The Iron Age 1928-04-12: Vol 121 Iss 15

THE IRON AGE New York, April 12, 1928 ESTABLISHED 1855 VOL. 121, No. New Method Making Cast Pipe Hand Labor Eliminated McWane Mechanical Process—Unique Multiple-Lip Ladle Pours Metal—Conveyors and Cranes Handle Materials—Plant Scheduled Like Rolling SIGNIFICANT departure pipe foundry prac- tice back the recent announcement the McWane Cast Iron Pipe Co. that the new me- chanically operated unit its Birmingham, Ala., foun- dries, which went into production Jan. 1928, was placed double shift basis March Essentially, the new process making cast iron pipe the McWane plant involves the substitution mechanical equipment for hand labor. The same oper- ations that were formerly used are still employed, but machines and mechanical devices, said, effect far greater economy and rapidity output than was ever possible with the old manual methods. This new process embodies features continuous operation and flexibility output that have hereto- fore been unknown the manufacture cast iron pipe. still retains, however, the former McWane features casting pipe in. and larger 16-ft. lengths, horizontally, green sand molds with green sand cores. This former method was based pat- Fig. 1—After the Pipe Mold Placed Special Jolt Ramming Machine, Filled with Green Sand. Notice the belt conveyor supplying sand the service bins 999 | ‘ | | a | Fig. Fig. When the Jolt Ramming Machine Has Finished Its Work, Ramming the Mold Completed with Pneumatic Rammers. This shows four workmen the mold, which, this instance, held four 16-ft. 3—Here Shown Core Machine Making the Last Core Set Four. quartet will picked overhead crane 12, 1928, The Iron Age lengths 8-in. pipe and immediately set waiting flask When completed, the Mm) i a Fig. 4—The Method Setting Cores Graphically Shown the Left This Photograph. Notice the two gages. These indicate how the cores shall adjusted the flask prevent sagging float- ing before and the molten iron en- ters the mold. the right, com- pleted mold looks when ready transferred the casting zone. both instances very good idea can gained the numerous gates which make possible pour two pipes few seconds, with the molten iron traveling minimum dis- tance from the ladle its final rest- ing place the mold Fig. (Below)—This Gives Excel- lent View One the Large Mul- tiple-Lip Ladles, Which Pours from Spouts Once. Two pipes are cast the same time this process. the background, the right, can seen one the shake-out machines The Iron Age, April 12, = | j 7 y H 4 = = j ented device for holding long cores central mold without chaplets. Schedule Production Like Rolling Mill The layout the new foundry unit interesting mainly that permits continuous operation all factors used this mechanical process making pipe. Instead certain number molds being prepared and the molten iron subsequently poured into them, ramming, core-making and core-setting, pouring, shak- ing out, core bar pulling—and the return the flasks, sand and core bars for immediate re-use—are simul- taneous operations. Perhaps the most outstanding feature this new the equipment this unit the McWane plant de- signed make pipe from in. diameter. Molds and Cores Handled Cranes Overhead cranes play important part the Mc- Wane process. One them handles the copes and drags the assembling zone, where from one six cores are set simultaneously. These cores are made special 16-ft. core machine, shown Fig. Another such crane picks the cores from the de- vice upon which they have been placed the core- making machine and sets them the drags. This sec- ond crane, after the flasks are closed, carries them completed form the casting and shake-out zone. Fig. 6—Here Shown One the Large Rattlers Which Included the Finishing Process the Plant. This machine capable handling approximately 6-in. diameter lengths 16-ft. pipe process that, instead certain division classes and sizes pipe making equipment arbitrarily fixing the relative output each day’s work, the entire me- chanical unit the McWane plant runs given size, the case rolling mill. Thus orders—and not the proportion plant equipment for given sizes pipe—determine the scheduling production. Sand Handling All Done Conveyors Molding sand used the McWane mechanical proc- ess handled entirely conveyor equipment. After the sand leaves the shake-out machines, carried reconditioning equipment consisting screen, pug mill, blender, storage bins and conditioner. Then belt con- veyor, which runs underground the foundry, returns service bins above and behind jolt rammers. When mold placed rammer, the sand discharged directly into it. This shown Fig. Then comes the jolt ramming operation, which fin- ished off with manual pneumatic rammers shown Fig. Any surplus sand that may have been dis- charged the rammer from the service bin shov- eled floor gratings immediately front the rammer. From there falls clean-up conveying system beneath the floor the foundry and is, this manner, restored service. The output each mold from one six 16-ft. lengths pipe, depending upon the pipe diameter. All 12, 1928, The Iron Age Throughout the process, these cranes keep from one six molds ahead the pouring ladles. Metal Poured Multiple-lip ladles, shown Fig. are employed entirely. Each these large ladles equipped with spouts and capable pouring two 6-in. two 8-in. pipes the same time. previously stated, the number lengths pipe mold varies with the size being cast. third overhead crane handles the ladles and, when this job completed, places the molds car which immediately carries them runway leading the core bar pulling machine. Another duty the third crane place the copes and drags the shake-out ma- chines. One these machines can seen the back- ground Fig. Following the shake-out operation, the endless con- veyor system recaptures the sand used the molding and smaller wall crane runs the flasks back storage near the jolt rammers. Then the entire process repeated. After they have been removed from the molds, the lengths pipe, with the core bars them, are con- veyed the core bar pulling machine. This interesting device extracts the core bars few seconds, and the pipe then rolled the tumbling mills. Here rattled with small steel stars. One the large rat- Multiple-Lip