The Iron Age 1928-05-24: Vol 121 Iss 21

THE IRO New York, May 24, 1928 ESTABLISHED 1855 AGE Bonus System for Foremen Controllable Burden and Labor Expenditures Feature Information Given Minor Executives ROGERS PECIAL information respect both the cost and economy plant policy taking each fore- man into its confidence far controllable burden and labor expenditures his bonus calculated. departments. department are concerned, are features foremen’s bonus system used Smith Corporation, Milwaukee. Results obtained blanks reproduced the next two operation, combined with the pages indicate how foreman’s monthly They cover the cases both so-called productive With perfect record, the bonus amounts per cent the foreman’s salary for the the month. One-fifth the bonus, per cent the salary, covers performance for which alone held responsible. The remainder, FISKE something interesting. They soon learn that burden active factor the the cost production, and that impossible man ufacture without it. The problem and non-productive burden the minimum and holding there becomes special interest the man when shares the sav- ings. the policy the are high-grade workmanship, points, allotment measuring the Smith Corporation low-cost production and perfect performance his department. The take its foremen into its con- broadened viewpoint the part the foreman, which makes him fill his present position more satisfac- tory manner than otherwise and ability that will pre- pared for further advance- ment opportunities occur. This system has now been operation for several years. has served its purpose incentive high-grade work the part those men who have been entrusted with the responsibilities minor ex- ecutive positions. once apparent that the aim this bonus system secure the best possible sults for the company and the same time reward. direct proportion the good results from these forts, those who are active that accomplishment. this plant, most others, men who step into positions foremanship, assistant foreman- ship, are practical men from the ranks. They are workmen with natural ability control and direct the efforts others. Previous the time their promotion, however, they have not had, most cases, any training the matter operating costs econ- omies, and result not have keen realization just what the expenditures department amount to, aside, possibly, from those involved directly production. these men the details operation presented under the bonus system come something new and *Western editor Iron Chicago. percentage these points that the foreman realizes equal the percentages his depart- ment reaches the standards set for its pro- duction schedules, its standard controllable does not confine itself burden expenditures, etc. fidence the matter con trollable burden expenditures. The company presenting list these ex- penditures after the bonus has been figured, but actually furnishes, day day, statement these expendi- tures, that the foreman may position head off unsatisfactory conditions soon they appear. The company records are kept that additional in- formation desired foreman along special lines which may interested can had short notice. The company does not any way stress the foreman the matter non-controllable expenses, but matter general education does give him some idea what they are and what they amount to. also given approximate idea the value the equipment under his control. short, each foreman put the position well-posted executive, far his own work concerned, and made par- ticipant the benefits accruing from his efficient management. The maximum, 100 per cent monthly bonus earn- ings foreman, amount per cent his regular monthly salary. Eighty per cent the bonus based finding fact, while per cent reserved for arbitrary rating. The policy has been adopted that this arbitrary rating shall belong fully the foreman, unless there shall have been some particularly glaring shortcoming his part, which case deductions may 1445 VOL. 121, No. | | Sheet 1 FOREMEN’S MONTHLY BONUS Dept No. ~ Month of May 19-8 pt. Actua thet mt Mes Poants Pet ‘ fax Earned 2 Attained { ‘ > 726 ‘ 12, Al , ~ NS (Sheet 2) DETAIL CONTROLLABLE BURDEN MONTH OF y 192 PRESENT | PRESEN’ MONTH | MONTH n Al I ‘ Acsis the pe Sweer« oO kers 245 1 ivr pve 27 6 4 M | 4 G ‘ ane | Me } gehts Pix XxX made the extent the full points. the productive departments this corporation the work highly repetitive nature and paid for almost wholly piece work schedule. This situation ideal for establishing bonus earn- ings based fact finding three clean-cut divisions; namely, the operation the productive work wholly piece work basis; ac- complishment the schedule laid down the production de- partment, and maintenance con- trollable burden expenditures the practicable minimum. The forms, D-202, sheets and shown this page, indicate the details the bonus regu- lar productive department. The details the controllable burden. shown Fig. are merely summary the departmental ex- penditures for the month, with extended column figured cost per $100 productive age rating. Against column also shown the rating the preceding month. In_ the upper form, this page, under “Basis Above Calculation” this burden shown equal 140 per cent the productive labor. This figure then entered column “Burden Relation Productive Labor” and the calcula- tions made indicated, resulting, points earned out possible 40. items and under “Basis Above Calculations,” shown the method calculating the re- lation piece work total pro- ductive work. The per cent shown the mark attained here then entered the schedule the top the sheet, and re- sults, after the indicated calcula- tions have been made, 12-point bonus earning under column like manner items through indicate the method which the accomplishment the depart- ment against its schedule meas- ured. will noted that this work rated double basis, that is, hours and jobs. This done that the depart- ment head will tempted pile forms shown this page when men’s monthly bonus production departments. Total points earned under column (upper form) represent the earned the maximum possible bonus. The lower form gives the detail the controll- able burden tabulated both and non-productive depart- ments. | tive " 1 . Piece