The Iron Age 1927-10-06: Vol 120 Iss 14

ESTABLISHED 1855 THE IRON AGE New York, October 1927 VOL 120, No. Conveyor System Doubles Capacity Furnace Maker Gets Away from Manual Handling and Saves Floor Space—Several Unusual Devices BURNHAM FINNEY* double the capacity plant reducing sub- the floor space previously occupied sounds like paradox, but that the achievement the Monitor Furnace Co., Cincinnati, manufacturer Caloric heating furnaces. Elimination 6500 sq. ft. heretofore used for production purposes has been made. And the total output the finishing and as- sembling departments has been increased 100 per cent the installation conveying system for trans- porting rough castings through the finishing opera- tions and thence the warehouse await shipment customers. addition, the mechanical handling material has cut down the normal working force men, considerable saving labor cost thereby being effected. Furthermore, the use conveyors has brought about other economies which, considered annual basis, amount impressive sum. Certain castings, after leaving the foundry, are sent the sand-blast department for cleaning. From that point they are lifted air hoist carriages *Resident editor THE IRON Cincinnati. Left Center the Process Turning Over One the Cast- ings, Permit Work the Op- posite Side. Movement the material along the conveyor hand power. This tion dia- gram which move two-rail conveyor distance ap- proximately 200 ft. delivery conveyor. route, however, the castings are ground, shipped, mounted and inspected. they emerge from the sand-blast room they are ground while resting small turn- table, which facilitates the operation. After grinding, each casting turned over, per- mitting the bottom chipped and inspected. This accomplished novel device the company’s own invention. Two carriages, one empty and the other containing casting, are moved points within few feet each other. workman then pushes lever which, air power, tilts the conveyor tracks occupied the carriages toward each other, that they ap- proach vertical position the same point. this way the casting transferred from one carriage the other and during the process turned completely over. For the convenience the workmen mounting the castings, and facilitate production, spur the conveyor has been constructed, from point about 100 ft. from the sand-blast room the delivery conveyor, * 4 ri that two lines castings are being mounted simul- taneously. The mounting operation takes considerably more time than the process grinding and chipping. Without the spur track, therefore, congested condi- tion would exist, with castings, ready mounted, backing and interfering with the activities the chipping department. Some castings which not pass through the sand- Conveyor Syste Showing How Mate- rials Are Moved from One Point Another. The letters refer the photographic PAINTING Delivery AND Spur of Conv yor Overhead Conveyor Castings turned arourid here Trac Ori nding YASTINGS Driven and Some Distance Above Them. blast room from the foundry the mill rcom, where they are placed large tumblers cleaned. After tumbling, the castings are placed carriages and are lifted transfer table operated air power gravity conveyor similar eonstruction that pre- viously described. Here, also, they are turned over and turned around the same manner the castings progressing from the sand-blast room the delivery conveyor, and are ground and chipped. which the fronts the furnaces are mounted. Here 1927, The Iron Age Delivery Conveyor transportation hand has been eliminated the in- stallation conveyor which the front rests inclined position, reduction from four opera- tions thereby being accomplished. These four opera- tions include mounting, painting, drying, decorating and crating. The paint conveyor dips various types castings into tanks, three different colors being used. The cast- ings then continue the same con- veyor through drying oven and are brought back the point from which they started. Here they are decorated. Upon removal from the paint conveyor they are crated and sent the ware- house the same delivery conveyor the other castings. right angles the hand-power conveyors the delivery conveyor, which operated 8-hp. motor. Feeding are the conveyors from the sand-blast room and from room. Castings are transferred the delivery conveyor, which several feet higher than the hand-power con- LACQUERING transfer table. After moving from ft. the delivery conveyor, the castings part the conveyor. they are weighed and the record the number units sent the warehouse kept. This record affords accurate index the amount finished work which the company has ready for shipment. From the scale the castings, still WAREHOUSE Transferred from the Hand-Power Conveyors Right the Delivery Conveyor, Motor- the conveyor, are run gradual slope and carried across bridge, which passes over street, and thence down into the warehouse. Here they move an- other conveyor, which right angles the delivery conveyor, and which.runs the length the warehouse. This conveyor level with the floor, and from the are taken hand and stored nearby. The entire length the delivery conveyor 500 ft., which 300 ft. extends along the end the finishing building and over the bridge into the warehouse. the point where the hand conveyors meet the de- Bridge Q + Vv) SAND tion gram) and Mov- ing Toward the Reader. They are here the long delivery con- veyor which car- ries them across the bridge warehouse = the Point the veyor (Left) Drops the Cast- ings Upon the Warehouse Sec- tion the Sys- tem, Carrying Them the Right for Stor- age Shipment. diagram Register Revolving Dry- ing Rack After Being Lacquered. the time revolution has been made, each register ready for the next This diagram “= | The Iron Age, October 1927—935 livery conveyor, the carriages which the castings have been transported are placed overhead power- driven conveyors and are returned the sand-blast mill rooms. One these conveyors utilized, also, carry certain castings the delivery conveyor after they have been chipped, ground and inspected. Incidentally, room adjacent the warehouse, furnace registers are lacquered. After the first cast applied, they are placed revolving drying rack the time the rack has revolved once, the register ready for second coat. The entire conveying system was designed and built the company. British Steels London Engineering Exposition “Spun-Sorbitic” Centrifugal Castings—Pig Iron with More Than Per Cent Carbon—Rustless Steels—Two Special Heat-Treating Processes LONDON, ENGLAND, Sept. 24.