The Iron Age 1928-01-19: Vol 121 Iss 3

THE IRON New York, January 19, 1928 ESTABLISHED 1855 VOL. 121, No. Moderate-Sized Plant Modernizes Installing Simple Conveyors and Trolleys, Re- grouping Machinery and Instituting Four-Shift Working Day industry are undergoing radical changes, be- period when manufacturing operations within comes necessary for the small and medium-sized plants well for the large companies adopt the innovations which have proved successful. least they can adapt their own peculiar needs the gen- eral principles underlying the new system. Upon their ability bring about these changes economically frequently depends their continued prosperity. Modernizing Without Rebuilding Such confronted the officials the American Foundry Co., Indianapolis, few years ago. their foundry, old standard practices were being followed consistently the manufacture auto- mobile cylinder Then came the introduc- tion many new customs into the foundry industry, such the continuous pouring process, and vari- ous labor-saving devices the molding room. The problem lowering pro- duction costs would have been easier new foun- dry could have been built. But the question revo- lutionizing old one that operations conform strictly the newest, ap- proved practice more difficult. Nevertheless the American Foundry Co. has answered satisfactorily without the necessity financing the erection new foundry. The buildings were sub- stantially constructed brick. The overhead struc- ture, however, sufficiently strong sup- port heavy cranes other equipment which would impose undue burden. was decided, therefore, install overhead monorail system would reach AND Taken From Shakeout From Storage which Mixing Plant Buckets. device tically every department the plant. The rails this track (manufactured the Louden Machinery Co., Fairfield, Iowa) are hung from the wooden roof trusses shown the various views. the same time new equipment was introduced and continuous molding established. might seem that much time would required effect these changes. But the work was coordinated that the foundry closed Friday afternoon after operating the old basis and opened Monday morn- ing ready produce castings new methods. Four-Shift Day Important Innovation The main foundry floor divided into two portions equal size, the division line running the length the structure. Along this central line cated the molding ma- chines. The workmen are grouped into tions, consisting the molding gang, the pouring gang and the shakeout gang. They operate four shifts day arranged During the first period the molding gang works one floor, with the pouring gang following about two rows behind. the same time the shakeout gang busy the other floor, getting ready for the pouring gangs use nine o’clock. When the second period arrives, the loca- tions the gangs re- versed, the molding and pouring gangs occupying floor No. and the shake- out gang, floor No. Because the continu- ous pouring system and the shifting the men Note switching from one section the q | 7 7 7 187 floor another, production has been doubled without increasing the amount molding floor space, the num- ber necessary flasks has been reduced per cent without decreasing the output castings, and night work has been entirely abandoned. Monorail Handles Material Production the practical working out production problems the American Foundry Co., the monorail system has been interwoven into the various operations that cannot well separated from them and deserving detailed study. trolleys suspended from the rails are numerous kinds carriers which differ ac- cording the particular service being performed. These carriers are moved about man-power. sufficiently heavy that two main lines track are necessary the greater part the plant. Many switches cross from one line the other that ma- CORE OVENS w FACING ARRIAGES Move Broad- side Through Sand Blast. Double turntable brings trolleys into monorail 4 terial can delivered almost any portion the plant. Switches are controlled rope pulls, shown one the views. The heat tapped into ladle hanging from the monorail front the cupola. workman then hooks the ladle and pulls the pouring floor, where pouring position. When empty, the ladle taken the crane back the monorail conveyor, which transported the cupola. Castings taken from the molds the shakeout gang are placed platform, and then carried monorail conveyor the knockout room. slight variation noted the arrangement for moving cylinder blocks through the sand blast room. Instead single rail there are two paralleling each other. From them suspended crosswise carrier from which dangle number chains. Attached WELDING POOM Sketch Map Showing Louden Overhead Conveying System American Foundry Co., Indianapolis 188—January 19, 1928, The Iron Age 7 x q ‘ 7 BINS be a’ i’ a! at ; | Slag Caught Pots, Transported Outside, Cooled and Dumped each chain cylinder block. Each block can turned completely around during the sand blasting and then shuttled one end the carrier make room for the next block. When all the blocks are sand blasted, the carrier taken the parallel mono- rails two turntables, operating unison, which transfer the trolleys that the carrier can run off right angles single rail the grinding depart- ment. the finishing room use made both overhead transport and gravity conveyors. Running the full length are three Logan conveyors the latter type, each handling different kind casting. the jour- ney down the gravity conveyor the castings are taken off hand several points for grinding and other the Effective Use Overhead and Roller Con- veyors Finish- ing and Reclama- tion Departments = ae - ar. machining work, and the end the monorail again picks the cylinder block and carries into the ship- ping room. number blocks may handled once chain hoist suspended from the monorail. The hoist equipped with long bar having numerous hooks, and from each hook suspended cylinder block. Blocks are taken hand truck from the door into the railroad car for shipment. Core and facing sand handled from bins mono- rail conveyor bottom dump buckets with capacity 1900 Some buckets are divided into compart- ments, each which contains special kind sand. this way special mixes can proportioned and