Work B 4 S-1 S34 $- 28 ITAL BURDEN 5 74 1446—May 24, 1928, The Iron Age credits neither solely matter hours, running all long jobs, nor the matter jobs running all short jobs. This rating then carried the schedule the top the page and necessary calculations made. Item indicates that the fore- man has been lax the enforce- ment fire regulations, and therefore penalized points his possible personal marks. The sum his points earned, 69.5 per cent. this foreman re- ceived salary $300 per month, his maximum possible bonus would per cent that amount, $90. His bonus rating for the month would entitle him receive 69.5 per cent $90, $62.55. for the non-pro- ductive departments are made indicated forms D-200 and D-201, shown this page. the upper form under entered the amount paid this depart- ment for service the plant plus the amount expended the de- partment for any items expense which may within the control the foreman. Service un- usual nature, and work items capital investment, are not in- cluded this calculation. The lower form used where department carries fair-sized overhead connection with the particular line service rendered. the top line figured the de- partmental standing the basis the amount service mainte- nance labor performed against the productive labor the depart- ments served. the second line noted the standing attained the department the matter its controllable burden its par- ticular productive labor. The maximum and minimum limits set for bonus this kind are determined only after care- ful study. These limits must equitable both the company and the men. the limits are too easy accomplishment, the com- pany can gain little. they are too hard, the foreman will only discouraged. The top limit must attainable for the man who de- livers exceptionally well. has proved interesting see what inspiration and spur the rest when the information goes out that and has made perfect mark. HESE sheets are for the bonus system extended productive departments. the case major non-productive depart- ments the bonus summary recorded the lower form. Burden details similar those shown page 1446 are furnished with this statement. (a) Service Labor {b) Prody Ra Rat ) Ratic Minimun (f) Difference ) Eff Ma pas, (k) Ma De im) Net k Total B st Rativ of of Dept I Peant Labor Prod ad} den of Departmer Total Labor of Demert Ratio (d ©) Dec from Pe MONTHLY BONUS Dept. vay 19 De ‘ > ©) i} Rat i i + car ‘ o MONTHLY BONUS Dept. Ne. @& rt 2 1.4 BASIS OF ABOVE CALCULATION ‘ t (Det Lint Attached) Rating ‘ ‘ form D 208 1M 228 form S03 m Bonus Bonus Points Earned Points Maxim ~ The Iron Age, May 24, 1928—1447 7 29 va an > 50, ¢ wo 4 out guards - 4 Foundrymen Meet Birthplace Hold Reunion Living Organizers—Much Interest Displayed Technical Sessions—Exhibition EETING the city its birth years later, the American Foundrymen’s Association Large and Successful held general meeting and exhibition last week Philadelphia, May 18. was 1896 that the concerted effort few live foundrymen brought culmina- +; ion movement which has grown its present very large proportions. The gathering this year was both reunion and celebration and resulted one the most successful conventions recent years. was the fourth one held Philadelphia, others falling 1907 and 1919. feature was the very decided interest manifested any session associated with gray iron. And new development was four sessions cupola operation, which attracted much atten- ion. Attend: exhibitors. The exhibition nently successful. Notable lance most the sessions was remarkably was its compactness, housed under Museum. discussed some detail this report. Commemorating the birthplace the organization the living organizers could present. large. these, about apers and several committee reports were presented leaders each important field. Total registration was about 6000, which record. 1200 were representatives equipment, while not the largest the association has conducted, was emi- one roof the Commercial A., special dinner was Dinner Tendered Living Founders entirely informal and con- the dinner tendered the ociation members who were present when the foundrymen’s ssociation was formally organized Philadelphia May, 1896. Over signified their intention present and nearly all these were able attend. list those who sent acceptances will found another page. Tuesday evening, May 15, the Manufacturers’ Club, which stands the site the old build- ing which the was formed, these original organizers, together with some the officers, directors and past officers the association—in all about gathered around tables presided over Johnston, chairman the committee which planned the reunion. Many greetings and reminiscences were exchanged pre- vious the dinner men who had not seen one another many formal post-prandial ad- dresses were scheduled, but the chairman, each side whom sat Howard Evans and Walter Wood, who were considered spe- cially honored this occasion for their pioneer work and their con- tinued activity the present day, 1448—May 24, 1928, The Iron Age called various foundrymen speak. Walter Wood traced the early steps the formation the 1896, pointing out that was due the efforts the Philadelphia ciation interesting the Western group and others come Phila- delphia May, 1896, and form organization. empha- sized the fact that those days only spade and shovel were the molder’s tools, but today tion revealed how machinery was revolutionizing the foundry. Mr. Wood stressed his belief that co- next step which the foundry in- dustry most needed take. Howard Evans, still secretary the Philadelphia local organiza- tion, said that the Philadelphia Foundrymen’s Association, when started the A., really laid the foundation for many other technical, business, and trade as- sociations. said that one in- spiration leading the formation the national organization was consideration business ethics and the demoralization price cutting. special invitation, John Penton, one the association’s founders and its first secretary, addressed the old-timers. said that had been fortunate any way his early association with the A., attributed the character the men worked with. some the circumstances surrounding the first meeting, which was the result call sent out the