The Iron Age 1928-04-05: Vol 121 Iss 14

THE IRON AGE New York, April 1928 ESTABLISHED 1855 Handling Materials Feature Plant Changes Chicago Company Readapts Its Buildings and Equipment for Increased Production Gas Stoves —Method Loading Trucks and Various Appli- cations Mechanical Conveying Are Noteworthy change from one product another keep step ahead public demand. taking such step will naturally try choose product with wider market appeal. the same time will give full consideration the selection and arrangement production and material handling equipment that costs will held the minimum consistent with quality product. years manufacturing experience the Cribben Sexton Co., Chicago, has kept close touch with the pulse demand. Until years ago the bulk its business was plumbing supplies, but about 1897 sold that branch and swung into the production coal ranges and, some extent, gas stoves. rapidly localities were served gas housewives were quick recognize the advantage that fuel compared with coal. The rural trade, large extent, was left for the coal range manufacturer, although even this field increasing competition from oil stove makers was Enameling Furnaces Are Charged Means With Rising and Lowering Bed. The buggy takes its load from carriage which suspended from overhead track 3 VOL. 121, No. \ 4 929 encountered. make long story short, the Cribben Sexton Co. still manufactures coal ranges, but not quantities comparable with its output gas stoves. Large Press Department Installed Make Gas Stove Parts The decision swing over heavy production gas stoves made necessary use pressed metal larger scale, thus releasing part the foundry pacity and entailing the expense constructing large press department and installing complete assortment machine tools for the production dies. About the time this was done became evident that social pres- tige was diminished unless the kitchen gas stove was red, green, yellow some other color besides the con- ventional gray, black white. With attractive gas stoves heavy demand, occurred the manufac- turer that yellow light blue enameled coal range would strike the fancy the “domestic engineer,” whose duty for years has been blacken old-fash- ioned Probably the most far-reaching change resulting from tendencies stove design and demand has been wider use pressed metal parts. Before this trend To Preve nt Through Their Rubbing Against Each Other, Damage Enameled Parts Platform Skeleton Trucks Are loading truck, such the one shown above, the operator mounts one tray over another rapidly each covered with enameled parts. The tray used consists end spacers and crosswise slats Used. In got under way, 180 molders and two cupolas were em- ployed the Cribben Sexton foundry. the pres- ent time stove castings occupy only one cupola and 110 molders, and larger amount jobbing work being done. Three buildings make the Cribben Sexton plant. The foundry one-story building, also the structure which houses the enameling department. The third building the multi-story type with base- ment. Shears and forming presses are located the basement, and the finished stock room and assembling department are the upper floors. Careful attention given economy materials- handling from the time the pig iron for the foundry unloaded from the railroad cars and placed piles that are separated concrete runways. Cupola charges are made four-wheeled box trucks which are moved means electric battery lift truck. The same transport equipment used remove cast- ings from the pouring floor the cleaning department and from the cleaning department the enameling building. Automatic Machines Polishing Room Incidentally, standard enameling practice this piant apply the undercoat castings within 1928, The Iron Age min. after the casting sand blasted. This time limit set prevent oxidation the casting prior its receiving its protective coating enamel. Parts that are nickel-plated the plating department, where standard equipment used. Ingenious equipment for handling material features the polishing room. One machine, used for polishing the tops stoves, ft. long and equipped with emery wheels. entirely automatic, moving platform carrying stove under the different wheels. this department also automatic pipe polisher, which employs rotating idlers force the pipe along and against power-driven polishing belts. Parts Mechanically Handled through Enameling Furnace Castings enameled are mounted small metal racks. These are placed spray booths, and liquid enamel applied with air guns. The racks are then delivered dryer, where they remain from min. hr, stream air heated 125 deg. Fahr. radiator-type heaters, which are equipped with motor-driven fans. Following the drying operation, the racks trays are placed either one two carriages that hang from structural frame which directly front the burner furnace. This furnace has pacity 7500 10,000 daily. soon carriage designed with rising and lowering bed. The furnace doors are then opened, and the charging buggy delivers the load into the furnace, after which the charging buggy bed lowered and withdrawn while the burning operation min. duration carried tempera- tures that range between 1300 and 1350 deg. Fahr. Special Trucks Used Prevent Damage Enamel previously stated, castings are delivered the enameling department box trucks. After the enamel applied great care must used handling the vari- ous parts that the enamel coat will not damaged. Therefore the trucks that are spotted the spray booths are skeleton type with four corner uprights fixed the truck floor. Cross bars and trays are super- imposed the truck the spray operator needs space for newly enameled parts. Trucks this type prevent considerable losses, because they eliminate the necessity sliding parts between shelves, with the danger one part rubbing against another part rubbing against shelf, thus destroying impairing the enamei coat. Many the trucks used this department con- sist merely platform and wheels. truck this kind spotted work station. Here within reach the operator are number wooden trays, which consist essentially end spacers and number crosswise slats. The operator mounts tray the floor the truck and, after having covered with the product which working, places