The Iron Age 1928-06-07: Vol 121 Iss 23

ESTABLISHED 1855 VOL. 121, No. Cupola Fired with Powdered High Temperatures, Greater Strength and Lower Total Fuel Consumption Absorption Sulphur and Close Control Carbon American Radiator has proved that through the uUSIVELY a> a unl € € ‘ reduce ‘ rati tietfanrt ‘ nite ) m y é j é ; y + + with satisfactory results. otal fuel consumed — + ; 14 § + . a l OL cast iron, so 1t i ause I reaction he behooved the foundry- Ong ween the carbon dioxide and men to meet tnis require- he / € tne carbon of tne oKe above f + ry ting ne The com- nm r > or 1090" 4 - + + } + + 14 EAA ried ree 14,544 B.t.u., where- it, and, doubtless, mar - is ir y ame amour m ave pee! ad arve I r ol eratior if Ssuaily iava I ] ] ru 3s ver erat nm is ti proDiem tnat must ~ in ipoia puiverizec dex le neotit > fu 2 + n + Dust + ehamber + 1 + + + on lane 1 stvie cupola ] a ga are + + it full ar Int About a ve: and a halt ae eslache Th, hetureen the amount ¢ Bow ut a year ana a ax. | ic, A vv ii aiti 4 i ai I American Radiator Co., conceived the idea amount powdered regulated L + no rn tr I + + ot ] an Imum coKé narge,. Dy ft al } iu itra jue 3s fact, tme coKe qucts of comopus to pass dir ma ] i i reiore, poss1Die ne ld up the ed na mn a charge of coke of ? ¢ zone at a velocity insuring penetration. ana mel a Cnarg K my Ww only one-half that ton coke, and, ie that running on +h + 2am melting + +ntal rex » Tne more arcvrate f eompus- meiting ratio, namely, iron total fuel, more ex- more accurate controi Ke with coal. } yaered ipoia, we overated in a ve Carpoon we use ik 4 a are ilxewl aseqd. AS tion coal takes the chambers and the r t gases nasa mt the th hot pass into the the New York, June 1928 1593 not pick any the sulphur the powdered coal and only very small amount the sulphur from +h L ac al DY ¢ { the coke, because, already mentioned, only r cent of coke between charges is used. the Illinois plant ran for comparison same iron mixture with the same grade coke both the powdered coal cupola and normal cupola and found that the sulphur the iron melted the powdered coal cupola was from per cent wer than the iron produced from the upola, and that the total carbon decreased approx 2 >> + tnere was iess oxidat I as tne r contr is Ss 43) no atm that neutr reducing atn heat ne two Samy} es S till uk 3 + +} melting the red ry la nine nt ty } ed innin } + n vaered i cu Sample hic ul I = Graphite Precipitation Very Fine Micros resear work al Ss ~ mix- lré a very fine gr \ I graphit There must this xtrer 4 temperatures (a powdere ve + ana } = + i! rs and I much has iblished regarding } ‘ no ¢ rec lre T Physical Properties Compared rmal cupola and powdered coal cupola, have | +> te 7») I y 00 It reakinge renot at) CU} a, 3300 transverse deflec- ir rom ¢ red 1 transverse strengtl rag 1468 } vit de- o! 1 Will igre a es r cast lil As efore i, iro! m the vdere cupola snows per ess content tnan tne same ! xTure 1Le¢ a ly a .e- leiting our emeit ir s wed a \ e} ing SUITICIE an u ne ce W n ai. ne I ] ] > up sulphur is practically neg] vidi Remelt iror with show average increase sulphur cont than 0.020 per cent. How account for the iron not picking our theory that the sulphur passes off the form either sulphur dioxide, sulphurous acid sulphuric acid. The question naturally arises: 1928, The Iron Age What the source the hydrogen? The answer lies the fact that coal used with approximately per cent volatile matter, which comprised partly hydrogen. addition this, the fuel carries per cent. not necessary dry this fuel before pulverized. Equipment Necessary The cupola stack ordinary straight stack and not differ any way from the stock Whiting upola without the wind belt. The powdered coal now use has melting zone diameter and shows hourly output about tons. has four combustion chambers parallel the cupola stack. the top each chamber the burner bottom each one the entrance for the hot gases from the combustion chambers the stack. the same elevation the tuyeres normal cupola and replaces them. Life Refractories Before starting the experiments, the present oper- the powdered coal cupola were the opinion ing the combustion chambers would not withstand the temperature, but experience has shown hat the lining does not give any trouble. date, the upola has been running over six months without re- ining the combustion chambers, and from all appear- they look the same when installed, except hat the bricks are well glazed throughout. for the patching operation the stack after heats, figures have been compiled which prove that sts more maintain linings this cupola than the normal type. Economies and Advantages Claimed For average heat takes 130 lb. fuel melt one ton iron, coke averaging per cent the 2 ‘ ke + tal 4 Pp ¢ tal coke melting, would take 250 lb. coke melt iron - $0.67 from $1.35 shows $0.68 The overhead for powdered coal installation esti- mated from the experience the Whiting Corporation Grindle pulverizers connection with malleable irnaces The costs coal and coke are those the Illinois plant Other Metallurgical Benefits Additional benefits estimated from metallurgical viewpoint cannot given dollars and cents. easy understand that, with the metallurgical advan- +h the use powdered coal, larger amount scrap can used the mixtures with beneficial re- tfagec Lanes recent tests the fuel ratio, coke coal, has changed our favor, which means that have been able change the fuel consumption per cent Theoretically possible coal and per cent coke. sults. fire the cupola with powdered coal alone, provided sufficient refractory material can found support the charge. The present installation does not permit such operation, but this paper not intended state that the powdered coal cupola has been perfected. Temperatures the iron the spout the pow- dered coal cupola compare favorably with those the normal cupola. They can best judged the light metal type castings which are being poured and which have tested from 400 1000 hydraulic pressure and 300 lb. air under water. The temperature the spout averages between 2650 and 2700 deg. Summarizing the advantages claimed for the pow- dered coal cupola: First: Avoidance picking sulphur the iron from the coal fuel. Second: Better control