—Although the present only the ninth the series, the London Shipping, Engineering and Machinery Exposition has, point age, reached its majority this year. The first exposition was held 1906, and now appears have become established biennial event the engineering world. possesses unique opportunities for representing the numerous industries concerned fully possible under existing conditions. The present display Olympia, London’s largest exposition hall, shows that these opportunities have been made good use of. Brief descriptions few the outstanding iron and steel exhibits are given hereunder. Pig Iron with Per Cent Total Carbon The only concern which lays stress pig iron its exhibit David Colville Sons Sheffield. This firm shows various grades foundry iron, including spe- cial refined variety guaranteed not contain more than per cent total carbon. Several firms, the other hand, show castings with claims much higher qual- ity than was formerly usual. particular centrifugal casting represented the displays the Sheepbridge Stokes Centrifugal Castings Co., which has acquired the patents and asso- ciated plant Stokes Castings, Ltd., and Newton Chambers Co., which has acquired similar control the Hurst-Ball process formerly worked Centrifu- gal Castings, Ltd., Kilmarnock. Both undertakings exhibit piston ring drums and similar articles, and the Sheepbridge company also has die-cast gray iron rods for tool-room work, which are rough machined before delivery, and are said, therefore, avoid the danger blowholes becoming evident finishing, addition having exceptional wearing properties. Newton, Chambers Co. also exhibiting “spun- centrifugal castings, which piston valve liners and cylinder liners for locomotive and internal combustion engines are produced gray iron with sili- con low 1.25 per cent, and the fine sorbitic struc- ture that the original German process was obtained the use red-hot molds. These castings are made in. diameter, ft. length and four tons. From the Farringdon Steel Foundry Leyland Motors, Ltd., come some fine iron and steel castings, made oil sand molds, and exhibited with the actual feeder heads which their soundness assured. The firm Green Son show castings for their high pressure economizers; Thomas Firth Son variety heavy steel castings; Hadfields, Ltd., cast steel, and British Ltd., firebars with per cent longer life than that ordinary bars. Rustless and Heat-Resisting Steels The Hadfield display includes variety the firm’s Era and Hecla special steels, and the Colville display includes the company’s Ducol and other structural steels, but the majority steelmakers have devoted their stands mainly entirely alloy steels, and especially the many varieties stainless, rustless, corrosion-resisting and heat-resisting steels that have been developed during recent years. The exhibit Brown Bayley’s Steelworks haps the most demonstrative the extraordinary re- sistance obtained from judicious choice these materials. consists largely specimens the firm’s various brands steel taken from actual service all 936—October 1927, The Iron Age kinds variety works, little none the worse for wear, after periods exceeding considerably the total life the materials they replaced. Chief interest the Firth stand centered around the heat and corrosion-resisting Staybrite steel. addition the numerous applications this steel many branches engineering, there shown ex- traordinary wire drawn from thickness one- half thousandth inch. British Hardening Processes Two very interesting processes hardening steel are shown Automatic Electric Furnaces, Ltd., and the British Oxygen Co., respectively. The former due Messrs. Wild and Barfield and based taking the criterion the point which steel should quenched when being treated before hardening, not the temperature has reached, but the disappear- ance its magnetic properties. Thirty years ago Rob- erts Austen showed that carbon steel containing not less than 0.40 per cent carbon ceased mag- netic the second arrest point the heating curve, and was then nearly the right condition quenched. The actual right condition was declared when the third arrest point was reached, and, hav- ing regard the effect the rate and duration heating well the temperature reached, was evident the inventors that the end attempts determine that point measurement temperature were bound unsuccessful. Happily, however, the highest critical point coincides with the middle one for all steels containing over 0.4 per cent carbon, and the disappearance magnetic properties consequently be- comes for such steels sure indication that the steel ripe for hardening. They therefore constructed resistance furnace with magnetic indicator, and quenching the point which all magnetism disap- peared they were able obtain the best results. Hardening Steel Gears The process the British Oxygen Co., known the Shorter process, for hardening the wearing faces steel gears, and consists conducting the proc- esses heating and quenching mechanically, that they occur regular and precise fashion. For this purpose the gear wheel mounted adjustable spindle and placed bearings within tank water, required. The gear then revolved and the cone oxyacetylene blowpipe traversed mechanically along the surface hardened, which practically all that allowed out water. The blowpipe fol- lowed immediately—also mechanical means—by jet cooling water, and, effect, part the gear being heated any time except that which under the blowpipe cone. When the operation completed the tool and core the wheel are unimpaired the treatment, and only the wearing surface hardened, although here the hardness penetrates comparatively considerable dis- gear. Moreover, the gear practically free from any sort distortion. The mechanical arrangements pre- vent anything the nature overlapping, and over- heating never occurs. sum, the hardening short and uniferm, blending gradually into the normal struc- ture. Sponge Iron Process Plant Kuji, Japan. Making Sponge Iron Japan Plant Built and Experience Gained Kuji, Utilizing the Anderson-Thornhill Process for Reducing the Ferrous Sands the District JAPAN, Aug. 17.