The Iron Age 1928-05-31: Vol 121 Iss 22

THE IRON AGE New York, May 31, 1928 ESTABLISHED 1855 121, No. ™m Vertical and Overhead Core Ovens Greatly Increased Capacity from Removing Old Ovens from Floor—Continuous Conveyors Handle Cores Through Ovens ROGERS FISKE* EMMED all sides that extension the foundry building was impracticable, the Nash Motors Co., Kenosha, Wis., has taken advantage its air-rights between the floor and the roof the foundry building, with the net result that, where for- merly appeared that all available production space was use, there now stands equipment that has in- creased per cent and has halved direct labor cost. Furthermore, laying out the new plan was found that the saving floor space was such that the new units can duplicated, thus doubling the pres- ent output. Not one square foot has been added the foundry building, nor will any increase necessary when the present equipment duplicated. Early.in 1926 truck conveyors and sandslingers were installed for the production cylinder, cylinder head and transmission case castings. The capacity this equipment was never fully utilized for the reason that core-making facilities, limited the floor space the foundry, were inadequate. This situation led the installation three continuous core ovens, two the vertical type and the third arranged overhead, that *Resident editor Chicago for AGE. molders may now use the space formerly occupied the old core ovens. One oven used for baking small cores, another for large core work, and the third drying oven for cores that have been pasted The small core oven used for work in. diameter in. thick. the vertical type and was made the Mahr Mfg. Co., Minneapolis. ft. wide ft. long and ft. high. rests the main floor and extends through steel and concrete mezzanine floor sufficiently large accommodate duplicate unit. Core sand, delivered the mezzanine floor overhead crane, loaded into two-wheel buggies, from which shoveled bins mounted the core-mak- ing tables. The conveyor for core baking comes through the mezzanine floor and then runs horizontally between two rows core benches. Ten girls work each side the conveyor, permitting loaded from both sides. Conveyor Speed Adjusted Suit Baking Time Each conveyor basket provided with three trays, which are adjustable height. The trays are made %-in. grating, which permits core plates laid Coming the Mezzanine Floor the Small Core Oven Conveyor Makes Horizontal Run Over What Known the Loading Station and Enters the Oven, Which Extends Through the Rooj the Building. core sand bin mounted the back each core bench 1523 any position desired and insures good circulation hot gases through the baskets, thus baking the cores uniformly and without burning them. travel speed may varied from 0.51 ft. 2.53 ft. minute. Under present operating conditions 1.10 ft. minute each basket the baking zone min. Entering the oven the mezzanine floor level the conveyor passes upward and over sprocket wheels near the top the oven. then passes downward sprocket wheels near the bottom the oven, where turns horizontal run and leaves the oven the main floor level, turn again later the mez- zanine floor. The lower horizontal run the unload- ing station, where one man unloads the cores made girls. removes the cores from the conveyor and places them boxes which are moved roller tables. stated that core breakage almost unknown. The drive from motor. single combination oil gas burner mounted the side the oven. The brick combustion cham- ber, which built with open slots its roof, extends the full width the oven and mounted between the two vertical conveyor runs. baffle extends from the combustion chamber point near the upper sprocket wheels. Products combustion escape through the roof the combustion chamber and travel along the down-coming conveyor run. They pass over the top the baffle and turn down, following the path taken the conveyor. Gases escape the atmosphere through stack mounted the loading end the The gas counter the direction travel the conveyor. The loaded conveyor enters the cool- est part the oven and gradually approaches the point highest temperature, after which passes re- chamber and then out the oven the unloading station. The products combustion are tempered with cold air point just above the combustion chamber. This method and the automatic control the burner opera- tion are used fix baking temperatures. The mix- ture air and gases first encountered the cores has temperature 330 deg. Fahr. the cores 1524—May 31, 1928, The Iron Age travel farther into the baking zone the temperature the hot air and hot gases increases 470 deg. Fahr. This maximum temperature encountered the end the baking zone, which located about ft. above the mezzanine floor, and the downward travel the cores. From this point on, the cores pass through the cooling and recuperative zone, encountering cold, in- duced, atmospheric air, which cools them permit their unloading. This also saves and carries back into the oven large proportion the heat the cores, core plates, core driers, baskets and the conveyor. WENTY Girls, Ten Each Side, Work the Mezzanine Floor (Left) and Load the Con- veyor Which the Small Core Oven. The oven shown the background. Empty baskets come through the hatch (lower right) from the unloading station below Serves Drying Oven Standing Near the Pasting Benches. occupies floor space ft. in. ft. in. Blower, gas burner, recording and controlling cabinets and stack show the picture Temperatures are controlled Leeds Northrup Co. four-point recorder-controller. The conveyor was furnished the Palmer-Bee Co., Detroit. Large cores are baked overhead oven made Young Brothers Co., Detroit. built three parallel sections, and served Palmer-Bee Co. the core-making stations, conveyor 980 ft. long. which are the main floor, the conveyor suspended from overhead track which forms large The baskets, each designed with eight trays, hang from the conveyor chain. These baskets, following the U-turn, pass between three rows core machines. Fourteen machines stand immediately outside one the straight runs, and machines have been placed along the outside the opposite straight run. Be- tween the conveyor runs are machines with work benches placed back