The Iron Age 1928-08-02: Vol 122 Iss 5

THE IRON AGE New York, August 1928 ESTABLISHED 1855 VOL. 122, No. Web Conveyors Serves Factory Unusual Combination Straight Runs, Curves, Spirals the foremost fac- tors reducing costs plants operating basis mass production ef- ficient system for handling mate- rials, The kind equipment best suited this purpose apt vary according the specific requirements each company. many cases combination standard conveying machinery and specially designed apparatus, adapted local conditions, se- cures the best results. the new plant the Kel- vinator Corporation, Detroit, manufacturer Kelvinator elec- refrigerating units and Nizer ice cream cabinets, provi- and Heavy Grades—Upper and Lower Runs Belt Both Utilized BURNHAM FINNEY* = flexibility features the con- veyor system the Kelvinator plant. Tote boxes, sent down the system need be, are emptied their products proper points and placed back the sys- tem, that they not pile anywhere. Trays for special materials are designed fit the boxes. Thus the loading and unload- ing, the boxes pass given point, are simple matters. certain points electric lift-trucks and other equipment are used, but mainly the manufacturing process relies which are booster belt roller gravity, imme- upon itself well straight-line produc- tion. Arrangement operations much like that automobile factories, with sub-assembly lines feeding main assembly lines, which turn supply final as- sembly line. practically all departments which there sub-assembly final assembly parts, the work done along motor-driven belt conveyors the movement which timed conform the necessity the various operations. the com- pressor assembly department, for example, the action the belt conveyor regulated that the crankshaft, valves and pistons can fitted the cylinder block sion has been made practically every department for transport- diate circumstances require. workmen stationed points along the conveyor. The same ing materials mechanically. fact, the plant resembles large web woven various transportation lines. Although this system has been operation only short time, has already effected substantial economies. exaggeration say that materials are carried through the entire plant without hand labor, from the time they reach the receiving department finished refrig- erating units are shipped customers. Conveyors even extend the length the stockrooms, that materials, moving from this central point any department the plant, are transported mechanical methods. Units Several Types Employed HILE roller and motor-driven belt conveyors pre- dominate, materials are not handled exclusively that manner. overhead monorail system and electric lift trucks are utilized for certain types work. Wher- ever materials must sent from one floor another, they are taken spiral gravity conveyors, “booster” inclined motor-driven conveyors automatic pendant- type vertical elevators. The manufacture electric refrigerdting units lends *Resident editor Cincinnati for AGE 9 “ true the thermostat as- sembly department and the departments which pressure controls, water valves, shut-off valves, expansion valves and float valves are as- sembled. the production refrigerating units necessary move from department department hundreds parts. One the most difficult problems confronting the management the company was find the most eco- nomical means transportation for them. The plan finally adopted provided for standard all-steel tote pans, each measuring in. width, in. length and in. depth, and capable carrying maximum weight 200 These pans, when once placed service the convey- ing system, remain constant use and are not removed except the end the conveyor the stockroom, where, after being emptied, they are transferred hand the lower run the conveyor move immediately back into the various departments the plant. many cases they are loaded with stock assembly operations before being placed the lower run the belt. Holders, fitting snugly into the tote pans, are provided for each kind part transported. The workmen remove these holders, Floor Plans Show Interconnecting ( YRAVITY Conve yor f Along Left Wall (Third Receives T ote Pans from Booster : First Floor and Passes Them Belt Con- ¢ yor Through Ce nte r of i Stockroon (Shown Also in i View Below.) Tote pans coming to belt fron right are fron vertical elevator. Pao Ss re turned on lowe r run of belt are deflected it} side on rollei irals, Man in center is operating deflector AN = it ry all Oo Connecting the hree Floors Are Shown Red the Diagram. floors are shown one ve the other as they occur in the build- ing, the one top page being the top floor. Mate- pass through the floor the second story booster conveyor w'th 30-deg. grade. This carries them | i through the second floor (BC) and the third floor the material delivered the belt con- vey r , lengthwise in the stockroom. A short conveyor facilitates distribution some the From the stockroom, material going partments placed the lower run the belt conveyor and may switched off either both which lead down through the floor lope into spirals the second floor, which the assembly department. What goes over traverses the spiral M and is delivered to the belt ¢ conveyor MN. What goes over traverses the spiral between / id O and much of it is delivered on the R which again goes down through the floor grade to the first floor. Here, after mak'ng ss spiral, the conveyor ends the op. Another conveyor the assembly takes other the other end shop. going down through the floor grade at |’ This traverses another spiral on ‘ floor, coming out at Il and then, over a belt a a feeds the line which leads the auto- elevator. This elevator carries material the three floors, with delivery each floor the stockroom deposits material the conveyor This conveyor eventually leaves this floor 30° going down through the second floor over another B spiral and ending All these spirals are fitted with rollers, that gravity carries the material downward tote boxes A — ~ | ] | | \ 266—August 1928, The Age — + sy j evator oO t | | i} | Elevator MACHINE 6) The Iron Age, August x bo {| OL 7, W FromAbove OLLER Spiral Second Floor (Below) Re- ceiving from Gravity Conveyor Shown Lower Left Photograph Top