The Iron Age 1929-02-14: Vol 123 Iss 7

THE IRON AGE New York, February 14, 1929 ESTABLISHED 1855 Wheel-Skids Lower Production Cost Used Carry Material from Railroad Cars, Feed Assembly Units, Serve Manufacturing Machines and Storage Racks SIDNEY KOON* only few units can through single order, doing utilizing stockroom facilities reaching close 100,000 items, problem not permitting the mass- production methods which have been much the lime- light this country the past few years. That the condition the General Electric Co. faces Philadelphia, where the entire switch-gear manufacturing the com- pany has been concentrated. productive have the methods devised become, however, that the assembling units have now been equipped handle number differ- ent devices each unit that they may kept con- tinuous About 1,300,000 sq. ft. floor space available, most one large structure seven stories. Here switch- gear made sizes from what man could carry readily *Associate editor THE New York. Use Wheel-Skids Screw Machine Section. new location, the truck platform being run side skid his pocket large outdoor units ft. tall—from what would pack 300,000 cartons one box car those requiring three cars for their various members. Much lost time, handling expense and damage part: are avoided liberal use wheel-skids uniform tern—some 2700 being employed throughout the plant these are added few more, identical design somewhat larger, and quota hand-push loaders wheels, used mainly collecting, for assembly, item: from nearby stock-racks. Most the standard skids are used connection removable bottomless boxes, which goods are placed some cases, where delicate wiring coil wrapping: might suffer from scraping against the steel sides ing unloading, the flat body alone used, and means are taken prevent the load from falling off transit Except where the travel very short, these skids VOL. 123, No. | i x 3 467 albeit roller-bearing wheels, are handled the custom- ary electric lift trucks. Ordinarily the truck platform run between the two wheels the same side the skid, this results dropping the skid correct posi- tion for being pushed, without turning, into the aisles between stock-racks. many cases, particularly connection with the gen- eral storerooms, the loaded wheel-skids are employed the bottom “floor” section the racks, being pushed into place below the lowest shelf and left portion the stockroom equipment. This especially the case items which move with some rapidity. avoids com- pletely all necessity for handling contents, thereby saving both labor cost and possible damage loss. the holds the top the box. The two corrugations crimps, extending all around the box, provide stiffening members, speak, and permit the whole structure take much more severe punishment service than would possible with flat sheets. general practice here use these wheel-skids for wide variety purposes. Not only they receive incoming shipments from the several railroad spurs en- tering different parts the plant, but they serve also storage, either local general, for parts received. Two them are placed alongside production finishing machines, usually one either side, and the operator takes his raw stock from one and deposits his finished pieces the other. This conserves handling labor the Wheel-S kids (at Right) Loaded and Lined Leave the Aisle Free. The locating track appears lower left. The snug fit the cor- ner angles down over the base seen—the box not at- tached the base. Welding beading evident several places the photograph Method Making and Assembling Standard Wheel-Skid, from Steel Sheet Thick and Few Fit- tings for the Wheels. The plan, upper left, shows bottom boards place stock-racks are open both sides, stop provided, center the skid properly under the How the Are Made TANDARD skids are made with bottom section heavy sheet steel, not only identical thickness with the shelves the stock-racks but also identical shape and with the same flanged edges. the stock shelves these pieces are placed with the flange downward. For the skids, however, they are reversed and, within the tray thus formed, bottom made hard pine, bolted place and easily renewable. Before the pine bottom inserted, the four wheel- trunnions are welded the under side the base and the wheels, built shown one illustration, are put place. The four corners where the flanges join are themselves welded and the wheel itself welded unit; its tread short piece steel pipe. this work done one section the plant devoted welding— large part the work here being the welding switch- gear parts. Similarly, the box which tops the wheel skid welded job. This consists, again, sheet steel heavy gage, which has been crimped along two parallel hori- zontal lines, between bottom and top, and welded four corner angles. Two sections pipe are welded opposite sides the top, serving hand-holds for those who have handle the skids. The corner angles project enough below the lower edge the sides that they fit snugly over the corners the base. Thus, the whole wheel-skid can pushed easily pressure the hand- 14, 1929, The Age nth degree and has meant saving great deal needless expense. most places around the plant, where the wheel-skids are used this manner, peculiar form stop short sections has been set into the wood-block floor, iocate the skid positively and- prevent its projection into the aisles its being inconvenient position for best use the operator. These sections floor stops, which appear some the illustrations, consist strip steel having two corrugations, one which much deeper than the other. The skid pushed over the shallow cor- rugation that one pair wheels butts against the deep corrugation and rests between the two. This locates with sufficient accuracy for the purpose. Use the Skids Stockroom HERE the skids are used the stock-rack units, lower portion thereof, these same sections stops are placed that the skid will take its position accu- 7 = K rately and thus not project beyond the regular position assigned it. such cases, the lowest shelf the stock-racks placed in. above where the top the skid will be, thus take care slight heaping material the skids. This heaping discouraged, par- ticularly where the stock especially heavy character, but little