The Iron Age 1928-03-22: Vol 121 Iss 12

THE New York, March 22, 1928 ESTABLISHED 1855 AGE VOL. 121, No. Hidden Defects Iron Castings Method Localizing Shrink Cavities and Blowholes Places Where They Can Real Harm the Casting PAUL RAMP* HIDDEN defect cast- ing defect which oc- curs point that not machined; under the surface, where not discovered unless the cast- ing breaks. These defects are often the cause failures service. They are more dangerous than defects which appear upon the surface, de- fects brought light machining, because the latter can often repaired and the casting made safe and sound for the purpose for which was intended. For this reason believe that, casting molded that all defects will appear the surface, will discovered during machining, there will fewer failures service. And many valuable castings will saved, which today find their way the scrap pile. solid casting made good metal, with defective places located indicate that they represent all the defects there are, much safer proposition, welded repaired, than many apparently perfect cast- ings which contain hidden defects, that cannot dis- covered until they cause the casting fail service. vitally important that more consideration given the method molding, with view making safe casting, free from hidden defects. The old plan molding casting—with the idea keeping the parts machined clean and free from defects, and allowing the unavoidable and other defects locate where they will not discovered—should dis- continued. mold should made such manner that, when poured, all the defects, any, will brought the surface, point where they will discovered machining. Then they can repaired and better and safer casting can produced. Engineers and machine shops are some extent responsible for failures castings service. They often refuse accept large, difficult casting, be- cause visible defects which could repaired. Hence, satisfy them, the foundryman makes his mold such manner make the casting pass visual in- spection. This sometimes the cost strength and safety, because defects such shrink cavities and *Superintendent foundry and pattern shop, Newport News Shipbuilding and Dry Dock Co., Newport News, Va. 791 blowholes, which cannot eliminate, moves point where they will not detected inspection. Most large, difficult castings have hidden defects, and some them are dangerous. When becomes possible have all castings X-rayed for defects, there will decided change molding methods; more minor repair work will ap- proved the engineers. may demonstrated that many apparently perfect castings contain hidden de- fects that are dangerous; but which, they could moved point where they could repaired, would not affect the quality strength the casting. While cannot look into casting and see these hidden defects, know they are there. the foundry- man knows how casting has been poured, also knows where there possibility hidden defect. Locating Hidden Defects methods molding turbine casings—shown Figs. and 2—form good illustration what are trying bring out. Fig. partial cross- section mold, with the bottom the casing cast up. This plan insures perfectly clean flange. When this casting has been machined would readily accepted, the inspecting engineers, desirable casting. When the flanges are cast down this man- ner, all foreign matter and indications shrink holes are absent from the face the flange. trouble likely experienced until the casting put under pressure. Then possible that leaks will found the bottom body the casting, caused blow- holes soggy metal. Insufficient metal pressure the surface the molds and cores the cause these defects. the right-hand side Fig. (and Fig. scale representing the pounds pressure per square inch, various depths, that exerted against the sur- face the mold and cores, while the metal the liquid state. Fig. only per square inch pressure exerted against the cores and moid that form the lower portion the body the casing. This not enough pressure prevent blowholes soggy metal points indicated and produce sound casting this character this point the metal pressure against the surface the mold should from lb. per square inch. the and gates this mold, shown Fig. were built high enough produce the required pressure this point, the pressure the joint flanges would increased lb. per square inch, which would 4 Care Pressure, Per Square A, B and By fects at B and C was furthered by gases from the ve ible strain the mold there and increase the thick- Such irregularity the thickness body likely create excessive internal strains the casting, causing crack more easily under Thus, while the plan molding shown Fig. produce clean joint flange, will produce also very poor and unreliable metal the bottom the When molding the casing this manner provide the proper feeding heads for ‘avy sections the mold that form the bearings. The only feeding head possible that shown Fig. which riser located directly over the bearing. But mly connection with the bearing section the mold through the thinner section the housing. fied, the thinner section the housing has become solid and shut off the supply feeding metal from risers the bearing. The result hidden defect which materially weakens the bearing. This defect far more dangerous than similar defect the machined side the bearing, where uld detected and repaired. and Strong Metal Occurs Naturally Lowest Point well known that the metal the lower part the mold denser, stronger and more free from wholes and soggy places than the metal near the top the mold. exerted the bottom while the metal the liquid ate. This pressure great enough the lower parts This the result the greater pressure resist counteract any action from generated gases produce soggy metal. Consequently, sufficient pres- sure the surface the mold cores the best remedy for hidden defects. This plan sometimes produces defects the ma- chined joints, case the turbine casing, but can repaired readily. There should hesitancy the part engineers accept such cast- ings, when they realize that the method molding has brought all defects the surface, and the same time has produced sound, perfect casting points where 792—March 22, The Iron Age Former Method Casting Casing for Steam Turbine, with Flange