back. Freshly made cores are placed the baskets the workmen any convenient point along the U-bend. The conveyor then pitches and enters the first over- head oven unit, which 200 ft. long and which has Shearing 7 Sprocket ‘Device | | Blower Combustion Chamber Flow Counter the Direction the Conveyor Travel (Baking Oven, Right). oven baffle extends from the combustion chamber the upper sprocket wheels. self-contained. That is, baking chamber ft. in. wide and ft. in. high. returns through the second section, which 200 ft. long, and then turns into the third section, which about 100 ft. long. the preheating section are five single gas burners, then follow double burners and finally two single units. Burners are not used the third section. Leeds Northrup Co. control equipment regulates temperatures, which range from 375 deg. Fahr. near the entering end the furnace 600 deg. the hottest point. the end the third section the furnace the WIT conveyor returns the foundry floor level, where unloaded the men who perform operations such rubbing and pasting. Slack adjustment the chain made this end the conveyor. From this point horizontal run brings the baskets back the U-turn the core-makers’ station. Space remains for second unit this kind. Since the oven mounted above the foundry floor, will practicable, need be, spot several rows molding machines the main floor beneath the ovens. Except under its entrance exit inclines, this conveyor has clear height ft. from floor level the bottom the oven supporting beams. The oven shell composed standard insulated steel panels, held heat-tight and rigid boltless tele- scopic joint. The body the oven carried struc- tural steel framework, and tied one the building side walls. The significant feature the use the floor area directly beneath the oven that the ~& Conve - —_= TRAVEL CORES the small core The drying oven (left) the conveyor and sprocket wheels are inclosed the oven casing oven temperature way inconveniences the work- men there. The insulation the oven floor such that normal room temperatures beneath are not changed when the oven operation. The conveyor carries 144 core racks, spaced ft. carry 3240 sq. ft. shelf area into the oven each hour. used this installation, probably will when peak production loads are required. Although the final refinements the installation The Iron Age, May 31, 1928—1525 Combustion x 7 r While the maximum speed has not yet been BS — « = Unloading Station, Where the Conveyor Leaves the mall Core Oven the Foundry Floor Level. have not been fully completed, preliminary test devel- oped the following: Production rate racks hour.... Number racks hour... 26.2 Total time oven hr. min. Shelf area per hour (not unused area) 2,200 sq. ft. Wet sand per 410 Wet sand per 10,700 Ib. Plates and driers per hour. 21,750 lb. Weight of rack and chain per hour. . 24,900 Ib. Total iron per hour.... 46,650 Ib. Irom tO SONG TALIO..... 4.36 Water evaporated from cores oi 640 Ib. Maximum baking temperature 450 deg. Fahr. Gas required per hour 5,800 cu. ft. Gas required per pound wet sand 0.54 cu. ft. the test above referred to, the oven was oper- ating about half capacity terms core tonnage. Subsequent the test the wet sand load for the same chain speed was doubled, and, while accurate read- ings were taken the gas consumption under these conditions, was estimated roughly below 0.4 cu. ft. per pound cores. The oven gas fired, using high-pressure gas system, the pressure being sustained per sq. in., with positive action blower. The pressure distributed burners located along the oven floor, each burner equipped with special inspirator which entrains the proper amount air for combustion. From eight special burner tips are mounted each burner, the number depending the amount heat desired the several points. The burners fire horizontally direction counter the movement cores through the oven—thus facilitating the ventila- tion system used. The flame from each jet impinges sharp angle upon fire brick surface which aids heat distribution and eliminates the possibility any single burner being temporarily smothered air poor oxygen. Each burner has individual pilot light fed from independent gas supply, another operating safeguard. With the heating and control elements dis- posed, the cores their passage through the oven are heated evenly and gradually until the moisture the core binder driven off. From the point which the 1526—May 31, 1928, The Iron Age the horizontal run beneath the mezzanine floor one man removes all the cores made girls. Gas burner, auto- matic temperature control valve, recorder and recorder controller and starting equipment for both blower and conveyor are shown here volatiles are entirely removed from the cores only suffi- cient heat added maintain baking temperature. Large and Small Cores Run Through Same Oven Although the oven was designed handle only one certain class and size cores, both large and small cores are being baked simultaneously. The baking time for this mixed load the same that originally expected for the smaller cores alone. The cores vary small cores in. thickness. The conveyor this oven the malleable iron universal jointed trolley type. The trolleys are fitted with two 6-in. diameter cast iron, chilled-tread, single- flanged rollers fitted with two Timken tapered roller bearings. These wheels are, turn, mounted high-grade steel shaft from which the load pended means portion the double-jointed trolley link. The other half this link forms the double joint which allows bending horizontal plane. The trolleys are spaced ft. in. centers and are capable carrying suspended load approximately 2000 2500 each. The trolley track, installed consists two 4-in. 3-in. %-in. angles supported approximately 5-ft. centers. This conveyor was furnished Palmer-Bee Co., Detroit. Mahr Mfg. Co. continuous vertical-type drying oven stands near the pasting and blacking benches. This unit ft. in. long, ft. in. wide and ft. high. self contained, that the basket conveyor chain passes over sprocket wheels located the bot- tom and the top the oven. The pasted cores are placed the baskets one side the oven and removed from the opposite side. This unit fired single combination gas oil burner. The change over