leeway allowed. The rated capacity 4000 lb. for the standard size and 6000 for the larger units. Stock-racks not using the skids lower member have their lower shelves much nearer the floor. prac- tically all cases the stock carried boxes trays made sheet steel. shown illustrations, these are built standard sizes varying according needs particular kind stock, and with varying depths. Gen- ible with regard location shelves. The framework consists vertical steel angles with bolt-holes placed in. apart, except for the lowest portion. Such stiffening required furnished the shelves themselves, which fit accurately between the angles and are bolted rigidly them. each shelf consists heavy piece sheet steel flanged all four sides, this stiffening adequate. Relocation any shelf vertically simple matter unloading it, unbolting and then bolting the new position. Access the top shelves afforded readily use step-ladder wheels. This non-collapsible and has enough spread the base that there danger its tipping over, even when man has heavy load Gap Provided Facilitate Not Finished A Weld in \ : ' BEARING The developed length the rim, cut from length steel pipe, approximately 26% in. bling the wheel Hand-Pushed Truck Used for Progressive Assembly System, Self-Centering Stacks erally speaking, they are designed that one man can handle the box with its contents from wheel-skids, either the standard type the type used for gath- ering material for assembling work. Each box has place its face for card, indicating contents and, where sent into production lines, show- ing where go, etc. Careful record kept each stock section that stock may replenished for any part soon begins show signs depletion. This accordance with general good practice along this line, different bogey having been set for each part, reach- ing which point definite amount new stock ordered. Some the switch-gear units are assembled infre- quent but somewhat regular intervals. cases where this placed three months thereabouts, special handling stock may required, practically the entire stock hand might used one time. Enough for the next quarterly assembling operation would then have All the stock-racks are constructed flex- arm’s length. With ceilings about ft. from the floor, this ladder high enough that man may take off tray from the top shelf without reaching higher than about the level his shoulders. Handling Materials Assembling Units LLUSTRATING particularly the method whereby stock kept close manufacturing assembling depart- ments, and handled from the racks through the assem- bling operation, sketch presented section one floor one building, which the company has the near- est approach makes what now know commonly “mass production.” Here, many other parts the plant, the building divided lengthwise into two parts not necessarily equal, wherein one part used for the stock-racks, while the parallel and immediately adjacent part used for the assembling production work. There narrow aisle between them, with other aisles along the windows, shown. Back the stock-racks, broad aisle serves for bringing materials put into stock. This done usually electric lift trucks. the opposite side the building, adjacent the assem- bling operations, conveyor for handling completed parts and delivering them for boxing and shipping. Sub-assemblies are made one side one the assembling units. These sub-assemblies are then put into general assembly the other side. Referring this sketch, stock taken from the racks put assembling skids (on wheels) and moved accordance with the ar- rows, shown the right, the assembly unit. Each tray lifted succession the power rollers, The Iron Age, February 14, running down the center the assembling tables, and when power turned carried stop the other end. The succession trays carrying the different parts required thus comes within easy reach the sub-assem- bly operators, standing sitting the outside the unit. These operators, after having used the materials the boxes, put the empty boxes short line gravity roller conveyors under the sub-assembly table, thus returning the boxes the aisle. Here they are which large switch-gears can put together. These fix- tures provide for turning the switch-gear upside down, when necessary work the opposite side, they may held any other convenient angle. Some the boxing, particularly small units assemblies, done this same floor, for which purpose the trays are shunted off the conveyor convenient means. Boxed goods thus prepared and assemblies which are boxed the general shipping room pass from Canvas Belt picked and put back into service the point where these particular parts are accumulated. soon sub-assembly has thus been completed, the unit slid the steel-topped table across the other side beyond the power rollers, and the main assem- bling takes place the center the unit. will not necessary into details the pipe rails used here for carrying fixtures which the assembling done. Suffice say that each sub-assembly tested the inclosure shown, before being sent further. Testing Each Unit Before Shipping Particular care taken connection with the elec- trical testing that there physical contact between the assembling rails and the source power. Inter-con- necting switches are adjusted that the section rail holding the piece being tested must withdrawn com- pletely from its previous position before the current will flow. Meantime, the man doing the testing outside the cage which the power applied and the door the cage closed. Controls operated from outside handle the entire operation, without the slightest danger any yerTson, Tested devices are then placed upon the conveyor ander the windows and carried toward the packing sec- This conveyor consists broad canvas belt over the area light assemblies. Where the pieces are indi- vidually much heavier, steel apron conveyor employed and the lighter parts, trays usually, reach the steel apron section over short run rollers bridging the space between the adjacent end pulleys the belt and the steel apron respectively. will noted that the heaviest units are assembled the floor, rather than one the assembling stations briefly described. For this purpose other interesting fix- tures are use, including sort A-frame