another tray top the first one. this way gradually builds the truck load great height safe for transport purposes. Sheet Metal Handled Chute, Elevator and Truck Sheets for press work are unloaded from railroad cars and passed down chute the press department, the basement the multi-story building, where they are placed stock. After having been sheared and formed they are loaded box trucks, which are moved electrically operated truck the end the build- ing, where elevator brings the load the yard level. The electric truck then transports its load over concrete roadway the enameling building, where the formed sheets are delivered the cleaning department. Here they are first dipped for min. caustic solu- tion, which removes all traces grease. They are then given cold water bath and allowed remain min. per cent sulphuric acid bath heated about deg. Fahr. The next operation rinse and sub- 4 7 | » J ™ = | = Parts That Are Japanned Are Hand-Dipped and Suspended Rack Which Hangs from Overhead Trolley Beam. The drip pan located only few feet from the japanning oven merge the sheets soda solution assure the re- porting enameled pressed steel parts are similar to, and moval any acid solution which may remain them. many cases interchangeable with, those used for The soda tank heated means steam coil. handling enameled castings. The burning period for The sheets attain the temperature the soda solution the ground coat min. Each part then given before they are removed and, therefore, are warm thorough inspection and, passed, delivered enough when brought into the air that evaporation spray booth, where given the first finish coat. Be- rapid and they are quickly air-dried, thus avoiding fore burning the first finish coat some stove parts are the installation dryer. brushed back means stencils and brushing wheels Sheet metal parts are hand-dipped the ground order produce attractive trim and also pro- coat, which always the same color regardless tect the from chipping edges that are bolted the color the finished coat. Trucks used for trans- together. Finish coats are burned for min. Stoves Are Assembled and Tested 130-Ft. Conveyor Line. Thirty men assemble 225 stoves 9-hr. day The Iron Age, April 1600 deg. Fahr. Careful inspection given each part before the final color coat applied. defects discovered are not too serious, they are re- touched and then the second finish coat applied and Belt Conveyor Carries Parts Store Room All enameled parts, including both castings and pressed metal, come together final inspection room, which the ground floor the enameling building. From this room 36-in, canvas conveyor belt pitches upward 17-deg. angle and then extends overhead across the yard store room, where complete line all parts kept facilitate the assembly opera- ions. The conveyor completely inclosed struc- ure which high provide headroom above adjacent walkway. This equipment was fur- nished the Chain Belt Co., Milwaukee, Wis. Enameled parts placed this conveyor are spaced that they not touch. Formerly enameled T he Foundry parts were transported from the enameling building the store room trucks. was necessary that time carefully pack each part the truck, and even then there was always the danger chipping and scratch- ing surfaces, which necessitated additional inspec- tion the store room and the rejection many parts that had reached the stage where they should have been ready for assembly. With the conveyor system, the final inspection made the enameling depart- ment. The conveyor reversible that the end American Steel Wire Co. Studies Special Properties Wire Research with various forms wire which, when under tension, are subjected vibration, being un- dertaken the American Steel Wire Co. labora- tory 5149 Agatite Avenue, Chicago. The work under the direction William Braid White. Among the instruments are two that have been de- veloped especially for piano wire investigations. One iron frame similar lathe bed, except that the sides the horizontal box member are open and lon- gitudinal slot extends the full length the top. the left end the frame tuning wheel and jaw for holding one end the wire. the opposite end the frame spring-loaded dynamometer. movable 1928, The Iron Age Well Equipped Supply All the Needs Modern Stove Factory. and the admission daylight are features this building day’s run materials may delivered from the store room back the enameling department need be. Monorail System Serves Japanning Furnaces Parts manufactured the multi-story building that can directly the stock room are transported from one floor another means elevators. this building are two japanning furnaces provided with loop monorail system, from which six baskets are sus- pended. Two baskets are always the oven and two are spotted front the charging door, where the parts japanned are dipped and suspended over drip pans. Two baskets that are being unloaded are run out the free length monorail, which re- turn line, the front the furnaces. Conveyor 130 Ft. Long Serves Straight-Line Assembly The assembly and crating departments are the same floor with the store room. Assembly starts benches, where the skeleton the burner and the oven Proper ventilation are put together. wooden skid, which part the shipping crate, bolted the skeleton, which then placed the receiving end 130-ft. assembly con- veyor. Thirty men work given spaces both sides this conveyor. Before stove reaches the end the conveyor has been completely assembled, acces- sories have been wired it, gas connections have been tested for leaks and burners have been adjusted for proper combustion. The assembly schedule this con- veyor 225 stoves 9-hr. day. bridge makes this machine adaptable for testing strings from in. ft. long. piano action slides along the lower member the box frame, and, when the key struck, the hammer reaches the string through the slot the top section the frame. The piano action can moved strike the string any point its length. Photographic studies strings under vibration are made the use oscillograph furnished the Westinghouse Electric Mfg. Co., Pittsburgh. This instrument special that adaptable the study low-frequency vibrations, the range being from 50,000 cycles per second. This unit, including