The Iron Age 1928-02-16: Vol 121 Iss 7

ESTABLISHED 1855 New York, February 16, 1928 THE IRON AGE VOL. 121, No. Profits Diversifying Products Moderate Size Plant Anticipates Disadvantage Single Line and Extends Activities Developing New Devices—Production Carefully Planned XCESS producing capacity has been put forward the past few years one the chief ills affecting many industries. have sought meet this situation diversifying their lines, and increasing number have successfully adapted their plants for the manufacture multiplicity products. working plant moderate size which has diversified its products and thereby attained volume output without sac- rificing profits that the Hobart Brothers Co., Troy, Ohio. facilitate conception the company’s policy, may well consider its history. *Resident editor Tue Ace, Cincinnati. BURNHAM FINNEY* Some manufacturers LOT NO. QUANTITY QUAN. IN ORDER iN LOT CHECK the early days the electrical industry, when the use electricity for lighting was being introduced, Hobart, president the company, saw the possi- bilities electrically-driven equipment. connection with his work manufacturing and installing light- ing plants, for instance, saw the grocery clerk tiring himself grinding coffee hand. electric coffee mill was the result. After his busi- ness had grown substantially, Mr. Hobart sold his holdings and for time left the electri- cal field. Meanwhile his two sons be- came enthusiastic the pros- pect offered driven devices. Soon after his graduation from college, one Material Machined Otherwise Processed Accompanied Through the Plant the Card Shown. Roller Conveyors are extensively used. 457 The view shows machines being conveyed from paint spray 7 DELIVER FINISHED REC'D. BY DATE REC'D. MATERIAL TO a the sons, Edward Hobart, opened electric motor repair shop. One his possessions was electric automobile, and order charge the battery the car built motor generator set convert direct current the alternating current provided the municipality. With the generator working success- fully, other owners electric automobiles began bring their cars Mr. Hobart have the batteries charged. that time the electric starter for gasoline auto- nobiles was just coming the market, and the owners such cars with that device also wanted their starter batteries charged. Realizing the field that was open- ing up, Mr. Hobart, with his brother, William Hobart, began advertising and sales campaign which caused their motor-generator manufacturing business grow rapidly. Foresees Danger Dependence Single Product 1916 Hobart saw danger ahead being entirely dependent upon single product, the use which was limited and for which substitutes were ap- pearing the market. was convinced that the automobile industry offered unusual possibilities and that the thing was add another commodity which would service the field which the company had already become known. Accordingly, began development small air compressor which, after four years experimental work, was ready for the market. Being familiar with automobile construc- tion, Mr. Hobart conceived the idea utilizing the rear axle spiral bevel drive air compressor and put the idea into practice. Having built two different products, the company did not hesitate add others the needs garages and automobile repair shops expanded. The result 16, 1928, The Iron Aze that the Hobart Brothers Co. today manufactures items and sizes equipment. The principal products are: Motor generator sets for battery charging, for motion picture show arc lights and for arc welding; air compressors for tire inflating, paint spraying and for industrial applications; battery testing equipment; electrically-driven grinders; automobile starting motor and generator testing equipment; and car washers. Control the material and parts required make such variety products has presented many prob- lems, and close cooperation between different depart- ments has been essential. designing new product, the engineering department takes into consideration the items already manufactured the company and makes many parts possible interchangeable with Parts, Making Motor-Generator Hous- ing, Are Machined Simul- taneously Automatic Lathes existing designs. avoidable, not even new size screw added. Before manufacture the new prod- uct begun, all parts going into the machine are listed under one two headings. Parts, such machine screws, bolts and nuts, which are purchased ready assemble, are listed non-processed parts and are kept non-processed parts stockroom. Perpetual in- ventory kept this stock means visual index filing system. Parts which machining any other work required before they are ready for assembly are classed processed parts. This material started through the necessary operations the production department, production order card accompanying it. This card, reproduced herewith, specifies the routing and lists all operations. Space provided the lower part the card for entering the daily production rec- Upon completion machining other oper- ations, the parts are sent finished stock storage bins along the assembly line, each part being stored adja- cent the point where will assembled. With approximately 2500 different items material going into products which about 7000 operations are performed, accurate records are essential. All rec- ords are headed with the number the drawing, the number being devised that employee who has been the factory only short time gets ciear con- ception what particular drawing number covers. make this clear: Suppose indicates certain bore and size housing, this case 8-in., and the 7 J =. | > ¢ A | 7 OTOR Gen- erator Shafts Are Machined Gridley Auto- matics. One end the shaft finished, ready for grinding, the unit the foreground, and the other end the shaft fin- ished the sec- ond machine symbol for compressors. Therefore seeing the sym- bol the workman knows that the subject 8-in. bore compressor part. The pattern number the same the drawing number, and all operations the piece have the drawing number prefix. For example, AP8-1 would the first operation piece AP8. With this simple system, possible for many employees know the drawing numbers great many parts, and consequently the numbers patterns, jigs and