Philadel- phia Foundrymen’s Association, mentioned the first officers, only three whom are still living, and pointed out that the Philadelphia meeting 1896 was really the foundation two large societies the and the National Founders’ Association. Looking the future, Mr. Penton said that those industries that are going survive are the ones having the most forward-looking policy, and added that research must more and more factor. this hoped the newly formed Gray Iron Institute would influential. The retiring president, Utley, pointed out that phia has become the birthplace many important organizations that the mayor may need social secretary keep track them. paid warm tribute Secre- tary Hoyt for the the association recent years. Other speakers were Mc- Fadden, Ponca City, Okla.; Hoyt and George Davies. When the question was asked any were present who had attended every convention, John Hill, president Hill Griffith Co., Cincinnati, arose. Gray Iron Topics Three Sessions HREE sessions were held the general subject cast iron. The first one, under the chairmanship Harrington, Hunt-Spiller Mfg. Corporation, Boston, was devoted cupola developments the founding cast iron and was featured three papers. The second cast iron session, under the chairmanship Bolton, Lunkenheimer Co., Cincinnati, dealt with cupola metal, temperature measurements, test bars, and the influence carbon and silicon variations. The third cast iron session, under the chairmanship Dr. Gillett, Bureau Standards, Washington, was devoted primarily research questions and was concluded report the committee gray iron. Test Bar for Testing Hardness the absence the author, Dudouet, foundry manager So- ciété Métallurgique Normandie, Paris, France, his paper was read Willard Rother, Buffalo. Its title was: “Study the Use Hardening Test for Cast Iron with Medium Silicon Content,” and was presented behalf the Association Technique Fon- derie France. The paper was devoted largely the development form test piece for making hardening tests with medium and high-silicon content the iron. The author traced the influence the depth hardening produced the thickness the test piece, its width, the character the chill used and its temperature, the humidity the sand, the tempera- ture pouring, etc. Variations these properties were traced means diagrams. insure comparability re- sults, necessary that all the factors affecting the hardening should maintained strictly con- stant. With such precautions the author concludes that unques- tionable that two test pieces, cast from the same metal the same temperature, will show practically similar depths hardening. opening the discussion this paper, John Shaw, Southsea, England, expressed the opinion that the test outlined not sufficiently practical for foundry purposes. The time required for making was believed too great. described briefly his own methods making wedge in. long, in. wide, and varying thickness from in. one end point the other. means this wedge rough idea can obtained the silicon and carbon contents various points and the depth the chill can measured. The chill described the paper was characterized Mr. Shaw too complicated for ordinary shop purposes. believes that the whole question gets down one method which can handled best advantage and lowest cost. Influence Carbon and Silicon Variations RAL presentation was made Anderson the paper prepared Mr. Anderson and Bessmer, foundry engineers Western Electric Co., Chicago. The title was “Influence Carbon and Silicon Variations Gray Cast Iron.” The paper was brief, con- sisting presentation results from heats melted induc- tion electric furnace with mag- nesia lining. Several curves and tables were given, showing results the 1.10 per cent silicon series, the per cent silicon series, and the 2.20 per cent series. Broken test specimens were exam- Men the 1896 Convention Who Sent Acceptances for the Reunion Dinner Enterprise Mfg. Co. Pa., Philadelphia. ARTHUR BARLOw, Barlow Foundry Co., Newark, WILLIAM COANE, Ajax Metal Co., Philadelphia. JAMES CRAWFORD, Philadelphia. DARKE, General Electric Co., West Lynn, Mass. GEORGE Pilling Co., Philadelphia. WILLIAM DEVLIN, Philadelphia. HENRY DRINKHOUSE, Elkins Park, Pa. HOWARD EVANS, Philadelphia. FINDLEY, The Iron Age, New York. GEORGE FRENCH, Philadelphia. FULTON, Waterbury Farrel Foundry Machine Co., Waterbury, Conn. JOHN Hill Griffith Co., Cincinnati. GEORGE JOHNSON, George Johnson Co., Philadelphia. JOHNSTON, Obermayer Co., Chicago. LAME, Philadelphia. JOHN LOGAN, Atlas Steel Casting Co., Buffalo GEORGE MATLACK, Wm. Cramp Ship Engine Bldg. Co., Philadelphia. JOHN PENTON, The Foundry, Cleveland. CHARLES PETTINOS, New York. GEORGE PETTINOS, Philadelphia. REBMANN, Philadelphia. HARRY REBMANN, Mt. Airy, Philadelphia. FREDERICK RIEHLE, Riehle Brothers Testing Machine Co., Philadelphia. BARTLETT Walker Pratt Mfg. Co., Watertown, Mass. SLEETH, Cambridge Springs, Pa. JAMES STIRLING, Wilmington, Del. VALENTINE, Valentine Brothers Co., Woodbridge, VAN LOAN WHITEHEAD, Buffalo. WALTER Woop, Philadelphia. STEINMETZ, Morris Building, Philadelphia. The Iron Age, May 24, 1928—1449 ined and photomicrographs were shown. The authors concluded that the total content gray cast iron per cent higher sili- without materially increasing the amount combined carbon the casting. This reduction carbon for these irons was reported re- sulting some improvement physical properties. Opening the discussion, James MacKenzie, American Cast Iron Pipe Co., Birmingham, referred the deflection calculations shown one the author’s tables. Mr. MacKenzie had roughly the modulus elasticity from the defiection figures given for the va- rious tests. found that these varied considerably, going high 25,000,000 for test No. the 1.10 per cent silicon series and 9,800,000 for test No. the 2 per cent silicon series. He recommended the use this ation showing modulus elastic- studying the properties ast iron. Another speaker reported the practice molding with the heavy ‘tion the top instead the bottom, and appropriate gating that the light sections the bottom would properly filled. reported getting far better re- sults his castings this means than any other which had the entire accuracy the color- ometric method