The Iron Age 1928-06-28: Vol 121 Iss 26

AGE New York, June 28, 1928 ESTABLISHED 1855 VOL. 121, No. The Place Overhead Conveyors What Requirements Have Covered Meet the Dictum That Today’s Plant Runs Wheels ALEX. PRIBIL WENTY-FIVE per cent for material handling! the material moving correspondingly with the speed That’s about what American industrv spends out production. its total payroll. The percentage would still Early installations, however, were made some- higher the automotive industry alone did not already have $200,000,000 invested material handling and conveying equipment. Until five years ago, the principal object efficiency and plant engineers was lay out the plant and place the machinery according the operations and allow each operator plenty space for storing material the floors. This method occasioned more less delay production and difficulties were encountered the handling material. Finally progressive production managers realized the necessity using every avail- able bit floor space for manufacturing operations and began utilize the ceiling the overhead con- veyor storage carrier and thus were able keep what haphazard manner, the main object being reduce trucking throughout the plant, floor space for trucking material around plant had become valuable. The modern conveyor laid out suit certain line-up equipment and assembling operations, and the enormous saving which has been effected its use has placed the overhead conveyor foremost the modern plant. Buildings are now laid out with def- inite routing materials conveyors and machines advantageously grouped. Material not only carried through the building, but also carried from one building another. This arrangement, course, ne- that overhead conveyors built sufficiently high that men can work underneath them and that president the Saginaw Stamping Tool Co., Saginaw, Mich., which manufacturer for conveyor builders conveyor trolleys, chain hoist trolleys, special trucks and indus- trial truck casters, Alex. Pribil approaches the subject overhead conveyors and equipment for handling material expert. this country when years age from Vienna, Austria, where was educated mechanical en- For two years was with the ordnance department the Bethlehem Steel Co. and then the next thirteen years was successively with the Wellman-Seaver-Morgan Co., Cleve- land; Brown Hoisting Machinery Co., Cleveland; the Cambria Steel Co. chief draftsman, the Ford Motor Co., Detroit, chief designer and checker, the Penberthy Injector Co., Detroit, general superintendent, the Bowen Products Co., Detroit, Auburn and Cleveland, consulting engineer and with the Westinghouse Electric Mfg. Co., East Pittsburgh, Pa., general supervisor tools. 1915 became general manager the Carde Stamping Tool Co., Saginaw, and since 1917 has been president and general manager the Saginaw company. admits having issued him over 150 patents covering machinery, tools and special equipment. holds that overhead conveyors and special trucks save per cent labor costs for material handling. ALEX. PRIBIL 1805 only occasional dips made the conveyor line for loading unloading material. Considerable engineering thought has been given not only the general layout for overhead tracks, but their strength and permanency order make the conveyor free from vibration and give absolute safety the worker underneath. conveyor endless chain supported sin- I-beam track, driven one point speed rang- ing from ft. per min. important that heavy parts carried the conveyor properly at- tached they can easily and quickly loaded and unloaded. overhead conveyor composed four units: Overhead track supported structural work Conveyor equipment, including trolleys and roller turns Chain and drive sprocket wheel Electric motor and speed reducer. Only one sprocket should used for the drive and roller turns used every corner bend, allow for the necessary take-up the chain. The driving mechanism should designed give continuous and steady pull, which may accomplished so- called speed reducers, which should amply propor- tioned. The opposite end the drive-end the con- veyor called the tail-end and generally made ad- justable. take the slack the chain. The bear- ings the shaft should mounted sliding guide, operated manually with screw that the tension the chain can adjusted take the slack the chain. All Iron and Steel Pipe Seriously Corroded Some Soils 1922 the Bureau Standards began investi- gation the corrosion piping soils wherein stray electric currents existed. cooperation with va- rious manufacturers and public utilities, some 14,000 6-in. lengths pipe were buried soils locations selected the Department Agriculture’s bureau soils typifying situations existing pipe networks. Specimens were cut from stock material and, after identification, weighing and examination, were buried pipe trench approved manner, each trench containing five groups. One group specimens was removed from all loca- tions 1924; second set 1926; and the work will continued two-year intervals until 1932. Studies the pipe after two and four years’ burial are de- scribed Technologic Paper No. 368 the Bureau Yeomans. This booklet also contains full description the nature the covering soils. When any one the test locations considered, velded iron and steel pipe various manufacture differ little loss weight extent pitting after burial for four years. Wide differences occur when corresponding specimens from the various localities are compared, ranging from practically corrosion gravelly, sandy loam near Seattle, Wash., worm- eaten, deeply grooved appearanace sandy loam Denver. evident that one the commonly used pipe materials superior under all soil conditions and, further, that serious corrosion may occur soil free from foreign matter and stray currents. Attempts have been made correlate the amount measured corrosion with various physical chemical character- istics the soil, such the hydrogen ion concentra- 28, 1928, The Iron Age This, course, accomplished several means, almost all which relate more extremely accurate field work than design, and among these are such items having the straight runs the I-beam abso- lutely straight and the roller turns having the cen- ter line the web the beam exactly vertical