operations. With diversity products the problem mate- rial handling less easily solved than plant en- gaged mass production single commodity. Mechanical conveying has been worked out success- fully, despite the fact that planning for there arose difficulties which ordinarily not occur. order bring about economies the use convey- ing equipment, was necessary arrange depart- ments that consecutive operations would fall logical order and material move along straight line from one operation the next. Where roller belt conveyors could not utilized advantage, lift trucks and platforms were substituted. The company has Compres- sor Crank- cases Are Milled tion. The ma- 4 chine equipped with three rough- ing and two fin- ishing cutters. Similarly, five cutters are used milling motor- generator hous- ings made strict rule that nothing piled the floor, platforms skids being used for the temporary storage material process. this way material can moved instantly. Use Modern Equipment Established Policy One the major factors maintaining high standard quality product and effecting manu- facturing economies has been the installation mod- ern machine tools. Practically all machines are indi- vidually motor-driven and are specially equipped for certain work. The two parts that make motor- generator housing are machined simultaneously automatic lathes, which, addition reducing the cost per piece, have permitted closer accuracy than previously. Air compressor crankcases are milled one operation Ingersoll milling machine, equipped with three roughing cutters and two finishing cutters which work simultaneously. Similarly, five cutters are used milling motor-generator housings one oper- ation. For making motor-generator shafts number Gridley automatics have been installed. One ma- chine finishes one end the shaft ready for grinding. f The Iron Age, February 16, 1928—459 4 : | 3 4 soon this operation completed, the shaft put the second machine and the other end finished. Cooperation Employees Fostered While efficient control production, installation simple system keeping records, setting me- chanical conveyance for transporting material and use modern machine tools have contributed the solu- tion the problems presented the manufacture multiplicity products, the most important factor has been the human element. keep each employee interested his work and have him take pride that portion the product for which responsible has been the goal set the company. this, different wage systems have been instituted dif- ferent departments. Varying conditions throughout the plant make undesirable uniform wage system for all departments. Instead the management has tried see that each man, judged his natural ability, his training and his productive capacity, receives the highest pay which entitled. Foremen have been recognized key men main- taining contacts between management and employees. every department hangs sign giving the name the department and the name the foreman charge. Beneath the sign the slogan, “Quality— First and Always.” The signs have splendid psy- IRON ORE IMPORTS GAIN Changing Sources Supply Notable Last Few Years iron ore into the United States 1927 are reported the Department Commerce 2,620,717 gross tons. This represents increase about per cent over the 1926 total and the largest incoming volume since 1923. With that exception, the largest total have ever brought in. Imports December, 131,837 tons, were far below the figure FRENCH AFRICA year earlier, and far below the November total. the December incoming movement had been ac- cordance with immediately preceding months, the aggregate for the year would have come close the 1923 record. Chile has furnished more than half the total iron ore imports each year for the last four years. This contrast with Chile’s position 1923, with less than one-fourth the total, and with smaller tonnage than came from either Sweden Cuba. This point brought out clearly the diagram, which shows the proportion the iron ore imports from the four prin- cipal supplying countries 1927 and Sweden, which was first 1923, has dropped fourth position. Cuba, which was second 1923, now third. Chile, which was third 1923, has advanced first, and French Africa, which was fourth 1923, now second. will noted from the diagram that the supplies coming from countries other than the four mentioned have dropped off markedly. This total all other shipments was under 169,000 tons 1927, against 345,- 000 tons four years earlier. Spain 1923 furnished about 215,000 tons, and 1925 and 1926 sent more ebruary 16, 1928, The Iron Age chological effect creating the foreman fine sense responsibility and making him properly feel that important the eyes the management. Foremen’s meetings are held monthly. few select employees other than foremen are invited these meetings that they may obtain first-hand knowledge some the problems confronting department heads. These conferences are conducted the lunchroom the plant and either speaker brought round-table discussion arranged. During the dis- cussion each man has opportunity bringing be- fore the group some the difficulties has encoun- tered, and the discussions have been valuable not only effecting cooperation but bringing each fore- man the realization that his not the only department, idea which likely take root such conferences are not held. The experience the Hobart company serves show how plant moderate size, during period intense competition and over-production many industries, has been able not only keep the position which reached years ago, but also extend its ac- tivities into new markets intelligently planning its production program and developing, within profit- able bounds, new commodities the demand for which has been created constantly changing conditions industrial life. than came from Sweden. Shipments from Spain have fallen about one-eighth the 1923 total, accounting for the major portion the shrinkage imports from the countries not individually shown the diagram. Sources American Imports Iron Ore (In Gross Tons) Months Ended December December 1927 1926 1927 1926 1,196 27,165 83,608 20,178 14,114 244,458 53,605 6,405 556 26,079 16,984 29,500 50,000 392,113 539,000 61,500 111,000 1,369,200 1,364,400 Other