determining the amount combined carbon the iron, Mr. Anderson agreed that not thoroughly accurate, but stated that had the advantage being inexpensive and giving results which might relied upon sufficiently accurate within the ‘tical limits foundry opera- Heat Losses from Hot-Metal Ladle ETERMINATION the heat ) losses from 75-ton hot metal car the Pollock type were re- consulting physicist Bu- Standards, Washington. The car was divided into seven temperature measure various places each zone. was found that the cooling rate varied con- iderably during the course hows loss temperature the molten metal deg. the first hour and only deg. the fact, the econd hour showed only deg. and there was gradual reduction hour until the last four wed deg. each. ucceeding hours. idiation losses from the surface the ladle, well convection ses and conduction through the lining. The average value the heat losses worked out about 140 B.t.u. second. Calculation the specific heat for molten iron was made from the determinations the test. was placed about 0.23. 1450—May 24, 1928, The Iron Age value, was stated, may error, due the fact that the weight and rate cooling the slag were not known and that some the iron was freezing with the slag. was concluded finally that metal tapped from blast furnace about 1500 deg. (2732 deg. Fahr.) can held for hr. be- fore freezing. matter fact, one case was cited where ladle metal went off the track and was not possible pour until hr. after had been cast. While there was large skull left the ladle, was successfully poured after that interval. Temperature Measurements Molten Cast Iron PTICAL pyrometers were given rather poor bill health Roeser, Bureau Standards, Washington. Many comparisons were cited the paper between the readings the optical pyrom- eter and those the thermo- couple, which wide variation was shown between the two, re- sulting necessity for erable correction optical pyrom- eter readings before they can accepted accurate. this cor- rection were uniform, reason- ably so, this might not cause trou- ble, but matter fact they varied considerably, being great- est not only actually, but propor- tionately, highest temperatures. ranged from per cent tem- perature around 1200 deg. per cent temperature around 1500 deg. difference more than per cent was shown one case, where the thermocouple gave about 1600 deg. One explanation the variance was given change the sur- face emissivity around 1375 deg. cast irons. was conjec- tured that this transition might from liquid solid oxide from liquid solid slag. While the melting points the various ox- ides iron are higher than this, believed the authors that the solid oxide formed below that temperature comparatively in- soluble molten iron, while the molten oxide formed point goes into solution fast forms. Discussion this paper cen- tered largely whether the alloy additions the heat were made the ladle before. developed that some the additions were made the ladle the spout, while others were made the fur- nace before the heat was poured. Recent Developments Cupola Metal out that our object foundry practice primar- ily make better and cheaper gray iron, John Miller, the Cresson-Morris Co., Philadelphia, read paper entitled “Some Re- cent Developments Cupola Metal.” The engineer continu- ally with higher tensile strength, and the same time demanding re- finement the irons for pressure work and high machinability. his plant the author stated that some cupola metal had been poured into bars giving high 65,000 lb. the square inch tensile strength. This three times the strength what for- merly was considered regular foundry metal and costs only few cents more ton produce it. Regarding iron made the electric furnace was pointed out that the additional strength over cupola metal about per cent, but costs per cent more produce this result. Con- sequently the comparison the two metals not fair the cu- pola, unless the difference the cost indicated the same time. There are other qualities besides tensile strength which are impor- tant iron. There unquestion- ably demand and place for cast iron the usual grades. Never- theless the speaker advocated extension the use strength cast iron. Castings High Strength the discussion Bancroft, superintendent John Deere Har- vester Works, East Moline, stated that the gray iron foundry not slipping back very far, de- spite the lugubrious statements some critics. The strength our metals general getting bet- ter. Formerly used be- lieved that per cent steel scrap the charge was the limit which could used satisfactorily foundry practice. Now, how- ever, found that charge all steel can used under proper precautions and control. Lots castings are made, according James MacKenzie, where fluidity the paramount consideration, rather than strength 65,000 the square inch. Along this line David Lain, Milwaukee, stated that, when was found possible attain strength 45,000 there was demand discovered for such cast iron. matter fact, said that his company had not yet been asked for it. For high-tensile cast iron, one speaker reported using charge including per cent steel rails. His practice add ferromanga- nese and per cent ferrosilicon the charge, getting spout metal containing 0.65 per cent manganese and from 1.25 per cent silicon. Additions the spout were made get silicon 2.5 per cent and other additions for nickel from per cent. obtaining these results found desirable melt with very high coke bed—up in.