The Iron Age 1928-08-23: Vol 122 Iss 8

THE IRON New York, August 23, 1928 wr Castings Without Green-Sand Dry-Sand Cores Iron Box Give Cylinder Blocks Close quired Dimensions— 7 Continuous Pour Conveyors for the Cylinder Blocks the Dodge Victory and Standard Cars Are Made Entirely Dry-Sand Cores. The rectangular wedge-shaped box takes the place the flask. The men are setting the last core which closes the mold REEN sand molds have been entirely eliminated First the water jacket core placed the bottom the manufacture automobile cylinder block cast- the box. top and around this placed the water jacket ings Dodge Brothers, Inc., Detroit. The mold block core, which forms the outside the water jacket now made entirely dry sand cores. This interesting the casting. top this valve spring housing core development foundry methods step the evolution placed. Then come two side cores which form the outside molding practices. said result marked the crank case and portion the barrels. Next, the saving labor and floor space and the production barrel core put the center the water jacket, between castings which are better than those made the former the cylinder block core and valve spring core. This forms practices, that they are more uniform dimensions, the inside the barrel wall. The crank case core placed metal thickness and weight. The mold, stated, between two side cores and two end cores, which form the held within closer limits because the dry sand core has less gear housing front end the crank case and the fly- tendency give than green sand mold. Heretofore for wheel mounting rear end the crank case, and over the several years the Dodge foundry has been making only the cylinder barrel cores. The joint around this core mudded drag half the mold green sand, using one-piece flask prevent iron from running out through the seam. and bottom board. Clamps are then placed top the boxes and two run- The mold now made rectangular ner boards are put on. The molds are then poured with box, which has superseded the one-piece flask and bottom two 100-lb. hand ladles, which are filled from bull board. This box machined the inside within 0.002-in. ladle. limits. The cores are made that they fit into one another. The cores are made core machines and baked con- Before they are assembled the box they are inspected tinuous ovens, usual methods being followed their manu- and gaged. The mold built upside down, facture. whitewash coating applied the cores. This carried along conveyor. used place black coating, because its high heat- 449 . — — 3 RANSFERRING the Mold from the Pouring Conveyor (Above) the Cool- ing Conveyor Overhead Chain Conveyor (at Right) Lifts the Cast- ings from the Cooling Conveyor Its Un- loading End. Here any cores that sticking are re- moved, this being the first step cleaning the castings resisting qualities, because cleaner work with and for the reason that white cores reflect the light and make the core room brighter, cleaner-looking room. Cores completion pass down inclined belt conveyor from the core room the foundry floor, and over another belt con- veyor the cylinder line. The inside the molding box oiled prevent the cores from sticking. This sprayed before the making each mold. Gas which arises dur- ing the pouring carried away through vents the bot- tom the molding box, that index with holes the water- jacket core. Passing the end the mold conveyor after pouring, the molding box, which provided with trunnions the two turned over its trunnions and the casting and cores fall out apron-type cooling conveyor ft. wide and 165 ft. long. The casting remains this conveyor min. allow normalize. the unloading end the apron 450—August 23, 1928, The Iron Age conveyor hooked off means overhead chain conveyor and cleaned any cores which may sticking the casting. The castings are then placed the floor, where they cool room temperature. When they the cleaning room the core wires are removed and they are sand blasted, chipped and ground. They are then water tested 100 lb. pressure. The cylinder molding unit oc- this there are three molding conveyor, return box conveyor and the shakeout and cooling conveyors. The unit has capacity 1800 cylinder block castings hr., and has established record 1600 cast- ings hr. with two shifts. With the old methods and without conveyor equipment 300 cylinder blocks were produced hr. foundry floor space approximately 350 ft. There also reduc- tion the space required for sand handling, molding machines and supplies. The number cores required depends the design the cylinder block and number cylinders. 6-cylinder block being made with 338 lb. core sand, lb. more than would used making the same casting green sand mold, but offsetting this the elimination the use molding sand. making 1000 cylinder blocks shift, compared with the old method using one-piece flasks and green sand molds. Traveling over the apron-type conveyor shown above, the castings are not under hood and the muffle effect which might thereby obtained not experienced. This contrast with the practice certain foundries, both | A = 4 J Dry Sand Cores (at Right) Move Down the Inclined Belt Con- veyor the Foundry Floor and Another Belt Con- veyor the Cylinder Line, Where They Are Assembled the Molding Box While the Latter Moving Conveyor the automotive field and elsewhere, providing hoods for carrying away fumes and heated air. Where these cooling conveyors are provided with exhaust fans the cool- the Accuracy Cylinder Core Means Jigs (Left). This most important part the pro- cedure, the casting maintain the close limits accuracy now demanded metal thickness, total weight and uniformity dimensions ing the castings proceeds, course, accelerated pace. Frequently, such cases, the product emerges the other end condition handled once Sea-Water Corrosion Steels IRST results are now available the extended study sea-water corrosion sponsored the British Institution Civil Engineers. Exposures iron and steel are being made Auckland, New Zealand; Halifax, Nova Scotia; Co- lombo, Ceylon, and Plymouth, England, three groups, in- tended continued during five, ten and years respec- tively. The five-year groups included not only single metals, but also pairs dissimilar metals contact