microphone, portable and may used for experi- ments the “monocord” any stringed musical instrument. > Typical Large Bend Made 16-In. Pipe 40-In. Radius and unusual process has been started the Pipe Bending Process Co., Louisville, Ky. The bends are really short pipe made production basis standard series sizes, and can made any “bendable” material any thickness. They should not confused with the long sweeping curves made order for expansion joints steam hot water lines. Their utility lies separate and distinct field, taking the same place welded pipe lines that cast fittings, el- bows, goose necks and returns screw-coupled lines. The manufacturers believe that definite series bends with long and short radius will take care prac- tically every requirement the way fitting for welded piping. Standardized shapes make available the trade those advantages incident tion, such quick delivery, low cost and in- ventory. typical standard series bends would include 180-deg., 90-deg. and 45-deg. turns, single radius, for each common size pipe. apparent that any angle bend can cut from the 180-deg. return bend. Should found inconvenient anticipate exact requirement, small supply 180-deg. bends long and short-radius types will provide for any kind turn less cost, said, than the pipe were mitered and welded the field. we Fig. 2—Flat Coil Spaced Two Diameters Steel, copper, brass, aluminum and special alloys have been successfully formed into short-radius bends the Louisville company. Bends are furnished with square chamfered ends desired, but are normally without tangents straight lengths, although short tangents for threading welding flanges can made additional press operation. When long tangents are necessary, they are welded on. contrast with other methods bending, the com- pany finds that thin tubes large small diameters can bent easily radii from one one and half pipe diameters without buckling the inner walls. The manufacturing process was invented Ger- many and protected patents. The essential parts Forcing Hot Pipe Over Horn-Shaped Mandrel Produces Short-Radius Bends Without Buckling Inside Turn Exces- sive Thinning Outer Diameter the equipment consist gas furnace, special man- drels and hydraulic press. The ram from the latter travels over long steel shaft, fixed into the station- ary head the hydraulic cylinder. Over this shaft straight length pipe slipped until strikes flat ring fixed the nose the ram. After the straight pipe placed the shaft, horn-shaped mandrel attached the forward end the shaft double-threaded turnbuckle coupling. The ram then moves the pipe outward until the forward end Fig. Compli- cated Outlet Pipe Made Three Methods: Left, Mitered Joints, Welded; Middle, Screw Fittings; Right, Short- Radius Bends, Welded binds against the turn the base the mandrel. gas furnace then moved surround the man- drel and the pipe end, and three gas blow torches play flames the end the pipe until plastic. More pressure applied from the cylinder the pipe pushed over the mandrel fast hot enough work. The design the mandrel deter- mines the curvature the bend and the wall thick- ness, and variations from straight bend wide coil are obtained the location the heat during the operation. Applications the bend are numerous. Changes direction welded pipe lines can secured with comparative ease using different combinations Fig. 3—Four-Inch Coiled In. Outside Dia- meter The Iron Age, Pipe Bends Made New Process the standard unit. illustrate this fact tortuous pipe string was made up, the using malleable iron fittings, and third mitering Same ( and welding all joints (Fig. 1). tank water was filled and drained three times, once through each these strings. The time noted was follows: Witl hort-radius bends 7 min Ibow mi \\ a joint iz min ndicates that pipe true curve, smooth side ets ip tewer eddy currents at changes in rection and has greater capacity flow. Tests these bends are said show them alent standard straight pipe strength. interest fabricators flat coils which pipe important the return bend Fig. This coil made straight pieces tandard thickness welded bends with STEEL HOUSES GERMANY Dwellings Steel Plate Construction Adapted Mass Production German Steel Trust shown considerable Domestic interest steel producers circular issued iron and steel division, Department Com- merce, the subject building steel houses Ger- many. The circular, based report received Hugh Fullerton, consul Cologne, shows that the steel German manufacture which have been view sale the Cologne district appear have features similar those found structures the United States. Durability, warmth from dampness are outstanding selling points these houses, and proposed have their parts available stock order that time may lost supplying the public. also planned have the construction simple that the purchaser may complete the house himself merely putting the various parts together and following directions elemental nature. The report indicates that German manufacturers obtained ideas from achievements the steel house con- field the United States and England. their Houses Will Built Quantities report has been confirmed that the Vereinigte Stahlwerke, the German steel trust, soon begin mass production steel houses and declared probable that many settlements for industrial opera- tive similar one Duisburg-Laar, will the re- sult. Row and block houses steel construction are reported strong demand the Rhineland, and large industrial firms are beginning find them ready and rapid solution for housing problems. the report says, the plant the Vereinigte Stahlwerke Weidenau, Westphalia, supplying the demand for steel houses western Germany, while understood that the BAMAG (Berlin-Anhaltische Maschinen-Fabrik Aktiengesellschaft) intrusted with this responsibility for eastern Germany. The German firms Gropius, Holzman, Phonix and Czech are re- ported producing experimenting with steel house construction. The so-called “Boehlerhaus tem” (Viennese), employing interior steel plates and plates covered with plaster for the exterior, said also used some parts Germany. present, Walls and Roofs Steel Plates Describing the steel houses the Cologne district, the report “The roof and the side walls are made strong