The Iron Age 1928-08-16: Vol 122 Iss 7

Over Sixty Modern Furnaces Required Harden and Temper Motor Car Parts—One Battery Handles 450,000 Pounds Rough Forgings Daily EAT treating operations parts used the man- ufacture motor cars Dodge Brothers, Inc., Detroit, are now with only few minor exceptions done electric furnaces. New equipment various con- tinuous and automatic types includes over furnaces, drawing total current 11,400 kw. All carburizing done two types electric furnaces, described fully later Among the more interesting heat treating operations the plant, because the methods and types furnaces used, are the anneal- ing and hardening tranmission gears and the hardening rear axle ring gears, subject worthy treatment the third paper this series. The Dodge company adopted electric furnaces with view improving the quality its product, closely con- trolling the temperature, reducing plant maintenance, improving working conditions cutting down smoke and heat, reducing rejections, and simplifying the automatic operations. Three years’ operations some the furnaces are said those charge have fulfilled the expectations concerning control and uniformity the product. Main- tenance costs have been materially reduced because excessive temperatures exist any portion the furnace. Dodge has two separate heat treating departments, Plant No, for finished machine parts, and Plant No. for forg- ings. The latter will described first. Many the heat treated forgings undergo further heat treating operations Plant No. after machine operations are completed. Rejections Plant No. for heat treating forgings, stated, not exceed per cent. No. plant particularly well arranged. The forge shop located nearby parallel building and the heat treating equipment placed that there direct flow work from the forge through the heat treat building the machining department the opposite side. Unique Charging Devices All furnaces for normalizing, quenching and drawing forgings have combined capacity 450,000 every hr. Their connected load 7500 kw. this work there are box type furnaces installed (20 for quenching and for annealing), six pusher type furnaces for drawing and normalizing, and two pusher type furnaces for anneal- ing gears, Box type furnaces were supplied the Electric Furnace Co. and are built batteries four. Each battery re- quires floor space ft. in. ft. in.; the furnace hearths are each ft. in. ft. clearly shown the head piece the cast iron door frames, struc- tural steel members and masonry are supported eoncrete piers. This places the furnace floor high that the quench- ing tables not need placed pits. The outer fur- nace walls carry in. brick and in. insulation; there also 11% in. insulation between the individ- ual furnaces each battery. The hearth floor consists three alloy plates locked one end and alloy steel wall rs THE IRON New York, August 16, 1928 ESTABLISHED 1855 122, No. Dodge 389 in. high. The floor supported fire brick standing between the heating elements. Thus the metal floor and sides form open-top trough, and heat transmitted from the glowing electrical ribbons through the alloy bottom without much drop thermal gradient, and from ribbons rung the roof radiating direct. Heating elements the grid type are supported from the roof brick and alloy clamps, and beneath the alloy floor they rest fire brick. the parts are delivered from the forge shop, approx- imately 1000 lb. are loaded slide bottom tray slightly narrower than the hearth. shown Fig. these trays are placed stands one side open aisle about the same height the. furnace bottom, the charging machines can pick them readily. The frame the tray made channel section, and has heavy cast steel end provided with slot for the charging peel. Handling done Alliance Machine Co. electri- cally operated charging machine having 3000 capacity. This machine has shaped casting the end the which engages with the corresponding slot the tray head and provided with lock. This for lifting the weight. screw under the peel carries nut, pro- jection the under side which engages hole the Fig. 1.—Charging Machine Picking Tray Loaded with Forged Crankshafts for Heat Treatment Prior Machining. Fig. 2.—Rear View Pusher Type Furnaces. Quench- ing baths three near batteries; baskets for air cooling far batteries. Note electrical control equipment power lines immediately above each furnace. 390—August 16, 1928, The Iron Age Trays are loaded into furnaces right and emptied sliding bottom out from under a bottom out from under the load. After the charging machine makes connection with the tray faces about 180 deg. and moves along its track position front the furnace charged. Both furnace doors are raised and the charger advances, push- ing the hot forgings remaining the furnace hearth out the discharge door the back. When the new load place the charging machine operator switches the motor controlling the screw, and the bottom the tray with- drawn, thus depositing the cold forgings correct position the furnace hearth. The peel then raised, lifting the tray above the charge, and withdraws from the furnace. Then both doors are closed. The entire time loading and unloading seconds, during which the drop furnace temperature approxi- mately deg. Fahr. Each furnace connected with one phase 220-volt, 60-cycle, 3-phase line, and takes 154 kw. when the furnace heating from cold. input 135 kw. required maintain operations 1650 deg. Fahr. shown Fig. quenching tanks are placed immedi- ately behind three batteries furnaces. Hot metal pushed out the furnace falls into submerged basket, and later handled overhead electric traveling crane. The quenching solution caustic solution deg. Baume) pumped through the tanks the rate 1000 gal. per min. Some furnaces not have these tanks; basket placed below the door and collects parts which are cooled more slowly. Most the chassis forgings are heat treated these box type furnaces. For example, axles camshafts are placed tray and remain the furnace hr. 1650 deg. The tray holds crankshafts, which are the furnace hr. 1550 deg. Heating times and temperatures naturally vary with the purpose intended and the chemical composition the steel. All work that quenched after heating the box type furnace goes drawing furnaces placed just across the aisle from the quenching tanks. Such work includes axles, crankshafts, connecting rods, spring clips, hub forgings, and flanges, gear shift levers and brake levers. Crankshafts are drawn 1090 deg. Fahr. and are restruck under 5000- lb. board hammer they are delivered from the continuous furnace. Ring gears are normalized 1700 deg. Cam- shafts, drive pinions, and ring gears are given only an- Fig. Furnace for Con- necting Rod Bolts. Work pushed tubes and out contact with outside air. Note electric trans- formers under furnace and simple pusher left Fig. 3.