The Iron Age 1929-01-24: Vol 123 Iss 4

THE IRON New York, January 24, 1929 ESTABLISHED 1855 123, No. Making Rolls for Paper Calenders Depth and Character Chill Vital—Unusual next position. There ment, parallel the roll axis Machining Practice, without Longitudinal Feed Tools WINFIELD HUSON* APER calendering machines are example foun- is, their making, some matter more than passing in- dry and machine shop procedure not ordinarily terest those who have deal with problems contin- found general practice, yet the everyday experi- uous production important adjuncts the processes ences those who build them may suggestive. The manufacturing commodity. recent construction the largest stack newspaper cal- newspaper invites little thought how newsprint, endering rolls yet built gives rise the thought that there commonly termed, made and treated; yet the final Fig. Heavy Calender Roll. Each tool (several are used simultaneously) toward the center un- til required di- ameter. tools are moved longitudinally the 6 - . because the finish itself, but also that uniform thick- ness maintained. However, the massive dimensions the stack, the corresponding weight, founding and ma- chining that appeal. This latest achievement the Farrel-Birmingham Co., Inc., Ansonia, Conn., comprises stack eight rolls high and 298 in. long the chilled hard-finished faces. The lowest roll diameter, superimposed which are one 24-in. and six 20-in. rolls, all approximating 160 tons iron, the 36-in. roll requiring over tons molten metal the cupola. While the finished face about ft. long, journals must added, making the total length ft. And cal- ender rolls are cast end, some idea can formed the foundry problem preparing pit this great depth, well placing cores for journals and chills for the face. The journals must soft and the body also, the middle portion, which will encased chilled envelope in. thick. Here are conditions which require knowledge anal- yses and closest attention them—not only grades and components the metal itself, but also procedure, tem- peratures, cupola control, ladling, pouring and shake-out. foundryman knowing the con- ditions his handiwork has meet will recognize liminary steps necessary pro- duce casting having thick shell cementite nature, hard and brittle, shrinking the rate in. the foot, around mass soft iron pearlite Fig. (Right) Stack Ten Cal- ender Rolls Set for Thin Work. The motor top operates the screw- downs, and the man forms scale indicate size. Notable great distance be- tween supports 266—January 24, 1929, The Iron Age — structure shrinking in., thus putting the brittle shell great tension because its greater contraction. The soft center necessary for strength, the chilled covering for hardness. Method Placing the Chills making the flask, sand mold placed for the lower journal. Then comes series annular cast iron chills, ft. long, in. thick, differing roll diameters may require, faced, bored and coated with wash prevent adhesion the molten metal. The required length chill surface being reached, heavy riser pro- vided for, the top journal mold set and pouring heads are placed match runners which carry the metal the bottom. Here the iron flow sent tangential direction, set upward eddy, carry the interior any foreign material which would tend spoil the re- quired clean face the roll. Chills are quite item cost; they last for nominal number rolls, when they must remachined restore their accuracy. Small sizes are rebored and replaced when the limit has been reached; for this purpose large boring mill kept constant service, reclaiming warped pieces and turning out new castings. The iron being ready the cupola, everything required for perfect and proper cast must move quickly. This may said general practice, but, where there latitude ordinary pouring large castings, there none for chilled rolls. Fig. (Above). Automatic Grind- ing Machine Car- rying Two Wheels Mounted Single Frame the Swing Rest Both move together, lat- erally, across the bed and accu- racy 0.00025 in. obtained 2 a “a 7 r 4 = . 1 > ~ — C—O § Fig. (Right) Caliper Used ing Roll. The arms are graduated and the reading taken from the dial showing just over the journal. The wheeled carriage indicates how easily the gage moved from one point another along the length The molten metal must clean, constant tempera- ture, rapidly ladled, transported quickly and continuously poured, Any hiatus, while might not result bad would affect the proper chilling, for, the iron strikes the chill, sets rapidly, and the depth and char- acter the chill imparted the casting depend large measure upon having the controlled temperature kept nearly physically possible. With such exacting conditions met, there can good roll, where the pouring starts down drop ft. more, then rises again swirling mass into riser, which ultimately feeds the fluid casting cools and shrinks. Nor must the hot casting uncovered too quickly, for there the imprisoned heat the central mass, acting against the chilled exterior the endeavor expand itself. So, heat necessarily controlled the start, also watched finally dissipated from the casting. That roll perfect and suitable for the class work meant for cannot fully determined until ma- chined. For this purpose centered, the riser cut off, and journals are turned, preparatory turning the chilled face. This done heavy, roll-turning lathes designed specifically for this class work. Equipment for Machining UCH lathe that Fig. This view clearly shows the setting-up for large roll which, while for calen- dering material other than paper, presents the same fea- tures operation. The journals are mounted very Fig. (Left) Open Bearings Support the Roll the Grinder, for Its Great Weight Holds Place The readings diameter the work progresses heavy steady-rests, that the chilled face, turned, run true with the journals. The lathe must also have the rigidity for resistance meet tool pressure and avoid chatter, for, instead the usual nosed turning tools, those used, shown work the front the lathe, consist broad flat plates. These are forced into the chilled face, cutting (or rather scraping) off sliver-like chip few thousandths This sounds slow; is. However, the resistance great, the surface hard—showing