The Iron Age 1928-03-01: Vol 121 Iss 9

IRO AGE New York, March 1928 ESTABLISHED 1855 Orders” for Munitions Plan Rotate Contracts for War Material Among Private Plants Essential Industrial Preparedness LIEUT.-COL. TOWNSEND WHELAN* XTREMELY unlikely that democratic nation will engage war with which the mass the people not sympathy. any war which the United States may engage hereafter there will probably difficulty getting all the man- power needed, either voluntary enlistment draft. But more than man-power Material— weapons, ammunition, transportation, clothing, food, supplies—is required also. This needed the shortest time possible because the waging successful war matter speed almost much numbers and power. The army which gets there first with equal greater number this man-power, the picture not encouraging. Reasons for Maintaining Reserves War Material nation can afford keep hand reserve arms, ammunition and supplies necessary wage complete war. The cost such reserve and the interest the investment would prohibitive. In- stead, each modern nation endeavors maintain reserve war material which will last its man-power until such time its arsenals and its industrial estab- lishments can take the burden manufacture and supply. our arsenals and our commercial plants can get into small pro- duction cer- well armed men usually wins. The man-power the United States unequaled that any other nation, and all probability there will difficulty obtaining the amount and the rate necessary. But when ex- amine bility obtaining the necessary ma- QUANTITIES tain type am- munition months after decla- ration war, and can produce that ammunition am- ple quantity after eight months, then the reserve that ammunition main- peace should that re- quired all the troops under arms for the first five months and part the amounts and the quired tosupply *Ordnance depart- ment United States Army. 123456789 MONTHS Fig. Curve Showing How War Materials Held Reserve Supply the Requirements Mobilization Until New Produc- tion Gets Under Way for the remaining three months. Fig. shows such ideal sup- ply curve. But curve such this 4 J ‘ THE VOL. 121, No. RESERVE HAND PLUS NEW PRODUCTION CQUALS HAND 587 country finds itself confronted with the case number very vital items equipment and sup- plies. Constant study and effort being made all concerned with national preparedness eliminate the shortages illustrated hypothetically Fig. Such shortage may eliminated either increasing the reserve expediting production. increase the reserve extremely expensive, and course neces- itates the appropriation funds Congress. some cases must done—there being alter The reserves certain essential articles are War Department. But the military student endeavors facture time peace very much time will gained, the serious shortages will greatly entirely elimi- nated and very large sums money will saved the taxpayer. The art manufacture now kept alive our Government arsenals, which are equipped manufac- ture most the technical articles needed our army, and which manufacture small amount such material each year meet the current needs the army, and replace deterioration our reserves. very necessary keep these arsenals alive the extent that will preserve the art manufacture, and retain nucleus officers, foremen and workmen familiar with the art. Further main- most the short- | age measures taken hasten | | very much The measures 800000 production have been termed “in- strial prepared trial preparedness for war the United States con tion all require ments advance, based the Fig. the man-power, the MONTHS Deficit Will Exist Whenever Reserve Too Small New Production Tardy illocating these to the Government arsenals and suitable selected industria! quirements lants, and planning advance the matters labor, raw materials and transportation. industrial plant which war order for the supplies allocated provided with the article, and asked indicate how soon can get into production the article, and how soon can reach the desired peak production. ked draw war plan covering new equipment needed, bills material, route sheets, labor, power, it It is also transportation, sub-contracts and any other essential tep. When these measures are taken, the getting into production that article very greatly facilitated. now know what wanted and who will make The contractor knows what make, and laid many his plans advance. have already reached this stage our plans Munitions Manufacture Now Exclusively Arsenals But there still one weak point the system, for, many cases, particularly regards rifles, can- tanks and airplanes, the manufac irer does not know how make the article, nor his plant more than generally suited its equipment for that particular class does not under- tand the art manufacture, and not equipped with the special machinery needed. Practically all manufacturers who made munitions World War have made such articles since then; they have lost the art manufacture, and the special ma- chinery has been scrapped. very large amount ime will necessary learn the art and design and procure the special machine dies, jigs, fixtures and gages needed before production can started. Conversely, can devise plan which will teach our manufacturers the art Ot manu- 588—March 1928, The Iron Age tenance these arsenals not necessary, but the preparation and training the commercial plants vital, for them will fall the bulk production war, the ar- senals have only sufficient capacity manufacture cent the mate- rial needed, de- pending upon the particular article. viously, therefore, the would allo- cate only such por- tion our peace- time manufacture our arsenals will necessary maintain the art manufacture these plants, and allocate the balance the form “educa- tional orders” those plants which have been selected make the particular article event emer- gency. For example, suppose during the next five years necessary manufacture 500,000 rounds ammu- nition for the 75-mm. field gun for target practice and replace deterioration the war reserve such am- munition. During the next five years would then allocate say 250,000 rounds our arsenals, and each year would allocate 50,000 rounds some one selected commercial plant. Thus within five years five