Ladles J | tlers, which capable handling lengths 16-ft. pipe, shown Fig. After leaving the rattlers, the pipe passes through the regular foundry routine chipping, inspection, hydrostatic testing and, finally, coating—when required. Thenceforth the pipe lengths pass either directly the shipping yard or, they are special McWane types that are equipped with joints, they are di- verted the joint-making department for insertion the pre-calked lead-and-jute joints. for high- pressure gas air service, the pipe threaded, male and female, the spigot and the bell ends respectively. should borne mind that the McWane pipe specifications are the modern weights ness, which factors have been determined subjecting the product, thus cast green sand with green sand cores, tensile and transverse tests and tests destruction. this manner the weights and dimensions the various classes pipe made the new McWane process are fixed guarantee the service require- ments older specifications, for both water and gas. Canteens Placed Handy Locations Large Plant Budd Body Factory Serves Five Million Orders Yearly Five Cents Each—Everything From Cup Coffee Full Meal efficient yet highly specialized lunch system functioning successfully the Edward Budd Mfg. Co.’s automobile body plant Philadelphia. Last year supplied employees with over 5,000,000 food orders. Each one sold the standard charge for everything served. The method dis- pensing food haps best described out the various plant buildings, conven- ient locations, are service stations canteens, all which are supplied from central kitchen. shown the illustra- tion, each wire cage, similar the modern tool crib, about 6x12 ft. area, equipped with shelves, counter, cash register and gas stoves. The latter are used only keep foods hot. these canteens 7000 persons may served with one more food orders very short space time, easily, satisfactorily and economically. the noon hour the men line their respective stations, give their orders, pay for them and are quickly served. all done rapidly that there hardly any waiting, and the patrons obtain good, substantial food low price. Rapid service means that when the whistle blows the men not need make wild dash for good place line; furthermore, they are able take full advantage their lunch hour for eat- ing, rest recreation. This unit cafeteria plan has now proved its use- fulness over several years the Budd plant, and has been found provide, among other things, the follow- ing distinct advantages: supplies good food low prices, thus conserving and even improving the health the workmen. uses with economy limited amount valuable floor gives quick service all during one lunch hour, thus Canteen Brings Lunch and Supper the Men BARE MORE insuring proper rest and avoiding the necessity staggering the working periods prevent overcrowding central lunch room. production, well convenience the employees. None these ad- vantages could ob- tained, however, were the system lacking popularity among the employees. insure this popularity the needs and desires the patrons are close- studied, their tastes analyzed their wants anticipated. With every food order priced 5c. there wide variety from soup ice-cream. man can supplement the contents his lunch box with sin- gle order hot soup does not carry “nose-bag,” can get well balanced meal. Since the Budd company’s canteens sold over 5,000,000 or- ders last year, stands reason that the system must highly thought the employees, else would not well patronized. glance the records the commissary depart- ment shows that the canteens used tons bread last year, tons sugar, 60,000 qt. cream, about 700,- 000 orders pie, close 80,000 gal. coffee and 40,000 gal. soup. Sandwiches, course, lead all food orders, over million having been sold during 1927. The above figures apply only lunches served the shop. addition this, the Budd company main- tains restaurant for office employees,-where some 000 meals are served annually. For many years past, business organizations have found that pays and pays well provide luncheons for their employees, even when the actual food cost considerably higher than the prices charged. Whether this end can served building central cafeteria, subsidizing restaurant neighboring ground installing central kitchen and number can- The Iron Age, April 12, 7 teens, such described herein, matter de- termined analysis the individual circumstances. Where the operations are spread over large floor areas, the canteen will usually found appeal the work- men. returns dividends time saved, better health, and therefore better and more efficient production, and direct factor preserving morale and good will. least this has been the result the Budd plant. has also been found that the curse has been taken from overtime night work the willingness sup- ply appetizing supper short notice. matter fact, service this kind refused, irrespective the cost, corresponding benefit accrues men and production management. New Drive for Three-High Plate Mills Driving Center Roll High Speed Gives Large Torque with Increased Flywheel Stored Energy MAJ. JOHNSTONE TAYLOR ROLLING mill slip drive designed and built Duncan Stewart Co., Glasgow, Scotland, stated possess several advantages. Its ar- rangement shown the accompanying diagram. has been existence for some time two-high reversing plate mills, both roughing and finishing stands, and now being applied three-high mills, where would appear have great possibilities. will seen that the customary pinions and pinion housing have been eliminated. Their place taken light nest gears between the flywheel and the mill spindles. the usual type pinions may cost $20,000 30-in. mill, the saving first cost and renewals important. The torque applied the center roll, which hitherto has not been driven. this method possible speed the flywheel about per cent with the same rolling speed, resulting great increase momentary mill power without increasing the size the mill motor the weight the flywheel. recent installation ton flywheel proved equivalent value the previous 150-ton unit, due the greater revolutions for the same rolling speed. The addition the plant involves but new pair machine-cut double helical gears and new middle roll having larger