scleroscope reading 70—and, while not question tools standing under the heat cutting, one maintaining hard- ness against very hard surface and keeping the cut- ting edges from breaking down under the strain. There longitudinal feed. Four tools usually are used. When they have been forced enough reach the required diameter, they are moved other areas and the process repeated, until the whole surface has been gone If, turning, bad spot shows which cannot ma- chined out, the casting lost. For paper calender rolls, because the nature the work they do, must have per- fect faces, clear every blemish which would leave its mark upon the paper. Tonnage and labor mount high when unfortunate result loss happens, hence the great care that must devoted them. Fig. shows ten-roll high calender. This not picture the largest size, but large enough show —using the man the pit gage—the magnitude the machine, simple itself, but involved manufactur- ing There way for supporting the rolls except their The Iron Age, January 24, 1929—267 4q 4 t a fe . ends. Their weight carried upon themselves, culminat- ing the lowest and largest rolls. Hence there sag which must met grinding, get perfect contacts within small fraction thousandth inch across the entire face. Computations derived from investigation and experiment, based known characteristics the iron and depth chilled face, have given working rule for the primary determination amount curvature re- quired give true contacts. The 36-in. roll the eight- roll high nest requires 0.090 in. crown offset the effect the weight upon it. Grinding for Finished Surface finishing roll surfaces, the grinder shown Fig. been developed. built the Farrel-Birm- ingham Co., not only for its own use, but for paper mill service well. Rolls are carried their journals, two grinding wheels oppositely disposed traversing the face for finish, the same time forming the required curvature. This done ingenious device upon the wheel carriage, automatically feeding the wheels out, curvature may require. interesting note that the grinding wheels are mounted what known the swing-rest principle, whereby the two wheels are permitted swing unit laterally across the bed. This movement extremely small, but responsible for grinding the rolls accuracy within 0.00025 in. Any variation the aline- ment the ways, caused settling the bed the sun striking one end, overcome this swing-rest. Both wheels must act alike, one works against the other and equalizes the cut. more comprehensive view the grinder appears Fig. The roll in. diameter, carried open bear- ings; obviously, the weight great that there need for caps. Facility for lubricating the bearing pads unobstructed and heat reduced negligible amount, although some the rolls weigh much tons. the near end shown caliper for gaging roll. This instrument, rolled along the face, gives reading the diameter every point, and thus indicates whether the roll has the required view the caliper had Fig. where the operator gaging 18-in. roll. The arms carrying the gage points are divided inches and fractions along their length, the dial indicator the right measuring any variation. The caliper made aluminum and, being mounted rollers, moves freely; readings are quickly taken and any deviation immediately detected and can corrected once. When stack installed paper mill, new condi- tions arise. The rolls are revolved the 1000 surface feet minute; they turn each other fric- tional contact; this generates heat. the course few weeks some the rolls will show the effect the heat and irregularity creeps in. When the point has been reached where too great, the rolls must removed and re- ground. The lowest roll, being also the largest, does not suffer much, but due course time that also must gone over. Now all this work for the facing common- and vital production the printed page. When grasped that the 298-in. calender machine rolls out continuous stream paper, slit and wound leaves the rolls into four webs average newspaper size, nearly quarter mile minute, run later through printing presses approximately the same speed; sent its mission the carrier general intel- ligence, then the main discarded waste, will seen that the means the end are unusual, phases production; yet the usual, because demand has made everyday job. Chemical and Mechanical Methods Make Cast Iron Stronger chiefly with the metallurgical principles un- derlying the claims. put forward connection with certain recently patented methods producing improved gray cast iron give better mechanical properties and strength generally, Dr. Norbury discussed cast iron recently Manchester, England, before meeting the Manchester Metallurgical Society. largely upon the size and distribution the separated flakes graph- ite that the properties gray cast iron depend, the object many the new processes has been reduce the per- centage graphite present reduce the size the flakes. appreciate the significance these processes the graphical method showing the position the “chill line” given section casting was taken and related the percentages total carbon and silicon which could varied within practical limits, increasing the silicon augments the tendency the iron solidify gray, that can found within what range the resulting iron can produced with matrix which consists entirely the most desirable constituent “pearlite.” Pre-heating the Mold Various Ways Extracts were given from the various patents con- cerned illustrate the means adopted achieve this de- sired end. One stipulates the pre-heating the sand mold certain temperatures, depending upon the compo- 268—January 24, 1929, The Iron Age sition the iron and the section the casting, this way getting gray iron from metal the composition which would normally produce useless white iron casting. Other methods arriving the same result were pre- heat very strongly the iron the cupola, that the mold material was strongly heated, and the casting cooled slow- through the critical point after being primarily quickly cooled the mold. third concerned the pouring excess metal through the mold heat without high pre-heating, and thus save the sand from being eroded. order lessen the total carbon content, special meth- ods cupola operation had been