The Iron Age 1928-07-12: Vol 122 Iss 2

THE IRON New York, July 12, 1928 ESTABLISHED 1855 115 Forging and Heat-Treating Units One Building—Several Types Used —Forming Ring Gears FAY LEONE FAUROTE* ROBABLY the largest group electric furnaces found any one building the world the Fordson plant the Ford Motor Co. This big in- stallation the spring and upset building. Here there are 115 electric furnaces using total about 20,000 kw. Seventy-six are operating the spring department and the forging department, the remaining being used miscellaneous work. Nickel-chromium ribbon form used resistor those furnaces where the temperature does not exceed 1500 deg. Fahr. some the high-temperature furnaces troughs carbide compound filled with pulverized carbon are used. Others are fitted with globar resistors, non- metallic resistance element resembling silicon-carbide appearance. Two the furnaces use wire and one uses graphite for heat source. Alternating current supplied the building 13,200 volts. From substation carried two distribution points, where transformed into 220 and 440 volts re- spectively. The furnaces the spring department are capable handling 6000 rear springs and 12,000 front springs for the new Model and 2500 springs for the truck, two 8-hr. shifts. Two the furnaces, the *Mechanical engineer, 420 Lexington Avenue, New York. head page general view one group the electric furnaces the spring and upset building the Fordson plant. eye operation, are equipped with transformers which permit the voltage increased when desired accelerate heating the springs. Ford engineers say that the metal resistor type fur- nace long lived, simple and efficient. The form its resistor makes easy matter locate the heat source any part.of the furnace, have varying degrees temperature different parts the same furnace. Ele- ments composed lengths nickel-chromium frames fused aluminum oxide and fire clay are installed floor, walls ceiling furnace, any two three these places desired. Thus heat may put exactly where needed. When break-down occurs these resistors may removed easily through panels the furnace walls, and repairs made short time. Ribbon resistor-type furnaces have been operated for long year without any apparent change the area the cross-section the resistor other deterioration its structure. Ribbons various cross-sections are used, 0.08 in.; in., and 0.05 in. The usual combination alloy for temperatures 1900 deg. Fahr. about per cent nickel and per cent chromium. small laboratory furnaces the resistor often the form continuous wire. The globar type resistor well regarded also, es- VOL. 122, No. | pecially for those furnaces that operate higher tempera- tures than 1500 deg. Fahr. temperatures range from 2300 2400 deg. Fahr., the globar units give excellent results. For forging furnaces, where They have been known last 1000 1200 hr. and with further development said 2500 hr. will possible. They are economical, easy introduce into the furnace, rigid, strong and not liable deterioration. They may used for lower temperatures also, and course give satisfactory results. The Ford Motor engineers began experiments with globar re- sistors 1925, but was not until 1926 that the results warrant their continued use. Since then, however, this form resistor has been steadily gain- ing achieved seemed The operation the spring-forming machinery in- Spring steel stock cut proper size put conveyor and carried through the furnace, both ends the tock being heated proper curling temperature mean- while. Leaving the furnace they pass downward, are lifted off and inserted double press which curls both eyes one operation. Each unit capable heating and curling eight spring leaves minute 3840 day. These fur- naces are rated 170 kw. 252 kw. LC The electric furnaces the forging department operate temperature 2350 deg. Fahr. and require total 7732 kw. Seventeen these furnaces use globar resistors, in. diameter in. There are twenty- seven heating elements the furnace. Total power per furnace: 337 kw. 220 volts, three-phase, cycles; which 187 kw. No. control and 150 kw. the second. These furnaces are approximately ft. wide, ft. deep and ft. in. high and are lined with suitable insula- tion and refractory brick provide heating chamber ft. in. wide, in. deep and in. high top arched roof. The whole inclosed steel-plate shell, well braced and reinforced prevent warping. Stock heated inserted through slot adjustable for opening in. in. The globar elements, rated kw. each 110 120-volt power supply, are star- connected for operation the 220-volt, three-phase 60- cycle alternating current supplied. They are controlled Leeds Northrup recording controllers. These forging furnaces are lined with fire brick, red and natural Silocel. The resistors are held each end water-cooled spring contacts, thus arranged for quick replacement. The furnaces can heat 1000 lb. steel hour 2250 deg. Fahr., with power consumption giving about heated per kwhr. stock in. diameter. special 450-kw. trough resistor type furnace de- signed operate temperature 2400 deg. Fahr. and 74—July 12, 1928, The Iron Age with capacity heat 2000 lb. steel hour deg. Fahr. power consumption not exceed 400 kwhr. ton, heating billets in. diameter long. carbide containing supported piers, extend lengthwise the furnace, hav- ing suitable power input connections the ends. Stock heated charged into the furnace through seven openings in. square the back the furnace. Heated stock removed from the front the furnace through similar openings. All the openings are fitted with hand- operated, counterweighted doors, sealed the top. The floor the heating chamber flat, with the bottom the discharge opening ft. in. above the floor Electrical equipment for this furnace includes 225 kw. oil-cooled transformers with primary windings for 440-volt, 60-cycle alternating current, arranged for connection 4 | — Sod Furnace Having its Heating Element Trough Carbide Compound Filled with Pulverized Carbon and Energized Through 78-In. Space Between the Two Large Electrodes. the Electric Furnace Co., Salem, Ohio This furnace was furnished three-phase power supply, with secondary wound with six taps for variable power supply furnace. The switching and metering equipment