commercial plants will have experience manufacture, and each five years each plant will renew its experience. may possible place orders an- nually with each selected manufacturer. This entirely hypothetical example, but some such plan could put into effect would result small line machinery being installed each plant for the manufacture the article (which line could easily duplicated war), nucleus foremen and workmen familiar with all manufacturing opera- tions, perfection plans for reaching mass pro- duction war, including really practical plans for the necessary raw material, power, facilities, labor and transportation. Such education our selected muni- tions plants, and such perfection their war plans might easily result advancing the date mass pro- duction one three months. This would result some cases entirely eliminating shortages, others making unnecessary maintain such large re- serves. The money gain the taxpayer will enor- mous, for has been estimated that month saved getting into production will result reduction the value the reserve required maintained approximately $150,000,000. | | | | ws = KO | 4 x detailed specifications and manufacturing information undeniable that will cost more manufac- ture supplies the medium educational orders placed with commercial plants than these same supplies were made Government arsenal. The Government arsenal has complete facilities and familiar with the work. The commercial plant will have tool for its initial educational order, and the planning cost will high. Also, taking the above hypothetical case, commercial plant cannot produce 50,000 certain article annually the same unit cost arsenal could produce 100,000 the same time. Our selected commercial plants have been consulted relative this plan for educational orders. They are unit stating that, more than anything else, will result perfection their war plans and their getting into production emergency very much earlier date tham would possible without such edu- cational orders. Moreover, they have quite generally indicated patriotic manner that they would willing undertake such orders cost basis. The plants which the ordnance department has selected for its war manufacture are almost all such large in- dustrial concerns that such educational orders would placed with them would mere fraction their regular annual commercial production. The increased cost educational orders over arsenal orders price should pay for exceedingly cheap form insurance against shortages war and will money well spent. should also understood that the placing educational orders does not neces- sarily mean large increase the amount money appropriated annually for munitions supplies. general merely contemplated that the money now ap- propriated annually for the procurement current supplies shall utilized procure those supplies little different manner which, the end, may slightly more expensive, but which will add very greatly our state preparedness against war. Present Legal Obstacles Most unfortunately the law does not now permit the placing such educational orders with commercial plants. The second paragraph Section the National Defense Act now reads: factured produced the Government arsenals Govern- ment-owned factories the United States all such supplies articles necded the War Department said arsenals Government-owned factories are capable manufacturing producing upon economical basis. our Government arsenals can produce the vast majority ordnance material and supplies needed time peace upon economical basis, follows that impossible place even small proportion these orders with commercial plants. There are also other existing laws which hamper CROSS and Hill have studied the “Density Hot-Rolled and Heat-Treated Car- bon Steels,” and their results are published Scien- tific Paper No. 562 the Bureau Standards. Four samples the purest commercial and electro- lytic irons available closely approximated the average density (7.864 gm. per cu. cm.) despite large difference previous history. Density hot rolled commercial steels decrease slightly with increasing carbon content. Annealed steels vary trifle from these figures. samples chosen such size that the structure would martensitic after water quenching from above Ac,, the density decreased considerably. Tempering various increasing temperatures restored the density gradually the figures for annealed specimens. Principal data are summarized the diagram shown the right, adapted from Messrs. Cross and Hill’s work. the War Department this connection, such Section 3709 S., which provides that all contracts shall made advertising and effect awarded the low- est responsible bidder. Such procedure would defeat the purpose for which orders for ordnance would placed with commercial plants, for awards all proba- bility could seldom made those well equipped and responsible manufacturers with whom the War De- partment has allocated orders for the manufacture supplies war, and whom desired train peace for such manufacture. Instead very likely that, under the present laws, such contracts would have awarded some manufacturer who was the low- est bidder, because his desire for work which would carry his overhead over lean period, for some other reason, and who might not equipped organized way that would permit his producing quickly and enormous quantities war. would little benefit from the standpoint preparedness have educational orders placed with such firms. They should distributed among all the plants whom war orders have been allocated conformity with the well formulated plans for industrial mobilization. order permit educational orders placed the manner which will best secure the results desired, the War Department recommended introduction bill the last Congress and reintroduction the pres- ent Congress 450, 5662 and 1824), which provides that: The Secretary War may authorize the placing edu cational orders for equipment, munitions and accessories needed the military service with commercial concerns the degree that is considered by him as being necessary to familiarize commercial factories with munitions manufacture and advance the industrial war plans the War Depart- ment, and in placing these educational orders the competitive bids