specified, together with the inclusion large percentages mild steel per cent, the melted charge. Very high tensile strengths had been obtained this way. Addition Silicides Suggested order convert material which, when melted and cast would ordinary white iron, into one which when cast from the ladle was perfectly gray and machinable, various chemical additions had been projected, these being chiefly silicides, order bring about the desired change the state the carbon from the combined the graph- ite condition. Another mechanical suggestion put for- ward was the rapid oscillation the melted iron before casting from the jolting-box which was received from the cupola. q Chrome Plating Progress Continues Nickel Plating Methods Advance With Chromium Process —Constant Temperature and Current Density, Well Proper Polishing, Important UCCESSFUL plating chromium steel can accomplished only after the piece has first been properly coated with some other metal, such copper nickel. Therefore short sum- mary the advancement this part the industry necessary before discussing the progress chromium- plating, because shows how great part the introduc- tion chromium has played the notable advancement plating generally. Ten years ago plating was done almost entirely manually operated tanks. The plater memorized form- and each had his own pet theories. the plate began bad would treat with some chemical, and that did not cure the trouble, would try another, feeling that did good was worse off than before. the plater found chemical that corrected the trouble, concluded that was necessary add the plating bath, and this practice hindered rather than aided advancement. The “P. H.” acid concen- tration the plating bath was unknown. The effects rough deposits the porosity the nickel and im- purities the plating bath and the anodes meant noth- ing the plating industry that time. Plating was done entirely with per cent nickel anodes; today, anode manufacturers use per cent anodes mostly, and nickel salts must contain almost their full theoretical amount nickel. Solutions never were filtered, and roughly deposited nickel was common. The temperature the plating bath was estimated feeling the solution. The manufacturer was the mercy the plater. There was way telling how many pieces the plater was hanging tank one time, nor how long was plating piece. The plater removed the piece when thought was sufficiently plated. When had solution trouble and lost time trying adjust the solu- tion, was natural for him slight the time plating catch with his required production. This resulted very poor plate, and two parts had the same thickness deposit. Increased output better plated work, putting more nickel the parts, was impossible with the prac- tices then existing. Some new kind equipment had designed, whereby more parts could plated the same floor space then occupied the tanks, and new plating solutions had found that greater cur- rent densities could used and the same greater amount plate deposited less time. This led the development semi-automatic plating equipment and the use hot solutions with moving cathodes. The semi-automatic plating machine designed that the work loaded and unloaded the same end the *Mr. Phillips the factory-production engineering section the General Motors Corporation and Mr. Macaulay with the Oakland Motor Car Co. The article abstracted from joint paper “Chromium-Plating Progress,” sented the annual meeting the Society Automotive Engineers, Detroit, Jan. 15-18. equipment. The operator hangs the part plated conveyor which carries the piece around the tank through the solution definite time-cycle. Possibility cheating the time plating thus eliminated, and equivalent amount plate each part assured. One tank about ft. wide and ft. long does the work six tanks ft. wide and ft. long, with saving two-thirds the floor space. Using hot solutions and moving cathodes, the current densities were increased from amp, about amp. per sq. ft. and for the same amount plate the time plating was reduced per cent. These accomplishments meant much the industry, but many undesirable factors still existed where the man- agement depended upon the human element. All opera- tions previous plating were under the control the operator, who could slight any one them and thus produce inferior plate. inspection parts was made after buffing the copper plating and before plating; most parts were buffed through the copper plate and down the base metal. these spots, where only comparatively small amount nickel covers the base metal, that rust first occurs. With production steadily increasing and still greater demands for quality work, the industry sought another answer the problem. The full-automatic plating ma- chine, which carries the work from the final polishing op- eration through ten more consecutive operations cleaning, rinsing, copper plating and nickel plating, with- out having operator touch the work until after has been fully plated and ready for the nickel-buffing operation, was then developed. The time each opera- tion was predetermined, and could not varied the operator. This resulted uniformly plated article that had even coat copper underlying the nickel. ad- dition improved quality plate, production was in- creased and still greater saving was made floor space. Begins Chromium Plating Car Parts 1925 FTER considerable experimentation, the Olds Motor Works 1925 started regular production chro- mium-plated parts for decorative purposes. the same time other divisions the General Motors Corporation were developing chromium plate resistant wear the surfaces tools, gages and engine parts. With the in- troduction chromium-plated pieces for the decorative parts automobile, chromium plating progressed with unbelievable rapidity. Today, every automobile man- ufacturer ready chromium plate car parts. the early test work were able make satisfac- tory chromium-plating solutions dissolving chromium anhydride, water which had been added amount chromium These solutions worked only for short time and then more parts could plated with them. found, after many tests, that this was caused impurities; for the most part, chromium The Age, January 24, P j | sulphate. was then decided use chemically