steel plates which are connected means screws with the rims which are turned. Wood borders, which are affixed the latter, serve sup- ports for the inner partition walls, consisting light boards (Tekton plates, etc.) which are nailed them. Between the outer steel wall and the inner light boards air space for protection against cold and sound. The walls, with thickness cm., which have been Says: 934—April 1928, The Iron Age radius equal the pipe diameter, thus providing center-to-center spacing only twice the diameter the pipe. Full strength maintained the returns; the wall thickness correct, both inside and outside, shown the bend which has been cut open. Spiral coils, give maximum heating refriger- ation area minimum volume, are made any pipe size. Fig. shows coil standard 4-in. pipe formed single section, the only weld being the outlet. Sim- ilar coils indefinite length can made welding together duplicate sections. underground piping kind afford easy means passing various obstructions. any such bends flanges are desired, they can gas, electric hammer-welded the bend section, thus providing fitting for attaching standard flanged castings. installed very short time, are claimed much insurance against cold brick wall em. thickness. “As the steel plates are all uniform size, 1.15 width, possible build the house any desired length. also practicable divide the dwelling space into more spacious rooms desired. the partition walls, apart from supporting middle wall, have basic connection with the outer walls, they may transferred according the individual desires the purchaser. Construction, therefore, very simple. The types described and now being manufactured the greatest extent Germany are the three, four, and five-room dwelling. “The foundation made with concrete walls, cm. thick, beneath the outer walls. Usually, one-third one-fourth the building space occupied cellars. The roof consists entirely steel. The steel sheets require stays support them that frame- work required. Doors and windows are furnished several sizes.” Costs Are Very Low five-room house, with two attic rooms, varies between 6,000 and 10,000 marks, about $1,429 and $2,390. four-family structure, with cellar space under every room the ground floor, quoted about 22,000 marks, about $5,238. Each the four apartments involved has square meters dwelling space. complete steel houses all sizes this part Germany, three four weeks are required, depend- ing upon the size. That short period needed for the construction contributes small degree the low cost the completed building, labor charges are reduced minimum. According specifications for inner fittings, the price for one-family house, con- sisting two rooms, plus kitchen, bath and closets, ready for occupancy, inclusive installations for gas, light and water, amounts from 6,000 7,000 marks, about $1,429 $1,667. These figures not include the cost fittings for the bath and kitchen. The weight one-family steel house, all ma- terials included and ready put together, ap- proximately tons, according the claims German manufacturers, while stone house similar dimen- sions weighs from 150 175 tons. cost The Interstate Commerce Commission pended from March Oct. the operation tariff schedules which propose cancel commodity rates iron and steel articles, less-than-carload lots, from the Pittsburgh district Pennsylvania Railroad stations between Salisbury, Md., and Ports- mouth, Va., and apply fourth class rates instead. The proposal would result increasing the rates from 48c. per 100 Ib. Perin Marshall, consulting engineers, New York, have moved the seventeenth floor, Salmon Tower West Forty-second Street, New York. | Why Much Talk About Safety? Considerations Responsibility Both Society and Share- holders—Safety Workers Menaced Automobiles IEWING the question industrial safety from the angle public safety, appears that there was grave question the safety the public until the advent the automobile. Today have the United States more automobiles than telephones. With the tremendous increase the number cars, the increase the number automobile accidents has been enormous—so great, fact, that adequate pro- tection for the public has almost got out hand. recently prepared statistics our company, which showed that employee’s chances losing time from being hurt outside employment were twice great that being injured while work. Think that condition—when few years ago was felt necessary legislate industry into safe practices. doubt, statistics other industries would prove the same point. With industrial accidents going down, motor acci- dents are decidedly the increase. The Metropolitan Life Insurance Co. paid accident claims during 1927 about $10,000,000. Deaths from motor vehicles were the most important, both from the number deaths and the amount claims. Over $2,500,000 was paid that alone claims arising from motor ve- hicle fatalities, increase 67.6 per cent since 1920. Cook County (Illinois), since Jan. people have been killed automobile accidents. most these cases the people killed injured were going about their business with more thought possible injury death than any one this room has this moment. Irresponsibility the Steering Wheel Yet this tremendous increase motor deaths and accidents not greatly wondered at, when remembered that there are about 30,000,000 drivers. other words, one person every four the United States supposed capable handling motor car—a car which instant may become naut destruction. Again, bearing mind that nearly 500,000 persons this country are confined institutions maintained for irresponsible surely looks we, people, are willing take some long chances with ourselves. 