carbon the mixture because the more accurate control combustion, and higher strength because superheat. Third: The possibility extensive reduction price various mixtures. Fourth: Saving melting cost because small- amount fuel required. Accidents Fewer and Less Severe Metal Industries Frequency Rate Dropped from 35.45 26.59 Per Cent and Severity Rate from 2.44 1.85 Per Cent decrease both the severity and quency industrial accidents the metal indus- tries during 1927 compared with 1926 shown the annual report accident experience members the National Safety Council, just published that organization. The average accident frequency rate, number lost-time personal injuries per one million hours’ exposure, 450 metal-working establishments reporting 1927 was 26.59, compared with 35.45 318 plants 1926 and with average for the five years ended with 1926 36.06. The accident severity rate, loss working days per 1000 hr. exposure, was 1.85 1927, against 2.44 the preceding year and five-year average 2.23. The frequency rate 208 establishments, per cent the total reporting 1927, was below the previous year’s figure, while plants, per cent the total, had lower se- verity rates 1927 than 1926. Thirteen establish- ments completed 1927 without lost-time injury. the accompanying table shows, eight groups into which the metals section has been classified re- decrease accident severity rate 1927 with 1926. tre- Those showing increase were machinery and machine tools, railroad car builders and manufacturers tubular goods. Increases frequency rates were reported bolt and nut manu- facturers, malleable iron foundries, machinery and ma- chine-tool makers and steel foundries, while the re- maining nine groups showed decreases. Metal Industries Close Average That the accident record the metal industries ap- proximates that manufacturing industries whole shown the fact that 2089 establishments reported the national council average accident frequency rate 1927 25.95 1927, compared with 31.87 1926, and severity rate 1.88 last year, against 2.50 the preceding 12-month period. The automotive industries had frequency rate 21.51 1927 and 23.60 the previous year, while the severity rate this field was 1.01 1927 and 1.37 1926. The con- struction and petroleum divisions reported higher rate both severity and frequency last year than 1926, while the higher the frequency rate was the rubber group. All the other industries reported decrease structural steel fabricators, gray iron foundries, makers both the severity and frequency accidents 1927. Comparison Accident Experience Metals Industries 1927 and 1926 N 4 Tota N No. Da Group Ce N Hours Lost-T L I j v E I ~ Work i A ler Na I t yk ri 228 9,266,885 401 59,947 $3.27 6.4 5,13 12,312,166 28 11,881 26.64 0.9 é 7 4,561,011 70 7,529 15.35 1.6 556 23,256,531 161 92,111 ] 7,216 17,725,475 $23 64,732 80.30 2 14,794 37,140,7 23 41,4 1 2.4 19,038 $8,551,841 132 64.52 2.1 : 2 10 | 26,465,019 1,103 44,454 41.¢ 1.¢ shops with undries 7 6 216,161,972 4,444 294,441 20.56 1 $0 8.509 94,560,087 2,521 166,581 26.67 1.7 Mach and machine l 89,315,238 3,234 175,90 36.21 1.9 51,010 128,918,842 3,706 219,568 28.75 1.7 1 6,9¢ 13,055,266 465 1708 35.61 4.57 1926 ) 9,870,834 415 16,44 42.04 1.67 Steel plants 1926. 252,275,354 750,018 2.09 2.97 Steel foundries: 21 7,747 20,13¢ 1,039 2,459 1.60 2.64 Tubular goods makers 23 12,612 35,171 1,151 91,110 2.73 2.59 7,845 20,794,330 684 38,628 2.90 1926. 15,593 37,880,332 1,424 71,077 37.59 1.88 Miscellaneous 3,946 10,914,285 314 28.77 7,070 17,960,452 520 28.95 $50 226.362 818,618,172 21,764 26.59 1.85 Total 1926... 318 261,441 686,213,992 24,328 35.45 2.44 Age, June The Enlarging Steel Mill Possibilities Greater Flexibility and Increased Range Product for Timken Plant—Unusual Melting Furnace the Timken from the two new open-hearth furnaces. Space for Ohio. will consid- these and for the new electric furnace will provided 240-ft. extension the steel plant building, which, Jot only will the output with leanto, 153 ft. wide. New handling equipment lling alloy steels installed the electric furnace and open-hearth lant will produce wider departments will include 165-ton ladle crane, 30-ton ex- crane over the charging floor and 5-ton open-hearth pected that, with equipment and with the charging machine. The stock house will enlarged will reduced considerably and the same time Melting equipment the enlarged steel making higher quality product will produced. en- plant, with the additional units, will include the new larged plant will have capacity 24,000 tons month. oval-type electric furnace, two 25-ton and one Construction now under way and expected that electric furnaces and three 100-ton open-hearth fur- new units will completed Nov. naces. addition, there are two 6-ton electric melting will include electric melting furnace furnaces another building. two 100-ton open-hearth new ingot stripping and hot top storage building, bar mill. 16-stand merchant mill which will being erected. This will equipped various interesting features, reheating furnaces, with 5-ton combination stripping and soaking pit hotbeds and other aux mill equip- which will moved from the old soaking pit ment. Several new buildings are being erected building. There will also new mold storage build- the new equipment and for storage. The arrangement ing, 160 ft., equipped with 30-ton electric travel- the mills and the ling les for wide operation. There will range the increased steel-making capacity necessitates aking pits, new soaking pit building, stand down rounds the last mer- 165 being erected. This will have three two- sizes ¢ finished bars. fror Rin r y a+ + Beat additional s¢ mill stand. hole soaking pits, each hole being ft. in. ft. The pit furnaces will served soaking The new electric furnace. Changes Rolling Equipment I } } 1] ons between the two mills. r ace 7 > jn ass from the 35-in. mill runout from the shear i rnaces will have end charge and end dis- They will ft. wide, approximately and natural gas fired. The charging table = cr = rna ec (Future) coin t ry i S Scale A Mill 1596—June 1928, The Age TEEL manufacturing Roller Bearing Co., erably enlarged nounced expansion program both steel making and terially increased, but the Exceptional Electric Melting Unit nit crane. 