which his opinion best secure these results may accepted; and shall make statement his action under this provision his annual report believed that this bill should enacted into law soon practicable. will place the nation far better state preparedness its munitions supply for possible war than now is. Should be- come law, the resultant training our commercial plants the art manufacturing munitions, together with the other well formulated plans and measures the War Department looking industrial mobilization war, will very long way toward against war. What are interested achieving state industrial preparedness which will match our unrivaled man-power with adequate munitions- power, that our country will secure from attack any power combination powers. are plan- ning for peace, continued peace, and think have hit logical way insure it, not the mere expression pious wish, but commanding it. Carbon Content The Iron Age, March 1928—589 J Density Plain Carbon Steels, Rolled, and After Heat Treatment Whirlwind Engine Parts Receive Careful Handling Thorough Inspection Made Every Stage Manufacture— Cylinders and Cylinder Heads Machined Production Basis FAY LEONE LMOST within year, namely, from May 1926, when Commander Byrd and Floyd Ben- nett flew from King’s Bay, Spitzbergen, the North Pole and return 15% hours Fokker monoplane equipped with three Wright Whirlwind engines, July 12, 1927, when Edward Stinson Stinson Whirlwind-engined monoplane covered more than 4000 miles the National Air Tour, eight major records, the greatest aviation history, were made. Six these were made over oceans and in- cluded the splendid flight Lindbergh, that Cham- berlin and Levine, that Lieuts. Maitland and Hegenberger across the Pacific, that Commander Byrd and his three associates, and the flight across the Pacific Ernest Smith and Emory Bronte. these spectacular accomplishments added the good-will tour Col. Charles Lindbergh his Ryan monoplane, the Spirit St. Louis. This tour through Mexico, Central America, portion South America, the islands the West Indies and Cuba, began Dec. 13, 1927, with non-stop flight from Washington Mexico City, the distance covered this leg the flight being 2000 miles and the flying time, hours. the finish the tour, St. Louis Feb. 13, Colonel Lindbergh had spent more than 116 hours the air and had traveled more than 9000 miles. When such records are remembered, hardly wondered that the world generally and metal workers particular are interested knowing something how the Wright Whirlwind engine built the purpose this and the succeeding article I engineer! New Y« K and former editor o of a series of Wright Whirlwind engine, the first having FTER Annealing, the Cylinde r Bar- rel Rough Machined All Over and Put Through Series Heat Treatments. The finished cylinder head and barrel are shown the right describe some the operations performed upon the cylinder, cylinder head, pistons, connecting rod, crankcase and other parts this famous power plant, well show how some the major parts are assembled. the outset, should said that piece commercial mechanism that have seen assembled gets greater care and more careful handling all stages. was very much impressed the manner which all the parts are protected between opera- tions, the care taken make sure that the castings are thoroughly cleaned, and parts metal that might afterward cause failure eliminated, the attention paid weight, and the sincere seeking after fine work- manship. general, one had the feeling being tool room rather than manufacturing shop. Nor wondered when one considers the great responsibility which actually carried the workmen themselves the manufacture this engine. Only when its motor operation airplane airplane; failure its engine disastrous—you cannot tow home. falls the earth sea, broken thing, lifeless piece junk; that is, unless one within gliding distance field. This, course, usually happens flight over land but not always over water. There fall perish. Workmen Realize Their Responsibility very intelligent class men employed the Wright shops. Their obvious seriousness and realiza- tion their responsibility, their great willingness everything within their power insure the lives the daring pilots who will afterward use these power plants, are evidenced throughout. Since oper- ations the Wright Aeronautical plant are quality manufacturing basis, all parts are governed carefully prepared drawings, operation struction sheets and routed through the shops accord- ing definite schedule. The usual special tools, such jigs and fixtures which must used large — | production assure interchangeability parts, point vitally necessary the manufacture this power plant, are found throughout. Although standard machines are used for most operations, con- siderable ingenuity has been shown the manner which some these standard tools have been adapted the work hand. The output, course, has not yet reached the point where mass production possible desirable. There are conveyor systems, overhead trolleys monorails, slide ways rollways. There are number assembly jigs mounted casters, and general may said that for the purposes for which they are used these are ample the present stage manufacture. While the company makes its own aluminum-alloy and bronze castings, its steels are bought from out- side vendors rough-finished form according rigid chemical and physical specifications. Machining and Assembling Cylinder Unique The manner which the cylinder machined and assembled interesting. The resulting product Turret Lathe Above, and Cooling Fins Are Formed operations this part are the facing the end close dimension from the flange, and the forming the back the flange. Cylinder Head Machine-Molded Casting The aluminum-alloy casting for the cylinder head produced the Wright foundry where molding machines and special chilled cores make duction good quality possible. this department the Machine Upper Right. The Mult-Au-Matic, YYLINDER Barrels Are Turned the Double-Spindle lower right, set for machining cylinder barrels, and will also used for cylinder heads unique. The cylinder barrel, shown accompany- ing comes into the shop forging special steel. After being annealed rough- machined all over and put through