necks and chocks. Thus for quite small outlay existing mill can given something like per cent increased mill torque. addition, the end the new middle roll can made suitable for the uni- versal coupling box the driving spindle, while the top and bottom existing rolls can made take the new attachment. addition there being per cent added mo- mentary power, the rolling power consumption re- luced well below the original amount, due the smaller diameter the middle roll. there in- creased size slabs, there may need for the in- creased diameter roll necks, though the increase power, known, rises more quickly than the in- crease roll speed. Only mill provided with slip drive can make use this method for operating three-high mill. posi- tive connection between the upper and lower rolls when producing finished plate inadmissible. the fin- ishing stands reversing plate mill the upper roll not driven, with the result that many rolls are broken, due shock, though little damage done the plate; but both were driven, thin plates would torn pieces. With this new equipment every roll driven and under full control. The top and bottom rolls are each driven through slip drive, which permits them adapt themselves the central driven roll speed. The result much more powerful machine, its total en- ergy increased, its speed drop negligible, while the increased flywheel energy and reduced mill torque in- sure steady running reason the lessened demand from the flywheel. The Cincinnati chapter the American Society for Steel Treating held its monthly meeting April the Cincinnati Milling Machine Co.’s plant. After in- spection the plant, the members listened short talk “Austenite” Stenger the Queen City Steel Treating Co., and informal presentation electric methods heat treating, normalizing, carburiz- ing, hardening and drawing Stanley Binns the Cincinnati Milling Machine Co. film showing meth- ods electric heating concluded the program. the Torque the Drive Applied the Center Roll, Heretofore Not Driven, the Fly- wheel May Speeded Per Cent, Giving Smoother Opera- tion 12, 1928, The Age Does Price Cutting Help the Buyer? Destructive Competition Inimical Interests Purchaser and Seller Alike, Says Charles Abbott Address New England Purchasing Agents’ Association OES price cutting work out the buyer’s in- terest?” was the theme address de- livered before the New England Purchasing Agents’ Association Boston April Charles Abbott, executive director American Institute Steel Construction, who has been speaking throughout the country business organizations the necessity curbing price cutting means securing ade- quate profits for industry. “In the long run, buyer and seller alike will adversely affected any influence which undermines the stability the other,” said Mr. Abbott. “The best assurance for the consistent prosperity and progress both, and American business whole, lies active cooperation foster constructive influences and stamp out those, such price cutting, which are re- sponsible for destructive competition that menaces the welfare all concerned. “Formerly, periods active business, practically all organizations except the markedly inefficient could depend upon enjoying share the general prosperity. Today this situation does not hold. Considered from most angles, the last few years have been prosperous. Wages have been good, the purchasing power the public has been high level, and the volume sales has been satisfactory. Why, then, did average 2000 business failures month all through 1927? Why find adequate profits monopolized comparatively small number organizations while the rank and file struggle along welter red ink figures, passed dividends and complaints about profitless prosperity? “Much the responsibility for these situations,” Mr. Abbott continued, “can placed squarely upon the selfish desire obtain all the business sight. Busi- ness men seem have lost all sense proportion wild scramble attain volume any price. The idea seems keep your competitor from getting any business all. Greed for volume, without due attention costs and profits, leads directly price cutting. Price cutting leads directly rancorous, cut- throat competition and obliteration all semblance salesmanship. Price Cutting Vicious Circle “In number our key industries there actually severe depression due largely the practice slash- ing prices meet the terms competitors who are expert slashers themselves. The whole thing vicious circle, and, the tendency continues its present rate, threatens bring trade prostration the worst kind. “The aggregate net income 385 important rail- road, industrial and utility corporations was $2,467,- 000,000 1927 compared with $2,570,000,000 1926. The decline amounted more than per cent. Forty- one the important industrial concerns reporting showed either decrease per cent more net income compared with 1926 showed deficit compared with net profit 1926. six out the industries listed, lower prices given one the basic causes the shrinkage. “The predicament which the seller finds himself result inadequate prices exceedingly un- comfortable one, but there any reason why the buyer should particularly worried about the price-cutting activities the organizations from which buys? these organizations want commit suicide sup- plying him with materials less than cost, there any reason why should concerned? there any reason why should not take the fullest possible ad- vantage buyer’s market while such market “The old-fashioned purchasing agent would have answered ‘no’ both these questions without the slightest hesitation. Practically his sole concern was with price. His tactics were limited question and protest. The first question put the salesman invariably was ‘What’s your price?’ The form the protest was equally invariable: ‘Too much. home and sharpen your pencil. Then come back and maybe can talk business.’ “The Bell Telephone System was one the first large organizations the country lift some the emphasis from price and place those other factors where belonged. Price remained important, but even more consideration was given the twin elements quality and service. “The advantages the shift quickly became apparent that number other organizations fell into line. Their purchasing agents were lifted from their former positions official hagglers, and were turned into purchasing engineers whose duties include the study fundamental factors that control price move- ments and underlie the production raw and semi- finished materials. Many Purchases Made Solely Price Basis “Marked progress has been made the right direc- tion, but there still plenty room for more. though growing number concerns are replacing the haggler with the purchasing engineer, there are innumerable organizations throughout the country where the haggler still reigns supreme and where the purchase made almost solely upon price basis. “No one will attempt condone the actions the price-cutter. must admitted, however, that the buyer frequently guilty what might called pur- chaser profiteering, contrast the seller profiteering that experience when demand abnormally high and supplies are short. “Purchaser profiteering usually takes the form jockeying one seller against another force down the price. Each seller, turn, told that the buyer would like give him the business, but that another bidder’s price lower. The bids are progressively forced down until the man who receives the contract obtains only losing figure. the practice continues over period months years, all transactions are com- pleted losing prices and the industry involved headed for the rocks. “As you know, the National Association Purchas- ing Agents has strongly condemned the subterfuge pitting one seller against another. The seller is, course, blame for being too weak-kneed look the order the face and say ‘no,’ when fully aware that will almost certainly entail loss. Neverthe- The Iron Age, April 12, 1928—1005 less, the interest the buyer cooperate with him eliminating this and other forms the price cutting evil which the present time proving heavy handicap the prosperity industry. “In the first place, quality and service inevitably suffer when the price cut below the line reason- able profit. The seller almost irresistibly tempted resort substitute materials inferior workman- ship. Deliveries lag. The seller tries every possible way repair the mistake made when submitted price based, not fair profit upon the transaction, but upon the vicious system trying beat out competition. “The buyer does not receive what ordered. receives exactly what pays for—no more and less. the end pays price much greater than one based upon cost plus fair profit, while the seller makes another red entry that brings him nearer bankruptcy. “Sometimes, true, the buyer penalty. Then the ultimate consumer who pays. But business this kind built foundation sand. can never permanent. Quality, reputation, good will, and all the other business building assets must thrown overboard for the sake quick sale price basis. “The maintenance his source supply another factor that makes fair profit for the seller about important for the buyer for the seller himself. The wise buyer realizes that unless those who supply him with essential materials are able make reasonable profit they will either forced out business alto- gether, will turn the production other materials the manufacture which they can employ their capital and brains better advantage. Sheet Steel Industry was Losing Ton “About year ago was reported that the producers sheet steel were losing average over ton every ton sheets turned out their plants. Think it! There industry, well established, with heavy investments plant and machinery, and supplying essential commodity. Business conditions were generally good throughout the country. The mar- ket for sheet steel was expanding. Yet the sheet mills were not only unable operate profit; they were forced operate loss. Price cutting was almost wholly responsible for this condition. large part the product the sheet steel manufacturers used automobiles. The automobile industry very nearly dependent upon the sheet steel automobile without steel body. the sheet steel industry were forced out existence, its efficiency were materially reduced, the automobile manufacturers would suffer irreparable injury. “The automobile manufacturers, however, did not hesitate take advantage opportunities obtain quotations below the cost production. This attitude, coupled with the weakness the sheet people, re- sulted utter price demoralization that shook the stability the entire sheet steel industry. Fortunately, the automobile manufacturers appear have realized the suicidal nature their policy, and they have an- nounced that they are willing pay fair price they can assured that the first price quoted will the last. “That incident itself adds tremendous weight the argument for the one-price policy opposed the horse-trading methods involved price cutting. Does Buyer Secure Real Advantage from Cut Price? “All that have said about the admitted disad- vantages price cutting, from both the buyer’s and the seller’s point view, might offset the eyes the buyer if, result price cutting, were able secure materials lower cost than his com- petitor. There question but that the success concern vitally affected the price which able obtain raw semi-finished materials. “Before possible prove that price cutting thoroughly inimical the interests all concerned, necessary show that the practice cannot give the buyer advantage over his competitors. Such demonstration not difficult. even possible show that obtaining price concession which may appear afford such advantage, the buyer has reality handicapped himself meeting competition. “Granting that sometimes possible keep price concession secret, nevertheless true that the salesman who offers one buyer cut rate will offer his competitor the same cut whenever necessary order obtain the business. Who profits then? concern will possess any advantage over the other. But, you may say, each concern has wider margin between its costs and its sales price. “The trouble that seldom works out that way. One the concerns the industry practically cer- tain use the cut price has been able obtain materials cut its own price. Other organizations will have follow suit. Price cutting that started intermediate industry transferred the buyer’s own industry. The final result lowered prices for all. “The buyer must recognize the essential nature the function performed the seller and the threat the well-being both buyer and seller which price cutting, with its constant seepage profits, inevitably entails. The seller must recognize that expects the buyer pay him fair profit, owes the buyer cut his costs the lowest possible level con- sistent with good quality and good service.” 