Page 266. Note deflector, switch and switch arm, which are loading table shown the form holder means which various parts are shipped the tote pans a >= UTOMATIC Loading Station, First Floor, Vertical Eleva- tor (Above) Which Deliv- ers Tote Pans from First- Floor Machine Shop Third-Floor Stockroom ONORAILS Carry terial Into and the Reception Treated 1928, The Iron Ace | AKE-UP End Belt (Threaded) Shown Right Coming Down from Second Floor and Delivering Curve and Roller Spiral First Floor. All spirals are ft. diameter, with pitch 7. Testing” Compres- sors, Which Are Carried Here from End Assem- bly Line Means Overhead Chain Con- veyor Run and (Third Floor) Discharge Vertical Are Shown Left. This grav- ity roller conveyor deliv- ers stockroom belt shown left lower photograph page 266 The Iron Age, August > Ve racks, from the tote pans, but not impede the move- ment the latter. Stockroom Control Tote Pan Movement OUTING the tote pans regulated chiefly from the stockroom. Material delivered from stock sub-assembly departments placed tote pans and sent out from the stockroom the belt conveyor. This delivers spiral gravity conveyors connecting with various and gravity conveyors running into the sub- assembly departments. When the tote pans have gone the length the assembly line which they are assigned, and have been emptied their contents, they may held for use the inspection point. they are not needed there they may returned the stockroom for rerouting. Raw stock coming into the plant carried means inclined conveyor from the receiving department the first floor the third floor, where the stockroom located. The conveyor equipped with standard pusher bars and runs speed ft. minute. delivers the stock, always tote pans, gravity roller con- veyor discharging belt conveyor moving down the center the stockroom. The belt conveyor consists upper and lower run, material moving into the stockroom the upper run and passing out the lower. Assembly work done principally the second floor. Material delivered from the stockroom the third floor the belt conveyors along the assembly lines means spiral gravity conveyors, and assembled parts are carried the storage and shipping departments the first floor similar manner. The general plan having material from the first the third floor and thence the second and again the first has been fol- lowed laying out production lines the plant, and the entire conveying system has been designed conform and facilitate this arrangement. Special Arrangements Facilitate Some Operations certain cases provision has been made for special carriers. For example, compressor units, after being painted, are placed special carrier suspended from overhead monorail conveyor running into continuous- type dehydrating oven. The carrier has three shelves, the bottoms which are perforated that material resting them can dry easily. When the compressors come from the oven they are removed from the carrier and are tested under gas pressure for leaks. They then are charged with oil and are put overhead conveyor for delivery the final assembly department, where they move into the condenser assembly line. For the silent testing compressors after assembly special room has been set aside the third floor. Com- pressors are carried there from the end the assembly line the second floor means overhead chain con- veyor. Ice cream cabinet condensers are assembled con- tinuous roller conveyor, but, account their bulk, veight and the peculiar requirements the assembly op- erations, they are pushed hand from one position another. the end the assembly line they are placed specially designed carriers and are moved a mono- rail conveyor into baking oven. From the oven they are transported vertical conveyor the charging room the floor below, where they are charged with sulphur dioxide and oil. From this point delivery made roller conveyor the department where the condensers are as- sembled into the holding cabinets. Still the roller con- veyor, the unit tested and then sent the crating room and the warehouse for shipment. Automatic Elevator Takes Machined Parts Stockroom ACHINED parts from the machine shop are de- livered means gravity roller conveyor automatic pendant-type vertical elevator, taken 270—August 1928, The Iron Age the stockroom the third floor. This stockroom serves for storage both raw materials and finished parts ready for the assemblying operations. The elevator motor driven, and the loading stations each floor are cable- controlled and are properly interlocked prevent jamming the elevator. the elevator being loaded the first floor, for instance, the loading stations the second and third floors are locked that material can fed the elevator. The elevator, which loads and unloads automatically, equipped with metal carriers each which just large enough accommodate comfortably one the tote pans. These carriers are spaced about ft. apart and their speed can regulated conform the movement the tote pans discharging them. Through the machine shop runs belt conveyor along which parts process move from one operator the next. The lower run the conveyor used carry chips from the machine shop, the chips being gathered the tote pans. Monorails are employed rather extensively, when they afford better facilities for transportation than roller belt conveyors. For example, addition being used carrying material into and through dehydrating ovens, monorails bring flywheels from the paint room and radi- ators from the sub-assemblies the unit assembly de- partment. Furthermore, monorail has been erected through the stockroom and through the radiator, condenser coil, evaporator and tank assembly departments. Considered whole, the system, which was designed and installed the Kelvinator engineers, comprised different units, many which dovetail into each other. has made possible the movement materials what- ever speed whatever quantities are called for pro- duction schedules, without the necessity employing con- stantly fluctuating number workmen. The permanent decrease the amount man power has been sufficient itself account for large reduction costs. However, state that these savings are all that has been accom- plished would omitting mention the most important results. has