dumped into the muller. the preparation facing sand the monorail The Iron Age, January 19, conveyor also indispensable. Drag molds are knocked out spot adjoining the conveyor, and sand shoveled into bucket and moved the monorail steel hopper feeding the mixing equipment. Tem- pered sand deposited boxes holding cu. ft. sus- pended from the monorail, whereby they are moved the molding floor. air hoist sets them down next the molding machines. During the process just de- scribed the sand shoveled but once. Only two men are needed for the entire operation. One delivers the sand the facing room and brings back the molding floor; the other operates the mixing ma- chinery. Unique Slag Disposal The usual practice smaller foundries let the slag drop into hole the floor. This hole kept full water, and the slag becomes stringy, spongy mess which shoveled into wheelbarrows and dumped. the American Foundry Co. cast iron dump bucket spotted under the weep hole the cupola and the slag runs into it. When the bucket full pulled out the monorail conveyor the dump yard, where the slag, still the bucket, al- lowed cool. The bucket then tripped and the slag drops out one large lump. intervals the lumps are loaded onto wagons and hauled away. These are the methods which the company has solved the problem producing castings economically. fact, the accomplishments can definitely meas- ured. The amount floor space has been reduced considerably without decreasing the volume output. Man-power has been cut minimum through the necessary curtail activities any time, this foun- dry has expensive transportation equipment and there are skilled operators lying idle but contribut- ing substantially overhead expenses. The general arrangement this foundry, therefore, designed meet, admirable way, the needs the com- pany, and sufficiently elastic respond readily period either expansion contraction. South’s Importance Iron and Steel Detailed Survey Department Commerce Publishes Book Which the First Nine Regional Investigations Industrial Growth WASHINGTON, Jan. 14.—An interesting fact about the iron and steel industry the Southeast that growing area which not many years ago did not consider itself industrially important, nor was looked upon other sections, says review the industry made publication, “Commercial Sur- vey the Southeast,” issued the Department Commerce. The survey, well illustrated, comprises 477 pages, and the first new series nine regional analyses covering the whole country. The purpose the survey present picture the fundamental economic conditions within the southeastern trade area, with particular reference the marketing products. Particular emphasis laid upon commodity movements, sales problems, indexes income, and consumption. The chief outlook the iron and steel industry the Southeast declared rest upon capitalizing and encouraging opportunities for the manufacture nu- merous items required for consumption and production the whole South develops. The growth and expan- sion the textile and knit-goods and allied industries throughout the Southeast are declared furnish one the most important industrial markets that area for hardware, building materials and goods required for plant operation and maintenance. the other hand, said, this development has offered market for specialized machinery and supplies, which over per cent still purchased from New England. stated that evidence the character allied devel- opment which taking place connection with the iron and steel industry may found the already established plants manufacturing sugar-mill, vegetable- oil mill, and cotton-compress machinery, cotton gin, agricultural equipment, ice-making, textile, lumbering, mining and miscellaneous machinery, stoves, heaters and furnaces, chemicals, and railroad-car equipment various points the Southeast, but chiefly centered around Birmingham. The iron and steel area, pointed out, promises concentrated manufactur- ing section, with increasing consuming population, having purchasing power determined current income. Iron and Steel Second Only Lumbering The review explains the advantages looking the building the iron and steel industry reason the close proximity raw materials and lower freight rates, together with labor and markets. Group- ing all phases iron and steel production Alabama makes the industry, whole, second only lumber- ing the average number industrial wage earners 190—January 19, 1928, The Iron Age 1925. Those engaged the production iron and steel and their products average more than 27,500, large numbers whom are negroes, both skilled and unskilled workers. the value product the iron and steel industry has rival, yielding output about $194,000,000 1925. The industry Ten- nessee employed somewhat more than 5800 with output $26,500,000. These facts, stated, all indicate that this in- dustry more closely confined the location raw materials than any other among the industries the Southeast, and far the important development limited the Birmingham area, Anniston, Gadsden and Chattanooga. These centers are declared representative the present status this industry the South. Alabama, said, the third State the United States the number blast furnaces, most which are the Birmingham district, and Ten- nessee eighth. This industry, pointed out, does not end with pig iron production, since nearly per cent the total output carried into further states manufac- ture the same plants, which usually operate works, rolling mills and foundries. The leading prod- ucts order tonnage, stated, are rails, wire rods, plates and sheets, merchant bars, structural shapes, hoops, bands, cotton ties and bars for reinforc- ing concrete. Copies “Commercial Survey the Southeast” may obtained for each from the Superintendent Documents, Government Printing Office, Washington. Construction Decreased Per Cent 1927 Contracts awarded for new building and engineer- ing work 1927 the States east the Rocky Mountains totaled $6,303,055,100, according the Dodge Corporation, New York. This was drop per cent from the record total 1926, and increase per cent over 1925. For the entire coun- try, 1927 construction volume was estimated $6,800,000,000, loss per cent from 1926. New construction begun December States