0 the furnaces will 114 ft. long, accommodating space for third (future) furnace. The furnaces will charged directly from the 35-in. mill with cold blooms from the chipping yard. They will charged with double pushers electrically operated. Direct Run 28-In. Mill the blooms the 28-in. mill, which will consist two stands with rolls in. long. This mill will served two traveling tilting tables reducing sets. are not reheated, they will directly y driven worm-gear speed The entering table will equipped with The mill will driven 1500-hp. induction motor through gear drive provided with fly- wheels. The runin table the mill will 150 ft. long. Bars finished 6-in. 8-in. sizes will made this mill. The 6-in. 8-in. finished sections will trans- ferred from the mill runout table rope transfer and past the 22-in. mill the first hot bed. However, most the product reduced smaller sections, and the usual operation this mill, which will applied rolling the smaller sections, will use the mill roughing mill for the 22-in. mill. The latter mill, which being rebuilt, will consist three three-high stands and one two-high stand. The first two three-high stands will have rolls in. long and the last three-high and the two-high stands will have rolls in. long. This mill will equipped with tables having solid standings and with rope transfers both the front and back sides. This will permit giv- ing the steel any number passes through the rolls. Finished bars sizes from down 1%-in. rounds their equivalent will produced the 22-in. mill. When rolls are changed, the mill housing and rolls will picked unit overhead 50-ton crane and transferred another section the mill building. New Structures Necessary The 28-in. and the 22-in. mill will located new building 288 ft. long and 100 ft. wide, which will connect the old 35-in. and 22-in. mill buildings, being located heretofore unoccupied space between these two buildings. New structures will include also bloom building, 385 ft. long and 100 ft. wide, served two 15-ton cranes. There will cooling pits this building for slow cooling some grades alloy steel which have tendency crack when cooled the open air. These steels, after leaving the blooming mill, will remain the cooling pits about hr. before going the re- heating furnaces. Cooling pits will provided also for cooling bars certain alloys after leaving the 22-in. mill. Leaving the 22-in. mill, the bars will ass runout table 260 ft. long the first two hot saws, located front the hotbed. Two hot saws working together will provided, increase the rapidity handling the steel. From the hot saws the larger sec- tions from 28-in. and 22-in. mills will new hotbed 109 ft. long and ft. wide. This will the flat skid with dog pullovers. The hotbed table will equipped with two motor-operated gage stops. Bars will handled from the hotbed with magnet, over the table, from which they will pass the end the hotbed. Smaller sections coming from the cold shear at nill will hotbed referred above, but will pass over runout table one this notched bar type hotbed, 120 ft. long and ft. wide, which was part the old equipment and has elo This will have cold shear the dis- Making Smaller Sections the steel further reduced after leaving the 22-in. mill, will the 16-stand merchant bar mill, located back the 22-in. mill. This mill will con- sist three 18-in. two-high roughing stands, five 16-in. continuous stands and two 16-in. three-high, four 12-in. and two 10-in. stands. this mill 3-in. 3-in. 4-in. billets rolled the 22-in. mill, and taken from adjoining billet storage yard, will reduced sizes other sections. From this mill the finished bars will pass mechanical hotbed, 240 ft. long. All mills, mill drives, tables and cranes equipped with Timken tapered roller bearings. The two 28-in. three-high mill stands and three new 22-in. mill stands and pinions, hot saw, transfer, tilting and roller tables, furnace pusher and bar shear will supplied the nited Engineering Foundry Co., Pittsburgh. The Wheeling Mold Foundry Co., Wheeling, Va., will furnish the traveling tilting tables for the 28-in. mill. The Mesta Machine Co., Pitts- burgh, will build the new merchant mill complete, and will furnish the furnace skid bed with runin table and pusher, billet shear, mill transfer and delivery tables, flying shear and the mechanical pack annealing cooling bed. The two open-hearth furnaces will built Alex Laughlin Co., Pittsburgh. The shear approach table will furnished the Mackintosh-Hemphill Co., Pitts- burgh. The Morgan Engineering Co., Alliance, Ohio, will build the hotbed. The James Criswell Co., Pitts- burgh, will build the new soaking pits. The Rust En- gineering Co., Pittsburgh, will supply the three re- heating furnaces. The waste-heat boilers will furnished the Babcock Wilcox Co. The drive for the 28-in. mill will furnished Gears Forg- ings, Inc., Cleveland. The American build the 20- 29-ft. electric furnace will Co. will AYOUT the New Rolling and Intermediate Handling Equipment the Timken Plant, from the existing Blooming Mill the Shear Beyond the Hotbeds. Flexibility feature, being possible run given bars through any one several mills the progressive stages breaking down the steel finished size Sump Tables {} Piercing Mill Heating Furnace Shear | The Iron Age, June 1928—1597 | | Big and Little Machines for Testing Wire Rope plants where operations are based the principle quality opposed mass production require meticulous care the test- found the factory Leschen Sons Rope Co., St. Louis, manufacturer wire rope. Research work has enabled ascertain the correct combination properties wire order produce rope for various exacting demands. make sure that each individual wire meets the necessary specifications, the testing laboratory samples and tests each bundle wire | 4 Ao BOVE Shown Corner the Testing Department With Battery Machines for Study- ing the Properties Each Wire. the portable holders the foreground for maintaining the identity samples without error. They straddle waste bar- rels alongside ma- chines and thus pre- vent accumulation litter comes from the mill for strength, elongation, torsion and bending. The laboratory adjacent the receiving depart- ment and occupies space 168 ft. long and ft. wide equipped with Olsen torsion and tension ma- chines, well with other special equipment. order avoid confusion identifying wire which being tested, portable holders shown the view have been built. Each consists metal tubes, into each which may placed sample wire, the extra length dangling. q 2 Only Must Every Wire Strong But the Ca- ble Maker Must Sure That Fabrica- tion Methods Pro- duce Rope Cor- rect Strength. 