from one fuel the other can made min. The combustion cham- ber in. square and extends the full width the oven. Products combustion escape through slots the roof this chamber and, after having been tem- pered with cold air, are guided baffle through 4 | the down-coming line baskets. This unit, like the other vertical unit previously described, two-pass oven with the air-gas mixture flowing counter the direction travel the conveyor chain. The air-gas mixture taken from the oven stack which located point just above the loading opening. Temperatures, which range from 100 deg. Fahr. 475 deg. Fahr., are automatically controlled. analysis the value this equipment shown the fact that core-making methods formerly em- ployed this foundry limited output the equivalent about 350 cars per 16-hr. day. The new layout steps this 500 cars and, duplicate units are installed, for which there ample room, the output this foundry, expressed cars per hr., will close the 1000 mark. Flywheel Production Unit Another example savings resulting from the use modern equipment foundries the new production unit recently installed Nash foundry. consists essentially elliptical Palmer-Bee Co. conveyor, 310 ft. circumference and carrying 138 fiask tables. Beardsley Piper Co., Chicago, sand- slinger mounted inside the conveyor and one end. Molds are made four machines, mounted turn- table. Electric hoists remove the drags and copes from the molding machines and mount them the conveyor tables. The completed molds are poured along one side the conveyor and then travel around the opposite side the shake-out station. The rough castings are removed from the sand and placed inclined con- veyor that elevates them overhead platform which are mounted three tumblers. This platform stands inside the area bounded the flask conveyor. The cleaned flywheels are rolled down chute the main floor level. With former practice 400 flywheels were made 10-hr. day floor space 2700 sq. ft., which does Looking Down the Molders’ Stations Along the U-Bend the Conveyor the Large Core Oven. not include the area required for tumbler equipment, located another part the building. Molding, pour- ing and cleaning operations 1200 flywheels are now performed 10-hr. day floor area 3915 sq. ft. This figures 6.75 sq. ft. per flywheel the old method and 3.26 sq. ft. required the new method. Cost per flywheel the new method only per cent the cost producing the old method. Worcester Engineering Society Organized Worcester, Mass., sections the various national engineering societies have come together establish the Worcester Engineering Society, the membership which will include all accredited engineers the city and vicinity. While the identity the various sections will not disturbed, all members the new society will receive the benefits participation, when desired, the deliberations the American Society Mechanical Engineers, American Society for Steel Treating, American Institute Electrical Engineers, American Chemical Society, American Society Civil Engineers and the Society Automotive Engineers. Officers elected mail ballot are: President, Ad- miral Ralph Earle, N., retired, president Worcester Polytechnic Institute; vice-presidents, Lester West, Albert Gifford and Clifton Hood; secre- tary, Fred Crosby; treasurer, Stuart Anson; counsellors—Prof. Arthur French, for civil en- gineers; Dr. Lowell Milligan, for chemical engineers; Robert Bigelow, for steel treaters; Roger Mater, for mechanical engineers, and Edward Bauer, for engineers not affiliated with the national societies. The Indianapolis chapter, American Society for Steel Treating, will hold its first annual June frolic June Idlewold Park, near Pendleton, Ind. Frank Oakes, Link-Belt Co., chairman the committee arrangements. Core- carrying baskets pass the left along the far side the bend and toward the oven the near side. The sand bins are filled overhead crane. The elevated oven the background The Iron Age, May 31, 1928—1527 | : Need Amended Laws Cut Waste Uneconomic Distribution Cannot Corrected Without Changes Statutes, Says President Schwab Institute Meeting— Suggests Committee Study Problem TEEL manufacturers were urged seek change existing laws step toward eliminating eco- nomic waste Charles Schwab, president the American Iron and Steel Institute, address opening the thirty-third general meeting that or- ganization, held Hotel Commodore, New York, Fri- day, May 25. recommended the directors that committee expert steel men appointed “to study this prob- lem with view frankly recommend the public and the proper public authorities constructive plan which may result such modification existing law will enable the factors the steel industry achieve those economies which are so.important, and the same time suggest such plan Government knowledge and possibly supervision such measures may proposed taken will adequately and thoroughly protect the public interest.” The steel industry, Mr. Schwab stated, has gone about far can expected the reduction costs, and, under present competitive conditions, “its low margin profit not conducive sustained na- tional prosperity.” prices would helpful the industry and fair customers, but even with change prices there remains possibility reduc- ing costs further eliminating wasteful methods distribution. Cross hauling steel one the most glaring examples waste distribution. Laws Force Uneconomic Conditions “The steel industry law-abiding industry and the members are law-abiding citizens. But surely where laws force uneconomic conditions into existence one may well consider whether the laws should not changed. obviously the interest that every industry should conducted upon the most eco- nomical basis possible. equally important that the public interest should all times protected against agreements affecting prices trade conditions which might themselves become burden upon the public. But surely between these two horns the dilemma there must middle ground which would the interest alike the manufacturer and the consumer, and national prosperity whole.” Proposed Changes Submitted Government commenting his proposal that committee study the problem the industry relation exist- ing statutes, Mr. Schwab said: ‘Business these days must