countries 14,254 12,269 115,282 176,099 131,837 205,035 2,620,717 2,555,441 Total From From From Imports Chile Cuba Sweden 2,620,717 1,369,200 392,113 244,458 2,555,441 1,364,400 539,000 53,605 2,190,697 1,113,900 535,130 141,324 2,047,055 1,144,775 285,288 310,436 634,600 692,979 749,765 Prizes Given for Accident Prevention Work Stanley Patterson, Inc., 150 Varick Street, New York, manufacturer electrical products, was the winner the 1927 metal manufacturers’ industrial accident prevention contest, conducted the Mer- chants’ Association New York. meeting held Feb. the employees the Stanley Patterson or- ganization were presented with $100 gold ‘reward. The company employs 250 persons and op- erated its plant for 214,416 man-hours without accident. the companies participating the contest, operated during the four months ended Dec. without lost-time accident and were given certificates attesting their records. The American Safety Razor Co., employing 750, operated 577,368 man-hours with but two lost-time accidents and the Sperry Gyroscope Co., with 500 employees, had only two lost-time acci- dents with 326,561 man-hours operation. These companies received honorable mention. The Hanna Co., Cleveland, has been appointed exclusive sales agent the Bulger Block Coal Co., with coal mines Bulger, Pa. OTHER SWEDEN CHILE FRENCH CHILE CUBA AFRICA Cutting Costs and Avoiding Accidents Mechanical Charging System for Cupola Saves Per Cent Operating Charges— Injury Hazard Reduced TEGAN* has been operation the foundry the Union Switch Signal Co., Swissvale, Pa., since last October has reduced costs for charging from $23.50 per day per day. But not merely this economy, one several which have resulted from the change from manual mechanical charging, that the management the foundry finds satisfaction. The new system eliminated accident hazard. Under the former method charging the raw materials, the bins MECHANICAL cupola charging system which were located alongside railroad spur track, directly under the loading platform. While fatal accidents occurred, happened fairly frequently that pig scrap from loaded charging box which had been im- properly placed the platform fell within few feet the men working the bins. Introduction the new system grew out the desire the management wipe out that danger. This system unique that the storage bins are built into instead above the ground and, besides the mechanical charging, there only one handling instead two, most installations, the raw materials. spur track runs over trestle, under which are the coke and limestone bins. Delivery these materials hopper cars obviates handling and incidentally AGE, Pittsburgh. effects very substantial saving. The coke and stone gravitate into the bins and longer necessary have the coke delivered box cars for protection against the weather, for which there extra charge 50c. ton $12.50 per car. Another track the other side the storage house serves the pig iron and scrap bins. This track served overhead electric traveling crane, used also the forging shop the company, lying parallel the foundry building. equipped with magnet Coke and Limestone Are Delivered Hopper Cars, Which Over the Trestle Under Which Are Located the Bins. Scrap deliv- ered the op- posite side hoist, and the pig iron and scrap are lifted from the cars and lowered into the bins. This much shorter lift and simpler operation than would the case with superposed bins. Few would question the claim that actually one-handling system. And safe system, since conceivable way can any the workmen injured falling loads. Proof this found the fact that men who formerly either refused work worked unwillingly about the bins are really eager work the new bins, which are well removed from the radius the charging bucket. The system was the idea the Union Switch Signal Co. which made the drawings. The Webb Engineering Co., Oliver Building, Pittsburgh, was the contractor and made the detail drawings. There are nine storage bins all, five for pig iron The Iron Age, February 16, Permit Entry the Large Charging Bucket, the Cupola Has Been Cut Away the Charging Door. The hoist operator, cable from the cage, releases the charge opening the bottom the bucket and one for scrap one side the scale car pit, and two for coke and one for limestone the other. The bins all have sloping bottoms, give gravity movement the materials within easy reach the loaders. The iron and scrap bins are open, while those which the coke and stone are stored are gated control the flow more easily, which rapid account the use heavy sheet steel covering for the bottoms. The floors the iron and scrap bins get additional support, well resistance the abrasion the metals, from use imbedded rails inverted. The structural steel and concrete bin house rugged construction. ft. long and ft. in. wide, and ft. deep the level the scale car pit, which approximately ft. below the bottom the bin floors. The iron and scrap bin doors, which serve also roof, are heavy corrugated galvanized sheet steel. The scale car, with automatic measuring devices, was furnished the Atlas Mfg. Co., Cleveland. placed steel bucket capable holding 4000 pig iron and scrap, 400 coke and lime- stone. Nothing could simpler than the making this charge, with scale bell warn the operator when the correct amount the several materials has been let down into the bucket. The charge made up, the scale car moves opening the end the bin building. Here the bucket lifted. 