series heat treatments. Brinell hardness tester used for checking the hardness. The cylinder barrels are then put two time double-spindle turret lathe where they are bored and faced. The outside diameter also turned similar lathe, the work being held expansion arbor. Following these opera- tions the barrels are placed heavy-duty automatic lathe where fins, approximately 13/16-in. deep and 1/64-in. thick the top, are cut from the solid barrel. The fins are tapered with separate tool fastened the top one the tool blocks the same lathe, the taper being from 0.030 0.060 in. Two sets tools, one each side, operate simultaneously the work. was informed that extra set tool blocks was being put into condition while the other set was operation the work. Operation con- tinuous, the machine being stopped only when the tools become dull the work changed. thread miller then cuts the threads the upper end the barrels which are cut 0.013 in. oversize take care the shrink fit the cylinder head. Minor one impressed with the liberal-sized sprues used and the excess metal which included secure sound castings that will not reveal internal defects after machining partially done. The aluminum for the cylinder heads and pistons the alloy, the composition which approximately follows: Copper, per cent; nickel, per cent; magnesium, 1.5 per cent; iron, 0.75 per cent; silicon, 0.50 per cent, and aluminum, 91.25 per cent. Each these castings thoroughly cleaned and sandblasted, and jected 70-lb. air pressure test for defects, after which heat treated normalize the interior. The part then chucked the inside diameter the open end and the first fin turned close-dimension diameter. %-in. hole then drilled the dome The Iron Age, March ~ $ da « § head, the this small bottom hole being provide stop for the boring object end ot the cylinder used the next machining operation. also determines the wall thickness and assures uni- form compression chamber the cylinder. Rough- facing the open end and rough-forming the dome performed heavy upright drill using Finishing done turret lathe. operation includes boring and threading cylin- den are now combination tools. Bullard Mult-Au-Matic now being in- stalled handle this work, well sequence operations the cylinder barrel. Before any further machine work done, the cylinder head subjected severe water test. All forced into the cavity pump until pressure 600 per sq. in. reached. there any evidence leakage, the are plugged and water openings cylinder head rejected. Rough and boring the ex- haust port, used locating point future opera- tions, upright drill press fitted with special fixtures and combination boring and fac- finish facing and next process. ing tools takes care these Similar boring and facing and tapping operations are then performed the intake port side, ; hese also being done upright drill press. Then comes the drilling and tap- ping the two spark-plug insert holes, one each side the cylinder. They are counterbored the inside with spe- The rocker-box pads are next milled vertical milling machine having cial index fixture. Then comes the boring the valve guide holes and the seats for the valve seat inserts. The cylinder heads are then placed furnace and heated 650 deg. Fahr. that the valve seat holes are expanded ufficiently permit bronze valve seats. insertion the soon this op- completed and the cylinder heads are cool they are placed fix- eration ture and the lower part the valve seat spun into its anchorage. They are formed gage insure uniform seats. The drilling and tapping the small holes done sensitive drill presses. The part then carefully inspected and 592—March 1928, The Iron Age for Cylinder Head Casting Are Made Machine Left. Boring, facing, ing the dome and threading the head are done turret lathe above pronounced fit, ready for assembly with the cylinder barrel. Before this operation can take place, however, the cylinder head again heated gas furnace 650 deg. Fahr., after which placed assembly stand and the cylinder barrel quickly screwed place. The intake pipe flange assembled the same time. The whole job put through final pressure test 600 per sq. in. Eight holes are drilled the cylinder barrel flange drill press. The flanges are milled with slotting saws gang set-up. The spark plug inserts are screwed and anchored place and the valve guides pressed into position, after which the whole assembly spray-enamelled all over and baked standard oven. Internal grinders are used for the next operation which the grinding the entire cylinder assembly. perfect, polished bearing surface secured honing operation which follows the grinding. this point all cylinders are checked carefully and the per- centage bearing calculated. All studs are screwed place, great care being taken that none them subjected torsional stress. Indeed, make sure SSEMBLY the Cylinder the Engine Preceded Painstaking Inspection — that there such stress straight line scribed the entire length the unthreaded portion. the thread is, therefore, twisted the least can readily detected. the job now ready for the engine assembly, again painstakingly inspected and placed individual compartment trays forwarded the assembly section. inspection the accompanying illustration the assembly the cylinder the engine will show what clean work- manlike job this is. Precautions for Hammer Operators Simple Safety First Measures Adopted Drop Forging Institute— Data Manufacture Satisfactory Keys ULLETIN 451 the United States Bureau Labor Statistics contains the “Safety Code for Forging and Hot Metal Stamping” recently adopted the American Drop Forging Institute, National Safety Council and American Engineering Standards Com- mittee. recommends that the following operating rules posted prominently and strictly enforced: Operating Rules Changing Dies and Repairing—Always block the hammer, shear punch substantially, using steel blocks hydraulic presses. Make sure operating mechanism closed, locked and protected against accidental open- ing. Board Drop Hammers.