800,000-lb. Olsen tension testing ma- chine, the largest 7 ever built expressly for wire rope test- ing > | 1598—June 1928, The Iron Age Bronze Bearings for Heavy Duty New Conditions Being Met Proper Design and Crystal Structure—Some Common Errors Design—How Select the Right Material for Bearings marked development improved materials for the manufacture mechanical units, and this has not been confined the steels and irons alone. The application alloy steels, especially hardened steels, shafts journals mechanical units has enabled the engineer use new types bronze bear- ings that would have been disastrous the days the old steels. Under present conditions heavy duty, neither the old steel nor the old bronze would have stood the present punishment. both would have been subject condemnation not truly their due, but most assuredly the fault the lack knowledge the part the designer. With the advent improved materials the shafts journals, improved methods obtaining accuracy machining such rotating parts were also available. This improved accuracy longer calls for bronze bearing that has one its characteristics con- formability plasticity compensate for the irreg- ularity the workmanship machining the journal itself. Through the elimination this requirement conformability, now possible use the harder steels for the shafts journals and the harder bronzes for the mating bearings. These bronzes, through their hardness, have less conformability but are, wearing capacity conjunction with the harder steels, vast improvement. the last few years there has been Bearing Mixture Hard and Soft Crystals bearing bronze essentially mixture hard and soft crystals, the hard crystals being the support- ing media for the load and the softer crystals being the matrix which the harder crystals are embedded. When subjected wear, bearing, the softer crystals abrade first, forming microscopical pockets which the oil film tenaciously held. The hard crys- tals, being harder than the surrounding matrix, not abrade fast, but have satisfactory results from bearing bushings other types bearings, the hard crystal the bronze must not out proportion the hardness the material the shaft journal; otherwise, the shaft journal scratched these hard crystals the bearing, friction increased with consequent temperature rise, which may, turn, destroy lubrication, with disastrous results lay down law relative the relationship be- tween the crystal hardnesses the bearing and those the journal shaft impossible the light present knowledge. has, however, been definitely proved that, with the advent the harder steels and the increased accuracy manufacture these shafts and journals from these steels, harder bronzes are not only improvement but are essential long life and satisfactory maintenance accuracy the fit jour- nal and bearing. interesting note this point that bronze given chemical analysis, such many those which are now used for bearings, may, intelligently *Secretary Lumen Bearing Co., Buffalo, PATCH* manufactured, when examined under the microscope, show diversity structures, each which would have definite hardness reason the difference the amount the hard crystals present therein. Laboratory Control Essential therefore apparent that laboratory control the manufacture the bearings bushings from these alloys essential insure uniformity struc- ture that may relied upon maintain the standard the relationship between the hardness the bear- ing and the hardness the journal. After engineer has decided upon certain kind steel for shaft journal, which have certain heat treatment and will consequently definite hardness, will, turn, need definite hardness bearing bronze mate with it, and all the parts mating with the steel the several machines must exactly alike and uniform. Many designers are not aware the improved ser- vice derived from bronzes which the crystal structure has been carefully controlled. Such struc- ture is, course, more important where extreme accu- racy one the governing factors, but also essential from the standpoint long life and uninter- rupted service given mechanical device. should borne mind that, with the advent the harder steels and the use mating harder bronze, improved precision workmanship these two mating parts imperative. This is, however, much easier matter today reason the improved precision modern machine tools compared with those use but few years ago. Too Many Oil Grooves Common Error Many the plain bearings that have been con- demned have not been fault, but the workmanship their manufacture should have been more thorough- investigated. Take the common error cutting quantities oil grooves the face plain bearing. Every oil groove bearing reduces the bearing area, not only the amount the area removed grooving, but also reducing the load-carrying capacity per unit area the bearing grooved. Examine some these grooves and will found that the corners are sharp become actual knife edges, cutting and destroying the necessary oil film, even though the best possible oiling mechanism available keep re-establishing the oil film. oil groove should well chamfered its edges, help the oil film develop rather than scrape the film from the journal. Other Errors Design Again, consider the erroneous practice the part many manufacturers who, order save small amount money the first cost the bearing bushing, recessed the back the bushing save the weight, thereby making the bushing thin enough spots actually weaken the bushing point where the load not supported sufficiently. Thus the The Iron Age, June 1928—1599 ~ actual supporting area the bearing materially reduced, frequently disastrous point, causing con- demnation the bearing material, when reality was case faulty design. Examine the clearances allowed between the jour- nal and the