consists one 1000-amp. mag- netically operated oil-break switch, for primary circuit for furnace temperature control through Leeds Northrup recording controller, one 2000-amp. six-point hand-operated selective type oil-break switch for secondary circuit for varying power input furnace, one indicating type watt- meter, one current transformer and the panel. There also relay for magnetic switch operations from Leeds Northrup controller. While the greatest number electrical furnaces are found the spring and upset building the Fordson plant, there are other installations the motors and roll- ing mill buildings. Three the furnaces the motors building are quench furnaces, ft. long, rated 237% kw. These are used for hardening the Model crankshafts. Each furnace here has capacity eighty-five crankshafts hour. They operate temperature 1500 deg. save floor space, the drawing furnaces are built top the quench furnaces. The Shafts are carried and through these furnaces conveyor, the drawing furnaces using 189 kw. and operating 700 deg. Fahr. Other electric furnaces the motors building include 82-kw. continuous furnace for hardening push rods, with capacity 4800 hour, one 149-kw. continuous furnace for hardening piston pins, also having capacity one This furnace approximately ft. long and ft. wide, built sheet steel, lined with in. Silocel powder, in. Silocel brick, in. C-22 insulation brick and in. high-grade fire brick. The furnace roof, arched type, removable, equipped with sand seal, lined with in. insulation and in. refractory brick. The heating elements consist two covered troughs silica- These troughs, | | > Firebrick j 4 LECTRIC Forg- ing Furnace the Ford Works. The height open- ing for charging and withdrawing adjustable max- imum in. The springs supporting the globar heating elements are back the screen. forg- ing hind the operator) close alongside each furnace 4800 hour; two rotary furnaces, 116 kw., approxi- mately ft. diameter, which are used for hardening camshafts and which have capacity 204 each hour; three continuous quench furnaces, 207 kw., operating 1500 deg. Fahr., and three drawing furnaces, 199 kw., for heat treating connecting rods and with capacity 11,000 rods hr. Practically all gears are drawn three continuous furnaces, each ft. long. the rolling mill building are two electric continuous furnaces for heating bar steel for forming ring gears. These use 400 kw. and 300 kw. respectively, both operating 2000 deg. Fahr. Six other forging furnaces, totaling about 2700 kw., and each operating about 2350 deg. Fahr., and two continuous hardening furnaces 300 kw. each, complete the present installation the rolling mill building. When electric power may had low cost, such lc. kwhr., the use the electric furnace would seem offer the solution many the troublesome problems arising the forming and heat treatment steel. the main the advantages far outweigh the disadvantages. While the first cost the installation, with its accompany- ing electrical control apparatus, high, and the cost energy per high, these costs are more than balanced other economies operation and control. true that electric furnace heats slowly from atmos- Ring Gear for the Ford Model piece steel bar right section and length heated forging temperature and then placed suc- cessively two presses. The first one bends the two ends into short circular segment, while the second one, shown here, completes the forming the circle. The forming elements are brought for- ward action the toggles, being pivoted the same center. The lower illustration shows the result after the forming members have been withdrawn The Iron Age, Jaly 12, 1928—75 | } ward balances its account this respect. “Opening t Arrangement Globar Furnace, Used Forging Practice the Fordson Works. and held place springs. with several its features developed Ford engineers ment supported both ends fixture, wate r-cooled pheric temperature the start, but its close control after- Costs repairs are apt high, too, but this condition may ameliorat- avoiding delays and making provision for quick replacement resistors other failing parts. Finally, there likely some loss case intermittent opera- tion. the other hand, the operation electric furnaces there first all temperature regulation which once simple and sure. easily controlled automatically, and can made stay within very variable limits. recording controller makes hand operation personal attention the part the workman foreman unneces- sary. The installation electric furnace simple. takes little room. clean, both outside appear- The workman can stand near the opening working position without discomfort. The out- side heat hardly noticeable, even the hottest weather. Strange may seem, there times actual neces- sity for closing the roof ventilators prevent excessive ance and operation. 7 76—July 12, 1928, The lron Age + Each globar ele- draft the spring department, some days when the wind the right direction cause excessive draft. The temperature this furnace room August not Incidentally, all Ford furnaces are painted with alum- inum. The effect both clean appearance and radiation once apparent. the case the electric furnace labor cost minimum and high quality product possible, for several reasons. There are troublesome gases deal with, products combustion the furnace escaping into the outside atmosphere the shops. The space around and above the furnaces may kept clean; there little cause dirt dust. Electric furnaces may moved easily, shifted about work process lines require. There little additional equipment needed and most can put one panel; moved with the furnace and set just easily. The stock can kept clean, there little tendency seale, opportunity for steel absorb harmful ingredi- ents, such sulphur, while being heated. The tempera- EAT Treatment Springs the West Half the Spring and Upset Building Accom- plished Battery Fur- naces. conserve space, the drawing furnaces, which op- erate lower tem- perature, are located top, shown. The parts pass from the lower furnace the one above means conveyor system | ture can maintained the desired level and there possibility burning the stock. The furnace can put into operation the throwing switch, and shut down the same easy way. The