made practicable the economical manufac- ture refrigerating units mass production basis, achievement which would have been impossible at- tainment were not for the comprehensive mechanical transportation lines connecting the various operating de- partments. Measures Temperature Welding Flame the meeting the Verein Deutscher Ingenieure, held Essen, June 11, Prof. Henning described his experiments the temperature the oxy-acetylene flame. According abstract the paper published Engineering, the temperature was measured Kurl- baum’s methods, the flame being colored for that purpose with lithium carbonate. The flame was measured number places different heights above the edge the burner and different distances from the verticai axis. The proportions acetylene and oxygen used were also altered. The maximum temperature, 3100 deg. C.. was obtained with the ordinary proportion 1:1 used welding blowpipes. The acetylene pressure was and the oxygen pressure per in. Handling Personnel Industrial accidents, factory management, hours work, fatigue and rest periods, lighting, heating, ventilation and sanitation are discussed 48-page mimeographed pam- phlet issued the Library National Bureau Casualty and Surety Underwriters, Park Avenue, New York. was prepared Mildred Pressman and includes review general literature these subjects, and literature their relation the questions safety and production. | 4 7 | | Carbon Deposition Near Furnace Top More Than Third Can Come from Volatile Matter Coke; Remainder Must Come from Blast Furnace Gases Themselves HOWARD* generally acknowledged that the manufacture pig iron the very basis the and ferrous alloy industries. Therefore any information the chemical reactions involved not only scientific importance but may real economic value. thorough understanding these reactions essential for the proper design blast furnaces, and should real benefit the furnace oper- ator. Many textbooks and articles speculate the reac- tions taking place and show the complete equations, but fail take into consideration the steps involved the rate reaction and the equilibrium constants. However, there much valuable data the literature which the physical chemistry involved has not been considered. Recent work done the Bureau Mines the Birmingham district real interest and significance. Technical Papers No. 397 and 391, entitled “Composi- tion Materials from Various Elevations Iron Blast Furnace” and “Iron Blast Furnace Reactions,” Kinney, Royster and Joseph, tests are described which sampled both gases and solids different levels the iron blast furnace for period many days. The gas analyses represent the average 1000 tests and should fairly representative furnace operation. The results are shown Table Table Analyses Different Levels the Blast Furnace Height Per Cent Volume Above Temp. ft. in. 204.0 10.3 27.0 1.87 60.8 Piane 12.1 26.5 1.69 59.7 Piane No. ft. 745.0 9.0 .28.6 1.64 60.7 Plane No. 4.. ft. in. 853.0 1.1 33.6 0.8 64.5 should noted connection with the above table that the content decreases steadily point ft. in. above the tuyeres, after which begins increase. The CO, content zero the bosh, increases steadily the same point and then falls off. should also noted that percentages are given volume, which equivalent molecular percentage. can assume that the nitrogen comes from the air and goes through the furnace unchanged. That the amount nitrogen coming into the furnace with the coke neg- ligible apparent from the following computations: Burden: 2626 coke; 2240 Ib. iron; 9695 Ib. air. Analysis coke: 0.6 per cent nitrogen; 1.0 per cent volatile. Molecular weight air assumed (79.1 per cent nitrogen). Molecular weight nitrogen 28. Correction for nitrogen coke assuming all goes gas The gas analyses were then recalculated basis mols nitrogen and the results are shown the fol- lowing table: Table Analyses Different Levels Blast Furnace Mols Gas per Mols CO, 10.2 26.7 1.85 60 0 Plane No. 13.2 26.6 1.70 60.0 8.9 28.3 1.62 60.0 1.0 31.2 0.74 60.0 *Department Chemistry, University Illinois, Urbana, recalculation these analyses the basis mols nitrogen shows the total carbon the gas and given Table III. Table Carbon Gas—Mols per Mols Position Total Carbon Position Total Carben 36.9 Plane No. 4... 32.2 real significance note that the total carbon the gas increases steadily from the bosh Plane No. Plane No. the total carbon decreases and then increases the Top Gas. This would seem indicate that there deposition carbon between Plane No. and Plane No. fact which was brought out the oxygen calculations Technical Paper No. 391, cited above. calculation shows that this increase between Plane and the top the furnace cannot due carbon coming from the volatile matter. Coke per cent vola- tile. Assuming formula for this volatile matter Mols carbon from volatile= 2626 0.01 0.86 Molecular proportion carbon from volatile nitrogen from Total carbon from volatile per mols 60—0.4. Total carbon top gas from Table III 38.0 mols and 36.9 Plane No. increase 1.1 mols. Com- pare this with 0.4 mol carbon which might have received from the coke volatile matter. This work strongly indicates that the deposition car- bon the top the blast furnace comes from the blast furnace gases themselves. this particular case amounts 1.9 mols compared with 0.4 mol that might depos- ited from volatile matter coke, and hence greater amount than would obtained volatile matter only were decomposed. The following table shows the total mols gases per Table IV—Mols Other Gases per Mols Total Gas Total Gas Position Except Position Except 38.8 Plane No. 4....... 