done the full light day. None has any thought entering into agreements arrangements along these lines which shall other than the broadest public in- terest. are perfectly willing, therefore, and hould perfectly willing, that competent Govern- ment authority should thoroughly advised that propose along such lines. should equally confident that competent public authority, act- ing under the influence enlightened public opinion, would sanction all such measures were obviously the general interest. Here problem practical business statesmanship which feel the American Iron and Steel Institute may wisely and con- structively address itself, and confident that the ability this industry capable developing meas- ures that will commend themselves the American people.” “No one can view the steel industry today without reaching the conclusion that this fundamental Ameri- 1528—May 31, 1928, The Iron Age can business apparently content with profit its investment amounting little more than the interest one can earn from savings bank deposit,” asserted Mr. Schwab emphasizing the poor earnings steel companies. “Here business which provides the essential elements practically all industrial, manufacturing and transportation effort. pays its workers higher wages than are paid almost any other line manu- other industry the world. Capital investment the steel business greater today than ever was. Our output reaches record volume. are wonderfully well equipped and organized perform the enormous service which the development growing country demands this basic industry. not think, however, that this country intends demand the service are rendering for the small return which the steel industry currently receiving. not mean imply that the steel industry expects large returns. But have right expect, and the public interest, that earn enough provide for the expansion, modernization, ana development our plants which the country’s ever-growing needs constantly require. “The economic ills the steel industry are well known and have been much discussed that need refer only the outstanding facts. The total investment the steel industry this country ap- proximately five billion dollars, which approximately one and one-half billion dollars has been added during the last years. The rate return upon this invest- ment five billion dollars has been approximately per cent, and virtually return all has been earned upon the additional one and one-half billion dollars last invested, the total earnings the industry today being only slightly more than they were years ago, before the additional investment plant had been made. The rate return upon investment our industry al- most, not quite, the lowest return earned any the principal manufacturing industries. Low Profits Imperil Wage Scale “Low profits, besides depriving security holders fair return upon their investment, also tend im- peril the general wage scale the country, affording they constant temptation the management industries reduce wages, the only solution their economic difficulties. Everyone agrees that the prosperity our country intimately connected with the liberal wage scale now prevailing, and serious- minded man would argue that reduction wages this country desirable thing can possibly avoided. “Assuming the general acceptance plea that the rate return the steel industry inadequate, let consider for moment what remedies can suggested. The two most obvious remedies are, course, reductions cost increase prices. the first suggestion would say that the steel industry has already gone very far reductions cost, the experience our own company showing total reduc- tion $7.27 per ton the average cost production between 1923 and 1927.” Cross Hauling Burden Producer and Buyer Alike commenting the economic losses through cross hauling steel, Mr. Schwab said: “It manifestly uneconomic for steel manufac- turer Chicago ship 100,000 tons steel Pitts- burgh time when Pittsburgh manufacturer shipping like quantity like material from Pitts- burgh Chicago. The sales each case must made prices prevailing the districts where the steel sold and consequently the sales price nets less the manufacturer each case than they would have netted the Chicago manufacturer had supplied the Chicago market and the Pittsburgh manufacturer the Pittsburgh market. “The example that have used cross hauling be- tween Pittsburgh and Chicago extreme case which, actual practice, probably seldom occurs, but illustrative cross hauling which does occur very large quantities from various districts. This problem which the buyer steel, well the producer, is, should be, vitally interested. must not assumed that all the cost this cross haul- ing borne the producer. obvious every- one that there economic waste permitting the cross hauling exist and should obvious that this waste paid for jointly, although perhaps indi- rectly, the consumer well the producer steel products.” Award Medal Memorial Gary Mr. Schwab expressed his appreciation the high honor paid him and the American Iron and Steel Institute the recent meeting the Iron and Steel Institute Great Britain, when the Bessemer medal was conferred him. also stated that decora- tion sent him the King Roumania was, his be- lief, intended expression gratitude the Amer- ican Iron and Steel Institute for its enthusiastic recep- tion Dowager Queen Marie her visit this country. Referring again the British honor, asked the approval the membership, which was given unani- mously, change plan regarding the Gary Me- morial. place commemorative tablet, now proposed found “Elbert Gary Medal,” which will the American institute what the Bessemer medal the British society, namely, annual award that person who has contributed most notable services the iron and steel industry any its branches. secondary medal bron.e was also ap- proved, awarded the name the institute the author the best paper for given year. Def- inite rules covering these awards are yet for- mulated. British Institute Meet Here 1932 invitation the Iron and Steel Institute Great Britain meet this country 1932 was very warmly received, said Mr. Schwab, who was the bearer the invitation his recent visit England. Later was disclosed that the invitation the British asso- ciation