with each other, the object being throw light the tendency such pairs for one metal preserved the expense the other. The first five years having fully expired, the samples from each port have been removed and examined Dr. Friend. each harbor each group samples was di- vided into three sets, respectively fixed the air above the water, half-tide level, and totally submerged. found that the five-year results from the various ports show very satisfactory agreement with each other. Among other observations found that there great difference between the extent corrosion mild steel and wrought iron, although pairs the two metals contact the wrought iron corrodes more quickly, while the steel partially preserved. Sulphur steel appears re- duce its resistance sea-water corrosion, and copper per cent increase it. Chromium steels and nickel steels, though very resistant sea air and half-tide level, are less when totally submerged, and are also liable severe pitting. weight and pitting combined, the cast irons give the best results, but some instances seem show internal cor- rosion. The protection afforded nickel chromium steel contact with mild steel the expense the latter very marked. The Iron Age, August 23, | : J fe : — Public Docks Encourage Water Shipments Chicago HICAGO now served three public docks equipped handle iron and steel. These are operated the 103d Street and the Calumet River, South Chicago, the East Chicago Dock Terminal Co., Indiana Harbor, Ind., and the South Chicago Coal Dock Co., South Chicago, Chain Water Terminals Lakes The first unit the Terminals Transportation Corpo- ration, terminal and warehouse Duluth, Minn., was put operation 1923. Since that time similar facilities have been provided Port Huron, Mich., Buffalo, Detroit and Chicago. addition these dock warehouses, the company has two transportation lines, the Minnesota-Atlantic Transit Co. and the Detroit-New York Transit Co. The Detroit- New York Transit Co. operates motorships between Detroit and New York regular schedules. The running time between the two cities less than six days. The Minnesota-Atlantic Transit Co. operates steel steamers between Duluth and Buffalo, with stops intermediate ports. The Terminals Transportation Corporation will finance goods storage, making loans based market value. Briefly, the whole service comprises: Unloading merchandise from railroad cars boats. Classification and storage. Freezing, bonding and other special services. 4. Delivery to railroad, boat, express company or truck. Transportation over Lake and canal line between Duluth, Chicago, Milwaukee, Port Huron, Detroit, Buffalo and New York. Financial cooperation. The McDougall terminal the Terminals Transporta- The illustration the top the page shows cargo struc- tural steel being unloaded the dock the East Chicago Dock Terminal Co., Indiana Harbor, Ind. The steel was shipped from a Lake Erie port. 452—August 23, 1928, The Iron Age tion Corporation Duluth has 1500 ft. dock, with two 3-ton electric cranes for handling heavy freight. The track capacity railroad cars. The terminal buildings are 128 ft. wide and several hundred feet length, containing 350,000 sq. ft. general storage space and 1,000,000 cu. ft. for cold storage. The main structure six stories high. Detroit there are 1300 ft. dock, handling bulk and package freight, the track capacity being 150 cars. The terminal building 160 500 ft., stories height, and contains 800,000 sq. ft. floor space. There are 2,500,000 cu. ft, cold storage space and 5,000,000 cu. ft. for general storage. The tracks inside the building accommodate cars. Buffalo, the Eastern terminus heavy ship tonnage the Great Lakes and the Western terminus the New York State Barge Canal, the company has 1580 ft. dock and track capacity 100 cars. The warehouse, 1050 ft. length, provides 2,000,000 cu. ft. general merchandise storage space and 2,000,000 cu. ft. for cold storage. The terminal Chicago includes dock 1440 ft. long, which equipped with two 30-ton locomotive cranes. The track capacity 100 railroad cars. The steel storage warehouse 600 ft. Dock and warehouse facilities Chicago were com- pleted near the end 1927, and therefore comparative fig- ures iron and steel shipments are not available. The company, least Chicago, the early stages de- veloping business. The terminal Chicago not equipped handle coal ore, but has facilities for handling pig iron and iron and steel products. The East Chicago Dock Terminal Co., newly formed corporation, subsidiary the Interstate Terminal Ware- houses, Inc., which owns and operates the North Pier Ter- minal the mouth the Chicago River, purchased No- vember, 1927, approximately acres ground the ‘4 -_ southeast bank the Indiana Harbor Ship Canal, between Canal Street and the fork, having 1500 feet dock front- age. also has three-year option approximately acres adjoining property, giving additional 1700 ft. dock- age. This will give total acres open storage, but the company contemplates building sheds soon de- mand warrants. The property located the entrance the Calumet River, which part the Illinois water- ways system, connecting with the Mississippi River. This dock served the Indiana Harbor Belt, the Baltimore Ohio Chicago Terminal, the Elgin, Joliet Eastern and the Pennsylvania railroads. The dock laid out with four tracks running parallel the water’s edge, having ca- pacity between and 100 cars the dock and from additional cars the lead-in track. The dock equipped with two 15-ton locomotive cranes, each having 55-ft. booms. There are also two 20-ton gantry cranes with 70-ft. spans. Ore-handling capacity 4000 tons per day. Pig iron can handled the rate 150 tons per hour means 55-in. and 65-in. magnets. Clam-shell buckets are provided and yd. capacities. Structural steel sections have been handled lengths ft. This company, previously stated, controls the North Pier Terminal the mouth the Chicago River, where 1,500,000 sq. ft. storage space available. also op- erates warehouses Cleveland and Indianapolis. This year there have been received this dock between and boats. Several have carried cargoes directly from European ports. Others have moved from the Atlantic Coast, Canadian ports, Buffalo, Cleveland and Detroit, with