The Iron Age 1929-01-31: Vol 123 Iss 5

ESTABLISHED 1855 THE IRON AGE New York, January 31, 1929 VOL 123, No. 5 All-Metal Airplanes Production Ford Tri-Motored Transports Are Now Proceeding Along Their Assembly Line the Rate Three Units Week ASS production huge airplanes was achieved 1928 the Stout Metal Air- plane Co. (division Ford Motor Co.), its plant the Ford Airport, Dearborn, Mich., miles from the heart Detroit. Concentrating but one only two sizes, and working two 8-hr. shifts, five days week, this plant turned out one complete Ford tri-motored Transport every second working day toward the close 1928, and now completing three planes week five working days. Without adding the present equipment the plant this production speed can stepped one plane each working day, five planes week, soon demand calls for such production. Popular demand has played important part They had been the air total 11,986 hr. GRODER bringing about this mass production. Four years ago the Ford tri-motored transport was custom-built job. Early 1925, Ford transports began flying regularly sched uled daily flights, carrying freight between Detroit and Chicago and, few months later, between Detroit and Cleveland. Two years later the Detroit Buffalo freight route was established. route was discontinued July 19, 1928, but the Chicago and Buffalo routes have been operated regularly since their inception. Jan. 1929, these planes had flown 1,060,175 miles, average speed miles hour. min., and had transported 6,444,073 freight. Stout Air Services, Inc., independent air transpor “¢§ Putting Finishing Touches Ford Tri-Motor Transport Built for the Byrd Antarctic Expedition The Detroit Cleveland | > « > 7 327 tation company ing passenger ter- minal the Ford Airport and using Ford tri-motored transports exclusive- ly, now carrying passengers two daily round tween Detroit and Cleveland and one daily round tween Detroit and Chicago. ‘The Cleve- land route was opened Nov. 1927, and the Chicago route one year later. Jan. company ported 19,005 passen- gers over these routes, from city city. Ever since May 1927, the company has been conducting its daily aerial tours, 25-mile “sight-see- ing” trip around De- troit. 1927, 6412 passengers took this trip, and 1928, 40,- 151 passengers. Since May 1927, the Ford transports owned Stout Air Services. TING Tip Assembly, Showing Duralumin Sheeting Added After Fore- have traveled and-Aft Cantilever Trusses Are Built into Skeleton Wing, Knitting 379.107 miles and Main and Auxiliary Spars. are flat duralumin sheet, with irregu have carried 65,568 and add strength and passengers. Public confidence commercial aviation has grown and growing. Public service corporations and private companies are buying planes for commercial purposes. Already railroads the Northwest have regular passen- ger planes operation between Chicago and Minneapolis. The Stout Metal Airplane Co. working order for ten Ford transports used the proposed rail-and-air route between New York and Los Angeles, which being developed Transcontinental Air Transport, Inc., con- junction with the Pennsylvania Rail- road and the Santa Railroad. Pull- mans night and Ford transports cut down the time for this 3100-mile trip less than hr. specially built trans- port, luxuriously fur- nished, was delivered last November this company, used traveling office Col. Charles Lindbergh and Maj. Thomas Lanphier ground layout work, such the selection and purchase able airports, inciden- tal the establish- ment this rail-and- air route. Everywhere new commercial air routes are being established are being planned. Commercial aviation fact, although yet The two trusses nearest outer end its infancy. has lar flanged holes, reduce weight increased the demand compression for large passenger and freight planes and has made possible their manufacture production methods akin those employed large automobile plants. Such methods are now employed the manufac- ture the Ford tri-motored transport. Manufacturing Space Without Columns The main building the Stout Metal Airplane Co. Dearborn 500 ft. long and 120 ft. wide, hangar con- che Stock Roon Production Plant Where Ford Trans- ports Are Made. The assembly line starts with three jigs for assembling fusel- age frames. Proceed- and the skin put and engines assembly pleted; soon the wing tips are attached the plane moved ahead for final adjustments, and thence out the jigs for assembly various ent parts 328—January 31, 1929, The Iron Age 7 7 struction, having center columns, the entire roof being sup- ported canti- lever trusses. Two series saw-tooth ventilator trusses, one either side the ridge and run- ning nearly the full length the build- ing, afford daylight and fresh air. Another building similar construc- tion, 120 ft. 300 ft., runs line with the main their end elevations facing each other, 100 ft. apart. Joining these two buildings with addition 100 ft. long would and would result single building 900 ft. long 120 ft. wide, with center columns. The smaller building now used warehouse and showroom for com- pleted planes, and hangar the many that land and take Been Put Together Separately Other Jigs. Later the group three assembled, with two other groups, into the complete fuselage off from the 719-acre floor jig nearly ft. long. This shows clearly the variety structural plane because has direction, all contrib- uting the comple- tion the finished plane. The greater por- tion the materials entering the westerly end the building consists crated duralumin sheets, the metal used through- out -the skeleton framework the fu- selage and wing the sheets clad,” the new alum inum-coated duralu- min, which for the outer cover- ing, “skin,” fuselage Both metals are sup plied the Alumi num Co. Amer ica, Metal was decided upon the basic terial for the Ford transport because its fact that its capabili ties can predeter mined with accuracy. Ford Airport. shapes used making the fuselage frame the tensile strength Practically all mild steel and the materials entering into the construction the Ford only one-third heavy. aluminum alloy having tri-motored transport, except the motors, enter the main nearly per cent copper and 0.60 per cent man- building, production unit, its westerly end and are ganese. Here typical chemical analysis: placed the stockroom, which runs along large part per cent the westerly wall the building. the other end the Luilding, 500 ft. away, completed planes pass through per door, ft. wide, into the open air. Between the stock- Iron ... 