—thus resulting from the start very hot metal. Readings with the op- tical pyrometer show this metal run from the cupola 2700 2800 deg. Fahr. Equally good re- sults were reported from 36-in. and 60-in. cupola. The maximum — GILMORE test showed 69,800 lb., with average running around 65,000 Only half dozen heats were made, all experimental and each result- ing about 1500 lb. castings. Not better iron but better cast- ings what are after, accord- ing Harrington. This opinion was voiced also other speakers discussing the paper. Unless the castings will what expected them the quality the iron going into them sec- ondary consideration. Research and Practice Gray search methods plans, Doctor Gillett pointed out that the term “research” applicable only when not know what are going find out. compared with the old-time navigation, par- ticularly that the day Colum- bus and immediately afterward. Cartographers put continents and islands old maps haphazard way and eventually the map as- sumed form which made pos- sible for the navigator reach any predetermined destination with the least possible loss time and effort. Enlarging upon Doctor Gillett said that the gray iron industry needs charts showing all the data available, make progress. Only filling the unknown territory and there- eventually producing com- pleted whole can this result achieved. Theory Practice Gray Iron Foundry PEAKING extemporaneously and covering considerable field not carried his paper, John Shaw, Southsea, England, pre- sented paper the above topic. dealt his paper largely with the theoretical side cupola prac- tice and the relationship the various elements the resulting iron characteristics. Melting tem- peratures and investigations the effect the size the test bar were discussed. The author took large number Maurer’s results, with the aid three lantern slides groups the Maurer tests. These groups were based certain uni- formity results under varying sets conditions. Working from these diagrams Mr. Shaw expressed himself very much opposed using base the sum the total carbon and the silicon for comparative work, unless the total carbon cally uniform and other conditions are unchanged. Otherwise, said, the variations will result giving discordant conclusions. practice which Mr. Shaw deplored was the use the pearlitic theory. said that perfectly possible obtain pearlitic iron which exceedingly poor its practical qualities, and equally possible obtain excellent pearlitic iron. From this argued that pearlite alone criterion the suitability the iron for any given purpose. Discussing Mr. Shaw’s paper, Bolton stated that the sum the total carbon plus percent- age the silicon gives much better base work from than the Formerly one-fourth one-third the silicon had been used dif- ferent investigators. Using per cent the silicon addi- tion the carbon was recom- mended. Under this arrangement the strength results, according Mr. Bolton, fall into proper rela- tionships with the reported carbon and silicon contents found anal- ysis, Research Problems the Gray Iron Foundry applied with advantage the engineering properties gray who read paper the topic car- ried the crosshead. known that the properties the metal depend largely the absolute and the relative amounts graphitic and cementitic carbon and their distribution and size. The silicon and total carbon content are the most important composition fac- influencing forms. Mr. Bolton classified gray iron into groups, according their silicon and content. The latter ranged from more than per cent and the silicon from more than per cent. gave large amount tabular material from tests and showed correlation groups irons. particular, showed certain correlation be- tween castings and test bars made from the same ladle metal. number specific cases cast- ings came for discussion this connection. Interpretation test results and discussion his data were given considerable detail. concluded that extension sys- tematic research furnish foun- drymen with proper information the properties their product. was admitted that the job obtaining this information going large, but the author believed that progressive foundrymen would undertake the task. Consideration pouring tem- perature the original superheat the metal, addition compo- sition and cooling rate the metal, must had, according Dr. Richard Moldenke, Watchung, portant factor our study con- The Iron Age, May 24, Contributors Gray Iron and Non-Ferrous Programs Chairmen a litions. expressed the opinion results from test bar with those from the casting. This was di- opposition Mr. Bolton’s That there are several difficul- ties this correlation was pointed John Shaw. questioned the use the shear test this connection. Discussing ng, James MacKenzie referred rse strength, well tensile and shear strength, be- ing due largely the size and character graphitic inclusions the metal. Deflection the test he other hand, repre- enting ductility, based the these inclusions. Committee Reports RESENTING sub-commit- tee report refractories for gra the iron foundry, James told sending out questionnaires about 200 se- lected foundries and receiving re- plies from 56. general, the data obtained were disappointing. Re- fractory costs, including labor, were reported varying all t ot way from 5c. $1.68 ton. These two extreme figures were reported foundries about the same size. Relations stack area tuyere area are varied 72-in. cupola varied from 3600 lb. 12,000 Analysis the slag some- thing which apparently outside the knowledge nearly all foun- drymen. Very few reported this. Heats obtained for each lin- ing the cupola varied from single heat foundry which re- lines after every heat run six months, representing perhaps 150 heats, another case. The hours operation the melting zone each lining varied similar- ly, from the case the single heat 3600. 24, 1928, The Iron Age H AGEBOEC K J. W. BOLTON Following the presentation the two papers, Mr. MacKenzie presented, the absence Mr. Jones, the chairman, the report the committee gray iron. investigation under way, conjunction with the American Ceramic Society, the enameling cast iron. One the items the program the committee fluidity test, involving among other things viscosity, which im- portant connection with filling the mold. Another problem that liquid shrinkage. This particularly important connec- tion with high-test cast irons, while wear tests and machinability are value affecting the use- fulness gray iron castings. Determination the gases the iron problem now being worked the Bureau Stand- the committee, conjunction with committee the American Iron and Steel Institute and other in- terested groups. Air Control for Cupolas necessity close control air the melting operation foundry cupola and the arrange- ment equipment intended as- sure such control, were dealt with paper “Automatic Blast Gate Control for Cupolas,” Crawford, industrial department General Electric Co., Schenectady, session devoted cupola de- velopments. Air should charged