—Various reports appear regarding the success the “sponge iron” plant which has been erected Kuji, Iwate Thornhill and Anderson. The plant now and steel made from its product high quality. The Japanese declare that the plant can operated eco- nomically, but foreign engineers, pointing inefficien- cies and higher unit costs for labor, ore and coal, ex- press doubts. correspondent for THE IRON AGE has interviewed both Anderson and Goro Matsukata, president the Kuji Iron Works, and had access unofficial sources information. Large Deposits Ferrous Beach Sands Kuji small town the eastern coast Japan, about 100 miles from the northern tip the main island. some earlier geologic period the coastline rose and now there strip high table land, more than 100 miles long and about miles broad, extending along the shore, with Kuji the center. Government surveys have found that deposits ferrous beach sand extend for about miles, averaging about ft. thickness. One estimate, made Government en- gineers 1921, placed the total such sand one area sq. km. 150,000,000 tons. The most con- servative estimates give the entire area minimum 200,000,000 tons ore. Others state that the field could fill Japan’s present requirements 2,000,000 tons iron year for several centuries. the feudal era Japan, when the samurai car- ried their two swords, the metal for those famous blades came from outcropping the Kuji field. the hand methods the time the tiny particles were extracted (95 per cent the ore will pass through screen having openings the linear inch) and then worked into iron and steel extremely high quality. The present Kuji plant using sand from the original tunnels this old sword industry. Sponge Iron Furnace System Used more than ten years Goro Matsukata has been seeking some modern commercial method util- izing this vast field ore. Ordinary blast furnace smelting would impracticable, the tiny particles ore would blown out the top would run from the bottom. Numberless experiments had failed prior use the Thornhill Anderson process. This process consists the reduction the com- mon oxides iron—hematite, limonite, magnetite and the calcines from the roasting iron pyrite—at tem- perature low enough prevent the melting any the iron other constituents the iron ore. This temperature lies between 500 and 1000 deg. flux used. The beach sand ore charged continuously through pipes annular hearth, sponge iron furnace. Coal, which has been partially distilled drive off moisture and light volatiles, charged with the beach sand the approximate proportions one part coal four parts beach sand. The annular hearth rotates slowly and heat ap- plied from the carborundum tubes installed imme- diately above each hearth. Gas burned these tubes and the waste combustion gases not mix with the gases formed over the rotating hearth, that there danger reoxidization the particles iron after they have once been reduced the metallic state. The rotating hearth ft. wide. ore and coal pass across they are mixed and the iron oxide re- duced metallic iron. The particles iron are the same size the particles ore. The time required for the charge pass across the hearth about min. The finely divided metallic iron, together with the waste material the original beach sands and the ex- cess coal, discharged continuously into revolving cyl- inders, rotating water cool the material at- mospheric temperature, prevent the finely divided iron quickly burning back iron oxide, which would occur the temperature discharge were too high. This cooled material then passed over magnetic separators, where the metallic iron (and certain pro- portion ilmenite, which magnetic) separated from the waste material. The ilmenite which car- ried over reduces the grade the iron somewhat. There particular disadvantage this other than that the ilmenite must charged into the melting furnaces later on. The finely divided iron, commonly known sponge iron, then briquetted with special presses 40,000 50,000 per sq. in. pressure. The resulting briquet has density about per cent that solid iron, permitting charged directly into open-hearth furnaces and insuring the sinking the briquet below the slag line. The temperature the reduction sufficiently low prevent the reduction phosphorus from its min- eralogical compounds and thereby eliminates one the most troublesome ingredients many iron ores. The low temperature also prevents the reduction tita- nium from the ilmenite, feature considered highly de- sirable the Kuji process. The result very pure wrought iron with com- The Iron Age, October 1927—937 - bined carbon present and without combinations phos- phorus titanium. order make steel sufficient pig iron added produce the grade steel desired. Vicissitudes the Development Mr. Anderson and other foreign engineers have en- countered many difficulties. spoke Japanese and naturally had some difficulty having his orders trans- mitted. Workmen overran the plant while was course construction and there were continually new and untrained men the job. When operation was begun there were breakdowns result the errors untrained labor. There was difficulty with the coal supply, which originally was expected come from lignite mine near the plant. Present Plant and Costs INALLY, however, one furnace went into produc- tion. The plant equipped with two sponge iron furnaces, each with outside diameter ft. and 12-ft. annular hearth. Original estimates were made the basis capacity 100 tons ore day for each furnace. The engineers, however, brought 24-hr. capacity 150 tons ore and tons sponge iron. About 200 tons the briquetted iron were sent the Kawasaki Dockyard plant near Kobe, where steel high quality was made from the sponge iron. Mr. Anderson says that original estimates pro- duction were based the assertion that coal could supplied the plant not more than ton deliv- ered. The lignite near the plant, however, could not used, clogged the gas producers, and be- came necessary purchase coal from the Hokkaido mines average cost $7.50 ton. interview Goto