0.43 per cent room and the 90-ft. door there steady flow ma- Silicon per cent terials, parts, sections, sub-assemblies, easterly “Alclad” duralumin the same composition, coated The Iron Age, January 31, both sides with thin layer pure aluminum, which rolled the sheet the mill. The object the aluminum coating render the sheet impervious corrosion. The plane with outer covering “Alclad” needs paint, the surface will retain its silvery sheen for indefinite periods, even though subjected the worst weather conditions. Some slight tendency corrosion has been indicated uncoated duralumin when has been subjected accelerated salt spray tests. For this reason the duralumin used the interior structure the wing and fuselage skeleton treated with two rust light-weight varnish, after the struc- ‘oats SSEMBLING Tail End Fuselage Frame (below) Jig This skele ton supports the sta Angles. section the bilizer, elevators, fin, rudder and the steel cables effect the adjustment, froth the cabin, end control surfaces ture riveted together and before the “skin” applied. Alclad and much the duralumin used the Ford transport comes crates sheets each, ft. long in. wide and 0.012 in. thick. Corrugation re- duces the Alclad sheets in. width, which has been found the most convenient size handle sheeting the plane. Some the heavier duralumin sheets used for structural shapes the framework the plane, such 0.020, 0.035, 0.049, 0.065, 0.083, 0.095 and 0.120 in., come sheets ft. long and in. wide. The two larger sizes are used the uprights the bulkheads which em- brace the cabin, and the upper and lower chords the center section the wing spars. 330—January 31, 1929, The Iron Age Sheets leaving the stockroom enter into the work are heat treated, before being corrugated worked into structural shapes used the framework. Brought temperature 950 deg. Fahr., they are quenched water; the duralumin must then worked into the re- quired shapes within one hour the effect the heat treatment lost. The Alclad sheets are corrugated standard machines built George Ohl Co., Newark, J., but the dies are special make, because the peculiar content the duralumin the base Alclad. Many the small structural pieces required the canti- lever construction spars are cut size before being SSEMBLING the Fin Wooden Jig (above). When completed the fin’s longest dimension, here shown the top, will riveted down the top the fuselage the extreme rear above center Upright channel running right angle base channel will carry two the three forged steel support the rudder and act hinges for shaped presses standard hand brake machines made Dreis Krump, Chicago. Even the rivets used throughout all joints and laps the fuselage and wing are heat treated and quenched before being driven. The rivets are all made duralumin, are all round headed and come only three sizes, 1/8, 3/16 and 1/4 in., lengths varying from 1/2 in. odd practice followed here driving rivets apply the pneumatic hammer the head the rivet. The dolly bar held against the other end the rivet the up” has its face three countersunk impressions which correspond with the three sizes rivets used. Applying the proper size the rivet being driven, the “bucker up” shapes his end resemble the head. This insures uniformity appearance greater strength the rivet. Almost half the floor space the main building, that is, the bays (of 25) nearest the westerly end, occu- pied the stockroom, cutting, corrugating and forming machines and sub-assemblies fuselage frame bulkheads. Most this space given over upright jigs built angles welded together, which the separate bulkheads are assembled and riveted together. There are OMPLETED Wing Tip Sec- tion Main Spar (below) Its Assem- bly Jig. Upper and lower U-shaped chord members are first as- sembled chord as- sembly jigs. chan- nel beam riveted in- side the full length the U-shaped chords, greatly increas- ing strength and rigidity, visible the lower chord near end. Cantilever construction the lines the regu- lar Pratt truss, hence the spars are “built like steel NTERIOR Com pleted Wing Tip (Left), Showing Can tilever Construction Main Spars and Fore-and-Aft Trusses, “Built Like Bridge.” Counting from left, the second, fourth and sixth spars are main spars, which carry the weight the wing tip. The five auxiliary the outer covering “skin” place 2 TABILIZER (Above), Covered with Being Assembled Jig. large and heavy beams strength and rigidity Forged steel fittings protruding through stabilizer the fusel- age. Note duralumin shapes used War ren truss The Iron Age, January 31, bulkheads the fuselage, all different sizes and shapes. These are made small quantities, several days’ supply being kept hand ahead immediate needs. this section the building there are also sub- assemblies, where small groups bulkheads are placed jigs and riveted together into sections which will become parts the fuselage frame. Bulkheads Nos. and numbering from the forward end the plane and em- bracing the cockpit and the forward end the cabin, form one group. Numbers and form another group and the last four bulkheads the tail the plane form the third group. When these three groups are com- pleted and moved into their next position they start their journey the final assembly line. (To concluded) Torsional Modulus Various Metals } ESULTS of tests on the “Torsional Modulus of Carbon Steel, Phosphor Bronze, Brass and Monel were given paper W.