32.9 will noticed that there increase from 32.1 40.5 mols the total gases from the bosh Plane No. then decrease 1.7, after which returns 40. other words, the total volume gases leaving the furnace not great that present the furnace Plane No. There apparent reason for variation 1.1 mols carbon the gases between Plane No. and the top gas (Table III). there are reactions involving car- bon which have not considered the furnace was not running uniform rate. Considering the size the equipment, variation material, differences the tech- nique the operators and other incidentals, the latter pre- sumption may correct. such the case, the use these data for qualitative study the reactions the blast furnaces are value, but would not safe use them for quantitative deductions about the furnace’s reac- tions. The Iron Age, August Eastern Pittsburgh Valleys Buffalo United States Rolling Mill Capacity Compilation Rated Outputs Leading Forms Steel Each Twelve Districts the Country HREE years ago last January THE IRON AGE pub- lished several pages tables and map showing the location and capacity all the steel rolling mill units the country. The tables indicated the subdivision the rolling capacity for each type product, showing how much could produced each plant each district under each class product. The total rolled capacity was there computed, Dec. 31, 1922, 43,157,845 gross tons. The figures have now been brought date. Refer- ence was had the 1926 directory the American Iron and Steel Institute—the latest comprehensive publication that character, and, addition, verification correction was made more than 200 companies for the individual fig- ures appertaining those companies. Representing nearly possible the situation Jan. 1928, the tables and diagrams shown herewith indi- cate the capacity various districts and how those dis- tricts are equipped various forms steel. The total capacity appears 52,196,000 tons, per cent greater than five years earlier. The districts, somewhat loosely drawn, are shown the map. One our diagrams shows the relative capacity the different districts the production nine specific, leading items. Each circle has area proportioned the others the ratio the tonnage capacity the different prod- Cleveland Ohio River Principal Products Each District Are Shown Top and Bottom total capacity, district district 1928, The Iron Age Southern ucts. Except for rails, which Chicago leads, the Pitts- burgh district the dominating influence each product. Pittsburgh’s share varies from 20% per cent the aggre- gate sheets per cent the tubular products. The Pittsburgh district has 26.9 per cent the total capacity. Chicago’s lead rails represented 30.3 per cent the total, against Pittsburgh’s 23.4 per cent. Another diagram shows the subdivision the capacity each district into the leading items product. most the districts bars furnish the principal item. This reaches nearly per cent the small Eastern district, but drops below per cent the Ohio River district. Plates take the lead the Philadelphia district, while sheets both the Wheeling and the Ohio River districts are ahead all other products. the latter, particular, sheets ac- count for more than per cent the total. Considering sheets and tin plate together, more than half the total capacity the Wheeling district thus covered. Here, the other diagram, the area each circle bears the same proportion the other circles the capacities the re- spective districts. While the total capacity for finished rolled product placed 52,196,000 tons, increase per cent over the capacity the end 1922, such increase has been made the ingot production capacity these plants. This reported the present table 59,973,000 tons, against e Chicago St. Louis age. Areas circles are proportional Bars | Districts ANNUAL CAPACITY FINISHED ROLLED IRON AND STEEL THE UNITED STATES JAN. 1928, SUBDIVIDED INTO TWELVE PRODUCING DISTRICTS SUBDIVISION FINISHED ROLLED PRODUCT (Thousands Gross Tons) Merchant Tubular Total Sheared Bars, Sheets Black Products Finished and Bands, and Plate (Incl. Wire No. Total Universal Structural Light for Seamless Wire (Net Districts Plants Ingots Product Rails Plates Shapes Plates Tinning Tubes) tods Tons) B—Philadelphia 7,148 6,382 588 1,655 1,458 1,33 426 182 386 355 344 C—Pittsburgh 15,201 14,044 1,058 1,840 1,532 3,879 1,317 697 2,418 1,305 1,216 D—Valleys 7,624 6,067 645 1,089 471 870 270 236 E—Buffalo 2,678 1,983 400 250 926 130 177 106 F—Cleveland 6,136 4,819 207 255 2,165 1,036 633 458 481 G—Ohio River 1,898 111 172 959 220 H—Wheeling 3,308 2,530 260 539 696 608 427 J—Chicago 11,281 10,126 1,373 1,566 914 3,730 272 738 1,002 1,038 K—St. Louis 740 814 128 395 100 L—Western 1,615 1,557 360 245 717 164 187 Ch; — ? 7 a | j | | District B—Philadelphia C—Pittsburgh E—Buffalo F—Cleveland River J—Chicago K—St. Louis I.—Western District B—Philadelphia C—Pittsburgh D—Valleys River H—Wheeling K—St. Louis WHAT MAKES THE STEEL OUTPUT EACH DISTRICT Total Finished Rolled Product 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 Tubular Sheared Merchant Sheets Black Products and Bars, and Plate Universal Structural Bands, Light for Seamless Wire Rails Plates Shapes Hoops, Etc. Plates Tinning Tubes) Rods Percentage District Total Each Product 25.9 22.8 20.9 2.9 6.0 5.6 7.5 13.1 10.9 27.6 9.4 5.0 17.2 9.3 10.6 44.9 17.9 7.8 14.3 4.5 20.2 5.0 12.6 46.7 6.6 ws 8.9 4.3 5.3 $4.9 21.5 1.4 13.1 9.0 sae 10.3 21.3 27.5 24.0 16.9 27.3 12.5 3.0 35.7 5.8 . 15.7 13.6 15.5 9.0 36.8 5.2 2.7 7.3 9.9 Sank 15.7 1.6 48.6 10.6 8.2 2 23.1 0.3 15.7 $6.1 4.3 10.5 Showing Contributions Distriets Total Capacity Nine Products Sheets Plates Pipe Rails Drawn Wire Wire Rods Tin Plate HOW MUCH EACH FORM STEEL MADE EACH DISTRICT Total Finished tolled Total Ingots 100.00 100.00 Product Percentage Each District the Sheared and Universal Structural 12.97 24.88 23.36 27.66 9.70 8.83 1.50 4.57 3.83 2.45 e 9.56 30.31 23.54 1.92 7.95 0.08 100.00 100.00 iates Shapes 1.07 20.37 0.84 5.46 100.00 Merchant Bars, Sheets sands, and Hoops, Light Etc. Plates Total United States 9 vo 7.50 6.63 21.82 20.49 15.32 16.95 5.21 2.02 12.18 16.12 0.97 14.92 3.03 10.83 3.19 20.99 8.25 2.23 1.34 4.03 1.03 190.00 100.00 Tubular Black Products Plain Plate (Incl. Wire for Seamless Wire (Net Tinning Tubes) Rods Tons) 0.54 4.93 7.71 7.01 7.95 7.97 29.49 43.95 29.22 28.18 19.94 15.81 6.05 5.47 3.96 2.33 2.75 11.51 10.26 11.15 4.93 4.87 25.75 7.76 5.56 6.72 11.52 13.42 22.44 24.05 2 2.24 3.67 4.3 100.00 100.00 100.00 100.00 The Iron Age, August 1928—275 Bars . S > { | Wheeling | 7 Q 0.91 1.59 0.09 11.92 12.23 32.47 25.35 26.91 34.13 12.71 11.62 4.47 3.80 5.57 10.23 9.23 3.16 2.80 5.52 4.85 3.00 3.04 a 18.81 19.39 2.69 2.98 - 55,522,000 tons for five years ago. The increase ingot capacity has been thus only per cent. Figuring the ratio between rolled steel production and ingot production per cent, which