3-ton hoist, built the Shepard Electric Crane Hoist Co., Mon- tour Falls, Y., and conveyed monorail the cupola, where the hoist operator, without leaving the cage, unloads the charge. true all foundries where mechanical charg- ing has replaced manual effort, the cupola this plant has been cut away the charging platform permit the entry the larger charge. interesting note that the charging platform this foundry, formerly littered with charging boxes and reserve supplies 462—February 16, 1928, The Iron Age materials and equipment, now clear the deck warship inspection days. The change the ‘sys- tem has released considerable space for other uses. The new system thorough and dependable that not necessary keep supply coke metal the charging opening the cupola. Definite Measure the Savings Based 300 working days year, the cost han- dling materials the cupola under the old system was $23.52 day ($7,056 year). Under the new method, per day $2,400 per year, which indi- cated annual saving, 300 working days, $4,656 year. The foundry consumes cars coke year. The old cost unloading cars the platform was $35 car $2,275 year. now costs only $1.20 car perform the same operation, $78 year, saving under the new system $2,197 annually. There addition saving about 100 tons coke year, valued approximately $700, which was lost han- dling. And taking coke shipments hopper cars instead box cars there the saving 50c. ton, which cars tons each amounts $812.50 year. Unloading three carloads limestone, the usual yearly consumption the company, formerly cost $35 car $105 year. now being done for $1.20 car through the use the trestle, saving $102 year. was formerly necessary maintain boxes for handling metals, $18 each year, total charge $864, while boxes now suffice. the same upkeep charge the annual cost $450, saving $414. The foundry charged for the use the yard crane hour. was formerly used hr. daily; its use has been cut hr. daily, saving $2,400 year. careful checkup the results during the first three months operation discloses that total costs for the year will run about $6,000, under the new system, against almost $16,000 under the old method. Besides this indicated saving there has been more uniform cupola charge and consequently improvement the quality the metal. ” ‘ y Charging Platform Now Serves Lane for Passage the Hoist Conveying the Charge Training and Paying Executives Development Administrators and Ways Compensating Them Considered American Management Association Meeting HILE scientific management has concerned it- self exhaustively with the methods training, supervising and compensating workmen, has not often become introspective and stopped consider the problem maintaining and regulating the execu- tive personnel. The development executive talent, incentives for and compensation executives, well methods for pensioning the men administrative departments whose age has diminished their useful- ness, were dealt with the winter convention the American Management Association, held the Hotel Roosevelt, New York, Feb. 10. New points view the training men the job were also brought out, and emphasis was laid telling how rather than what during the training periods. Training Young Executives Dependability, vigor, resourcefulness and personal leadership were suggested Dr. Charters, pro- fessor education, University Chicago, the qual- ities which should developed the training young executives. During well directed training period possible determine whether any these attributes are lacking individual. the subject does not respond special training along the line which deficient, usually possible shift him into another department the company and into duties which are not essentially executive. Dr. Charters’ paper was based upon investigation the methods used for the development executive talent various members the association. found that number companies continue place much stress actual classroom instruction. many cases this form teaching supplemented considerable practical experience various departments the com- pany. Other firms have derived splendid results with- out any formal classroom work, and develop their future administrators well planned building execu- tive knowledge with consecutive training the dif- ferent departments. such cases the young man permitted sit conferences devoted policy and other administrative functions, and al- lowed considerable personal contact with the manager located. Special administrative problems are assigned, and careful study made solutions suggested the junior. Criticism such efforts frequently war- ranted, but Dr. Charters pointed out that praise should forthcoming when deserved, the student has other way definitely knowing what progress making. This also leads self confidence, which, not developed extreme, very desirable quality the young executive. The speaker emphasized the fact that the advance- ment executive always more likely prop- erly trained assistant available step into the job. spite the fact that number men feel that training young executives only training them out their jobs, this seldom occurs progressive and ex- panding institution. Better positions nearly always await the man who able train others attend his own work properly. Incentives for Executives That incentive plans for executives may used advantage industry was brought out the experi- ences number companies outlined two ses- sions the meeting. Yet discussion indicated that the application any sort universal plan might easily nullify possible benefits. Howard Coonley, president Walworth Co., Boston, outlining the plan used that organization, stated that the company had made success its system largely through recognition the fact that different classes executives respond different kinds incentives. The better type executive, Mr. Coonley pointed out, cannot handed bonuses the way they are given shop workers. This true partly because the product the executive somewhat intangible and cannot set down immediately dollars and cents. Yet well regulated incentive plan for executives will have its effects the earnings company, and the speaker brought out the fact that bonus methods used the Walworth organization are expected result ma- terial increase profits within the next few years. discussion Mr. Coonley’s paper, Jordan, industrial engineer, New York, opposed limiting in- centives set rules. Pensions Are Business Proposition pointing out that the payment pensions superannuated employees direct aid management keeping efficiency, reducing aceident hazards and lowering manufacturing costs, Cowdrick, indus- trial relations counsellor, New York, was able place his plea for adequate pension plans practical busi- ness basis. “For this reason,” said, “it probable that industrial pensions will permanent and grow- ing form business administration. the same time likely that, with clear thinking the subject, bet- ter administration and more adequate financing, pen- sions will become increasingly valuable employers raising