life the heating chambers long, because there combustion taking place them and hence deterioration from gases fumes. The fact that there available Fordson 500,000 hp. made low cost makes the use electric furnaces for the purpose heating steel for forging and hardening realized elsewhere that the advantages electric heating are many that even this element power cost may not important seems. Certainly Henry Ford has shown his confidence it, and the results seem justify judgment. Automatic Control Operations Instruments Giving Both Records Past Performance and Man- ipulation Valves Under Pre-determined Conditions recording and controlling instruments the iron and steel industry was reviewed Eagle and Roy Walker, Bristol Co., Waterbury, Conn., the Chicago meeting the Association Iron and Steel Electrical Engineers. They said that the in- creasing use are welding has created demand for instrument record the cycle operations and give history the work done the welder. shunt ammeter does this well that regularly fur- nished with some welding machines. gives record time worked the welder, that the faithful welder gets full credit for his work. The character the curves shows the type work. large stick two sticks are used, instead one, rush the work, this shown the excess current. Reversed polarity hastens the work and badly weakens the weld, and unmistakably recorded the chart. electrode thrown the ground and left there, the straight line curve shown the chart indicates the grounding the electrode. Refer- ence the chart help the welder and enables the supervisor correct irregularities. Checking operations the reversing valves open-hearth furnaces considered the greatest im- portance most steel plants. essential that the reversing valve thrown schedule from one checker chamber the other, that each may brought the proper temperature and fuel not wasted after the checker has absorbed this heat. effective way checking this operation install electric time recorder the reversing valve. This time recorder has yen operated electromagnet. This pen wired contact the reversing valve, placed that, with the valve one position, the circuit open; with the valve the other position, the circuit closed. The pen moves over when the valve one position and moves back when the valve reversed. The resulting record shows glance the exact time each reversal. addition this record for the superintendent, one plant uses single-pen recorder each valve guide the operator and indicate him how the furnace was running during the previous shift. Automatic Control Eliminates Human Factor Some tendency has been shown late more than keep record the reversing valve operations. has been felt that automatically controlling these operations, thus removing the human factor, would decided step forward and well worth some expenditure. This plan also takes into consideration the fact that the checker chamber one end the furnace frequently heats more slowly than that the opposite end. scheme accomplishing this control has been worked out, using two pyrometer controllers. The location the thermo-couple has been the greatest problem consider here. Temperatures the hot part the checker work are high require the use platinum couples, resulting not only great initial expense, but also great care and upkeep thermo-couples. has been pretty definitely established that cooler spot the rear the checker work can located where the changes tem- perature are directly proportional those the hot zone. This permits the use base metal couples and results comparatively little upkeep. Once this cool spot has been located, and the tempera- ture there corresponding the maximum temperature desired the checker work determined, the rest simple procedure. located each checker chamber and each couple connected pyrometer controller. The spotter each controller set the temperature corresponding the maximum temperature desired. The two controllers are then wired the motor the reversing valve. soon checker chamber reaches the desired temperature contact closed controller which starts the motor the reversing valve, reaches the desired temperature, contact closed controller and the valve thrown back means automatic reversing switch from the thermo- couples, one controller only will this work. Reversing Valves Temperature Differential successful installation has been made control the reversal valves differential temperature. con- necting the two thermo-couples series, and opposed each other, the control instrument operated the dif- ference the temperatures the two checker chambers. Some open-hearth departments have found highly desirable keep daily check temperatures different parts the checker work. This gives valuable line stoppages from dirt, soot, etc. For this work portable indicating pyrometer used. The usual range 2500 deg. Fahr., using base thermo-couple with nichrome some other high-temperature metallic protection well. warehouse where sheets are stored, considerable expense caused the rusting the sheets, including those the center pile. This condition may guarded against reference recording psychrometer. This recorder supplied with small motor and fan assure circulation air over the wet bulb. The range about 110 deg. Fahr. satisfactory. the record shows the atmospheric condition when dew will form, fans are started circulate warm air throughout the ware- house, prevent moisture collecting the sheets. get the best possible efficiency from instrument must selected with the right thermo-couple bulb, the right length lead, and the right range. Accuracy the readings, under the severe operating conditions usually encountered steel mill, the prime requisite. Then models are selected with protection cases suitable for the surroundings. Heavy cast iron cases, out place fine switchboard, are ideal room filled with gas acid fumes. The Iron Age, July 12, 1928—77 7 New Products from Old gray iron foundry, the principal product which was brake shoes, into manganese steel and gray iron production shop has been successfully undertaken the American Man- ganese Steel Co., Chicago. This company purchased the Burnside, plant the American Brake Shoe Foun- dry Co., which consisted seven and one-half acres ground, improved with modern