each body sheet inspected individually the Budd plant upon unloading, and the top sur- face satisfactory marked with rubber stamp; not, the sheet turned over the hope that the other side passable. neither side is, rejected; but such rejections are infrequent. physical tests are made unless the lot develops trouble the press shop. This itself economy, for much variation can expected from sheet sheet, and even different parts single sheet, that make fair sample would require cutting least Cowl Stamping, Made from Single Flat Steel Sheet, Showing Possibilities Rounded Forms Combined with Square Flanges and Graceful Panels per cent the shipment for test pieces various parts the sheet. seems good management avoid this unless trouble develops fabrication; then attended the manufacturers’ representatives, held. course, when this occurs often delay press shop operations seriously, time get sheets from alternative source supply. the 2,764,000 motor trucks use the United States, only 497,000 are classified the National Automobile Chamber Commerce commercial car- riers. The remaining per cent are owned ship- pers, including department stores, groceries and numer- ous other similar owners. the commercial carriers, 304,000 are classified contract carriers while 193,000, per cent the total, are known common carriers. Following shutdown five months, one the largest New England manufacturers fire arms will resume operations effective Oct. with full working force approximately 600 hands. The Iron Age, September 22, INCE 1910 the writer has patented series improvements blast furnace construction, the main features which have porated gradually into the stacks the Sloss-Sheffield Steel Iron Co. Birmingham, Ala. When be- came necessary reconstruct old furnace No. was considered that sufficient satisfactory experience with these innovations had been accumulated war- rant incorporation all them the new stack. New No. furnace (as shown the photograph and the detailed drawing) now production, and has come expectations every way. With four these furnaces now operation, purpose this paper give brief descrip- tion this type, and set out some the reasons why claimed better furnace, and why oper- ates better than possible with the old type. The hearth construction may any suitable design. prefer heavy cast iron hearth jacket least in. thick, made sections suitable size. The size the hearth proper, crucible, determined the size the cast and not the other general dimensions the furnace. Excess crucible area objectionable since tends lower the grade iron produced, especially physical structure, and cause irregular casting conditions. inside cooling required any point below the tuyeres, but the hearth should cooled its outer surface water sprays and the ordinary well con- struction. The principal advantage this well that prevents breakouts and the accumulation heat the extreme bottom the crucible and its foundations. Therefore this type crucible de- sirable from safety viewpoint. should spring leak, the molten iron could not cut away this heavy cast iron very fast; therefore could not rush through quickly and little damage would result. Seven fur- naces using this hearth have had breakout fifteen years’ service. Bosh Built Inside Metal Jacket tuyere jacket provided similar construction, provided with openings for tuyere coolers and for least two bronze cooling plates between. The latter should located plane with the tuyeres and extend nearly far the nose tuyere coolers. Directly above the tuyere jackets are located three four rows bronze cooling plates, thrust through series cast iron housings (securely bound to- gether means steel bands, thus forming the lower *Vice-president Sloss-Sheffield Steel 782—Se ptember 22, 1927, The Iron Age Furnace Southern Ores Steeper Inwalls, Water Cooled, Permit More Uniform Stock Distribution with Corresponding Gains Tonnage and Lowered Coke Ratio DOVEL* part bosh) all arranged that replacement can made from the outside. The upper part the bosh, shown the draw- ing, consists plate jacket, protected cooling plates cast iron and wrought pipe con- struction, placed just inside and extending well above the mantel. This bosh construction has had ten years almost continuous service one furnace and still first-class condition. The angle which the bosh constructed should such that the true working angle (which represents slight curve from the nose the tuyeres the spring bosh) may maintained, with some allow- ance for using tuyeres different lengths. constructed deg. and with working angle deg. has proved desirable Southern ores with this type furnace. Column and mantel construction may any standard design. Inwall protected throughout several rows bronze cooling plates, connected and supported the shell, and built they can detached inserted from the outside. independ- ent lining brick 22% in. in. thick used point where abrasion from the stock would commence. Above this the wall metal, consisting outer cast steel jacket, machined and bolted to- gether, and provided with bolting lugs support inner lining cast iron wearing plates suitable dimensions provide for expansion and wear, and prevent excessive radiation. Large Top