Matsukata admitted that there Propose National Census Distribution national census distribution, which will serve barometer consumption and guide for produc- tion, will the outstanding project the field dis- tribution considered the meeting directors and national councillors the Chamber Commerce the United States held West Baden Springs, Ind., Oct. 18. Secretary Hoover has proposed that the first na- tional census this kind taken 1930. What steps can taken business relation the project and assist the gathering information which will most effective preventing the glutting mar- kets and the consequent demoralizing business slump will discussed from the viewpoint business whole and many individual industries which will represented the meeting. understood the idea Mr. Hoover that national census distribution should taken decen- nially, and should the census now taken man- ufactures. The cost national distribution census has been estimated $2,000,000. Change Organization Bureau Standards WASHINGTON, Oct. 4.—With view increasing efficiency through better grouping its activities, important change the administrative organization the Bureau Standards has been made. Dr. Briggs has been appointed assistant director, charge research and testing, while Ray Hudson becomes assistant director, charge commercial standards. Dr. George Burgess, the director, declared that the regrouping is, fact, recognition the impor- tance standardization the commercial world. This portion the bureau’s work has grown with astonish-, rapidity during the last few vears. The first two main groups into which the bureau activities vill divided will under the immediate supervision Doctor Briggs and will include all the bureau’s scien- tific research and testing, the development, construc- tion, custody and maintenance reference and work- + 1927, The Iron Age was too much labor being employed but pointed out that the average wage for 12-hr. day sen, about cents, and that attempts are being made reduce the total number workmen em- ployed. also said that, while the mining equipment has been erected site where only about 40,000 tons ore can recovered the basis per cent re- covery, excavation under way between the plant and the original mine site the high table land and shortly open-cut mining will instituted considerable saving. present the cost per ton for ore delivered the mine about 1.14 yen. With open-cut mining, be- lieved that this cost will materially reduced. The coal problem, Mr. Matsukata admits, the most diffi- cult solution. Hokkaido coal still being used, but experiments are being made and believed that, with some adjustment the gas producers, will pos- sible use the lignite originally planned, thus re- ducing the cost the coal used less than half the present charge. Already the lignite being used the reduction process, although gives higher ash content than the Hokkaido coal. claimed that ton sponge iron can made under present conditions for yen ($10.50) and can sold for yen ($19 $20) ton. The cur- rent market pig iron about yen per ton for Indian iron and from yen ($25 $28.50) per ton for Kamaishi and Kenjiho iron. There some dif- ficulty being encountered introducing this new prod- uct the steel mills, which are unwilling pay much for for pig iron, but Mr. Matsakata believes that, once the mills have tested and discovered that high quality, there will difficulty selling the current pig iron market. ing standards and their intercomparison, improvement and application science, engineering, industry and commerce, The second group, headed Mr. Hudson, chief the Division Simplified Practice, will include the supervision, direction, formulation and coordination commercial standards, with particular reference the needs industry, involving oversight the Division Simplified Practice, the past, and part the work the Division Building and Housing relating codes and standards. addition, the correlation the work the Federal Specifications Board with com- mercial practice, and liaison duties with other branches the Department Commerce and with other depart- ments questions regarding commercial ‘standards, will included this group. Doctor Briggs will act executive head the bureau when the director absent, the management and supervision the administrative, scientific and technical work the bureau. will also continue act liaison officer matters aeronautics between the bureau and other branches the Government. Hudson Valley Furnace Soon Blow Out The Hudson Valley Coke Products Corporation will blow out its furnace Troy, Y.,some time this month, after accumulating sufficient iron take care its business during the period which the furnace out blast. The coke, which the furnace ordi- narily takes from the corporation’s by-product oven plant, will toward filling pressing orders for domes- tic fuel during the winter months. planned blow the furnace when the demand for domestic coke decreases toward the end the winter. Average weekly earnings representative factories New York State are reported the State Indus- trial Commissioner $29.29 for August. This the highest August figure record and, except for six months through last fall and winter, the highest figure for any month. compares with $28.95 July and with the maximum $29.78 last March. — Airplane Fuselages Constructed Alloy Steel the Army, Plain Carbon Steel Stinson, and Duralumin Ford ANY details about the production aircraft fuselages were given technical session the American Welding Society, Detroit, Sept. 20. Formal addresses were given Johnson, McCook Field, Dayton, Ohio, who described the con- struction army aircraft, and Maylor, chief engineer, Stinson Aircraft Co., Detroit, who told how his company builds commercial planes such the “Pride Detroit,” famed for its America-to-Japan tour. Much the specialized information reported below may best read the light the more article “Commercial Aeronautics and Steel” William MacCracken, Jr., THE IRON April 1927, page 987. those attending the meeting, more vivid impression was made trip the Ford Airport. Army Uses Alloy Steel Tubing According Mr. Johnson, small air craft may have fuselages built low strength carbon steel tubing, be- cause while lighter alloy steel design would strong, would