-P. Wood, associate professor metallurgical engineering the University Michigan and consulting metallurgist with the Cook Spring Co., Ann Mich., presented the convention the American Society for Steel Treating Philadel- ia, Oct. 12. Abstract the paper follows: The term modulus elasticity” defined and its general relation the modulus elasticity tension and compression discussed. review the published work the determination the torsional modulus made and values this constant for steel determined other investigators are given. Four methods determining the torsional modulus are available: (a) The direct method, (b) the spring deflection method, (c) the torsional pendulum method and (d) the elongation method. the present investigation the de- flection method was chosen, dead weights being used for loading and cathetometer for measurement deflections springs. The modulus calculated from these data inverting the usual spring deflection formula. Several Metals Studied Modulus determinations were made upon three types steel, phosphor bronze, brass and metal. Varia- tions all the factors appearing the usual spring formula were made, determine whether not they influenced the determination the modulus. was concluded that they have little influence. Results are given the form averages many tests and grand average value for each metal studied included. That for steel was found 11,454,000 lb. the sq. in.; for phosphor bronze, 6,330,000; for brass, 1,950,000; for monel metal, 8,003,000 Ib. Other Values Used Practice Miss Frances Clark, vice-chairman the session, read, the absence the authors, two written discussions regarding the determination the modulus. Mr. Stewart, William Gibson Spring Co., Chicago, uses 11,500,000 the modulus value for drawn steel wire, 6,250,000 for phosphor bronze, 5,000,000 for brass and 9,200,000 for monel metal. believes that the modulus elasticity the most constant all the properties use han- dling metals. Because the many adjustments which have made it, Joseph Wood, consulting engineer, New York, the second communication, referred the cathetometer instrument into the use which the personal equation enters unusual degree. stated that Professor Wood’s method determination not entirely general its application. The “constant” 3 4 his *equation not applicable all cases. measuring square wire, for instance, instead round wire, there distortion the square section when the spring flexed. About ships 1000 tons displacement heavier were built and equipped with Diesel engines annually the British Isles from 1924 1927 inclusive. During 1928 the number jumped 73. diameter of wire in in V is number of active coils. » 4 ¥ — - ~ | + 3 § as ITUATED advantageous position, this traveling gan- try crane the plant the Rockwood Mfg. Co., Indianapolis, manufacturer paper pulleys, used for unloading scrap, pig iron, coke, sand and coal. The coal hoppers for the gravity feed the boilers the power house are directly under the bucket, shown the illustration. The cupola treme left the photograph. Still further the left are the coke and sand bins (not shown) 332—January 31, 1929, The Iron Age 7 4 4 3 wt 4 — = 7 rends Engineering Alloy Steels Lower Carbon and Higher Alloy Content Insure Adequate Strength with Greater Toughness and Simpler Heat Treatments Possible ONTENDING that there present lack balance between the carbon and alloy content many the present-day alloy engineering struc tural steels, MacQuigg, director research Union Carbide Carbon Research Laboratories. Long Island City, Y., addressed the Hartford Chapter American Society for Steel Treating its January meet ing, Tuesday evening, Jan. 15, Hartford, Conn. His subject was “Some Present Trends Engineering and the following notes cover leading points the Alloy steel business this country has been greatly fostered the developments naval armament, beginning say, the late 80’s and extending through the period expansion the American Navy. Since the turn the century, the greatest impetus has derived from the de- velopment the automobile. The modern motor car was made possible only the development the heat-treated engineering alloy steels. Early Stages Motor Development “It was not long before the delight traveling self-propelled vehicle led the desire ever- increasing speeds, uphill well along the level. Accordingly, engines were increased size and multiplied number cylinders until, horsepower was added horsepower, breakage followed breakage, and hardly part the car escaped. Crankshafts discarded their rear ends, crankpins seized and, welding themselves their encircling bearings, twisted asunder connecting rods and thrust them through the sides the crankcase; axles fractured, gears stripped their teeth, springs went the way the rest and steering mechanism belied its name. fact, the whole car was next door failure.” Such were presidential remarks made few years ago before the Institute Automobile Engineers. Improved Metallurgy Made Better Design Possible The whole aspect design was changed the ad- vances made possible through improved metallurgical products. Quoting Sir Dugald Clerk: “Until the commencement the present century, the only prime movers had were either steam gas en- gines, and may almost said that one the merits such engine was that should heavy; the more solidly was constructed, the longer was expected endure, and, far from trying design engine light weight for its power, the designer those days was commended disposed his materials most liberal manner; hence specific stresses all parts such engine were relatively low. The consequence this was that all forgings were made ordinary mild steel and, long the carbon content was held about 0.25 per cent, and the sulphur and phosphorus were not excessive, nothing more was demanded. Heat treatment was unnecessary and practically unknown, and for the most part mechanical engineers went their way happy disregard, even ignorance, the metallurgist. “With the coming the motor car, however, all was changed, and the designer—faced with the necessity reducing the weight and the cross-sections the vari- ous parts his machinery—was obliged seek help the steelmaker provide which would possess the necessary strength withstand the stresses which was subjected. Thus was started what now great industry engaged the production steels. Nickel, chromium, vanadium, cobalt, silicon, manganese and molybdenum were one one added varying proportions the original carbon steel, each its turn providing some new alloy fur nish the designer with material greater strength and resisting power meet the ever-increasing demands con- sequent upon the higher stresses imposed. “Under the older methods alloy tool steels had, course, been use for many years, but they were hard- ened the rule-of-thumb methods the blacksmith, and