Has Many Advantages the use such inwall and top construction (which practically indestructible and whose lines are maintained all times) will unnecessary pro- vide pitch inwall great where inwall will become uneven service. While pitch furnace inwall constructed this method requires in. less per ft., the practice the old style has been give from in. in. per ft. will readily seen that the relative area the top the furnace will greater this type furnace than the old type. This increases the total area for stock. This additional stock acts recuperator the hot gases, thereby delivering the gases the downcomer lower temperature and making direct saving the heat units retained the furnace. further advantage this type furnace, due its indestructible inwall and top construction, that possible use relatively smaller bell. This results throwing more coarse material the walls, causing the furnace work freely along the wall well through the middle, thus insuring rate travel impossible furnace wherein necessary work fine material the outside for the protection the inwall practice very common today the old style furnace). The largest practical area the upper section the furnace desirable; the area sufficient and the distribution stock uniform throughout, the upward passing gases will filter slowly through the stock and not forced rapidly through openings craters, picking large quantities dust. This slow and easy movement the upward pass- ing gases, filtering through the stock uniformly, 7 | ana — = ETAILS the No. Stack, Are Shown the Drawing the Right, While the Table and the Diagram Below Cover the Operating Data the No. Furnace Coke used per month (31 days), Coke used per ton iron, Stone used per month, tons..... 1,759 Stone used per ton iron, Ore charged during month, tons 23,440 Gross burden charged, tons.... 25,199 Iron produced, tons............ 9,796 Gross burden charged per ton iron produced, 2.55 Average ...... 3.42 lysis ore) Lime 21.13 charged ...)Phosphorus ... Manganese .... 0.70 iron... 38.44 1.73 Fixed 85.08 0.76 ...... 5.75 Dolomite Alumina ...... 0.50 55.96 2.75 Ave. analysis( Silica ......... 38.47 Alumina ...... 13.43 Lime 47.13 pig Sulphur ...... 0.028 Phosphorus ... 0.75 Grade: Foundry Coke burned per day per sq. ft. hearth area plane of nose of coolers, Ib 7,312 Coke burned per day per cu. ft. entire volume includ- Coke burned per day per cu. ft. volume between top bosh and ft. below 73.92 Air blown, cu, per min... 32,000 Blast temperature (ave.), Capacity hearth, 100 tons of iron, RRA x S > STR SNS => « 893¢ 4 The Iron Age, September 22, 4 \ 4 7 Wl 4 \ i 4 | j serves several very important functions: The gases are cooled, thereby retaining the maximum amount heat units the furnace; the gases reach the downcomer with very low dust content, which great saving material; longer and better contact provided between the hot gases and the ore the upper reduc- tion zone, resulting better preparation the ore for final reduction, and better grade, more tonnage and lower coke consumption per ton produced. This the explanation why this type furnace runs steadily uniform grade and rate travel impossible with the type commonly built. these changes several Sloss-Sheffield Steel Iron Co.’s furnaces, including new No. the dust over the downcomer has been reduced has been common practice the industry use large charging bells throw the finer material the walls, thus causing the furnace work more the center protect the walls—a very good reason, for brick without protection will stay the inwall section furnace that has uniform stock distribution and driven rapidly. Much has been said about distribution and much has been ac- complished, some the stock distributors are mechanically perfect could desired. But this whole effect such machines place the material uniformly distributed the bell. the bell then places this stock the furnace such manner that crater forms vertically the center the furnace the stock reduces, then the stock must fall from omewhere around the walls without any regularity all, and only can have irregular working con- dition with all its attendant evils. has been definitely determined that the inde- structible inwall and top construction, with increased areas upper section the furnace together, with better distribution the stock from the bell, have greatly raised the ultimate limit production, and have reduced coke consumption per ton iron. The ultimate possibilities have not yet been fully deter- mined, but probably are per cent increase pro- duction and per cent saving coke. Furnace No. (an operating chart which given) when changed this type, has shown 30.4 per cent increase pro- duction, and decrease coke 12.9 per cent. hot-blast can maintained normal, production this furnace can raised further, have not yet reached the ultimate practical limit volume air heat that this furnace will take. believed that the notably increased production and lower coke consumption this furnace are due relatively larger area its upper part and the re- arrangement the furnace lines, together with stock distributed the bell place sufficient amount coarse material along the walls, the center, thus causing the upward passing gases