weight, not volume, said Mr. Crawford. Only per cent standard air oxygen; therefore only tion fulfils the purpose for which the air introduced, and the other per cent works against the melt- ing operation. The total weight air used during any heat more than the combined weight the coke and iron, which fact empha- sizes the importance air control. discussing the amount air required was pointed out that for fuel ratio, 24,000 cu. ft. air instead 30,000 cu. ft., all that required melt ton iron. This based good coke having about per cent fixed carbon, and takes account car- bon taken carbon dioxide, also air leakage, etc. the 30,000 cu. ft. figure used per cent too much air, per cent too much oxygen, introduced exist free oxygen and oxidize the iron. Also, per cent more inert gas introduced help re- tard the melting operation. More coke can added, said, but this decreases the ratio and slows the melting rate. Calculations the paper were based the weight air stand- ard conditions 14.7 barometer and deg. Fahr. temperature. was pointed out that these condi- tions were not always standard be- cause the air temperature will vary from zero 100 deg. some lo- and the barometer will also vary. The weight given vol- ume air will therefore change with the temperature and barom- eter, and therefore blowers should operated give constant weight, rather than constant vol- ume. The effect temperature, ba- rometer and humidity were briefly discussed, and concluding this section his paper Mr. Crawford said: above figures show that serious error made the air required figured the old basis 150 cu. ft. air per pound coke, 30,000 cu. ft. for ton iron for all conditions the in- take air. the minimum condi- tions deg., 15.2 barometer and humidity, the excess air oxygen will the difference be- tween 30,000 and 20,500 cu. ft., 46.5 per cent. The effects too much and too little oxygen, and the part that air pressure plays the melting oper- ation were outlined, and the appa- ratus for automatically assuring the supply constant weight air the cupola, irrespective atmospheric conditions and the re- sistance through the cupola, were described detail. This electrical control system connected with the line supplying the current electrical motor which oper- ates the centrifugal compressor. This control operates blast gate placed the pipe between the blower and the cupola. Details the system, such the hand and automatic blast gates, control pan- els, meters, etc., well test and operating curves, were shown means lantern slides. The equip- ment was also demonstrated the booth the General Electric Co., during the exposition. Describes Manufacture and Prop- erties Cupola Blocks Refractories,” Bales, Ironton Fire Brick Co., Ironton, Ohio, was another paper the session devoted cu- pola developments. The clays used were described and the manufac- findings. ture the blocks hand, ma- chine and dry press method were outlined and pictured lan- tern slides. section the paper was devoted the properties various types cupola blocks. Steel Foundry Problems Reviewed HREE sessions were devoted steel foundry subjects. Eight papers and several important committee reports were presented. One session was given over largely alloy castings and heat treatment, another foundry practice and third general topics. Corbett, Steel Founders’ Society America, Pittsburgh, was the chairman two the sessions, and Fletcher Harper, Allis-Chalmers Co., Milwaukee, presided over the other. the following account possible touch only few the papers. PAPER which attracted con- siderable attention fourteenth series exchange papers between the Institute British Foundrymen and the Melmouth, manager steel foun- dry, Thos. Firth Sons, Ltd., Sheffield, England, entitled “Variables Steel Foundry Prac- the absence the author was presented abstract George Batty, director research Steel Castings Development Bu- reau, Philadelphia, old friend and co-worker the author. British View Foundry Practice Mr. Melmouth’s paper quite long and deals with many phases the subject. Briefly says that factors influencing the largest extent the production steel casting are: The human ele- ment; various molding operations; metallurgical behavior the steel the form sand casting, and heat treatment. Each one these factors are treated detail. Castings have been described, says the author, “badly designed ingots” and with this quite agreement. search still necessary produce ideal “perfect” steel casting which also true the ingot. The lower the carbon content, the more difficult produce casting porosity type. normal quan- tities silicon has very little effect physical properties, but high silicon mild castings tends produce coarse ferritic structures with lower strength and impact resistance. Serious variations manganese, Mr. Melmouth says, should avoided. sulphur, 0.06 per cent can taken perfectly safe upper limit. processes not true that theoret- ically steels equal general com- position should behave similarly, irrespective process. Based their comparative ability pro- duce steel with degree fluidity high proportion the tempera- ture, the author places the con- vertor first, the single slag electric furnace second, the open-hearth third and the double slag electric fourth. Various deoxidizers such aluminum, ferrotitanium and cal- cium carbide are discussed also heat treatment. The great majority specifications for mild steel castings can met straight annealing, cooling either the furnace the air, de- pending the type casting being handled. attributable incorrect manipula- tion during treatment are due too low temperature, too high temperature too short period temperature. the discussion Major research director Electric Steel Founders’ Research Group said that the author’s views sulphur and spond closely those this coun- try, far they have been determined. Interest was displayed the question tarring steel casting molds, and this was ex- plained Mr. Batty resulting casting with better surface and one more easily cleaned, also one less liable burning in. Many opinions were expressed the use deoxidizers, par- ticularly aluminum. was gen- erally agreed that this deoxidizer must used offset the bad effect green sand molds, but more should used than neces- sary. The