—Pusher Charging End Continuous Normal- Furnace. Pans parts are lifted tongs and over- head pneumatic cylinder nealing operation this stage the process. They are cooled the air, leaving them soft for machining. Sub- sequently they are carburized and hardened. Six pusher type continuous furnaces are installed Plant No. for drawing and normalizing forgings. Four are ft. length and two for higher heats are ft. length. Two produce 5200 per hr. 1350 deg. with power input 430 kw. Two furnaces have output 5200 per hr. 1350 deg. with power consumption 570 kw. Each pair double-chamber recuperative furnaces installed another department redraw crank- shafts after finish machining has capacity 3300 per hr. with two 150-kw. power zones. Two the fur- The Age, August 16, | sliding bottom the tray. This for pulling the tray naces Plant No. have adjustable controls, they can used for either annealing drawing. These furnaces shown Fig. have three alloy tracks running their length carry alloy shoes which sup- port trays for light forgings, crankshafts and other larger forgings. 5-hp. motor through reduction gear and bell crank provides power pushing the shoes the charging end. The pusher motor actuated time clock set that both doors open simultaneously. The clock closes relay which operates the motor driven doors. The door mechanism connected with the pusher mechanism, causing the pusher operate one stroke, approximately in. While one charge being pushed into the furnace one end, another being discharged from the opposite end. Tube Furnace Protects Bolts from Air Five electric furnaces are provided for heat treating miscellaneous parts the Dodge cars. Brief notes these are follows: tube-type Hoskins furnace for hardening connecting rod bolts. which pushed through the tubes. After reaching heat discharged through the same pipes, extending down into oil quenching tank. Thus there exposure the air. Hardened bolts are then drawn Rockwell hardness B-92 100. This Hoskins furnace has two- zone control and temperature 1600 deg. Fahr. The heads exhaust valves Silchrome steel, and intake valves chrome nickel steel, are reheated 35- kw. continuous furnace temperature 1650 deg. pre- vious operation coining press. rotary furnace 125 kw. with 18-in. hearth used for normalizing and hardening flywheel starter ring gears. Rear axle hub flanges are brazed the tubes two 12-in. rotary hearth 110 kw. furnaces. These furnaces oper- ate temperature 1750 deg. and the work for min, Some castings such flywheels, manifolds and valve stem guides are annealed four Rockwell continuous oil- fired furnaces. The work put ten troughs the left, from Alloys Substitutes for Diamond Dies Hard Tungsten Products for Wire Drawing Cost Less and Last Longer, According German Claims ALFRED DREBES* replace diamond dies for drawing other materials back the war time when the price diamonds constantly increased. Work this direction led the production metal alloys which, while not possess- ing all the properties the diamond, were suitable for the wire industry. They increased production and, through the obtaining exact sized wire with smooth surface, improved the quality and increased the possible usefulness the wire. Also the increasing introduction machines making many passes affords unusual opportunity for these materials substitutes for diamonds. not too much say that these materials have future, not alone substitutes for the diamond but also replace the ordinary drawing dies made steel and iron alloys. producing these artificial die materials, alloys tungsten, titanium, iron, chromium, cerium and carbon were first investigated. has been found that the most suitable per cent cobalt. Such alloys are produced from mixture tungstic acid and oxide cobalt, powdered aluminum being used reaction material. The alloy then cast into shape. Another kind hard metal made sintering hard metal alloys containing tungsten carbide with about per cent carbon and metals with fairly low-melting points, such tungsten, nickel, cobalt iron. These additional materials not exceed per cent amount. Also these alloys contain tungsten the principal constituent amount- ing least per cent. Dies from these sintered and pressed materials are harder throughout than the cast material. The principal requirement for the dies not hardness alone but absolute uniformity the material, which must also free from blowholes well uniform other properties. Before being used the dies should carefully examined with magnifying glass see they are free from defects. *Herborn Hesse-Nassau, Germany. 16, 1928, The Iron Age The die opening must exhibit highly polished surface and roughness else the wire will tear and crack. The advantage the hard metal dies compared with the diamond is, first, their decreased cost. Further, there the constant danger the diamond cracking during use. Compared with iron and steel dies the hard metal also offers great advantages, such considerably increased life; also the wire remains much more exact diameter, has more polished and smoother appearance, and the speed draw- ing can considerably increased. Drawing through hard metal dies not different from drawing diamond steel dies. The material drawn should previously well softened. The reduction should not too light. For soft iron, brass, copper and alumi- num wire reduction about per cent recommended. For harder wires, such steel, bronze, hard copper and brass about per cent, and for very hard wires, such tungsten, molybdenum and nichrome, about 7.5 per cent. The first drafts after annealing can about per cent greater. The usual lubricating agents should used and frequent cleaning the dies