flow uniformly through the whole mass, and main- tain uniform temperature and flow throughout the furnace. This brings into active service every cubic foot space, and approaches ideal operating condi- tions, there cause left for heavy slips the burning bronze coolers with the accompanying expense and delays. Tests Metals High Temperatures Accurate Tensile and Other Results Claimed for New Amsler Apparatus —Compression and Other Tests Possible the demand the metallurgical industries for efficient apparatus for the investigation metals elevated temperatures, Alfred Amsler Co., Schaffhouse, Switzerland, have developed special accessories for use with their tensile and compression testing machines. The special furnace, shown Fig. applied tensile machine can used the following manner: 1. For determining the tensile strength of a test bar at a definite elevated temperature For determining the yield point elevated tem- peratures For determining the period time required break a test bar at a constant elevated temperature and a constant load. For determining the modulus elasticity bar at elevated t peratures For test No. the machine must equipped with special apparatus, able maintain any desired load Amsler Apparatus for High Temperature Tests Metals, Including Tensile Strength, Yield Point and Modulus Elasticity 784—Se ptember 22, 1927, The Iron Age within the capacity range the machine, automati- cally constant, for any desired period, independently the elastic and plastic deformation which the bar un- dergoes during such period. For tests this kind, the Amsler tensile machines provide that the load-measuring apparatus automati- cally counterbalances the loads applied during each entire testing operation, until the bar actually breaks. Automatic load-maintaining apparatus for these ma- chines was developed Doctor Amsler few years ago. For test No. the Amsler-Martens mirror extenso- meter, shown Fig. used. For high-temperature tests, this apparatus equipped with special compari- son strips and clips for transmitting the elongation the test bar from the inside the furnace the out- side and able withstand high temperatures. The Amsler electrical furnace cylindrical body, pended from which are fastened one the columns the frame the testing machine. men, the furnace swung out the axis the ma- chine. Rheostat, thermo- couple and millovoltmeter for the regulation and measure- ment the temperatures ap- plied form standard equip- ment. The apparatus can also applied compres- sion tests and, connection with pulsator, repeated stress (fatigue) tests high temperatures. This equipment obtain- able the United States and Canada from Herman Holz, testing engineer, Madison Avenue, New York, American representative the Amsler Works. per cent. J | hol | | | | ial | YAN} | The Steel Industry Since 1900 Increase Productivity United States Due Enlarged and Improved Equipment Rather Than Fundamental Changes Process THEODORE been experiencing the unprecedented economic con- dition continuously falling commodity prices, high wages and continued prosperity. Any intelligent attempt explain this anomaly must recognize certain elementary economic principles. clear that wealth cannot divided until produced, and obviously the more there produced each workman the more there di- vided. Wages and dividends are matter wealth’s distribution- -not its production. High wages mean sigh consumption. The larger the output the individual workman the greater the tendency lower costs and the greater possibilities return wages and dividends. Present easy money and low inventory are factors that in- fluence but not answer the question before us. High wages matter distribution instead production are effect rather than cause, and raw ma- terial, which our forefathers had much more than we, but potential value until converted. These are elements that enter into complex problem, but not explain it. Neither would increased production ac- complished merely proportional in- crease the number workers. The true answer this economic paradox combined high wages and lowering price goods, and the underlying primary cause the late industrial progress the United States, lie the in- creased and unrivaled output the individual American workman, and the large accumulation wealth that has resulted from it. United States during the past few years has Large Gain Productivity American Workman The extent this wealth indicated figures re- cently compiled the National Industrial Conference Board from Washington statistics. These show that the value the yearly product the average work- man all manufacturing industry the United States rose from per capita production value $3,214 1904 $4,682 1925, measured the common purchasing power the 1914 dollar. This represents increase 45.7 per cent the manufacturing out- put the average individual workman, which ap- plied the total volume manufactured product sig- nifies that the increase wealth 1925 due solely the increase per capita production amounted $12,- 304,000,000 more than would have been had the out- put the average worker been greater than was 1904: other words, one-third all the wealth that was produced that year from the nation’s manufac- turing