commodities destined not only Chicago, but points be- yond, such Denver, Kansas City, St. Louis and Milwau- kee. There have also been number boats loaded for out-bound movement from Chicago both American and Canadian ports the Great Lakes. The dock the South Chicago Coal Dock Co., South Chicago, used unload ore for rail shipment Granite City, Four hundred thousand tons ore passed over this dock 1927, and equal tonnage will handled Terminal at PORT HURON Z Terminal and Warehouse at DETROIT rehouse before the close navigation 1928. The shipping charge ore loaded Escanaba, Mich., for delivery Chicago gross ton and from Superior, Wis., Chicago, 70c. gross ton. The rail rate ore from Chicago Granite City $1.20 ton. The South Chicago dock charges gross ton for unloading and putting the ore cars. This dock 700 ft. length. equipped with gantry crane which will unload free running ore the rate 350 tons hour. Consideration now being given the in- stallation second crane equipped handle structural material. Open air facilities are available for storage ore, pig iron and structural material. The storage charge pig iron varies from 5c. 10c. gross ton per month. Sharp Gain Water Shipments Steel Lake shipments structural shapes Chicago thus far 1928 have averaged about 3000 tons week. Aug. fully 20,000 tons bars had been brought Chicago boat, and equal tonnage expected unloaded dur- ing August alone. 1927 the Lake movement structural shapes Chicago was practically nil and the tonnage bars shipped was negligible. Boat shipments pig iron from Lake Erie ports Chicago totaled about 30,000 tons 1927. The movement this year, Aug. aggregated about 25,000 tons. The shipping season for pig iron 1928 opened much earlier than 1927, but, because recent reductions prices Chicago furnaces, there less incentive for Chicago brokers bring cargoes pig iron than there was year ago this time. understood, however, that sev- eral vessels are still under contract and will handle cargoes Chicago regardless the existing relation between fur- nace prices pig iron Chicago and Lake Erie ports. boatload low phosphorus pig iron has been shipped Chicago directly from England this season naviga- tion, and negotiations for second shipment are now un- der way. also planned arrange for direct boat ship- ments ferromanganese from England ‘and spiegeleisen from Germany Chicago. The low phosphorus pig iron shipped from England was delivered Chicago dock for somewhat less than $5.50 ERMINALS and Warehouses Have Been Located Strategic Points the Great Lakes One the Companies Handling Water Shipments Iron and Steel. This organization also operates two Lake trans- portation lines new JERSEY The Iron Age, August 23, 1928—453 q “a » 2 | . > ' 4 gross ton. rate $5.50 gross ton now being quoted proposed shipment from England Chicago includes stops two ports. Ferromanganese can also handled The vessels that will available for these voyages across the ocean are said boats now being this rate. built Europe for Canadian service the Great Lakes. The Lake rate pig iron from Cleveland Chicago ranges from $1.25 $1.50 ton. Structural material can moved from either Buffalo Cleveland Chicago Performance Records Stainless Steel British Firms Find Preferable for Pistons for Hydraulic Pumps, Blades for Steam Turbines, and Gas Engine Valves UTLERY the most natural application stainless steel. Its use enables large dining rooms abolish the cleaning machines, save work and reduce the wear the blades. Surgical and dental instruments which must protected against sterilizing agents are now usually made stainless rather than silver plated carbon steel. Sheffield alone 750 tons this metal produced an- nually for cutlery manufacture. There are three important further applications me- chanical construction which deserve special mention; name- ly, pistons for pumps hydraulic presses, turbine blades and valves for internal combustion engines. Pump Liners Resist Erosion Davy Brothers, Ltd., Sheffield, England, built 1915 three cylinder pump, electric driven, for pressure 10,000 Ib. per sq. in. One the pistons was made stain- less steel, the other two the more usual phosphor bronze. This pump worked day and night until the end the war. inspection the diameter the stainless steel piston was found reduced only 0.4 mm. diameter, while the other two pistons were 2.8 mm. smaller. This reduction wear evidently favors the conservation power and the satisfactory working the pump. Tests Steam Turbine Blades Thomas Firth Sons, Ltd., Sheffield, manufacturers stainless steel, possess Westinghouse steam turbine work- ing 3000 r.p.m., and receiving steam 170 lb. per in. superheated 315 deg. works uninterruptedly under load factor varying from 100 per cent. The original blades were made per cent nickel steel. June, 1920, some these blades were replaced others made stain- less steel and few replacements were made nickel steel. The following table gives the characteristics the two metals. Stainless Steel 0.30 per cent carbon 13.4 per cent chromium 122,000 lb. per sq. in. Elastic limit...... 99,000 per sq. in. Elongation ... per cent Brinell hardness .. 255 Nickel Steel 0.19 per cent carbon 4.7 per cent nickel 78,000 per sq. in. 54,000 per sq. in. 32 per cent Composition Tensile strength mentioned before, June, 1920, blades were re- placed the high pressure wheel. the one side this wheel which functions dry steam high temperature, non-polished stainless steel blades were placed; the opposite side six the same metal, with three made pol- ished stainless steel and three new nickel steel. the last wheel blades were also replaced. the one side this wheel, which works damp steam, three non-polished stainless steel blades were fitted and three nickel steel, while the opposite side three polished stain- less steel and three nickel steel blades were fitted. The turbine thus altered worked uninterruptedly for *Metallurgical engineer, Birmingham, England. 