pure chro for the solution, price 74c. per sulphate content proved only one bles found that the temperature and cur- rent density used were exceedingly important factors. proper combination these two, provided the part had been properly cleaned and that the plating solution was 3 + with sufficien Unl niess the un- ] from slightly 4 hr¢ m im ali + ugh polish was nagnified the chromium, giving the part ap- pearance rather than the true blue white chromium, while poor nickel buffing produced spots. was nec- essary considerable experimental work find the proper anode use obtain the best results. The percentage sulphate the bath plays very important part the resulting plate, regard the color and the throwing power, that is, its ability plate into recesses. sulphate determination the laboratory takes hr., production department would From the production standpoint, the correction can made only one way; that is, the trial-and- error method. Temperature and Current Density Conditions Important Obtaining Bright Plate obtain consistent results the temperature and the current density must maintained constant. Increasing the amount current the cathode produces satin matt finish, while raising further will produce flaky, bright plate obtained only under certain conditions temperature current density. the temperature all parts the piece the bath same, the parts low currer density urrent density may the current lowered the resistance lowering the volt- age decrease burning the high-current-density areas the protruding points, the low-current-density areas may not plate. From this can seen irregu- larly shaped object, one containing holes indenta- tions, difficult plate. This now partly overcome shading the high-current-density areas with screen and raising the current density sufficiently plate the low- areas recesses. Too high temperature gives bluish soft plate. All chromium-plating solu e within 2 do. ain tne temperatu Unless the underlying nickel-plate good, the money spent chror plating goes for nothing; the nickel very likely peel after minute less chromium plating. chromium plate piece less than 400 amp.- nin. with efficiency not than per cent seems slighting the job, because will not stand the polishing that some over-zealous car owners may give it. The only excuse for plating less time obviate peel- the nickel, which, properly ated, would not peel min. chromium plating. But has been definitely proved tests that any plate more than 500 amp.-min. weakens, rather than improves, the chromium-plate re- > + netineg sistance to rusting. Proper poli the secret successful plate, ish better than the finish given the base metal. eliminate the polishing costs would de- crease the total finishing cost about per cent. This the aim all manufacturers and they have met with success some instances. One large company presses the parts from highly polished steel, keeping the dies such condition that polishing required after forming the piece. Great advancement has been made polishing methods through the adoption automatic polishing-machines, and even greater accomplishments will made the coming years. Successful polishing, however, has its beginning the drafting room, the cost polishing depends largely upon the design the piece. Wheels very large diam- ter are more economical than those small diameter. should designed, therefore, eliminate all unnecessary projections, depressions, angles, recesses reverse curves, which can polished only with narrow, small wheels excessive cost. the polish- ing department the finishing department, the piece must good condition when comes into that department. Dies should kept condition eliminate scratches and deep marks. Low-Carbon Steel, Fully Annealed, Used Anode e The part polish solution has been subject much discussion. Chromium, iron, steel, lead, aluminum and various other anodes have been recommended for regular production work. found chromium unsatisfactory, because went into solution, thereby increasing the resistance. Aluminum also was unsatisfactory, rapidly attacked the platin bath. Lead and steel were both satisfactory; but, the latter the metal generally used for the tank, was more satisfactory because the tank could made the anode. Lead, after being used anode production tank, covered with coating lead chromate. This causes resistance the flow current and thus lowers the cathode efficiency. Considerable experimental work indi- cates that the type steel best suited anode one low-carbon content, fully annealed. Alloy steels, such silicon and chromium steels, are soluble and therefore are not satisfactory. Production Inspection Plated Parts Requires Good Lighting Proper inspection chromium plating important. Methods vary different plants, but the main problem how make certain that the part has been completely chromium plated. This can determined the labora- tory various methods, one which place the chro- mium-plated article acid copper-plating bath where copper will deposit all exposed nickel surfaces and will not deposit the surfaces covered with chromium. An- other subject the piece atmosphere hydrogen- sulphide gas; all nickel surfaces will then immediately show black, the chromium remaining unaffected. But laboratory methods cannot used for production inspection. The only way the surface can inspected for coverage visual inspection and, this depends for its success largely upon the lights used, important that the part uniformly lighted that the slight color- differences nickel and chromium can distinguished. Daylight ideal, but most factories are constructed that the use daylight impossible and necessary use artificial light. The Society En- gineers recommends that half-cylinder, in. long and in. diameter, painted flat-white inside, suspended from the ceiling. The interior lighted from small cave, containing 200-watt daylight lamp. The cut-off the trough falls inside the drum. The claim that the slight color-differences between nickel and chromium can thus detected. Mechanical applications chromium plating have been Today chromium used plate such growing rapidly. 