had been accepted, and that the British Institute Metals would meet the United States the same time the guests the American Society Mining and Metallurgical Engineers. Industry Must Unite Solve Distribution Problem the conclusion his address Mr. Schwab called upon number directors for remarks. “The great problem today,” said George Verity, president American Rolling Mill Co., Middletown, Ohio, and new member the institute directorate, “is intelligent distribution. That problem will not met until attack industry, not individuals. Only when think terms the industry will begin make progress.” Eugene Buffington, president Illinois Steel Co., Chicago, spoke briefly similar vein. Col. Thomas Cantley, chairman the board Nova Scotia Steel Coal Co., and one the two Canadian directors the American Iron and Steel Institute, characterized Canada’s tariff policy unwise, saying that steel imports his country last year totaled $248,000,000 and would probably reach $300,000,000 this year. amendment the constitution increasing the number institute directors from was unani- mously carried. The six additional directors, however, are still chosen. James Campbell, president Youngstown Sheet Tube Co., Youngstown, has suc- ceeded Willis King the Jones Laughlin Steel Cor- poration, Pittsburgh, one the vice-presidents the institute, Mr. King having been made honorary vice-president. Sir William Ellis and General Lord Speak Banquet The attendance the banquet, held the Grand Ball Room Hotel Commodore, Friday evening, was 1635. introducing the speakers, Mr. Schwab read cablegram from James Farrell, president United States Steel Corporation, conveying best wishes for successful meeting. Mr. Farrell, who has spent sev- eral weeks the Continent, visiting the home his ancestors Ireland. Mr. Schwab also related how Marshal Foch, whom recently met France, asked that the institute apprised how highly prized the honor bestowed him some years ago. The first speaker the evening was Sir William Ellis, managing director John Brown Co., London, England. Sir William honorary member the American Iron and Steel Institute and past presi- dent the Iron and Steel Institute (of Great Britain) and the Institution Civil Engineers. knight the Grand Cross the Order the British Empire, doctor engineering and, for four years during the war, was Master Cutler Shipping for his country. paid tribute American hospitality and engineer- ing genius, being particularly impressed with our rail- roads. recalled that his firm had supplied the first steel rails laid between St. Louis and Kansas City. concluded with plea for still closer rela- tions between the English-speaking countries. Gen. Lord, director budget, Washington, effectively outlined the great savings that have been achieved since the Government has had balanced budget. Technical Program Shows Progress Quality Output The papers presented the technical sessions, ab- stracts some which follow, were impressive be- cause they indicated the steady progress being made improving the quality steel, notwithstanding high records the quantity produced. Basic Open-Hearth Steel Practice DR. process has now developed the most im- portant steel-making process, not alone here but most countries. This paper devoted develop- ment this theme along three directions: point out that the basic open-hearth proce the most important the steel-making discuss briefly some the reasons for this point out some the methods which this standing can maintained. Present Position the Process The best way bringing out the present position the basic open-hearth industry means sta- tistics, and the appendix are given tables the WATERHOUSE steel production the United States, Great Britain, Germany and France since 1900. consider our own country first, the proportion has steadily risen from per cent 1900 more than per cent 1926 and 1927. has been more than per cent for the last four years, that more than four-fifths all the steel make produced this process. the case Great Britain the proportion has risen from per cent 1901 maximum 64.2 per cent 1925, dropping slightly 1926 62.8 per cent. Since 1921 has been about per cent above. There has been marked increase since 1920 Germany. More than per cent the steel made The Age, May 31, 1928—1529 ORN Sheffield, England, Waterhouse was graduated from the University Sheffield 1901, where did post-grad- uate work until 1903. received his Ph.D. degree from Columbia University 1907. Coming the United States 1903, became naturalized citizen 1910. For years was associated with the Lackawanna Steel Co., Buffalo, metallographist, metallurgist and metallurgical and inspecting engineer until 1922. the fall 1922, was called the head the department metallurgy the Massachusetts Institute Technology, Cambridge, Mass., which posi- tion still holds. has already contributed papers the Amer- ican Iron and Steel Institute and his translated abstracts from the German and French THE IRON AGE have been feature for number years. member the American Iron and Steel Institute, the Iron and Steel Institute (British), the American Insti- tute Mining and Metallurgical Engineers, and the American Soci- Germany made the basic open-hearth process. 1923 the proportion was per cent but the last few years appears somewhat stabilized per cent. must remembered this for ingots alone; castings made this process could have been included, the percentage would have been higher. The production curve for basic open-hearth steel rising France, but the basic Bessemer still the predomi- nant process. Reasons for This Supremacy order supplement the conclusions the first part this paper, may well consider some the reasons for the supremacy the basic open- hearth process, particularly the United States. One its outstanding advantages the ability deal with raw materials that vary greatly chemical com- position, particularly the amount phosphorus contained. This well known and the exhaustion much the low-phosphorus iron ores has required methods that will make good steel from pig iron with varying amounts phosphorus above the Bessemer limit. For many years the basic open-hearth process was considered the method which handle raw materials that lay between the acid Bessemer limit phosphorus