Downward. Defects shown vere caused having insufficient metal pressure above the points indicated. Formation de- ts, working upward instead downward, intended hidden defects have always existed, never dis- covered until the casting put under pressure fails service. Where the Gases HEN turbine casing this character cast bottom up, Fig. all the gas generated the cores must forced down through the bottom the mold. These vent passages are shown Fig. the pressure the metal against the cores not great enough this case, the casting liable have internal blowholes soggy places and This follows, because, instead the gas traveling down Pouring Basin. Feeding Head Cope Mold Fig. 3—Method Previously Used Molding Shaft and Face Plate. This gave excellent face the plate, but defects and produced condi- tion damaging the strength the shaft Cope f t consequence, long before the bearing proper has solidi- | Side Riser Vents 4 ow» Ww NY Fig. 2—Correct Method Molding the Turbine Casing. With the flange placed upward, the defects form- ing, from whatever cause, will segregate themselves there. Extra thickness, permit planing them off, may allowed and welding will readily repair any holes remaining that point through the vent passages prepared for it, will work its way through the metal against the insufficient pressure until the metal solidifies. This action pro- duces blowholes, soggy metal and other hidden defects, which are the most difficult kinds defects repair. turbine casing cast shown Fig. liable develop cold shuts. These are the most dangerous kind defects, and can often classed hidden defects. producing iron castings this character, important remember that the height the riser value only while the metal the thinner sections the liquid state, except where the riser can directly connected with heavy section. should Fig. 4—Better Method Molding the Shaft and Face Plate. Strength the shaft maintained, while extra metal put the face accommodate poor top planed off smooth surface then kept open with churning rod and additional hot metal added. Avoiding Hidden Defects turbine casing cast with the bottom down, Fig. the gas generated the cores takes its natural course upward through the vent pas- sages prepared for it. addition this advantage, square inch exerted against the surface the cores and molds the lower point, instead lb. pressure per square inch, when the bottom cast up. also possible feed directly the heavy sections the mold, such bearings. This should entirely eliminate the danger hidden defect, such shown Fig. With the feeding head connected di- rectly the heavy section the mold, possible keeping the feeding head liquid state, churn- ing, maintain open channel from the head the heavy section. This makes possible add new metal the metal the heavy section cools, and settles away from the upper surface the mold. This in- sures solid and safe bearing, any other heavy section where feeding head can used. Often cavities are produced directly under the feed- ing heads, because the molder has neglected keep this channel open long enough add all the new metal required the heavy section make solid. But defect directly under the feeding head never hidden defect, and can safely repaired. With proper care preparing the molds, pro- viding adequate vent passages for carrying off the gas, and properly drying the molds and cores, defects the flanges turbine casings can avoided, even though the flanges are cast up. This done the use side risers, feeding heads, providing the metal the right temperature. There always less danger from defect flange, cast up, than hidden defect and leak the body the casing, with the joint flange cast down. And the defects the joint flange can safely repaired; but the defect the body can seldom safely repaired, except case loose chaplet, which can plugged. molding and casting large desilverizing kettles (Concluded page 841) The Iron March 22, 1928—793 Pounos Per Square PPLICATIONS special machinery, both for heavy and light parts manufacture, and production con- trol were the keynotes struck machine shop practice meeting the Chicago section the Ameri- can Society Mechanical Engineers, held the Mor- rison Hotel, Chicago, March 14. The history the pressed steel automobile frame this country dates back 1903, said John Kelley, sales manager Smith Corporation, Milwaukee, who, paper entitled “Production Pressed Steel Frames Automatic Machinery,” outlined methods employed the frame plant operated his company. Counting 7000 frames maximum daily production and 552 operations each frame, the automatic ma- a ve = Smith Corporation, Milwaukee, With What Virtually One Gigantic Machine Occupying Large Building, Can Turn Out Per Day 7000 Wholly Assembled Frames chinery performs nearly 4,000,000 operations single day. The number men employed supervise this equipment about 200, less than one-fifth the num- ber that would needed for equal production semi- automatic plant, one which also operated the Smith Corporation. This machinery tooled for individual orders calling for many 75,000 frames year and has handled single runs 10,000 frames. many 100,000 frames have been manufactured single set-up. complete change tools ac- The first unit the manufacturing line the auto- matic inspection machine. All side bars and most cross bars are made from strip steel, and the automatic inspec- Parallel Lines the Left Side Bars, the Right Side Bars and the Different Cross Bars Come Forward from the Far End the Building, Receiving Automatically the Way Various Machining and Other Operations. the foreground the part the machine which these sub-assemblies bars are delivered, progress now being transversely across the building. The parts are clamped together and fastened rivets fed 794—March 22, 1928, The Iron Age through compressed air tubes the riveting guns > HERE Are Six Presses the Starting End the Side Bar Manufacturing Line. Besides the piercing, blanking and forming the strip steel used, they give the offsets (in the plane the strip) provide for the over the rear axle and the front and rear end drops tion machine rolls this steel remove curvature, meas- ures and stacks loads predetermined sizes. The strips are measured for length, width, thickness and curvature, and