The Iron Age 1929-03-14: Vol 123 Iss 11

EIRON ACE New York, March 14, 1929 ESTABLISHED 1855 VOL. 123, No. Aluminum Vieswith Steel for Chairs Manufacture Alloy Metal Put Production Basis the Buffalo Plant United States Aluminum Co. PRENTISS* place with steel substitute for wood the manufacture office furniture well for the manu- facture chairs for other uses. With steel desks and cabinets and metal doors, sash and trim now be- volume, the only field left for the metal fabricator extend the use his products office furnishing and furniture seemed chairs. The familiar wooden swivel and other types wooden chairs are now facing the competition aluminum chairs, extensive line which was developed and recently put production basis the Aluminum Co. America through its manufacturing subsidiary, the United States Aluminum Co., its Buf- falo plant. Advantages claimed for aluminum chairs are strength and lightness. the same time they are attractive appearance. Their weight about one-half that wooden chairs the same general type and, they are made one the strong aluminum alloys that has ap- the physical properties mild steel, they are said practically indestructible, and they have dowels become loosened joints reglued wooden chairs. complete line office chairs side types. with straight and curved backs and arm chairs with plain and swivel bases *Resident Editor, Cleveland. ORMING Back Frame Alum- Bending Machine. The ease with which these operations are performed im- portant factor the commercial success the development furniture being made, well chairs for hotel dining rooms, restaurants, cafeterias and for railroad dining cars and for steamboats. Saving motive power from reduction weight and minimum maintenance are factors which are said have made the aluminum chairs popu- lar with both rail and water transportation lines. The aeronautical industry promising field for aluminum chairs because their lightness and strength. Chairs are now being made aluminum for use airplanes and other types are being developed. This line will in- clude seat chairs for airplane pilots and navigators and cabin chairs for passengers. For dirigibles there will chairs for pilots, navigators, also chairs for passengers, including lounging and bedroom chairs. addition chairs, other office accessories such waste paper baskets and costumers are being made aluminum. Aluminum Alloy 51-S Used Because Good Forming Qualities While several strong aluminum alloys are suitable for structural work, the one known 51-S was selected for furniture fabrication because its good forming quali- ties and other general mechanical properties. steel, these mechanical properties can changed annealing, quenching and aging, permitting the fabricator select metal which heat treating can suited the re- quirements. This alloy its annealed condition, desig- nated 51-SO, which attained heating 662 deg. Fahr. followed slow cooling, very ductile and can subjected severe forming operations. Cold working after annealing increases its strength, and this can further increased heat treat- ing 960 deg. and quenching water. The alloy subjected these heat treatments, designated 51-SW, used for making alumi- num furniture, being sufficiently ductile, used within few weeks after its manu- facture, for most form- ing and bending opera- tions, that only the most severe deforma- tion requires the use annealed metal. After fabrication the alumi- num strengthened and stiffened the ex- pense ductility artificial aging. This done heating the metal 320 deg. Fahr. for from hr., the operation being car- ried with the baking the The physical properties the alloy after the treatments are: Tensile sterngth per sq. in.) 45,000-50,000. Yield point per sq. in.) 30,000-40,000. Elongation (per cent 2 in.) 10-18. Brinell hardness (10 mm. Ball 500 kg.) 85-100. large portion the fabrication aluminum chairs con- sists forming parts presses and brakes, and stated that the ease with which these operations are performed important factor the commercial success the development aluminum furniture. Such parts legs and back frames are made from uniform tubular sections, which are purchased the form seam- less tubing. This cut required length with circular band saws and given the proper curvature dies op- erated presses. Some back frames having curved cor- ners with 4-in. radius are formed special bend- ing machine. Channel sections such leg braces and seat frames are formed from sheet aluminum blanks bent into shape brake. Tapered legs are blanked out from sheet aluminum with dies and bent the proper section and then welded along one seam. Parts requiring deeper draw- ing and more difficult forming are saddle shaped seats, swivel chair bases, etc., for arm chairs, and caster forks. Most these are completely formed two three suc- cessive draws. The formed parts are assembled into complete chairs autogenous gas welding. All joints are welded into 730—March 14, 1929, The Iron Age HAIR Parts are Held Jigs for Tack Welding During Assembly. All jig parts are made either steel cast iron, and every type chair requires separate jig integral whole except where the back frame joins the seat and one two other places where two