bearing. many instances the allowance for oil films between the two mating parts insuffi- cient permit satisfactory film present, and consequently some part the bearing dry. Ob- viously, plain bearings the materials therein get bla eye here, when, matter fact, the design hould held least partly responsible Such errors the few outstanding ones mentioned are not infrequent ones, and yet the bearings, properly manufactured from the right materials, would have given satisfactory service. true that, the production the modern plain bearing, not only the correct bronze must present, but the bronze must have the proper crystal structure within fit mate for such steel jour- nals are now available and are coming into more and more common use. Then, too, both the steel and the bronze must accurately machined and, they are give the best results, they must properly housed the machine itself and held place such means preclude local pressure any one point the bearing, and thus avoid distortion. Vital Factors Design Bearings Designers who understand the application mod- ern steels modern bronzes for such bearings recog- nize that many factors must borne mind. Among these are the following: Accuracy ining Proper allowa for 1 film 3 Proper oil gr ving ; Consideration of the heat dev ped b frict i its proper radiation an i « trol These, course, are the important factors after the proper materials have been decided upon for the service intended. Such factors speed and pressure per unit area are, course, the prime ones. Ob- viously, these have been considered since engineering has been considering the design bearings, but now that the users machine other mechanical device expect double triple, frequently increase many fold, the production from given machine, the factor safety such bearings can increased only the use the best bearing material for the service conjunction with the right kind material journal mating with it. Correct Manufacture Essential Here enters the problem the correct manufac- ture the bronze for the service. few years ago bronze given analysis would have been consid- ered satisfactory the chemical analysis proved true formula. Today not only the chemical analysis must correct but the structure must also conform that best suited for the service intended. Makers bearings and bushings should equipped structure well uniform chemical analysis. Modern Worm Gears Cited Look the improvement the service the mod- ern worm gear result the control the crystal structure therein, mate with the hardened and ground worm, giving resulting maximum life. Here the punishment frequently most extreme. Lu- brication frequently inadequate, yet such gears are proving eminently satisfactory for this service and are demonstrating conclusively that the relation between the crystal structure the bronze and that the steel 1600—June 1928, The Iron Age must carefully considered give maximum satis- faction. Crystal structure bronze important from the standpoint life under bearing service, but also important such materials other types service. Witness the leaky valve pump body, subject hy- drostatic tests, which, cast the identical alloy but having proper crystal structure would develop leaks. Here, again, one sees the importance scientifically controlled castings for modern industrial needs. the preceding remarks, using the term “new bronzes” reference made bronzes produced today. They may not differ chemical analysis from those which have been made for many years but uniform- ity structure and uniformity analysis they are far superior. some cases the physical character- istics the bronze may mean heat treatment; others, the scientific control temperatures the scientific control the cooling from the liquidus the solid. The term “new bronzes” may also refer new applications the bronzes, which have been well known for years, but were considered too hard for ser- vice before the advent modern steels and modern precision machining. Selecting the Right Bronze for the Service doubt, many readers this article will ask what the proper crystal structure for mating with given steel and how can this best determined? the writer’s opinion, this subject for specialists decide and each individual case must have individual consideration. make decision this kind necessary know many details which heretofore have been somewhat passed over negligible. Some the factors that must borne mind today are fol- lows: Horsepower transmitted shaft. tevolutions per minute shaft. Load per square inch bearing area. Character workmanship machining journal and bearing. Type material and hardness thereof shaft. after hardening not? Lubricating device. Type service (whether intermittent con- tinuous). These and other minor factors all have much in- fluence the decision the right bronze for the service. Further, the question impact vice very important. thus apparent that the use and application plain bearings have advanced to- day case where specialist their application fields. Conference and Exhibition Industrial Advertisers Industrial advertisers will hold their annual con- ference St. Louis, June 11, and 13, with head- quarters the Hotel Chase. The speakers include Pollard, Jr., Harvard Graduate School Business Ad- ministration; Arthur Little, Thew Shoved Co., Lo- rain, Ohio; Sherman Perry, American Rolling Mill Co., Middletown, Ohio; John Blitz, Detroit Steel Products Co.; George Miller, president Dodge Mfg. Co., Mish- awaka, Ind.; Morrison, Ingersoll-Rand Co., New York; and Fred Davis, General Electric Co., Sche- nectady, There will exhibition covering industrial ad- vertising campaigns, placed competition for eleven different awards. The meeting held under the auspices the Na- tional Industrial Advertisers Association, which von Thomas, Bussman Mfg. Co., St. Louis, secre- tary-treasurer. q East Chicago Trains Apprentices Chamber Commerce Organizes Group Manufacturers and Local School System Into Cooperating Unit—Desirable Students Rapidly Recruited million young men should training our industrial plants, according the National Industrial Conference Board; yet less than per cent this number now being trained through for- mal apprenticeship. Only few establishments main- tain apprenticeship programs, because