use silicon-zirconium was suggested being both deoxidizer and diffuser sul- phur. Less New Sand Needed information steel foun- dry sand problems con- tained paper “Reducing New Sand Consumption the Steel Foundry” Mason, as- sistant superintendent Gould Coupler Co., Buffalo. The author, who presented the paper, described new system reclaiming sand which economies far beyond their expectations were realized. New sand consumption has been reduced from 1200 300 Ib. per ton good castings. Clay consumption has dropped from 150 lb. per ton. Savings made have averaged $3,500 per month. Thus the original investment $3,000 for the sand. reclaiming unit and the small additional cost for high grade bonding clay considered money well spent. Three Kinds Alloy Castings PAPER considerable inter- est entitled “General Char- acteristics Alloy Steel Castings,” Frank, chief metallurgist Chicago Steel Foundry Co., Chi- cago. statement which met with cordial response was the effect that foundrymen have all seen tendency advertise extensively steels with fancy names even numbers, steels with varying con- tents carbon and manganese, which cannot compared the real alloy steels which carry, addition, nickel, chrome, vanadium and molybdenum, Mr. Frank divides alloy steel castings into three distinct classes. physical properties; second, those with extraordinary properties such resistance corrosion and mag- netic permeability, and the third classification puts heat-resisting alloys. Manganese, nickel, nickel- chrome, molybdenum alloy castings are then discussed some detail. straight molybdenum steel not common castings the present time, the molybdenum usually run- ning 0.20 0.40 and sometimes high 0.80 per cent. The main advantage this alloy relative ease welding such cast- ings other parts fabricating. Authors Steel Foundry Papers | 4 The Iron Age, May 24, 1928—1453 Molybdenum conjunction with chromium produces steel, the use which increasing leaps and bounds, says the author. The ad- chrome steel results metal that should particular interest retains all the good quality the nickel and the chromium, the ease machining addition, has the peculiar haracteristic hardening almost iquid medium were used Special Heat Treatment for Castings heat treatment plant for mis cellaneous steel castings was pre- lurgist Bucyrus-Erie Co., South Milwaukee, Wis. modern nt, uniquely equipped for the quenching and tempering miscellaneous steel castings. With this plant output over 500 per month may obtained been found, said the author, that when certain types alloy quenching treatment, their properties may improved from 100 per cent. When such results can obtained rela tively small increase over the cost casting, the subject heat treatment becomes lively issue, suggesting many which would otherwise hibited. The author’s statements are based upon his company’s experi ence with heat-treated castings for interesting note that the present time approximately one- third the entire foundry output fully quenched and tempered product. the discussion which the author answered numerous ques- tions, developed that all castings are annealed first before quenching and tempering. Economies Oxyacetylene Cutting ARGER risers and more pour- gates are now used than earlier steel foundry practice, because ample reservoir capac- ity above the casting essential compensate for shrinkage and thus prevent pipes and blowholes. This made possible economies oxyacetylene removal such risers, said Carter, consult- ing engineer Linde Air Products Co., New York, paper entitled “Economies Oxyacetylene Cut- ting for Riser Removals.” this way the foundry sure getting good casting when risers and gates are used. Other Papers THER papers presented the steel foundry sessions were Evans, metallurgist Pettibone Mul- liken Co., Chicago, describing some detail the metallurgy and heat treatment high-manganese steel castings, well their uses, and description interesting new research stee] foundry labora- tory contributed Hamil- ton, research director American Steel Foundries, Indiana Harbor, Ind., entitled “Research Laboratory American Steel Foundries.” Specification Controversy Unsettled the close one the ses- sions the chairman the com- mittee steel castings, Jameson, Deemer Steel Casting Co., New Castle, Del., made re- port, the discussion which con- sumed much time. dealt with the old controversy concerning the specifications for flanges, valves and fittings carbon steel cast- ings for high temperature use. Ref- erence was made the action which was taken year ago the the annual meeting the Amer- ican Society for Testing Materials when the serious differences opinions which existed ferred back the committee. Mr. Jameson then related the attempts that have been made effect compromise the appoint- ment arbitration committee. Failure resulted the formation this committee, suggested the M., but compromise was suggested those interested which did not meet with the ap- The compromise was the effect that the words “other approved processes” should used the specification, instead eliminat- ing the names the converter 1454—May 24, The Iron Age life. Flew Convention IRPORT facilities well railroad connec- tions may soon play important part the selection sites for future conventions and Kreicker (reading from left right) the Beardsley Piper Co., Chicago, maker sandslingers and other foundry equipment, may taken precedent. These men went Phila- delphia from Chicago airplane order save time transit and present the opening the exhibit. Messrs. Beardsley and Piper have retained confidence airplane travel spite the fact that about six weeks ago they went into dive near Sharpsville, Pa., the crash resulting injuries which for time threatened Mr. | the crucible process. was also suggested compromise that the sulphur limits raised from 0.05 per cent 0.06, but the stip- ulation definite limits for car- bon, manganese and silicon were still stand. Bull presented lengthy minority report, urging the adop- tion the so-called “Cleveland compromise” the only solution controversy which had lasted altogether too long and which was doing harm the producers this particular grade castings and the making specifications general. After many opinions had