wheels, 470—February 14, 1929, The Iron Age Passageway for Electric Trucks Delivering Material Stock Racks General Arrangement One Sub-Assembly and Assembly Group Units, Showing Close Relation Between the Parts, the Stock-Racks, Through the Assembling Oper- ations the Conveyors Lead- ing Shipping Depart- ment. The solid arrows show movement assembling portion and act integral part the storage system. This shows well the varying trays used for differ- ing parts and the way they are identified i ranged for Flexibility Shelf Location. left shown wheel-skids occupy the lower the end the steel apron conveyor spiral conveyor which carries them down the shipping department. Comprehensiveness will recognized feature the system described above. Experience has, naturally, suggested few departures from the original layout uses for the wheel-skids, but, the main, they function was designed when they were first installed. And the benefits standardization are everywhere apparent. Follers Testing How Use Scrap Increasing Old Material Consumed 1928 Estimated 34,000,000 Tons, Half From Market—Melt Has More Than Doubled Years CARLYLE STRAND increasing economic importance the scrap industry may judged from the fact that the aver- age daily consumption iron and steel scrap valued more than $1,000,000. this article and the accompanying tables attempt has been made analyze the country’s scrap terms production and consump- tion. The estimates made some the tables are based the most reliable information obtainable, but are sub- ject variation according actual trade conditions. For the purposes this analysis, scrap divided into two classifications—home and market scrap. Home scrap that consumed the plant where made. steel plants usually consists butts and crops, ladle pit and runner scrap and other products incidental steel manufacture. Market scrap that which purchased from outside sources. About one-half the scrap used home scrap and about one-half market scrap. The railroads furnish the most desirable grades steel, pig iron, iron castings, etc. Exceptions have been made instances where special conditions are known prevail, such unusually large scrap supply Michigan due automobile manufacture and abnor- mally great consumption the Chicago district due the many steel foundries, bar rerolling mills, etc., ad- dition the large steel plants. Such districts New England, the Northwest, South- east, South Central States and the Pacific Coast have overabundance scrap, while the great manufactur- ing belt the Northeast and North Central States deficient supply, giving strength these markets. probable that the actual scrap production the South- east and South Central districts not large indicated the table geographical production, rail- roads, building construction and other industries have not kept pace there with increase population. These dis- tricts, however, are developing rapidly and will probably market scrap, usually heavy and well sorted. The automotive scrap here shown includes scrap made automobile plants well worn-out cars. This latter grade returns market comparatively short time. Collection country scrap junk men probably amounts about per cent the total supply, both home and market scrap. accompanying table gives analysis scrap supply and consumption industries. prove increasingly important potential sources supply. Transportation costs principal scrap con- suming centers are the stumbling block the present time. Various observers have from time time made esti- mates scrap consumption the United States. bring these estimates date and make use more uniform method estimating, there has been com- piled tabulation scrap consumption various branches the iron and steel industry. This given accompanying table. The data are based largely production statistics the American Iron and Steel In- stitute. was, course, necessary make many as- sumptions, and the results necessarily are only approxi- mate. The methods determining the consumption Production and Consumption Districts Another table gives analysis scrap production and consumption geographical districts. this table the production market scrap has been based mainly population, while the production home scrap and the consumption both kinds based the production OLLOWING his graduation from the Case School Applied Science, Cleveland, with degrees bachelor science and metallurgical engi- neer, Carlyle Strand took post graduate work metallography Har- vard University under Prof. Albert Sauveur and Prof. Boylston. His practical experience has consisted work the metallurgical department the Steel Co., the test department the Pennsylvania Rail- road, chief metallurgist the Crown Cork Seal Co., Baltimore, senior inspector for the Bureau Aircraft Production during the war, metallurgist with the United States Bureau assistant chief inspector Lackawanna Steel Co., Buffalo (now Bethlehem Steel Co.), and metallurgist and chemist for the Ohio Forge Co., Cleveland. the author the Bureau Standards technologic paper Iron for Locomotive Cylinder Parts,” and 1914 published paper “Heat Treatment Open-Hearth Steel Castings” conjunction with Young and Pease the proceedings the American Institute Mining Engineers. His address 1135 Sixteenth Street Washington. The Iron Age, February 14, Scrap Production and Consumption H } R Build 2 i t v té | STRI¢ Northe 1004 Te D Md £00, Ne Jer 600 New Yor 1.600 Oh 1,000 Pennsylvania 1,500 We Vire iit) 1.100 Ind Ot low: Mich 1,090 Mir M oo W Northw 000 t 1.900 h ¢ ihe > I’ Tot 17,000 & t, Ma Massachu Idah Kansa Mon Alat i, Florida, Georgia, N * Ar i, Arkansas, Kentucky Or and Washi Price a Pig ire pig iron Scrap Low pl billet and b I Ni ] hinery « t N l h ry ¢ t No ] h rv Old ron carwhee ‘ bled {) arwhe id wrought R malleable ()) rolling rail St ly and r He te No road ca No. 1? road wrought Heavy lting steel Heavy g stec Cast ire borings Machine shop turnings Cast borings | 1 Fre THE ] AGE, J 7 Scrap nneé Per Cent T< ot Total 000 000 lt ( 11 ) ) 4 non j New (1928) AP Hon T Gross T S 100,000 11.200.f ) 100,000 2 000 700,000 2 800.000 700,000 4 ) 2 100,000 00.000 THe tit 10¢ 100,000 0000 { 17,000,000 South Hampshire, Nebraska Carolina, ( Nevada, PRODUCTION Total, Tons 1,300,000 16,600,000 $00,000 