about the yield finished steel which ingots have been producing the past few years, the ingot capacity reported has called for finished ~teel capacity about 44,400,000 tons. The rolling capacity reported, however, excess that amount per cent. This follows natural conditions, inasmuch ments vary from year year, and rolling mill capacity al- ways has excess the total the probable require- ments. Rail mills are thoroughly busy only small portion the year, and for the most part are not used for other products; similarly with other types mills which are suited only narrow range output. happens, how- Blowing Materials ever, that the finished rolled capacity today considerably further above the per cent ratio ingots than was case five years ago. Evidently the several forms made given plant are not likely simultaneously full demand. Using the capacity figures given and the production figures for the various items reported AGE May 17, page 1401, find that capacity wa: used 1927 about the following average proportions: Rail making capacity per cent. Plate mill capacity per cent. Structural shapes per cent. Merchant bars, etc., per cent. Sheets per cent. Tin plate per cent. Tubular products 72% per cent. Wire products per cent. into Blast Furnace German Experiments with Ore and Fuel Additions Hearth Through Tuyeres—Problems Far from Solved LOWING ore and fuel into the hearth the blast fur- nace was discussed interesting article Stahl und Eisen. was contributed Bertram the Hal- berger plant Brebach-Saar, Germany, and gives brief account tests carried out that plant since 1917. Blowing Dust Through Tuyeres Tests were first made covering the use flue dust. arrangement was worked out which flue dust could taken from one the large dust catchers and introduced into pipe leading into the tuyeres. Details the ar- rangement are not given. With good operation, the blast carried the flue dust smoothly into the furnace without pro- ducing dirty tuyeres. Also the dust production the fur- nace did not increase even after long blowing. From the first test was observed that the dust exerted cooling effect. the furnace operation remained un- changed, was not possible produce No. foundry iron, completely saturated with carbon. partially saturated iron was made that was used directly for castings. the chemical otherwise, was hardly changed, the reason probably sought change the physical constitution. Further was noticed that, with the blowing large amounts dust and with even furnace operation, the quality the iron was not good. The explanation that undesired lowering hearth temperature brought about. This can avoided only increase coke the charge. Under the conditions the Hal- berger plant, calculations based tests showed that the blowing dust economical, compared with briquet- ting, only when not more than 30.5 lb. coke per ton pig iron has added the charge. The process economical only when the furnace working with great excess temperature which has equalized with cold air additions the blast. Whether recommended for the production pig iron for steel making doubted, the reduction man- ganese and other reactions will, without doubt, influ- enced unfavorably. The blowing fuels much more difficult carry out. After many failures screw-feed was worked out that carried the material uniformly the tuyeres and now from per cent the coke charge can blown fuel additions. Tests showed that coal mud. raw coal, coke 1928, The Iron Age dust and small coke cannot used, least long they are introduced into the chief blast main. comparison with the effect produced putting blast from hot stove cold working furnace, that produced blowing dry coke dust sadly wanting. What needed such case not more fuel, but higher temperature. Blowing cold fuel lowers the temperature. long oxygen not mixed with the air nor the fuel preheated, this will always the case. The tests the Brebacher plant have shown that the hope unfortunately only dream that, when feeding arrangement fuel the hearth was worked out, blast furnace would operate like machine. Also the blowing cheaply made producer gas above the tuyere level appears untenable practice. There remains only the hope that flue dust and fuel can blown into the shaft the furnace. this way the cost briquetting will saved and the material will preheated when brought into the hearth. However, the necessary arrange- ments cost money and the heat balance the furnace re- quires that, with large amount flue dust addition, corresponding increase coke made the charge. Results Summarized The author’s summary that the blowing ore flue dust gives rise difficulties with blast furnace working under low pressure. not suitable practice for the production high-quality foundry iron irons high manganese, and economical only one run- ning with the object producing gas considerable cold blast has used equalize temperature. Blowing fuel gives rise operating difficulties. Tests and theory show that the process unworkable long fuel introduced into the main blast line. There still remains the possibility working out improved meth- ods introducing fuel the furnace hearth. Facts About Accidents,” the second series publications issued the Policyholders’ Service Bureau the Metropolitan Life Insurance Co., New York, outlines current industrial practice obtaining and using accident facts means promoting plant safety. Accident forms are provided, which have been found helpful re- cording the necessary facts and making them available for study. | | { = Economies Automatic Welding Lowest Costs Require Rapidly Melting Electrode Proper Size and Correct Balance Between Current Input and Speed Welding Head BREWSTER* AVING adopted welding cheaper more satis- factory process than others, the next question is, “How can welding operations speeded ob- tain the maximum output minimum cost?” Naturally, quality must not suffer. the following discussion, the principal variables affecting operating costs will consid- ered. will assumed that (1) handling charges have been Motor Drive and Gear Reduction Set (Above) Comprising Welding Head for Arc Welding — Welding Head Mounted Motor Driven Carriage for Making Long Straight Joints. Carriage also car- ries reel welding wire, current control, and indicating