foundry buildings housing two cupolas, and raw material storage yard served gantry crane. New equipment installed includes ton per hour electric furnace, annealing furnace, core baking oven, new sand-handling and preparing equipment, and miscellaneous items, such 500-ton press used for straightening frogs. The two cupolas (Whiting No. and No. were allowed remain their former location, which the west side the main building and easily accessible the storage yard and the material-handling and charg- ing equipment. These units are available for use sup- plying gray iron castings the jobbing trade. The elec- tric furnace located the northwest corner this building, not far from the cupolas and close the mate- rial yard, which extends parallel the main building. Beneath the gantry crane industrial track, from which spurs extend frequent intervals into the main building. This plant produces work requiring large molds and flasks, and was therefore decided that large shake- FEEDER Apron (Below), In. Wide, Delivers Sand Large Flasks Holt Rollover Machine out hopper would serve two purposes: first, that pro- viding shake-out floor area for the large molds and, second, storage reservoir for the shake-out sand. This hop- per ft. area, and the top, which covered with bar grating through which the sand drops, set level with the floor. Used sand fed through the bottom this shake- out bin apron conveyor, the head which placed short-center magnetic separator belt for removal scrap, gaggers, etc., before delivery the bucket elevator. Scrap removed through trap door and then loaded boxes, which are carried away overhead crane. From the magnetic separator the sand elevated volving screen, which acts breaker lumps and also screens and removes refuse. This screen housed steel box which attached suction line and dust collector for the removal dust and fines from the sand. From the screen the sand delivered belt con- veyor, the head end which two-way spout ar- ranged for diverting the sand the facing-sand mill. backing sand being prepared, water added proper quantity spray pipe, which extends across the Shake-out Hop- Conveyor. This hopper, covered grating, acts also storage for used sand ron | 12, 1928, The Iron Age the bed sand passing the belt conveyor. The sand then discharged double paddle mixer pug mill, which mixes and reconditions it. Backing sand handled short cross-belt conveyor and long distributing belt conveyor operating alongside the columns the main foundry bay. means adjustable plows, this sand may discharged any point shoveling hoppers for floor molding purposes. old sand required for preparation facing, the water spray shut off and the sand diverted hop- per which was erected over No. Simpson mill, located side room just off the main foundry. This hopper has two compartments, one fed with old sand means the belt conveyor described above, and the other re- ceiving new sand from the storage means the crane and grab bucket. Facing sand distributed from the mill throughout the foundry boxes mounted electric lift the end the distributing belt conveyor, sand discharged large overhead hopper, fitted the bot- tom with 8-ft. apron feeder that delivers sand long flasks used for making guard rails. These flasks are about sec., and the feed regulated electric push ASES the Working Chamber the Annealing Fur- nace (Above) Through Give Proper Heat Distribution Modern Equipment Transforms Chicago Plant That Electric Manganese Steel Castings Can Made—Sand Handling and Annealing Furnace Features buttons, which control the motor operating the apron feeder. This sand-preparation and handling equipment was installed the Link Belt Co., Chicago. The electric furnace was designed the Pitts- burgh Electric Furnace Corporation, Pittsburgh. has been located that another unit, with capacity tons per hour, can installed later date. Power supplied 12,000 volts, three-phase, cycles the Commonwealth Edison Co., Chicago. Electric Furnace Has Special Features One the features the mechanical construction this furnace that ball and roller bearings are used throughout the electrode-operating gear mechanism, and the electrodes are counterbalanced that the regulating circuit has only overcome the inertia the system. The electrode arms which the clamps are fitted are fastened one end flexible steel cable, which passes over ball-bearing sheaves and around fiber sleeve winch drum and then through ball-bearing sheaves where counterweight fastened. This counterweight equal weight the electrode arm plus the usual oper- ating length the electrode. When the electrode lowered the point where touches the scrap the furnace, the tension the wraps Annealing Furnace (Below) Designed with Double-Pass Combustion Chambers and Has Capacity Tons per Hour. The Iron Age, July 12, cable around the fiber sleeve the winch drum loosened and the sleeve expands, allowing the winch motors turn without unwinding the cable further. The same operation occurs when the electrodes are raised too high. The counterweight then comes against its stop and releases the “friction bite” the fiber sleeves the winch drums, and again the winch free turn without fur- ther overhauling the cable. This system counter- weighted friction-bite hoist mechanism avoids the use limit switches the top and bottom the travel the electrode arms. The core drying oven ft. wide ft. long. fired means coke heaters, and the temperatures range from 700 800 deg. Fahr. the lift-door type and loaded means cars, which are moved and out the oven crane. Made the Swartwout J Prepared Sand Hoppers Are Filled from Dis- tributing Belt Conveyor Co., Cleveland, the oven constructed with walls contain- ing in. insulating material, which protected both sides 14-gage, rust-proofed steel sheets. Annealing Furnace Has Reducing Atmosphere The annealing furnace has capacity tons castings per charge. The annealing period hr., which unit was designed the Carborundum Co., Niagara Falls, Y., anneal manganese steel castings reducing atmosphere temperature about 1950 deg. Fahr. The loading car ft. wide ft. long. feature the use Carboradiant combustion cham- bers, means which uniform temperature and con- trol furnace temperature and atmosphere are said obtained. The combustion