1927 there were over 14,000 motor accidents Chicago alone. Ten thousand adults and 4600 children were injured, and over 600 adults and 200 children were killed. Many came from small farming communi- ties less than 1000 souls. Picture every man, woman and child your little home town killed motor cars within year. Industry would not for one moment think in- trusting inexperienced hands the operation punch press, drill press, high-powered machine. filling vacancy one insists upon the applicant meet- ing certain necessary requirements. The State, fact, prohibits the employment individual under years age and between the ages and must present working certificate. The main purpose, course, far the State concerned, see that the boy’s education con- tinued, least until years age. But another real reason postpone until that age his introduc- tion industrial life, and the machine hazards which inexperienced hands might meet. the same time, another law permits any boy girl, provided she accompanied adult person, drive automobile which, instant, can changed from pleasure vehicle instrument *Assistant works manager, Hawthorne Works, Western Electric Co., Chicago. Extracts from address the sixth annual Mid-West Safety Conference, March 19, Chicago. destruction. And any person years older, is, law, qualified drive car his own responsi- bility. this daily toll injuries and deaths from auto- mobile accidents mounts higher and higher, believe time consider seriously the adoption more rigid requirements for persons who are allowed operate motor vehicles. Safety Promotion Accomplished Industry Within the memory most us, the danger snuffing out life existed primarily dustry was the defensive. Finally the recognition the hazards industry, and the possible loss the breadwinner the family, resulted legislation re- garding guarding machines, workmen’s compensation acts, industrial boards and other means insuring that industry did carry what the law considered was its responsibility. Industry proceeded see that its machines were well guarded, only find that, even with the guards, the number accidents did not decrease materially. Then industry began preach its personnel the “Safety and the accident ratio began coming down. During the years preceding 1925, our own com- pany expended about million dollars machine guards. 1925, with our equipment well guarded today, our lost-time accidents were 4.5 per 1000 employees per month. 1927, after intensive effort train our people think, talk and act safety, our lost-time accidents were only 1.2 per 1000 employees per month. And don’t believe that have reached the ultimate. Small Plants Must Fall Line may argued that the smaller industries cannot afford devote much time and effort safety work some the larger ones. not believe they can afford not to. matter what the business is, large small, its owners are interested eliminating waste and improving methods operation that the plant may run efficiently. But how can efficiency had, without consideration the men and women who are the plant? Machines without competent operators are worse than useless. The extent the cooperation the men and women the plant largely determines the success failure the enterprise. make that cooperation possible, for other reason, management justified mak- ing any expenditure necessary keep its force safe. industry will fully meet its moral obligations its workers, will not need worry much about its financial responsibilities its stockholders. Industry has made splendid progress its safety work, in- dustrial statistics show, but have means ap- proached its possibilities. shipment all-steel passenger cars was made March the American Car Foundry Export Co., Sao Paulo, Brazil, for the Paulista Railroad. This the first all-steel passenger equipment installed South American railroads. There are first-class coaches; second-class coaches; parlor cars; dining cars; mail cars and baggage cars. These cars were built Berwick, Pa. The Erie Railroad Co., development service, has is- sued industrial map its system for use the lo- cating new industries. The map available the company’s offices, Church Street, New York. The Iron Age, April 1928—935 SAAS | Cap Screws Made New Method Blank for Threading Produced Extrusion Process—Tumbling and Lubricating Machine, Electric Heat Treating Furnace and Quenching Machine Are Features FRED PRENTISS* satisfy the more requirements the automotive industry, manufacturers cap screws given increased attention improving the quality their product. The importance this small part the construction motor car indicated fact that about 400 cap screws are used the average motor car, and stated that the new Ford Model taking less than other cars, uses nearly 300. Recent improvements manufacturing processes making cold-headed cap screws include new method that employed the Cleveland Cap Screw Co., Cleveland. This method designed increase the quality the product both accuracy and tensile strength and, the same time, save material and reduce the cost manufacture compared with the } usual method cutting the thread. increase per cent tensile strength claimed for the prod- uct, compared with cap screws made the ordi- nary upset method. The process used was developed Charles Kaufman the Cleveland Cap Screw Co. and covered patents owned that company. One the important parts the process the heat furnace, which insures close temperature control and, consequently, uniformity the heat treating opera- tion and finished product that very uniform hardness. The furnace was built the Westinghouse Electric Mfg. Co., East Pittsburgh, ] \ e Ve + 936—April 1928, The Age treating, which done recently installed electric 4 . the method commonly employed making cold- headed cap screws the threads are rolled the blank the original diameter the mill stock and the por- tion the blank that forms the shank body between the threaded portion and head built being ex- panded die the upsetting process, that its diameter corresponds the external diameter the threads. part the same upsetting operation the head formed. Wire Reduced Proper Pitch Diameter with Heading Under the new process, wire the same diameter the body the unthreaded portion the finished screw fed into the solid die double-stroke header standard type and cut off the proper length. the wire forced into the die the portion threaded reduced diameter the pitch diameter the thread formed. The heading operation com- pleted the second stroke the plunger. The female die member, which stationary, has irregular-shaped cavity including outer head-forming portion, section smaller diameter approximately the same diameter the stock and, the base this, section having further reduction diameter which the stock forced, decreasing the diameter the portion threaded the pitch diameter the