all rejections are automatically thrown out into separate piles. The machine has capacity 900 strips per hour. From the inspection machine the steel conveyed monorail crane the pickling department. Loaded crates are carried through acid tanks, rinse tanks, alkali and oil, the last give sufficient protective coating oil for the subsequent fabricating operations. The crew this department consists seven men each shift, and the pickling capacity 500 600 tons hrs. Pickled steel for side bars carried monorail crane the feeder for Unit No. where the strips are automatically conveyed the side bar manufacturing line. There are six presses this line, all driven single 500-hp. motor, with the following order opera- tions: Vertical offsetting blanks for kick-up over rear axle; also for front and rear end drops Piercing left-hand bars. Piercing right-hand bars. Blanking left and right-hand bars. Forming left-hand bars. Forming right-hand bars. The capacity this line 900 bars per hour. The pickled steel for cross bars conveyed mono- Are Shown the Parallel Ways for the Right and Left Hand Side Bar Assemblies, Which Are Completed the Far End. are stations each which there are special machines for various operations. The progressive shift from station station all this mass metal controlled apparatus which spots every part the precise position opposite the working tools The Iron Age, March 22, 1928—795 rail cranes Unit No. which the cross bar manu- facturing and parts assembly line. There are four lines this unit, each driven single motor 100 hp. Each line consists blanking press, drawing press, automatic drilling machines and small power riveting presses—the latter for the completion cross bar sub- assemblies, required. All holes that can conveniently and correctly Alongside the Sub-Assembly Section, as indicated in the So > a 3 » } 4 + station to the bars in CESS f assembly q 796—March 22, 1928, The Iron Age placed the bars are pierced automatically the blanking operation. The holes subject distortion the drawing operations are drilled with automatic ma- chines after the forming the bars. The end-lapping cross bars done the forming operation. Steel fed the four lines automatic feeders and carried between the presses reciprocating feed- (Concluded page 840) ELOW View the Upper Part Lofty Storage Building, Which Com- municates with High Production Continuous Painting Machine. the upper right may seen the traveling monorail crane, which can run over any aisle space,depositing groups frames the ex- tending brackets ore Thinking Needed the Top Manufacturer Finds Danger Delegating Too Much Authority Courage Required Make Necessary Changes Policy SAUNDERS night last week had most interesting talk with manufacturer. told that had always been successful conducting profitable business until the slump 1921. That memorable year, common with the rest us, was caught all spread out. said that did not get the worst until 1922, and then his concern almost went the rocks. However, secured financial assistance, sweetened his loans the banks and managed pull through. Today his business, for its size, one the most prof- itable the country. this manufacturer sat and smoked his cigar easy chair the club, smiled and remarked that man’s business education complete unless has been through such experience—that getting busi- ness the rocks and then getting off one the best commercial courses that any business man can receive. “Now,” said “tell just what happened your business. Give some the high spots.” smiled and replied: “First all, had very high-priced sales manager. was good man and was loyal the concern, but was just full lot theories, and never seemed able get the idea into his head that finances had anything with the busi- ness. When got into the ‘hole,’ never took our condition seriously. When told him about our finan- cial situation, always seemed think that could raise the money some miraculous manner. seemed think that talk him about the real condition our business was just for the purpose heading him off from asking for raise. Sales Department Reorganized with Eye Profits “Now, course,” said this manufacturer, “this sales manager was optimist. Every good sales manager should optimist. Then again, notwithstanding the fact that our concern was losing great deal money, was getting his salary—and was large one—without any interruption whatever. Naturally, rather difficult for man who has stake the business, and who drawing good salary, fully sympathize with the management business when the losses are very heavy. “Finally, after talking and talking this sales man- ager, effort get him cut the suit our sell- ing expense according our cloth, and after finding was simply impossible secure his cooperation, decided let him go, save his salary and take charge the sales myself. announced this part- ners, they were very much opposed it. They called attention the fact that this sales manager knew all the details our business. knew all our business. knew all our salesmen. knew all our customers. let him out critical time like this was almost suicide. right,’ replied. ‘If are dependent upon our sales manager, more than ever convinced that should let him and learn the sales manager myself.’ did let him go. did take the work being sales manager. did work about hr. per day my- self. the end six months, knew our selling or- ganization thoroughly. Somehow instructions going salesmen direct from the president the organiza- tion seemed carry more weight. Somehow letters customers selling matters, signed the president, *President Remington Arms Co., Inc., New York. NORVELL seemed carry more weight. Somehow, when was selling conferences with customers and with sales- men, seemed get better and quicker action than through the sales manager. matter fact, getting into the details personally, was able reduce the number our salesmen, cut down expenses, advance the price our product where were selling entirely too low and, strangest all, increase the volume our sales. Now, course, had known the business thoroughly years past. had grown it, but later years had become less, did not take long, when got back into the game, pick the threads and see hole the grindstone when the hole was there!” Conservative Factory Superintendent Blocked Changes Then continued: “Having got our sales depart- ment reorganized and straightened out, decided de- vote practically all time for few months pro- duction. Our factory superintendent was one the old school type. constantly talked about old times. was wedded old methods. had never left our factory for single week for years. When talked him about new methods that were being adopted re- duce costs modern factories, shook his head and talked derogatory manner about these ‘efficiency experts.’ “When put large part time the fac- tory, even though have never claimed factory expert, common sense indicated that many improve- ments and changes could made that would lead economy. many directions there was duplication work. Many things were being done which, while interesting, were not profitable. were condi- tion where was necessary for cut things down hard pan. “Again, just the case the sales manager, found strong opposition these changes that would save money, the part our factory superintendent. talked about the loyalty our employees, about the splendid organization had, about what ‘fine lot men they were, etc. matter fact, had fatherly feeling toward the whole organization. The workmen were his children. Even some them were pretty poor, sympathized with them. When came question replacing them with others more ability, could not part with them for senti- mental reasons. Yes,” said friend, “personal ac- quaintance business fine thing. Personality excellent thing. The human touch great. How- ever, all these things can overdone when they lead losses and inefficiency and when the business itself going the rocks because profits are too small and costs and expenses are too high. Engineer Hired Introduce New Methods thought the matter out very slowly and care- fully, and the end hired man who knew nothing whatever about our business. was, however, trained engineer. had worked several modern plants. had analytical mind. was not the type man who thought the main object life for factory superintendent was popular with his employees. let out our old superintendent, and then worked with this new man reorganizing our factory. “Of course, first there were attempts block The Iron Age, March 22, 1928—797 . these changes. There were murmurings. There were threats the part number employees that they would quit. But somehow they did not quit, and after while the foremen began see that the new factory superintendent knew his business. When put changes, would call his foremen together and ask what objections they had the changes. they could bring sound objections, would sometimes modify his plans, but usually, the time the suggestions were made the foremen, they were well worked the new factory superintendent could answer every question and explain the advantage every move. “To make long story short, the end six months this new superintendent had the respect, not the affection, all the foremen and workers our fac- tory. They saw clearly that was not working for personal popularity. That did not seem cut any However, was working handle factory manner that would lead reduced costs and greater efficiency. the end the year his new factory superintendent was able show reduced costs almost every department. “Another thing that appealed his work was the fact that worked with records. put everything paper. was not case carrying things his head. divided the work and the re- sponsibility, that, when was necessary for him leave from time time, everything was not held for his return. organized things that the fac- + v tol apparently ran just well without him with Success Large Companies Due Emphasis Getting Results “Too many manufacturers,” said friend, “are afraid take hold the business themselves. They are afraid the amount work that involved. One trouble today with good many manufacturers the United States who are not making any profits the fact that the owners—the head men—have delegated practically all the authority, along with all the work, sales managers and factory superintendents. Now, these men are usually fixed salaries. They get their salaries whether the business makes any money not, and with this condition they are natu- rally not keen study improvements, economies and possibilities making profit direct owners who manage business and who, reason their stock holdings, share largely the profits or, the other hand, suffer severely when there are losses.” “But,” inquired this manufacturer, “how does happen that many large corporations this coun- try are doing very well indeed and are taking the busi- ness away from the smaller corporations, when these large corporations are managed almost entirely sal- aried “Well,” said this manufacturer, “in almost all such cases you will find not only that these managers have arrangements which they share the profits the business, but that there are comptrollers, auditors and accountants who are carefully checking the results every department. One the advantages large corporation the fact that the personal element actu- ally cuts little figure that not personal popularity, but results. The men the top these large corporations hardly know the men the bottom, but they receive regular reports giv- ing the progress all parts the business. The ex- ecutive committees these organizations are influ- enced, not the charming manners pleasant ways some department manager, but only the results his department. Just soon satisfactory results are not obtained organization, you can count change following very quickly. These great corpora- tions rule are not expecting men who unsatis- factory work reform. They haven’t time bother with reformation. They work the basis that there are plenty good men found for the jobs they will take the time and trouble look for the good men.” Lack Thinking Top Main Weakness Business “What were the weaknesses you discovered your business,” inquired, “when you took hold personally 798—March 22, 1928, The Iron Age “One the main weaknesses,” replied, “was lack thinking the top the business. that mean that the men had running the business were too much immersed details. They were cleaning their desks every day. They were too much inclined clerk’s work. “For instance, when asked