800,000 2,300,000 7.200,000 700,000 §,300,000 2,100,000 ,600,000 300,000 200,000 500,000 300,000 300,000 1,300,000 500,000 $00,000 1,100,000 3 £000,000 de Islan Supply and Consumption Industries (1928) Scrap Consumption Consumption in Steel making Blast furnaces Iron foundries Rail rerolling Other industries Total, home 29 100.0 Vermont. mills and market Long Tons 25,000,000 4,000,000 3,700,000 1,000,000 300,000 34,000,000 Districts Total, Home and Market, Gross Tons 200,000 22,200,000 1,000,000 100,000 1,500,000 7,600,000 11,400,000 700,000 4.100.000 4,200,000 200,000 200,000 100,000 100,000 600,000 1,200,000 $00,000 400,000 34,000,000 Per Cent Total 100 SCRAP CONSUMPTION Per Cent of Total 100.0 North Dakota, South Dakota, Utah and Wyoming and Virginia. ee, Miss Chicago Philadelph Philadelphi: Pittsburgh Chicago Philadelph Chicago Chicago Chicago Pittsburgh Cincinnati Chicago Philadelphi: Pittsburgh Chicago Pittsburgh Pittsburgh Chicago issippi, New Mexico, Oklahoma, Louisiana and Texas. Ratio Heavy Melting Ton Per Cent $25.08 +38 23.44 +29 22.40 +24 21.52 +19 21.20 +17 20.70 41-14 065 114 20.08 +11 9 80 + 9§ 19.64 18.89 + 4 18.71 3 18.53 18.13 0 18.01 1 16.6 16.35 10 16.33 10 15.73 13.89 23 12.77 11.45 7 14, 1929, The Iron Age Scrap, Pgh., Present Price, per Gross $19.75 17.50 inalysis Various Grades Iron and Steel Scrap Quoted The Iron Age Average 10- Year Post- War Price, per Gross Ratio Heavy Melting Steel Scrap, Per Cent Supp! 14 12 1 17 7 ( of Total 0.6 48.8 65.6 2.9 0.3 6.7 4.4 14.1 22.3 33.5 2.3 12.2 no 3.5 0.5 7 1.5 0.7 an 0.9 0.4 0.9 0.2 1.7 7.4 3.6 1.3 0.9 etts rth eton Philadelphia Vallex Pittsburgh 17.64 Cincinnati i 16.25 16 16.50 16.00 14.00 —27 i 15.50 —19 19.25 0 14.84 16.00 -17 1929 (prices as of Jan. 15) scrap iron and follows: (1) Steel manufacture.—There ap- proximately per cent melting loss manufacturing steel ingots from pig the various branches the steel industry are shown Estimated Domestic Scrap Consumption (Millions of Gross Tons) metalloids pig iron and scrap, iron 1900 2.4 0.4 1.0 0.5 0.8 5.1 teeming, and lesser extent the 1911 8.7 0.7 1.5 0.5 0.7 12.1 first column therefore were obtained 1916 16.0 3.2 0.9 0.9 23.4 ingots and castings 0.89, giving the 1919 14.5 1.9 3.0 0.7 0.6 20.7 total pig iron and scrap charged. From production basic, Bessemer and low 1924 18.4 3.3 3.3 0.8 0.4 26.2 steel manufacture. The figure per cent melting loss, strictly speaking, ap- plies only open-hearth steel manufac- ture, but this large percentage the total was thought that seri- ous error would incurred assuming the same loss for all steel manufacturing processes. (2) Blast the manufacture pig iron blast furnaces there has been large increase the use scrap. Amounts scrap used blast furnaces shown the preceding table were obtained the use the following percentages: per cent total pig iron production prior 1915; per cent from 1915 1923, inclusive; and 10.5 per cent from 1924 date. There has been considerable increase the amount and pro- portion scrap used blast furnace burdens recent years. (3) Iron and malleable iron foun- dries, estimated, used scrap the extent about per cent combined foundry and malleable pig iron production prior 1915 and about per cent from 1915 date. This illustrates the manner which compilations were made under this caption. (4) Rail rerolling 1,000,000 tons old rails are rerolled annually into smaller rails, reinforcing bars other products. The manner obtaining these figures was take the ratio this amount recent annual average rail production and applying the same percentage, which amounts per cent annual rail production from 1915 date. Twenty per cent was used Analysis Scrap Consumption Basic Open-Hearth Process (Millions Gross Tons) figures. prior 1915. both instances, renewed and rerolled rails were deducted from the annual rail production before making computations. (5) Miscellaneous processes.—The principal item un- der this heading consists scrap used the manufacture wrought iron. Lesser amounts old axles, tires, and similar products are forged rolled annually into vari- ous products and are included this estimate. The figures are approximate constant relation annual production rolled iron, was believed that this would give the most accurate picture the situation. Pig Iron and Steel Production Compared with Scrap Consumption interesting analysis the iron and steel industry, showing its relation increasing scrap consumption over period more than quarter century, here shown. Total Produc- tion Steel Ingots and Castings, Estimated Scrap Con- sumption Total Pig Iron Production, Estimated Total Scrap Consumption, Steel Making, Year Gross Tons Gross Tons Gross Tons Gross Tons 1900 13,459,480 10,188,329 5,100,000 2,400,000 1913 30,618,169 31,300,874 15,300,000 11,000,000 38,000,000 51,650,000 34,000,000 25,000,000 figures. will noted from the preceding tabulation that 1900 more pig iron was produced than steel, while 1928 the situation was reversed. also ap- parent that, while steel production increased five Scrap Usedin Scrap Steel Mak- Used Total eof fold this period, the use Used ing Basic Basic Pig and Heavy steel making All Steel cesses Other Open- Pig Used Per Cent Melting Making Hearth Basic Steel increased ten fold; during Year Processes Open Hearth duction pen arth the same interval con- 1910 9.0 0.6 8.4 9.1 17.5 $15.3 1911 8.7 0.5 8.2 8.5 16.7 12.98 sumption scrap all 1912 12.0 0.6 11.4 11.4 22.8 1913 11.0 0.7 10.3 12.5 22.8 12.92 1914 0.5 8.4 9.7 18.1 1915 12.5 0.8 11.7 13.0 24.7 seven fold. the other 1916 16.0 1.1 14.9 17.7 32.6 46 18.14 hand, less than three 1917 19.2 1.2 18.0 17.7 35.7 29.90 1918 18.3 1.2 17.1 18.7 35.8 times much pig iron 1919 14.5 0.8 13.7 14.5 28.2 8.35 1920 18.5 17.7 16.8 34.5 25.74 was produced 1928 1921 8.9 0.3 8.6 7.8 16.4 13.76 1900. 