with the center line the chain. fabricating and erecting steel work for these overhead conveyors, the most successful contractors work limits which are totally unknown the struc- tural iron shop and are, fact, plus minus 1/64 in. Every bit this care for the purpose reducing chain reaction and undue wear the various parts. One reason why the No. 458 rivetless chain manufac- tured number chain manufacturers pop- ular that has the property telescoping some- what the driven side the power plant. all cases, the conveyor should driven elec- tric motors, and these electric motors should con- trolled push button switches. There should many push button switches practical stop the con- veyor instant’s notice and the conveyor should started again only after signal that everything clear. The conveyor should properly guarded and must properly installed insure absolute confidence. All floor openings into the drive must properly pro- tected and, course, the unloading material from the conveyor must carefully studied. While the overhead conveyor absolute neces- sity for production minimum cost, nevertheless there are great many places where conveyors must sup- plemented with trucks, the “modern plant today runs wheels,” order make the moving mate- rial flexible possible. tion, soluble salt content, soluble salts the ground water, and soil resistivity, but without success. certain the soils, cast iron seriously affected pitting, developing the phenomenon “graphitic corrosion,” different from the observed effects electrolysis, even though certain that electric currents existed the soils which the pieces have been buried. Preliminary results have also been secured the soil corrosion iron and steel protected various metallic and organic coatings, and several non-fer- rous metals. Great Improvement Safety Bethlehem Plants Safety education employees the Bethlehem Steel Corporation has helped reduce lost-time acci- dents Bethlehem plants per cent the last years. This improvement was announced connection with the company’s fourteenth annual “First Aid and Mine Rescue Meet,” held June 23, Sparrows Point, Md. Employees from all the Bethlehem plants and mines entered into competition contest efficiency first aid and mine rescue work. Cash prizes awarded Eugene Grace, president the company, totaled about $2,000. Bethlehem now trains about 1000 men safety and first aid every year. More than 8000 employees have received intensive course instruction this work during the last years. Marked improvement accident prevention was effected the employees during the first quarter 1928. The company whole improved its best pre- vious record 17.8 per cent. The steel plants alone bettered their safety record per cent. 7 Flectrical Steel-Mill Developments Large Number Main-Roll Drives Installed—Some Units Particular Interest Because Methods Control BURR* 1920, the electrical development committee re- ported motors driving reversing mills and 113 mills various types which electric motors had been installed, making total 157 motors main-roll drives that time. January, 1928, there were reported over 1500 main-roll drive motors the United States and Canada. During 1927 there were purchased 122 drive motors ranging size from 300 hp. 7000 hp. this number were d.c. motors, were 60-cycle, were 25-cycle, and two were 50-cycle motors. More than half the motors were d.c. motors, condition quite different from that existing few years ago. Eighty these motors were used connection with gear drives, which evidence that the modern reduc- tion gear has proved its reliability the satisfaction the steel mill industry. Recent Main-Roll Drives During the past year the American Sheet Tin Plate Co. has placed operation one the heaviest power tandem hot-strip mills the country. This mill located the Chicago district. The six finish- ing stands are driven individual 2500-hp. 600-volt, adjustable-speed d.c. motors, running 160 320 r.p.m. Power for these motors supplied from three 3000-kw., three-unit synchronous motor-generator sets operating parallel. One 3000-kw. set used start the six 2500-hp. motors means variable voltage control. There now under construction for the American Rolling Mill Co., the Cincinnati district, hot-strip mill which will equipped with motors somewhat larger than those mentioned above, making the largest capacity mill this type this country. The total main-roll drive power 21,800 hp., which includes ‘both a.c. and d.c. main-roll drive motors. The roughing stands are driven two 800-hp., one 1000-hp. and one 1200-hp. wound-rotor motors. The motors have been designed that mechanically their individual parts are interchangeable. This ar- rangement necessitates only one spare rotor with shaft and one spare stator, due the fact that these parts can placed any the bases and bearings. The three intermediate stands are driven in- dividual 2000-hp., 600-volt, direct current, adjustable- speed motors, operating 300 500 Each the four finishing stands driven 3000-hp., 600-volt, d.c., adjustable-speed motor, running 180 360 r.p.m. The main-roll drive motors are supplied from three 4000-kw. three unit, synchronous motor-generator sets operating parallel. The auxiliary motors are sup- plied from two 750-kw. synchronous motor-generator sets and the excitation for all main-roll drive d.c. motors and generators supplied from 300-kw. syn- chronous motor-generator set. Close Control Speeds Two mills recently purchased for the Cleveland dis- trict include main-roll-drive motors, ranging from 400 1200 hp. and total 6050 hp., continuous capacity for both mills. Due the high delivery *Electrical superintendent, Lukens Steel Co., Coatesville, Pa., and chairman electrical development committee, As- sociation Iron and Steel Electrical Engineers. This abstract the committee’s report presented the associa- tion’s Chicago meeting, June speeds, close center distance stands and wide speed range the motors, was necessary incorporate special design features both motors and control, maintain the correct speed relation between adjacent stands, that stretching and buckling the metal between stands will eliminated. There have been purchased for the Birmingham district main-roll-drive motors for rod mill installa- tion, which