7 { the nickel would pulled from the part. learned proper cleaning the nickel was essential, because, It the SOLULION Was lOO ainaiine, enromium burnt deposit, else peeled entirely. decided that ii Wwe ever cnron piace Lo Lie puUosoue we would have better polishing work the base metal 7 tne 270—January 24, 1929, The Iron Age parts plug gages, thread gages, snap gages, broaches and steady-rest rollers, obtain greater resistance wear. plating plug gages have found the life the gage increased least three times that ordinary gage. the case thread gages the life has been doubled. Broaches used broach the babbitted end connect ing rods have been chromium plated, and have been able produce more than five times the number rods per broach that can produced with regular production broach. This branch chromium plating, well that for decorative purposes, just its infancy. Further uses for chromium are becoming evident daily. Some the best electrochemical engineers the country are devot- ing their time almost entirely solving the many prob- lems. With the spirit cooperation and the friendly ex- change findings that exist the plating industry day, contrasted with the secret art but few years ago, hope see quick solution many these plating problems. All-Welded Storage Tanks Temporary Cleats and Dogs Used Force Snug Fit Between Mill-Run Plates During Erection 60-Foot Gasoline Tanks GROUP all-welded gasoline storage tanks have recently been erected Australia Robert Bryce Co., Melbourne. Sizes range from ft. diameter ft. high, ft. diameter ft. high. Tops are flat and water cooled. Plates were ordered maximum length avoid transverse seams, and range Fig. Method Taking Bulges Out Bottom Plates Upper Course e/d Wedge cenvjTers Us le US Welds Corners Welds Fig. Erection Methods Side Plates 1 thickness from in. in. in. plate. All lap joints are im. and erection holes were use According information Engineer, Dec. 21, some the %-in. bottoms had lap joints welded top side only; others had tack welds in. ters the under side well. For the first clas all the plates were assembled the sand undation, series tack welds joined all seams. Where one the other plate occurred, the two were drawn together use wedges between dogs and roof beams, placed shown Fig. and temporarily welded Where was necessary tack weld the under side the seams, erection and tack welding was done in- clined platform about ft. wide, and each seam was finished the was pulled away distance the width one plate, thus allowing the completed portion settle down the sand foundation. The bottom was cut some in. large diameter. after erection the sides the weight did not force snug fit the bottom seam, temporary cleats and anchor bolts were used, shown the lower part Fig. This sketch also indicates how the successive rings side plates were erected resting the upper ones series a } service dogs about in. apart. Proper curvature was maintained service ring, made six sections, placed temporarily the inside the joint. All outside circum- ferential joints were welded continuously the down position. After the erection dogs, wedges and rings were removed, and light fillet was run (in overhead position) all inside laps insure oil tightness. shop work any sort was done the plates roof beams, except bending the curb and service angles. Two the 60-ft. tanks were erected four months the following crew: one two welders, four iron- worker assistants. Total weight these two tanks was 180 tons. Welding was done the process, using the quasi-are covered electrode. Welded Tank Bottoms for Oil Storage Oil storage tanks 150 ft. diameter are now built with welded bottoms and roofs, according Moore, Union Oil Co. California, Los Angeles, writing for Welding Engineer. Bottom plates are laid directly the grade, edges lapping least one inch, and “tack-welded.” The tank circumference then marked off and projecting corners cut with oxy-acetylene torch. Over-lapping seams are also trimmed back short distance sufficient form butt-joint under the curb angle. This method avoids all shop fabrication, well erection horses. The curb angle then placed around the edge the tank bottom; after one two side courses are erected the angle forced down the bottom plates the weight when continuous fillet weld run around the outer flange, with 2-in. welds 12-in. centers the inside. squad welders then starts the bottom; beginning the middle they first work outward make all seams, the work being organized that the men are located symmetrical positions. Testing done pumping light oil 6-in. head under the bottom. The Iron Age, January 24, | Wedges Pant R “ Tack Weld "VO", CUT DiaTeé | . | > | Bottom which onveyors Reduce In-Process Time Lawn Mower Maker Uses Roller and Belt Conveyors for Inter-Department Hauls and for Loading Freight Cars HAT mechanical handling devices can adapted the needs the small metal-working plant manufacturing Packed Cases Reach First They Are Transported Roller and Booster Belt Con- veyor Running Just Below the Ceiling Roller Conveyor Parallels Wall Plant (right), Adjacent Railroad Switch Track. Packed cases are de- flected into freight cars spurs run- ning through hole wall build- ing (middle background). Note that the conveyor high enough per- mit working headroom below 272—January 24, 1929, The Iron Age operations are compactly arranged has been the experience the Lawn Mower Co., Richmond, Ind. The amount space required make large quantity lawn mowers small com- pared with numerous other products, that the elimination waste factory floor area somewhat simplified. Even so, this company has found that the greatest econo- mies can attained utilizing for certain hauls, the in-process time hav- ing been thereby substantially reduced. the company’s machine shop, which the first floor, tools have been placed close proximity, that the easiest way get castings from one operation the next container located behind his fellow worker. However, when the end the machining line reached, necessary take cast- ings tote boxes the mower assembly department the second floor. This . | | ] ‘ 4 « - @ 1 ASTINGS Are Car- ried Tote Boxes (above) from Machine Shop Assembly Department Conveyor Apron Conveyor. Note hinged section form- er, which can raised permit passage along aisle Packed Cases Mowers Are Lowered from Pack- ing Department Third Floor Spiral Roller Conveyor (right), which delivers first