not stiff enough for service. the larger machines, saving weight becomes more important, con- sequently the trend away from hard drawn tubing chromium-molybdenum alloy. account its air hardening properties the strength the alloy the re- heated zone near the joint not much affected, (as in- dicated the accompanying table showing average many tests various sizes and thicknesses tubing). The Army has experienced less difficulty getting uniform materials the alloy steel than carbon steels, especially during recent years. Oxy-acetylene welding has done much simplify the construction. The picture the Stinson fuselage indicates that consists four trusses made tubu- lar members welded the ends; tension members wire shown the close-up detail are becoming obsolete. Added weight rigid tension members less objec- tionable than the continuous necessity adjusting the tension wire ties. Controls are being made with “push-pull” rods operating through graphite bushings. Wall thicknesses are limited 0.035 in. minimum the main members the Air Service, although even lighter ones are used ribs for control surfaces. Jigs for assembling Army planes are made with vertical pillars which jaw clamps are universal joints permit easy removal the completed skeleton. Stinson fuselages are made jigs angle iron, bolted together, the tubing passing through saddles made split pipe and held down dur- ing erection U-bolts. usual start welding from one end, assembling and welding all the cross members they are encountered. this way expan- sion controlled and Mr. Johnson seldom finds more than 1/16 in. eccentricity 30-ft. Army plane. Mr. Left—Fuselage Skeleton Made Stinson Aircraft Co. Thin Walled Carbon Steel Tubing At- tracted Much Attention Exhibit American Welding Society Detroit Below—Close-up Panel Point and Fish-Mouth Tension Splice Lower Longeron Army plane, Loaded for Test Purposes. Tension rod diagonals are now usually tube welded into the joint Maylor said that 48-ft. longerons which would normally move in. during welding could kept within in. proper clamps the jigs. Welding High Strength Aluminum Alloys present only the largest wing skeletons are welded steel; aluminum alloys are often found smaller ones since gives better weight-strength re- lation. Unfortunately strong aluminum alloys cannot welded without loss desirable properties the joint. Composite designs have been made the Army The Age, October 1927—939 | J é 4 a a where steel fitting encircles duralumin member, and struts are then welded outstanding lugs ears the fitting. this point, however, discussion Ernest Lunn, electrical engineer, Pullman Car Mfg. Corporation, Pullman, Bissell, general engi- neer, Westinghouse Electric Mfg. Co., and Nagel, assistant technical director, Aluminum Co. America, New Kensington, Pa., brought out that con- siderable progress being made welding heat treated alloys both resistance spot welding and fusion welding. the latter processes welding wire containing per cent silicon desirable; melts somewhat lower than the pieces being joined, has low contraction solidification, and readily absorbs the temperature strains. minimum heat used making the joint, the hot portions will get air quench. region in. away gets air annealing, and this the weakest point. Seventy per cent the ultimate strength the metal may developed. Gas tanks gal. capacity are made corrugated sheet aluminum 0.042 0.049 in. thick the Stinson com- pany, weighing little 0.35 lb. per gal. capacity. Joints are made gas welding 3/16 in. upstanding flanges. Commercial Fuselage Made Man-Hours Stinson Aircraft Co., according its chief engineer, Maylor, uses plain carbon steel tubing, contain- ing 0.20 0.30 per cent carbon for the fuselage and rudder skeletons. Landing gears, tail skids and motor mounts, however, are made chromium-molybdenum tubing order provide the maximum strength resist impact and vibration motor, unbalanced pro- pellers improper valve setting. After welding, these portions are annealed relieve internal strains. instance how heat treated steel may welded, Mr. Maylor cited the landing gear axle, which after machining was heated 1650 deg. Fahr., quenched water, and then drawn 900 deg. Fahr., giving tensile strength 150,000 lb. per sq. in. This axle welded into the fabricated and heat treated landing gear, the joint being placed position where the stress relatively low. Construction skeleton very easy. All that necessary are jig, hacksaw and grinder fit the members together, and oxy-acetylene welding equip- ment make the joints. requires man- hours for the fuselage; more will make the rudder skeletons, elevators and stabilizers. The com- pleted job weighs about 200 lb. Knerr, consult- ing engineer, Philadelphia, pointed out that square tubing now commercially available and easier cut and assemble into closely fitting mitered joints. square tube having the same distance across flats the diameter round one equal weight both stronger and stiffer. The half-tone shows typical joint truss with tie rod tension members. The tubular members the intersection are slotted receive the gusset plate, which thereby transmits loads the longerons without danger collapsing the thin-walled tubing. “fish- mouth” splice the horizontal also shown, whereby tension compression loads are taken largely shear the joint. Field Repairs Flying Officer Luke the Canadian Air Forces said that the adoption all metal fuselage skeletons was introducing special problems repair. the old days wooden construction, accident usually left nothing repair; now wreck seldom bad can- not rebuilt. Bent tubing can cut out and re- placed with straight sections; crushed joint may sheet metal piece, cut and bent fit the original shape, wrapped around the joint and welded all edges. This often must done the open with strong breeze blowing, and the welder will use much larger flame than indoors, with corresponding danger overheating the metal. Fumes from the outside paint and the linseed oil the inside the tubing also add the difficulties. believes that the tube were hermetically sealed inter- nal corrosion would impossible. Johnson said that such sealing impossible; aircraft examined after service the Pacific Coast was found have sea water inside the tubing, and