and the limit for basic Bessemer prac- tice, but now being increasingly recognized that this process through certain modifications can success- fully handle pig iron very high phosphorus. Another reason for the growth the basic process its well-known ability successfully deal with the large amounts scrap. This scrap varies greatly kind and composition. However, not generally recognized how flexible this process regard the percentage scrap that can the charge. De- pending upon the amounts pig iron and scrap avail- able and economic conditions, also some extent upon the kind steel that made, the percentage scrap can vary from 100 per cent. The amount scrap usually runs about per cent, but there ety for Testing Materials. tributed papers, well discussions. most these societies has con- are plants that have regularly used far higher scrap percentages than this. This flexibility regard the kind metallic charge has added the growth the process. brief mention should also made the size the furnaces. This can vary over very wide limits, much wider limits than generally supposed. Fur- naces small capacity are operating successfully, even down %-ton size. There so-called 1-ton furnace running with splendid results plant near New York. From this small size, stationary furnaces range all capacities the big Weirton furnaces generally called 250-ton capacity, but often tapping two heats together weighing 300 tons. One-hundred- ton stationary furnaces are now very common and this size furnace more less standard. The so- called Talbot, tilting rolling furnaces, are built many sizes from those moderate capacity fur- naces holding more than 300 tons. One such furnace the Pittsburgh district usually gives three 100-ton heats that follow each other quickly the ladles can brought the furnace. Variety Steels Possible Attention should also drawn the great variety and kind steels successfully made the basic open- hearth process. regard carbon percentage open- hearth steels cover very wide range. the low side have material with practically carbon, often called ingot iron, then the large tonnage rivet steels and sheet steels very often with less than 0.10 per cent, the next great class probably structural steel with carbon varying from about 0.15 0.30 per cent. Many forging steels have from 0.35 0.45 per cent carbon. Rail steel, which about three million tons made each year, varies from about 0.60 0.90 per cent, and spring steels and steels for special purposes are made with carbon reaching high 1.4 per cent some cases. remarkable range steels, but this does not tell the whole story because does not in- Volume Business Promises Exceed That 1927 speaking business conditions, Mr. Schwab stated that was presenting the joint views all the Institute directors. His remarks, part, follow: “America enjoying amazing period prosperity volume. been one the most prosperous periods have The past winter has ever known, and though this Presidential year, the moderation business which Presidential year usually brings about has been less manifest this year than has been the case other years when political uncertainties hovered over the horizon. The seasonal conditions are favorable, more than this time last year, and there every justification for our anticipating that the business the calendar year will, volume, excess the business last year.” 1530—May 31, 1928, The Iron Age | clude many special steels nor the alloy steels. list such steels would impressive. common with the acid open-hearth process great variety fuels can used. Producer gas still the main fuel for the basic process, natural gas still favored fuel when can obtained, and coke oven gas being used increasing amounts. The process can successfully combined with other methods steel making. For instance, under certain economic conditions, together with plentiful supply liquid pig iron, the combination the acid Bessemer process with the basic open-hearth recom- mended. This usually spoken the duplex process, the steel being marketed basic open-hearth steel. Methods Maintain This Supremacy One the main methods now being used main- tain this supremacy the basic open-hearth process keep conversion costs low and make every effort reduce them. This being striven for many dif- ferent ways. The refractory question very vital one and one phase has somewhat escaped general attention, namely, the widespread and increasing use “pre- pared dolomite” for refractory purposes, particularly hearth repairs. Dead burned magnesite, imported from abroad, still the standard material for putting new bottoms. Each year sees increasing amount “prepared dolomite” being used the expense largely this im- ported magnesite and single-burned dolomite. Some the trade names this prepared material, arranged alphabetically, are: Kendymag, Magdolite, Magnefer, Magnite and Syndolag. good deal this class material being used. accurate figures are col- lected but estimates those qualified judge believe low figure 200,000 net tons annually, correct, and that may high 300,000 tons. The question the amount fuel consumed the basic open-hearth process constantly receiving much attention. There has been splendid series papers presented before the institute, starting with Mr. Whig- ham’s paper 1913, dealing with the questions the various fuels used, port design, regenerator design, waste heat boilers, gas producer practice, thermal effi- ciency and studies the heat balance the process. Fuel problems were gone into rather fully Mr. Forbes’s paper, last October, need not considered here. However, mention should made the fact that coke oven gas alone being successfully used. More becoming available from year year. battery coke ovens being built one steel plant that will heated with blast-furnace gas that all the coke-oven gas will set free for other uses. The use this fuel for the open-hearth furnace will simplify certain features design. regenerators are needed nor should used for the fuel, and the port design will approach that used for another high value gaseous fuel, natural gas. Another method maintain supremacy pay the most careful attention furnace design. This ORN New Brighton, Pa., Smith was graduated from Ohio State University, Columbus, 1913, where spent addi- tional year special work before becoming connected with the Gary Later entered Colum- bia University for further special training, following which became instructor Ohio State University. During the war was con- nected with the aircraft production office Pittsburgh. 