meters reduced minimum, (2) the clamps other fixtures used for holding moving the product while being welded are correctly designed, (3) the welds can backed up, has been effectively done, (4) disturbing magnetic ences have been reduced minimum, (5) the material welded flange quality steel and (6) the joints are properly assembled and, necessary, beveled the edges. These are either plant layout machine design problems. Our investigation confined study reducing welding costs proper balance welding conditions only. The following motions, materials and conditions remain considered: The rate electrode feed. The rate travel along the weld. The kind type electrode. The diameter the electrode. The value welding current. The voltage across the arc. ore order determine the optimum conditions, the rate which satisfactory bead can laid steel plate, affected the above variables, was studied. arc welding machine was used because easier control *Industrial Heating and Welding Engineering Department, General Electric Co., Schenectady, and measure the welding variables when their regulation automatically controlled. The principles discussed, how- ever, are equally applicable hand welding operation. interesting note that the automatic welding machine originated piece research apparatus for studying certain aspects hand welding. bead flat plate was used because eliminated other variables such joint preparation, backing up, and ol + 4 — the need for giving special attention magnetic disturb- ances. not assumed that bead flat plate equivalent weld joint, but regardless whether joint bead considered, raising the current in- creased speed can employed, there will saving welding cost. Likewise changes electrode diameter and type electrode may effect savings welding. The object being stated above, the use bead flat plate preferable some arbitrarily selected type joint because fewer welding variables are involved. The physical dimensions bead made with No. wire, diameter, using 190 amp. and travel speed in. per min. was arbitrarily selected standard. This bead possessed the qualities generally required satisfactorily deposited weld metal. Good appearance, adequate penetra- tion and absence noticeable porosity were considered sufficient evidence “satisfactory” bead. The limits current and speed were considered reached when any one these suffered. Practically all the inspection was made without destroying the bead because believed that The Age, August 1928—277 — 1 familiar type weld bead can adequately judged without doing so, the same the probable soundness riveted joint can determined without testing de- struction. Rate Electrode Feed the motion hand are welding operator analyzed, may divided into travels two directions: (a) along the direction the weld, and (b) down toward the work order hold the are length constant the electrode consumed. automatic welding the second motion—that feeding the electrode downward consumed—is ob- tained wire-feeding device, easy vary and capable fine adjustment, called welding head. The wire feed down through the vertical tubes, shown the accompanying re- productions photographs, easily adjustable over wide range proper rotation the two rollers with milled edges. Control devised that practically any predeter- mined voltage used metallic arc welding can held. The rate electrode feed depends primarily upon weld- ing current and the melting rate the electrode. This melting rate has important effect the ultimate speed which good weld can obtained and will consid- ered further. Rate Travel Along the Weld The travel along the weld may obtained either moving the work past the welding head mounting the welding carriage that moves the head along the work the direction the weld. standard carriage, such that shown, speed may varied from in. per min. desirable observe certain important welding con- ditions. Too much emphasis cannot placed even, smooth travel when working the highest possible speed. this end, final reduction the movement should through worm gear. small disturbance any one the welding conditions will result slower ultimate weld- ing speed. Needless say this travel movement should easy vary small steps over and above the probable velding range. Uneven, jerky travel particularly objec- tionable. Melting Rate Electrode the many kinds electrodes available, impos- sible class any definitely good -bad because the lack standard for comparison. Some are good for one job, some for another. The proper plan select the one best suited for the particular job. The first consideration, not only the electrode prob- lem particular but any welding job, the qualities de- sired-at the joint. The relative importance strength, duc- tility and resistance leakage corrosion should care- fully considered. Other items that should given atten- tion are the design the joint, the heat treatment, any, and whether the joint machined ground. Tabulated Welding Conditions and Costs order bring out another item often neglected, assumed that several electrodes give welds that meet the conditions desired. Then select the one that will the job the highest speed. This depends not only the elec- trode diameter and the welding current, but also the melting rate the electrode. Consideration this factor often neglected. That the melting rate the electrode differs may seen from the curves the accompanying chart, deter- mined making satisfactory bead flat plate, de- scribed. The diameters the electrodes are identical and the metal the two welding wires the same analysis. The electrodes differ the fluxes used and the method combining them with the electrode. The melting rate aver- ages about per cent less for No. wire than for Similar results have also been obtained with one two other types electrodes. Melting rate curves are seldom available the shop foreman. will interesting consider case where these curves were not hand. was found that with 190 amp., %-in. diameter electrode, and travel speed in. per min., satisfactory bead could obtained with No. electrode, the wire feed being in. per With No. wire, and the same conditions otherwise, the wire feed was found in. per min., indicating that the second elec- trode had per cent greater melting rate. The bead made with the