industry was directly due the increased pro- ductivity the average individual workman. How profound influence such vast sums have the whole economic structure the country per- haps better visualized when realized that 12.3 bil- lions dollars, the basis present individual pro- duction, equivalent the output 2,628,000 men, number equal nearly one-third the entire work- ing force the United States engaged the manu- facturing industry. That the productive efforts such *Vice-president Illinois Steel Co., Chicago. Abstract address delivered before the Iron and Steel Institute Glasgow, Scotland, Sept. 21. ROBINSON vast army workers can laid aside machinery and management and rendered available for other ad- ditional work without average increase the coun- try’s non-employment striking commentary the stimulating and absorbing effect increased individual production. explanation the increased efficiency attained the manufacturing industry the United States found the development its iron and steel production. all basic industries the manufacture iron and steel ranks first fundamental importance and sec- ond the amount wages paid. 1901 the United States with its output, round numbers, 13,500,000 tons ingots and castings, produced per cent the world’s steel. This 1926 had expanded more than per cent the world’s total with its pro- duction over 48,000,000 tons steel. Whereas years ago the steel ingots made the United States consisted more than per cent acid Bessemer, nearly per cent the steel now pro- duced basic open-hearth. This, brief, tells the nation’s accomplishment for the first quarter the century, and records the large replacement the converter the open-hearth furnace, change superinduced the changing character the country’s ore reserve. The causes for this impressive growth, while clearly complex, are largely predicated upon economic and social change rather than upon any pronounced tech- nical difference method manufacture. principle the blast furnace, open-hearth, Bessemer converter and rolling mill are still the unchanged agents reduction and conversion, and there has been but little progress made the fundamental metallurgy iron and steel during the twentieth century. Momentous advances technique and the refinement operation have re- sulted increase output which can attributed only partially multiplication plants. Marked Increase Per Capita Output South Chi- cago Works The production records the past years the South Chicago works the Illinois Steel Co. furnish concrete illustration the effect such advances. This works represented 1901, does now, the best modern practice. The average daily output each the South Chicago blast furnaces increased from 318 tons 1901 679 tons 1926. During this period the acid Bessemer department increased its produc- tion from 70,000 tons 100,000 tons per month, and the basic open-hearth furnaces increased from aver- age output per furnace 586 tons per week 1379 tons per week. The South Chicago rail mill had average capacity 60,000 tons per month 1901, while the Gary rail mill, which has been replaced the rolling rails, has capacity 100,000 tons per month. These figures reasonably illustrate the unit advance physical production which has taken place the iron and steel industry the United States. still more important development American practice the increased per capita output the aver- age iron and steel workman. This strikingly illus- trated the following South Chicago records: The Iron Age, September 22, 1927—785 | ‘ | | |---| | Illinow Steel Co.—South Works (Tons Produced Per Man-Hour) Increased 1902 1926 Percentage Ore unloading : 2.087 16.835 706.7 Blast furnaces 0.155 0.698 277.3 All open-hearth ingots... 6.252 0.418 16.0 Rail mill—South Works 1902 } Gary Works 1926 0.189 116 This table shows that the average man modern iron and steel plant producing from one and half eight times muchas did years ago. trans- lated into yearly volume, these figures indicate that South Chicago the average workman has increased his ore handling capacity since 1902 from 6000 48,000 tons; his pig iron output from 675 2405 tons; his Bessemer ingot production from 1761 5730 tons; his open-hearth ingot production from 1049 1842 tons, and his rolling capacity from 603 1240 tons rails. That this accomplishment fairly typical the changes that have taken place like branches the industry, for the country whole, supported data lately published the United States Department Labor, which shows average increase worker productivity upon man-hour basis 165 per cent from 1899 1926 for crude iron and steel products. These results are impressive when recalled that they are based upon actual continuous records running over quarter century plant which 1901 represented the latest development equipment, or- ganization and method, and one that during the inter- vening years has kept abreast current change. Such transformation essentially due the en- largement units, refinement design and the in- stallation labor-conserving appliances rather than fundamental changes process. Behind these, how- ever, the large addition mechanical energy which these improvements have been and back all lies enormous investment and coopera- tion