23, 1928, The Iron Age 3471 hr.; was then taken down and while the steel blades revealed the usual corrosion, the stainless ones were intact and had preserved all their original polish. Results these trials have been confirmed those ob- tained the Thomson-Houston company one its own turbines. the beginning 1916, this firm installed blades trial composition the middle wheel tur- bine, but the wheel began show corrosion very soon. Two hardened stainless steel blades were then fitted into this wheel, two the same material hardened and tempered, two phosphor bronze, two nickel bronze, two ordi- nary soft steel and two brass ones. This turbine was started the autumn 1916 and was not examined until April, 1918. With the exception those made stainless steel all the blades suffered slight erosion. Brass blades were especially worn. The extremities the blades made soft steel had become slightly uneven, while the nickel bronze ones had resisted well those made stainless steel. The turbine then operated until July, 1921, when was found that the stainless steel blades were absolutely un- touched the edges. The inlet edges the nickel bronze blades well the phosphor bronze ones had become un- even; those soft steel were heavily corroded, the wear being about Such records show the advantage stainless steel for the construction turbines. The outline the blades has great influence upon the performance; variations the edges impart shocks and eddies, and reduce the efficiency. Non- corrosive blades reduce the necessary repairs and stoppages for cleaning and replacement. Air Engine Valves Require Strength Heat Lastly may mentioned the application stainless steel for valves for internal combustion engines, especially those for aero engines and for the high-speed engines now popular for motor cars. Noncorrosive valves and seats lengthen the time between regrindings and maintain unim- paired efficiency during operation. What has really made the use stainless steel for valves success aero engines the security gives during working because the high strength elevated temperatures. For such purposes the Derihon plant Manchester supplied the Allies during the war 15,000 stain- less steel airplane engine valves per week. The automobile industry leaning more and more toward the building high output engines and obtain this many English makers have fitted overhead valves. This arrangement has the serious disadvantages that broken valve may fall into the compression chamber and break the piston and even the cylinder. Valve regrinding also lengthy and expensive operation such engine. Cer- tain British firms using stainless steel valves guarantee 20,000 miles before necessary regrind. Also the strength residing this steel high temperature permits the use stronger springs and short valve stems. 7 | | By 7 143 | | 7 8 q a Making Electric Manganese Steel Details Modern Practice for Ingots—Less Loss Manganese—What Advantages Are Claimed Over Open-Hearth Method HRUSKA* the history the metallurgical development man- ganese steel, the general application electric melt- ing methods has resulted important improvement the chemical well physical properties this ma- terial. Originally, the alloy steel manufacturers were favor the generally used method mixing low-carbon Manganese, Per Cent steel with molten ferromanganese else risk large percentage the added manganese and melt both together. either case great losses had expected. With the use electrometallurgical melting and refining not only have these losses been eliminated, but high-grade material has been obtained. course, the melting and refining operations con- nected with the manufacture electric manganese steel were higher cost compared with the older methods and was for this fundamental reason that took some pioneering put electric manganese steel commercial product the market. Preparation the Molten Metal the successful manufacture manganese steel the so-called austenitic type, the important relationship be- tween carbon manganese—as originally observed and determined Léon Guillet (Fig. 1)—and partly also be- tween carbon, manganese and silicon has steadily held mind. Thus certain standard analysis rather minimum content the various constituents resulted more less automatically. This generally accepted “specification” reads follows: Per Cent Carbon less than *Metallurgical engineer, 2328 South Euclid Avenue, Berwyn, Fig. (At Left)—Relationship Between Carbon and Manganese Originally Observed and De- termined Although many other specifications the chemistry high-manganese steels were introduced the metal trade, most the quality products steel works producing this grade steel may ranged within these limits. order avoid rather tedious description the metallurgical processes during the manufacture high- grade manganese steel, complete outline very satis- 8.2% TRANSIORMER © 13% Fig. 2.—Heat Distribution RAD/ATION Per Ton Electric Man- factory heat, made recently 7-ton basic Heroult fur- nace, presented: Charge used making the heat: Initial metallic charge............... 12,100 Record the heat: Length Time Operation Operation 9.47—Charging started. Charging, 10.10—Current on. min. scale added lime added. 12.51—-No. samples steel and slag taken. 1.00—Furnace tilted order skim off the Melting, hr. greatest part oxidizing slag. min. 1.04—Current off and remainder slag cleaned off the surface the bath. Particular care taken carrying out this opera- tion. 1.07—Slagging finished: current again. min. After slagging, successively added: 45 lb. lime lb. fluorspar 770 ferrosilicomanganese 1.22—75 Ib. lime added. 1.28—Four shovels powdered ferrosilicon thrown over slag mixture. 1.34—No. samples taken, after thorough stirring the bath. The Iron Age, August 23, 1928—455 AUSTENITIC STEEL >. 5 Carbon, Per Cent 1.37—Four shovels powdered ferrosilicon thrown slag surface. 1.40—30 lb. of lime added. 1.52—Four shovels powdered ferrosilicon thrown surface. No. taken after the bath was thoroughly stirred. lb. ferromanganese added and lb. lime added. lb. ferromanganese added. No. taken. 2.35—30 lime added, then three shovels powdered coke thrown slag Bath stirred, and left quiet for the est the heat No. taker off. few large pieces lime thrown near taphole the slag. steel tapped into hot ladle (bottom pour ladle). 24—Lad filled rted steel (No. taken rs samples 0.04 0.21 1.04 1.00 1.01 Mar 13.93 3.31 12.89 S 0.01 0.31 0.26 0.29 0.23 0.22 Phosphorus : 0.002 0.032 0.035 0.049 0.052 0.047 Sulphur 0.018 0.027 0.018 0.013 0.010 0.006 ] ¢ slag sa? les All Greenish Dark Gray, Crumbling White Greenish Green Powder Appearance Brown Gray Silica 8.92 23.11 24.83 24.42 25.53 Ferrous Oxide 24.62 7.63 2.29 1.86 Manganous Oxide 23.41 14.06 7.29 3.66 Oxide.... 