amounted $477,363,800, per cent increase over November, but decrease per cent from December, 1926. last month’s total per cent was for resi- dential buildings, per cent for public works and utili- ties, per cent for commercial buildings, per cent for industrial projects and per cent for educational buildings. Improvements Ferrous Sintering Continuous Dwight Lloyd Process Shows 500 Per Cent Production Increase—Profits Had NCREASE daily production sinter from 180 tons 1200 tons single sintering machine due primarily two factors, both having with the mechanics the process rather than with its chemistry. The chemical constitu- ents and physical structure sinter have been already discussed the pages THE IRON AGE and, far tion these prop- erties shows, the 500 per cent in- produc- tion cannot thus accounted for. The largest the early sintering machines had grate area sq. ft., while the latest large size machine has grate area 380 sq. ft., increase over 300 per cent. The first factor the improve- ment materials control and the sec- ond the improve- ment sintering machines. Materi- als control extends not only the raw materials, but also mixture. Closely related materi- als control the regulation igni- tion and air sup- ply. factor consists the increase ma- synchronizing machine speeds with the control sintering materials and improved reg- ulation air blast. Continuous pro- duction sinter having the proper structure and minimum fines depends large extent close observation raw materials and sin- tering mixture and instant alteration any the functions mixing, sintering ignition equipment and the fan blower. *Mechanical engineer, 110 Clinton Avenue, Clifton, EDWARD TOURNIER* RAW MATERIAL RAILROAD CAR TRESTLE TRACK HOPPER TRACK HOPPER FEEDER CRANE BELT CONVEYOR BELT CONVEYOR COKE FEEDER FEEDER| RAILROAD CAR COLLECTING BELT CONVEYOR OVERSIZE COKE RAILROAD CAR CROSS CONVEYOR ELEVATOR GRIZZLY RETURNS HOPPER ETURNS FINISHED SINTER RAILROAD CARS Flow Sheet Continuous Sintering Plant, American Sintering Co., from the Raw Material Cars the Finished Sinter, Also Railroad Cars Flue dust admittedly ore waste which the present has been unavoidable. constitutes bur- den pig iron production costs, principally the loss the ore value. All flue dust can sintered physical state su- perior natural ores, fraction the unit cost equivalent ore. Profits from sintering current make flue dust still greater than that from stock pile dust. addition the net gain ore values reclaimed, this saves (1) cost transportation and from stock piles, (2) losses from the elements and (3) loss un- reclaimable dust from the ground storage. Further, the use 100 per cent sin- ter the blast furnace will effect economies not be- lieved heretofore. In- deed, the use all-sinter ac- very recent date. being done, however, the Chateaugay Ore Iron Lyon Mountain, Y., where only sinter used the blast furnace. The Brooke Iron Co., Birdsboro, Pa., uses 100 per cent sinter part the time. The continuous sintering process makes possible the high-quality sinter required accom- plish the results just mentioned, reason instant control the com- plete cycle oper- ations, such a—Proportioning the constituents the charge, b—Regulation proper moisture, c—Proper depth bedding the grates, d—Correct intensity and distribution ignition, e—Constant observation and means adjustment, The Iron Age, January 19, 1928—191 x q HEX.SCREEN HEX.SCREEN WATER WATER SUPER-HOPPER] [SUPER-HOPPER SPOUT SWINGING SPOUT] IGNITION FURNACE CLASSIFIER GASES FEEDER FEEDER CRANE time element sintering zone, g—Automatic synchronism proportions and vol- ume feed the demands the sintering machine. addition, makes possible the automatic control uniformity the sintering charge, provides means for inspection grates outside the sintering zone, and also makes provision for the replacement grates without interruption operations. The continuous dis- charge relatively small stream facilitates effective screening. Sintering Machine Improvements REVIOUS 1917 sintering machines were made two sizes: in. ft. and in. ft. in., the dimensions being those the windbox area. Pal- lets were carried wheels having plain journals. Pallets the upper strand the sintering zone were actuated pair sprockets the drive end the machine, engagement with the rollers pallet. Fig. Disk Feeders and Collecting Belt Bin Building Sintering Plant The body the latter served pusher for the entire load sintering material front it. The return strand traveled back gravity inclined track the starting point. the pallets engaged the sprocket teeth and were lifted into working position the top the machine. The transmission connecting the drive shaft the countershaft consisted several trains spur gears between the pallet strands. The total reduction average speed was ap- proximately 2000 the low-speed gears being the annular type connected the drive sprockets. Due this construction, the drive shaft not sub- jected torsional strains. therefore need not large would required with power transmitted through spur gear the shaft. the same time, however, the intermediate gears, brought within the space between the strands pallets, are exposed the abrasive dust and grit from dropping sinter. New Drive Avoids Dust Trouble the present design, sintering machines are oper- ated through two countershafts and spur-gear reduc- tions. The first countershaft connected speed reducer which eliminates the intermediate gear trains. The larger size drive shaft required, because the overhung gear drive, offset the freedom from abra- sive dust trouble, and the advantage the inclosed speed reducer. The latter are usually Cleveland worm Falk herringbone gears. 