1919 joined the Central Steel Co., Massillon, Ohio, chief inspector. Since then has successively held the positions mill metallurgist and chief metallurgist and now assistant general superintendent the Central Alloy Steel Corporation. member the American Institute Mining and Metallurgical Engineers, American Society for Testing Materials, American Society for Steel Treating, American Chemical Society, Iron and Steel Institute (British), and the Institute plant the United States Steel Corporation. Metals (British). constantly followed. Almost every time furnace rebuilt some change made which hoped will im- prove its efficiency, speed the time operation, improve quality and reduce costs. The present ten- dency larger furnaces, particularly the case stationary furnaces, and experience has shown that quality has not suffered growth size the heats. author gives this point rather detailed discussion the tilting furnaces, which important part the paper.] Study the Reactions Which Take Place One the main ways which the supremacy the basic open-hearth process will maintained will further study the reactions that take place steel making, the reactions the slag, and the inter- reactions between slag and metal. All these are profoundly affected temperature and the concen- tration the various reagents both slag and metal. now the custom call this whole subject the physical chemistry steel making, very so, for the reactions obey the laws physical chemistry. This wide subject will provide most fruitful subject for research for many years. will undoubtedly show how make more steel given time, thereby reducing costs; and how make better steel, thereby improving quality. The importance the slags the steel-making processes not yet fully recognized the steel mak- ers. All the recent scientific work teaches and demon- strates that the question slags the greatest importance, and should the effort those inter- ested the basic open-hearth process take every ad- vantage this information. Before many years, believed, regular tests will taken the slag during the working the heat, sent the laboratory and analyzed similar ways the steel samples. When open-hearth men are agreed the prime impor- tance slag volume and composition, then systematic tests will worked out which the volume can determined any time during the working the heat and the composition found out regard the ele- ments compounds that are important. Another element that could readily determined the slag the manganese, and the results might value estimating the slag volume. the man- ganese the charge were known, and manganese had been lost run-off slags, the determination this element both bath and slag might value, be- cause are learning good deal about the laws gov- erning distribution manganese between bath and slag, and the effects brought about. Determination Slag Volume Valuable fairly accurate method for determining slag vol- ume would great value. All open-hearth men realize the need keeping this low possible order speed the transfer heat from flame metal, save fuel and increase production. the other hand the volume must great enough that enough lime, oxide iron, may present carry The Iron Age, May 31, 1928—1531 | the reaction with the bath and sure that the im- purities are not concentrated the slag that they are readily reduced back into the bath. The present ten- dency often carry too large slag volume, shown the high percentage limestone charged, the safe side and help make the process fool-proot, Another the main methods which the suprem- acy the basic open-hearth process can maintained the production still better steel than present, that is, steel improved quality. This calls for con- stant attention metallurgical practice and increased care every step the process. For most the steels made, demands the greatest possible freedom from the non-metallic impurities, the “sonims” Mr. Hibbard’s excellent paper presented here 1919. The Manufacture Alloy Steel SMITH ITHOUT attempting legal exactitude, alloy properties are dependent upon one more alloying elements. This leads the conclusion that alloy steels must special steels and that chemical composition hardly the vital factor. true that the special product today will hye +h the standard product tomorrow, will well consider trends alloy steel manufacture. may more interest consider the advancing knowl- edge steel working. The increased study routine requirements establishing the brand type speci- fication. alloy steel must meet very specific set requirements. this type specification liable become more widespread, inquiry into alloy prac- +, conditions will interest. Control Charge Necessary thods conversion are re- tonnage. Essentially the sources—open-hearth and elec- greatest tonnage es, the are type electric arly meet the requirement sfully melt all combinations satisfactory for basic open- ld, therefore, cover the essen- ating processes. country, the essential the pig iron. The problem not ivert teel scra use the into special alloy steels process which pig iron primary steel production. pig iron with about per sulphur well under 0.05 per anganese ores carry the per cent the iron apparent- ming standard practice. nanganese to about ding metallurgical reason which necessity remelting pig iron. The in- dustry essentially dependent upon hot metal melting practice, with limited production cold melt steels. The usual production from cold iron limited chem- combinations require special iron nganese peculiar sulphur re- the ecial steel business steels are based upon the melt- ting ra} Railroad scrap might lered the most de rabl nd i 1 standard mate- rial hould carefull eparated into definite ranges compositior physical characteristics; rail steel should structural teel another. Balanced charges designed melt properly can made only definite lots chosen + ] + sath + + + 45 erial. rather startling find that certain spe- steels are successfully made only with light scrap. The iterials