the same could said case hardening the cementa- tion process. These constituted the whole the heat treatment which was carried out, until the introduction alloy steels the inauguration heat treating department part the general factory sys- tem, and professional metallurgists had introduced into the personnel every factory necessary part the organization.” Silicon and Manganese Steels Have Certain Advantages The so-called silicon steel interest because its high yield point. the past few years this steel has been discussed the technical press number times because the data published German journals, where has been described steel. matter fact, attention was called the inter- esting qualities this steel Dr. George Burgess 1922. Even before that, steels this general type analy- sis were called attention to, their toughness and high ten- sile strength being article THE IRON AGE, Aug. 25, 1910. The specific purpose for which their use was advanced was that deck plates, torpedo flasks, for the United States Navy. present some these so-called silicon steels are being used large struc- tures, where their high elastic limit has permitted smaller sections and hence greater clearances. was estimated that the saving cost recently built large power house was about $150,000 due the use this steel, which had carbon content 0.04 0.14 per cent, 0.48 0.88 per cent manganese, with silicon 0.67 1.10 per cent. should noted, however, that some the so-called silicon steels much the enhancement physi- cal properties may ascribed their manganese con- tent, which higher than for ordinary low-carbon struc- tural steel. Manganese steels are establishing name only one example, the so-called manganese rail steel. This alloy, with between and per cent manganese, characterized toughness and resistance wear. Balance Between Carbon and Alloy Content Mr. MacQuigg took occasion stress point which has made for several years discussing alloy steels, namely, that heretofore, the best characteristics me- The Iron Age, January 31, { 4 dium content alloy steels for many purposes have not been realized because the lack balance between car- bon and alloy content. Developments with several dif- ferent steels have demonstrated clearly the advantage gained keeping the carbon content low, namely 0.2 0.3 per cent, and boosting the alloying element over hat heretofore deemed desirable. an_ alloy with 0.25 0.35 per cent carbon, 1.50 per cent manganese, particularly adapted certain engineer ing purposes with the simplest type heat treatment, air cool from around 1500 deg. Fahr. The merit low carbon and high alloy that the high tensile strength alloy steel may combined vith the toughness and ductility (shock resistance) plain carbon steel low-carbon content. This ticularly important where certain high tensile values must obtained while still retaining the ductility mild, plain carbon steels, with the additional advantage these properties being obtained the simplest heat treat- ments. Three Per Cent Chromium Steel Low Carbon the low-carbon, per cent chromium steel, consid- work has been done the past few years. Rail steels somewhat similar type have proved quite suc- cessful England. Because the specific effect the element chromium, fineness grain, hardness and tough- ness exist throughout the section, permitting greater re- sistance wear, evenness structure and lessened lia- breakage. How Attain the Best Properties Reheating Steel Ingots HANGES which are produced steel ingot when first reheated the forging temperature and then worked under press, hammer rolls were discussed juced Reheating Steel delivered joint neeting the Institution Automobile Engineers (Grad- ates’ Branch) held recently Derby, England. According the London Jron and Coal Trades Review, the author described how certain features ingot struc- ture, notably the primary crystallization, are broken down reheating and working, and indicated that others, such the distributed non-metallic matter, various forms segregation such “ghosts,” and the dendritic outline the original primary crystallites remain, distorted forms course, affect the mechanical properties finished forging, even bar. Mr. Dickenson also showed the advantages heat treatment improving the physical properties forged rolled part meet particular working conditions. After review the mechanical properties steel regard resisting various types failure service, notably the limiting-fatigue range, the elastic limit, duc- tility, shown the behavior tensile bend test piece, and toughness measured the notched impact test, the speaker went show how, any given steel, the best combination the desirable physical prop erties could attained securing the finest possible association the two essential constituents any heat- treated steel, the hard cementite and the softer ferrite indicated that with plain carbon steels impossible. even with the most drastic quenching, get this desired close association the two essential constituents through- out any but small pieces steel. The speaker also explained the effect nickel, chro- mium and other elements restraining the separation during oil quenching, even cooling air. thus making possible the production large masses steel having high combination the desired physical properties throughout the mass. The author concluded with description few se- lected tempering graphs and mass graphs show how the effect heat treatment various sized bars any se- lected alloy steel could worked out into data for guid- ance practical heat treatment. Magnesium Alloy Castings Now Commercial impression that the manufacture magnesium alloy castings the experimental stage was declared entirely erroneous Player, director the Sterling Metals, Ltd., Coventry, England, paper, “The Pro- duction and Properties Magnesium Alloy which delivered joint meeting December the Staffordshire Iron and Steel Institute, the Birmingham Metallurgical Society, and the Birmingham local section the Institute Metals. Describing the practical processes involved manufacture magnesium alloy castings, Mr. Player said that the production these alloys all forms now commercial scale, offering the engineer new material possessing many desirable qualities. Magnesium forms alloys with zinc, aluminum