250 200 150 100 Monthly Gross Orders for Ma- chine Tools Shows Upward Trend INDEX NUMBERS (Average Monthly Ship- ments From Data Compiled 1928 Machine Tool Builders Association 1006—April 12, 1928, The Iron Age Intricate Spun-Sorbitic Castings Produced Great Britain New Process—Have High Strength, Machinability and Wear Resistance—Useful for En- gine Cylinders and Pistons All Kinds HURST* has been extensively applied the production cylindrical castings cast iron, such piston ring drums, cylinder barrels for pump and motor en- gines, and sleeve valves. Great Britain today ap- proximately all the piston rings used automobiles are produced from centrifugal castings. the past few years the centrifugal process Desirable Structure Resist Wear generally accepted internal combustion en- gine designers that the best material withstand the wear and heat conditions which the cylinder liner subjected has the lowest silicon and total carbon con- tents compatible with commercial machinability and soundness. the ordinary centrifugal process the sil- icon must have fairly high values. has been established connection with the lower- carbon alloys—steels—that the sorbitic condition one which highly resistant wear. reasonable expect that this structure will accompanied sim- ilar results cast iron. the tensile strength can taken index the resistance wear cast iron, will seen from the typical results quoted below for iron that this conclusion amply justified. r Structure Casting, Magnified 200 Diameters well known metallurgists, the struc- ture one the intermediate structures between the hard unmachinable martensite which occurs quenched iron-carbon alloys, and the pearlite which occurs these alloys when slowly cooled. The “spun-sorbitic” process, now operation Thorncliffe Ironworks, near Sheffield, England, spe- cial improvement (for which patents have been ap- plied) certain details the Hurst-Ball centrifugal casting process, described THE IRON AGE, June 11, 1925, page 1704. devised that the cooling *Newton, Chambers Co., Ltd., Thorncliffe Ironworks, Sheffield, England. the casting under close control while rotating the machine, and the result that the combined carbon the alloy retained the sorbitic condition. Such con- trol the cooling rate also enables adjust the silicon according the mass, radial thickness and other chemical elements present, would done sand casting, and permits equally low silicon contents. typical chemical composition, taken from series piston valve liners, given below: Per Cent Total carbon 3.00 Combined carbon . ‘os 0.97 Graphite .... 2.03 Silicon .... 1.31 Manganese ...... 0.42 0.11 Two tensile strength determinations made after the Half-Ton Diesel Engine Liner, and Locomotive Cylinder Liner Cast and After Machining manner laid down the British Engineering Standards Association Specification No. 5004 are follows: 28.9 tons per sq. in. (64,800 Ib. per sq. in.) 26.4 tons per sq. in. (59,200 Ib. per sq. in.) These test results are obtained from test rings ma- chined from the actual castings, being impossible cast separate test bars the centrifugal method. The above tests therefore represent the actual strength the castings. The microstructure illustrated demonstrates the sor- bitic character this material. has been etched picric acid and photographed 200 diameters. Small areas pearlite, with the laminations accurately focused, may observed, but the bulk the gray- toned ground mass entirely too fine structure resolved. definitely sorbitic constituent. Intricate Castings Made One feature the newly developed spun-sorbitic process that larger and more intricate castings may made. This extends the centrifugal casting process the production the larger cylinders required The Iron Age, April 12, | | j ‘ heavy gas, oil and Diesel engines, piston valve liners for locomotive and steam engines operating high degrees superheat, and similar cylindrical castings more intricate type. Typical examples spun-sorbitic castings are illustrated. The view shows cylinder liner weighing about half ton for internal com- bustion engine and piston valve liner both before and after machining. These castings are greater intricacy than the simple cylindrical forms hitherto produced. The heavy flange, with the cored-out waterway passages, the ribs, besses and belts are clearly shown the cylinder liner casting and the ports the piston valve liners have all been produced cores inserted the rotating molds. These products have the characteristics cen- trifugal castings, ordinarily understood, being close grain and free from internal defects, well being correct microstructure and external form. The rapid development motor transport during recent years has been reflected the greatly increased annual mileage done automobile engines. This fact has drawn attention the wear the engine cylinders. realized that the generally accepted monobloc cylinder design, the primary consideration deter- mining the character the cast iron the production sound castings free from defects. The resistance wear the material secondary nature only. Un- der these circumstances increasing attention being paid the construction automobile engine cylinders inserting previously machined cylinder barrel liner into water jacket casing. This exactly the same method cylinder construction adopted al- lows the use cylinder barrels material specially de- signed withstand the wear conditions, and this forms additional application the spun-sorbitic process great promise. the heavier internal combustion engine design. Smaller Use Pig Iron Open-Hearth Furnaces Charge Proportioning Affected Price Ratio Between Iron and Scrap Shows Close Watching Markets the proportion pig iron and scrap used open-hearth charges the first quarter 1928 indicate that the pig iron constituted under per cent the charge and scrap over per cent. The fact that steel ingots the first quarter the year made new