thread and lengthening that part the blank the drawing extruding process. The stock driven into the die cavity point which engages adjusta- ble stop member gage which serves ejector. The blank produced for thread rolling the extrusion process, pointed out, unusually accurate pitch diameter and does not have the structural weakness ( Y AP Scre ws Going Through Combination Tumbling and Lubricating Machine, Sawdust Being Mixed with the Work Before Goes screws are lubricated with wax preparation go- ing through sizing dies = — N NIFORMITY the Heat Treating Operation and the Hardness the Finished Product Secured Passing the Screws Through Elec- tric Furnace the Rotary Type. From the furnace the work dumped into quenching machine. There are two these machines, one for quench- ing carbon steel screws water and the other for oil quenching alloy steel screws. the left, the control equip- ment for the furnace outstanding feature the process the reduction the wire the proper pitch diameter the same time that the heading operation per- formed. The part the blank that reduced diameter given skin surface hardening the drawing proc- ess, which, pointed out, advantage steel used for screw-forming purposes. the shank retains its original diameter, can any length, which also true the part threaded. stated, the diameter the shank the same the stock, but should there any variation the size the stock the shank portion enlarged reduced the die, assuring greater accuracy, said, than pro- vided mill tolerances. Less Severe Upsetting Blow Reduces Possibility Crystallization Since the head formed larger stock than usually used the cold-heading process, not severe upsetting blow required forming the head would necessary were the shank and head upset from smaller stock the more common process. Conse- quently, pointed out, there less possibility crystallization and fracture the body and there less tendency set strains the body and head. The method heading said knit the steel structure more closely together, increasing the tensile strength that there less danger heads shearing break- ing. using the more common upsetting process manufacturing cap screws which the body built upsetting, stock 0.340 in. diameter with mill tol- erances used for %-in. cap screw. Under the proc- ess described 0.370 in. stock used, and this reduced the threaded end 0.344 in. diameter. The fin- ished product held, screw with threads the inch, within 0.3479 in. maximum and 0.3455 in. mini- mum pitch diameter, allowing maximum tolerance 0.0024 in., including lead and angle errors. This American standard screw thread, Class fit, classifi- cation that includes the better grades interchange- able screw thread work for cap for automobiles. manufacturer claims that because holding the blanks very close limits possible keep within the above tolerances more easily than when screws are made the standard upsetting process. The cold- heading and drawing operations are performed standard cold-heading machines, the being equipped with eight these machines, supplied the Manville Machine Co., Waterbury, Conn. Trimmed Screws Pass Through Tumbling cating Machine After the combined upsetting and drawing opera- tion the secondary operations trimming the head into its hexagonal form, sizing and burnishing, point- ing, facing, shaving, threading and heat treating are performed the order named. The common thread- rolling process used making the threads. After trimming, the screws through combina- tion tumbling and lubricating machine that has series three rotating barrels. The screws are shoveled into loading skip with sawdust, which adheres the oil the work and aids taking off the rough edges during tumbling. While one lot going through the tumbling mill another lot being dumped into the skip. The tumbling barrel in. diameter in. long. Work tumbled for min. From the tumbling barrel the screws pass over revolving screen, through which the sawdust discharged, and from there second rotating section—a perforated metal barrel, in. The barrel extends into tank con- taining hot wax preparation through which the screws pass. The barrel then dumps the screws into small revolving barrel which the surplus lubricant drained off, and spiral the latter barrel discharges them into handling receptacle. The lubrication provides film the screws and takes the place oil that would required the siz- ing dies the screws themselves were not lubricated. All stock sizes pass through the tumbling and lubricat- ing machine and then are sized die punch press secure good fits wrenches having close toler- ances. The head forced through the die, which bur- nishes it, the same time bringing accurate size. Some the products made alloy steel are an- nealed after heading and before the secondary opera- The Iron Age, April 1928—937 ANNAAAAAAS ASS AAS 4 tions relieve strains. This done rotary-type annealing furnace. Screws Heat Treated Electric Furnace The heat treating, which the final operation, done 90-kw. three-phase 60-cycle 230-volt rotary, tilting, tray-type, automatic discharge, hardening fur- nace having capacity 900 lb. per hour. While the furnace does not differ materially from other furnaces this type, some its construction features are new. Screws 5/16 in. in. diameter are kept the furnace min., during which they make one rotation the hearth. The time cycle slightly increased for the larger sizes. The furnace can set for time range the rotation the hearth from min. The work carried through the furnace cast nickel-chrome trays, each having capacity lb. The screws are shoveled into the trays through the charging door, the trays usually carrying two layers work weighing about lb. The furnace divided into two zones, heating and soaking zone. temperature 1525 1550 deg. Fahr. maintained the soaking zone, and slightly lower temperature the heating zone. When tray completes its circuit the hearth, automatically dumped mechanism operated motor located top the furnace. The motor that operates the hearth located the back the furnace. The automatic electric control the two motors interlocked that the hearth makes one-twelfth complete circuit, bringing trap discharge position, stops. Then the tilting motor operates the lifting mechanism, causing the