32.56 42.10 51.84 57.12 6.97 Ferros omanganese (63.84 per cent Mn)......... Lime (87.22 per cent CaO, 0.59 per cent MgO, 0.91 per cent 0.064 per cent ..oxidizing slag 262 reducing slag 210 Fluorspar (84.26 per cent CaF,) ladle 20 Coke dust Thermal efficiency of furnace: AC rding to a scheme, outlined in one of the author’s previous (THE TRON AGE, Dec. 31, 1925, page 1845), similar Safety Hints Hartford Accident Indemnity Co., Hartford, Conn., has issued for free circulation second edition attractive pamphlet entitled “Spray Coating—its Hazards and Safeguards.” gives brief but clear account the constitution modern lacquers and the various precau- tions which are necessary avoid injuring the health employees endangering the plant. Practical suggestions are made approved methods designing the spray- booth and the ventilating system, and simple but effective and cleanly housekeeping methods are suggested. The booklet should source useful information op- erators who relatively small amount finishing this new process. The following safety hints are given sheet, suita- ble for framing and posting, which will sent the com- pany those who ask it: lacquers containing poisonous substances h as methyl alcohol, benzol, or tetrachlormethane. Provide adequate exhaust ventilation before beginning pr operat Arrange ventilating equipment that fumes will not 1. Respirators and masks should not be depended upon to mbat fume hazard unless they are equipped with tube lead- ing fresh air supply. Employ gun pressure that does not produce ex- cessive amount mist. Workers using lacquers containing lead should periodically examined physician. Separate booths should provided for each spraying operation. Lacquers should stored fire-resistive structures, well ventilated and lighted with vapor-proof globes. 456—August 23, 1928, The Iron Age balance sheet was worked out for the heat mentioned the pre- ceding paragraphs with the following (calculated per ton finished manganese steel, Fig. 2): Per Cent 100.00 Ingot Practice Austenitic manganese steels are mostly teemed into rather small square ingots, the weight each ingot rarely exceeding five tons. Many quality steel works, here and abroad, use bottom pouring, which method, this case par- ticularly, has the advantage quicker teeming and con- sequently more uniform pouring conditions well better yield sound metal. After teeming, the molds should stripped off the in- gots soon possible. Obviously, “stickers” must attended immediately and, stripping impossible, the mold must broken. The ingots should delivered the soaking pits very high initial temperature and ar- rangements should made maintain the time charging approximately the same temperatures the pits those the charged ingots. Conclusions Comparing the manufacture ingots austenitic man- ganese steel made basic electric and open-hearth furnaces, the following points are mainly considered: Advantages Disadvantages 1.—Homogeneous metal. often the steel finished 2.—Practically negligible and tapped too hot, which fact losses mang causes the usual higher shrink- with the product open-hearth lic and furnaces: clusions. Open-hearth ...2.1 2.5 per cent 4.—Possibility hotter 2.7 3.0 per cent steel. using tilting ladles slag interferes very often, tom pour ladles should con- sidered standard practice. 3.—Mostly higher production costs. for Lacquering Main supplies lacquer should not stored the factory proper. 10. Solvents and diluents should not stored the fac- tory proper. 11. Use only incandescent vapor-proof globes for lighting. 12. Guard approved manner all switches and plugs. 13. Motors and flames should safely isolated from spraying rooms. 14. Ground all electrical connections and make sure that thinner containers are grounded metal supports—thus guarding against static electricity. 15. Iron sparking metals should not used for clean- ing and scraping. 16. Steel lacquer drums should not used for pressure containers. 17. Lacquers should not mixed the spraying room. 18. Air compressors should not located the spraying 19. Fire protection apparatus, extinguishers, sprinkler 20. Keep equipment and factory clean—organize strict, systematic cleaning schedule. The part played the foreman the control labor turnover the third booklet series the subject labor turnover which has been issued the Policyholders Service Bureau the Metropolitan Life Insurance Co., New York. The foreman, pointed out, “can help employees become adjusted their work quickly, can develop loyalty and should the first learn problems and difficulties which confront every wage earner.” composite the views manufacturing concerns contained the booklet. | q Methods Forging and Forming, In- cluding Bending and Stretching Oper- ations for the Model-A Car FAY LEONE FAUROTE* parts are interesting processes. Especially interest- ing the manner which the left-hand spindle arm forged and shaped and the means used bend the front axle proper and stretch its required length. Stock for the front axle first cut length No. Niles Jones shear, which handles 300 pieces stock hour. 4-in. Ajax forging machine then used upset and bend each end, this operation proceeding the rate and forming the Ford Model-A front axle *Mechanical engineer, 420 Lexington Avenue, New York. OUNTING Azles the Car Frame Just Before Transferring the Frame the Start the Final Assembly Line Conveyor 188 ends hour. 5000-lb. Erie hammer and Bliss press are used for blocking, finishing and trimming each end, after which the forgings are given bench inspection. The parts are then heated the central section, put into spe- cially Ferracute press, shown one photograph, where they are bent and stretched proper length. This work proceeds also the rate 188 hour. They are then heated, quenched and annealed, after snag- ging Ransom grinder. After torture test 92% Toledo press they are ground for Brinell test, ~~ 7 q ys 7 The Iron Age, August 23, 1928—457 ~ 3 Spindle Arm—Left No. Operation Machine A Cut to length N and J shear B Heat Box furnace Forge 2500-lb. Erie hammers D Trim