—When replacing board, keep hands away from ram. When adjusting mechanism, keep hands from under roll-releasing devices from over the knock-off. Keys must not project. Idle equipment noon and night should left with hammer resting anvil. Mushroomed tools must repaired immediately. Tongs forks must used handling metal. Cold metal parts must handled with tongs picks long enough prevent hands from getting between dies. Quenched forgings for quick inspection should reheated draw temper and prevent accidents fur- ther operation. Goggles must used hammer men, heaters, helpers and cold-trim press operators. Clothing.—Leather asbestos aprons, gloves with asbestos leather palms, congress shoes and leggings must used men handling hot metal. Wear hand leathers moving rough cold stock. Furnaces should lighted oily waste placed front burners. Open all doors, use long tongs and stand aside avoid explosion flare back. Turn air slowly. Handling countersunk holes all dies should provided convenient places rods, screwed in, can used for handling and adjusting. Minimum sizes follow: Number Weight Dies Holes Depth Diameter 500 to 1000 Ib. ..... 2 2 in 7% it 1000 lb. more.... in. lin Transfer Boards Prohibited—To move dies from bench machine use transfer truck and chain block. Other Safety Precautions The code recommends that aisles should least ft. in. wide, properly marked, kept clear every- thing except moving traffic. Machines should arranged that operators stand between them, clear the aisles. Many items safety equipment are noted, such gear guards, valve locks and fan screens. Steam ham- mers should have springs prevent piston (not piston rod) striking upper cylinder head. Hot steam pipes should guarded. mechanical hammers, where the work small can held one-hand tong, the machine should operated hand lever, rather than foot treadle. the work placed the lower die and not held hand, guard should descend before the hammer falls, else the operation should depend two hand levers. Substantial pulley keepers should installed prevent pulley flywheel from falling should the shaft break. Board hammers should have inclosures that broken board will not topple down the operator; railed platforms should provided for adjusting the overhead mechanisms. Shears should have their maximum capacity tem- per and size prominently placarded, thus: “Limit, 0.30 0.40 per cent carbon, in. square, in. round, Manufacture Keys Loose fitting, bruised protruding keys have been the cause many accidents that the code gives these definite recommendations key manufacture: Hammer die keys shall material that will not splinter fly off, and shall not project endanger workmen Note It is sug sted that hammer die keys be made of open-hearth materia, (manganese, 0.40 to 0.50 per cent; car- ~ > = Key Backer Holder for Key Backer. Part “A” threaded round bar enlarged square end This end has cap “E” with round hole which part “C” moves freely. Part “B” flat piece that screws and down bar operate it, part placed the lower die and adjusted that the left-hand end part “C” opposite the die key. The hammer then lowered top part “B” hold firmly between the upper and lower dies, and part “C” struck with ram drive out the key bon, 0.50 to 0.60 per cent); that they be machined accurately fit notches, and that the ends tempered prevent spreading, upsetting, breaking. The ends keys should redressed when necessary. For backing out keys “key backer” held fixture recommended, such the one illustrated. Another method which has been found satisfactory use softer keys (carbon, 0.37 0.50 per cent), heat treated quenching oil until black and then cooling the These keys upset before they split. This necessitates fre- quent dressing but reported much better than using hard keys. the small end the key upsets before starts out the die, the key driven far possible, then the end burned off with acetylene torch and the key driven out. Wheelock, Lovejoy Co., Inc., distributer alloy and tool steels, has removed its Chicago office from North LaSalle Street the Pure Oil Building, East Wacker Drive. The Iron Age, March 1928—593 A ! + | -+>| | > ! ‘ x4 B Bree Nut } ' 4 _ Blast Furnace and Open-Hearth Topics Feature Technical Meetings Mining and Metallurgical Engineers Hold Large Convention—Railroad and Other Steels Discussed —Secretary Hoover Signally Honored OME excellent papers blast furnace, open-hearth and other steel problems and ovation Secretary Hoover were features the 136th general meeting the American Institute Mining and Metallurgical Engineers New York, Feb. 24. With attendance about 2000 members and guests, the convention was one the largest ever held the institute. tribute Herbert Hoover, past-president the institute, was made when the Saunders medal was conferred him the largest banquet the organization’s history. Other promi- nent metallurgists were also honored. sessions, are reviewed the The chief features the technical papers, delivered five following columns. Modern Blast Furnace Problems Reviewed character the papers was that larger attendance and i broad r di cussion were me rited. George Hansen, American Roll- Mill Ashland, Ky., acted Sweetser, who was confined his n? eY S s-Sheffi i Steel & Iron Co., Birmingham, Ala., the exper replace relining blast fur all the prof d cribed is teps tructi n } inent. It ned and lap bound gether with wrought iron bands which can repaired from the without blowing out. The whole bosh incased metal and does not depend upon work any extent. The author reports that the oldest structure this type has been service years and still perfeci condition longer service will needed establish its permanency. Frequent and early failures the inwall section above the man- tel were dealt with inserting 1928, The lron Age series rows bronze cooling- plates from the outside, attached and supported the shell, which after five years’ service still good condition. Perma- nency the top has been accom- plished discarding the brick the top section and substituting heavy cast steel jacket lined with cast iron blocks which withstand the wear and make permanent stock-line. Flue dust production coke consumption, the same time increasing the capacity the fur- nace. Discussion Meissner, United States Steel Corporation, New York, in commenting the paper, said that Mr. Dovel has blazed the way making possible increase the tock-line and other parts the Mr. was GEORGE OTIS SMITH New Presi- Mr. Smith, tor the Unit- States