1922 18.3 0.8 17.5 13.8 31.3 17.62 1923 19.0 0.9 18.1 19.8 37.9 20.38 very unusual situa- 18.4 0.7 17.7 16.0 33.7 18.51 1925 0.8 21.2 19.7 40.9 tion has recently existed 1926 23.1 0.8 22.3 21.2 43.5 17.10 the istrict 1927 22.0 0.7 21.3 19.4 40.7 15.50 district, 1From THE IRON AGE. with heavy melting scrap quoted higher than basic pig iron. The firm prices The Iron Age, February 14, 1929—473 for heavy melting steel scrap recently are accounted for the high rate steel production and the increased consumption scrap basic open-hearth furnaces. analysis scrap consumption the basic open- hearth process, together with prices for heavy melting steel scrap, given accompanying table. The fig- ures this table merely substantiate the generally known fact that scrap proportions increased during and since the war. The decrease per cent 1923 probably accounted for the high rate steel production and the shortage and high price scrap during that year. While steel production was still greater 1926, the price scrap easier and more scrap was used, although there was slight recession the proportion for that year. Advisory Department Assists Employees Crane Co. Helps Workmen Solve Intra and Extra-Plant Problems—Handles Accident Claims and Cases Wage Assignment management into closer touch with ees, Crane Co., Chicago, operates advisory Vet Leag has been the company mol This vas chosen alone be- ] ong W h ( ( p laintal € n deal experience with both men and women personnel Young Men’s Christian Association and { Y head the advisory department comes face face with from 6000 8000 men and women during the period year and helps them solve their personal troubles. Each case brought the attention the ad- viser considered its own merits the privacy office built especially for this purpose. The employee dvised the best course follow get him out his difficulties, regardless whether they family financial troubles pertain conditions the shop. instructed watch the behavior work- Ordi- narily man does not lose his energy, and show signs Y their attitude toward their work. worry the point where plainly noticeable and where ome burden his department, unless there some real underlying cause. the foreman’s duty refer cases this kind the adviser. case broken home, the adviser brings man and wife to- gether and openly reviews their differences careful and friendly manner. family almost in- variably the result, and, best all from the company’s viewpoint, the employee enabled hold his job and once more contented. Interest family matters does not cease the time worker’s death. The widow welcome advice. She given aid gathering and safeguarding papers relating her husband’s estate. The department protects her from unscrupulous advisers, whether they friends, relations lawyers, placing her affairs the hands reliable attorney. When children are left orphans, efforts are made bring about adoption. Personal acquaintanceship with attachés the juvenile court and juvenile detention home often smooths the way for parents whose children have become wayward. When investigation reveals that families are living dark and gloomy quarters, arrangements are made that they may move into more suitable apartments homes. When police officer appears with warrant for the arrest the employees, the family friends are one of notified arrange for proper bail and attorney se- cured protect the employee’s interests. All difficulties arising from wage assignments and garnishees are referred this department. This practice not only results satisfactorily settling many disputes 474—February 14, 1929, The Iron Age and claims, but also affords the workman the knowl- edge that has reliable and unprejudiced source advice, which will aid him avoiding future entanglements like kind. frank statement facts the adviser often results the cancellation partial payment con- tracts, which times are obviously unfair the buyer because changes conditions beyond his control. Ways and means are suggested reduce personal debts and plan has been put into action whereby stock certificates, valuable papers and securities different kinds are put away for safe-keeping one Chicago’s largest banks, with charge whatsoever the employee. The department offers aid when employees’ savings are threatened. workman may lend life’s accumulation friend personal note buy home, pay mort- gage doctor’s bill, only find that the money not forthcoming when the loan matures. Such case taken the adviser, who follows through without the expense legal action, usually effecting settlement satisfactory all concerned. Foreign born who are still aliens are urged take out papers. Arrangements have been made with large insurance company whereby blanket policy has been issued cover personally owned cars workmen low rate. Close 800 employees have availed themselves this opportunity. shelter employees’ cars, hundreds steam-heated stalls have been erected, and gasoline and oil are dispensed cost plus overhead charges. Often employees meet with street car accidents, auto- mobile accidents and the like. Crane Co. maintains friendly relations with the claim departments the street car company, taxicab companies and insurance companies. Adjusters work through the adviser, and claims are settled without legal cost the employee loss working time. When personal disputes arise the shop, the men involved are brought together the adviser’s office effort reestablish friendly feelings. Some time ago the president the company, Crane, Jr., owned number vacant lots the neighbor- hood the plant. deeded them the adviser with instructions that they sold old employees the con- dition that they used home sites. Every lot was sold reduced price with taxes paid full. standing policy the department encourage employees own their homes, and they commonly consult the adviser their real estate problems. the present time per cent all the employees the Chicago plant own their homes. Employees are showing hearty appreciation the advantages the new department. steadily increasing numbers, they are bringing their problems the adviser, whether they arise outside the plant. Economies Result When Steel Replaces Wooden Reels and Used Tex- tile and Wire Industries—Sizes Range from 114 In. Ft. Diameter another instance the way welded units pressed steel gain footholds important industries found the manufacture spools, bobbins, beams and reels. Such carriers for thread, braid, wire and woven fabrics are known these and other names, but all are essentially spools, diameter and length rang- ing from in. ft., according the purpose in- tended. few years ago all those used the textile industry were made cast iron wood; even where some device was needed