chambers, which are the double-pass type, are arranged pairs both sides the annealing furnace. One burner for each chamber fires into the lower pass, which vaporization the oil and mixing with air are accomplished. The gases are then led the upper pass, from which they travel into the working chamber through ports provided spacing the top tiles the upper pass. These ports are dimensioned 80—July 12, 1928, The Iron Age proportion the amount gases discharged along the length the chamber give proper heat These chambers are designed have uniform tem- perature throughout their length, and they deliver heat radiation the lower portion the charge the car, thus offsetting the drop temperature the gases they pass down through the castings the off-take ports located along the sides the level the car top. Proper atmosphere maintained within the furnace because the oil vaporized and mixed with the air sup- plied for combustion before entering the working cham- ber. Burner adjustment regulated observing, through peep holes the furnace shell above each combustion chamber, the color the gases leaving the ports the top the combustion chambers. Between the combustion chambers and the charge interposed firebrick screen wall, designed regulate the radiant heat delivery from the combustion chambers the load. The lower section the wall checkered permit greater quantity radiant heat reach the lower zone the charge, where the combustion gases are their lowest temperature. Excessive temperatures and destructive action are confined within the combus- tion chambers, conditions which the chambers are said capable resisting because the high refractoriness the silicon carbide tile from which they are constructed. The output the foundry varied. Several standard lines are made, such manganese track supplies, centrifugal pumps handle gravel and coarse material, and steam shovel dippers. The gray iron capacity devoted almost wholly jobbing orders, most which come from railroads. High-Pressure Steam Boilers Conclusions the best type high-pressure steam boiler under present limitations were recently submitted the American Society Mechanical Engineers George Orrok, consulting engineer, New York Edison Co., New York. For three pressure ranges the conclusions are: 1—Very high-pressure boilers (2000 and over). Flash type, tubes in. less diameter, header, drums, all welded joints, except collectors and manifolds where flanged coned joints should used. These boilers may consist single coil for small outputs multiple coils the Benson boiler. 2—High-pressure boilers (800-1600 type, consisting bank tubes larger diameter than those indicated for the flash with walls not exceed one-tenth the outside diameter thickness. Tubes expanded headers small-diameter drums whose thick- ness when exposed fire should not exceed one-tenth the outer diameter. Water-line drum should not contain when half full more than per cent the water content the boiler. The boiler should high rather than low, that the water the tubes may under sufficient static head insure steadiness steam, and restrictions discharge opening steam drums should sufficient obviate se- rious moisture the steam. Dry pipes separators should precede the superheater. Steaming economizers should not used, but the feedwater should heated economizer the regenerative system that little water heating left done the boiler itself. Water-cooled furnace walls should used sufficient amount make the fur- nace repairs negligible quantity. temperatures excess 750 deg. Fahr. must content with life tubes and pre- pared replace coils tubes from time time. The only alternative the use much-higher-cost alloy steel. Mr. Orrok discussed his paper such matters the effect tube inclination, the releasing surface and steam space, boiler materials and safety operation. | The Rising Tide Iron and Steel Curve Production from 1919 1927 Closely Parallels the Record-Breaking Pre-War Trend article Edwin Eckel the June issue THE IRON AGE, entitled “Iron Industry Facing Great Changes,” contains many observations which should thoughtfully considered all men the metal industries who are planning ahead for future growth. find myself unable agree with one his conclusions, namely, that “we are not likely resume our normal pre-war rate increase THUM United States last year 120 million people consumed million tons pig iron, per capita consumption 650 Ib. round numbers. this basis appears that the mechanical age has called for more and more iron; the acceleration pro- duction between 1904 and 1916 may taken definite trend and not tempo- rary burst speed. But, course, there must for good many years maximum some time. The come.” The very graph production will uses show the world pig sooner later show iron output indicates that 100 point From production now, and has then the curve will re- rate closely parallel War proaching the time when the pre-war trends, save new production merely re- setback due that up- decay. such point certainly predict the future placed the year 1912 from the past, except 1913, and the line exactly ence; nevertheless, good in- reversed curvature, believe the predictions formation formances, the light current events, the best basis for predic- tions about industrial de- point, person 1895 would have been justified would not have been un- duly optimistic and would would have happened normal growth. Dr. John Mathews the Cruci- ble Steel Co. America has also the Annual Pig Iron Production, millions gross tons plotting future production pig iron slowly ris- opinion that the rate fu- ture increase will cur- ing curve, extrapolated tailed through the econo- from the known trend mies resulting from alloy history would have proved ing alloys. this curve represent- the conservatism prophecy. Even 1905, after the had taken definitely higher rate, Sir Robert Hadfield his presidential address before the Faraday Society prophesied that the world’s production would continue increase the same rate had during the preceding years; that is, slightly over million gross tons yearly. The graph shows how much under- estimated the ability the people absorb iron; for took the profound dislocation great war bring his trend line within calling distance actual production. making