19, 1928, The Iron Age Pallets have been redesigned fitted with Hyatt Timken roller bearings, and also the wind seal arrangement. addition, the method bringing the pallet the sintering zone has been changed. The ends the pallets have been designed that they come contact with faces the sprocket teeth shaped the form gear tooth. The wheels the pallets roll curved track the drive end the machine, and the sprocket teeth engagement with the back pallets propel the latter around the curve. This new arrangement eliminates great deal friction. also avoids the occasional stoppage the return pallet strand, immediately the point en- gagement with the sprockets. Present designs sintering machines are made in. ft. in. Accompanying the increase grate areas, there has been also gradual speeding from the original in. per min. the present in. per min. average speed. How Custom Plant Operates indicate more readily how the various function controls are effected, possibly best describe briefly the equipment typical plant sintering flue dust. The American Sintering Co., Hubbard, Ohio, has developed successful business devoted exclusively the custom sintering flue dust. The plant consists trackage, trestles, conveying and mixing equipment, two in. ft. in. sintering machines, ignition sys- tem, blower, synchronizing controls, electrical equip- ment and dust-settling system. The flow sheet indi- cates diagrammatically the materials process. All incoming flue dust and outgoing sinter are sam- pled and weighed over recording scale. When the flue dust received greater quantities than the ca- pacity the storage bins, dumped from the trestle into ore yard alongside the track. reclaimed crane which drops into track hoppers under the trestle. Dust that can handled the plant dumped into other track hoppers the trestle. Each track hopper fitted with revolving disk feeder which feeds the material collecting belt conveyor. The latter discharges inclined belt running angle the collecting conveyor. The inclined conveyor dis- charges the flue dust into two revolving hexagonal for taking out over-size coke, which drops through chute into railroad cars. drops the fines into square storage bins, which there are four, each having capacity 250 tons. Each bin fitted with revolving disk feeder the bottom. All feeders discharge collecting conveyor which takes the material into the sintering plant, where transferred inclined cross conveyor. This belt takes the material vertical belt and bucket eleva- tor, which discharges double hopper over the sin- tering machines. The double hopper has patented loading device, arranged that, when material enters excess the requirements the two sintering ma- chines, trigger arrangement will break electrical circuit, thereby stopping the feeder motor. soon the level the material the hopper drops below certain fixed point, the circuit closed and the feed- ers are restarted. The feed hopper fitted with two revolving disk feeders, one for each sintering machine, the discharge from each feeder being received pug-mill which mixes and moistens the flue dust. Each pug-mill dis- charges sintering machine through spout, which distributes the material uniformly the grates the sintering machine. Two heavy-duty type sintering machines are used. These machines, especially designed for the American Sintering Co. the American Ore Reclamation Co., are in. ft. in. over the sintering zone, the equivalent approximately 222 sq. ft, suction area. Each machine fitted with grate-carrying pallets mounted Hyatt roller bearing wheels, and driven through two spur-gear reductions and one Cleveland worm-gear reducer. The latter connected 10-hp. machine this size, the New Castle, Pa., plant the Carnegie Steel Co., was illustrated and described Jan. 17, 1918, page 200 7 7 a 4 4 « 7 7 7 7 Fig. 3—Top Strand Con- tinuous Sintering Machine Op- erating Floor the Sintering Plant Birds- boro, Pa., Brooke Iron Co. motor flexible coupling. The sintering charge each machine ignited ignition furnace using fuel oil. The oil consumption about 0.6 gal. per ton sinter. Combustion gases are drawn into dust-collecting chamber through ten suction pipes each machine. The gases within the chamber are divested heavy particles the reduction velocity and the reversal direction. These heavy particles then fall film water covering the sloping side the chamber. The water and dust are washed into Dorr rake classi- fier, where the fine particles are raked out the water and the cross conveyor last mentioned. The lat- ter returns the sludge the bucket elevator, which turn places the material for retreating. Each dust-settling chamber connected 60-in. gas main Buffalo 100-in. double-inlet, center-plate wheel fan having capacity 60,000 cu. ft. free air per minute, under pressure in. water gage. Each the two fans equipped with spherical, self- alining, water-cooled bearings. Each fan directly connected 300-hp. motor flexible coupling. Overflow water from the Dorr classifier flows Fig. 2—Cast Iron Pug Mill, Plant Shown Top Page, Which Prepares the Raw Mate- rial for the Sin- tering Process Grinding Proper Size Be- fore Delivering the Ignition Strand through tunnel into sump, where the remaining fine particles material are settled out. Periodically the sump cleaned out aid locomotive crane, which takes the sludge from the sump railroad cars. The latter are then shifted the trestle and discharged into the track hoppers. Taking Care the Product Finished sinter discharged over stationary grizzly bars into railroad cars. The fines are collected so- called return hoppers, fitted the bottom with revolv- ing table feeders. These feeders drop the material the cross conveyor coming from the storage bins. This conveyor all times covered with flue dust, which serves protective layer against the hot re- turns. this way sinter returns enter the stream the material treated. flue dust, the carbon content usually higher than required for maximum sinter production. The returns, which consist largely fine particles sinter containing carbon, serve lower the average carbon (Concluded page 243) The Iron Age, January 19, ¢ 7 ~ basic mechanism administration, elaborated the stage too much “red tape,” which acts slow rather than facilitate produc- tion. Avoidance such over-elaboration fundamental consideration the Landis Machine Co., Waynesboro, Pa., developing production order system for the coordination its manufactur- ing operations. this plant production orders are issued and re- turns collected central department. Each manu- facturing unit receives copies orders manu- factured and responsible for executing its opera- tions economically, the latter being watched closely the general superintendent through current cost records. Production for the most part lots for stock. The amount stock carried