our sales manager tell the three most important things should our business the next year, had stop and think long time before could offer any suggestions. Now, don’t you think that any first-class, thinking sales manager would know the three most important things that were needed make the business prosperous? Then, when did make suggestions, they were detailed nature. The same thing was true our old factory superintendent. When asked him tell the three most important things should our business the next year, also immediately went into comparatively small details. “Now, when took hold the business myself, very short time became apparent that three things could done that would help the busi- ness very much. Two these things were the di- rection increasing our profits. The other important thing was the direction economies. immediately went work these three things and finally put them over, but concentrating effort these three things, there were, course, lot little things that neglected. was working hr. per day. could not everything. could not see everything. How- ever, just made mind that would concentrate efforts certain directions, and the result the end proved that this policy was wise.” Competition That Proved Mythical One the things that this manufacturer soon dis- covered when went into the details about his busi- ness was that very large part his product was be- ing sold its figured cost. was assured that com- petition made this absolutely necessary—to advance the price was out the question. This manufacturer very carefully went into the entire situation. decided that this important line goods must two things, viz., must reduce the cost production and must get slight advance price. accomplished both results. was freely predicted that when the price was advanced there would large drop sales. matter fact, while the beginning there was some slight resistance the advanced price the part buyers, the end the year found that had sold more this line the advanced price than ever before. other words, the competition which seemed serious his sales manager was largely mythical. The goods this house had been well made for years. They had established reputation. The trade was the habit buying them. Therefore, when the small advance came along, which amounted next nothing the jobber, the retailer and the con- sumer, was easily absorbed, while the manufac- turer this advance, coupled with reduction the cost the goods, was life-saver. World’s Largest Stainless Iron Chain LONDON, ENGLAND, March 10.—Special Sheffield steel has already been employed the work which being carried for the strengthening St. Paul’s Cathedral this city, and two further interesting applications this material have been decided upon. One them consists stainless iron chain which embedded concrete inside the dome order strengthen and preserve its shape. This chain, which being made Brown Bayley’s Steelworks, Sheffield, will 450 ft. long, each link having length ft. in. and width in. The links are laid four parallel lines. The chain will weigh 33.5 tons. will the largest chain ever made stain- less iron. The second application consists the use large tie bars stainless iron, which have previously been used the repairs the cathedral, for bracing the masonry together. him. 10-Stand Continuous Sheet Bar Straight-Line Layout Has Also Three Edgers— All Driven Seven Electric Motors, Two Being Askew ROGERS HEN the Youngstown Sheet Tube Co. first sheet bar and skelp mill its Indiana Harbor, Ind., plant, thought was given the necessity in- stalling additional power plant equipment furnish part the electrical energy required the new unit. Through ingenious method electrical hookup, however, has been possible increase the power factor the entire system more than points, that the power factor now close unity. The greater effectiveness power equipment thus derived has made unnecessary any expansion the number generating units the power plant. Prior the installation the 21-in. continuous mill there was operation 28-in. two-high reversing mill which stood line with the blooming mill. The 28-in. mill was housed building ft. lets rolled that mill were transferred the skelp mill furnace rope-operated cars that traveled track. This 28-in. unit still serves the skelp mill, but billets are now delivered from the run-out table the heating furnace direct conveyor line. This method has practically made obsolete the cooling table which formerly served this mill. That the blooming mill might adequately meet the requirements the new continuous mill, was decided place the latter parallel with the 28-in. mill and adjacent it. Therefore the old building was widened ft., that now houses both the 28-in. and the 21-in. mills. *Western Editor, IRON Chicago. Formerly the bloomer rolled plate slabs and also blooms for the 28-in. mill. now furnishes blooms and slabs for the continuous mill, also. This arrange- ment called for special equipment installed be- tween the blooming mill and the two bar mills. the end the run-out table from the blooming mill there has been built slab transfer table, 1000-ton up-cut, motor-driven shear; run-out table; scales; kick-off and slab pilers. The shear was furnished the Mesta Machine Co., Pittsburgh, and the transfer and tables were built the Mackintosh-Hemphill Co., Pittsburgh. All this equipment was placed one side the old shear that was ahead the 28-in. mill. Immediately beyond the old shear transfer table was built means which blooms are delivered the new 21-in. continuous mill. The 28-in. mill was left undisturbed except for the installation Mesta Machine Co. electric manipulators. later date electric screw-down mechanisms may substituted for the present hydraulic devices. This mill now rolls steel into sections varying from 1%-in. The Morgan Construction Co., Worcester, Mass, fur- nished the complete mechanical equipment for the 21-in. continuous mill, and the General Electric Co., Schenec- tady, Y., built the motors, converters and the elec- trical control system. Sections rolled include 16%-in. skelp and standard sheet bars all thick- nesses. The feed table this mill equipped with roller bearings the off-drive side. Bronze bushings are used the drive side. All the drive gears have Between the Roughing and Intermediate Sections 18-In. Vertical Edger Which Driven 200-Hp. Separate Motor The Iron Age, March 22, cut teeth and are run oil bath. Ahead the No. roll stand up-and-down-cut shear which used for cropping ends for the emergency cobbles the mill. Make-Up the New Mill Ten horizontal stands and three edging stands com- prise the new 21-in. continuous mill. Rolls the first three stands, which make the roughing section this mill, are in. diameter. These are driven 3600-hp. motor through reduction gears and three sets bevel gears. Following these stands 18-in. edger, which driven separate 200-hp., 300 900 r.p.m., motor. Stands Nos. and are known the intermediate section the mill. The rolls are in. diameter, and they are driven 1040 7500-hp. motor through four sets bevel gears. 