during use necessary, great difference being recommended ordinary practice. These hard alloy dies should carefully polished, which may conveniently done needle polishing machine. Wages the United States reached their highest point 1920 with index 234 average hourly rate, using 1913 (106) the base year, with sharp downward trend 1922 and after that gradual rise, that 1926 wages were 129 per cent higher than 1913. This shown compilation made the Bureau Labor Sta- tistics, Department Labor, Washington, for the period 1840-1926, and published the February number the Monthly Labor Review. All lines employment except agriculture are covered. — 4 Studying Gas Learn Conditions Watching Formation Graphite—Some the Conditions Which Produce Rapid Driving and Much Iron Are Analyzed WALLACE IMHOFF* [That the color the smoke end the burning gases rising from the open-top blast furnace -character the metal was shown the first instalment this article. The second instalment carried the story forward, through tracing conditions particular cast metal typical illustration ideal conditions for lime combination with sulphur form calcium sulphide. Con- ditions giving high production were entered into, one crite- rion being the fluidity the iron and the slag, together with high hearth bluish purple gas. The hearth temperature has fallen much lower and the fusion zone has come down into the hearth. The temperature the hearth has fallen low that the iron when cast, instead being bright yellow color, cold orange. glistening and shining, owing the supersaturation carbon. When cast, the excess carbon the iron, under reduced pressure and atmospheric temperature, thrown out the form graphite and fills the iron runner depth in. The analyses the iron and slag are given below: conditions carried further produce heavy, IRON SLAG Silicon 0.94 0.93 1.02 0.93 0.81 Silica 36.14 Sulphur 0.033 0.033 0.030 0.030 Alumina 10.68 Manganese 1.06 MgO 8.37 0.45 1.60 Silicon 0.61 0.90 0.87 1.06 1.02 Silica 36.08 Sulphur 0.039 0.033 0.031 0.027 0.028 Alumina 10.52 Manganese 1.02 MgO 7.87 0.63 1.56 These two sets analyses show quite contrast with the analyses for hot, yellow gas. The silica 36.14 per cent, showing that the hearth much colder. The sulphur 1.56 instead 2.17 per cent, another fact which verifies the statement that the hearth temperature much lower; and the iron the slag has risen 0.63 per cent. interesting note that the first example for hot, yellow gas has the tendency promote the formation graphite having high lime, low fusion zone and hot hearth. The graphite the second case, however, comes from entirely different cause, decrease hearth tem- perature. the first case the iron thick and mucky, due the fact that the carbon has been removed the form graphite. the second case the iron thin and fluid, but simply cold and oversaturated with carbon, due falling temperature. Hence when comes out the furnace into new conditions pressure and temperature supersaturated, and therefore large quantities separate out graphite. the former case, the furnace hearth there tendency for the iron not take carbon; the latter case, there tendency for the iron take all the car- *Metallurgical Engineer, Sixty-second Street and Allegheny Valley Railroad, Pittsburgh. This the final three instal- ments the article, the first having appeared our issue June 14, page 1686, and the second, July 26, page 203. the Reactions Iron Blast Furnace.” Reports investigations, Department Commerce, Bureau Mines, Serial No. 2747, April, 1926. tThe Blast Furnace and the Manufacture Pig Iron, Forsythe, page 189. bon possible. The first condition supplies large quantities carbon for the gas; the second condition takes away the carbon from the gas and holds the iron. The excess carbon gives hot, yellow gas; the shortage carbon gives thin, cold, blue gas. Wide Variations Heat Value Gas Many other examples could given illustrate the conditions which produce heavy, hot, yellow gas and cold, thin, blue gas. Practical furnacemen know that there wide variation the heating value the gas from time time, since necessary some cases fire the boilers with coal keep steam. This practical condition there- fore indicates that there must change the composi- tion the gas. Studies the reactions going the iron blast fur- nace and the gas composition, etc., have been made Kinney, Royster and These investiga- tions were carried out 300-ton furnace, making foundry iron, operated the Central Iron Coal Co., Holt, Ala. Study the results given this paper shows that blast furnace gas made essentially CO, CO, and small quantities hydrogen, They show also not only that the composition the gas varies across the furnace the same plane, but that there variation the gas different planes the furnace. The change compo- sition from top bottom given Table II, page their study, shows increase the volume from 28.1 per cent the top gas 34.1 per cent the bosh gas, and decrease the volume ratio CO, from 9.9 per cent the top gas 0.0 the bosh gas. This shows The practical side blast furnace gas has been ably covered Herman Brassert his paper (pages 47- 54), “Modern American Blast Furnace Practice,” read the sixth general meeting the American Iron and Steel Institute, New York, May 22, 1914. Charts showing the “Effect Coke Rate Analysis Blast Furnace Gas,” “Effect Coke Rate Production Blast Furnace Gas,” “Relation Tons Iron Per Day Coke Rate,” “Effect Tons Iron Per Day Amount Gas Produced Per Minute” and “Effect Tons Iron Per Day Amount Gas Produced Per Ton,” are given. The gas analysis shows: Per Cent Per Cent 3.0 The most significant fact, shown his Chart that, the higher the tonnage iron produced hr., the lower the coke consumption the ton. The question which immediately arises is, “What are the conditions that pro- duce ton iron 1700 1900 coke; how van these conditions obtained?” The most important ingredients the gas are and shows the percentage volume from the top the furnace the bottom for each these. There direct relation between the coke used, tonnage produced and gas formed. explanation will now offered for the conditions which give high production, low coke con- The Iron Age, August 16, | | | a | { 7 7 4 sumption and good gas; other words, answer the above