result the members were corroded and embrittled. Maylor also said that rust the worst enemy welded joints. finds that iron oxide primer followed spar varnish con- taining aluminum powder pigment will give satisfac- tory external protection for years. Since that the maximum life the fabric covering, the skeleton will exposed for repainting correct intervals. Repair welding over brazed soldered joints should course prohibited. Tests McCook Field also indicate that rewelding over sound welded joint will weaken per cent its original strength. Significant the times was the fact that one the most heavily attended plant visitations National Metal Week was the Ford Airport, which included the opportunity taking hop over Detroit Stout all-metal airplane. the hangar located one side the superb mile flying field, the mail and express planes used the Ford Detroit-Buffalo-Cleve- land-Chicago routes were inspected. center in- terest was the Fokker tri-motored plane used Com- mander Byrd his North Pole flight, now temporarily stored the Ford hangars. the factory the airplane division the Ford Motor Co., next the hangars, planes were seen various stages construction. This part the Ford industries not the traditional Ford standards production, being still the formative stage. One plane turned out every six weeks. These large mono- planes are designed carry passengers alent load mail express, and are powered with three Wright whirlwind engines. There dual control, the pilot and mechanician second pilot are housed glass-windowed cockpit, forward. Heat Treatment Duralumin Members The fuselage and wing spars the planes are duralumin angle and channel sections, assembled riveting. Wing surfaces and body are covered with thin corrugated duralumin sheet. All duralumin mem- bers, including the fuselage and spar sections, and the surfacing sheets which require forming are made from rolled strip. These strips are coiled, immersed electrically heated bath molten nitrate for heat treat- ment, quenched, rinsed and immediately passed through straightening rolls, after which they are formed the desired sections rolls under press, and allowed harden with age. Rivets are heat treated the same bath, and driven while still plastic. Important highly stressed terminal members are made steel drop forgings sheet steel, welded brazed and heat treated. This method construction admittedly more cost- than that using seamless alloy steel tubing, assem- bled welding, now adopted most aircraft manu- facturers. Its continued use Ford due the fact that the riveted type construction was developed the Stout planes before the advent tubular steel con- struction, when welding was viewed with suspicion. Effect Oxy-Acetulene Welding Tensile Properties Seamless Steel Tubing Chemical Composition: Carbon TEVTEETELITTT TTL 0.11 to 0.15 0.23 to 0.29 0.28 to 0.35 0.30 0.60 0.30 0.60 0.30 0.60 Unwelded Welded Unwelded Welded Unwelded Welded Tensile strength, in... 54,000 44,000 60,000 98,000 96,000 Yield point, in....... 34,000 22,000 38,000 35,000 75,000 72,000 *Low elongation due change section account welded seams. 940—October 1927, The Iron Age Testing Engineers Holland Impact, Elastic Limit, Fatigue, Magnetic Analysis and Welding Testing Problems Discussed—New Constitution for International Association (Special Correspondence) AMSTERDAM, HOLLAND, Sept. 14.—A paper “Po- tential Measurements with Rustless Steel Test Pieces,” Dr. Staeger Baden, Switzerland, opened the session Wednesday morning, Sept. 14. The point was brought out the discussion, Doctor Benedicks, that the protecting oxide coating, which supposed the basis the non-rusting qualities steels that type, will not stand alkaline bath, and hence the metal will attacked. More Study Wear Essential “Testing Wear Materials,” Spindel the Austrian Railways, Innsbruck, was then presented. pointed out how little the ordinary tests for strength, elongation, etc., made steel other metals, reveal the resistance they have wear, and said that this property would have studied means special machines constructed for the purpose. The resistance wear material not comparable the capabil- ity oil lubricate, but depends upon the surface condition the rubbed parts, whether oil used not, the specific pressure applied, and more particularly the rate travel the parts contact. The paper was discussed several the railroad officials present. Prof. Roos, director the Swedish Bureau Standards, read paper Lundgren the Swedish Government Testing Institute “Testing Hardened Steel.” covered the experimental results the be- havior steel for machine shop use. The test methods were given, with the effect different proc- esses annealing, the influence hardening and tem- pering methods; the promise was made that much val- uable information should result from the investigations the direction selecting the right kinds steel for tools and their treatment. Some Recent Impact Tests Professor Schminning the Dresden Institute Technology then read paper “Impact Testing Ordinary and Notched Bars.” showed large number slides illustrating the effect the depth and shape notches, the relation the impact tests the other, more common ones, for strength; and emphasized the necessity standardizing the notched test piece, that the results obtained might comparable every- where. The effect the test speed, the temperatures involved and the preparation the specimen were gone into. general discussion the paper brought out the fact that much had still done before the real value the impact test might become generally appreciated. Resistance Material Repeated Stresses Professor Rabozée the Military Academy Bel- gium brought the session conclusion with paper the “Influence Heat and Mechanical Treatment upon the Resistance Materials Repeated Stresses.” excursion all the members the congress and their ladies was had the afternoon inspect the ex- tensive harbor works Ymuiden, the coast, where locks were being built larger size than those the Panama Canal, though not deep. The use concrete piles for the foundations, and the enormous amount reinforcement steel was highly impressive. *In Sept. 29, page 883, report was published several the early features and papers the International Congress for Testing