16-in. edger located between stands and driven from the same large motor. similar edger, inde- + Rolls w | a | us ue ~ x pendently driven, has been placed between stands and between the intermediate and finishing sections the mill. The three finishing stands, Nos. and 10, are driven separate direct-current variable-speed motors, each rated 2000 hp., 165 r.p.m., 600 volts. The rolls the last three stands are in. diameter. billets are delivered direct from the blooming mill the continuous 21-in. mill, the question con- serving heat important. The bars must reach the finishing stands hot enough properly worked. further this condition was foynd advisable space all the stands the continuous mill closely possible. Their distance center center only mat- connection with the low-speed motors operating these stands, bevel gears have been used the first seven regular stands. account the speed rela- tions some these gears are much ft. diam- eter. This greater than the distance center center the stands. avoid increasing the spacing between stands, diagonal arrangement the motor shaft was ised, that there would interference the one set gears with its neighbor. This arrangement sketch form shown diagram. 800—March 22, 1928, The Iron Age short section table delivers the rolled product steam-operated flyer shear, which used for cut- ting sheet bars and wide skelp. Then follows motor- driven, rotary-type shear which used for cutting the smaller sizes skelp and other sections %-in. 15-in. Each shear has its own automatic measuring device. Sheet bars skelp, the case may be, are then run out conveying table traveling bar piler located the sheet-bar yard. The run-out table from the mill extends across two storage spaces. The first the billet yard and the second, which are lo- cated the bar piler and three cooling beds, each ft., the sheet bar storage. Each these yards 120 ft. wide. The Morgan Engineering Co., Alliance, Ohio, furnished three 15-ton, 120-ft.-span cranes, one which serves the billet yard and two the sheet bar yard. Sheet bars are loaded cars cranes for shipment Arrangement and Gearing Driving the Mill (Left). Two large motors were placed “askew,” accom- modate clearances (Below) the New Bar Mill, Showing Also Its Relation the 28-In. Billet Mill, the 35-In. Blooming Mill (Off the Picture, the Left) and the 10-In. Skelp Mill Right Border). Steel passes from blooming mill through the new mill without reheating. The bloom- ing mill feeds, also, the billet mill and plate mill (not shown) the tin mill, and skelp loaded the same means transfer cars for delivery the pipe mills. special interest the new mill the fact that the last run-out table equipped for “shingling” the bars that they overlap before reaching the bar piler. This table designed with inclosed spray boxes for quenching the sheet bars. Water for this purpose drawn three motor-driven centrifugal pumps from 200,000-gal. capacity underground tank. Overflow water drains back the tank and make-up taken from the yard mains. The distance center center between the 28-in. and the 21-in. mills ft. The scale pit, which located between the two mills, measures ft. built concrete and lined with rails. 20-ton Morgan crane serves both mills. Looper tables the 21-in. mill are hydraulically operated. Roll turning shop space was obtained building 110-ft. extension the 28-in. mill motor house, and rolls are stored be- tween the feed tables the two mills. The central pulpit for the five main drives the new mill located above and just beyond the last fin- ishing stand. was built the wall which the mill room from the motor building, that the oper- ators can readily see into the motor room and also con- Bloom Shear | 16-In. Edger Located Between Stands Nos. and hinged looping table has been placed between this edger and the next intermediate roll stand trol operations the mill. Bench board controls are used throughout. Other pulpits for auxiliary motors are located the incoming end the building and the first shear and opposite the intermediate stands. The 18-in. edger, looping tables and roll setting first and second edgers are controlled from this last station. Served 50-ton crane, the motor room 308 ft. 4 long and ft. wide. The roof constructed tile made the Federal Cement Tile Co., Chicago. The tile has been overlaid with cork insulation, which turn water-proofed means composition roof- ing material. The walls are laid with bricks, the inner surface being coated with aluminum paint. Air filters made Midwest Air Filters, Inc., Brad- The Traveling Bar Piler Has Been Placed Under 120-Ft. Span Crane Which Serves the Billet Yard The Age, March 22, 1928—801 7 : ford, Pa., are mounted the outer walls. Air which used for cooling the motors drawn through the filters three Sturtevant motor-driven fans. These force the air through the motors, after which discharged into the motor room. The switch gear and the sub- station are located the basement and the main switch- board panels are mounted the motor-room floor. Electric Drive Units Mill motor equipment consists five units. The three roughing mills are driven 1940 3600-hp. induction motor provided with speed regulation from ator sets the two-generator type and three synchro- nous converters, each which rated 1700 kw. The generators are all interchangeable, that only one set spare parts kept stock. Current brought the motor switch gear 2200 volts, three phase and cycles. Current