men and management. Productivity Expanded Use Mechanical Power The manufacturing productivity any nation can roughly measured the amount its mechanical energy, and the marked growth power application the United States has made possible its expansion and prosperity. From 1899 1925 the country’s primary horsepower more than trebled, and result this increase there now 4.25 hp. the service every manufacturing wage earner. the conventional assumption that hp. equal the unassisted physical effort men, the average capacity the individual worker the United States more than times what would unaided mechanical energy. The manufacture iron and steel has more than kept step power installation with the progress made general industry. During the last years its use power has increased nearly fourfold, and each its workmen there now given the energy over hp. The extent which power usage has been amplified and the electrification plant increased, strikingly exemplified the Gary works the Steel Co. short generation ago the reciprocating steam engine was the principal prime mover both primary and sec- ondary units. Gary the production and utilization power are dependent upon the blast furnace gas en- gine, steam turbine, electric generator and motor. Here 11,716 men were able 1926 turn out more than 2,500,000 tons finished product because back each them was the electrical energy nearly hp. Wages Have Increased More Than Commodity Prices but natural ask whether not the increase worker productivity which power usage such important factor has been followed increase “real wages.” Wages and earnings the Chicago district may considered typical those existing elsewhere the iron and steel industry the country. 1901 the daily wage was based 15c. per hour and the average yearly earnings all employees the South Chicago works for that year was $825. 1926 the hourly rate had risen 44c. and the average yearly earnings $1,870, increase 127 per cent, more 786—Se ptember 22, 1927, The Iron Age than double the amount earnings received before. With this increase earnings went also reduction nearly per cent the hours the men were re- quired work. Prior 1922 the iron and steel in- dustry had been operated almost universally the basis hr. for continuous operations and hr. for non-continuous operations. that year the pres- ent and 10-hr. day working schedule was adopted, and several years earlier the seven-day week had been replaced the six-day week. the first decade the century there was strik- ing change the basic cost living the wage scales. 1914, however, there had nounced that vicious circle high commodity prices, high cost living and high wages which few years before had begun evidence itself. War conditions aggravated the situation and commodities, living costs and wages rapidly pursued one another upward ever expanding sequence until the deflation 1921. The social and economic consequences the wage earner and industry are told the following result Governmental investigation. Earnings repre- sentative industries increased 115 per cent between 1914 and 1925. Living costs workers’ families rose per cent and the hours labor decreased more than per cent. These figures indicate that wages manufacturing industry have more than kept pace with the increase commodity prices. The surplus earning power thus represented well explains the present wide consump- tion luxuries and the high standard living that now exists. The Investor Has Not Fared Well Granting that the economic change during the last years has been distinctly beneficial the wage has been the contemporaneous effect upon the consuming public and investor? take the price relation that existed between the composite steel price and the wholesale price commodities 1913 base, find that whereas 1901 the price steel was relatively per cent higher than that commodities, was 1926 per cent lower. The composite price steel now prac- tically per cent higher than 1901 while the whole- sale price commodities has increased per cent. Due efficient management, the spending many millions power and machinery, and the cooperation labor, the consumer, relatively speaking, buying steel now cheaper than did years ago. With the investor today somewhat dif- ferent story, and this especially true there borne mind the difference the amount money represented capitalization upon which dividends are paid, and the much larger sum that represented the balance sheet, and upon which earnings are de- pendable. While there are from the Government exact fig- ures the amount money that now invested the iron and steel industry, the published balance sheets steel companies representing over per cent the country’s ingot capacity show capitaliza- tion approximately four and one-half billion dol- lars. According these reports earnings for the years 1925 and 1926 are respectively 5.61 per cent and 6.70 per cent the capital invested. thus appears that, while the wage earner, the consumer and the public general have been very distinctly benefited, capital has not fared well. Inefficient Equipment Scrapped Reduce Cost Due the exigencies and stimulation the war, the ingot capacity the United States increased slight- over 15,000,000 tons