his calculations Sir Robert assumed that the million tons iron made 1900 was consumed only 200 million people; and two-thirds the total population the earth would eventually use the metal the same rate the annual consumption would above 250 million tons. This gives what thought was the eventuality—an annual consumption 400 lb. per capita. But the Production Pig Iron Entire World Since 1870 ing pre-war trend moved over parallel itself years, will found fit closely the recorded pro- duction since 1919. And why shouldn’t it? The urge use labor-saving devices, travel with speed and comfort, beautify our buildings, bridges and highways, here just strong now before the war. The war absorbed much wealth and man power that the entire civilized world staggered along dazed condition, having lost sight the old economic landmarks. surprising such substantial recovery shown the actual production figures could made little years. But the figures show has been done! This post-war trend line crosses the year 1936 production 105 million tons. Dividing this figure the factor 0.87 (the ratio between world production pig iron and that steel, constant ratio since 1915) the figure 120 million tons computed the expected produc- The Iron Age, July 12, 7 | 4 “av } 4 | | | | 4 | tion steel that year. This checks fairly the figure 115 million tons, estimated the probable 1936 pro- duction steel, THE IRON AGE editorial printed June 23, 1927. erefore agree with Mr. Eckel that the maximum rate annual increase iron and steel production may have been reached passed. But believe that nothing less than another devastating war will prevent the steady expansion output called for the post-war trend line sketched the figure. Production and Use Die Castings European and American Practice Contrasted—Availability Depends Machining Labor Eliminated—Heavy Price Dies Must Absorbed Savings SAMUEL ENERALLY speaking, the pressure die casting process requires (1) machine capable deliver- ing molten metal under pressure die; (2) metallic mold die receive the molten metal; (3) suitable alloy which will function the machine and form the die, and which will yield casting with the desired physical properties. Die castings, properly speaking, not include castings poured gravity into metallic mold die, but presup- pose the use definite pressure. Proper combination the three essentials noted gives casting sharp detail, finished practically finished, requiring little ma- chining, checking close dimensional tolerance and rapidly producible large quantities. The process often makes possible the use much thinner walls than can cast any other method. incorrect say that castings cannot considered practical die-casting jobs lots less than 10,000 pieces. general rule, the pressure die-casting process most economical where the elimination machining and finishing operations possible. The number castings necessary absorb completely the jnitial cost the die depends, therefore, upon the amount costly machining and finishing operations eliminated the use pressure die castings. Often this saving great that 1000 cast- ings even few hundred will justify the construction die. Present estimated annual production pressure die castings the United States from 10,000,000 12,- 000,000 aluminum-base castings and from 50,000,000 60,000,000 lb. zinc-base die evident, therefore, that these types castings are being widely used. Pressure die castings are used automobile parts such steering wheel spiders, carbureter parts, oil purifier parts, oil pumps, fans, water pumps, electric starters, spark and throttle control parts, windshield wipers, instrument boards, speedometers, hand rests, interior trim handles, cowls, etc. They are used extensively vacuum cleaners, washing machines, typewriters, check writers, adding ma- chines, calculating machines, small motors, magnetos, radio condensers, radio frames, loud speakers, telephones, vend- ing machines, instrument parts, instrument cases, small machine parts, ornamental parts, furniture, cooking uten- sils and electric refrigerators. Producers generally purchase their raw materials zinc, aluminum, lead and tin-base and mix their own alloys. Customers usually designate which type alloy desired and supply information service requirements the *Metallurgist Doehler Die Casting Co., Batavia, This in the last week of June, at the meeting of the American Society for Testing Materials. 12, 1928, The Iron Age finished castings. They then depend upon the producer select, the type specified, the particular composition which his experience tells him will result the best cast- ings for the purpose. Obviously, one alloy will meet the service requirements all such castings. European Die-Casting Practice another appendix the committee report, Pannell, consulting engineer, British Aluminum Co., Ltd., New York, discussed the construction die castings Europe, the type commonly called that name the United States. Great Britain estimated that the heavy metal die-casting production from 3,000,000 5,000,000 lb. year. some cases, said, the machines used are quite primitive, being entirely manual operation. number them, mostly the plunger type, are Swedish de- sign. Another Swedish design, semi-manual, uses air also, from pressure. With small castings this machine driven from counter-shaft and produces castings hour not more than each. With manual operation, much heavier castings can made. English machine designed with plunger and rack and pinion feed has die-preheating chamber. will operate with metals melting point 930 deg. Fahr. The metal pot holds Ib. zinc-base alloy. The production light alloy die castings England does not possess the potentialities the American situa- tion. Castings from given pattern are called for rela- tively small numbers. the orders average perhaps not over one-tenth the number called for the United States single order, the die charges for castings are ten times great. the automotive field, particularly, this limiting con- dition found. the United States 4,500,000 automo- biles are produced about leading makers and average 100,000 each. Great Britain 100 makers produce 150,000 cars, average 1500 cars given design. Stand- ardization, therefore, carried much smaller degree