flat sur- faces come together. Here mechanical joint bolted construction employed. Problems involved the welding strong aluminum alloys had solved the company’s research en- gineer before one-piece aluminum chairs could satisfac- torily produced. These included the development spe- cial welding wire, fluxes and baths and new methods relieving strains set the welding operation well providing highly trained labor. Skill applying the torch with the oxy-hydrogen flame and the control tem- peratures are important matters technique and when properly em- ployed are said re- sult welded joints which develop over per cent the ultimate strength the metal. The development suitable metal jigs for the accurate assembly parts has been given much attention. After being formed dies cut size, the parts are first gether for welding sub-assembly jigs for back frames, leg braces, arms, seat frames, etc., and these are finally fitted into complete as- sembly jigs. The vari- ous parts are held firm- with lever cam ac- tion, which allow rapid fitting and re- moval after welding. All jig parts are made either steel cast iron, and every type chair requires arate jig. rule, the chairs are only tack welded while the jigs, the welding being completed separate operators the floor bench. This allows higher rate production per jig. The use very rigid jigs this type permits the easy maintenance the exact size and dimensions, that all chairs given type are said exact counterparts each other. Where smooth finished surfaces and fillet joints are required, the excess welding metal taken off rotating steel cutters and abrasive disks operated portable shaft ma- chines. The final finishing operations are performed with fine carborundum cloth. few places, where two flat surfaces coincide, they are bolted together previously noted. This assembly effected inserting the large heads the bolts suita- ble slots the leg tubing, where they are held their proper place coincident holes the seat frame channel section. special plate fitted over the threaded ends the bolts which nuts and lock washers are tight- ened. While some the chairs have plain seats formed with dies from aluminum sheets, most types have leather up- holstered seats, backs and arm pads, the trimmings being attached concealed screws that they can re- moved for refinishing. Casters and Swivel Devices Are Also Made Aluminum Casters and swivel devices, usually made steel and brass, have been developed aluminum for use these chairs. The swivel device made strong aluminum alloy sheet, rod and extruded angles, usually the same > gages steel. The only steel parts the de- similar that which they receive actual service. These tests, stated, have failed develop structural weak- ness. order give the chairs the most durable finish pos- sible investigation was made various types fin- ishes from vitreous enamels and electrolytic deposits air dried paints and lacquers. Vitreous enamels and color applied electrolytically were tabled, because the high baking temperature required for the former and the thin- ness the latter. The survey, stated, demonstrated the superior durability paint enamels baked elevated temperature and considerable time was spent developing the technique these proper applications. Be- fore painting, the chairs are sandblasted that the paint film will bind tightly the material. operating the sand blast, air pressure not exceeding lb. used and the blast directed rather oblique angle. After sand-blasting the chairs are handled with clean cotton gloves prevent contamination from grease perspiration. The priming coat contains long oil (China wood oil) varnish mixed with sufficient iron oxide burnt umber give decidedly dark color. This sprayed and dried for hr. baking oven maintained 325 deg. Fahr. with thermostatic control. Even distribution the heat attained the use fans that circulate the air effectively that the greatest variation the temperature the oven only deg. The prim- ing and succeeding coats are lightly sand-papered vice are two bolts with wing nuts. The use aluminum has reduced the weight the swivel from 12% lb. to6 Several types casters made strong aluminum alloy had been developed the company cooperation with caster manufac- turers and these have withstood severe tests. One these casters consists die formed fork %-in. material attached stem another strong alloy and fitted the socket the bottom the chair leg aluminum adapter, also die formed. Any standard make caster can fitted the chair employing the proper adapter. The wheel made leather disks bound together aluminum flanges. The wheel fitted with steel bushing, but the axle made heat-treated strong aluminum alloy. One popular type caster has rubber tired wheel and ball bearing swivel. Swivel chair bases have die-formed aluminum scuff plates protect the paint from the wear shoe heels. Metal being more resilient than wood, provision made deaden any resultant sounds hard flooring. Straight chairs have combined gliders and silencers and swivel bases are partially filled with balsam wool eliminate sound vibration the legs seats caused the click casters their sockets. Tests Have Failed Develop Structural Weakness Physical tests were