Materials. this issue some the other important papers are briefly re- viewed. The morning session Thursday, Sept. 15, was taken two highly interesting, but principally theoretical, lectures great value. Prof. Koerber, director the Kaiser Wilhelm Institut Eisen- forschung, Diisseldorf, spoke “The Problem the Elastic Limit” for hour and half, giving the outline theories and illustrating his points with many lan- tern slides. discussed the conditions which are nec- essary before elongation will commence and the mechan- ism the stretching itself, the upper and lower limits the elastic limit and how these are affected tem- perature, speed test and other conditions. The effect aging, the preparation the sample were also gone into, and the probable future developments research predicted. This lecture, after recess, was followed one given Dr. Rosenhain the British Government Physical Laboratory “The Plastic Deformation and Fracture Metals.” this, critical review our present knowledge the subject plastic deforma- tion was given, the mechanism which such de- formation takes place, the way the changes prop- erties associated with deformation are brought about, and general what known the mechanism frac- ture. Flow material comes about through slipping one crystal another, the crystal itself along cleavage planes. If, then, eventually get know more about the properties the unit crystals our materials, shall have definite scientific basis which build our testing program learn the proper- ties the entire structures. Fatigue Metals Again Reviewed the afternoon tession, the paper Prof. Moore, University Illinois, Urbana, “The Fatigue Metals,” was read Lynch. This was study changing concepts stress, strain and strength. While formerly was supposed that under repeated stress the structure some metals changed from what appeared fibrous structure one that was crystalline, modern investigation has shown that crystallization occurred, but rather slip along intracrystalline planes, and that fatigue failure consisted spreading crack which was thought starting from surface slip. probable that there limiting stress be- low which destructive fatigue cracks will form, even under indefinite and infinitely large number cycle stresses. Prof. White, University Michigan, Ann Ar- bor, next read the paper Dr. McAdam, Jr., Annapolis, “Fatigue and Corrosion-Fatigue Met- als.” This proved elaborate array tables and fig- ures fatigue results combination with corrosion data, and should studied power engineers when the paper eventually published. Similarly the paper “Tests and Properties Metals High Temperatures,” Prof. White, which was read later the author, gave valuable in- formation this subject, for use the boiler engineer who desires use very high pressures and tempera- tures. the paper, Professor White brings out the value the high-chrome steels for this work, but their comparatively high cost prevents general adoption, ex- cept for smaller parts, steel with 1.55 per cent man- ganese seemingly answering very well and being com- mercially available for the bulk construction. long paper “Tests Connection with Specifica- tions for Steel Rails,” Toutain the Chemin The Iron Age, October ; fer Nord, was next read. was profusely illus- trated lantern slides and can studied those interested when published later. Views Heat-Resisting Alloys Then came very interesting paper Dr. Rohn, who gave number data “Heat-Resisting Alloys for Use Annealing Boxes, Furnace Elements, etc.” stated that elements this kind now had serve for 25-ton furnaces, operated 2000 deg. Fahr. for periods from yr., without failure. one the alloys gave one with iron 17, nickel and chrome per cent. paper was then presented “Contributions the Study Effects Viscosity Un- der Heat, and the Application Various Metals and Alloys.” This paper was Jean Cournot and Andre Michel. Professor White then closed the session reading his paper, previously stated. soirée artistique was tendered the congress par- ticipants the concert hall the city for the evening’s entertainment. Friday, Sept. 16, Grossman the United Alloy Steel Corporation, Canton, Ohio, read paper “Durability Nickel-Chromium Resistor Materials,” prepared Brash and Harsch, and cover- ing the work being done committee the the subject. This work being done ob- tain accelerated test which will demonstrate the quality these materials with results comparable actual service. Three classes resistor materials were discussed. First, the platinum group, which not oxidize. Next, the nickel-chrome group, which oxide skin formed and acts protector. Final- ly, other metals which oxidize but are satisfactory used non-oxidizing atmosphere. Developments Magnetic Testing Mr. Grossman then read another paper, Forest, American Chain Co., Bridgeport, Conn., the “Use and Development Magnetic Analysis the United States.” Moving pictures were shown the actual testing steel pins with the picture the curves flashed before the operator. This enables him reject all the faulty pieces. Inclusions Steel Discussed Dr. Karl Benedicks then presented paper written himself and Loefquist, Stockholm, “Our Pres- ent Knowledge Regarding Non-Metallic Inclusions Iron and Steel.” began with general description occurring inclusions, and study their equilibrium diagrams. Referring Hibbard’s designation the unavoidable inclusions carried along during the process “sonims,” Doctor Benedicks proposes the designation “Sonex” for the inclusions picked from without the actual processing. This was objected the discus- sion that followed, adding unnecessarily the al- ready large stock bad English metallurgy. Next Professor Benedicks discussed methods analysis slag grains, the different factor influencing the appearance the slag grains and their distribu- tion the metal, the influence the slag grains the material, the comparison between the amount in- clusions different kinds steel, and finally what means these inclusions can reduced. The importance the subject brought out much discussion. Professor Piwowarsky had sent paper “Com- parative Wear Tests Cast Irons Various Phos- phorus Content.” This was read Doctor Esser, and brought out the observation that the higher the phos- phorus the worse the wear. Papers Electric