Geo- logical Survey. Hibbard Howe Memorial Lec- turer for 1928 Direc- furnaces, the same time reduc- ing fiue dust tions, however, the South are much different from those the North blast furnace operation. the North flue dust production very heavy, involving large loss ore already paid for. This per cent iron, while the South the dust contains not more than per cent iron. The adop- tion Mr. Dovel’s devices the North depends good deal the extent which they will reduce flue dust production, said Mr. Meissner. Studies Metallurgy Lime and Dolomite valuable contribution the metallurgical problems involved the use limestone and dolomite HENRY HIBBARD valuable papers were presented the session blast furnaces, but unfortunately the attendance was very small. home because illness. Blast Furnace Life Prolonged Some important new develop- ments blast furnace construction were offe red by we P. D vel, vice- | was offered Oliver Bowles, su- pervising engineer Non-Metallic Minerals Experiment Station, United States Bureau Mines, New Brunswick, J., paper entitled “Utilization Problems Metallurgical Limestone and Dolo- mite.” Mr. Bowles points out that relatively little study has been given the nearly 24,000,000 tons limestone and dolomite used each His paper based extensive re- view metallurgical literature, and consists exposition some the facts based thereon. discusses blast furnace flux, its action the furnace, the effect impurities fluxing stone and offers formula for calculating the relative values different grades flux. The slagging effect magnesia and its function re- mover sulphur, well its effect slag viscosity, are gone into. The size stone for blast furnace flux also reviewed, well the use impure fluxing material. Basic open-hearth flux discussed along similar lines, concluding with analysis the problems the use dolomite furnace lining. Discussion the discussion George Stone, chief metallurgist New Jer- sey Zinc Co., said that, making spiegeleisen, magnesia much more effective than calcium, and American Cast Iron Pipe Co., Bir- mingham, Ala., described the use dolomite for slagging the cu- pola. had found that less dolo- mite than limestone was necessary and that better results were ob- tained using %-in. 1-in. stone instead larger sizes. The ques- tion the use limestone burnt lime open-hearth practice American Rolling Mill Co., Middle- town, Ohio, who said that burnt lime gives faster heat, but lime- stone, because the larger boil, produces cleaner metal. Coal Cleaning Methods Reviewed paper that was considered val- uable blast furnace men gen- eral was one entitled “Cleaning Bi- tuminous Coal,” Campbell, American Rheolaveur Corporation, Scottdale, Pa. The author dis- cusses various methods cleaning coal, both wet and dry. Curves were thrown the screen, illus- trating results ash and sulphur removal the use various methods different grades coal. general the author em- SECRETARY HOOVER Awarded Saunders Medal phasized the following fundamen- tals the mechanical cleaning bituminous coal: washability studies, type plant adaptable the coal studied, plant control performance, and all fac- tors the cost washing. Discussion The wisdom putting this paper blast furnace session was commended Meissner, who said that clean coal means clean coke, very important con- sideration making good pig iron. Commending the paper for its thoroughness, Mr. Meissner said prefers the dry method cleaning, and stated that need more coal cleaned. While the quality coke has been improved, uniform pig iron insured the use uni- form coke, which can made more certain proper cleaning the coal. Gas Washing Methods Contrasted comparison American and German methods washing blast furnace gas was contributed paper Arthur vice- president Brassert Co., Chicago, entitled “Gas Washing.” The author states that the logical order the use blast furnace gas follows: hot blast stoves, gas engines where such engines exist, open-hearth and mill heating, coke oven under- firing, and under boilers. After discussing the wet cleaning method and its various phases, Mr. Boyn- ton goes into some detail discuss- ing the Halberger-Beth system Germany, and then devotes some space the newest method gas purification and one which ex- citing considerable interest the part all German iron and steel men, the electrical precipitation system. Some the results ob- tained from this the United States and Germany, well the costs various systems, are dwelt upon. “The reduction the cost steel possible through the proper application washed blast fur- nace gas remains the most impor- tant single unrealized means re- ducing the cost American steel.” the meantime, says the author, wet cleaning the disintegrator method remains the simplest, cheap- est and most flexible the thor- oughly tried systems developed Continental experiments. Other Papers The subject high alumina slags blast furnace operation was covered paper entitled “Production High Alumina Slags the Blast Furnace,” Jo- seph, Kinney and Wood the Bureau Mines. paper the program which was not pre- sented was entitled “Operation the Blast Furnace Plant, Columbia Steel Corporation, Ironton, Utah,” Phibbs, general superin- tendent Columbia Steel Corpora- tion, Provo, Utah. Open-Hearth Session Features Metallurgical Topics IVE papers were scheduled for the session the open-hearth committee, Tuesday afternoon. Leo Reinartz, assistant general superintendent American Rolling Mill Co., Middletown, Ohio, pre- sided. Brief abstracts two the papers, which were summarized their authors, are given the fol- lowing paragraphs, together with the main features the discus- sions which followed each paper. third paper, describing 1-ton open-hearth furnace and telling results its operation, will published, abstract, separately. The two other papers were not heard, the authors were not present and the papers had not been preprinted. Elimination Carbon largely controls the time required make heat steel the basic open-hearth process and im- portant degree determines the cost refining, according Alexander Feild, metallurgist Union Car- bide and Carbon Research Labora- tories, Long Island City, Y., paper entitled “Rate Carbon Elimination and Degree Oxidation the Metal Bath Basic Open Hearth