include five 6600-volt, 60-cycle, synchronous motors ranging size from 1300 2750 hp. and total- ing 9650 hp. The synchronous motors, with the ex- ception 2750-hp. motor, are all designed that they can started applying full voltage their terminals. reduce satisfactory value the starting kva., taken from the power system, reactors are used connection with the starting equipment for the 2750-hp. motor. The finishing stand for the rod mill will driven 1200-hp., 230-volt, d.c. adjustable-speed motor. Power for this motor supplied from generator driven 2100-hp. motor, which also drives portion the mill stands. The combination generator and mill drive represents new feature for this class service. The synchronous motors pur- chased for this installation represent the first large synchronous motors applied mill this class. Replacing Steam with Electricity There has been purchased the Illinois Steel Co. 6500-hp. single-unit reversing-mill motor for the electrification existing steam engine-driven mill. new pinion housing and the motor will installed the opposite end the mill from the present drive. This will reduce the shut-down period the mill dur- ing the change-over the minimum, due the fact that the entire equipment can installed with the mill service. One recent improvement the mechanical features for electrical equipment has been incorporated this equipment. The individual bedplates for both the reversing motor and the flywheel motor-generator set are “built up” welded steel construction. 4600-hp. 700-volt, single-unit reversing-mill motor for driving roughing mill has been purchased for installation India (Jamshedpur). The motor will supplied flywheel motor-generator set which includes two 1900-kw., 490 r.p.m., d.c. generators. These generators indicate that continued progress being made developing larger generator capacity higher speeds for reversing-mill service. There has recently been placed service the Carnegie Steel Co., the Youngstown district, 4000- hp., 450 r.p.m. synchronous motor for driving 24-in. continuous billet mill. The motor represents the latest design synchronous motors for this class service, that the motor has completely fabricated welded frame and bedplate. New Strip Mills Electrically Driven cold-roll strip mill for production wide ma- terial was placed operation the American Roll- ing Mill Co. during the last year. The mill driven five 600-hp., 230-volt, d.c., adjustable-speed motors, operating 400 800 r.p.m. For use connection with this installation there was developed and perfected special screw-down drive, that each screw can motor driven independently the other screw. The Iron Age, June 28, 1928—1807 7 desired operate both screws the same time magnetic clutch energized, which causes both screws turn the same rate. inching arrange- ment provided which allows the screws travel one revolution and then stop automatically. About the middle last year the Steel Co. completed remodeling its 16-in. hot strip mill, which was first placed operation during 1918. The mili now laid out for continuous rolling and will produce strip 36-in. wide. The driving power applied the mill was increased one new 5000-hp. adjust- able-speed Scherbius-controlled induction motor. that the total capacity driving motors now 13,000 hp. With the exception one 300-hp. and two 100- hp. edger motors, which are adjustable-speed d.c. ma- chines, all the driving motors are the slip-ring induction type, with speed adjustment obtained the Scherbius system. The horizontal roughing stands are driven 1500-hp. motor, and each the last three stands driven 2000-hp. motor. The speed each motor can adjusted between 270 and 450 r.p.m. The Scherbius speed-regulating set used with the 5000-hp. motor especial interest, the first application using two a.c. commutator-type machines series. This design permits the use smaller and higher speed units, and the higher regulating voltage obtainable permits designing the induction motor with lower secondary current. Another large strip mill recently placed tion that the Weirton Steel Co., Weirton, Va. This mill will produce strip in. wide. There are driving motors, totaling 16,600 hp. The three motors the stands are 1500-hp.. 6600-volt a.c. machines, one which operates 200 r.p.m. and the remaining two 450 r.p.m. Ther are three edger motors, each 200 hp., 400 800 r.p.m. lirect current. The five finishing stands are driven two 2000-hp., 200 400 r.p.m. and three 2500-hp., 200 400 r.p.m., 600-volt, motors. Power for the direct-current machines obtained from chronous motor-generators, each consisting two 1500- kw., 600-volt, d.c. generators driven one 4200-kva., 6600-volt synchronous motor. The five d.c. motors started simultaneously control the voltage the four d.c. generators. Continuous Skelp Mills Two large mills the continuous type for rolling skelp have been placed operation during the past One the Benwood, Va.. plant the Wheeling Steel Corporation. This mill provided with eight driving motors, all which are adjustable- speed, d.c. machines. There are four edger motors, three which are hp. and one 150 hp. These ma- chines are operated from the 230-volt machines, power being supplied them from motor- generator consisting two 2000-kw., 600-volt genera- tors driven one 5600-kva., 4000-volt, 60-cycle, syn- chronous motor. The first two stands are driven 500-hp. motor and the remaining eight stands three 2000-hp. machines. The other skelp mill referred 27-in.-24-in.