efficiency and morale and preventing the re- tention superannuated workers active payrolls.” Pension plans, the speaker stated, have developed rather recently American industry. surveying 248 plants found that only five had had pension systems prior 1900 and that per cent these companies had began pension payments since 1910. This growth was due partly the increase life expectancy. The increase, however, has not been offset lengthening the working period, which, the contrary, has grown shorter. The spread education and the decline child labor are sending workers into industry much higher age than was true the past, and there less work for the laborer who has grown old has even come late middle life. Mr. Cowdrick stated that there are several theories underlying pension payments, notably the deferred wage theory, the supposition that the pension char- itable gratuity and the conception that reward for long and faithful service. the de- ferred wage theory,” said, “money expended for pen- sions comes out funds available for the compensation labor and merely part the wages which might have been paid the worker during his productive years. this theory were accepted there would arise once moral question the right the em- ployer any part the wages due em- ployees and then restore the money only those who, longevity and continuity service, fulfill the pension requirements.” rejected this objection, however, because company not forced pay the pensions order hold and secure labor force. The keen manager asks stronger reason than char- ity for the payment such pensions, and will not ac- cept the theory that reward must paid for long ser- vice. this were the only reason for pensions would cheaper secure new employees stated intervals. But upon realizing that paying pensions increases the morale the worker and decreases labor turnover, thus (Concluded page 510) The Iron Age, February 16, arge Pipe for High Head Made Arc Welding Penstock INCE the end the great war, striking progress has been made Japan the scientific study electric weld- practical applica- tions. zation becom- ing more popular year year. Modern, high- scientific weld- ing exclusively employed the construction important strength members pressure ves- sels the three dockyards Mit- subishi Shipbuild- ing Co., Ltd., lo- cated Kobe, Nagasaki and Hikoshima. One the earliest applications welding large scale was the construction 1942-ft. penstock our Kobe works for the Azumi Electric Power Co., Ltd. This penstock was built 1924 for their Naka- fusa No. power station Nagano Prefecture; was the first penstock built means electric arc welding Japan, and its successful operation proves the soundness the design and manufacturing methods. The dimensions are follows: Total length the penstock, 1942 ft.; upper riveted portion, 796 ft. long; lower welded portion, 1146 ft. long; maximum statical head, 1031 ft. The welded portion two sizes with reducer the middle part the line, the upper section being 625 ft. length in. diameter includes pipes numbers 31, and the lower highest pressure section 521 ft. length in. diameter. Individual sections pipe were made ft. long; plate thicknesses ranged from in. in., shown the accompanying table. 4 wuss a» Manufacturing Procedure Flat steel plates were cut shape guillotine shear, and the edges were milled the correct bevel shown the figures. Then the plate was bent the required semi-circle means mast roller. *Welding engineer Mitsubishi Shipbuilding Co., Kobe, Japan. Ltd., 16, 1928, The Iron Age for Japanese Hydroelectric Plant Made Bent Plates, Longitudinal Joints Welded Hand Two plates formed the pipe; with temporary band outside and inner core each end, then welded specially designed roller saddles. Each piece has two longitudinal welds, diametrically oppo- site. After having properly prepared the edges the plate and assembled the joint, light tack weld initial layer weld was made 8-in. intervals along the outside both seams. The welder then made complete weld between the first two tacks. then omitted three spaces and welded between the fifth and sixth tacks, and on, until the end the seam was reached. This process was again repeated starting between second and third tacks, skipping three, and on, until the whole seam was welded. Finally, finish second layer weld was made the initial light tack welds along the entire line complete the work. Cast steel flanges, approximately in. in. in. were then attached each end edge welds, shown The routine the work was about the same just described for the longitudinal seams. The anchor rings shown Fig. were bent from straight bar, 0.66 in. in., and the ring was butt welded the closure. Each was attached series 3-in. corner welds alternating with 5-in. open spaces, the series either side being staggered position. Pipe No. has T-branch welded lead one turbine, while pipe No. 54, addition similar turbine outlet, closed domed end. Each completed pipe was subjected hydrostatic pressure test ranging from 368 670 Ib. per square inch depending the thickness the pipe wall, shown the table. The result was satisfactory; welded places failed. Electric Arc-Welded Steel Pipe for Electric Power Co., Ltd. Max. Statical Test Max. Pres- Pres- Thick- Statical sure, Pipe ness, Length Kind Head, Lb. per Number In. Pipe Ft. Sq. In. Straight 565 245 368 Straight 565 245 368 Bend 654 283 425 Expansion 654 283 425 Expansion 826 358 537 Straight 826 358 537 Expansion 918 398 597 Straight 1031 447 670 Bend 1031 447 670 Expansion 1031 447 670 51A Bend 1031 447 670 51B 1031 447 670 Straight 1031 447 670 Straight 1031 447 670 Straight 1031 447 670 Cast Stee/ Flange Fig. 1—Details Straight Pipe. Each length has two longitudinal seams, double vee Fig. Assembly and Details pansion Joint Field joints between pipe sections were made depending upon the stress carried. All tests, including proof test the completed line, were com- pleted the entire satisfaction the customer; the work also passed the severe survey the Japanese Communications Department. Advantages Welded Construction Listed Experiences with this penstock indicate the fol- lowing advantages this type construction: First, tight joints, metal solid against metal, can obtained without punching single