and copper which have ex- cellent casting qualities and physical properties. Copper, however, forms alloys which are subject corrosion under certain conditions commonly met with, such ex- posure damp atmospheres, the corrosion arising from the galvanic action set between the magnesium and the copper. For that reason copper does not form principal 334—January 31, 1929, The Iron Age constituent any the Elektron alloys which mag- nesium the base. Magnesium alloys possess excellent machining qualities, comparing favorably with aluminum They can machined considerably higher speeds than most other metals, and fine and accurate finish ob- tained without the necessity costly finishing operations. Substitution magnesium alloys for heavier materials the construction high-grade motor cars, said Mr. Player, has appreciably improved the power-weight ratio reducing the dead weight, giving the effect enhanced engine output without increased running costs. regard aircraft, results indicate that magnesium alloy castings will the future take important place the con- struction engines. Elektron rolled sheets are finding increasing applications constructional engineering, especially aircraft building. This has been particularly the case since the very difficult problem making satis- factory welded joint was solved. The sheet can worked most shapes, but for deep pressing the work has carried out number stages and the article suit- ably annealed after each operation. | Lumber Company Makes Castings Foundry Operated Electrically Throughout, California Plant Makes Iron, Steel, Alloy Steel and Non-Ferrous Equipment for Its Extensive Operations PERATED throughout electricity, the new foundry the Red River Lumber Co., West- wood, Lassen County, Cal., can appropriately all-electric. Why Lumber Company Needs Foundry panies operating that part the State, water rights are exchanged for power, and 7200 kw. power can obtained from this source. This permits the steam- driven units Westwood run synchronous con- densers practically all the time, thus improving the plant might well explain why lumber company needs foundry and why should electrically operated. The mill and factories the Red River Lumber Co. are located near Mt. Lassen the heart the great California pine forest. This com- pany carries the largest lumber operation the State and one the largest the country. The saw mill and plant are modern every respect and are electrically operated throughout. has capacity 300,000,000 ft. lumber year. Besides the saw mill, the company operates Westwood veneer plant, box factory, sash and door power factor. EARLY 500 Tons Wide Variety Castings Made Each Year Large California Lumber Company Maintain Its Equip- ment. Annual Production Over 850,000 lb. Gray Iron and Steel, 50,000 lb. Brass and 1000 Alu- minum Castings. Nickel Steel Castings for Gears and Blanks, Since the mill and factories were electrically equipped throughout and the results obtained were highly satis- factory, and since there was ample supply electric power avail- able for this purpose, was deemed advisable operate the foundry, far possible, electric equipment, thus utilizing electricity throughout the entire plant. Elec- tricity also permits the automatic control furnaces and ovens. The foundry frame structure 272 ft. long, ft. wide, and ft. high. Production car- ried continuous line with raw materials entering one end and factory, molding factory, and plan- ing mill. The saw mill and factories run six days week throughout the year, the saw mill and parts the factories running both day and night. Over 100 miles standard-gage railroad are main- tained transport the logs the mill; miles the main line track are electrified. Over 25,000 loaded cars logs are transported each year the mill Westwood. Six rod engines, two Shay engines, two Diesel-electric locomotives, two electric locomotives, and 250 log cars are used transport the logs the mill. The two electric locomotives haul practically all the logs over the elec- trified portion the main line the mill. fleet caterpillar tractors used the woods collect and haul the logs the railroad loaded. Four loaders are kept busy loading logs the cars. From this can readily seen that considerable maintenance necessary keep the logging equipment, power plant, mill and factories successful operation. good-sized machine shop, electric shop, pattern shop and foundry are operated order carry main- tenance work, make and install new parts, and, many cases, construct new machines and equipment. Products. Ample Electric Power Needed keep this great plant operation, connected load over 10,000 kw. electric motors, 850 kw. lights, and 625 kw. heating equipment use. steam power plant 5500 kw. installed turbine generators and hydroelectric plant 4800 kw. are maintained. Under agreement with one the large power com- *Red River Lumber Co., Westwood, Cal., and General Ele tric Co. respectively and Shovel Teeth Among the finished castings leaving the other end. This facilitated the use overhead electric traveling crane 6000 capacity, which runs the full length the building. auxiliary, hand-operated, over- head traveling crane 10,000 lb. capacity also installed. The various equipment will described the order progression. with the core department, this has motor driven sand riddle, motor-driven Simpson facing sand mixer and two electrically heated core ovens. The ovens have common front, flush with the foundry wall, with the ovens proper projection outside. One oven, the smaller the two, used bake small cores; for ease handling, seven doors about in. long and in. high, hinged one end, are used. Each door has quarter sectional, arc-shaped bar rack projecting into the oven. Opening the door thus brings out the rack. The large oven has two doors opening out. This oven about ft. high ft. wide and ft. long. car having adjustable shelf racks runs track into the oven, making convenient handle large cores. The large oven heated with ten 3.8-kw. nickel-chromium oven heaters connected for three-phase service. The small oven heated with four 3.8-kw. units the same type. These units have maximum temperature rating 750 deg. Fahr. This temperature held constant model 877, bulb-type temperature controllers