- 21-in. continuous installed the Bethlehem Steel Co. the Sparrows Point plant. addition pro- ducing skelp, this mill designed roll sheet bars also. There are four main driving motors. The first 4000-hp. r.p.m., 6600-volt, synchronous motor which drives the roughing train. The intermediate train driven second synchronous motor rated 6500 hp. 187 r.p.m. The third 6700-hp. slip- ring induction motor with speed adjustment between 250 and 500 r.p.m., obtained the Scherbius system. Incidentally, this the largest Scherbius equipment the world. The driving motor the last stand 600-volt d.c. machine rated 2600 hp. 275 320 r.p.m. ( Rolling H-Beams High-Power Mill From the standpoint total horsepower involved, the new electrically driven beam mill for the produc- tion wide-flange structural shapes the Lacka- wanna plant the Bethlehem Steel Co. one the most highly powered mills this country. The complete equipment consists three units: 54-in. 1808—June 28, 1928, The Age reversing blooming mill, 48-in. intermediate mill, and 48-in. finishing mill. The finished sections are produced without reheating the steel from the time the ingot removed from the soaking pit. The ingot first rolled the blooming mill H-shaped bloom with web from seven times the thickness the web the finished section. This bloom then passes the intermediate mill, which consists two separately driven stands rolls. One stand, known the supplementary mill, has two horizontal rolls, and the main stand has two horizontal and two vertical rolls. The H-shaped bloom enters this intermediate mill with the web horizontal. The supplementary rolls act only the top and bottom edges the flange. The horizontal rolls the main mill effect the reduction cross-section the web, while the vertical rolls reduce the cross-sections both flanges. the main mill the driving power applied only the horizontal rolls, the vertical rolls rotating due their contact with the beam. After several passes back and forth through the intermediate mill, the beam passes the finish- ing mill, which also consists two stands, main and supplementary, where several finishing passes are made. [This the same action that illustrated and described page 1381 THE IRON AGE May 17, connection with the new Carnegie parallel-flange beam mill the Homestead works. Editor.] Unusually Large Motors The motor for driving the 54-in. reversing blooming mill the largest single-unit d.c. rolling mill motor which the General Electric Co. has ever built. rated 7000 hp. continuously, r.p.m. This motor capable exerting maximum torque 2,400,000 1-ft. radius. Direct-current power supplied from flywheel motor-generator consisting one 5000-hp., 275 r.p.m., 6600-volt induction motor, one 50-ton flywheel, and two 3000-kw., 750-volt generators which are operated parallel. This 54-in. blooming mill one the two largest reversing blooming mills this country. The intermediate mill has two reversing motors, one which drives the supplementary rolls and the other the main rolls. The main-roll motor rated 7000 hp. continuously, 125 r.p.m. The supple- mentary mill motor rated 1500 hp. continuously, 225 The flywheel motor-generator which furnishes power these reversing motors consists 5000-hp., 375 6600-volt induction motor (duplicate that the blooming mill set), two 3000- kw. generators for the main motor, one 3000-kw. gen- erator for the supplementary motor, and one 50-ton This set duplicate the blooming mill set, except that has three generators instead two. The finishing mill equipment the same that for the intermediate mill. The total capacity the main equipment for the blooming, intermediate, and finishing mills just about 71,000 hp. Changing Over the Rail Mill The Bethlehem Steel Co. placed order for new electrical equipment for the Lackawanna rail mill. Engine drives will discarded and the layout the mill will changed. will consist 44-in. revers- ing blooming mill, the driving motor for which will rated 7000 hp. continuously, 120 r.p.m. Blooms from this mill will direct 36-in. revers- ing roughing mill, which will driven d.c. motor, rated 5000 hp., continuously, 120 r.p.m. Power for these two reversing motors will obtained from single flywheel motor-generator con- sisting one 8000-hp., 375 r.p.m., 6600-volt induction motor, two 3000-kw., 375 r.p.m., generators operating parallel, supply power the 7000-hp. blooming mill motor, two 2200-kw., 450-volt generators operating series, supply power the 5000-hp. roughing mill motor, and one 75-ton More Synchronous Motors Being Used Increasing use synchronous motors for main roll drives noteworthy. Seven motors sold the Gen- eral Electric Co. during 1927 totaled 12,600 hp. The largest these rated 5000 hp., continuously 100 r.p.m., and 2200 volts, and used drive 19-in. continuous sheet bar mill the Kokomo, Ind., plant the Continental Steel Corporation. motor the same horsepower rating but 240 r.p.m. used drive piercing mill in- stalled the Standard Seamless Tube Co. Am- bridge, Pa. This the largest seamless tube mill drive the world. The Standard Seamless Tube Co. has placed operation also 32-in. reversing bar mill which driven 2150-hp., r.p.m., 550-volt d.c. motor. Power derived from synchronous motor-generator consisting 4200-kva., 2200-volt synchronous motor, direct-connected two 1000-kw., 275-volt, d.c. gen- erators operating series. This the first installa- tion reversing rolling mill motor deriving its power from synchronous motor-driven generator. the Union plant the Bourne-Fuller STARTS USING HOT METAL Improved Hamilton Furnace Now Connected with Armco Middletown Works from the blast furnace the Hamilton Coke Iron Co., Hamilton, Ohio, the open-hearth furnaces the East Side works the American Rolling Mill Co., Middletown, Ohio, was formally celebrated June when party officials and guests the two com- panies journeyed special cars from Middletown over the newly-constructed tracks the Baltimore Ohio Railroad Hamilton where they saw molten metal taken from the furnace and sealed ladle cars. The return trip was made the East Side works Middle- town, where the party the plant. luncheon was given the officials the American Rolling Mill Co., which brief addresses were made Daniel Willard, president Baltimore Ohio Railroad; Blackwell, president Union Gas Electric Co., Cin- cinnati; and Rust, president Hamilton Coke Iron Co. The plant the Hamilton Coke Iron Co., which originally consisted blast furnace owned the Hamilton Furnace Co., has been enlarged and im- proved. The program improvements included the remodeling the blast furnace, hot blast stoves and gas cleaning system, installation equipment suit- able for the delivery hot metal Middletown, miles distant, and the construction modern by- product coke plant comprising 14.8-ton Koppers ovens the Becker type with capacity 1200 tons coal each day. The blast furnace with rated capacity 550 tons daily equipped with McKee revolving distributor. The hearth has been enlarged from ft. diameter. The gas cleaning system, after the