than America and the great diversity parts called for best served the use permanent-mold castings. For reasons growing out this situation, and similar situations other industries, the entire annual production light alloy die castings Great Britain probably does not exceed 1,500,000 similar amount produced Germany and appreciably smaller quantity France. Europe there certain amount prejudice against the use the air-operated machine. This doubt account the relatively high cost compressed air for small shop. asserted also that air leakage and the behavior compressed air the molten aluminum are disadvantage. Lack density the castings men- tioned. | ) 1 Better Planning Production Crux Distribution Problem bution affects our whole Output Keeping with Market pen convenient for the national economy; manufacturer produce, re- the marketing program the individual manufacturer, de- clared Magnus Alexander, tic Dumping, Says Economis president National Industrial Conference Board, New York, ——Research Distribution Urgec addressing the distribution conference held New York, June and 29, under the auspices the bolt, nut and rivet industry. “Distribution,” said, “involves much more than trans- portation, marketing and handling. many distribution means simply the disposal their own output, that is, the problem marketing their own goods. Market analysis and salesmanship, believed, can solve the problem. must examine the issue, however, not from the stand- point the individual producer alone, but from the broad viewpoint national economy. “It seldom recognized that the distribution problem goes much deeper and, fact, has its roots production. Faultily planned production cannot rectified—although part may corrected—by even the most excellently planned marketing program, fact evidenced the failure many carefully designed and strongly financed advertis- ing and sales campaigns.” Growing Proportion Employed Engaged Distribution One heritage war days, Mr. Alexander pointed out, our over-expanded plant capacity, condition aggravated greatly accelerated pace production resulting from continuously increasing industrial efficiency. “The fact remains, however, and much evidence has been adduced prove the point, that productive efficiency certain lines, particularly the last few years, has set pace which might easily outstrip domestic consumption un- der present conditions. There has arisen, therefore, great deal discussion the ‘distribution problem.’ “Statistical data the process distribution are yet remarkably scant,” said Mr. Alexander. “It claimed, the basis individual observations and inquiries into specific lines commodities, agricultural products, for instance, rather than comprehensive, scientific data, that the cost generally has been steadily and disproportionately increasing and that economic gains, achieved efficiency production, part are lost waste distribution. “We know that many instances the consumer price several times that production cost, and census data for the past years give substantial evidence that the eco- nomic cost distribution has been constantly rising compared with the cost production. 1870, 8,629,000, per cent all those gainfully occupied production and distribution combined, were engaged production proper, that manufacturing, mining and agriculture, against 24,470,000, less than per cent all those thus gainfully occupied 1927.” Domestic Dumping One Cause Higher Distribution Costs The essential waste distribution, according Mr. Alexander, occurs the competitive over-production pressure sales campaigns and frequently ruinously low prices. This kind market- ing has been characterized domestic dumping. “Every well informed busi- ness man_ knows,” declared the speaker, “that goods are being sold continuously even below the cost production. This naturally raises far-reaching question: economically sound and socially desirable that goods sold without profit, loss, over considerable period time? that sound con- structive competition? producer may able dispose certain amount his output profit even loss and continue exist virtue the profit made the bulk his output. But not inevitable, because the interdependence one business transaction another, and pendence all industries, that such policy bound disorganize trade and the end bound react disas- trously upon him who sells below the cost pro- duction? “It this very circumstance selling portion quantity production below the cost production that has sharpened competition between producers many in- stances the point being ruinous, and probably has tended greatly increase distribution costs where high- pressure selling has been applied.” The speaker urged more thorough market analysis and closer study consumer demand avoid needlessly sharp competition with resulting dwindling profit margins. Large-Scale Enterprises Sharpen Competition “One the most interesting and significant features our business evolution during the past decade,” asserted Mr. Alexander, “is that large-scale enterprise, which quarter century ago was feared danger free competition, today prime factor accentuating com- petition. “Business conditions the United States during the past decade have presented paradoxical situation: Great national prosperity with record business activity, but the same time competitive struggle which has resulted precarious profit margins. “We see, furthermore, that the very method produc- tion that has contributed much our national income, namely, efficient mass production, which has effected high productivity per worker and has made possible com- bine high wage levels with low prices, the very factor that today accentuating the competitive struggle and thereby emphasizing also certain distribution problems which trade associations might well devote their earnest attention.” Although, broadly speaking, there can over-pro- duction, there certainly can surplus output given variety commodity given time. “It therefore planning what produce that the fundamental solution the distribution problem lies,” declared Mr. Alexander. The Iron Age, July 12, ™ | | ~ 3 § Jobbers and retailers, indicated, are not necessarily blame for mounting costs distribution, they are called upon customers for increasingly elaborate