high record tonnage, whereas the output pig iron was more than per cent be- low high record and was exceeded nine previous suggested inquiry into the situation. This study has covered the first quarters six sepa- rate years—1928, 1925, 1923, 1920, 1917 and 1913. Without going into details year year, the figures n7 z 50 Qa c lu 4 7 + A Zz V.00 w , 2 4 f\ 1920 1923 1925 1928 Close Parallelism Shown Between the Calculated Percentages Pig Iron Used Open-Hearth Fur- naces and the Ratio Scrap Prices Those Pig Tron for 1928 may analyzed show the method ap- Total ingot output placed 12,644,000 tons. this amount, Bessemer steel accounted for 1,644,000 tons, open-hearth steel for 10,900,000 tons, and crucible ind electric steel for about 100,000 tons. Steel-making iron the quarter aggregated 7,018,000 tons. this the Bessemer converter absorbed 1,770,000 tons, the basis per cent loss conversion, with per cent the ingot tonnage made use scrap. This left 5,248,000 tons used the open-hearth fur- nace. Castings have averaged recently 2.8 per cent the total steel output. this basis, 148,000 tons the steel-making iron may assigned castings. There left for open-hearth steel ingots total 12, 1928, The Iron Age 5,100,000 tons steel-making iron. assume per cent conversion loss from this iron, most which, course, loss weight through oxidation metalloids, the amount pig iron represented the ingots was 4,692,000 tons. Figuring per cent conversion loss account the scrap used the open-hearth furnace, find total scrap consumption 6,439,000 tons indicated. Adding this the steel-making iron going into the ingots gives total charge 11,539,000 tons, which 539,000 tons, 4.7 per cent, represents the total loss conversion. the total charge, pig iron represented little under per cent and scrap little over per cent. Similar figures for the five other years’ study show pig iron maximum 1925, when the cost scrap with relation the cost pig iron was considerably higher than 1928, and minimum 1917, when the cost scrap. with relation pig iron, was consider- CHARACTERISTICS FIRST QUARTER-YEARS Open-Hearth Charge Prices Components Price Pig Iron Serap Pig Iron Ratio 192s 44.3% 55.7% $18.59 $13.69 0.736 1925 54.1 45.9 23.35 18.42 0.789 1923 51.6 48.4 28.76 22.16 0.770 920 47.7 52.3 41.42 25.54 0.617 1917 40.2 59.8 32.87 22.23 0.678 48.5 51.5 17.45 3.39 0.767 ably lower than 1928. Other years showed varying percentages pig iron used the charge, indi- cated the diagram. Alongside the curve iron the charge the curve price ratios the two com- modities. establishing the price ratio the average heavy melting steel Chicago, Pittsburgh and Philadelphia was placed against average three steel-making pig iron prices—Bessemer iron Pittsburgh and basic iron Valley furnace and eastern Pennsylvania. The scrap average was $13.69 1928—the lowest the entire list, except for the $13.39 1913. Similarly, the pig iron average $18.59 1928 was lowest, with the exception the $17.45 1913. The ratio between the two 1928 was 0.736 (scrap price divided pig iron price) which compares with maximum 0.789 1925 and minimum 0.617 1920. The table gives these ratios and prices, alongside the calculated percentages pig iron and scrap the charges year year. ‘ ‘ PRICE RATIO i | = s . ‘ : Useful Copper Alloys, Old and New High-Copper Brasses Needed Resist Corrosion Cracking—Copper Hardened with Silicon and Manganese Nickel Has Strength Mild Steel—Copper-Nickel Alloys Favored for Quality Hardware WILLIAM BASSETT every article made from sheet cop- made mass production methods. Faulty material disturbs the orderly sequence opera- tions and, addition, requires expensive inspection and unbearable rejection finished product. Rolled and Drawn Copper Requires Rigid Control Ingot Metal Modern electrolytic refineries have their methods well under control that the product meets all require- ments properly fire-refined and cast. The “if” this case important. necessary that the melted should saturated with oxide dispose sulphur and that the copper should then poled the proper pitch set. Sometimes these operations are slighted; the result that the rolling mill produces seamy slivered sheets strips. The condition the molds, their temperature, and the temperature the metal are all important good copper cakes, wedges wire bars. Cracked and burned molds leave rough places and porous spots. Molds which are out shape cracked make shrinkage eracks which gap open when hot-rolled. Dampness means porosity. Drops oil mean porous honey- combed areas. Poor irregular dressing means mold wash the castings. Cold copper slow pouring means cold sets. “Low set” copper means high mill scrap and trouble subsequent processing. produces shrink holes, which change the sheet mill blisters and slivers. High oxygen may increase tensile strength slight degree, but decreases toughness, perfection sur- face and, some extent, resistance corrosion. Oxygen copper not solid solution. The oxygen eutectic separates between the large bladed crystals and the source the dark dull patterns pol- ished copper sheets. These matters were carefully and thoroughly worked out years ago, and the experience which has followed confirms the wisdom the conclu- sions then arrived at. High Copper Alloys Not Season-Crack Dezincify Yellow brass does not easily corrode, but when used engineering work and exposed outside atmosphere has two bad habits: One season corrosion crack- ing, and the other dezincification. Experience shows that brass which season-cracks also dezincifies the presence slowly acting corroding agents. The oppo- site statement, that brass which will not dezincify will not readily season-crack, likewise true. have observed season-cracking mospheric corrosion the seashore brass containing per cent copper, and have -also observed de- zincification the same composition. have never observed either season-cracking dezincification brass containing per cent copper and, consequently, are the opinion that per cent copper brass actually solid solution zine copper all tempera- tures, and behaves all respects believe solid *Technical superintendent and metallurgist American Brass Waterbury, Conn. This condensed version informal after-dinner talk the Institute Metals, Feb. 22, 1928. solution