based the sales experience the previous few years, tempered considerations the immediate future outlook generally recognized that system, although Manufacture Effectively Coordinated Simple System arrived study general conditions the in- dustries served the company. Manufacture comprises three more less distinct divisions departments according products follows: Pipe and bolt threading and cutting ma- chinery, pipe die heads and chaser grinding machin- ery; chasers; die heads, marketed under the trade names Land-Matic, Lanco, the machinery, some basic designs are produced and from these 300 different combinations, such one, two three- head machines, belt motor drive, with without lead etc., can furnished. The machinery and pipe die heads, the produc- tion system connected with which outlined the following paragraphs, are manufactured the gen- eral machine shop. The equipment this shop arranged according the group plan, with milling machines one group, turret lathes another, etc. Manufacture supervised the general foreman Machines Are Assembled They Are Sent the Testing Department Tested for Accuracy Alinement, etc., the Class Work for Which the Machine Intended 194—January 19, 1928, The Iron Age q Form 631 Supply the following material for Their Req. No. For Stook Their Shop Order 11/21/27 Date Pipe Threading and Cutting Off Mechines, Style "F" Mill with geared headstocks, pumps, and wrenoh e@ uizmment, each e uipped with one Stationary Pipe Die Head. & Head Stk. ROUGH MATERIAL REQUISITION | | wo. res werent | j ove LOCATION CASTING NO Of OF STEEL } Tora. Re: cost { TO DEFT TO FTER the General Production Schedule stores and erecting department. The per- Has Been Drawn Up, Manufacturing petual inventory rough and finished mate- Orders, Shown Fig. Are Issued. The rial, respectively, kept the cards shown work tag, Fig. with time tickets, blue prints Figs. and Cost records for every indi- and operation sheets, sent the general vidual part the machines and die heads are machine shop, and material requisitioned kept cards, Fig. the case abnormal the form shown Fig. The stores stock- cost any item, the general superintendent room requisition, Fig. issued both notified The Iron Age, January 19, 1928—195 4 = | Fors 608 Work Tac SCRAPPED 7 J and number assistant foremen charge op- erations the various groups equipment. The company maintains production engineering department, which, addition being responsible for tool design, jigs and fixtures, etc., also analyzes operations, makes standard operation-sequence sheets, determines standard speeds and feeds for vari- ous classes work and makes time studies for use establishing bonus rates. this connection should mentioned that all workers are stand- ard hour rate, with bonus for completing the work within the standard time, and additional bonus for work done less than the set time. Production Orders Issued Central Department the case the machinery and pipe die heads, the production for stock schedule drawn every three four months. Manufacturing orders are is- sued and records finished parts and machines are kept production order department, operated connection with the cost department. Schedules for stock, well for sales, are submitted the man- agement the production order department, which makes the general manufacturing order shown Fig. Several copies this order are made, one each for the secretary (in charge sales orders), the erect- ing and other departments. Detail manufacturing orders are then issued for lots individual parts that make the machines listed the general order. These detail orders in- clude rough casting order for the foundry, and “work tag,” Fig. for the machine shop, which authorizes that department proceed with the ma- chining the castings, forgings and other material. Materials obtained from outside sources are requisi- tioned through the purchasing department. The work tag, time tickets, blue prints and the operation sheets furnished the production engineer- ing department are then sent tranparent en- velope the general machine shop foreman. The operation sheets, not shown, specify the sequence operations for given part, the sub-department and number the machine which the work done, and the speed and feed used. From the general machine shop foreman the en- velope and its contents the assistant foremen charge the various divisions the work. The latter see that all materials, tools, jigs and fixtures are hand for the prompt start operations. When the assistant foreman ready for material, notifies the rough stores department, which delivers immediately the machines. This material has been assembled and held readiness the stores department, having been requisitioned the produc- tion order department the form shown Fig. the same time that the detail orders were sent the general machine shop. Jigs and fixtures are drawn ahead from the tool crib and set-ups are made most cases the workmen the machines. After machining, the parts are sent the finish inspection department tested for size, and some cases for hardness. The latter tests are de- termine the condition case hardened and other heat-treated parts after the machining operations. each lot inspected, the results are reported the production order department, which posts the infor- mation its record the finished parts available. The inspected parts are delivered the finished stock department. When issuing the detail manufacturing orders, the production order department also issues the store stock requisition shown Fig. This lists the vari- ous parts and sub-assemblies needed for the complete machines. forwarded the erecting depart- ment foreman, giving him the authority draw the necessary parts and sub-assemblies for each lot machines. Erection the machines large department which, like other sections the plant, arranged for the convenient and rapid movement materials. individual machines are assembled they are sent the testing department tested for accuracy alinement, adjustment, the actual work for which the machine intended. The machine then moved the painting department, and finally stock, the production order department being noti- fied accordingly. Perpetual Inventory Kept perpetual inventory all rough material finished parts