for the six years 1915 1920 inclusive, the rate approximately 2,500,000 tons per year. The end the war left the country with excess plant development, and for six years subsequent 1920 the total ingot capacity increased less than 3,500,000 tons, the approximate rate 500,000 tons per year. The theoretical steel ingot capacity the nation today, round numbers, 58,000,000 tons. While during the war expense was spared en- large the country’s steel capacity, investment during the last six years has been made with special refer- ence the reduction costs, diversification product, and the betterment quality, instead increased pro- duction. This explains why the installation power and labor-saving machinery has been late strongly emphasized and why there has been such heavy scrap- ping inefficient and obsolete machinery and plant. Irrespective its physical condition its length service not good business continue use ma- chinery better design will pay fair return its investment reducing cost. The American practice drastic this regard, and only such pro- gressive policy that any concern any nation can hope keep abreast the times and successfully main- tain its position. Management and the Human Side Industry Management early the century began recog- nize more practically its obligations the human side industry. found that the minimization occu- pational hazard, sanitary surroundings, hospitals, bet- ter housing and other welfare work which promoted the health and happiness the worker and his family, not only was humane but paid the good will and the co- operative spirit that the development and application this new science human engineer- ing the iron and steel industry, inspired the ex- ample the United States Steel Corporation, has taken most prominent part. 1906 the United States Steel Corporation inaugu- rated campaign safety, sanitation and welfare which has ever since been vigorously pursued. Tonnage and costs became longer the sine qua non achieve- ment, and the safety and welfare the worker vital consideration mill operations. Accident prevention has naturally been most prom- inently stressed. The safeguarding machinery starts with the drafting board all construction and dili- gently pursued thereafter experience permits. Edu- cation and organization men into safety commit- tees plays important part, and that expense not al- lowed interfere with the desired object indicated the expenditure the United States Steel Cor- poration last year $1,750,000 safety work. Sharp Reduction Accident Rate result such intensified effort extraordinary reduction the accident rate has been achieved. Among the quarter million men employed the United States Steel Corporation 1926, the rate dis- abling accidents was 3.26 per cent compared with 20.57 per cent 1912, reduction 84.15 per cent the former rate. That means that the company men have been saved from disabling injuries since 1912 measured the sum the reduction accidents each year. addition the payment liberal wages various corporations seek improve the financial condition their employees affording them the privilege stock advantageous terms. the United States Steel Corporation, illustration, there were 17,647 employees registered stockholders Dec. 1925, who held 665,801 shares the corporation’s preferred and common stock, with aggregate value over one hundred millions dollars. Like the cor- poration’s safety and other welfare activities, this method encouraging partnership relation abso- lutely divorced from any paternalistic method condi- tion, which both men and management rightfully object. Large Increase Per Capita Steel Consumption the beginning the century the United States with population 76,000,000 people produced 000 tons finished steel, while 1926 with popula- tion 117,000,000 this output had risen 35,500,000 tons. other words, each inhabitant average used 739 Ib. finished steel 1926 compared with 279 1900, over two and one-half times much now formerly. This expansion essentially due increased domestic demand and has been little in- fluenced the small percentage growth the coun- try’s foreign trade. The following statistics show how this change has been. The iron and steel imports and exports the United States, round numbers, were respectively 200,000 tons and 1,000,000 tons 1900, compared with imports 1,000,000 tons and exports 2,000,000 tons 1926. The increasing ramifications steel’s new uses are continually making for widening markets. the be- ginning the century the production rails absorbed per cent the country’s entire steel output. Last although the rail tonnage was half again large was years ago, represented only per cent the country’s steel production. the new demand for steel the most important de- velopment the expansion the automotive industry, which last year took per cent the nation’s output. Prosperity Based Thriving Public, Contented Labor and Adequate Earnings The economic progress retrogression any na- tion depends upon the expansion curtailment the individual production its workers, and the secret America’s well being lies its unrivaled per capita out- put. Back all accomplishment, however, human effort, and the installation power and the wealth material