No. 5514 Toledo presses 90 206 Bliss press Hot bend No. 306 Bliss press P-5 Ferracute press 250 Quench Ford special quench machine Anneal Gas furnace 1,500 Pickle x 6 x 5-ft. tank 2,000 1 Mill flats on No. 3 Frew hand mills 200 two balls Turn ball 4-ft. Reed-Prentice steering arm lathe 26 (long) 3 Turn ball on 14-in. x 4-ft. Reed heavy-duty ’ short arm ball lathes 4 Machine ;¥ in. x 21-in. Cincinnati drill press 135 1 in. shoulder Mill flats No. Frew hand mill 200 length on balls Center drill Ford centering machine 300 bearing lathe 40 Turn oil groove 14-in. 6-ft. Reed-Prentice lathes 150 9 Mill 532/.534 5-in. Pratt & Whitney hand mills 225 Drill in. hole No. 6-D Kent Acme drill, spindle arm 6-spindle 300 left 11 Thread ¥* Special Illinois threader 300 Straighten P-4 Ferracute press and AKING the Left-Hand Spindle Arm. shown drawing and photographs. One view shows Bliss press bending the steering knuckle; another shows an Erie hammer forging the steering spindle arm from straight bar. Steps the forging are shown below } j af 4 4 458—August 23, 1928, The Iron Age 5 Fin Front Axle Assembly Operation Assemble oilers, top and bottom, two spindles...... Fit one and one spindle arm into one spindle Put two steel and felt washers, one set each Put spindle bolts, left and right................... Put two spindle bolt locking pins and nuts........ Assemble one radius rod axle. Assemble spring perches front axle................ Assemble one brake shaft assembly and onto Assemble brake assembly axle putting cam end spindle bolt housing first. Assemble spring and ball seat assembly connecting rod and put adjusting Assemble connecting rod spindle arm Paint one coat Primer and bake one hour 250° heat. Machine Bench fixture Bench Bench Bench Bench Bench Bench jench sench Bench Bench REPARATION and Assembly Front Axle, Showing Forging the Axle Erie Hammer and Bending the Axle Exact ished Contour Means Special Dies. The heating oven appears upper right. The drawing shows assembly one axle The Iron Age, August 23, 1928—459 q | i . > straightened Ferracute press, put through pickling operation conveyor and finally given bench inspec- tion for cracks. They are then ready for machining. special Ingersoll milling machine handling pieces hour mills the spindle and spring perch bosses, after which four-spindle Foote-Burt drill drills spindle and spring perch bosses and reams them the rate hour. Two 9/16-in. holes are then drilled and reamed, single-spindle Cincinnati drill press. similar ma- chine takes care the next two operations, which are the countersinking four 11/16-in. and two 9/16-in. holes and the spot facing two 9/16-in. holes. Finish milling the spindle bosses done No, Kempsmith milling machine the rate hour. After this the axle receives one coat paint and dried oven the rate 400 hour. The accompanying photographs show the dies, hammers and work various stages the forging operation. The nine operations the forging and forming the left-hand spindle arm are graphically shown progress photograph. Until one actually sees the progressive steps whereby straight bar steel forcibly cajoled into yielding this grotesque but most efficient form one can hardly believe that such result possible. Forged flat, the two arms are finally brought their final shape bending over die the Bliss press shown another illus- tration. Six actuai operations and the machines upon which they are performed are detailed tabular form. Two these lists operations appear alongside the illustrations show- ing respectively the left-hand spindle arm and the front axle assembly. The others follow: Spindle Arm—Right No. Per No. Operation Machine Hour 1000-lb. Erie hammers .... No. 73% Bliss press...... Ford special quenching ma- 125 400-lb. Erie steam hammer 750 Mill ball No. Frew hand mill .... 300 14-in. 4-ft. heavy-duty ball lathe, two spindle speeds, and 250 r.p.m. tail-stock feed, in- dividual water pump, 12- in. air cylinder ........ 2-A 1/16 1-in. 21-in. Cincinnati drill press, Mill flats length Potter Johnson shaver, using and mill ......... 300 Center drill ....... Ford centering machine, Ford design—single end. 300 bearing ........ tice lathe, wet table, tail- stock power, individual Turn oil groove ... 14-in. 6-ft. Reed-Pren- tice lathe, wet table, in- dividual 150 Mill 0.532/0.534 in. Pratt Whitney hand mill; No. Brown Drill 5/32-in. hole 6-D Kent Acme 6-spindle spindle arm drill, wet table, equipped 300 Thread 9/16-in. Special Ford threader .... 300 standard and bench .... 150 460—August 23, 1928, The Iron Age Front Radius Rod Assembly No. Operation Weld one Ford part (A-3412 foot) and Ford part A-3411 B-6 Winfield tube welders. 125 Machine Hour Trim flash foot and tube assembly CA-4 Ferracute punch foot assembly Ford part A-3409- 100-kva. flat-top welders.. 100 Trim from one tube, yoke and foot assembly CA-4 Ferracute punch foot assembly tube, foot and yoke assembly welders.. 100 Remove flash ..... CA-4 Ferracute punch Front Spindle Assembly No. Per No. Operation Machine Hour Press bushing No. Ferracute press 300 Press bushing No. Ferracute press 300 other lug ...... Burr oil hole 14-in. 3-spindle Leland Gif- Rough line ream Cincinnati drill presses.... 300 Broach and burnish No. Ferracute press 400 13/16-in. hole Front Spring Perch Assembly No. Operation Press front spring perch front spring perch P-3 Ferracute press; PG-3 upright punch press .... 