prevent overwinding act drive, ratchet teeth would cut into the wood one end (if the bobbin were moderate size), driving gears cast iron would bolted cast the ends the longer “beams.” Certain well known disadvantages wooden carriers were endured because solution was apparent. Not only did the wooden teeth wear out rapidly, and the cast iron beam-ends break under rough handling, but when splin- tering started the wooden spools the yarn would catch and either break cause rough imperfection the woven fabric. Such troubles are cured the use steel spools, according the experience the Mossberg Pressed Steel Corporation, Attleboro, Mass., which has specialized since 1920 such products. Much textile machinery equipped with all-steel beams, and considerable volume business beam ends comes this concern from plants need- ing replacements for broken cast iron parts. These beam ends are infinite variety—each loom designer seems have his own ideas about the best way support and drive these fixtures; replacement work consequently the “tailored-to-order” nature. Sheet steel and plate In. Loom Beam Head. Semi- steel gear, bar steel center bushing, friction band and plate sheet steel, all welded into one Welded Construction. Barrel extends through end and fillet welded form stiff rim; arms channel iron; shaft and diagonal braces tubing correct gage, cut circles bent and welded into short cylinders, appropriate shafting and semi-steel gear rings form the elements from which any such design can duplicated relatively indestructible construction. Should loom beam filled with yarn dropped and one the heads broken, serious loss occurs, oftentimes the entire amount yarn. Steel construction removes this risk. many cases the steel heads can made considerably lighter. This particularly desirable sec- tion beam heads, which may filled with yarn and then transported oftentimes long distance from one mill another. The extra weight the cast-iron beams shipped back and forth totals big expense item, even dam- age done route. Steel also takes different freight classification and lower rate. Quantity production various sized reels more important output the Mossberg plant, the wire industry being among the largest users. Even small bobbins and “cop holders,” all steel, have replaced wooden ones eco- nomically; steel spools have smaller barrels and ends and can carry more thread wire, and thus pensate for freight the slightly greater weight. Construction details reels and spools vary according use. Circular ends usually are curled flanged the edges for stiffness; larger sizes have radial ribs pressed into them for lateral strength. Small barrels may made tubing; larger ones are bent from flat sheet All-steel Beam with Adjustable Heads. Barrel steel tubing with inserted steel ends, welded place; hubs made bar stock, clamps bent shape, one end welded head, the other end drawn clamping screws The Iron Age, February 14, Welded Steel Replaces Wood and welded the longitudinal seam. They are affixed the ends various ways; the smaller ones may have pro- jections fitted into slots the circular ends and clinched over headed. Larger reels are welded all joints. smooth joint required, fillet weld run around between barrel and head and machined. Welding method construction such that hollow shafting, special reinforcing pieces braces can easily added the requirements the design demand. Skeleton construc- tion, with barrel made perforated plate, especially the wire industry, for annealing, impregnat- saturating purposes, where the mass the reel Electric Heat Treating May Shortly Expand England Dealing with the subject the speeding production, Page, the metallurgical de- tment the Birmingham Small Arms Co., Ltd i nent ol ne oirmingnam omMmail rm Birmingham, England, his presidential address the ers the Birmingham Metallurgical Society late last + +) + } < ar year, pointed it that the heat treatment of carbon too! steels very important operation. The high tempera- tor n t hardening 1th contro] Ires necessary In correct hardening are aimcuit to control and, even satisfactorily obtained, they are not easy accurately. The most heating gas-fired Mr. Page, but this actually the least satis placed the hands —the salt bath electric furnace popular method has the engineer two methods hardening- thod and what termed the “dry” extremely accurate control temperature ind ease measurement. That the utilization electricity for industrial heating nas got to come, even Great Britain, appears have substantial reasons for belief, said the speaker. For very large heating installations probable that gas, oil solid fuel will hold its own, but based the industrial cost gas and electric power Birmingham for furnaces moderate size, electric heating not only affords advantages operation and improvements the quality the product, but actually cheaper, taking all into consideration, than any other methods heating. Stability Metals High Temperatures Decreases Under Load Methods testing steel pipe rupture elevated temperatures were described paper, “Evaluation Stability Metals Elevated Temperatures from Expansion and Short-Time Tensile Test Data,” Prof. Albert White and Claude Clark, University Mich- igan, Ann Arbor, read Oct. session the Amer- ican Society for Steel Treating, the convention Philadelphia. Slides were presented showing curves plotted from observed data. was found that the destruction the pipe proceeded rapidly when its load was enough sub- But about 3000 lb. the square inch pipe 1250 deg. Fahr. had run more than 2250 hr. result the experiments, however, the authors hat the formula commonly used for such case From the formula, the “curves” should ines, which they are not. ject heavy tensile stress. without showing distress. concluded unreliable. straight With the great variety engineering steels now avail- able, said one speaker, discussing the paper, one must (1) choose the one best suited the purpose, and then (2) use safe working stress the material under the conditions temperature, met. 476—February 14, 1929, The Iron Age should reduced the minimum and the fullest oppor- tunity given for the heat fluid penetrate into the coils. Steel construction has several collateral advantages: Beam barrels made