resources will but abortive aids unless util- ized and directed the hand able and willing labor. The character any people depends upon their education and environment, and their material welfare can assured only founded upon sound economic methods. The irrevocable law supply and demand nothing but human nature reduced formula, and composite human nature unchangeable its primary instincts spite civilization’s veneer. Consumption vitally affected costs produc- tion, but for management lower costs reducing wages they are reasonable just shortsighted for labor try improve its condition restricting its output. Both, continued, must inevitably lead lower standards living. Prosperity continue must based upon thriv- ing public, contented labor and adequately remunerated capital. any one this essential trinity becomes unbalanced the wheels industry will slow down and prosperity disappear. prophet may not without honor, save his own country, venture the prediction that, war has given way peace, will ignorance give way eco- nomic enlightenment, and that the new spirit in- dustrial cooperation there will found both greater prosperity and better understanding between the nations the earth. Over $1,000,000 Wasted Annually Mail Advertisers Under the heading here given, Postmaster Kiely, New York, has issued bulletin from which the fol- lowing has been taken: “The direct-mail advertisers the United States the year 1926 wasted, literally threw away, over $600,000 through the use obsolete mailing lists com- bined with the failure the advertisers use return cards their envelopes. These figures, however, in- clude only advertisers who mailed their circulars under first class postage. very much larger amount was lost advertisers who used third class postage. This, however, cannot estimated, since separate record not kept undeliverable third class matter disposed “The records the Post Office Department show that during the year, 12,688,567 letters containing circulars and advertising mattter, all mailed first class matter, were disposed waste the dead letter service. Figured 5c. each cover the cost material, printing, labor and postage, the total amounts $633,428.35. This advertising matter furnished over per cent all the dead letters handled the year.” The Iron Age, September 22, 1927—787 tt : Seven Sheet-Metal Parts for 1000 Automobiles Day Are Cleaned This Metal-Washing Machine 4 “Ve Washing 7000 Sheet Metal Parts Day Handling Equipment Features Installation Automobile Works Water Recirculated After Skimming Off Grease METAL-WASHING machine having capacity for washing parts for 800 1000 automobiles day included the equipment installed aid rapid production the new “Pontiac Six” plant the Oakland Motor Car Co., Pontiac, Mich. This believed the largest machine ever built for this class work. was built the Detroit Sheet Metal Works, Detroit. The machine designed wash and rinse various parts preparation for enameling after they leave the manufacturing departments. These pieces include the four fenders, two running board aprons, the radiator plash shield and certain forgings and castings. The work hung monorail chain-pull conveyor and travels over 100 ft. moving from the entrance the exit the machine, whence the same conveyor carries drying oven. The conveyor operated vari- able speeds, traveling about ft. minute for production about 1000 cars day. the machine are three high-pressure washing zones. The work first washed with washing com- pound and then given two clear rinse water sprays. each cleaning zone 1200 gal. water used min- ute. This water recirculated continuously means double-suction centrifugal pumps, and kept clean arrangement grease-skimming baffles and partition extends through the center the ma- chine. The work passes down one side, loops around and returns the end from which started. The clear space provided for the work about ft. high and ft. wide. Exit End the Machine, Showing Splash Shields Coming Out Right and Radius Rods Entering Left 788—Se ptember 22, 1927, The Iron Age 7 g Oil,Gas and Electric-Fired Furnaces Advantages and Disadvantages Each Type Analyzed for Specific Operations—Control and Atmosphere Stressed general proposition the ideal furnace one which will produce perfect product the low- est overall cost. Because each problem fur- nace applications involves many variables not possible set specific solutions. possible only establish general principles which may applied specific problems. Every ideal furnace must repre- sent such combination design elements and fuel that: 1.—The smallest initial investment required, 2.—The greatest output per dollar investment secured, 3.—The labor for operation minimum, 4.