tray tilt and discharge its load. The hearth motor cannot again operate until the tilting motor returns the lifting mechanism its starting position and the timing mechanism has completed its cycle. The furnace has push button control and mag- netic starters. heating zone has separate Leeds Northrup temperature controller. The heating zone has non-in- dicating controller and the soaking zone recording controller. One thermocouple located the heating and second the soaking zone. The tempera ure control very close, the range being within deg. plus minus the temperature which the control set. having accurate control over the rate heating and the actual temperature readings there hardness the product. important new construction feature the fur roof can removed permit the PAPER No. 570 the Bureau Standards contains data the thermal expansion stainless iron secured Peter Hidnert and ney. Nine samples were investigated within the sketch shows the relation between change length and temperature for 0.09, 12.2 steel, which quite typical the group. Transformations are quite marked. will ob- erved that the coefficient expansion increases slight- with increasing temperature (that is, the curve turns upward); furthermore, that the expansion juite markedly lower than that for pure iron. 938—April 1928, The Iron Age rebuilding the hearth. When replacement the hearth necessary the roof raised unit means hoist. other types rotating furnaces the ro- tating member dropped into pit beneath when the hearth replaced. Access the furnace for minor repairs made through the charging door. Screws Passed Through Quenching Machine into Rust- Proofing Solution The screws are dumped from the furnace trays through chute into Greene quenching machine. This consists rectangular tank which motor- driven perforated drum revolves. One end merged the quenching liquid, and the other projects over the end the tank. The work slides down in- clined plate through the quenching medium into the drum, and the spiral the drum causes circulate through the medium and, the same time, elevates out the tank and discharges into rust-proofing solution. The screws are then ready for packing. Two quenching machines are provided, one for quenching water, which used for carbon steel screws, and the other for oil, which alloy screws are quenched. The oil quenching tank connected with oil cooling equipment, the oil being circulated coils through drum which water kept circulation. This has capacity for cooling 100 gal. oil per min. Cooling equipment was supplied the Griscom-Rus- sell Co., New York. The furnace made airtight possible, that air and moisture are kept out and the work passing through the chute the quenching tank exposed only moment the cooling action the air. Con- sequently oxidation held minimum. assure the accuracy the product now de- manded the automotive industry the company has just completed chemical and laboratory, and its manufacturing processes will closely tied with laboratory work. check will made all in- coming shipments steel make sure that the mate- rial conforms the specified analysis. Other checks will made during the various stages manufac- ture, and the finished product will tested for tensile strength and hardness. The products the company include cold-headed cap screws made carbon and various grades in. The plant equipment includes one the first l-in. heading machines built for cold upset work. Expansion Stainless / Af Af Jf , AA 4 aa 7 4 4 Tom Linear Thermal Expansion Stainless Steel Heating and Cooling Compared That Pure Iron . E 0.03 per cent arge Expansion Electric Drive Nearly 2,000,000 Hp. 1510 Mill Motors—Units Purchased 1927 Added Per Cent Horse- power HREE years ago (Feb. 12, 1925), page 488, and June 25, 1925, page 1880) THE published details regarding the extent installation elec- tric drives rolling mills the United States and Canada. This was based comprehensive tabular compilation made the Association Iron and Stee! Electrical Engineers. Data covering 1927 and the en- tire list the end that year have now been available. Present installations, analyzed THE IRON aggregate 1510 units total 1,949,800 hp. these, 116 motors 170,350 hp. were added 1927. The average. size the 1927 units was 1469 hp., while the average all units 1291 hp. motors under 300 hp. are covered the tabulation. Types Mills Showing Heaviest Use Bar and billet mills, with 242,175 hp. 152 units, lead the list. Merchant mills make close second, with 235,100 hp. 277 units. Strip and hoop mills have 217,355 hp. 150 units, while rail and structural mills with units aggregate 205,800 hp., and blooming mill units make total 200,500 hp. Other types mills are powered shown Table TABLE I—ELECTRIC DRIVI Total Equipment Type Mill Motors Ave blooming . ; 44 20 00 Bar and billet... 152 242,17 Sheet bar and skelp 165,000 Rail and structural.... 205,800 Strip and hoop 150 21% 14% Sheet and tin plate Loo SO St Rod Piercing Wire 23 { Cold roll Non-ferrous 210 Miscellaneous .. lo 12 ) Totals Averages. SIDNEY \ Growth the Application Electric Drive Main Rolls The dotted portions the yearly solid black, those 2000 4999 hp.; shaded, those 5000 hp. and over Shown Clearly Above. columns are motors 300 1999 hp.; Previously Employed KOON rs Total Horsepower All the Mill Motors the Principal Classes Mills, Showing Separately the Additions 1927 and the Two Preceding Years l' pon the Accumulated Totals of All Earlier Years MERICAN ROLLING MILLS Added i! Z4and el L926 and 7 1925-27 28.4 14 ] 72,050 oo. 72.1 70.040 1.84 40.7 13.700 2.730 80.7 2 99 71 0 2.639 0 14 208 18.2 1s 731 77.9 624 72.494 6 214 72.8 4.7 17 219.2 1s 18,8 671 63.6 (,42 21,750 oming mill 25,050 hp. made the largest gain 1927, five units. Rail and structural with units, added 22,000 hp., while ten bar and skelp mills for 20,800 Additions 1927 smaller than the preceding years, which saw 313 new motors aggregating 482,000 hp., average over 240,000 hp. year. Except for wire mills, how- » 16 types repre sented showed some ive sneet were addition during the year. Something the advance being made pro- duction seamless tubes shown the pierc- ing mills. With 17,300 hp. added, they showed gain more than per cent over the 33,300 hp. previously installed. The 1927 addition was almost equal the 17,450 hp. 1925, and was than the total all years preceding but 15,850 hp. The average size these mills increased from less than 800 hp., units installed prior 1925, more than 1900 hp. the 1925 additions and almost 2906 hp. the 1927 additions. While the total number motors advanced 1927 only per cent, the total horsepower rat- which was The Iron Age, April ] 927 2 1 [ = m= 4 ] TABLE II—LARGE MOTORS OPERATING ROLLING MILLS 5000 Hp. 2000 to Added in and 4999 Hp. 1925-26-27 Mill Motors Hp. Motors Hp. Hp. Per Cent Bar and billet... 