second type wire looked little heavier but the apparent difference was slight. The next step was increase the current and speed each type wire until limit was reached. With the first type wire, the limiting condition for the kind bead desired was 240 amp. travel speed in. per min.; with the wire with the higher melting rate, the limit- ing condition was 265 amp. and in. per min. travel. will seen that the travel speed along the line weld was per cent faster when the electrode with the higher melting rate was used. obvious from the example cited that, other condi- tions being equal, the melting rate important factor speeding production. Larger Electrodes for Poorly Fitting Joints automatic welding, electrode seldom used with welding current over 200 amp.; hence the above work 3/16-in. electrode the same type was tried using the same welding conditions employed with wire; namely, welding current 265 amp., and travel speed in. per min. The electrode consumption with %-in. wire was in. per min., which, with welding speed in. per min., gives deposition electrode 0.076 per ft. weld. With 3/16-in. wire the electrode feed was in. per min., which, with welding speed in. per min., gives consumption 0.061 Ib. electrode per ft. weld. These data illustrate that when the work consists making weld abutting plates, and not laying down the for Beads Flat Plate Mild Steel Electrode Costs in Dollar > parison Elec- Diam., In. per In. per Lb. per per Lb. $0.02 per ing Hourly Labor Cost Compar n lting rates 190 0.038 0.0035 0.005 0.034 0.047 0.061 070 Determination maximum speed for each type electrode and its effect cost B I \% 240 18 20 0.044 0.00385 0.0057 0.099 0.04 0.051 ; Effect of increase in wire size when excess current is used on smaller size Effect increase current speed and cost 278—August 1928, The Iron Age d . maximum amount metal, may advantageous increase the size electrode because less electrode material removed from the larger diameter wire given current and travel speed. There are, course, other factors equally important considered with reference electrode diameter. Larger diameter electrodes permit heavier currents which tend increase the speed. The type joint also has share determining the electrode diameter. Poor fitting joints are uneconomical for welding when tight fitting joints can made. some few applications, however, hap- pens that the saving welding cost does 600 not justify the ex- tra joint prepara- 500 Since the greater amount welding, particularly automatic welding, consists making linear joints seams, cost calculations will based the cost per linear foot. The welding data used will that employed the preceding portion this discussion, assembled the table. order bring out the points illustrated the earlier part this article, the data have been divided into four groups. Group compares the melting rate No. and No. wire. Group gives the conditions the highest speed with diameter wire both types. Group illustrates the saving effected changing larger diam- eter electrode, other conditions re- maining the same, and Group shows tion secure al- together suitable fit. Small diameter wire, course, bead, but will result welding speed and very often poorer quality weld metal. such Welding Current, amperes the economy in- creasing the current obtain high weld- ing speeds. This last point may also comparing sults with No. wire Group with those No. applications where 100 wire Group considerable opening The same compari- spanned the weld Electrode Consumption per minute with No. wire generally found these same groups. that the larger the Curves Showing Melting Rates 5/32-In. Electrodes Different caleulating diameter wire that electrode costs, the can following electrode more satisfactory the finished product will be. weights were used: clearly shown the chart that the melting rate electrode............. 0.0409 per ft. the electrode increases the current increased. This 3/16-in. electrode............ 0.0902 lb. per ft. makes given type bead higher speed. has also been shown that there may saving electrode con- the welding current remaining the same. will shown later that increased welding current resulted slightly higher electrode cost, but decrease the labor and power cost per foot weld. Voltage Across the The are voltage usually measure the length the arc; the longer the are the higher the voltage for any given type electrode specified diameter. gen- erally agreed that, although the proper length will not alone insure good weld, long are generally results poor weld. With short arc there greater heat con- centration. With bare electrodes the long more un- stable than the short arc; the greater the are length the more opportunity for the absorption oxygen and nitrogen the weld metal. This absorption detrimental the quality the weld. Because the better control conditions possible with the automatic are welding machine, stable conditions can obtained with longer shorter arcs than can held the average hand welder. With all other conditions except the arc voltage the same value, will found that short arc makes narrower bead with higher crown and sharper curvature. the are length increased, the bead widens out and flattens down until either the are be- comes unstable the quality the bead suffers from ex- cess absorption gases from the atmosphere. Whether limit first reached the flatness the bead the quality weld metal dependent, large extent, the type electrode used—highly fluxed electrodes gen- erally permit the use higher voltages. Costs Three principal items considered calculating welding costs are labor, electrode material and power. Power costs general are calculated finding the kilo- watt input the motor-generator set for given welding current. obtain this, necessary have the efficiency curve the motor-generator set used. The following formulas give cost per running foot weld: find the electrode cost dollars per foot bead multiply the electrode feed in. per min. the weight the electrode per ft. bead and the electrode cost dollars per pound, and divide the running product the travel speed in. per min. find the cost electrical energy dollars per foot bead multiply the kilowatt input the motor-generator set times the cost the electrical energy