500 Machine Hour press; No. Allen sensi- Special threading ma- Seams Forgings Defined special committee was appointed 1926 the American Society for Testing Materials consider whether possible prepare definition “seams” and “injuri- ous defects” available for the interpretation these words when they appear specifications for forgings. After considering the wide variety the design and uses for forgings, was voted the committee its last meeting that the definitions already proposed are good can formulated. These are follows: seam separation the metal deter- mined splitting chip taken right angles parallel with the direction the seam. Seams other surface imperfections finished forgings will not considered injurious they can removed machining the surface the forging depth 1/64 in. for each inch diameter the forging. The depth the imperfections may developed taking several light cuts with chipping tool until the deepest chip does not break the line the imperfection, filing machining right angles the line the imperfection until its depth has been established. No. Per No. Per t ™ : Completes New Foundry for Compressor and Engine Gray Iron Castings Chicago Pneumatic Tool Co. has completed new foundry Franklin, Pa., for the production gray iron castings for the air compressors and engines manu- factured the company’s Franklin works. storage shed measuring 330 ft. has also been erected. The new foundry building 130 ft. wide and 220 ft. long and ad- jacent the main plant, which consists power house, ma- chine shop, erecting floors, pattern shop, offices and shipping platforms. The buildings and foundry equipment, which modern design throughout, represents investment more than $400,000. The equipment includes two cupolas, one 4 | q 4 Equipment the New Chicago Pneumatic Tool Company’s cupolas, several molding machines and automatic hopper may noted from Foundry Modern Design Throughout. type sand handling units. exterior view above includes two The type building construction The Iron Age, August 23, 1928—461 . | ae Ay 7 tons per hour capacity and the other with half that ca- pacity, tons per hour. Two rotary blowers have been in- stalled and crane equipment includes five traveling cranes, three which are ton capacity, one ton and one tons, and yard cranes. Several molding machines various capacities from 1000 20,000 and including four squeezers, have been installed. Other major equipment in- cludes three hopper-type automatic sand handling units, mold drying ovens and two large and four small core ovens. daily capacity tons provided, with ample pro- vision for doubling this tonnage meet the needs growth the business. Approximately 225 men will employed. stated that the new foundry unit will permit complete supervision every step entering into the manufacture the com- pany’s products, from raw material the finished ma- chines. The company has other large plants Detroit and Cleveland, where pneumatic and electric tools are manu- factured. Use Foreign Structural Steel Warily Method Manufacture and Lack Usual Tests Cast Suspicion Uniformity and Acceptability for Important Structures WARNING has been issued the American Institute Steel Construction, through its executive director, Charles Abbott, that the structural steel now being im- ported into the United States has not been made under the specifications customarily imposed American steel. Con- sequently should used with caution, and placed into im- portant structures only after careful and systematic testing indicates that its quality uniform and better than the minimum limits strength assumed the designing en- gineer. While taking the stand that technical association such the institute not concerned political matters, Mr. Abbott’s statement points out that his organization vitally interested the quality the material which goes into construction work. The institute has evolved standard specifications for steel construction work which have been adopted practically every city the United States. These standards require that the steel measure the high quality specified the American Society for Testing Materials. Imported Structural Steel Mostly Bessemer “If the material passes these tests may made either the Bessemer the open-hearth process,” the state- ment continues. steel not uniform qual- ity and realize that only when the steel made the open-hearth process can fully assured that will meet the high standards required. “Inasmuch most the imported structural steel produced the Bessemer process word caution issued building owners the United States. Foreign steel produced the Bessemer process should subjected the most rigid tests before incorporated any American structure. Aside from the chemical structure the foreign material not infrequently happens that its geometric proportions also make inferior for American practice. Our 12-inch beams have certain desirable flange width, and their webs specific thickness. the other hand, the European product has less metal the flange, which makes easier roll but less efficient per pound steel. the United States uniform quality steel used and, matter what mill may make the beam, produced according known standard specifications. inspected before leaves the mill determine whether not meets the necessary requirements. “It will wise for steel contractors not look for price savings the purchase foreign-made structural steel, for most cases nothing gained thereby. Should consignment steel reach here and found impractical for use, much time lost replacing that shipment the domestic product. Word comes from Miami, Fla., that construction work the Twelfth Avenue bridge held because the steel was purchased Europe. Owing 23, 1928, The Iron Age strike, the shipment still held Belgian port. The contractors would have completed their work May but for this delay receiving the steel. “Not all losses are incident delays delivery, when contract based upon foreign steel. Some contracts Brooklyn, Y., were held because the foreign steel did not measure specifications and American was substituted. Albert Kleinert, building superintend- ent Brooklyn, states that has found imported struc- tural steel per cent weaker than domestic structural steel. Europe does not find necessary make steel American standards, for they usually construct buildings not over five six stories height, where strength material not important. Foreign Mill Tests and Markings Inadequate “Domestic steel manufacturers make and record the tests made each melt, which record can compared and checked against the finished steel from each melt. gen- erally impracticable obtain such record steel imported from abroad. Tests made after its delivery are inadequate. May this year certain steel reported have been im- ported was tested Columbia University. The results that test were not conclusive, and were reported building inspectors, for they established only the value the pieces actually tested and failed connect them with all the imported steel question. “The American Institute Steel Construction, Inc., not opposed imported steel because foreign made, but