floor accomplished means short roller conveyor discharg- ing inclined apron conveyor leading from the first floor the second. Since the roller conveyor crosses aisle just before connects with the apron conveyor, has hinged section, and counterweighted that can raised easily. similar inclined apron conveyor elevates the assem- bled mowers the packing department the third floor. After they have been packed, for shipment customers, the packet cases are lowered means roller spiral conveyor point just underneath the ceiling the first floor. Here the conveyor runs for short distance sufficient height avoid interfering with the maximum use the floor space. feeds booster belt con- veyor, which discharges the packed cases roller conveyor running right angles the belt conveyor and extending the length the plant just inside the outer dentally, this conveyor high enough allow the space underneath used for manufacturing purposes. The conveyor line parallels the switch- ing tracks the Pennsylvania Rail- road, and intervals along the line spurs lead through openings the wall the building, that packed cases can deflected directly into waiting freight cars. The cost handling steel bar stock from railroad cars stock bins has been through the operation overhead monorail conveyor, from which sus- pended hoist with pan basket hooked it. The portion the mono- rail conveyor extending outside the building movable that can run into railroad cars when necessary, and can placed alongside the factory wall during idle periods. The con- veyor inside the building extends over eight stock bins, its total length being approximately ft. The conveyor pan basket can raised lowered the hoist. Symposium No. has been issued the National Slag Association, Cleveland, citing data and opinions authorities supporting the proposition that iron steel contact with crushed blast furnace slag, embedded concrete made with slag aggregate, experiences undue corrosion. The Age, Jaruary 24, | j 4 ‘ i | Leaves from the Foundry Apprentice — FROMMELT* June 1.—Have been transferred for few days the sand control department. One the regulars off sick leave. June sand?—Well suh, It’s jes cratic dirt,” according the big darkey the sand muller. But he’s mistaken; it’s educated dirt. Why all the attention requires—more than six months old darling being made ready for prize baby contest. sand engineer,” the old darkey goes on, “jes much water, pinch new sand—that’s for the ‘voids’ the Big Boss seys—you all knows what they mean; the hollow places between the kernels—and little dash this heah clay make her strong and robust like; suh, I’se sand engineer. Without they couldn’t make good castings.” that guess the old smoke isn’t far from being right. any rate when the sand goes into these molds, all over this shop, they know just what and how will act. there special pour, big, heavy casting and all that, the sand mix changed. These few days have given far more respect for foundry sand than ever had before. June 10.—Back the training bay again. Just com- pleted set tools now; two nice slicks, several gate cutters, set lifters, swab, level and few mis- cellanies. Now let one those grease balls from the machine shop call sand rat! Why, you’ve got several different kinds mechanic and engineer June 15.—The old dispatching system continues click without miss. Today, according schedule, had the first the illustrated technical lectures. was part the series “The Making Iron and Steel.” got down the blast furnace operation. The slides were wonderful; good views the iron mines Minne- sota, the mining operations—who would have thought iron ore shoveled off the surface?—the loading into Great Lakes ore boats and the unloading Gary and elsewhere. was wonderful half hour; but now for the report. glad Jack put wise taking many notes could possibly jot down. June bitter lesson experience. scrap casting today because thought was saving little, parting sand. Somehow never really did under- how and the why parting sand. But now—and how! June the meeting the association tonight the savings plan was started. signed have dollar deducted monthly. After the first payment made interest the whole share begins our favor. know now what par value means; this stock sells Wall Street for $15.50 and steadily advancing. The par value $10. must watch the quotations the daily paper. beginning feel like relation the Big Boss. June 27.—And who wouldn’t know how stick nails into sand! here say that there are nail stickers and nail stickers and belong the last and lowest the two. nice big overhanging lip sand would not stay stuck with the nails rammed straight and, *Consultant, St. Louis. 24, 1929, The Iron Age course, there was dirty spot the casting. the next one the foreman gave lesson pinning sand. June 30.—Took course foundry beauty culture today. Lifted the faces molds. finisher excellent sledge hammer artist. July 7.—Still doing the beauty stuff second molder pretty big job—some guide vanes for medium- sized water turbine. Aug. 3.—Six months the training bay ended July Right the dot was transferred the core room. Jack says good idea keep your patience tucked away under your galluses they happen run over the schedule few days. But this sure business-like outfit around here. They have lived their end the contract great shape, far least. Aug. 5.—I thought these little stop-off cores were noth- ing but pastime for kids. didn’t earn dime today for the company. Tray tray had ditched because fingers are clumsy thole pins. And yet got raise July 29, written the contract. Just about the time got earning some money for the company making ordinary castings, transferred over here where huge liability. This training must cost the company some money. Aug. 10.—Mr. Blakely, the core room foreman, ex- plained some the difficulties have been getting gray hairs over. Oil sand cores, paste flour cores, and their uses. often wondered why linseed oil cores were used molds that stayed over the floor day two before pouring. Oil, course, moisture proof. And that explains another point. Molds that lie over night must examined for moisture the chaplets and other parts. The hot steel forms steam, which will probably cause blow-out least blow hole. What little moisture mold will do! Aug. 12.