these characteristics used the two mill induction motors and the three motor- generator sets. One generator each motor-generator set con- nected direct one the three finishing mill direct- current motors through Ward-Leonard control sys- tem. Speed regulation the two large induction mo- Each the Three Finishing Stands Driven Individual Motor, Shown. The main pulpit located right the “askew” above these motors, motor driving the four intermediate stands and the edger op- erated with them 156 290 r.p.m. The reduction unit this drive consists gear with 147 herringbone teeth and pinion with teeth. The pitch and the faces are in. wide. Each these three stands driven through set bevel gears. The four inter- mediate stands are driven through bevel gears 4040 7500-hp. induction-type motor with speed regu- lation from 134 250 Each the three finish- ing roll sets driven separately 2000-hp., 165-r.p.m., 600-volt, 50-deg. motor. This room also houses three 3400-kw. motor-gener- Materials-Handling Meeting Held Philadelphia Papers and speakers for the national materials-han- dling meeting the Society Mechanical Engineers the Benjamin Franklin Hotel, Philadel- phia, April and 24, have been announced. the morning session, April 23, Frank Campbell, chief engineer Eastern Steel Castings Co., Newark, will read paper materials-handling methods his plant. second paper, “Materials-Handling Features the DeLavaud Process Casting Pipe Centrifu- gally,” will read Hoffer, Eastern manager United States Cast Iron Pipe Foundry Co., Philadel- phia. That afternoon will devoted inspection tours, four trips being offered. One trip will devoted study interior plant handling Philadelphia; sec- ond, interior plant handling Camden; third, bulk exterior handling, and the fourth will visit the plant the United States Cast Iron Pipe Foundry Co. Burlington, informal din- ner Monday evening addresses will presented 22, 1928, The Iron Age tors accomplished means interconnection be- tween the two synchronous converters and the three remaining direct-current generators the motor-gen- erator sets. This hook-up functions essentially Kramer drive. Steel partitions between the motor room and the mill room are bolted place, facilitate removal when repairs are being made the mill drive. Sheet metal housings over the bevel and reduction gears the motor room are easily removed the overhead crane. certain interesting aspects and sidelights the mate- rials-handling problem. technical session Tuesday morning will fea- tured three papers. Woodruff, assistant freight traffic manager New York Central Railroad, will read paper “Modern Handling Methods Railroad Transportation.” This will followed “Material Handling Steamship Piers Home and Abroad,” Willard Brinton, president Terminal Engineering Co., New York. third paper, “Storedoor Delivery Freight Motor Trucks,” will read Scarr the Transportation Service, New York. Two technical sessions Tuesday afternoon will devoted respectively interior handling and bulk handling coal, ore, ash, etc. The interior handling papers are two: “Handling Methods and Equipment Large Mail Order House,” Odenath, chief engineer Sears-Roebuck Co., Philadelphia; “Pneu- matic Handling Materials,” Harry Parks the Holly Pneumatic Systems, Inc., Philadelphia. nical session Tuesday evening will devoted primarily mining problems. The outstanding paper, entitled “Materials Handling,” will read Harold Coes, vice-president Belden Mfg. Co., Chicago, and past vice- president American Society Mechanical Engineers. Blast Furnace Practice Germany Ores Various Characteristics Used Burden— Some Good Coke Available—Methods Charging Outlined WILLCOX* materials used the Ruhr District Ger- many are assembled from Newfoundland, Sweden, Spain, Africa, and from the minette mines France and Luxemburg. Perhaps per cent the raw materials originate Germany. Fifteen years ago the furnaces were based larger proportion minettes and the steel works used Thomas iron, e., 0.3 0.4 per cent silicon and 1.5 3.0 per cent phos- phorus. While the steel capacity recent installations largely open-hearth furnaces, usually tilting type, there remains heavy preponderance Thomas converter capacity, and the major part the iron production Thomas quality. This requires high-phosphorus ores. The basic iron for open-hearth work very high man- ganese, per cent, always over 2.5 per cent far observed. believe this because they con- centrate practically all their scrap into the open-hearth, where the pig iron charge about per cent, the remainder being good plant scrap from mills and pits, with major part being rather poor light outside scrap. the high-scrap heat, with its low iron content, melts down with about per cent manganese, about the same starting point with our per cent hot metal per cent Mn. content open-hearth practice, and tapped with the same residual Mn. This di- gression explain why they use high-manganese basic pig iron. Manganiferous ore nil Germany. The Germans import all the manganese and conserve it, reusing open-hearth slag and using old ferroman- ganese and even spiegeleisen slag. This concen- trated, and so-called slag concentrate—running per cent Mn—is recharged. Manganese ore comes from Sweden, Africa and the Near East. Burdens Most Composite With such wide sources supply the burdens found various plants are the most composite character. One extreme case was three-furnace plant, each stack with 17,000 cu. ft. capacity, producing 1500 1800 tons iron day and using different iron-bearing mate- rials. inland plant nearby used burden made per cent Wabana, per cent high-grade lump minette, and per cent roasted and sintered German spathic and limonite ores, together with the usual plant by-products. Going over toward Dortmund, one large plant was using per cent Swedish magnetites, about per cent sintered, with the remainder made manganese ore and plant by-products, while ad- jacent operation Wabana made the major part the burden. Bochum, with four furnaces, the bur- den was made sinter, produced from mixture flue dust, Spanish, African and Swedish concentrates, all fines, mixed with from per cent per cent coke braize and sintered Dwight-Lloyd machines. The Swedish would correspond roughly our Harmony