question. Production depends primarily upon the rapidity reduc- tion the iron ore metallic iron and the smooth, rapid driving the furnace. the conditions can discovered which control these two factors, then have discovered the conditions which will continually produce high ton- nage with low coke consumption. Without entering into detail, brief discussion will given some the conditions which give rapid driving. These are: Low fusion zone Proper stove heat con- 2. Moderate use of lime trol High hearth tempera- Clean raw materials ture Right burden Proper wind Good condition equipment low fusion zone prime importance obtaining high production pig iron. The main cause raising the fusion zone the mantle, higher into the middle the furnace, continued use cold air. Besides being disturbing factor the driving, cold air upsets those chem- ical and metallurgical reactions going inside the fur- nace which gives high production. Instead using cold air the wind should slightly increased; this will increase the tonnage instead decreasing it. Too high wind will raise the fusion zone. This will the driving and the top heat. Practice soon establishes the proper amount wind use. The use cold air should avoided whenever possible, eventu- ally starts the furnace slipping and brings about irreg- ular driving, which lowers production. Lime Practice Causes Some Difficulties The proper use lime difficult feature under- stand blast furnace practice. essential able distinguish whether the furnace really needs lime, lean simply from being cold. The slag should always kept fluid, other conditions being right. With the proper hearth temperature, the lime will com- bine with the sulphur and the silica will reduced con and then into the iron. hot hearth abso- lutely essential factor for these two reactions take place. the fusion zone down the hearth, and the hearth cold, disastrous results may encountered there too much lime the burden. There reserve heat this case and remedy except slow down the revolutions the engines. This reduces production. proper wind meant that volume wind which will give the highest production with the smoothest driving. The temperature the hearth should controlled from the engine room, and not the use cold air. Cold air trouble maker. the hearth too hot, the logical procedure cool down getting larger tonnage, not decreasing the tonnage. The running furnace this method requires greater skill, but pays well the increase production obtained. Control stove heat another means raising lowering the hearth temperature. The best practice use the full stove heat all the time. average, uniform heat the ideal; there should violent fluctuations. previously stated, the cold air by-pass trouble maker and should used only last resort. the furnace too hot, increase the wind slightly and get rich return more pig iron, Importance Good Raw Stock Clean raw materials are essential, also, maintaining high production continuously. Fine, dirty coke, dirty limestone, used long enough, will tighten the stock and disturb the proper metallurgical reactions essential high production. Proper mixture and proper proportions raw mate- rials are also important obtaining the greatest output. Too much ore hot furnace will make drive fast, but care should taken does not drive itself cold. Too little ore will tighten the furnace and slow down driving. The gas the former case will change from hot, yellow gas thin, blue gas; the latter case, the gas will bright yellow color. hardly necessary mention the fact that all equip- ment must good working order, obtain high pro- duction. Delays the skip house, the furnace, the engine room, reduce the tonnage iron produced hr. Stops shutdowns for any great length time affect the character the gas. When known ahead time that the shutdown will for some time, extra coke will put in. This furnishes abundant supply both heat and carbon and the gas usually bright, yellow color when this extra coke comes down. The two prime factors producing heavy, yellow gas are abundance lime and coke. With the fusion zone down the hearth, these factors set conditions which promote the formation large quantities graphitic carbon, and abundant sup- ply carbon for the gas. the recently organized educational com- the American Foundrymen’s Association are outlined report prepared the former president, Utley, Detroit Steel Casting Co., Detroit, and approved the board directors. Members the committee will appointed soon. outlined the report, “the object this committee shall originate and disseminate engineers and man- ufacturers information tending produce better realiza- tion the value the foundry industry and the possible use castings all kinds manufacturing processes.” Its function purely educational and shall not have its direct object the merchandising any particular kind casting the creating specific market for any mate- rial. will work with the various trade associations con- nected with the foundry industry. direct advertising will done, this left, now, the various individual companies, but hoped persuade manufacturers include their advertising copy information which will help tell the story the foundry industry. 16, 1928, The Iron Age Publicity matter will worked for publication the technical press and some extent the daily press. Another function the educational committee will furnish speakers for technical societies and for confer- ences schools and colleges. Exhibits motion pictures the foundry industry are suggested feature this work. Furthermore, the educational committee hopes “im- press upon the buying public that there more casting than certain number pounds metal; that the char- acter the foundry, its technical control, its engineering ability and the ability its organization vital interest the fact that has cupola furnace. The greatest drawback the success the foundry industry today the poor. quality castings turned out the unprogressive units, and the fact that the buyer considers the product the well organized, progressive foundry the same plane the others. The bringing this reali- zation the purchasing public should make membership the American Foundrymen’s Association much more sought a 7 q a Brown, Boveri Blower Braddock New Turbo Unit Edgar