such ferroalloys, bottom ime, fuel material, etc., should carefully ore reasons than are apparent rlan ltin glance. All melting practice, whether open-hearth, electric crucible, actually fine art. the raw materials are kept very uniform, the Furnaces and Fuels Used ing will | ] may assumed that all vill simpler + the physical constants the metals alloyed are 1532—May 31, 1928, The Age similar. the essential base, body centered over its workable ranges except from 1400 900 Ironmaytherefore expected alloy more nat- urally with body centered materials: chromium, molyb- denum, tungsten and vanadium. Gamma iron may also expected alloy with certain face centered cubic materials and find nickel, cobalt, copper and alumi- num this group. more important grouping whether the alloying materials oxidize melting. Nickel, molybdenum and copper are stable, and chromium, manganese and vana- dium are not. thus find the alloy steels sharply divided into two groups. may expect the oxidizing open-hearth process the main source alloys nickel, molybdenum and copper, while would expect the chromium, vana- dium and similar steels made electric furnaces under conditions nearly neutral possible obtain open-hearth furnaces. The open-hearth for alloy steel conventional design. Probably the most satisfactory fuel coke oven gas with enough liquid fuel tar oil give the proper flame conditions. Liquid fuel, such tar oil alone, very desirable. ore charged with the lime and fact ore rather sparingly used. This characteristic guarding against over oxidation would appear the essential dif- ference between tonnage practice and special practice. The elapsed time from last ore feed clean usually two hours and the clean and alloy period usually one and one-half hours more. Burnt lime, silicon pig (both and per cent), spiegel and silicomanganese, pig iron billets, are used for slag shaping. customary indicate the mate- rials used shaping and finishing the heat even more carefully than the choice scrap used the charge. Many Intangibles Included Demands Essentially coarse-grained fine-grained steels, steels that anneal under certain conditions, steels that machine, forge, roll certain ways are all characteris- tic requirements the industry. The user the future will desire the privilege incorporating intangibles into the requirements. That this the trend has been well shown the spread specification for carbon- izing steels with intangible physical requirements. importance the maker tonnage steel recognize that the intangible physical requirements are detriment tonnage production and any attempt combine will result compromise quality the special steel and cost the commercial tonnage steel. These intangibles are usually intimately associated with the finishing stage the heat and are inti- mately connected that the judgment trained melters usually cannot relied upon and certain specific rou- tines are set up. The average result safer than in- dividual judgment. example, might mention order for bar stock for differential gear forgings. The order may The intangibles this specific order may fol- lows: “Two-inch round 2315, for John Doe Co., regularly used for spiral bevel driving pinion model Forging produced upset process; bar ends make smaller gear; size must accurate; length important but not vital. Chemistry must low aim carbon 0.11 0.14 per cent. Stock will checked for McQuaid-Ehn rating, two five desired. Stock will (Continued page 1578) | VW All the commercial sponsible for some tric furnaces. far the pen-hearth material. the secondary furnace appears most ! unit that can which ar rot wnicn are not commerel } +h +o neartns. The St idy tials the two domin A ope rate d in this Diast convert the most necessary pig iron teel products. The x actually i crap con not dominating TI + t \ is ent silicon, which ent The addition nect } om more nearly constant. | Machine Tool Sales Problems Discussed Confidence Future Industry Expressed President Bliss Builders’ Association—Best Policy Establishing Prices and Appraisals Used Tools for Considered EVIEW problems encountered and appraisal opportunities the machine tool industry held the close attention 140 who were attendance the twenty-sixth spring convention the National Machine Tool Builders’ Association, which May and 23, the Hotel Stevens, Chicago. Papers price making and appraisals for trade-in deals were read general session which followed the busi- ness meeting. Interest the group meetings was clearly shown the fact that discussion ran such length that difficulty was experienced adhering schedule. Report the exposition committee favored holding machine tool exhibit 1929. Benefits derived from uniformity cost analysis and methods and also standardization were presented report Ernest DuBrul, general manager the association. Confidence the future the machine tool industry was ex- pressed address the president the associa- tion, Bliss, the Warner Swasey Co., Cleveland. said, however, that many problems are still solved. tremendous amount free service being demanded, and many have recited how heavy are the costs engineering service both for special adaptation standard machines and for the invention and design special fixtures and tools. Opportunities were divided Mr. Bliss into two general classes. First are those which afford chances better the general situation result individual efforts. Undoubtedly economies many sorts can effected and probably one these more likely result substantial savings than that reequipping and retooling machine Impartial studies individual companies would also show oppor- tunity for either reduction selling cost more profitable use the money spent that direction. second general class opportunities arises, first, from cooperative activities, and, second, through those activ- ties which may best organized and promoted through group meetings. How Selling Prices Should Established The best policy selling prices set figure that will bring the highest continuous returns, said Flanders, manager Jones Lamson Machine Co., Springfield, Vt., paper entitled, “What the Best Basis for Executive Policy Making Prices.” Primarily the low limit pricing set the cost production and distribution, said Mr. Flanders. the price be- low th