only the larger ones can set and maintain adequate training facili- ties. difficult realize that less than one-half one per cent all manufacturing establishments employ over 1000 men; more than per cent employ less than 100 men. Some plan must evolved means which the smaller industries can participate and their proportionate share the training. About year ago the Chamber Commerce East Chicago, Ind., realizing the importance such industrial training activity, directed its attention the evolution adequate plan for its industries. was discovered that the “community plan” for training skilled personnel was not only feasible but that had been proved success other districts. Apprentices Attend Special Classes Weekly With the beginning the current year, paper pro- grams were translated into realities. the present time indentured apprentices are work learning the essentials their respective trades and attending school one-half day per week for the related tech- nical training essential their apprenticeship. Dur- ing this period, for which they are paid apprentice wages, they attend high school class set aside for their particular needs and conducted the vocational educational department the local school system. This “continuation” plan was decided upon being the most practical and best suited local conditions. Apprentices are indentured individual plants and are schooled through the essential operations their trade actual shop work. This portion the plan continuous and distinctly different from the “co- operative” plan education, wherein the students work and attend school alternate periods equal length. Thus the two essentials modern trade training are adequately met. The manual craft portion their training provided detailed schedules shop work covering all essential operations. The educational phases the trade work, which cannot provided the job, are supplied class room and study. order studies suited each trade carefully pur- sued. general, these cover the following four main divisions: English, mathematics adapted the trade, technical related studies and, finally, general di- vision including shop economics, safety and hygiene. advisory committee administers this program. Its personnel consists representatives from each participating plant and from the local school system. The policies and general direction the program rest with this main committee. Various sub-committees are follows: Apprenticeship Administration Committee deals with training programs, not only within individual plants, but also community program where details are common all plants. *Secretary-manager East Chamber Commerce, East Chicago, Ind. PACKARD* School Methods Committee the link between the industries and the local school organization. Shop Schedule Committee provides interchange apprentices wherever complete programs are impos- sible any one plant, owing either lack diver- sity quantity production and manufacturing oper- ations. this manner adequate shop schedules can presented every apprentice. Wage Scales Committee has general jurisdiction over apprentices’ rates pay. Obviously essen- tial that all establishments pay the same rate pay any given trade. All prospective apprentices are interviewed the apprentice training department the Chamber Commerce. complete and adequate file enables provide young men, apprentices are required the cooperating industries. Routine machinery arrange school program satisfactory both shop and school, the parents and the apprentices, has been set the Apprenticeship Administration Committee. Interchange Between Shops Gives Rounded Experience Unless adequate schedules shop work comprising the essential operation each trade are provided any apprentice training program, must necessity fail sooner later. insure this the East Chicago plan, ideal schedules for each trade Each participating plant for those trades next pre- pared the schedule operations best suited and pos- sible its own manufacturing operations. These schedules were then compared with the ideal insure that large discrepancies might creep into any indi- vidual plant program. However, where has been impossible for indi- vidual plant conform quite closely the sched- ule, interchange apprentices has been agreed upon. Accordingly, the apprentice from such organization will able complete his training larger plant the community least one which can provide such operations are lacking his original schedule. The apprentice, however, indentured indi- vidual plant and remains the employee that plant throughout his apprenticeship. While work an- other plant participating the program, comes under the immediate jurisdiction that plant and paid the plant for which working. Apprentices are paid rate which insures the possibility supporting themselves. Rates increase every six months until the end the four years’ training the apprentice receiving about per cent which differ slightly for the various trades, can made only under the direction the Wage Seale Com- mittee, whenever such revisions seem necessary. All participating plants pay the established rates. Grade School, High School College Graduates Accepted The minimum educational requirement which has been set grade school education. boy leaving grade school must spend four years trade training. young man who has completed high school given one year’s credit and will therefore complete the same The Iron Age, June 1928—1601 ks shop schedule three years. college graduate must devote two years the same program. The program both regards shop and school work has been prepared meet the needs these three classes, since the related school portion this appren- tice training entirely individual basis. Each apprentice pursues course studies adapted the trade has entered, and proceeds his own pace unhampered. Instruction devoted entirely assis- tance and guidance for the individual. This neces- sary, not only because the varied previous educa- tional experience, but also because apprentices must necessarily inducted any time throughout the year. The student given hr. per week the em- ployer’s time for class room work; also required spend equal amount time home study. All the essential factors this program are in- corporated into apprentice indenture