and Autogenous Welding Next came series papers electrical and auto- genous welding steel. Fuechsel Berlin gave general discussion the subject, and stated that the weld could relied upon—if well made—to have about per cent the strength the rest the metal tensile, and somewhat less bending. Director Sonderegger Zurich, his paper the “Status the Art Welding, Its Problems and Aims,” urged the annealing the welded construction wherever pos- sible. the afternoon session, Dr. Welter read his 1927, The Iron Age paper the “Elasticity Metals and Alloys,” taking more specifically the testing chains. was criticized the discussion for not giving sufficient at- tention the elastic limit, held that all chains are overstrained regularly, and the ultimate strength was what counted particularly. Norbury the British Cast Iron Research As- sociation delivered paper “Tests for Cast Iron,” and the present status the test bar question. Next came Dr. Keockgyarto Budapest “Torsion Tests.” This was extremely mathematical and full tables. New Machine for Testing Hardness Pomey then described his Machine for Test- ing Hardness,” giving all its advantages; after which Prof. Dustin read paper himself and Rosen- thal Rational Calculation the Elements Welded Constructions.” The session was closed paper the “Italian Railway Tests Materials Un- der Their Specifications,” Steccanella. How Testing Machines Should Calibrated Saturday, Sept. 17, Professor Memmler the Ger- man Government Testing Bureau delivered lecture the “Testing and Calibration Testing Machines,” go- ing into the matter thoroughly. described the very exact method use his establishment, and then showed illustrations number the more common arrangements general use for judging the accuracy machines commercial work. paper “Temperature Measurements Made the Test Piece During the Application the Load” fol- lowed. Then Toutain, chief engineer the French North Railway, gave description the “Tests Ap- plied the Purchase Rails.” This was discussed Prof. Welikhow and Sakaharow the Soviet Rail- way Systems. Dr. Daeves Diisseldorf concluded the work the metals section the congress paper “The Evaluation and Utilization Data Obtained from Quan- tity Testing.” When great number test results given line are bunched together, becomes possible construct curve giving the optimum strength values the material, together with acceptable tol- eration both ways, which information serves excellently for specification purposes. Also, the extreme ends the curve show the range and percentage what might classed the exceptional results. The paper was much discussed and differed with. Committee Reports Constitution for New International Congress The final plenary meeting the congress was then held, and the committee reported proposed constitu- tion for the newly suggested International Association for Testing Materials. during the con- gress that the great progress made since the last test- ing congress necessitated the formation some body which would have charge this kind work. Hence the recommendation form “New International As- sociation for Testing Materials,” which recommenda- tion was adopted acclamation. The several paragraphs were then read three lan- guages, and covered the usual details such move- ments. was especially noticeable, however, that all connection with specification work was disavowed. Fur- ther, the very low annual dues American money stamps the movement one loose connection, with work other than preparation for congresses held three more year intervals. The secretary Prof. Ros the Swiss Bureau Tests, Zurich, and the next congress, held 1930 1931, was fixed for Zurich, Switzerland. The congress then adjourned, with the banquet held Schereningen, near the Hague, the evening. The sixth regular monthly meeting the Wiscon- sin Gray Iron Research Group was held the Repub- lican House, Milwaukee, Wis., Wednesday evening, Oct. The speaker was MacPherran the Allis-Chalmers Mfg. Co., who talked cupola prac- tice. imitations Structural Welding Cheaper Steel Shipped from Mill Welding Best for Strengthening Bridges—Problems fronted Railroad Car and Automobile Builders last technical session the Detroit meeting the American Welding Society, occurring Thursday afternoon, Sept. 22, was many re- spects the most notable. Under the genial chairman- ship Llewellyn, American Bridge Co., New York, number impromptu contributions equal importance the formal papers were made from the floor. Field Welding Tall Buildings More Expensive Joseph Matte, Jr., construction engineer for Albert Kahn, Inc., Detroit, read paper entitled “Welding Structural Steel,” opening the session with account how first used welding about ten years ago making caps and bases for wrought iron pipe col- umns, and since then had found increasing opportuni- ties introduce into regular designs, modify more conventional designs submitted his company for bids. For some time welds were considered only where they would take small stress (as rings and shelves support linings), where the stress was compression (as extending steel columns column reinforcements when adding story building) where waterproofing smoothness was required (as for tankage charging floors). the size this work increased, the cost and time completion entered into the problem; one open-hearth charging floor with 43,000 lin. ft. joint was put with countersunk and chipped rivets because the erec- tor was unable sublet the field welding price which would compare with the riveted work, nor get guarantee rapid completion the work. With such occurrences mind, Mr. Matte formu- lated the working rule that the present state the art field welding more expensive than riveting. Some inherent advantage must overbalance the extra cost its application not justified. line with this prin- ciple cited swimming tank constructon where the extra cost water tight welded joints more than counterbalanced saving waterproofing and felt required surround riveted Connections new buildings old ones alongside made welding are certainly preferred, for such joint merely requires the surface the steel bared, and not big hole punched the wall get all sides the new joint, which extensive damage not only interferes with the utility the ol