been expressed various members present, Mr. Jameson of- fered resolution that the sense this meeting opposed the sug- gested compromise and also op- posed principle the inclusion chemical limits where physical results are stipulated. The final vote showed decided majority favor the resolution, although the total attendance that time was but 26. Among those who took part the discussion were John Howe Hall, one the mem- bers the committee and Spring, Crane Co., Chicago. Progress Made Sand Control MPHASIS the progress that being made sand conservation, making successful synthetic sands and developing satisfactory tests both the laboratory and under practical shop conditions were brought out the one session sand control. Five papers and eral committee reports were scheduled. Ferric Oxide Film Sand Has Influence Bond Strength LTHOUGH has been recog- nized that colloidal ferric ox- ide films might have important influence the bond strength sands, quantitative data have been available show the effect the films. Such data, showing the relation colloidal ferric oxide absorbed the sand grains and the clay bonding material the strength bond the molding sand, and the successful prepara- tion synthetic molding sand, were presented paper entitled, “The Influence Ferric Hydrogel the Bond Natural Molding Sands.” Brown, professor chemical engineering University Michigan, Ann Arbor, who was joint author with DeWitt, professor chemistry Michigan College Mining and Technology, read the paper. investigate the cause bond natural molding sand, sample fresh Albany molding sand was adopted for testing and analysis. This sand was tested for permeability and compression, and was then separated into silica, iron oxide and clay. was found that the presence the natural film colloidal ferric oxide has meas- urable effect the strength the base sand. was also ascertained that the absence bond material “clay substance” causes marked decrease the strength the natural molding sand. Synthetic molding sand was made pure silica, kaolin and ferric quantities approx- imating the base sand, bond and ferric oxide the natural sand. Numerous other constituents natural molding sand that have been identified were not found es- sential. The synthetic sand vir- tually reproduced the properties the natural molding sand. Similar results were obtained making synthetic bonded sand, using clean Michigan City beach sand base. Why Bond Strength Decreases AUSE the Decrease Bond Strength Heating Molding Sands 600 Deg. was the title another paper the same authors. The loss bond heating, least 600 deg. Fahr. for hr., not due any change the ferric hydrogel ab- sorbed the silica, the experi- ments disclosed. the other hand, heating the bond material before mixing with the silica base material causes the mixture lose practically all the strength lost heating the mixture. This clearly indicates that the loss bond heating due entirely changes the clay bond dis- tinct from the sand colloidal ferric hydrogel. New Machine Test Sand “An Automatic Precision Strength Test for Sand,” the title third paper these two au- thors, describes new machine for making compressive tests sand. The device was built with the fol- lowing considerations mind: initial loading sample. Freedom from impact forces. Constant rate loading. Automatic operation, stopping and indication breaking load. less than gm. With this machine the compres- sive strength sands ascer- tained with accuracy plus minus per cent. Although such accuracy probably not nec- essary industrial routine test- ing, valuable careful re- search work. The machine was used the investigation the influence ferric hydrogel the bond molding sands. Bank Sand Additions Core Sand Conditions Cast- ings Affected Core Sand Mixtures,” was the title paper Campbell, associate pro- fessor metallurgical engineer- ing, University Michigan, Ann Arbor. obtain definite infor- mation the effects different core sand mixtures the surfaces metal castings, special mold was designed which permitted test specimen cast contact with dry sand cores. The mold was formed from two cores which were clamped together vertical po- sition. The investigation showed that the most desirable properties dry sand cores are obtained when the core sand contains grains uniform size and sufficient fine ness produce required smoothness the surfaces the cores, The smoothness castings formed contact with cores will practically the same the smoothness the cores, provided the metal sufficiently fluid when poured fill the minute cavi ties the cores. all cases where smooth surfaces quired castings, the cores which form these surfaces smooth. The additions bank sand other finely divided materials core sand mixtures within reason- able proportions not improve, any appreciable extent, the smoothness the surfaces cast- ings made contact with these cores. Sand Control for Gray Iron Control and Sand Con- servation Gray Iron Job- bing Foundry” was the title paper Kiley, metallurgist Brown Sharpe Mfg. Co., Provi- dence, Various tests used reclamation sand are described. The company has used clay re- bonding spent molding sand since June, 1925, and shortly after that sand tests were adopted guide the proper use and treatment this material. The character clay was found have consid- erable influence over the rate drying out reclaimed sand. The more colloidal the clay, the less the rapidity the drying out the reclaimed sand. Tests indicated that clay-treated sand bakes strong one the natural sands used large ex- tent medium work; that fine sand weaker the green state than coarser sand with the same amount clay present each case seems bake stronger than the latter, possibly because less rapid destruction clay bond the fine sand. Fines silt tend accumulate the heap when sand repeated- used. However, this tendency not serious because attempt made reclaim sand that ad- heres strongly castings, which removed the cleaning room. The addition new sand piles lessening quantity, sharp sand additions rebonding, un- avoidable core droppings claimed sand, formation com- pound grains casting into the sand; all these probably have their The Iron Age, May 24, influence preventing such accumulation silt cause concern. After about two and one-ha