Thomson Works Applied Blast Furnace 750 Tons Daily Capacity—Cooling Water Required Only for Oil Coolers the Edgar Thomson Works the Carnegie Steel Co., Braddock, Pa., there has recently been put into service the first blast furnace turbo-blower Brown, Boveri design installed this country. The unit was furnished the American Brown, Boveri Electric Corporation, Camden, J., which holds exclusive rights this country for the manufacture machinery the designs Brown, Boveri Co., Ltd., Baden, Switzerland. Longitudinal Section Through Blower Unit, This one three new blowing units the plant, mentioned THE IRON AGE April The unit the four-bearing type, and consists five-stage, single-inlet, uncooled centrifugal blower direct connected claw type coupling com- bined impulse and reaction steam turbine, designed op- erate with steam 225 per sq. in. gage and 150 deg. Fahr. superheat, exhausting into vacuum 28% in. light baseplate extends under the exhaust casing the turbine and the adjacent bearing the blower, the outboard pedestals blower and turbine being pro- vided with soleplates. The set was designed blow furnace which has daily capacity 750 tons pig iron. Accordingly, the maximum operating load was specified 60,000 cu. ft. minute blast pressure lb. gage. service the set has shown itself capable delivering inlet volume 70,000 cu. ft. minute lb. The operating speeds are conservative, ranging from about 2100 r.p.m. when delivering 50,000 cu. ft. lb. 2700 r.p.m. when delivering 70,000 cu. ft. Ib. From the sectional view and the view the lower half Showing the Five Stages. Water cooling not used the casing course manufacture idea may obtained the design, which does not use water for cool- ing. The only cooling water required for the set that for the oil coolers, two which are furnished, connected parallel, that either one can cleaned without shut- ting down the set. The blower rotor handled special lifting device furnished facilitate erection. There ancing piston mounted the high-pressure end the shaft. This piston balances the greater portion the axial thrust the blower, and also carries labyrinth glands. can seen from the section, the chamber after the piston may connected the inlet branch the blower, the atmosphere. result, air atmos- The Iron Age, August 16, 1928—395 PERATION the Governor the Steam Turbine End the Unit May Noted from the Center Illus- tration. For ease tracing the func- tions the mechanism the governor shown misplaced, right the turbine upper half the casing, cast and machined, shown below, and the lower half casing posi- tion, with rotor place the right. This shows the makeup the rotor stages. special lifting device facili- tates erection handling the rotor 4 396—August 16, 1928, The Iron Age pheric pressure only back the shaft-sealing glands, and leakage slight. the extreme right the shaft are the three thrust collars, which maintain the rotor alinement, and take any thrust not balanced the piston. One illustration shows the rotor place the lower half the casing. Surrounding the impeller wheels can seen the curved diffuser blades through which the air passes before being directed into the inlet the next impeller. Perhaps the most striking feature the turbine the speed-governing device. the illustration the governor shaft has been the right, for ease tracing the functions the mechanism. The vertical governor shaft worm-gear driven from the turbine shaft Oil under pressure for lubrication and for actuating the turbine nozzle valves supplied the gear oil pump mounted the lower end the governor shaft. The oil under pressure for governing drawn through adjust- able needle valve The movement the spring-loaded nozzle valves dependent upon the oil pressure the oil pipe This oil pressure controlled the governor by-passing more less oil from the oil pipe decreas- ing increasing the oil pressure under the nozzle valves. 1 ep = 7 3 Through the throttling action the needle valve the oil pressure the governing system can vary without affecting the pressure the lubricating system. Oil by- passed the governor lubricates the governor shaft mechanism. The arrangement such that the turbine cannot started before oil pressure available the bearings, nor before sufficient pressure has been built thereafter operate the nozzle valve system. case failure oil pressure, either the bearing nozzle systems, the nozzle valves will close automatically, thereby shutting off steam admission the turbine. independent over-speed safety governor strik- ing the arm the trip shaft turns the shaft and re- leases the pressure the column balls This trips the spring-loaded main steam valve which cuts off the steam supply the turbine. addition, the set provided with constant-volume governor, tied with the speed governor such man- ner that the action the former supplanted the latter when service. connecting the volume gov- ernor, additional pipe line connected the annular chamber the speed governor. this pipe placed relay-valve whose movement controlled spring-backed diaphragm. This diaphragm actuated the differential pressure between straight tube and bent tube (Pitot principle) the blower suction line. This differential pressure function the volume drawn into the blower. Any change the volume will, therefore, alter the position the diaphragm, and, consequently, the oil relay valve. More less oil by-passed the valve, and, therefore, the oil pressure the line varied, changing the position the nozzle valve admit more steam, thus varying the speed the set. The diaphragm- relay unit, with small amount piping, all that ap- pears the machine floor. For slowing down the set when making check cast, the control sleeve the speed governor may displaced, independently volume governor and speed governor, means electric motor controlled push-button, requiring change the setting the volume governor. The contro] pillar carrying the push- button located convenient point for the operator. Research Aids New England Plants Survey Various Industries Discloses Efforts Solve Manufacturing Well Marketing Problems success with which many New England manufac- are using research methods developing new products and new uses for old ones shown the first series reports “Applying Research Production,” issued