—The quality product uniformly maximum. Popular conception furnace design would place automatic control the first essential the ideal fur- nace. The effect this control reduce labor, increase the percentage perfect product and assure uniformity product. well established that gas and electricity, both controlled through the same in- strument are practically foolproof operation. Both fuels possess form value which readily lends itself automatic control. the other hand, oil has such characteristics that demands eternal vigilance, high quality fuel and skillful original design produce comparable results. Engineering ability must called upon produce the majority the other elements the ideal furnace. electric furnace for gas furnace that will pro- duce any conditions automatic continuous operation temperature cycles, provided the engineering ability put into the design. Disregarding the factor in- fluence atmosphere the product, reasonable assume that equal engineering ability can produce, with ras electric fuels, equally satisfactory furnaces from the standpoint operation product. comparison between the two types furnaces will then generally resolve itself into comparison actual heating costs. Gas vs. Electricity This matter heating costs, while favor gas the furnace efficiency disregarded, may result final cost considering the furnace efficiency, favor electricity. The difference furnace efficiencies be- tween gas fired furnace and electric fired furnace represented the amount heat lost through the products combustion escaping from the working chamber the furnace. This statement based upon the premise that the fuel-fired furnace has such com- bustion equipment that, independent the operator, the scientifically correct proportions fuel and air will always pass through the burners the furnace, and that the maximum energy the fuel will liberated, without excess air deficiency air and without fuel loss due improper intimacy fuel air mixture the furnace. meet these conditions necessary that the gas-air mixture independent the operator, and the Detroit chapter the American Society for Steel Treat- ing, the Motors Building that city. The author vice-president Surface Combustion Co., 366 Gerard Avenue, The Bronx, New York. MAN KER homogeneously mixed matter design charac- teristic the burner, that enters the furnace com- bustion perfect explosive mixture. Under these conditions the maximum heat will liberated. The form value gas makes possible this premise. the case oil such premise not possible. The difference efficiency the electric furnace and the gas furnace doing the same work, built with the same wall thicknesses, having the same door open- ings and the same cycle operation, will repre- sented the amount heat carried away from the furnace the waste products combustion. Electric Furnace Advantage High Temperatures the waste products combustion leave room temperature, then the efficiencies the gas furnace and the electric furnace are identical. the waste prod- ucts combustion rise above room temperature, the efficiency the gas furnace drops below that the furnace. For this reason the obvious applica- tion for electric furnaces, secure the maximum ad- vantage over fuel-fired furnaces, the range extremely high temperatures. Operating costs should therefore more compar- able where the electric furnace used melting steel than where used low-temperature drawing operation. The production electric furnace steel for castings and the use the electric furnace for pro- ducing alloy steels conspicuous example this ap- plication. this example, however, the form value the fuel great benefit controlling the quality the product, that the electric furnace not only high efficiency compared with other furnaces but gives valuable control over the product. Another example the form value electricity plus efficiency and high temperatures the melting copper al- loys, where has had wide application. Influence Furnace Atmosphere electricity has waste products combustion, erroneous conception has arisen regarding the in- fluence electric heat ine surface the work. When the work charged into electric furnace charged into normal atmosphere the room, which contains per cent free oxygen. not possible operate the furnace without free oxygen unless special means are provided for eliminating it. Therefore the characteristic every electric furnace inherently highly oxidizing. contrast, the gas fired furnace products combustion may contain free oxygen free oxygen and excess carbon monoxide, which reducing, depending upon the characteristics the work treated the furnace. The use special means prevent decarburization the only way elec- tricity can used fire certain furnaces for heat treating operations. Normalizing Conditions the production steel which satisfactory for deep drawing, fenders for automobiles, the mill has been forced type heat treatment known normalizing. This normalizing operation takes the place the first box anneal, the former practice. The Iron Age, September 22, 1927—73 ™ 7 Washing 7000 Sheet Metal Parts Day Handling Equipment Features Installation Automobile Works—Water Recirculated After Skimming Off Grease METAL-WASHING machine having capacity for washing parts for 800 1000 automobiles day included the equipment installed aid rapid production the new “Pontiac Six” plant the Oakland Motor Car Co., Pontiac, Mich. This believed the largest machine ever built for this class work. was built the Detroit Sheet Metal Works, Detroit. The machine designed wash and rinse various parts preparation for enameling after they leave the manufacturing departments. These pieces include the four fenders, two running board aprons, the radiator plash shield and