—Have been ramming some pretty good- sized cores. cannot understand why some those long round cores are rodded the center and some are not. shall have find out tomorrow. mix some the core sand today. And now have pretty good idea the amount oil “glutrin” used the sand. Aug. 15.—This interesting department. never thought all the tricks core can play the wrong time. You have pretty clever ventilation engineer for these temperamental cores. Naturally the gases formed when the steel flows around the sand must given good exit. mold certainly complex chem- ical laboratory once the hot metal poured in. had chance see the elaborate system necessary keep track the core boxes, their parts and the patterns which they belong. library has nothing them for the indexing they here. 29. New Alloy Structural Steel Germany new structural steel has been suggested Ger- man metallurgist. copper-chromium alloy steel. According Dr. Schulz recent issue Stahl und Eisen, steel containing 0.50 0.80 per cent copper, about 0.40 per cent chromium, 0.15 per cent carbon, 0.25 per cent silicon and 0.80 per cent manganese possesses all the valuable properties per cent silicon steel for structural purposes, even rolled into the heaviest shapes widest universal flats. The author mentions that its preparation unattended the difficulties met with casting and rolling the silicon steel. Physical properties the new steel are about tons (75,000 81,500 per sq. in., yield point 23.50 27.50 tons (51,800 60,600 lb.) per sq. in., elongation per cent and reduction area per cent. The steel easily welded and resists corrosion far more than copper-bearing carbon steel. — 7 | 7 BOOK REVIEWS Turbine Construction and Operation Analyzed Steam and Gas Turbines. With Supplement the Prin- ciples the Thermal Prime Mover. Dr. Sto- dola. Authorized translation from the Sixth Edition. Dr. Louis Loewenstein, Two volumes. Pages, 1356; illustrations text, 1565; folding charts, Published the McGraw-Hill Book Co., New York. Price, $15. guide the study turbines all kinds, well help their practical construction and operation, this work valuable addition thermodynamic literature, well engine construction, maintenance and opera- tion. For comparative purposes record progress, and, for present use, reliable aid. The fundamental laws are consid- ered, with special reference entropy. discussion the flow elastic fluids, first fluids channels with straight-line axes, particular attention given friction losses the channels themselves and nozzles with vari- ous changes cross section. The graphical representa- tion the entropy diagram the work done friction and the kinetic energy loss especially interesting, are the paragraphs concerning the efficiency expansion the beveled part the nozzles and the clearance. this section are important details relating curved channels, namely, buckets. The friction losses bucket channels found Stodola himself, well others, are tabulated. The flow through clearance and labyrinths taken up, and proper attention paid steam friction and rotation losses turbine “wheels.” The general rules concerning efficiency, both and mechanical; the impulse and the axial pressure principles; preliminary descriptions principal turbine types, and the theoretical and actual bucket heights are taken sequence. Axial turbines come for section treating single- stage and the multi-stage impulse turbines and the reaction type, both few-stage and multi-stage. Radial turbines are given comparatively little space, but the fundamental equations for the uniformly rated channel one type are available for reference. The behavior the steam tur- bine under changing conditions operation gives the key the solution many difficulties, especially those con- cerning efficiency turbine operation. The section the construction the most important turbine parts thoroughly complete. Marine turbines and those for spe- cial purposes are each given chapter, and condensation takes the entire range from the ideal type through surface and jet condensers and their accessories. Spe- cial problems steam turbine theory and construction are well handled from the theoretical point view. treating the gas turbine, the author ranges from the theoretical gas turbine and exhaust heat economizer, along the line experimental and actual gas turbines. Descriptions the various types are included, and some pages are devoted the centrifugal compressor and the phenomenon loss contact. The supplement the prospect the thermal prime mover somewhat optimistic, but highly interesting, taking the highest possible conversion into work, the basis the second law thermodynamics; the cal- culation the maximum useful work Nernst’s law, and consideration the proper process for the most favorable heat conversion into work both steam tur- bines and internal combustion motors. review the present state development the piston engine, the gas turbine and the turbine concise, thorough and fair. Electricity from coal and gas batter- ies finds place, and there good section the best results attainable present well known means. The author congratulated having been properly represented, and the translator having given his profession standard work. Robert Grimshaw. Time and Motion Study Analyzed and Applied Time and Motion Study and Formule for Wage Incen- tives. Stewart Lowry, Harold Maynard and tions, Published the McGraw-Hill Book Co., New York. Price, $4. The economic necessity for measuring time and motions and cutting out the unnecessary shown the authors this book. They lay down the qualifications time- study man, give hints analyzing and standardizing the job, describe the necessary equipment and aid the beginner classifying the skill and ability each worker and the amount effort that devotes each operation. The necessity for more than average ability, intelligence and system the time-study man’s part demonstrated concretely and also the proper computa- tions make and how make them. this connection the determination preliminary standards leveling, the need for allowances and how make them, and the distribution set-up time over various manufacturing quantities pieces for each operation are dealt with. chapter the study existing conditions gives