should. evidently best not approach too nearly saturated solid solution. Perhaps under the extreme conditions internal stress and corrosive attack, all metals are subject the intercrystalline fracture which know Copper when extremely hard-drawn will not season-crack when attacked mercurous nitrate ammonia. But the effect the corona discharge from high tension conductors the atmosphere pro- duces compounds which, absorbed moisture and held fibrous material long contact with very hard- drawn copper, may produce such cracking. Long ex- posure moist ammonia salts may bring about crack- ing 80:20 brass under severe internal stress. Condi- tions this kind are seldom met actual service that, spite the misgivings some engineers the reliability alloys containing any zine whatever, the low red brasses are good engineering materials and safe under atmospheric aqueous conditions. Bronzes are somewhat less corrosion-resistant than the red brasses, and are more subject the stress cor- rosion fracture. The length service expected from brass pipe has been questioned. Nearly always the pipe will out- last the building which installed. some dis- tricts the water supply such that dezincification has been set the Muntz metal pipe (60:40) commonly supplied, and this account number the manu- facturers are supplying standard alloy containing per cent copper. Red brass (85 per cent copper) being used where the water supply known par- ticularly corrosive character, and this alloy ad- vocated some metallurgists, including the speaker, for general purpose material, and being used increasing volume. have recently heard the use compressed ammonia gas for testing water pipe in- stallations. brass would stand it, but course yellow brass cracked badly. Various Forms Hardened Copper Several new copper alloys not subject stress cor- rosion have recently been proposed and seem particu- larly adapted new uses engineering construction, since they have greater strength and rigidity than pos- sessed the older copper alloys. desire speak particularly the copper-silicon alloys. 1905 Sperry proposed the use copper-silicon alloys for springs and for other purposes for which the copper-tin bronzes were used, since sili- con about two and one-half times effective tin for strengthening copper. But one succeeded ar- riving practical alloy containing more than small fraction per cent silicon. “Silicon bronze” has been made for considerable time, but this was merely copper-tin bronze fluxed deoxidized with silicon, and generally contained only per cent tin. May 26, 1925, Charles Jacobs patented alloy silicon and manganese with copper. This al- loy was called “everdur” and the formula copper, 94.4 per cent; silicon, 4.5 per cent, and manganese, 1.1 per cent, when used for making castings. Copper, per cent; silicon, per cent, and manganese, per cent, the analysis when rolled drawn. The Iron Age, April 12, 1928—1009 | particularly corrosion-resistant hydrochloric acid and chlorides. readily cast sand molds and takes the place gun-metal and bronzes. can easily hot-rolled, cold-rolled forged. can drawn, spun worked the same other ductile metals. Its physical properties the wrought form are similar those mild steel, and excellent engineer- ing material. makes excellent bolts and rivets and may either hot cold-headed. Another silicon alloy the hardened copper pat- ented Corson this year. has the approximate Copper, per cent; nickel, per cent; and silicon, per cent. The nickel silicide solid solu- tion copper and above 750 deg. The alloy may readily hot-rolled forged, and ductile and easily wrought cold-working when quenched from tempera- tures above 750 deg. When this silicide solid solu- tion heated just below red heat the nickel icide precipitated and the material becomes hard and strong, resembling mild steel. The reaction sim- ilar that used harden aluminum duralumin. The engineering uses for such material are evident. Unfortunately both the alloys described have high electrical resistance and cannot used conductors for power lines. For low resistance and high strength must continue employ copper alloved with cad- strength 80,000 lb. per sq. in. and with con- ductivity per cent that pure copper. small per- centage tin can used connection with cadmium alloying copper, and this way higher strengths can obtained but, course, with some sacrifice conductivity. Copper with about per cent cadmium maximum can cold-rolled, but the metal not sufficiently resilient replace tin silicon spring bronze. Copper-Nickel Alloys Used Increasingly for Hardware Stronger alloys copper suitable for engineering and architectural purposes include the copper-nickel alloys. Those carrying per cent nickel and those carrying about per cent nickel are particu- larly attractive where easily-worked corrosion-resisting white metal desired. usual add these alloys small amount third and, times, fourth ele- ment which goes into solid solution with the nickel and copper, and acts deoxidize and desulphurize. They are very malleable and ductile, strong, and great ornamental value. These alloys are being used increasing volume for plumbing and architectural purposes, both cast- ings and wrought forms tubes, sheet and rods. They are much superior plated metal, whatever the plating may be, for they not have surface which will wear off with use change character with the combined action moisture and scouring. Urges Performance Standards for Electrical Products Supply User with Apparatus Best Possible Qualities Respect Durability, Operating Cost, mium. Copper with 1.25 per cent cadmium can hot- rolled readily, but this about the maximum alloy for This material will make power cables with DOPTION minimum standards performance for electrical products, the next logical step + the standardization program the electrical industry, was recommended Rugg, vice-president West- inghouse Electric Mfg. Co., East Pittsburgh, Pa., who was the principal speaker the second general session the policies division, National Electrical Manufac- turers Association, Chicago recently. “Tf electrical manufacturers the United States are maintain their place the world market, and the same time maintain scale wages which will per- mit our present advanced