opposed anything that tends lower American standards. foreign steel imported for structures here should subjected the same rigid tests the mill which subject our domestic product, and when fails meet those requirements its use buildings and bridges should prohibited.” The effect nutritious food upon the health and conse- quent efficiency employees and the inadequacy com- mercial facilities for the needs many industrial estab- lishments has led the installation many companies industrial lunch rooms, the problems which are amply set forth booklet issued the National Industrial Confer- ence Board, Inc., New York. Types and physical charac- teristics lunch rooms are fully covered together with their management and cost. summing brought out that “the most popular type lunch room for all types plants the cafeteria, which requires managerial skill and considerable outlay money for its operation. result number companies that find urgent luncheon facilities, but impractical engage program management and finance foreign their business, deem advisable turn the management their cafeterias over concessionnaires.” may obtained from individual cylinders com- pressed gases, from cen- tral station where the oxygen and acetylene are generated and piped various outlets. Frequently, portable acetylene generators are used advan- tage. shown the view, small generator, rated cu. ft. acetulene hour, can produce enough gas through cast iron fly-wheel in. web. ULKY and intricate material, ranging from steel ship down locomotive, offers particular difficulty scrap yard properly equipped with blowpipes and handling equipment. double walled firebox, with numberless rivets and stays, would probably cost more than the old material worth dismantle any other way than gas cutting. XY-ACETYLENE cutting used fre- quently and such good effect dis- mantling and wrecking operations that now excites little comment. Such equipment also used advantage scrap yards supplement the drop ball and the alligator shear the job reducing ungainly massive pieces cast iron Steel charg- ing box size. Photographs courtesy The Linde Air Products Co. EAVIER cutting cast iron may done cutting half way through from one side, then turning the piece over and completing the job. The view shows block in. thick being reduced smaller this manner workman under close supervision another, skilled cast iron cutting. LAIN carbon and alloy steel can flame much more readily than cast iron. Twelve-inch armor plate may trimmed shape cut into section special blowpipe mounted simple traversing mechanism, driven long screw. The Iron Age, August 23, 1928—463 éSs Cutting Massive Scrap - = Aa & Leaves from the Diary Foundry Apprentice March 4.—Only here month and half, but feel like old-timer; not bit sore, fit fiddle and liking this game better every day. Jack says you get feel like the papa new baby, without the after effects doc- tor’s bills, every time you see yourself the “daddy” nice, bright, bouncer steel casting. “Jack has got right,” the Dutchman our scenic railway would say. (Until rode the crane our bay wondered why they called the “scenic railway”; now know.) March 10.—Received schedule “Related Studies” for the full four years. With the hr. per week home study, “go school” actual time more than one year— 1600 hr. exact. They spoke this apprenticeship “more education than just job” the first interview. was reminded yesterday while looking over cir- cular apprenticeship that the company publishes.—That reminds me, must give that Andy C., who interested this apprenticeship business.—Well see. I’m going copy the schedule here and check off they hand out 4 ble Time Hi hr. per year obligatory four hr. per prescribed home study, four years ble for related studies Required for I ted t & pare S91 Average number of unit lessons........ 54 Average time to complete each......... ; 16.5 Inspection trips (four trips per year, four hr. each) Technical lectures (0.5 hr. each four hour period, o1 Non-technical lectures (same technical).......... 100 Collateral trade and technical reading and study. 100 Advanced studies (junior foremanship).......... 345 Technical Lectures (Tllustrated) The Making Iron and Steel, six half-hour lectures Elementary Metallurgy, twelve half-hour lectures Heat Treating, twelve half-hour lectures... Alloy Steels, six half-hour lectures......... Company Products, twelve half-hour lectures Modern Machine Shop Practice, twelve half-hour Modern Pattern Shop Practice, twelve half-hour Modern Foundry Practice, twelve half-hour Modern Industrial Buildings, six half-hour lectures 10. Materials Handling and Equipment, twelve half- 11. Economics Mass Production, six half-hour 12. Modern Management, twelve half-hour lectures... 13. Modern Foundry Sand Control, six half-hour 14. Open-Hearth and Electric Steel Castings, twelve 15. Power Modern Manufacturing, twelve half-hour 16. The Specialty Steel Castings Field, twelve half- 17. Steel Castings, twelve half-hour lectures Production Schedules and the Customer, six half- 19. Financing Modern Business, twelve half-hour lec- 20. Miscellaneous, twelve half-hour lectures *Consultant, St. Louis. 464— August 23, 1928, The Iron Age Non-Technical Lectures. The Apprentice as: Learner (Attitude shop toward fellow appren- tices, journeymen, foremen, al.), lectures, Employee (As producer, manufacturing costs, Member Community (Civic and social obliga- tions, home owning, etc.). 16 lectures........ 16 Member Industrial Society (Labor policies, or- Individual (Duties self, safety, hygiene, Future Journeyman (Opportunities, obligations, Can you beat that! never thought hard-boiled foun- dry outfit would get down figuring out the number hours took complete lesson. Supervisor Haney certainly some generalissimo. explained the course studies general way and said that would undoubtedly become better acquainted with time went on. say will, know anything about the way they run things around here, week probationer was let out be- cause failed keep with his related studies. Mr. Haney explained that “related studies” mean studies re- lated the work are doing the shop. (Phew! that’s the longest entry I’ve made you yet, Diary. old dear.) March 15.—Just returned from first inspection t