and sub-assemblies, kept the pro- duction order department the cards shown Figs. and respectively. Records pertaining finished machines and die heads are kept loose-leaf ledger form. This ledger shows the number and location the plant completed machines and other products. Shipments from stock are recorded the ledger, and note made the name the customer order have convenient data for use case repairs, duplication the order the future. Close attention has been given the matter cost records, the system established being simple and thorough, the case the production order routine outlined above. Cost ledgers are tied with the general accounting system. Cost comparisons are frequently drawn the cost department for the superintendent and other executives, who use this the general control operations. The system includes the comparative cost cards shown Fig. which are kept for every individual part going into each ma- chine and die head. These records, maintained over period years, permit convenient comparison current costs with those former periods. case deviation from what has been established the normal cost any given manufactured part, the cost department notifies the superintendent form provided for this purpose. This form shows the ab- normal cost for lots parts they are manufac- tured and permits the superintendent remedy mat- ters before while the next lot production. Bricks with Bias Ends for Furnace Wall Construction the opinion great many engineers, one the most difficult problems furnace construction make fire brick stay “put” under actual working condi- tions. There always the tendency for walls loosen and joints open, resulting heat losses, slag pen- etration and eventual disintegration. This problem stronger wall has been met General Refractories Co., Philadelphia, unique shape called Biasbrix. shown the illustration, Biasbrix are laid angle, one brick overlapping and tying together three others self-locking construction, that serves pro- duce wall unusual strength with tight joints. Although different shape, Biasbrix are found meet requirements readily the ordinary straight brick any thickness wall from in. in. They seem particularly well suited for hollow wall construction, where strong bond paramount im- portance. 196—January 19, 1928, The Iron Age Hollow Wall Laid with Cameron Ma- chine Brook- lyn, Y., makes slit- ting and roll winding machines. Some its products are shown this view the assem- bly room Camachines, they are called coined from the company’s name. GAS fired furnace employed for hardening speed steel tools for the machine shop. pots, similarly fired, are used for heat treating the cutters and other high-speed steel. Re- cording pyrometers are fitted all the furnaces. The piping painted with silver paint, give instant notice any leaks, gas dis- colors such paint. the pack hardening carbon- izing the platon rolls, cutting cylinders, the steel parts are packed bone bonite, air tight pots, and then heated for varying lengths time hr., when they are cooled from hr., de- pending the size. They are then heated again another furnace and quenched brine and oil for the final hardening. Gas used for fuel under the Surface Combustion sys- tem, employing refractories which are kept incandescence the gas com- bustion. The venturi tube method control shown. Marked economies over open flame combustion are claimed. American Navy Uses More Sheet Steel Its Quality Ab- sorbing Vibration Without Damage Important + Feature— also plays important part the United States Navy. Thin and sturdily tough, hums the cadence whirling dynamos and turbines, while also holds its steady. place under the strain and ten- sion gunnery concussions. One month before this was written, the battleship Nevada, for the first time modern navy, fired her dead ahead. Ships habitually fire port starboard, that the recoil can absorbed the roll the ship. But firing dead ahead the ship can- not must “sit back upon itself,” and absorb the shock within its confines. equivalent the ship’s actually being hit the shell. The Nevada was chosen for the test, discover modern battleship could fire dead ahead without seriously damaging her- When the Nevada had fired dead ahead, she sat heavy the sea, her bows submerged, her gun crews stunned momentarily being cast against the sides steel, indispensable American industry, *Maritime Air Service, Oakland, Calif. guns, bore, throw 1400-lb. projectile muzzle velocity 2700 ft. sec. The kinetic energy, for one gun, 70,800 foot-tons. Five guns dead ahead.— 198—January 19, 1928, The Iron Age “We EP Non Splintering, Steel Sheets Find Many Uses Over the Ships their turrets. But when the gun captains sang out through the voice tubes the bridge, “Bore clear!” was known that American ship had successfully performed internationally feared experiment. Now, enemy “crosses our T,” passes his fleet dead ahead us, know that can fire him. Below decks the investigators found that all glass the ship had been shattered, even wired glass. Slight strains were observed beams and other pieces. But the sheet steel members had not yielded the fraction inch which was expected them under the storm they endured. Sheet Steel Held Its Position the main control room the sheet steel partitions were well place; the torpedo rooms the sheet partitions had not much cracked their paint. And with the sheet steel partitions the radio rooms, the fire rooms, and all the gun decks. Sheet steel holds. moments disaster never splinters —quite estimable quality where confined space the Sailor’s Head Sheet Steel Coping Which Wards Off Wind and Rain from the Destroyer’s Bridge (Heavy Seas, Too, Course). The navy has found that shells can- not splinter Housings Masts (at Head Page) Are Sheet Steel | | | | 1 7 might cause accidents assume greater proportions splinters were fly about. piece sheet steel from Pittsburgh plant was placed hill one the naval proving grounds recently and fired ypon with shell, without splitting any manner, the bits shell simply holing it, but not splintering it. This vindicated the naval policy using sheet steel for cabinets, files, desks and all ship office equipment. the event the ship being action with enemy and shell pouring through the spaces reserved