Practice.” Practical experience has led the generally accepted belief that the use slags relatively high iron oxide, such are required bring about rapid refining, leads cer- tain sacrifice quality the product. consequence, com- promise must made between the exceedingly slow rate carbon drop which would correspond the ideal case and the rapid rate which would best satisfy the condi- tion minimum cost. increase rate refining necessarily implies increase the concentration iron oxide The Iron Age, March 1928—595 + # | dissolved the metal. However, even for the infinitely slow rate that corresponds equilibrium, the metal would con- tain certain definite concentra- tion dissolved iron oxide. matter great practical impor therefore, determine the quantitative relation between the minimum equilibrium concentra tion iron oxide the metal and the higher concentrations which must actually obtain practice. The slag comprises the immedi ate oxidizing agent. is, for prac tical purposes, insoluble molten tance, iron and actual removal the 1500 1550 1600 TEMPERATURE*C temperature, the product carbon and FeO equal constant— the equilibrium constant for the above-mentioned reaction. Diffusion Equations Developed Equations which express the re- lation between rate carbon drop, FeO content the metal, and va- rious other factors have been de- veloped. Assuming that the data used the calculation are accurate enough for practical purposes, becomes possible calculate how the FeO content the metal varies with rate carbon drop for the particu- Effect Temperature Solubility FeO Iron elements from the must accomplished diffusion transfer iron oxide from the slag the metal across the slag- metal interface. Since FeO sol uble molten iron and since Fe.O converted into FeO upon coming into contact with molten iron, the above-mentioned transfer from slag metal transfer FeO alone Oxidation carbon proceeds virtue the reaction CO, product the reaction, saturates the metal and thereafter escapes gaseous pressure equal the mean effective hydrostatic pressure. dis il Unless outward diffusion practical importance, there can neo such thing equilibrium be- tween carbon and FeO the metal bath, excepting the hypothetical equilibrium extremely low pressures, where dissolved would thermal dissociation equilibrium with the oxygen pres- sure dissociated FeO the slag metal interface. When carbon elimination ceases measurably progress, the car- bon and FeO dissolved the metal are substantially equilibrium mosphere. Hence, for any given 596—March 1928, The Iron Age lar operating temperature. The proportional increase FeO due rate carbon drop, over and above the equilibrium value, inverse measure the degree which furnace practice approaches the ideal. The first conclusion that there conflict between theory and practice, and that the commonly accepted beliefs and ideas, far they go, contain the germ truth, most cases least. How- ever, the next conclusion, which in- evitably follows from consideration the complexity the physico-chemical process which comprises basic open-hearth refin- ing, that can only through the application perfectly elab- orated theory the process, con- firmed and based upon accurate experimental measurements, that the metallurgical and economic factors involved will brought within intelligent understanding. The ability science predict quantitatively measure its tion requires adequate theory and the necessary fundamental data. Solubility Iron Oxide Iron oxide (FeO) plays ex- tremely important part the man- ufacture steel, according Herty, Jr., and Gaines, Jr., physical chemist and assistant physical chemist, respectively, Pittsburgh United States Bureau Mines, paper entitled “Effect Tem- perature the Solubility Iron Oxide Iron.” the open-hearth furnace and the Bessemer converter the chemically predominant compound and controls large extent both the operation the furnaces and the composition and quality their products. Almost all the refining action carried out through the medium FeO, which oxidizes carbon, manganese, silicon and phosphorus. the end any open-hearth Bessemer heat the steel con- tains dissolved iron oxide, which must wholly partly elim- inated. The type deoxidation product depends the amount dissolved iron oxide and the deoxidizer used. After the heat has been deoxidized and while be- ing teemed, iron oxide diffuses from the ladle slag into the metal, causing losses deoxidizer and in- crease iron oxide content the steel. generally believed that non- metallic inclusions are responsible for great many failures steel service and for decreased yield steel during rolling. The basis most non-metallic inclusions dissolved iron oxide. This investi- gation was undertaken deter- mine the amount iron oxide that will dissolve iron under various conditions. Steel-making slags are complex and has been thought best determine solubility under simple slags first step. The study being continued under slags whose compositions approach those operating slags. Experimental Method making determinations the solubility iron oxide iron, 50-kw. Ajax-Northrup furnace was used. This was equipped with magnesia-lined graphite crucible which electrolytic iron was melted and held the required temperature. When the metal was melted, the desired slag—either iron oxide mixture lime and oxide—was added sufficient quantity give liquid ring the surface the metal. Tem- perature readings were taken frequent intervals and when the temperature had been constant for min., samples slag and metal were taken. The slag was analyzed the usual laboratory methods for FeO, MgO and One two samples metal from each heat were analyzed for the usual constituents, carbon, mangan- ese, phosphorus, etc., and all sam- ples were run the modified Le- debur method for oxygen content. The fact amounts oxygen are found the metal with increasing tempera- ture indicates that oxygen dis- solved the metal present compound and not gas. Gas + + 4+-+ + 4 +—+4 Determined under iron oxide slags Z. | = } | | | | | | Beans 444-444 4444-444 444-444-444. i | | | } SS SRS SSSSSSS SSS SSS SSS SSS SS SSE See SSeS SS SS Se SS SSS SSS SSS Bee i | i i | | SSS SSSR SS SSSR SSS SESS MSS SRS SSSR ES! | | SSR SS SS SSS SSS SSS SSS SSS SS Wa | dissolved liquids shows decreas- ing solubility with increasing tem- perature. Solubility FeO Iron Under Operating Slags The exact amount FeO the metal equilibrium with finish- ing open-hearth Bessemer slag cannot predicted until data are obtained the compounds present such slags. The initial steps toward knowledge solubility FeO iron under commercial slags are determinations solubility un- der slags consisting FeO and and FeO, CaO and Furthermore, open-hearth op- eration, equilibrium between slag and metal seldom reached, be- cause carbon elimination pro- ceeding all times, preventing the metal from taking iron oxide its equilibrium value. Under open-hearth conditions the amount dissolved iron oxide depends the carbon content the metal and the temperature, unless, course, deoxidation with some other metal- loid has taken place. The rate which carbon Some EETINGS considering the properties various steels were held Monday, Feb. 20. The morning was given over the more scientific aspects alloy sys- tems and results laboratory study. During the afternoon sev- eral papers the utility steels were read, and the Howe Memorial Lecture was delivered Henry Hibbard. Rail Steel Made Germany More discussion was accorded Gennet’s paper “The Man- ufacture Some Foreign Rails” than any other. This has already been printed full abstract THE IRON AGE, Feb. page 405. Bronson the New York Central Lines dwelt chiefly the comparative value the roller straightener and the gag press. HREE Metallur- gists Whom Awards Were Be- stowed the Ban- quet. Mr. Blaylock, the James Douglas medal; Doctor Ma- thews, the Hunt medal Herty, the Hunt prize BLAYLOCK eliminated controlled primarily the rate diffusion iron oxide from the slag into the metal and this large extent depends the saturation value FeO the metal under the slag ques- tion. Discussion Running discussion followed the presentation the three papers open-hearth subjects. Among the principal points brought out were the following: Slag analyses determine FeO are available the practical open- hearth man and can reported the laboratory sooner than the car- bon determination comes back. these samples are taken hour before tapping they will great help controlling the ore addi- tions and finishing the heat. Dissolved FeO the bath af- fects the rate carbon drop. contrast, however, inclusions iron silicates have effect upon the rate carbon drop. suggestion was made for ob- taining the temperature the bath metal means other than those depending largely upon the consid- eration the temperature the slag. This involves the use definite weight platinum, which would immersed the bath refractory receptable held there long enough acquire the bath temperature. then would put into mercury calorimeter and accurate determination the bath temperature would thus become available. was hinted that thermocouple for this pur- pose now process experi- mentation prominent labora- tory, and that announcement may expected shortly its char- acteristics and utility. Deep baths require higher per- centage FeO the slag than shallow baths, give equivalent removal carbon from the bath the ordinary reaction Fe. This due the fact that, with equal FeO the the rate removal about propor- tional the area the contact plane between slag and bath. With deep bath (and more tons it) there larger amount carbon removed from the bath than with shallow bath equal plane. Steels Used Railroads said there were six debatable points, which the first most important: (1) Does straightener, severely kneading the entire rail end end, less damage than few separate blows the gag press? (2) Will the more costly roller straightener the work cheaper? this point recognized that the tendency toward longer and heavier rails (two-thirds them now weigh more than 100 per yard) making the straightener’s and help- er’s job very exhausting. (3) Will require expensive changes lay- out the finishing end the rail mill? (4) Can handle satisfac- torily all reasonable variations line and surface the rails from the hot bed? (5) Can second handling gag press remove kinks the very end avoided? DR. MATHEWS (6) Does roller straightening iron out and cover surface defects? George Comstock, consulting metallurgical engineer, Niagara Falls, Y., was the opinion that the reduced piping observed the Krupp rails was due the slow rate pouring group in- gots rather than the fact that they were bottom cast. Segregation more important defect than piping, and unfortunately the avail- able data are insufficient deter- mine whether the foreign rails are any better this respect than American rails. suggested that the method making the drop test may not have revealed the true story segregation. Henry Hibbard, consulting engineer, Plainfield, described the mechanism whereby slow bot- tom pour reduced the pipe even HERTY, JR. The Iron Age, March 1928—597 though the mold were small end up. The metal, being the bottom the mold for much longer time, chills thick wall. the end the pour this chill progressively thinner toward the top, thus in- closing liquid core which has greater cross section the top than lower effect big- end-up condition. George Waterhouse, profes- sor metallurgy, Massachusetts Institute Technology, Cam- bridge, Mass., emphasized the fact that the raw material used for these rails was very carefully se- lected low-phosphorus scrap and pig, thus enabling carbon caught the way down. in- spected the rails delivery and straight. After months the track, they appear good shape the average American rails after similar service. Railroad Steels Are Meeting More Severe Duty Robert Job, vice-president Mil- ton Hershey Co., Ltd., Montreal, Canada, discussed “Types Steel Railroads, Past and His general remarks the development axles and forg- ings were ground already cov- Used by Present.” for Locomotive Forgings,” printed THE IRON AGE, Jan. 26, page Properties Boiler Steels Chemical Analysis Carbon, per cent Manganese, per Silicon, per cent...... Phosphorus, per cent. Sulphur, per cent. Nickel, per cent Physical Properties: Ultimate strength, lb. per sq. in Yield point, lb. per sq. in.... Elongation in § in., per cent. Reduction area, per cent. Annealed Nickel Carbon Steel “Silicon Steel(a) 0.20 0.28(b) 0.16 0.40 0