steel tubing have the advantage over wood that steel barrel will remain straight and true dimensions, whereas wood will warp even does not get battered damaged handling. pos- sible use barrel smaller diameter when made steel, and thus the beam will carry more yarn. This par- ticular feature special advantage the carpet weav- ing industry and the plush mills. did not agree with the adequacy the authors’ test methods and did not believe them suitable for the purpose intended. Productivity Merchant Blast Furnaces productivity merchant blast furnaces was more than twice great 1927 the pre-war period, according investigation the United States Bureau Labor Statistics. Average output pig iron per 100 man-hours labor increased from gross tons 1911 tons 1927. other words, required hr. min. labor produce gross ton pig iron the pre-war period, against hr. min. 1927. This increase productivity, which has taken place almost en- Labor IVUCT/IOI?, OTOSS 10S Ol Man Hou 20 | Average Stack Production per Hour Both the Furnaces and the Men Have Shown Improve- ment Performance tirely the past six years, due large part closing down many inefficient plants, owing keen competition steel works furnaces. Japanese Opinion Density Quenched Steels study the density quenched steels, the results which are found paper contributed recent issue “Science Reports” the Téhoku Uni- versity Japan, the following conclusions are arrived the author, Sekito: The expansion quenched steels may explained the expansion of the space lattice. The internal stress calculated from the diffusion the spectral lines quenched steels was shown the same order of magnitude as the tensile strength. The plane right angles the plane maximal atomic density (the most easily slippable plane) sub- ject the greatest internal stress. Prof. explanation the diffusion the spectral lines quenched steels more reasonable than that Westgren, who considers due the refine- ment of the crystal grain. | | Axle Housings Electric Steel How California Foundry Overcomes Defects Nickel Alloy Castings—Composition and Heat Treatment ETHELBERT HEN was difficult ob- tain steel castings from the East during the war, the company with which connected built its own electric furnaces from the specifications furnished Vom Baur, New York. this type the di- rect arc with ducting hearth used. alternating current employed with three carbons entering the furnace. The larger, 3-ton, furnace provided with automatic regulation the arc; the smaller, furnace hand regulated. Due low cost the electric current the Pacific Coast, the cost for small furnaces very low indeed. is, however, necessary that the man charge have thorough knowledge the electric furnace process. order produce good sound steel, necessary that the metal does not contain impurities, oxides gases. For the production castings, the electric process offers large advantages because high temperature easily obtainable which reduces the scrap loss encountered with other systems. The furnace may also used for the production both iron and steel castings. hot metal also necessary run thin sections when outlines must sharply maintained. Manufacturing Axle Housings When our company first started produce axle housings for six-wheel trucks, several difficulties were encountered. the first samples made, like those shown Fig. shrinkage cracks were found the corners and These cracks developed because the greater mass metal these points, which adversely affected uniform cooling. overcome these, the next step was leave off the corners and add extra metal these corners, shown Fig. which was after- ward turned off. eliminate cracks still more effectively, metal chills, were added shown, but the present time these chills have been eliminated and instead softer core used, which obtained the use softer binder for the sand. The shrinkage cracks were most difficult overcome and had eliminate the circumferential ribs and cast longitudinal ribs, shown the small ring, being attached the ribs instead the outer housing. result, sound casting produced free from cracks. The ring necessary support the end the chrome-nickel steel tube which supports the wheel bearings. These castings contain about 0.30 0.31 per cent *Part paper presented the Western Metal Congress the American Society for Steel Treating, Los Jan. 18. The author consulting engineer, Moreland Motor Truck Co., Los Angeles. carbon, with per cent nickel added the bath. soon they are poured, they are withdrawn from the mold (the core being removed), then permitted cool slowly. Afterward they are annealed, the temperature being slowly raised (in hr.) 1625 deg. Fahr., where they are soaked for hr. They are then slowly cooled. The tensile strength the metal approximate- 120,000 per sq. in. produce these axle castings requires careful at- tention throughout the process. Special core mixtures, sand mixtures, and careful workmanship are necessary preparing the mold. The specifications for these cast- ings call for metal the following limits: Per Cent Silicon ... 0.20 to 0.30 ..... 0.05 maximum Phosphorus ... 0.05 maximum The charge for the furnace made approximately per cent purchased scrap known analysis con- Fig. the First Axle Housings Made, with Location Shrinkage Cracks Shown Fig. 2—Where Extra Metal Was Added Overcome Cracks and Defects sisting punchings, plate, butt ends, I-beams solid tire rims. The remainder the returns the form rejections, heads, gates and sculls spills. About 100 lb. metal from the previous heat left the furnace and the new charge put into it. This forms solid, gummy mass and gives immediate electric contact and hot are. eliminates the use starter such coke. Some care exercised the charging eliminate the necessity much poking down the melt progresses, Preliminary melting done high tap. melt down the charge usually takes about one hour. sam- The Iron Age, February 14, 1929—477 a Metal Chill... W ple taken and color test run determine the pre- liminary carbon content. The reading fracture highly refined steel rather uncertain and laboratory, equipped test the carbon the color method, recommended. Since the low-carbon steels are used base, the melt will usually run low carbon and this, one its many forms, added. The immersion