agreement, which the employer and the apprentice, with his pa- rents guardians, are parties. The indenture sets forth detail the shop and school schedules, well the rates pay according which the apprentice will work throughout his term training. The employer agrees provide employment approximately according this schedule, and the apprentice assured em- ployment regardless business conditions, except the case complete shutdown. The apprentice and his parents turn agree that remain training throughout the term specified. Each month the ap- prentice and his parents receive report setting forth the shop and school grades attained. Eighty-five apprentices now attend classes the SOLUBILITY IRON OXIDE Results Special Heats Made Check Blast Furnace Conditions the last technical session the open-hearth com- mittee the American Institute Mining and Metallurgical Engineers, held the Ohio, Youngstown, May the discussion open-hearth problems was closed the presentation informal paper dealing with the solubility iron oxide iron and with the influence changes silica upon the silicates appearing the iron. Influence Changes Silicon Upon Silicates Ap- pe aring in the Ire n foreshadowed the Detroit meeting the com- mittee, several heats steel have been made the plant the Bourne-Fuller Co., Cleveland, which iron greatly varying silicon content was used. Five heats were reported Herty, Jr., two with iron about per cent silicon, two which the silicon was coming down low figure, and one about per cent silicon. These were rolled into billets 1602—June 1928, The Iron Age local high school. They are divided into five groups, one which school Monday, another Tuesday, and on, thus utilizing the teaching facilities good advantage. Approximately 125 apprentices are. em- ployed the eight manufacturing establishments now participating this program. The extra were pre- viously employed and had progressed the point where was thought inadvisable arrange for related classroom instruction. More than 115 applications are file the Cham- ber Commerce, source excellent recruits. In- formation about the plan spread through the schools, parent-teachers’ associations, and civic and social or- ganizations the community. From survey made about year ago, would ap- pear that between 350 and 400 apprentices placed training the industries East Chicago, the present basis employment. This maximum number will approached gradually. New manufac- turing establishments are being added the program intervals, thus allowing the administration this plan expand safe and reasonable manner. The East Chicago industrial community has deter- mined place itself firm foundation regards the skilled personnel necessary for its continued in- dustrial well being. The plan adopted the Cham- ber Commerce has some successful experiences other communities justify it. Some adaptation nat- urally was necessary meet the needs this com- munity, but thorough preliminary study and careful organization has surmounted such difficulties have arisen. and rounds and into galvanized sheets, the latter in- cluding some from the low-silicon iron well the normal. was found that, long the silicon the pig iron remains approximately uniform, good results are obtained the When change occurs the blast furnace, however, resulting change the sili- con content, come the silicates the iron. This occurs whether the silicon content the pig iron increasing decreasing. And the good results come with uniform silicon, whether high low. Very little trouble experienced open-hearth practice, according Doctor Herty, unless the iron gets above 0.10 per cent silicates. All the steel made from these special heats was rimming steel about 0.10 per cent carbon and 0.40 per cent manganese. the low-silicon irons the slags were much higher iron oxides all the way along the heat. Four the heats were made about 11% hr. each. The last one, from the low-silicon iron, took hr. Doctor Herty expressed the opinion that, for 0.10 per cent carbon steel, the iron oxide the slag ought not run over per cent. stated that addition 200 deg. the furnace temperature would get rid three-fourths the iron oxide content the slag the steel. Second International Conference Bituminous Coal Eleven different countries, represented scientists and fuel technologists, are expected partici- pate the second international conference minous This will held the Carnegie Institute Technology, Pittsburgh, the week Nov. 19. The list includes about men from Europe, including Eng- land, France, Germany, Italy, Austria, Denmark, Bel- gium and Russia. Japan and Canada will represented also. The forty-eighth annual dinner and meeting the Cleveland Engineering Society will held June 12. The principal speaker will Elmer Sperry, presi- dent the Sperry Gyroscope Co., Brooklyn, whose subject will “The Engineering Contributions the Gyroscope.” > | | | | | | Powdered Furnaces Thirteen Years’ Experience Eastern Steel Co.— Between 500 and 600 lb. Per Ton Ingots and 200 Heats One Roof use pulverized coal basic open-hearth furnaces, covering the experiences the plant the Eastern Steel Co., Pottsville, Pa., was dis- cussed brief paper contributed the Pittsburgh meeting last month the American Society Me- chanical Engineers Herndon, receiver for the Eastern Steel Co. The experience supplies the record years’ use the fuel without any word advocacy otherwise for such plant. What dis- cussion developed the presentation the paper left the impression that pulverized coal for the metal- lurgical furnace had particular friends among those the Pittsburgh meeting. However the facts and figures the case were generously contributed Mr. Herndon, shown the following, which the paper substantially full. The use the powdered coal, the author mentioned the outset, came about the result the continued advance the price fuel oil. The open-hearth-furnace plant consists four 50- perators " Platéormn Copocity Coal Bin +360 Cu | Bin Line of Fore Peta ” SECTION LINE B-B and Collectors ton furnaces and two 80-ton furnaces. All have basic bottoms, all are stationary, and all are the ordinary design. When the pulverized coal was first used the fur- nace, was found that the checkers were filling with ash. was realized that this could not