dollars per kwhr., and divide the product times the travel speed in. per min. find the cost labor dollars per foot bead di- vide times the rate dollars per hour times the travel speed in. per min, hand welding instead automatic welding were considered, the electrode consumption would greater because per cent each length used discarded. automatic welding, this eliminated continuous wire feed from reel. The usual hour rate for hand welders within the range covered the labor costs assumed above, but the welding speed hand welders job which automatic welding can successfully applied only the speed the latter. Test, performance and manufacturing standards elec- trical apparatus have been published the National Elec- trical Manufacturers Association, 420 Lexington Avenue, New York, the NEMA Handbook Apparatus Stand- ards, formerly known the Electric Power Club Hand- book Apparatus Standards. The book embraces stand- ards electric power, control and measuring apparatus for the generation, distribution and utilization electric energy. The Iron Age, August 1928—279 | Establishes Steel Foundry Laboratory Large Equipment for Research—High Frequency Electric Melting Furnace, Testing and Heat- Treating Equipment Available the standpoints location, construction, equip- ment and personnel the new research laboratory the American Steel Foundries serves well ex- ample the growing tendency American industry search out, with the support adequate facili- ties, methods and materials satisfy the increasingly ex- acting demands purchasers. The laboratory located the East Chicago, Ind., plant the company, building constructed during the war, when served power plant for forge shop, which has been dismantled. the power house was located the opposite side the forge shop from the foundry units, the laboratory now 300 yd. away from the nearest manufac- turing building. The framework the laboratory building steel, and the walls are brick filled. The roof trusses are over- laid with cement tile, and the column and wall foundations are concrete. special interest the fact that the massive foundations, which formerly supported power ma- chinery, are now being used most satisfactorily testing machinery bases, affording degree rigidity which often highly essential for work calling for high degree accuracy. About one-half the structure, which ft. wide 320 ft. long, now used for laboratory purposes. 100 per 1928, The Iron Age cent expansion floor area therefore possible without additional constructional expense. Photomicrographic equipment, which located separate room, was furnished Leitz, Inc., New York. allows magnification 10,000 diameters. Ordinarily the work performed calls for magnification 100 1000 diameters, with occasional magnification 5000 diam- eters. This apparatus equipped for photomicrographic work specimens in. square actual size. The machine equipped with shock absorbers, though there has been occasion for their use account the massive foundation. Adjacent the microscopic room locker room and across the hall chemical laboratory. These depart- ments, including offices and library, occupy the north half that portion the building now use. The remaining half occupied workroom which are located the melting units, the heat-treating units, the machine shop and the physical testing laboratory. general the arrange- ment provides for the location testing machines the north end and along the east wall. Near the middle the room and along the west wall well-equipped machine the south end the room are located the melt- ing furnaces and the heat-treating equipment. testing apparatus consists essentially the fol- shop. Physical Testing Laboratory Contains Wear Testing Ma- chine, 100,000-Lb. Riehle Testing Machine, Izod Impact Test- ing Machine, Fatigue Testing Machine, Rockwell Dilatometer and Brinell Rockwell and Scleroscope Hardness Testing Machines. also equipment for preparing specimens for tests There | } Electric Melt- ing Furnaces (at Right) and Three Heat-Treating Fur- naces (at Left) Have Been Provided lowing machines: Amster Fréres wear testing machine continuous service. Instead the load being applied with spring, originally designed for the machine, floating load has been substituted order maintain constant load the specimens wear. electric blower has been installed keep the specimens from heating. The Riehle Brothers Testing Machine Co. furnished testing machine and impact testing machine the Izod type. There also Moore fatigue testing machine, built the Thompson Grinder Co., Springfield, Ohio. Fatigue tests are run speed 1800 r.p.m. speci- mens approximately 3/10 in. diameter the center. Weights are added whereby load about 80,000 lb. per sq. in. may applied. Other equipment includes machines for preparing speci- mens for microscopic work and Brinell, Rockwell and scleroscope hardness testing apparatus. which was furnished the Stanley Rockwell Co., Hart- ford, Conn., used determine the expansion and con- traction specimens when subjected heat and cold. Machine tools are all driven individual motors. They bench lathe, 20-in. 48-in. engine lathe, 14-in. 36-in. lathe, metal band saw, 16-in. shaper, drilling machine and grinder. Special Melting Furnaces Two melting furnaces have been provided, one the carbon pile resistance type and the other induction fur- The latter was constructed the Ajax Electrother- mic Corporation, Trenton, J., with electrical supple- mentary equipment General Electric manufacture. This induction furnace has melting capacity 100 min., and heats 150 can made. The furnace con- sists crucible which surrounded water-cooled coil flattened copper tubing wound edge. This tubing insulated from the crucible. Incoming current the 60-kw. motor-generator set three-phase, cycles and 220 volts. Outgoing current single-phase, 960 cycles and 900 volts. With this equipment are installed condensers, six which are controlled automatically relay device which was furnished the Leeds Northrup Co., Phila- These condensers are necessary for power factor correction. Ferroalloys and fluxes are kept steel drawers near the induction furnace and bulky materials, such scrap, are stored nearby steel bins. Two monorail chain hoists extend the full length the physical l