the Policyholders’ Service Bureau the Metro- politan Life Insurance Co., cooperation with the research committee the New England Council. The recent survey the uses research New Eng- land industry made the Metropolitan company coop- eration with the council disclosed that many New England manufacturers have been alive the importance re- search developing established products and introducing new ones, Examples are presented under the headings “Improving Present Products,” “Utilizing Waste Products” and “New Products for Today’s Demands.” One striking instance furnished the Winchester Repeating Arms Co., New Haven, Conn., which maintains physical, chemical, metallurgical and ballistic laboratories and-an experimental development department. The Morse Twist Drill Machine Co., New Bedford, Mass., maintains development laboratory which new and improved tools are developed and tested before being manufactured quan- tity. The Max Ams Machine Co., Bridgeport, Conn., went deeply into chemical research and succeeded developing gelatinous preparation which could used instead solder- ing close the tops tin food containers. The Scovill Mfg. Co., Waterbury, Conn., brass manu- facturer, adopted three methods for improving its product: first, maintaining uniformly high grade metal; sec- ond, constantly overhauling and renewing mechanical equipment; third, through continuous development work carried through research laboratory. new type road machine was developed through research the High- way Products Co., New Bedford, Mass. The Max Ams Chemical Engineering Corporation, Bridgeport, builds equipment for the manufacture rayon all processes, and maintains experimental plant which rayon actually manufactured, effort develop and this equipment. The problem utilizing waste products, New England manufacturers interviewed this survey reported, often solved through research. The Rumford Chemical Works, Providence, discovered that by-products phosphoric acid production could made into excellent plaster building blocks. The Acme Wire Co., New Haven, found out that short lengths wire, previously discarded, could used lead wire radio condensers. The Graton Knight Co., Worcester, through the use research, has been able utilize per cent its scrap. the Win- chester Repeating Arms Co. plant all wastes and serap ma- terial and equipment are routed central salvage de- partment. Research Market Conditions large number New England manufacturers have used research methods developing products keep with current market conditions. the case the Blanch- ard Machine Co., Cambridge, Mass., by-product grew popular that became the principal praduct that company. The Carr Fastener Co., Cambridge, Mass., devel- oped number its successful products research into market conditions. The laboratory used the American Writing Paper Co., Holyoke, Mass., the development paper for new uses. using research test out the in- sulating properties seaweed, the product Samuel Cabot, Boston, was developed. The Eastern Mfg. Co., Bangor, Me., has developed device which automatically weighs paper other material passing through the mech- anism web form. The Bigelow-Hartford Co., Thompson- ville, Conn., through research, changed its products keep with the changing fashions the rug industry, intro- ducing also the first mats for “table throws.” The Scovill Mfg. Co. also introduced side lines which have increased the business volume the company and have afforded steady employment. The Iron Age, August 16, | 4 = | Old Japanese Blades Sharp DEVICE for determining the sharp- ness and durability cutting edge has been patented Prof. Honda. consists fixture which holds the blade, edge down and strictly horizontal, upon pile paper strips, cm. wide. definite load (1500 gm.) can applied press the blade against the paper pile, and then lever motion, the blade drawn back and forth cm. The “sharp- ness” measured the number sheets paper cut during this operation, and the “durability” the number cuts re- quired reduce the sharpness per cent its original value. Such values have only relative meaning, only necessary use one kind paper for series comparisons. Cutting pressure alone done wedge action; hence the sharpness de- termined without drawing back and forth function the angle the edge. This angle easily determined pressing the edge lightly piece lead; the lead then cross sectioned and the impression measured 400 magnifications the focusing plate the camera. Such im- pressions also show the amount wear edge after testing. Before testing, the blade honed and then finished microtom polishing de- vice, until the edge free from feathers, and when viewed sidewise 400 magnifica- tions has wavy undulations nor nicks deeper than 0.02 in. Tests made this way various pieces cutlery the inventor, and described Science Reports the Imperial Uni- versity, Sendai, Japan (October, 1927), are summarized Table When corrected for edge angle, these data convince Prof. Honda that the Masa- Table Tests Ancient and Modern Blades Edge Original Dura- Implement Angle Sharpness bility Stainless Kitchen Knife..... Carbon Steel Kitchen Knife. 25 55 12 Ancient Japanese Swords ‘J. Ferdinand Kayser, Journal Sheffield So- ciety Engineers and Metallurgists, 1925, No. 11; The Engineer, June 1928. 16, 1928, The Iron Age mune swords made some six hundred years ago are superior anything known today, both sharpness and durability. Safety Razors Examined Tests were made series safety razor blades, made for experimental purposes, and having edge angle deg. was found that initial sharpness and durability increased 1.3 per cent carbon; be- yond 1.5 per cent carbon the became too brittle. The best heat treatments and results are shown Table II. Studies modern safety razor blades have also been recently published England.’ hundred examinations indicate that four types edges are now marketed, the most common which has chisel cross section, with the metal near the cutting edge slightly rounded from both sides. Microscopic exami- nation such edge will give very discordant re- sults, unless mounting fixture used which places the Best Modern Razors the tangent plane the very edge exactly perpendicu- lar with the optical axis the microscope. Characteristics Good Blades Modern safety razors are usually made 1.1 1.3 carbon steel strip, heat treated and sharpened. The microstructure good blades shows globular cementite embedded structureless matrix; but the size and distribution the excess cementite varies greatly. After sharpening and before etching, according Mr. Kayser good blade should exhibit perfectly straight edge under 400 magnifications, and have Firth dia- mond hardness 650 This generalization, however, denied other investigators. After etch- ing, globules cementite seem project from the cutting edge. Desch and Roberts think that the size and uniformity such projections are related the ability the razor keep cutting edge, but Kayser can find such relationship. The latter investigator believes that Prof. Honda’s Swords for the Forthcoming Coro- nation the Japanese Emperor Made Tokio Kyusuke Mori the Old Manner, Despite the Modern Iron Siding His Shop. (Wide World Photo). The border decorations are photographs ancient Japanese swords and scabbards the Metro- politan Museum Art, New York testing machine unsuitable for razor blades, because single cut through pile paper slips will ruin even the best razor for shaving. The only test now known Kayser actual shaving. finds that shaving never causes good razor edge become wavy. ade- quately protected from corrosion, wear eventually breaks down the edge tiny patches, and the last stage usefulness, cementite particles may found protrud- ing from the cutting edge. practical works test, microscopic examination diameters the finished edge (unetched) placed adequate fixture will sufficient, because the edge has perceptible nicks undulations that enlargement, good permitted the limit accuracy the grinding ma- chinery now use. The time-honored practice drawing the honed blade across the finger-nail (in the cutlery shop soft horn substituted) still used the workmen Sheffield cutlery houses determine the fitness razor blades for duty. Putting edge the safety razor blade done the following manner: Rough grinding emery wheel. Fine grinding emery wheel steel rolls. (Alternative method: honing flat hone.) Stropping. Final stropping apparently what pro- duces the slight curvature the ground surfaces just the edge. straight chisel edge likely feather, and also liable too brittle for satisfactory use. Frequently the published literature em- phasizes the fact that razor blades should wiped scrupulously dry and kept from moist atmosphere, for appears that corrosion the greatest enemy well-made blade. One author recommends careful drying with soft linen, then washing absolute alcohol, then oiling acid-free light machine oil. Table Heat Treatment for Safety Razors Original Dura- Steel Quench Draw Sharpness bility 0.9 Carbon ....740 150 102 1.3 Carbon ..... 740 150 127 ....800 (a) 200 108 (a) 200 115 1.3C,0.5 ....800 (a) 200 114 (a) After first heating 900 deg. C., then cooled slowly furnace quenching tempera- ture. The Age, August 16, | | | | 2 : 4 is Electric Heating Discussed for Commercial Executives Electric Heating. Edgar Wilcox. Pages, 469, in.; illustrations, 252; tables, 129. Published the McGraw-Hill Book Co., New York. Price, $5. Once while author deserves vote thanks, and for the preparation this second edition pretty good one appearing twelve years ago, this author should have one, suitably engrossed. undertakes show that “the merits electric heat- ing are now being accorded deserved recognition.” might said more use commercial executives and salesmen than purely technical readers; other words, market creators. Comparisons are made the merits and limitations fuel and electricity, and the processes which they may applied with technical commercial advantage with relation comfort and safety. most the smaller and many the larger appli- ances for electric heating depend resistor elements, there given long list factors temperature, surface, ex- posure, etc., that should considered. The chapters are and resistance heating—arts that are bound importance, not only boiler making but also shipbuilding and steel bridge and house con- struction, say nothing repairing defective castings, well prepared. From metal furnaces for steel incubators and brood- ers long jump, but the author does not neglect either. That electric heating employed painting, vitreous enameling and metal and chemical coating may news many, and they will find much interest this line. Under the head tempering there are some statements that are not quite orthodox, view recent researches and experiments; for instance, that the rate cooling usually immaterial, whereas has been shown Weber, Frankel, Heyman and others that very important factor, and that this time element depends very largely upon the temperatures employed for hardening and quenching drawing; the same results being obtained low hard tempering and long drawing temperature with high temperature and short drawing period. The chapters devoted heating furnaces are unusually full and detailed; the limitations fuel furnaces regards large floor space, maintenance, labor cost, and difficulty control with solid fuels, the necessity auxiliary equip- ment, the frequent refractory repairs needed, the constant burner attention necessary for liquid fuel, and the explosive and poisonous nature, lack availability many industrial sections, diminishing supply and unreliability from year year and also during cold weather, natural gas, are pointed out. the relative costs fuel and electricity for fur- nace heating, the author states very properly that they are influenced many variables that general compari- sons can made; the most carefully prepared preliminary estimates seldom check with the final results. is, how- ever, quite right saying that such estimates are usually more correct and constant for electric than for fuel instal- lations, provided all factors have been considered. The rea- sons for this statement are given page 211. The figures the range annealing temperatures for carbon steels, page 213, are hardly reliable enough for mod- ern practice. The table colors corresponding tempera- tures should have been omitted, two workers have the same sense color, and the conclusions any one worker 400—August 16, 1928, The Iron Age BOOK REVIEWS vary with the amount