pre- vented, and therefore arches were substituted for the checkers because the greater space. The arches are placed about in. apart rows, one above the other, with about ft. between the rows. The furnaces are reversed two one placed each flue between the checker chamber and the stack. This gives the products combustion direct path the stack. The slag pockets are equipped with removable structural-steel boxes which fill about days. The time ordinarily required pull two boxes and get the fuel the furnace again about hr. The boxes used for the 50-ton furnaces are ft. ft. ft.5 in. deep; for the 80-ton furnaces, the dimensions are Bins SECTION LINE SECTION _Y LONGITUDINAL SECTION SHOWING COAL BINS WITH RELATION 50-TON FURNACES Coal Pulverizing Plant One End the Open-Hearth Plant and the Coal Carried Compressed Air Bins the Furnaces The Iron Age, June 1928—1603 " I " Coa/ are tapered, and the boxes are lined with 9-in. lining old bricks laid common clay. Each furnace supplied with two storage bins for pulverized coal, which have capacity sufficient oper- ate 50-ton furnace for hr. and 80-ton furnace for hr. The coal supplied the furnace from the bins compressed air siphons. the 50-ton fur- naces the air jet in. diameter and the 80-ton furnaces, 9/16 in. diameter. The air pressure used Each furna ment supplied with the necessary equip- fuel oil case emergency. The oil supply stored the usual way, tank con- siderable capacity, and all times tap. The plant for pulverizing the coal situated near building. Preparation drying, and grinding. mine and slack have been ists three Raymond five- nond four-roller mill. Each There are addition two Jeffrey single-roll coal crusher. the railroad car placed mped into the pit. From the building, height tis automatic dump-bucket buckets, which are operated aun 1 Int as raz o} any ] + av AL two carioads; + | ated directly belov + + dropped into another 1 I tne ariers. wit ™ 1] are quite sma eCAUSE + msiderabl quanti ne rag compartme¢ } ] 4 } + 4 the pulverizing mii ind tr nt oi arier ve x compartmen ] nt tor Slee tune ] } } + ; ] to ve + n rty irrar ed amount dried the rround + + +} pa I yA A + There re two steel tar eacn tank rr nen xed 4 } WELDING BUILDINGS Detroit Architect Speeds Erection with Welding and Cutting Equipment m ting the Cle n Am erican Wel ing Sockets held at the rooms th nd Engi- neering Society, various operation which, because rapid work and reduced costs, are welding than riveting. Field work, said, offers for the larger welding operations, since mal tructur re be me D tha rocess Comme! to the eftect tt eld its - about the same place riveting was ears Lincoln, vice-president and general rer Lincoln Electric Co., Cleveland, a ) prea that gre rogre will | made in tl ndustry. Mr. Matte said that common ob- ment and subjec ting five, and welds have been made that carry loads lb. shear. While the human element has much with welding, the same true the manu- facture the best steel. assure good work the supervisor welding must welder and should the ability his men, that one 1604—June 1928, The Iron Age the scale shows the amount coal the tank when being filled, and also shows the amount when the coal being discharged, that the readings show the weight the amount taken the furnaces. Com- pressed air used for transporting the pulverized coal through 4-in. pipe which connects the tanks just mentioned with the coal boxes over the furnaces. The distance from these tanks the box the farthest furnace 450 ft. Each furnace supply box fur- nished with valve that any box may refilled needed. 12-in. mill located about the same distance from the tanks the farthest open-hearth furnace, pulverized coal used continuous furnace. The same method transport used for this supply. The average analysis desired for coal suitable for pulverizing for open-hearth purposes about fol- lows: Volatile, per cent; fixed carbon, per cent; moisture, under 1.25 per cent; ash, per cent; sulphur, under 1.25 per cent. The operation the open-hearth furnaces does not now present more difficulty than with producer gas, though not simple with oil. All-cold charge used, and the time for charging about hr. The scrap is, general, quite light and the percentage pig iron kept low possible because cost. One heat hr. considered 100 per cent, and usually possible keep fairly near this through the campaign. The life furnaces about 200 heats for one roof. Usually second roof can put without disturbing any other part the furnace, and additional 100 150 heats can obtained this second roof. The coal required runs low 500 and high 600 per ton ingots. The wide variation partly due character coal, partly the charge, the analysis required the product, and little age the furnace, although the time from tap tap varies less than was formerly thought possible. The temperature maintained the furnaces essen- tially the same that with producer gas. There have been infrequent explosions, one which one life was lost and considerable damage property resulted. The others were not consequence. The the serious explosion not known, although theories and some conjectures are held, but proof. The experience during thirteen years does seem indicate extra-hazardous occupation. reas mat trained put the job. addition, numerous safe- guards can provided. Good welders can secured ‘ll good riveters. Some structural jobs require welding, declared the speaker. Referring specific operations, mentioned the erection large house having complicated hip and valley roof with intricate framing. Drawing elaborate details would waste time. Instead, have the various sections cut mill lengths and welder would the job about the way car- penter would wood construction were used. The real way attach bar joist floor supports the steel struc- ture welding. The right way build steel swimming tank weld it, said. Welding and cutting great assistance factory construction placing mechanical equipment and pipes. Another place where welding fits in, said Mr. Matte, when the owner building under construction de- cides changes, which would stop the work and re- quire new drawings and new shop fabrication. With the application welding, beams the right length are sent and welded the field, the job goes right