for control offices, the desks can crumpled into cruel masses without sending splinters through the air the further injury personnel. Right Foreground Shown Sheet Steel Tennessee. Minor partitions throughout the ship are this material consequence this policy, and also because the Bureau the Budget insists the economical operation the Navy, every piece office equipment all combat ships—battleships, light cruisers, de- stroyers, submarines—is sheet steel. enemy never shells them, then the equipment will last long the ship. fact, naval ships were scrapped today, the sheet steel office equipment could all dis- mounted, detached and placed other ships. not intended the naval estimates ever replace office equipment the combat ships. Desks, Lockers and Bunks Sheet Steel Seven first line destroyers the Navy were wrecked the rocks Honda Head, Cal., 1923. The ships were thoroughly “done up.” Some even were turned upside down several fathoms water, with their hulls torn miserably, heavy loss life having attended the accident. Pictures the wreck the morning after occurred demonstrated how thoroughly the ships had been destroyed wind, water and rocks. And yet, the sheet steel desks from those ships are today doing duty other ships. They were not even bent—by storm, wreck salvaging crews. And they had detached divers under water. Your naval officer, after arduous watch deck, the bridge the engine room, tumbles into sheet steel bunk, made fast the bulkhead his room. The sailors pack their belongings sheet steel lockers. ONIC tion Finding low), Made with Sheet Steel Cabi- net AVAL Mess Room (Left), Showing Sheet Steel Lockers. Each battleship carries many hundreds such lockers The old-time sea chest gone. its place, the neat sheet steel locker possesses the dual advantage in- destructibility and not attracting vermin. Long rows such lockers are mounted all ships except air- craft and submarines. destroyer the first line sheet steel its bread, potato and vegetable lockers, and for partitions below decks. All water and wind sheds destroyers were recently converted, the various navy yards the Pacific and Atlantic coasts, sheet steel construction. Previously had been termed objectionable place sheet steel above destroyer bridges, shelter personnel from wind and seas. Canvas was used create overhead which would serve wind and water shed. After the tests with shell sheet steel, all destroyers. The Iron Age, January 19, _~ the battle fleet the Pacific Coast took turns going the Bremerton Navy Yard receive sheet steel over- heads their bridges. Sheet steel will not splinter war and peace will last long the ship. recently three years ago our destroyers used canvas overheads their bridges. Today they are all sheet steel. Observation Posts and Sounding Apparatus Simultaneously, the observation posts the cage masts the battleships were converted sheet steel, light and durable. Protection from enemy fire the masts naturally not seriously considered. does not matter how heavy the sides the observation lofts may be—if enemy shell hits, will carry that par- ticular post away. fact, lightness may save more than weight, the event hit. With the advent the sonic depth finding appa- ratus, which vessels may make soundings cast- ing oscillation toward the bottom the sea and receiving another instrument, the Navy turned sheet steel for the construction this equipment. did likewise with the direction finding apparatus, which submerged microphones bring central collecting instrument the sounds made the pro- pellers other vessels moving sea. this instru- ment, discover other are near, what type vessels they are, and the speed and direction which they are moving. The casements for these fit- tings are sheet steel, the first two the type being fitted the Zeilin and Corry, the battle fleet de- stroyer squadrons. After the tests, within the fighting forces the Navy, sheet steel equipment for the office “con- trol” personnel, was decided make the ruling effec- tive throughout the Navy, ashore the Naval Dis- tricts, well afloat. Ashore was not considered necessary scrap all the desks immediately, but rather replace them with sheet steel material they are removed after long service. Consequently, all Naval Districts ashore today utilize sheet steel filing equip- ment, while retaining certain extent wooden desks. These latter will gradually disappear land they have sea. Metal Industries Expect 1928 “Fair” “Good” Business Survey National Metal Trades Association Discloses Many Optimistic Opinions Outlook for This Year EMBERS the National Metal Trades Association, comprising many the large metal-working in- dustries the country, are divided their opinions the business outlook for 1928 between “fair” and “good.” the replies received list questions sent out from the association’s office, 52.2 per cent pre- dicted 1928 would “good” year, 34.75 per cent inclined the view that would “fair” year, while the remainder were divided between “extra good” and “poor” 7.25 per cent for the former and per for the latter. Many the replies indicated reasons for expecting better business and only few expressed the view that 1928 business conditions would not good those 1927. Broadly, the opinions indicate belief that 1928 will fairly prosperous, with extraordinary increases decreases sales operating volumes. Among the conditions upon which optimistic expec- tations for 1928 are based are: Good crops, relatively cheap money, flexible credit structure, small inven- tories, better possibility export, low commodity prices and increase stock orders; while actual orders booked and inquiries received recently, together with the possibility increased automobile production, were taken into account also. Some Companies Expect Make for 1927 Recession “Conditions related trades exert large influence the prosperity the metal trades,” says bulletin which the association’s questionnaire analyzed, “and interesting note that even those indus- tries faced with the most adverse conditions reported, there still underlying expectation steady flow business. For instance, members associated with the coal mining and oil producing industries, both af- fected overproduction 1927, report good prospects for 1928. the other hand, members