hole the pipe wall; sec- ond, the weight the pipe can considerably reduced below riveted design, and the expense punching and caulking also eliminated; third, the diameter the entire line was reduced about in., because the internal friction caused rivet heads elimi- nated; fourth, continual inspection and caulking leaks has been dispensed with; fifth, the appearance the welded line better than riveted one and way; sixth, after installing the penstock the site, and passing water into it, trouble stoppage has occurred; and seventh, operation, the water passed more satisfactory man- ner than ever experienced with riveted pipes. All those who have been connected with this power project, who have inspected this penstock, are the opinion that offers positive demon- stration the advantage electric arc welding securing rigidity pipe, low frictional resistance, less weight for transportation and installation, greater capacity for the turbines, smoother in- terior and exterior surfaces and freedom from corrosive tendencies. The Mitsu- bishi Shipbuilding Co. confident that the process applied under strict super- vision technical engineers will give great economies and satisfaction. Fig. 2—Bends Are Made Welding Straight Nipples Inside Flanged Connec- tors Welding Gun Metal Hitherto has been impossible weld gun metal bronzes (90 per cent copper, per cent tin) because the microscopic crystals delta constituent existing such castings cooled moderate rate will melt and boil out before the alpha solid solution, which forms the bulk the alloy, reaches its melting point. The result concentration tin next the weld line, inducing brittleness, and spongy zone just be- low, through which cavities rupture occurs rela- tively low loads. Miller, welding engineer, Union Carbide read before the Montreal meeting the American Society for Steel Treating, notes that this trouble can avoided heating the casting before welding 1000 deg. Fahr., when the delta constituent changes higher melting, tough beta solid solution. After welding the rate cooling should about that the original casting. Fig. 4—Pipe Sections Testing Yard The iron Age, February 16, 1928—465 Anchor Rings Detail Lap Weld = Grease Packings < bin the top Sintering Variety Materials Magnetic Concentrates and Iron-Bearing Ores Handled Continuous Dwight Lloyd Process EDWARD discussed, many its general aspects, page 191 IRON AGE for Jan. 19. The present article carries the subject forward into consideration the possibilities the process for two particular types raw materials —magnetic concen- trates and iron-bearing ores. The series will sintering ferrous materials was concluded with third article, pub- lished early date. previous series three articles, the same author, covered intermittent sintering. They were published THE AGE March 17, April and July 14, 1927. Sintering Magnetic Concentrates For number rea- sons the sintering plant the Chateaugay Ore Iron Co. con- siderable interest: First, has opera- tion the largest con- chine ever built; sec- ond, treats magnetic concentrates. The ore, which contains about 62% per cent iron, conveyed from con- the sintering plant. Plant Sintering Adjacent the ore Magnetic Concen- bin similar bin for trates anthracite culm, which used Both bins have Ameri- can Ore Reclamation Co. revolving table feeders which discharge materials directly into pug-mill, where they are mixed and moistened with water. The mixture then goes belt conveyor the swinging the 72-in. 64-ft. sintering machine. Sintering fuel approximately per cent. The sintering machine has suction zone ft. wide and ft. in. long, and has pallets mounted Timken roller bearing wheels. pallet fitted with six grate bars. The driving mechanism consists two sets gears and inclosed reducer. This ar- rangement brings the gears outside the machine frame, making them more also takes them out *Mechanical engineer, 110 Clinton Avenue, Clifton, 16, 1928, The Age TOURNIER* the path sinter dust from the pallets. The ma- chine has capacity tons sinter per hour. Oil Used for Ignition After the material has been spread the grates the swinging spout passes under the ig- nition furnace, which fired oil. About 0.40 gal. oil per ton sinter used. Air for combustion fur- Finished Sinter Railroad Cars nished turbo-compressor. Air and oil, mixed Hagen burner the side the furnace, pass through heating coil directly in- the combustion chamber the furnace. Combustion gases pass through cast iron tubes preliminary dust-settling chamber, where separation the coarse particles effected. The prelimi- nary charges into hopper having double bell valves the bottom. These valves are oper- ated intermittently, the coarse dust being thus veyor, which takes small belt and latter discharges the dust over stationary Cooling bar screen the dis- charge end the sin- Stack tering machine. The larger pieces are de- livered railroad car and the fines drop into the return hopper. The gases then pass into centrifugal separator where the fine particles dust are eliminated. The dust separator connected center-plate fan, 100 in. diameter, having capacity 60,000 cu. ft. 350-hp., 2300-volt General Electric synchronous motor. Returns Hopper Sintering Ores blast furnaces where sintering plants are oper- ated, the depletion the flue-dust stock piles creates condition which necessitates the employment other materials that can treated profitably. Such con- (Concluded page 510) Lompressor NOTICE- ABLE Point About the Dis- charge End the Sintering Gap Between Pallets Older Designs. Both the top and the return sides are actuated the sprockets the drive end (shown tom page) 100-in. from the Left-Hand Fan Bearing Which Tend treating concen- trates RIVE End (Right) 4-in. Sintering tween top and ft. in. The Iron Age, February 16, Non-Deforming Steels Require Heat Treatment Prevent Cracking, Warping, Soft Brittle Skin, and Get Desired Hardness and Exact Size PAUL HERE are two important classes so-called non- The first and hrinking oll-hardening tool steels. lly 0.85 per cent car- older type contains usua 1 at + and 1.50 1.75 per cent manganese; some brands have 0.15 0.25 per cent vanadium. The second later development the simple manganese irdening steel. contains the same amount L 