dust catcher, entirely new. The gas, after passing through the dust catcher, cleaned vor- tex collector furnished Brassert Co. The collector removes dry process large percentage the dust remaining the gas and delivers hot gas sufficient cleanliness suitable for use the boil- ers. centrifugal action the collector separates the dust from the gas, and the dust collected recep- tacle the bottom. intervals about hr. the dust dumped into railroad cars. The clean gas passes out the top the collector, part going the boilers without further cleaning and the remain- der going Feld five-stage scrubbing tower, ft. diameter, where wet washed for use the stoves. After leaving the Feld scrubber, the gas passes through vortex eliminator and thence the stoves. The action the eliminator similar that the collector, its function being separate the gas from the entrained moisture and sludge. Three the four stoves were relined provide the necessary increase regenerative capacity re- quired the furnace. The stove shells, each which ft. diameter and ft. high, have been left in- j Cleveland, 10-in. merchant mill has recently been placed operation which, from the standpoint the electrical equipment, particular interest. The mill has eight driving motors totaling 3400 hp. Five are 500-hp., 267 800 r.p.m., 230-volt, d.c. machines and three are 300 hp., with the same range speed adjustment. The four stands driven the three 300-hp. motors and one the 500-hp. motors are tandem and placed very close centers, that the metal being rolled all four stands simultaneously. For this reason, special provision has been made the control provided for these four motors, reduce the speed regulation (that is, the change speed from load full load) each machine minimum, and maintain within close limits the relative speeds all four machines. tact, but the relining are said represent inno- vation stove design from anything now operation this country. The arrangement the gas passage, together with the center combustion chamber, con- forms the Diehl type stove. The checkers the Brassert type, consisting octagonal shapes with cyl- indrical openings the center, result series square and round openings from the top the bot- tom the checker work. Insert columns specially shaped fire brick have been placed these openings, the size the inserts being varied effect some- what higher and more uniform gas and blast velocity throughout the checkers than has been employed ordi- narily the past. estimated that increase per cent heating surface per stove obtained with these checkers compared with the type stoves previously used this furnace. Incidentally, the four stoves have been equipped with Steinbart pressure burners for economical and efficient gas burning. The coke plant will produce furnace coke and also coke for industrial and domestic uses. The surplus gas from the ovens delivered waterless gas holder, from which taken the Columbia Gas Supply Co. Koppers phenol recovery plant and Bartlett-Hayward centrifugal benzol ab- sorber are features the by-product plant. Three specially-designed mixer ladles the Pugh type, each 150 tons capacity, will carry the molten metal from the furnace the open-hearth furnaces Middletown. The ladles have been double-lined with fire brick and are capable holding the metal for hr. view one the ladle cars was given page 1746 THE IRON AGE June 21. Because the concentrated load metal, plus the unusually heavy weight the ladle cars, was neces- sary for the Baltimore Ohio Railroad design and build special bridge over the Miami River route from Hamilton Middletown. For ladle car make the round trip from the furnace Middletown re- quires about hr. and estimated that aver- age four trips every hr. will made. The Hamilton Coke Iron Co. the successor the Hamilton Furnace Co., which first built blast fur- nace Hamilton 1907 make foundry pig iron sold the open market. Ten years later the blast furnace was rebuilt, but for long period previous its purchase the Hamilton Coke Iron Co. was idle. Today, under its new joint ownership the American Mill Co. and the Koppers Co., enables the former reduce its steel production costs using the hot metal for its open-hearth furnaces Middletown instead securing cold pig iron from the Armco fur- naces Columbus. Foundry owners Worcester, Mass., Monday, June 25, met the Hotel Bancroft, that city, form foundry council the chamber commerce. Roscoe Goddard, general secretary the chamber, presented the plan. Most the foundrymen present were favor and concrete developments are ex- pected soon. The Iron Age, June 28, 1928—1809 Magnets Control Weiding Arc Produce “Electronic Tornado” and Stabilize Carbon Arc— Joints Welded High Speed Have Superior Ductility, Appearance and Strength DAVIS* has long been known that the electric are nor- mally difficult phenomenon for the welder con- trol. creates its own magnetic field and the passage the welding current through the parts being welded creates other magnetic fields variable direc- tion. The arc, therefore, tends wander around seek- ing the path least resistance. When studying this characteristic effort stabilize the arc, research investigators the Lincoln Electric Co.’s laboratory many months ago found that, after superimposing strong magnetic field the are flame, the arc travels through variable fields without disturbance. This mag- netic appears give the arc gyratory motion and the controlled arc has been properly called “electronic tornado.” the time was thought merely inter- esting scientific phenomenon particular commer- cial value, but experimentation was continued. De- cember last year series welds were produced such extreme ductility and smoothness that more per- sistent efforts apply commercial machines were justified. illustrate the kind metal remaining after melting under carbon controlled strong, induced magnetic field (the electronic tornado), some welds were made plate. appearance these welds have series ripples shaped like fish mouths, characteristic the highest uniformity the joint. This partly due the higher speed welding and, part, inherent the process. The welded joints were then sawed out the form long bars. Some these resultant bars were twisted through 1080 deg., three olutions, without