operating conjunction with magnetic switches and control relays. The controllers have range from 100 700 deg. Fahr. Electrically heated core ovens have been found far superior wood oil-fired ovens. The temperature con- trol very simple. The controller set for the desired temperature, and this temperature maintained the The Iron Age, January 31, | q q automatic control apparatus and the electric current with- out any further trouble worry the part the core maker. Large cores that take several hours bake can placed the oven the evening and left bake over night without man watch them. When the core maker returns work the morning, the core finished and ready for use, and the oven available for his use during the day. the opposite side the building from the core ovens are four sand bins with fronts flush with the foundry wall, the bins projecting outside. Each bin has capacity more than carload sand. The roof over the bins equipped with removable hatch. Carloads sand are run siding the end the building and unloaded into the bins with clam shell bucket and crane. Both Cast Iron and Steel Made Electric Furnace The next equipment line the electric furnace. This furnace handles all the iron and steel used, the sources being scrap resulting from the lumbering opera- tions. The furnace the Moore type, size No. with normal capacity 500 although the average charge 800 1000 lb. The furnace arc 220 volts, three- phase, cycles. The three electrodes are automatically regulated furnace regulator controlling direct- current electrode motors, one motor each electrode. Electric Brass Furnace Built Company Near the steel furnace horizontal, arc-type, single- phase brass furnace 750 lb. capacity. This furnace was manufactured the company’s shops Westwood. Two 2300/220-volt, 100-kva. transformers and reactor sup- ply current for this furnace. far superior the old oil-fired brass furnace which replaced. Much larger heats can taken down much shorter time. There oil smoke contend with, and the control and operation are very simple. higher grade brass Every Fr. There are Light Units Having Reflectors for Illumination 336—January 31, 1929, The Iron Age Welding and Cutting Equipment Used Extensively Cutting Off Heads and Repairing Slight Defects turned out lower cost. The furnace practically air tight and the losses from oxidation are small. the present time ladles are heated with temporary oil-fired furnace. electric heating device being worked out, however, and will soon put into service. This will entirely eliminate the use oil heat the foundry, except for the oil-fired torch used times dry molds. The next department the progression line the molding floor. This divided into three sections: One for brass, one for cast iron and one for steel. one corner the iron floor snap flask bench where small pieces are molded. electric vibrator used here loosen the small patterns the sand molds. Several air ram- mers are used the molding floor. Air supplied large motor-driven air compressor the power plant. Another motor-driven sand riddle used here screen the molding sard. Electricity Cleaning and Welding Next line comes the cleaning floor. This depart- ment equipped with sand blast machine, two swing grinders, one pedestal grinder, tumbling mill and metal-cutting band saw, all motor driven, and also electrically-heated acid pickling bath and electric burn- ing and weldirg set. The band saw used mostly cut gates and risers from cast iron and brass castings. one side the cleaning floor 70-kw. motor- generator set. This machine supplies direct current for electric cutting and welding. Practically all the gates and risers the steel castings are cut off with the elec- tric torch. Considerable electric welding also done steel castings correct minor defects. Seven combina- tions current can obtained means switches each panel the two-panel switch board. Thus two men can work the same time, either cutting welding | —_ oi 7 Grinders, Well Tumbling Mills and Sand Blast Equipment, Are Operated Electrically both. The switches select and short out sect ons re- sistance. For cutting, currents high 1000 amp. are used. Annealing Done Electrically Next the motor-generator set the electrically- heated annealing oven. This oven has its front flush with the inside wall the foundry. car-type oven kw. capacity, three-phase, 220 volts. The heating ele- ments, nickel-chromium ribbon, are mounted special insulators the sides and top the oven. Temperatures 1950 deg. Fahr. can obtained, and any desired temperature this range can maintained within few degrees. Two alumel couples operate Brown instrument. Temperature limit fuses set for 1950 deg. Fahr. open the control circuit case this temperature exceeded. This electric annealing oven simple operate, regu- late, and control, and steady and uniform temperature maintained. The controller set the desired tem- perature and the automatic control apparatus and electric current the rest. The oven needs further attention until the castings are ready removed. The oven practically air tight and little carburization scal- ing takes place during the annealing process. 200-kva., 2300/220-volt, three-phase transformer supplies current for the annealing oven and the two core ovens. Near the annealing oven water-cooled oil quenching tank used heat treating steel castings. Nearly 500 Tons Castings Made Annually The building exceptiorally well illuminated, having light units consisting reflectors with 300-watt lamps, suspended from the ceiling every ft. Two lamps the same size are suspended over the core bench and one over the snap flask bench. Over 850,000 Ib. iron and steel, 50,000 brass and 1000 aluminum are cast year. the iron and steel approximately per cent steel. About per cent the steel cast nickel and nickel-chromium steel, the rest being mild carbon steel. The cast iron prac- tically all gray cast iron. There little use for white cast iron the operation. The power consumed melt iron and steel approxi- mately 1100 kwhr. per ton metal. (No segregation has been kept the energy required melt steel and that required melt iron.) Many Uses for the Castings Cast iron used for log car and locomotive brake shoes, grate bars for the power boilers, pistons and piston