light the room, and from time time according his eye not fatigued. Today must rely upon the pyrometer get accurate results. There excellent alphabetical index. will prob- ably some time before there better book this sub- ject. there is, will probably Mr. Wilcox. ROBERT GRIMSHAW. Working Canadian Labor Disputes Act Postponing Strikes: Study the Canadian Industrial Disputes Act. Ben Selekman. Pages, 405, in.; tables, 24. Published the Russell Sage Foun- dation, New York. Price, $2.50. This book which wealth well chosen and timely material has been collected experts and put to- gether and commented with good judgment. the result observations “from the outside, looking in,” and the compilers very candidly state that the conclusions reached the subject are some respects exactly the opposite from those arrived 1916. The change base, however, was paralleled that the workers, who first opposed the Canadian law concerning arbitration, and are now favor thereof; the employers also expe- rienced change heart. The study considers the questions: Has the Disputes Act prevented strikes? What suggestions have been estab- lished the boards for the technique mediation and conciliation, investigation, and arbitration? What factors explain the change labor’s attitude? What has the Cana- dian Department Labor worked out prevent strikes and walkouts? What light does Canadian experience throw the possibilities governmental intervention indus- trial disputes our country? The provisions the Canadian act are laid down considerable detail, and its operation from 1907 1925 tab- ulated and analyzed, showing that out 640 applications which only the machinery the act was invoked, 431 boards sat and 536 cases were handled, over half which were unanimous. fact, only per cent was the strike not averted ended. with us, coal mining shows the largest proportion (40.7 per cent) working days lost through strikes. regards administration the act, officials the Department Labor constantly refused prosecute for violations the law; and the boards have discouraged publicity, some even excluding newspaper men from the hearings. There has been code industrial principles laid down developed govern decisions the boards. Complaints concerning the administration the act have been due to: (1) Difficulty employers and employ- ees agreeing the chairman, resulting the De- partment Labor’s selecting him; usually, thought the employees, unfavorable them. (2) The long time between establishing boards and submitting reports. The last chapter devoted the significance Cana- dian experience for the United States. The record “seems point conciliation excellent method govern- mental intervention industrial disputes.” Its chief value lies the fact that enables those intervening indus- trial disputes take realistic view the situation hand.” There are two reasons for conciliation: places upon the shoulders employers and employees the responsibility for arriving amicable settlement, because whatever settlement made must translated into everyday prac- 7 7 | 4 a tice the employers and employees involved; and puts the actual details working out the settlement upon those most familiar with the technical aspect the industry which the dispute has arisen. The report shows that the Canadian railroads, where conditions are fairly stabilized, the machinery the Dis- putes Act, where employed, has worked well. the coal mines, however, has failed. And fine, seems that compulsion compared with conference and negotiation under governmental auspices futile. ROBERT GRIMSHAW. 1928—World’s Greatest Foreign Trade Year American Foreign Trade 1928. Official Report Fif- teenth National Foreign Trade Convention Houston, Tex., April 25-27, 1928. Pages 261, in. Issued the secretary, Davis, National Foreign Trade Convention headquarters, India House, New York. Beginning with the organization meeting Washing- ton, C., 1914, these foreign trade conventions have had great output high-grade literature the develop- ment the foreign trade the United States. From the beginning, James Farrell, president United States Steel Corporation, has been chairman the National Foreign Trade Council, and the steel and metal-working trades have been well represented every gathering. Secretary Davis, issuing this 1928 volume, says that this the world’s greatest foreign trade year since pre- war time. The principal trading nations the world did $19,482,000,000 worth export business last year, com- pared with $18,400,000,000 for 1925, which was the first year which the world actually exceeded the pre-war vol- ume exports. The 1913 export total nations was about $17,700,000,000. Thus, the figures for last year, com- puted 1913 dollar values, showed gain $1,782,000,- 000, slightly above per cent, the course world rehabilitation from the war. The Houston convention, which there were 1132 dele- gates, including more than from foreign countries, specialized Latin-America. was brought out that nations south Panama made total gain exports for the past two years almost per cent, giving South America world leadership rate increase export trade. Combined purchases made Latin-American coun- tries the United States exceeded $900,000,000 and were greater than their total purchases from England, France and Germany 1927. The Proceedings take papers and discussions three general sessions and three export mer- chandising sections. each the latter three phases the problem were handled experienced men. Blue Book Scrap Industry revised Blue Book has been issued the National Association Waste Material Dealers, Inc., Times Build- ing, New York. The new publication, the first since 1923, contains 324 pages and bound imitation leather. addition the constitution and by-laws the association, brief history and description the asso- ciation’s activities, there are separate sections devoted iron and steel scrap, non-ferrous metals, scrap rubber, etc. The metal section contains the standard classification non-ferrous scrap, printed parallel columns English, French and German and the classifications the American Railway Association. There also classification for nickel and monel metal suggested the association. Lists are given chemists, assayers, testing companies and sworn weigher