15 90,500 21 60,900 46,550 44.4 Sheet bar and skelp 37,200 98,750 67,400 98.3 Rail and structural 86,000 81,000 54,500 48.4 Plate 40,500 64,650 15,850 17.8 Strip and hoop 72,150 50,700 137.2 Merchant 5,610 52,900 17,610 43.1 Sheet and tin plate 40,000 21,500 116.2 Rod 33,300 15,000 82.0 Piercing 29,000 31,500 1260.0 Miscellaneous con 2 4,000 4,000 TOUR, 68 419.810 219 593,300 395,860 64.1 Average size 6,174 2,709 3,503 21.5 14.5 20.4 19.6 11.7 27.1 ing increased about per cent and the average size motor installed 1927 was per cent greater than the average previous installation. This gain shows particular the largest size units. 1927 there were installed motors 3000 hp. and more operate American rolling mills. This com- pares with 138 service the end 1926 and repre- TABLE SIZES MILL DRIVES 1924 and 1925, 1926 Total Earlier and 1927 Per Motors Hp. Motors Hp. Motors Hp. Added 300 499 hp. 375 133,325 307 108,155 25,170 23.3 500 999 488 314,750 224,750 137 90,000 40.0 1000 359 486,545 261 355,930 130,615 36.7 2999 127 278,120 162,770 70.9 3000 4999 317,250 200,050 58.6 5000 andover 419,810 256,500 163,310 63.7 1,949,800 416 641,645 49.0 sents increase over 16% per cent number. motors under 3000 hp., there were added 1927 the 1256 previously use, representing gain not quite per cent, less than half the rate gain the heavier motors. Horsepower added 1925, 1926 and 1927, the list units 2000 hp. and over, added 64.1 per cent the aggregate power existing those units the end 1924. Additions the smaller units represented only 35.7 per cent the earlier installed horsepower. Diagrams and tables show the principal character- istics the motors, both total driving force for American rolling mills and regards distribution ac- cording size, type mill and other particulars. Warns Against Quickly Applied Chromium Plating From Ten Minutes Twenty Hours Required Make Satisfactory Sur- face Depending Upon Expected Duty and Character Underlying Metal meeting the Chicago section the Ameri- Society Mechanical Engineers, held March 14, Dr. Becker, chief research chemist Vacuum Can Co., read paper “The Relation Chromium Plating Industries and the Truth About Its Value and Application.” After recounting the history the metal and describing the rapid increase interest plating experiments during the past four years, the speaker emphasized that slight variations the chemicals the solutions any other factor relating deposition create distinct variations the properties the plate. Rule Thumb Inadequate “The man who can chromium plate few steel golf heads will dispute this and min. explain all the factors which thinks have produced the result, but ask him plate golf heads that not only look pretty but will stand hard service, quantity run and reasonable cost, and then must either deal with exact science grope the dark. the ama- teur should asked chromium plate golf heads different shape made different metal plate entirely different article for different kind ser- vice will find himself completely lost. “Any intelligent, careful and systematic workman can successfully chromium plate particular types articles the highest standard quality, but when and only when furnished complete detailed in- structions. “Decorative chromium plating may adapted all instances where beauty appearance and easy cleaning desired, but unless real plate and the first place the base metal determines the thickness chromium plate which should applied. urally decorative coat not subjected wear need not very heavy, provided, however, that such plate produced from solution which will give coherent and homogeneous plate. Otherwise such plate worse than none and will hasten instead retard corrosion. “When considered that good chromium sola- tions have higher efficiency than per cent, that there are many with efficiency low per cent, and further that the deposit chromium from ex- cellent chromium solution only about 0.00025 in. thick from 150 amp. current density per square foot hr. plating time, you will realize how little metal 1928, The Iron Age and how thin plate you receive from the average plater, who considers sec. min. plating time sufficient for chromium plating radiator shell, re- flector plumbing fixture. Such plate less than millionths inch thick and, though nice appearance immediately after plating, will last but very short time. Thickness Decorative Coatings chromium plate, consider necessary that such pieces should the solution about min., which will result plate about ten-thousandths inch thick, provided highly efficient chromium solu- tion used. metal has homogeneous ad- herent and continuous nickel plate (as the case steel) copper copper-and-nickel plate, chromium thousandths “Articles which have withstand abrasion and cor- rosion, like plumbing fixtures and valves, should treated entirely differently. chromium applied directly brass bronze fixtures, hr. plating time recommended. such fixtures are first nickel plated, min. should the minimum, resulting chromium. “The average nickel plating not adapted base for chromium plating. has been pointed out that chromium plating has tendency raise and make the nickel plating peel, but this occurs only when the nickel plating not adherent. great deal nickel plating will stand buffing and give good appearance, though does not adhere the base metal, and such layer may withstand sec. chromium solu- tion, but will peel and blister immersed longer than this period. This the reason why only flash-coat, taking less than minute, often given platers. “Where chromium applied for wear, bear- ings, shafts, rollers, plungers, pistons valves, spe- cial solutions are necessary which give the desired and demanded