showing any indication *Vice-president Lincoln Electric Co., C levelana 1810—June 28, 1928, The Age ure (Fig. bars cut from welds were twisted cold and tied into krots without any sign fracture. Welds heavier plates were given bending and twisting tests which could not even approached welds made ordinary methods. series welded bars tested tension there was not single failure alongside the weld. was quite appa- rent that there impairment the strength the parent metal the new process. The three microphotographs show common steel plate, are weld and electronic tornado carbon are weld, respectively, all the same magnification and etching. They show the clearest possible man- ner the pronounced difference between the common arc weld and the new process. will observed that the grain size the new process exceedingly fine and uniform, whereas the metallic are weld irregular and coarse. The crystal structure the electronic tornado weld almost identical with that original mild steel; the only discernible difference the refined size the crystals themselves. The structure metal melted this new process very similar that highly refined low-carbon steel brought about rolling forging and suitable heat treatment. Such success has been had commercializing this invention that now being applied the manufac- ture pipe, tanks and the welding structural steel. illustrate the adaptations, automatic machine for welding special piece oil field equipment shown, with some the work delivered. These are corner clamps for oil well derricks, made ordinary pipe instead timber. Each clamp made three pieces; two them are alike, square plate with central portion bent into 125-deg. and two Seam Cut from Plate, Twisted Three Complete Times without Cracking Machine for Making Angle Oil | “ 1 7 4 ” = ~ | 5 ~ Figs. 100 Diameters, Steel Plate, Metallic Arc Weld and Electronic Tornado Carbon Arc Weld wings back radial direction. The third piece 90-deg. portion the cylinder with short wings, rest- ing the two others the assembly shown Fig. The clamps thus assembled are fed into the welder and are carried under the are continuous line chain drive which there are dogs set intervals. These devices are concealed sheet-metal guards. will noted that there are two the new type welding heads with their electrode holders crossing each other sharp angle. This construction peculiar interest, for, with uncontrolled arc, would impossible operate two flames such close prox- imity. One would continually blow the other out. With Maintained Uniformity Malleable Iron Castings notable showing uniformity high physical properties malleable iron castings disclosed the record the Fort Pitt Malleable Iron Co., Pitts- burgh, covering period months and includ- ing March this year. This record, part the ex- hibit the company the last annual convention the American Foundrymen’s Association Philadel- phia, shows that 1104 heats made during this period there was only one month which the average the tensile strength dipped under 58,000 lb. per sq. in.; that all but three months the average yield point was above 38,000 per sq. in., and only two months did the percentage elongation fall below per cent. The machinability the iron was, emphasized, way affected the high physical properties. Prizes Announced for Foundrymen’s Apprentice Contests Owing some unexplained delay transit, steel castings for the apprentice molding contest conducted the American Foundrymen’s Association its Phila- delphia convention May did not arrive time considered. This limited this feature the convention and exhibition examination the patterns and gray iron castings submitted. All the patterns reflected credit those who made them and all might used with perfect propriety commercial practice. First prize was awarded No. 61, made Frank Cuzzone, General Electric Co., Schenectady, Second place was given No. made Arnold Behrens, Milwaukee Pattern Mfg. Co., Mil- the electronic tornado welding head, however, they work smoothly and without conflict. This new machine placing double welds the rate better than ft. hour for each head, which exceptionally high speed. filler rod used; the arc from the carbon electrode fuses the wings the top plate into the metal below. general the cost welding %-in. plates, includ- ing operators’ time, electric current and carbon elec- trodes, will range from 3c. 7c. per ft., dependirg principally upon the cost setting the work and the amount that done. The cost welding plates other thicknesses will direct proportion. waukee. Third place was awarded No. 31, made John Anderson, John Deere Harvester Co., Moline, The judges were Joseph Goostray, Hunt-Spiller Mfg. Co., Boston; Pat Dwyer, Foundry, Cleveland, and John McDonald, Bucyrus-Erie Co., Erie, Pa. the gray iron casting contest, first prize was given No. 94, made Peter Bathgate, Brown Sharpe Mfg. Co., Providence, Second place was given No. 74, made George Shuster, Olney Foundry Co., Philadelphia, and third prize was awarded No. 75, made Antillo Cresson-Morris Co., Philadel- phia. The judges this contest were Murphy, University Pennsylvania, Philadelphia; Fuller, Whitehead Brothers Co., Cleveland, and Pat Dwyer, Foundry. Officers the Purchasing Agents’ Association the thirteenth annual convention the National Association Purchasing Agents held Kansas City, officers were elected follows: President, Bowman, general purchasing agent Humble Oil Refining Co., Houston, Tex. Vice-presidents: Leonard Leavy, purchaser supplies, San Francisco; McAuliff, Texas Electric Railway, Dallas; Whitehead, Fairbanks, Morse Co., Chicago; Ramage, Diamond Chain Mfg. Co., Indianapolis; Christie Clark, Rolph-Clark-Stone, Ltd., Toronto; Cranford, Toledo Edison Co., To- ledo, Ohio; Kerrick, Mengel Co., Louisville; Harris, Jr., Pont Nemours Co., Wil- mington; Paul Brennan, Stafford Co., Readville, Mass., and Lewis Jones, New York Power Light Corporation, Albany, The Iron Age, June 28, Uniformity Duplex Steel Quality Product Obtained Controlling the Temperature the Steel Bath and Fluidity the Slag Just Before Molten Pig Iron Charged FOLKE UPLEXING has been given the least scientific attention all steel-making processes, prob- ably because the grade steel that has been made this way has satisfactorily