several examples the use time study, among them being the making reinforced concrete slabs, cleaning alloy castings, de-taping armature coils, crating articies and using band saw. Subsequent pages deal with the study and the principles formula construction, far the latter practicable; tabulation; classifying opera- tions, and determining constants and values where analy- sis difficult and necessary. Many concrete examples time and motion study are included the book, and formula for metal ratio very interesting. The group system advocated for train- ing new men, although well suited some cases, cannot applied advantage many others, this depending whether the job one which several men perform the same operations. However, the authors have filled one the real needs the literature industrial engi- neering and the reader should able adapt indi- vidual cases the principles outlined. Problems the Forge Shop Elucidated Lectures Steel and Its Treatment. John Keller, Engineering Extension Division, Purdue University, Lafayette, Ind. Pages 267, illustrations, 166; in. Published Evangelical Press, Cleveland. Price, $3.50. Professor Keller has characteristic way presenting metallurgical information. man unbound academic tradition, discusses puzzling things which occur the shop language which shop men generaily understand. Having worked the forge shop himself, realizes the difficulties which actually occur, talks about the horrible examples shop practice, and generally bares skeletons The Iron Age, January 24, ‘ | q q | : which are uasuspected discreetly curtained more conventional literature. scientific investigator might not approve some the explanations. would easy criticize many expres- sions. But the critic would have difficulty presenting more plausible theories equally understandable word- ing. has been said that the practical man much theorist scientist; only his theories are nearly always wrong. Professor Keller not that kind prac- tical man. But does cling his beliefs with great tenacity. For instance, persists thinking that wrought iron chain, embrittled heavy duty, has coarse grained metal its links, beeause, when broken, its fracture shows “large shiny grains, self evidence that the entire link coarse grained.” must know that several investigators have found the microstructure such “brittle” links show larger grains than after the chain has had its ductility restored annealing. Perhaps the microscope, which called upon him explain many things about metal, must take secondary place the evidence fracture, when the two are apparently contradictory. all odds, the most authoritative and valuable por- tions the book are those which treat forging, heat- ing, quenching and annealing practice and the reasons for warping, cracking and shrinkage metal after heating— the problems the forge shop. These portions the book give unique value all readers. order round out the series lectures (which have been given many industrial centers during the past few years), such sub- jects steel making, thermal analysis, and physical test- ing are also included. These portions will most valu- able introduction scientific metallurgy for those who have never studied physics Foreman Training Conference Method Foreman Training. George Mellen. Pages 150, in. Published McGraw-Hill Book Co., Inc., New York. Price, $1.75. Prepared for the Department Engineering Exten- sion Pennsylvania State College result the growth foreman training the conference method, this text provides concise and definite guide and manual for this important phase industrial technique. Much has been written the conference method foreman training, particularly the form papers before trade and technical associations, but the tendency literature this kind has often been emphasize specific applica- tions based the writers’ individual experiences. The technique set forth this book has been developed from the results foreman training conducted more than hundred industrial plants, and may therefore consid- ered broadly applicable varied manufacturing plants. outlining the purpose foreman training the author states that the object “not impart technical information concerning the job, but rather, develop the part the foreman correct perspective his rela- tions the men under his control and the manage- ment.” More specifically lists the objectives fore- man training follows: assist developing latent leadership the foreman. emphasize the importance dispensing supervisory justice. aid the foreman studying and analyzing his job. enable him see the plant whole and his own immediate place the picture. prepare him for positions greater responsibility they become available. assist him the better understanding human relationships industry. develop the importance teaching one the duties. assist him lowering costs. 276—January 24, 1929, The Iron Age Before taking the specific duties, responsibilities, the author prefers call them, the foreman, Pro- fessor Mellen analyzes the job considered thing itself and its responsibilities and authority. then takes production and cost responsibility, maintaining that, within the limits his department, each foreman has the same objectives the general manager the plant. His entire responsibility secure the required amount production standard quality specified time and the lowest cost consistent with the general policies the organization. the succeeding chapters are discussions the various responsibilities the foreman including cooperation, discipline and morale, interest and satisfac- tion, handling men, supervision and leadership. The book adequately indexed and each chapter briefly summarized the end, making well suited for classroom use. New Books Received Mechanical Power Transmission. William Staniar. Pages in., illustrated. Published McGraw- Hill Book Co., Inc., 370 Seventh Avenue, New York. Price, $5. Laws Management Applied Manufacturing. Alford. Pages 266, in., illustrated. Published Ronald Press Co., East Twenty-sixth Street, New York. Price, $4. Human Engineering and Industrial Economy. Law- rence Hartley. Pages 344, in., illustrated. Published Marshall-Jackson Co., Chicago. Price, $3. Enamels: Their Manufacture and Application Iron and Steel Ware. Laurence Mernagh. Pages 234, P