7 7 ~ Hand Broach Made Straight Manganese Steel, with Vanadium. Hardened salt bath 1500 aeg. Fal) Gre ind on cutting edges only bon but about one-half per cent less manganese older steel, and has approximately 0.5 per cent each chromium and tungsten; some brands vanadium. sulphur and silicon both types are kept low practicable. type also contain small amount phosphorus, Both steels are made er electric crucible furnaces, principally the appears that the chrome-tungsten type very slowly displacing the The newer have small volume change hard- has the older, and addition have some- what better cutting qualities. straight manganese. alloy seems true, nevertheless, great many applications the two steels may interchangeably. much used for gages—in plug gages they among the tool steels iney are ‘neralivy conceded bes wear resistance concerned. They are widely for stamping and blanking dies, thread-rolling hobs, taps and broaches. perhaps goes without that many the applications are for master ols dies which, owing complicated design lack special equipment, are inconvenient impos- ble grind after hardening. Yet successful prod- cannot produced consistently without very care- handling and knowledge the peculiarities such Procedure Avoid Cracking Both these steels, and especially the early manga- type, are far from immune cracking vercome this hazard, apply the same principles for other steels: (a) re-annealing, before harden- ing, any tools very complicated design which much work has been done; (b) careful design, elimi- nate far possible immediately adjoining thick and ions and sharp corners and angles; (c) careful inspection the steel for defects; (d) slow, even heat- ing the tools, using preheats whenever possible; (e) careful quenching; (f) tempering soon after quenching; (g) annealing, whenever rehardening necessary. course, there steel which absolutely non- deforming heat treatment. The difference volume *Metallurgist Geometric Tool Co., New Haven, Cont Care EDDY, JR.* change between these steels and most other tool steels one degree only. Non-deforming steels have very low volume changes after correct heat treatment. Although these steels scale somewhat less than plain carbon steels, they show marked tendency toward forming soft skin during hardening. With ordinary methods will often found that file easily digs into the surfaces depths which may vary from 0.001 in. 0.005 in., depending upon the size the tool, the method used and the care exercised. must re- membered that the slightest skin softness may fatal precision tools which probably are not ground. Non-deforming steels transform with comparative sluggishness when passing through the critical range during heating. They require considerably longer times heating than plain carbon steels. This means that the opportunity decarburize scale in- creased. sometimes found advisable raise the Fig. Gage, Ground All Working Sur- Made same steel and hardened same way broach shown Fig. hardening temperature order reduce the time heating. The real problem produce hard surfaces with expected that many heat-treating have facilities for all methods hardening, the re- sults expected the use several methods will discussed. Open Fire and Muffle Liable Produce Soft Skin The open fire method, using either gas-fired oil-fired oven furnace, will produce fairly good results the hands expert treater. Possibly the ma- jority tools, especially the larger ones, made oil- hardening steels are hardened this way. prob- able that the chemical compositions these steels developed largely experimentation this type furnace. The rate heating therein about correct produce minimum distortion the hardened and drawn tools. With the class tools which are consider- ing, however, imperative, has been said before, that scaling decarburizing practically nil; there- fore success depends upon the expertness the hard- ener. Smaller tools may hardened with fair using such suspending the pieces hooks wires empty crucible pot-type furnace. alloy even pressed pot may used, although the life the latter comparatively short. This method, giving about the same rate heating the open fire, will cause but little distortion, but good sur- | teels. 16, The Iron Age face least difficult retain the semi- muffle oven furnace, and the same reservations about skill the workman apply. For both these methods the hardening temperatures recommended the steel manufacturers, usually between 1425 and 1475 deg. Fahr., are suitable. Pack Hardening Requires Slightly Higher Quench Tools such taps and plug gages may packed charcoal (some prefer mixture three parts char- coal and one part carburizing compound) pot heated cylindrical pot furnace. this prac- tice advisable heat not more than two three tools time; they should approximately the same size, and should arranged, with the thermo- square, with all objects equidistant from the walls the pot and near the center the pot prac- ticable. The rate heating should not rapid, else the tools will heat unevenly. more satisfactory method packing, especially when variety shapes must hardened, use ordinary carburizing boxes oven furnace—automatic temperature control the furnace very desirable—using charcoal the above-mentioned mixture. Slightly higher tempera- tures, namely, 1450 1500 deg. Fahr., should used with either pack method. These methods are entirely satisfactory these temperatures for giving good surface From the standpoint distortion, however, they are not good, except for tools whose three dimensions are about equal. Tools such taps, owing the slower rates heating and longer time holding heat, diminish length and increase slightly diameter. This change can modified varying the hardening and draw- ing temperatures, but this produces undesirable metal- vanadium may able withstand some variation hardening temperature, such changes should made with the utmost caution. Furthermore, even charcoal slightly higher temperatures than 1500 deg. Fahr., often resulting the formation brittle surfaces. tap one-half one inch diameter, for example, may contract 0.0015 in. 0.002 in. per inch length Lengthened when pack-hardened 1475 deg. Fahr. the tempera- ture raised 1575 deg., the shortening will re- duced about 0.0005 in. per