ring stock, machine frames, face plates, bushing stock, Steel castings are made for caterpillar tractor parts, sprockets, cast tooth gears, gear blanks, teeth for power shovels and drag lines, shovel parts, railroad frogs, winch and hoist drums, bearings and journal boxes, side frames for log car trucks, center plates, coupler yokes, and jour nal boxes for log cars, and many other things. Nickel and nickel-chromium steel castings are made for gears and gear blanks, railroad frogs, shovel teeth, and any parts where the service severe and the stresses are high, Brass castings consist log car and locomotive jour nal brasses, locomotive side rod brasses, bushing and stock, etc. Practically all the aluminum cast made into patterns which are used great deal and have more serviceable than patterns wood. The foundry was laid out and the various equipment chosen under the direction Fletcher Walker and his sons Walker and Fletcher Walker, Jr. operated under the supervision Stoker, foreman, and Soares, master mechanic. | | | | | 4 | Electric Annealing Oven Car Type with Front Flush with Inside Wall Building The Age, January 31, Leaves from the Diary Foundry Apprentice FROM 18.—Our month’s vacation from school about really believe shall glad when starts again. Mr. Haney told the other day that had nice new lot slides for the lectures school. This will give chance brush bit what lass room work have done during the past seven months. And certainly needs brushing up. This stuff comes fast that can hardly keep track all, say nothing beri And Jack tells they give examination over all branches before the Jack will finish some time November and just now begin- ning plug all his branches. certainly have lifferent idea this whole thing than had just seven remembering the important things. ‘esident signs his name the certificate. This serious business. the “baker,” gave the dope run- ning core ovens today. fine old darkey is. fact, like whole lot them here, least far. Getting with these fellows you work with half the battle. Jack says it’s more than that—it’s half the victory the battle. believe right. Now even with old col- fellow like Sam apprentice can get information that isn’t the books, for you. Sam has charge all the ovens the small core room, some gas and some And these ovens sure perform the tune The company installed calls them. believe pays give men good equipment with, just because makes them proud their vork Old Sam wipes the faces his they were human. The only time saw the old boy riled was the day one the kids the bench shied core somebody and spattered all over Sam’s electric. sings. 30.—Remained over tonight see them pour generator housing—something like tons. Three 25-ton furnaces all steamed up, and the chief them watching like Pinkerton himself. The analyses had the same all. And the three them had ready the same time. The chemical laboratory located right back the melting floor, and the chemists the shift nothing but analyze specimens, one right after the Mr. Haney stayed over with about half dozen And guess hoarse from shouting answers lot this stuff will come out the But too good wait for. questions. wash class. Sept. 3.—I discovered new kind core made green sand and used the big casting poured the other night. fudged bit core-making lesson and galloped ahead see what the book had say about it. Well, the time had that answered satisfaction, half dozen other questions stuck their heads up. Now have got worry about “shrinkage,” “pouring and lot other technical things. course here four years will get the point where won’t find questions where only one grew before. *Dean, mechanical engineering, waukee Marquette University, Mil- 338—January 31, 1929, The Iron Age Sept. 5.—School off with bang. deep into core making, mensuration, rules grammar, and sketch- ing. Jack warns heavy the sketching, claims that the basis blueprint reading, which the language the shop. course, they don’t use the foundry among the molders much except the big floor when they lay out big job. But notice that everybody from foremen and inspectors carry prints around with them most the time. Whenever there heavy argument going between the foundry and the machine pattern shop you may sure there blueprint the bottom it. always the last resort the inspec- tion department; when they can’t win any other way they pull out the old blue sheet—and they usually are top the end. Sept. 15.—The lectures the “Making are the garlic, the Italian the coreroom puts it. They are strong and they are healthy for mind that did not know the difference between gray iron, steel and wrought iron. Carbon seems the queen bee the making steel. Strange what difference few hundredths per cent will make! Something new every hour here, and don’t know the half yet.” Sept. 20.—Going eight months now, and seems that for every step take forward here the field edge increases the square the distance; which put- ting mathematics some good use anyhow. Sept. 21.—Just when thought the shop “math” was only for mental exercise, was asked figure the weight simple cylinder casting. course, had forgotten all about the rule find the area circle among many other annoyances like kind. And what you suppose the foreman wanted know that for? have check the pressure the core. Naturally, the metal poured into the mold weighs 1000 the pressure the core will 1000 Oct. 1.—Started metallurgy today the lecture series. have got try keep “silicon,” “manganese,” “sulphur,” “phosphorus” and “carbon” from getting all mixed until they find good resting place bean, know where find them when want them. getting can hand readable report these lec- tures. Oct. 10.—Three months will soon the small coreroom, and just beginning wonder whether know anything about it. There more stuck away these small cores than most people think. course, will have another three months the large coreroom some time soon. Oct. 15.—Perhaps ought ask for additional month this department. Checking and inspecting cores now for the remainder the time here. Just started today, and beginning realize how little know. Inspection the best cure for big head anything know. Oct. 21.