standard living, this must done through increased attention the costs production and distribution. achieve this, there must degree standardization sufficient maintain given model, the expensive machinery necessary for its production quantity justi- said Mr. Rugg. Successful standardization al- ready accomplished the industry apparatus char- acteristics, such capacity, speeds and dimensions, should followed establishment quality levels performance, Mr. Rugg’s opinion. the minimum standard performance direct means achieving economy and efficiency production, and, above all, insuring the user apparatus against unbalanced design and performance, and generally unsatisfactory service, Mr. Rugg de- the ideal minimum standard accomplishing balance among: Lowest cost manufacturing and distribution. Greatest adaptability the purpose for which the Greatest durability, length life. Lowest cost maintenance. Lowest cost power for operating it. Such standards should developed meet the in- terests the major groups concerned. These are the manufacturer, the application engineer, the manufac- 12, 1928, The Iron Age turer power and the user. The standards should adjusted require immediate undue cost re- design and retooling, and permit gradual raising the standard the producer’s skill increases. Minimum standards performance should espe- cially advantageous all lines electrical apparatus which have been long enough established have ar- rived more less stable condition, said Mr. Rugg. “There could objection devices having certain characteristics better than the standards. There should, however, penalty at- tached devices which any characteristic below the minimum agreed standard.” Cooperative Efforts Urged Adoption the National Electrical Manufacturers Association minimum standards performance should made “only after careful consultation with other branches the industry,” said Mr. Rugg, who added: “As time goes on, will find that the process naturally accelerates practice and acquaintance, and would but short time when would become more less common practice. “If the various members the could come mutual agreement that after certain date all bids, upon the apparatus for which minimum stand- ard had been adopted, would contain statement that the apparatus bid upon conformed the standard, believe would effectually bring all manu- facturers into line. The salesman manufacturer who had adopted the standard would naturally call attention this fact and would make selling argu- ment. The salesman manufacturer who had not adopted would, therefore, continually urge upon his manufacturing plant and engineers get line. other words, manufacturer who would not conform this minimum standard would have make excuses.” German High-Tonnage Furnaces Details Greater Weight Than United States—Exceptional Control Methods ours, e., brick stack with steel bands with plates set in, and steel plate bosh and tuyere jacket without plates, water cooled the ex- terior. The whole structure supported heavy structural framework extending the top platform. Even American-type shells, such have adopted for our designs abroad, the Germans insist heavy structural beams running vertically from top column top platform. Their bells are usually smaller. are 0.9 meter (35% in.) thick the inwall. They have our conventional type stockline protection the top, where they not resort metal tops. Inwall cool- ing carried right the stockline wearing plates. rule they use cast iron box 3-ft. vertical cen- ters, the plate having 7-in. depth the face and 9-in. horizontal spacing between plates. The end open and the water under pressure. The plate about in. from the face lining. Tremendous quantities water are used the bosh, tuyere and hearth jacket, with sort pigs-in- clover puzzle run-off arrangement the bottom under- neath the operating floor, prevent breakouts getting into the sewers. There not infrequent evidence breakout. Inwall batters are less than ours the newer furnaces. Boshes are higher than here, and not usually over deg. angle, though one finds high deg. However, the same hearth and bosh diameter seems hold. one ran 10-ft. 80-deg. bosh 13-ft. 84-deg. bosh, the hearth and bosh diam- eter remaining say ft. in. and ft. each case. The opinion was frequently expressed that, for their material and rate driving, was better not beyond deg. bosh angle over 1300 deg. Fahr. blast temperature. Large Furnaces Not Uncommon Furnace sizes vary. Perhaps the best relative tonnage figure was maintained average 915 tons furnace 16-ft. 5-in. hearth, 22-ft. 6-in. bosh, ft. in. high, 17-ft. stockline, having height ft. and cubic capacity 22,300 cu. ft. This was Swedish, minette and German ores, using eight large tuyeres and 1325-deg. blast. From there one may find increasingly larger hearths, the largest encoun- tered during trip, ft. in. with 24-ft. bosh and total cubic capacity 33,000 cu. ft. height ft. This stack used Swedish magnetites, part nodulized, and was credited with 985 tons average pro- duction about 2050 Ib. coke. might say that using American tons; the output about 1002 metric tons. the plants and operating furnaces seen, would credit with better than 800-ton production rate. The remainder would average under 600 tons. se- cured published figures, but would believe the aver- age rate per works furnace the Ruhr some 100 more tons less than similar American figure the Chicago-Pittsburgh districts. High Outputs Being Made Speaking now high-tonnage furnaces, some re- markable rates are being maintained. For instance, *Vice-president Freyn Engineering Co., Chicago. This concludes the article page 803, March 22, being abstract address before the Eastern States Blast Furnace and Coke Oven Association. one plant makes 930 day 22,300-cu. ft. fur- nace, iron notch within ft. closed bell. This done without outside scrap yield per cent. The same size stack 1914 made 550 tons. The wind volume 120,000 cu. per hour, 70,000 cu. ft. per minute, blown lb. pressure through eight tuyeres. blast temperature 1300 deg. Fahr. carried. Over million tons had been produced the lining, with expectation 1,500,000 tons. The coke rate 2080 lb. seemed high, did the top temperature 650 700 deg. Fahr. But the rate driving such that the re