con- centrates fineness, but the hematites were seemingly fine flour. Low-Grade Native Ore Not Much Used Germany has considerable ore reserves Bavaria and southern Germany. They are low-grade and ap- parently have roasted before they can con- *Vice-president Freyn Engineering Co., Chicago. This abstract address before the Eastern States Blast Furnace and Coke Oven Association, the William Penn Hotel, Pittsburgh, Feb. 17. second and concluding in- stallment will published early issue. centrated. has been found cheaper import ores than develop the low-grade deposits. interest- ing note that the turn toward imported ores has given the Ruhr District distinctly better grade ore work with than was the case formerly. gives dis- tinctly superior burden, compared with our some- what easily reducible ore burdens. The magnetites, sinters and probably Wabanas are not quickly af- fected the reducing influence the furnace gas. Their working furnaces have practice which follows that our Eastern district, where mix- tures have been used for many years ranging from per cent sintered ores and per cent hematite, per cent sintered ores and per cent hematite, not mention the 100 per cent sintered ore practice. Such burdens invariably give lower blast pressures, lower coke and greater regularity, the furnace taking heat— even unfavorable lines—without serious tendency stick and hang. They use some ores lumpy condition which think would refuse charge. two plants are designing for Germany have provide clearance the throat for 14-in. lumps. surprising that the German furnaces work they do. again surprising, first glance, that, working with burden naturally coarse, they show much interest render- ing fine ores coarser. think this can traced two factors: First, the fear fine ores well founded because many plants where the tonnage has been brought are blown gas engines that cannot keep the volume with much over Ib. blast pressure. Moreover, the production Thomas iron, with its lower silicon, more sensitive, and, regardless furnace lines, combustibility coke and slag characteristics, high blast pressure has avoided. Second, the Germans have materials that nat- urally have agglomerated nodulized sintered —the latter process being practice than with us. Some the Spanish and Algerian ores are finer than any have contend with and are dry bone, and then large quantities undesirable grades, like pyritic residue and spathic ore, have treated. Sintering African Ores Difficult was informed that not easy sinter fine African hematite ores mixture hematite and magnetite. The tonnage the Dwight-Lloyd ma- chines drops off per cent. this respect, be- lieve they check our experience with flue dust and well prepared magnetite concentrate, such found Chateaugay. However, their Dwight-Lloyds are not well laid out are certain our sintering plants with respect return screenings for admixture with the fine ores. They often have good preparation plants for the mixture ores, the different components being weighed correct proportion, put through concrete type mixer before being charged the machine. com- pared with the rate production here, they run slower tons per square foot per day basis. The quality sinter poor, compared with some the Amer- ican sinter, but much superior admixture fine hematites and magnetites that not difficult see justification for the practice. Their cost stated 35c. ton. Swedish shippers are said screen out the lumps, (Concluded page 842) The Iron Age, March 22, 1928—803 Thousand-Ton Structure Welded Simplicity Joints Trusses and Erection Details Eliminates Several Thousand Gusset Plates and Short Angles— Per Cent Saving Steel Effected LARGE manufacturing building has been erected the General Electric Co. its West phia, Pa., plant, which the structural steel was fabricated and the erection joints were made means metallic arc welding. The building, shown end elevation the view, approximately 145 550 ft. line columns runs down the center, thus dividing the structure into two bays, the one the left being equipped for overhead cranes. Steel was fabricated the Trenton, J., plant the American Bridge Co., which also erected it. The structure weighs 989 tons, which 745 tons passed through the welding shop. The remainder made purlins, punched for angle-iron connecting clips, and erected bolts. design made for the more conven- tional riveted details was figured weigh 1114 tons; thus saving 125 tons, over per cent, was made the weight steel. Prof. Frank McKibben, formerly Union Col- lege but now consulting engineer for the owners, de- structure detail the Philadelphia En- March 14. said that this building its size, weight and the use heavy roof but that merely represents orderly de- velopment new art. has data concerning buildings with frames either wholly welded welded great part; miscellaneous structures which have either been constructed reconstructed and re- welding, and ships barges which have completely welded main frames. pew 4 4 al al NS > 4 = | 7 ——e- 22, 1928, The Iron Age believes that welding has very promising future for steel truss work, because requires less steel and cheaper method fabrication, yet producing just good (or even better) joint, and with noise. The problems yet solved before the method widely used are (a) revision building codes and education building inspectors, (b) methods insur- ing the skill welders, (c) educating the draftsmen and detailers, (d) devising proper shop fixtures and jigs and (f) adapting automatic welding machinery. indicated the view, the truss assembled without gussets, except for the lateral bracing, and the metal symmetrically placed. All the welds are placed act shear. Previous tests had shown that fillet has average ultimate strength shear 13,400 lb. per linear inch, and fillet, 10,900 design stress 3000 per linear inch fillet weld was adopted, thus giving factor safety 4.5. Column details are very simple. shown the photograph, the loose base slab was usually grouted correct level, and the Carnegie H-beam column with milled end was placed thereon. The single-angle bolt bracket much more economical than riveted detail requiring least five nicely fitted pieces. cap plate was welded the top each column, and clip angles land the lo