—Told the association speed the deduc- tions buy shares; take dollar each pay day instead those stock certificates. Have been watching the stock sheet each morning. Our stock now $16.50. must making some money for the company somewhere. Oct. 30.—Started the side floor today own right. Fine business. Nov. 3.—Making dry sand molds now. Changed related studies class accordingly. There hasn’t been hitch yet the program, and it’s going year. Nov. 10.—Delaney now head the inspection depart- ment. Mr. Haney told when started here that the company policy hire foremen only those trained its own shops, this all possible. Another place where their deeds check with their promises. q | Nov. 18.—Jack finishes today. Felt kind blue, though, expecting Jack would out the apprentice bunch until told they had accepted him for post- graduate course. has pattern shop, heat treating and the production department his list advanced studies for the next two years. Jack will come into the class that graduates the first the year. Then will receive his certificate, bonus and all his papers. tells that this includes all his lessons, exams, drawings, etc. wondered why they made turn our lessons and exams and when, ever, they would come back. Jack reports some bums sold their papers other apprentices. course, they have more sense after they graduate. It’s funny how dumb some people can be! Longer Life Molds Busselmann Process Mixture Developed Germany Seems Make Possible Semi-Permanent Molds Having Definite Advantages for Iron Castings (Special Correspondence) LONDON, ENGLAND, Jan. 6.—As only small propor- tion the iron castings used marine engineering and shipbuilding are repetition nature, molding machines are not largely employed foundries that specialize marine work. There are certain small valves and similar castings used shipbuilding that are made molding machines, but they are generally obtained from specialist concerns lower prices than they could made for small quantities. But repetition castings are not re- quired for engine deck work, there often the need for six, 12, even castings, and new molds have made for each one. The new “Busselmann” process, developed the Han- over (Germany) firm that name, which castings can obtained from one mold, ought particular value foundries specializing ship castings. For brass and aluminum, molds are common, but until now, apart from centrifugal casting, there has been successful casting iron permanent molds this country. Loam molds are the hardest used iron foundries, and they are broken after each cast. The composition the Busselmann mixture ap- proximately, (with slight variations according condi- tions): Two parts ground fireclay, two parts kaolin, one part coke, three parts clay matter, and four parts high-quality green sand. The nearest plastic molding ma- terial this hitherto used Britain was steel molders’ “compo,” which much ganister used. Asbestos added the German mixture increases its permanence consid- erably. When the molding box over one meter square, the life the mold correspondingly reduced. marine engineering several cylinders and bed plates may re- quired and the patterns have “handed” between each cast, according whether the casting for port star- board engines. Thus, when firm obtains order for two twin-screw vessels, four sets castings are required, with steam branches and bosses different positions for port and starboard engines. The Busselmann molds would have made sections, with drawbacks, that the necessary alterations could made; this, any rate, appears possible. would appear that ordinary foundry tackle can used with this process. The various materials are ground and mixed until they are completely homogeneous, and the mold actually consists hard shell, well backed with ordinary sand that cannot become distorted when the casting being delivered. many cases molds have eased immediately the metal becomes set prevent fracture through thin sections cooling first and drawing away from thicker sections. may sometimes pos- sible more cores reduce the contraction dan ger and, course, the majority cases, iron castings are allowed cool without the mold being touched. castings are more troublesome regards contraction. Instead the addition horse manure other or- ganic materials the sand used for permanent molds which would repeated heating, Aus- trian micro-asbestos used. addition the lowered molding costs, permanent molds mean less coke consump- tion the drying ovens and considerably less handling materials. certain districts heavy marine castings are molded loam, and has often appeared that the loam was nearly permanent. British experts are interestedly awaiting hear if, the “Busselmann” process, the molds can made with strickles, must made with patterns. British Opinion Expansion Die Casting TATING that the die-casting has developed enormously the last years, particularly Amer- ica, Russell, Cammell, Laird Co., Sheffield, En- gland, lecture the “General Aspects before the Sheffield branch the Institute British Foundrymen, traced the origin its success the auto- matic pressure mechanism the linotype machine, in- vented Mergenthaler 1885. Mr. Russell said that most people not realize that one the essential parts the newspaper business relatively large foundry. Between and tons metal day cast provincial newspaper and this work represents the highest art the die-casting process. Today die-castings are being made alloys which have their base tin, lead, zinc, magnesium, aluminum, cop- per iron. Radio sets, gramophones, and carpet sweep- ers could not placed within the economic reach the average householder, said the lecturer, were not for the use die-casting. the heavier engineering trades die-castings alu- minum bronze, having the tensile strength cast well-forged 0.30-per cent carbon steel, are replacing mal- leable iron castings, said Mr. Russell, and some extent drop forgings and pressed products. inevitable that their use will extend still further when designers better understand their mechanical properties and when buyers themselves help assist cheapening the castings or- dering large numbers, which could all produced from one mold. There growing demand among makers die-castings high-melting point alloys for steel, some other alloy, which will better stand its work. The Age, January 31, ’ q Heat-Treat