filled its purpose. Keener competition, with subsequent demands for bet ter quality, has forced makers give the matter greater attention. advantage the duplex has been quires from hr. produce 200 steel from single furnace can onl ne-fifth this rapid rate The disadvantages are the double conversion and handling costs; the decrease yield, due the oxidation and mechanical losses; and the quality the different heats. While the one common American practice pour enough varia- duplex process can worked different full-blown metal into tiltir open-hearth fur- nace able tap out about 200 tons finished teel and still have tons left the furnace. When the required amount blown metal poured ind enough scale and lime have been and highly basie and oxidizin melted make slag, so- called “jigger” raw basic iron added from The weight the jigger depends upon the a red carbon content in the fini ed tee] When this iron introduced and heat evolution takes place, due reaction between iron the scale and carbon the pig iron. Carbor monoxide formed and passes through the metal and causing the charge boil and foam, and thus forces the slag overflow through cinder While the violently stirred the phos rus the metal also eliminated and joins ith the lin lag, much which ejected into the cinder boxes. After this reaction, test generally sent analysis, and, the return satisfac +h } a+ } ul temperature corre ie heat 1s tapped urtace it very simple matter from practical standpoint make duplex heat. reality each charge contains unstable conditions which fluence the quality the product. Consequently manufacture duplex heat relatively free from rases rather complicated proposition. The factors which vary for each charge (o1 the blown metal. are the The temperature depends silicon the cold, it If can cooled judicious addition scrap temperature and chemical com sition the primarily upon the the too hot, into the converter charge. cannot blown metal too vessel. the temperature the hearth added, too wild molten bath the iron reaction, uncontrollable foaming slag and subsequent bath While carbon can added the ladle, the metal will probably too high phosphorus, since eliminated best furnace too high time the carbonless phosphorus when carbon present. iwn, J812—June 28, 1928, The Iron Age SUNDBLAD the other hand, too low bath temperature will delay the reaction, sometimes min., but then suddenly starts, and with such violent boil that even thin slag will whipped into one too thick few This prevents the slag from overflow- ng, and such heat liable high both phos- ‘us and sulphur. From should be seconds. these considerations seen that the tem- the bath the time the jigger properly controlled. added Variable chemical composition the blown metal also important, since the furnace operator must ad- just the nature and the fluidity the slag take care the impurities eliminated. Fluidity the slag depends upon the furnace temperature, and its content basic and oxidizing agents. Temperature and fluidity are directly proportional other; increase the temperature and fluidity increases. the sulphur the blown metal above 0.06 per cent, one practice calls for adding manganese the metal remaining the furnace after pouring, but before filling up. Otherwise the fastest way de- crease the sulphur run the furnace with ex- and oxidizing slag together with very dizing flame. These conditions should prevail hroughout the filling-up stage, except during the last few minutes just before the iron added, when the flame wered somewhat, allowing the relatively thin cool little. This done avoid unnecessary the slag when the iron introduced, time full flame again turned on. pro- ducing succession reactions moderate intensity, possible run off quantities slag rich sul- The proper way add iron bath average composition, however, give sufficient produce reaction that raises the slag ‘lowing without tilting the furnace much. When the bath settled again, second amount may in- chemical troduced, producing not quite strong boil. After this one final jigger can added raise the carbon content the bath, producing only mild boil. The should then sufficiently high carbon that additional iron needed before the preliminary test eported, and that way the heat given proper le tie. time to set insure greater uniformity the finished product necessary find point the operation that can made stable for all heats. This possible control the temperature the bath and the nature the slag. other words, can tell advance what kind reaction are going have, the prob- lem solved. From practical standpoint possible regu- late the operating conditions that, the time all the blown metal poured into the furnace, the slag has certain fluidity and the bath certain temperature. thus possible make this stage the operation stable point for all heats. practice this depends Tar, oil producer gas great deal upon the fuel. are undoubtedly best. Coke oven gas combination tory and the with any these would make much more difficult, not impossible. Due its lightness this latter gas has the tendency raise the flame, and, when used duplex furnace with bath big area, the result too great difference the absorption heat the incoming and outgoing ends. order prevent such flame from raising toward the roof, more air and steam must used than otherwise; thus the operator handicapped conditions call for less oxidizing flame. Available literature covering this process, while mentioning the variations encountered operation, makes attempt state cure. Some operators are satisfied that the working duplex heat and the subsequent result are not subject scientific control but are solely dependent their practical experience. Valuable results would undoubtedly gained some research work aiming find working relationship between different slags and the intensity the reac- tion. would then possible, taking slag test immediately before the iron introduced, determine from its color and density structure when the “stable point,” defined above, has been reached and the time ripe for adding the molten pig iron. Low-Manganese Plates for Shipbuilding Save Per Cent Lloyd’s Register Approves “D-Quality” High-Tensile Steel Used British Navy for All Important Hull Members SIR WILLIAM BERRY* first ships wholly steel for the Royal Navy were 18-knot despatch vessels ordered 1875, 3730 tons displacement, and were built steel pro- duced the open-hearth process. was found that mild ductile steel the kind required for shipbuilding purposes was produced with much greater uniformity the open-hearth than the other methods, and was this process which, the end, eclipsed all its rivals, far the shipbuilding supplies were con- cerned. 