the graphite electrodes will usually accomplish the desired results. Cast iron and pig iron may also added desired. Should the test show higher carbon content than speci- fied, high-grade, clean, hard hematite, low-phosphorus iron ore added bring down. The ore added small quantities until the desired specification finally reached. The bath then brought the pouring temperature and tests made the metal and the slag ascertain whether thorough deoxidation has been accomplished. This can ascertained from the slag—a light green color the fracture showing complete deoxidation. further precaution there added the ladle small amount pure aluminum. The entire heat tapped into large ladle, the slag carefully skimmed off and protective covering clean silica sand put on. The metal then transferred pouring ladles about 100 lb. capacity. obtain satisfactory results the material used, mentioned before, must very carefully selected. Lime- stone and fluorspar are always hand dissolve slag when necessary alloys are added, adding silica sand afterward bring the slag its normal con- sistency. Zinc-Cadmium Solders Used for British Dirigible ROSS bracing between main longitudinal and trans- verse frames the British airship R-101 now under construction made high-strength steel cable, strand which zinc coated. with special solder called each End connections are made according neering. After the cable clamped in. from the end prevent unraveling, cut length. fitting shaped with internal cone (called capel) then slipped over the end, the wires splayed out, and the internal cone filled with the solder. Cazin eutectic composition (82.6 per cent cadmium, 17.4 per cent zinc) which melts 263 deg. C., low enough not impair the strength the cold drawn wire the cable. also unites with the galvanized coating the wires without acid chloride flux (only little pure resin being needed) thus avoiding possibility corrosion under traces flux. The capel Sherardized and slightly oxidized, the solder does not adhere it; the cone merely acts mold. Shearing strength cazin from 15,000 16,000 lb. per sq. in., and does not extrude through the fitting when the cable under load. When the solder cold the end surface ground off square, and clevis forked end attached each capel. Each assembly given proof load per cent the ultimate strength the cable; this beds the cone end into the fitting and also stretches the cable sufficiently prevent creep under the working loads. Cazin was developed the Research Association British Motor and Allied Manufacturers 1925, re- sponse request for soldering material for bicycle frames, which would flow over cold drawn steel without tempering them and yet remain firm enamel baking oven. Shear strengths high 25,000 lb. per sq. may had other solders this family. Increases Calorific Value Coke Oven Gas Increasing the calorific value coke oven gas from about 4136 5368 thermal units can accomplished the following method, according three German authors, Schoenfelder, Riese and Klempt: The gas passed successively over catalytic material 700 deg., the material being made nickel precipitated mag- nesite destroy organic sulphur compounds and break down heavy hydrocarbons and, after the removal hydrogen sulphide, over pieces clay containing reduced nickel 520 deg. reduce carbon monoxide and carbon dioxide methane and water means the hydrogen the gas. Oil-Burning Steam-Operated Railroad Coach Perfected Locomotor steam-operated railroad car developed the Ryan Car Co. and the International Harvester Co., Chicago. The Locomotor requires only one operator and may run from either platform. The controls consist merely throttle, reverse lever and air brake valve handle. The fuel used ordinary distillate, which vaporized and de- livered special type burner the heart the steam generator. steam delivered two eight-cylin- der, single-acting, poppet-valve uniflow engines, simultane- 478—February 14, 1929, The Iron Age — ously controlled, which are located underneath the frame the car. Each engine drives directly the inner axle the adjacent truck through propeller shafts that accommodate themselves truck radial movement and spring action. From 300 500 hp. delivered the wheels, making the car capable handling trailers and attaining speeds miles hour. The Locomotor can built suit any standard car design. ens a Leaves from the Diary Foundry Apprentice FROMMELT* Dec. 2.—Only month the side floor, but the more jobs get the more realize how little know. Each one different and each one requires good judgment; and that comes with experience. Dry sand molding interesting. Dec. 10.—The foreman the side floor gave first real lesson gating today. see; first, the gates must large enough and the sprues numerous enough allow the mold fill quickly. True enough, but only good judgment will determine that. Here again that means experience and lots it. You can’t develop judgment without lot experience. Well, hope four years enough. No. The metal upon entering the mold should not drop considerable distance and thus wash out the bottom the mold. That easy enough; and ought able place gate that the metal does not have Niagara get into the mold. No. Avoid sharp corners; the metal should not run far after entering the mold; the gates and sprues should placed that they will not cause shrinkage cavities strains the mold. And all these demand experience and nothing but; how else can you tell when steel will will not get tired before filling the mold get disgusted the gate and pull away, causing strains and shrinkage cavities? un- derstand, course, that steel shrinks when cools and naturally sets strains. But only experience can tell where and how place gates avoid all this. The books can’t tell because every case different. Experience, ex- perience and then more experience; wonder they have apprenticeships four years. Dec. 20.—Had first real lesson gates today from the standpoint acting reservoirs feed the mold. It’s not enough that these pesky gates have just right usher the metal in, but they have certain size and certain number them must stick their heads above the top the mold that there will enough metal feed the mold. The foreman took over the shake-out floor and demonstrated what meant pointing out sorry look