the automo- bile field report excellent outlook for 1928, due low production 1927 and the absorption used ears. The re-entry Ford into the market, coupled with new designs announced other manufacturers, are factors expected take the slack caused the 1927 recession. “Members close touch with the railroads and the textile industries report increasing activity their markets, which leads general feeling improved conditions for 1928. Members supplying the building trades not feel equal degree optimism the assumption that the general building shortage has been overcome. the other hand, the extent building 200—January 19, 1928, The Iron Age permits being issued for 1928 erection opens the door for larger possibilities metal building materials.” Replies the questions sent the association its members showed that fully per cent those expecting fair good year base their expectations upon general economic soundness American industry whole, and upon the special conditions obtaining various members’ own industries. About per cent base their expectations upon the outlook industries which they serve, while per cent base their hopes orders and inquiries already received. few men- tion the political situation affecting their business. Some members reported larger volume business 1927 than 1926 with less profit, while others re- ported smaller volume business with greater profit. increase productive efficiency plants was re- ported per cent those replying, and the most important reasons underlying such increase efficiency were: New improved machinery, incentive plans wage payment for workmen and supervisors, improved methods and processes, new buildings and equipment, better supervision, better tools, changes personnel and training employees. productive efficiency reduced the number employees per cent the cases where new methods equipment have come into use, while per cent definitely stated the saving labor amounted per cent. good many replied that increased quality production absorbed any saving brought about greater plant efficiency. Suggestions for improving working conditions and stabilizing business included the following: Better education and training for all employees Closer contact between management and men General refusal accept business less than profit-making figures Stop regulatory legislation Better wages employees through use incentive plans wage payment Better purchasing practices Standardization Consolidations Greater cooperation between empleyers Production control Budgeting Renovating plant during slack productive periods Improved cost finding Personnel research Better supervision Better employment methods Exercise caution expansion Developing new machinery Inspection Aircraft Mild Carbon Can Separated from Alloy Steels After Normalizing Testing Individually for Rockwell Hardness HORACE KNERR* the manufacture seamless steel tubing such used aircraft construction, and for many other purposes where accuracy and high quality are essential, the first operation pass the hot billet through piercing mill, from which emerges short, crudely formed tube hollow billet. This subjected one more stages hot rolling over rod, during which reduced about in. diam- eter, in. wall, ft. more long. Manufacture Requires Repeated Handlings Subsequent stages manufacture consist cold drawing through die and over mandrel suc- cessively lighter walls and smaller diameters. The tube must annealed after each pass remove the hardness produced cold work, and must pickled after each annealing remove scale oxide. After pickling and rinsing the tube coated inside and with lubricant, preparatory the next cold pass. tube thin wall and small diameter may through this series operations many times before reaching its final dimensions. the tubes are elongated each passage through the die, they soon become too long for the draw bench annealing furnace, and must cut two. These halves again are drawn and their turn are cut two when they reach limiting length. From single dozen twenty tubes thin wall may therefore produced. Many lots tube different stages manufac- ture are passing through the cold drawing mill one time. The lots are handled bundles, consisting few dozen few hundred tubes, according their *Consulting metallurgical engineer, Tubing Co., Bridgeport, Pa. size and weight. Each bundle identified tag and job card, which its progress recorded. The ut- most care given the segregation tubes various types analyses steel their progress, but spite this, human fallibility sometimes results dur- ing the many handling operations placing tube one analysis the wrong bundle, after which loses its identity. This chance not confined the tube manufacturer’s plant, but exists also the user’s shops and stock Segregation Stock order avoid the possibility mixing tubing ordinary commercial grades with those the higher grades required for aircraft use, one the Summer- ill Tubing Co.’s mills devoted exclusively the pro- duction the latter. complete unit itself, including draw benches, annealing furnace, pickling tanks and necessary auxiliaries. The aircraft industry, including the Army, Navy and commercial builders, have present standardized seamless tubing three types composition, listed the table specifications. Any all these steels may progress through the mill one time. Because its satisfactory fabrication qualities, and its excellent physical properties either cold drawn, slightly tempered after drawing, normalized, oil quenched and tempered, steel finding wide application, not only the construction aircraft, but wide variety industries where requirements are exacting. The two alloy steels not differ widely their physical properties, either drawn after like heat treatments. one more tubes one type became mixed with tubes the other type, and heat-treated accordingly, the properties obtained while not the best would not cause danger. Moreover, trouble should Tubing The Iron Age, January 19, 1928—201 Section Cold Drawing Mill for Making Thin-Walled Seamless > > arise from mistaking alloy steel tube for one mild carbon steel, since its physical properties would supericr. But tube mild carbon steel became mixed with lot either per cent nickel steel chrome-molybdenum steel, serious results