1877 Lloyd’s formally sanctioned the use mild steel for mercantile vessels, and issued the standard tests for steel. Mild steel has held almost undisputed sway for the last years for shipbuilding purposes, and worthy note that the standards adopted the Admiralty and Lloyd’s for mild steel have remained unaltered for that period. Ever since became possible com- pute with some degree accuracy the stresses which ship structures were subjected service, has been the aim keep such stresses within what might loosely termed the elastic range. The assumption had usually been design work that elastic limit about half the ultimate strength could safely taken, notwithstanding the fact that the figure was seldom determined. The attached table shows that the true limit proportionality mild steel far less than ordinarily assumed. Use 1.25 Per Cent Manganese Steel for High Strength the case commercial structural steels ordi- narily produced, the proportional range elasticity extremely variable, and might almost said accidental property the steel; but this feature subject control if, for specific purpose, definite proportional limit desired. This point was investi- gated with great thoroughness the time the Ad- miralty was drawing the specifications for the steel for some the recent warships. With the help some the foremost steelmakers the country, steel has been evolved for Admiralty use (now widely known quality), which proportional limit 38,000 45,000 lb. per associated with ulti- mate strength 83,000 96,000 without sacrific- ing any appreciable extent the ability the steel withstand ordinary manipulative treatment ship- yard. The tests actually specified are: (a) mini- mum proportional limit 38,000 Ib. per sq. in.; (b) minimum elongation per cent in.; (c) bend through 180 deg. around curve whose radius one and one-half times the thickness the specimen tested. All these requirements are regularly exceeded supplies obtained the Admiralty under its contracts. secure such results great care has paid the first place chemical composition, and the second the choice and control the finishing tempera- ture the rolls. regards chemical composition, advantage taken the beneficial effect increased percentages manganese, elevating the propor- *An “Introductory Note” read before the Institution Civil Engineers, London, June tional range without detracting from ductility. fairly representative composition would carbon 0.33 per cent, manganese 1.1 1.4, silicon 0.12, sulphur and phosphorus being kept about 0.03 0.04 per The temperature finishing the rolling all-im- portant, enables normalizing effect ob- tained without actually going through the procedure separate treatment. For steel the composition given, temperature 830 deg. 860 deg. (or rather above the critical range) the one aimed at. Rapid Method Determining Proportional Limit word should added the method stipulated for recording the proportional limit elasticity. this with scientific precision would necessitate plotting curve for each specimen tested, and locating the particular point which the load-extension curve departed from the straight line. Obviously this out the question where thousands tons steel are passing under inspection rapid rate the early stages construction ship. After hundreds specimens had been dealt with under extensometer test the preliminary investigations mentioned, simple and expeditious system was evolved which provided all the relevant information. The Ewing extensometer was the instrument and this registered with fair accu- racy 1/50,000th inch. insure absence slipping the grips when the lower reading was taken with ordinary commercial test bar, load 4500 lb. per sq. in. was first put on, and reading taken; the load was then gradually increased 38,000 lb. per sq. in., and second reading taken. The load was then reduced 4500 per sq. in., and third reading recorded. meet the specification this final figure was not exceed the original reading more than 0.0004 in. This system, which now daily use many the largest works the country, has given complete satisfaction both the makers and the purchasers. 1925, Lloyd’s issued memorandum the subject “Special Quality Steel for Merchant Shipbuilding,” sanctioning the use steels similar character that adopted the Admiralty. Another specification similar character followed Alfred Holt Co. both these cases, the elongation and bend tests are the same for mild steel. The method measur- ing the proportional limit follows every particular that laid down the Admiralty for D-quality steel. interesting note that these new types steel are also being adopted for merchant shipbuilding the Continent. D-Quality Steel Fabricated Ordinary Metheds and Equipment While D-quality steel such great value for the pure strength girder ships, must not supposed that the modern warship wholly this steel. For minor and partitional bulkheads, for the ends vessel The Iron Age, June 28, 1928—1813 4 where the bending-stresses are small, for unimportant flats and decks and for deck structures, the cheaper mild steel still fills its particular niche. small vessels also, where longitudinal stresses are little impor- tance, the initial and subsequent cost using the higher quality steel could not justified. must also remembered that steels the types described suffer some slight extent from the defects their special qualities. Ease difficulty flanging and bevelling dependent entirely the low high value the yield point. Under the shearing, punching, and drilling machine, one cannot expect quite the same ease operation with mild steel. Owing also the carbon and manganese content, heating and flame cutting, now common shipbuilding, have carried out with somewhat more circumspection. surprising, however, how quickly the building employees adapt themselves the sli