ser- vice. The average ratio profits receipts consider- ably smaller trade than manufacturing and other lines business activity. Some Increases Distribution Costs Justified “It necessary discussing the increasing costs distribution distinguish between what constitutes actual and avoidable waste, such unnecessary cross-hauling, congestion perishable commodities, unnecessary handling, misdirected high-pressure sales methods, and such other elements which increase distribution costs but add nothing the products; and those elements distribution that increase either the convenience the desirability the commodity and are demanded the producer, as, for in- stance, packaging, quick delivery small quantities and other various services performed the dealer for his customers,” said Mr. Alexander. “These latter services essence become the products and are classed manifestations our rising standards living rather than costs repre senting economic waste.” Need for Scientific Research Distribution Prosperity the United States the past decade has been due, large measure, industrial productivity and the elimination economic waste production through mechanization, asserted. Rationalization the dis tributive process, combined with careful production plan- ning, should result further substantial economic gain “The pressure our present competitive struggle challenge renewed effort our utmost stimulating scientific research and apply its results production and distribution alike. Constant vigilance, comprehensive and accurate information and scientific analysis all facts and economic trends having any bearing our business activity are the keys the maintenance our economic well-being,” asserted Mr. Alexander. “Ours may rightly called machine civilization,” said Mr. Alexander conclusion, “but should always remembered that owe the machine both the leisure and the price for our cultural and social progress.” Individual Roller Table Drives Improvement Control, Compared With the Inflexibility Group Drives —Breakdown One Roller Does Not Cripple Train ROUP roller drives, for roller tables, whether the cable and sheave type, bevel gear type, lack flexibility that the individual rollers cannot controlled, said Dobelbower, Crocker-Wheeler Electric Mfg. Co., Ampere, J., speaking the Chicago meeting the Association Iron and Steel Electrical Engineers. “In case motor trouble, breakage cable gears, the entire table out commission. With the roll-out motor drive the failure driving motor affects only the one roller—in fact, number motors the train could fail without shutdown the table. This also permits shutting down some the motors, produce drag the speed the strip bar, desired. There are also fewer bearings lubricate than the group drive, which means less maintenance and fewer chances trouble. “With any the types motor for roller drive essential that the insulation throughout such that will stand under the heat obtaining and all parts must extra rugged construction. installing roll-out vy) motors essential also that each motor protected overload relay fuse prevent roasting out case the motor stalled, due jamming any other abnormal condition, unless the motor designed stalling. Control Speeds Desirable “Power for driving roll-out motors is best obtained by use motor-generator set. This should consist variable-speed d.c. motor driving alternator. the use this combination the speed the altcrnator can varied, thus changing the frequency and voltage current delivered the roll-out motor. This permits the operator control the speed the strip bar the table. “Roll-out motors the general purpose design can, desired, ventilated. necessary that clean air supplied; the ventilation can obtained bringing the air one end the motor the bottom, and discharging the bottom the opposite end. This type motor, however, should not 84—July 12, 1928, The Iron Age require ventilation, comparable any fully in- closed motor operating hot place. The roll-out motor the design where the motor built directly the roller is, however, different problem. The motor, this case, subjected directly the heat from the strip rod being carried the outer surface the motor. Thus heat applied the surface which, the ordinary design motors, the surface from which heat radiated.” American Standards Association Succeed Standards Committee the American Engineering Standards Committee keep pace with the growth the industrial standardization movement the United States now under way, announced the committee. The princi- pal features the reconstruction are the definite federation national organizations, under the name American Stand- ards Association, such way that trade associations interested standardization may more readily join the direction the movement; placing the technical work approving standards standards council; and concen- trating administrative and financial responsibility board directors composed industrial executives. The underlying principles remain unchanged. The basic functions remain completely the hands the represen- tatives the member-bodies. The individual members, whether the board directors the standards coun- cil, are appointed nominated the member-bodies, which thus remain the fundamental units the organiza- tion. The name American Standards Association being adopted more accurately descriptive the reorganized association, and also because the misunderstandings and misconceptions which have frequently occurred connec- tion with the words “engineering” and “committee.” The scope the work is, however, being limited those fields which engineering methods apply. | ‘ Cast Steel Core for Bronze Gulls 30.000 Lost Sea “ <4 A a the more than 30,000 Americans who have perished sea since the nation was founded—heroes naval bat- tles and martyrs commerce, rescue work adventure, striking monument built the banks the Poto- mac River, Washington, site East Potomac Park granted Congress, not far from the National Cemetery Arlington. The memorial cost $500,000. About third this sum has been contributed, many gifts coming from school children. national campaign raise the remaining $350,000 being directed William Fellowes Morgan, Jr., 107 Cliff Street, New York. reproduction below photograph the model this Navy and Marine Me