inch, average. Fur- ther raising the hardening temperature produces little change the contraction. here that temperatures 1450 deg. and 1550 deg. Fahr. the open fire muffle method would usually produce expansions length such taps about 0.001 in. and may said per inch, respectively, with decrease diameter. Baths May Produce Brittle Surfaces One inevitably wonders bath method hard- ening will prove satisfactory. lead bath, kept free from impurities, may give good results with very small tools, although not, the writer’s opinion, the most desirable for larger masses oil-hardening steels, account its very rapid heating rate. Tempera- tures around 1475 1500 deg. Fahr. should used with lead bath, even when hardening small pieces. Change dimensions after lead hardening the above range temperatures are usually very small. commercial case-hardening bath using calcium cyanamid the active agent produces good results varied sizes tools about 1475 deg. Fahr., far distortion concerned; the surfaces the tools are not softer than the interiors, but anything trifle harder owing absorption nitrogen. However, the brittleness the edges cutting tool unquestionably undesirable. Attempts have also been made use mixtures commercial heat-treating salts and sodium cyanide; such mixtures have about the same characteristics the cyanamid bath; the brittle Fig. Chasing Tap Which Lengthened 0.001 In. per Inch After Heat Treatment surfaces the hardened tools are usually even more pronounced; furthermore, will found very difficult maintain constant percentage cyanide, and the limits for successful operations are narrow indeed. Claims for Salt Mixtures Exaggerated There are several salt mixtures the market which are claimed melt into baths that are perfectly all steels. have not worked with all these baths; but upon considering only those with which have had experience, opinion that many the claims are exaggerated. Some baths not retain their property neutrality for any great length time; others never had it, least for oil-hardening steels. Some baths require the use rectifiers, puri fiers inhibitors, which, however, are usually only partially efficacious. These statements not apply, course, all commercial salts; some apparently what claimed for them. All the six eight baths which have tried for carbon steel hardening will, when properly used, practically eliminate scaling. The temperatures necessary for hardening tools non- deforming steels salt baths, obtain the desired change dimensions, are between 1450 and 1500 deg. Fahr. Some operators believe that better surface can assured raising the temperature slightly and shortening the time heating. Lest the words “desired change dimension” the reader should member that all tools should tempered, and that above paragraph seem foolish, the changes dimension may take place during the tem- Whatever the method hardening, contraction length occur pering operation well the hardening. during tempering low temperatures. This tion increases amount with rising temperature about 400 deg. Fahr. change decreases. Most tools oil-hardening steels, reached, above which the rate especially cutting tools and gage are tempered from 275 375 deg. Fahr. example, the hard ening temperatures suggested above for salt baths and draw 275 300 deg. Fahr, for min. are ised, almost dimensional change may expected. But if, for instance, slight expansion desired, say 0.0005 in. per inch length thread gage tap, with the same hardness before, the hardening tem- perature may raised about deg. Fahr. with reason- able hope success. entirely possible work out schedule temperatures and times for both harden ing and tempering for the various sizes and shapes tools treated, which, careful control exercised, will surprisingly consistent the results produced. final word caution advisable regard The Iron Age, February 16, 4 3 quenching: comparatively gentle quench sufficient harden these steels, provided there surface change carbon content during heating. violent quench increases distortion and warping. Recommended Heat Treatments ig. represents hob mill in. diameter the later type oil-hardening steel, contain- se, chromium, tungsten and vanadium. was not ground the threads, but merely edges, on the ends and the inside of the This tool was packed charcoal alloy car- urizing box and heated 1475 deg. Fahr. elec- equipped with automatic temperature was withdrawn from the box means wire, which had previously been attached, and quenched oil with slow, regular up-an-down motion the axis the tool. was drawn 300 deg. Fahr. for min. oil tempering furnace. This hob lengthened 0.0005 in. per inch. Fig. shows chasing tap made the same type steel above. This tool in. diameter, 12-pitch, Whitworth thread tap and was ground only the cut- ting edges after hardening. was pre-heated about 150 deg. Fahr. and suspended vertically wire salt bath 1525 deg. Fahr. and heated for min. was quenched exactly the same way was the mill and was drawn 275 deg. Fahr. for min. This tap expanded length 0.001 in. per inch, which was desired. Mining Engineers Prepare for February Meeting Papers the Open-Hearth, Blast Furnace and Special Steels— Fine Program for Institute Metals iron and steel will much the fore the annual meeting the American Institute Mining and Metallurgical Engineers, Feb. 23, the Engineers’ Societies Building, West Thirty- York. excellent program has The first session scheduled for Monday morning, lich Prof. William Campbell, Columbia preside. The session will devoted alloys. “Critical Points Chromium-Alloys” will discussed Kinzel, and will include scription new type furnace which may find variety applications the future. Hugh O’Neill present paper “Effect Annealing Cold- Worked Single Crystals Silicon-Ferrite,” and Corson will discuss “The Constitution the Silicon Alloys,” while Wohrman will present paper “The Heterogeneity Alloys.” the afternoon the same day session special steels scheduled and will presided over Dr. John Mathews. Robert Job will discuss ‘Types Steel Used Railroads, Past and Present,” and Gennet, Jr., will present “The Manufacture Some Foreign Rails.” “Aircraft Lloyd Jones, the Bliss Co., Brooklyn, will dis- cuss “Continuous Rolling Sheets.” Sessions Open-Hearth an