selected during the development work determine the ability aluminum chairs with- stand the strains service. They were given static tests show the effect the imposition definite loads and dynamic tests which they were subjected racking Welding Swivel Base Left). Finish ing Chair Joints Bench Right) before adding more paint order as- sure good adhesion. was found that little over 300 deg. Fahr. the tem- perature best adapted the dry- ing the baked priming and ground coats, and this coincides with the aging temperature the aluminum alloy, these operations are performed simultaneously. Physical tests also showed that the period aging in- volved the painting operation was just sufficient im- part the properties stiffness and resilience the chairs, that they would withstand normal service conditions. present the chairs for the most part are given wood grain users are accustomed that finish The Iron Age, March 14, wood furniture. The Von Webern plate graining process employed transfer the chairs exact photographic reproduction the wood grain. Present equipment re- stricted walnut and mahogany plates and several dif- ferent popular shades brown and red baked enamels are used ground coats. Two ground coats are successively sprayed directly the priming coat, each being baked for hr. The plate process for giving the metal wood grain finish consists transferring means printers’ roll- ers the desired grain pattern from copper plate upon which has been etched the exact photographic reproduction the wood grain. The ink used the printing process 732—March 14, 1929, The Iron Age ? a at 1. a ~ in > SSEMBLY Seat and Back Frames. Formed parts are assembled into complete chairs autogenous gas welding. few places, where flat surfaces meet, mechanical joint bolted construction used especially prepared black varnish called graining compound. This sprayed upon the copper plate means roller and scraper, which leaves the compound only the etched grain depressions. When the grain pat- tern has been imprinted upon the ground color, dried approximately 150 deg. Fahr. for hr., after which the metal varnished varnishing wood. finishing the grained surfaces baking varnish used, which selected give hard and tough coat when baked between 200 and 300 deg. Fahr. for nr. Three coats varnish are applied, the last one being rubbed with rottenstone and oil produce high grade satin finish. Baked varnishes were selected because tests, stated, showed that they were more durable than other types clear finishes. When grain finishes are not called for and high dura- bility importance, baked enamel finish used. URFACE Finishing Chairs After Welding. wood grain finish bling walnut mahogany used f | Measuring Open-Hearth Yields Consideration Various Forms Losses and Recovery Scrap and Ingot Butts— Influence Pig Iron Ratio KING* ratio method for calculating ingot yields, are made iron lost slag pocket accumu- lations, checker chamber dust and stack losses, free me- tallic iron slag, loss due SiO, contributed erosion furnace structure, and non-recoverable pit spillage. miscellaneous losses were developed some length the author, giving results investigations made several previous writers. Table shows distribution free metallic iron the slags.] The various losses per unit metallic charge, com- prising miscellaneous losses, are made follows: Per Cent dust checker chambers, waste gases, etc.... Due erosion furnace 0.09 Due unrecoverable spillage—pit side.......... 0.11 From these empirical determinations, one can assume that every ‘unit the metallic charge suffers loss 0.75 per cent the form these miscellaneous losses. Obviously, differences should allowed when compar- ing coke gas, natural gas and liquid-fuel-fired furnaces. Spillage, Oxides and Foreign Losses all reports basic open-hearth yields, one forced assume that the hot metal, designated con- sumed the furnace, ‘represents all that actually re- ceived. This far from true plants where provi- sion made for deduction the kish blast-furnace slag that may accompany the hot metal from blast fur- naces mixer. the kish has been deducted from the gross metal, even estimated the basis occasional checks, then for practical purposes the reported net weight ficiently accurate. However, failure account for kish, productive possible serious errors yield, particularly high hot metal charges. This will better understood from the analysis kish and the weights thereof per ton metal. [Figures showed varia- tion from 0.90 2.86 per cent the hot metal existing kish.] If, indicated, least per cent kish part the gross metal, and consideration given it, then, per cent hot metal charge, the yield will show error least 0.50 per cent. The yield such cases will fictitiously lower, and the cause for many apparent low yields may found this condition. the kish greater amounts than per cent, this situation will intensified. transferring hot metal from the mixer open- hearth furnaces some scrap produced the mixer *United States Steel Corporation, New York. This con- clusion abstract paper delivered Feb. 18, before the Iron and Steel Division the American Institute Mining and Metallurgical Engineers, the annual meeting the Engineer- ing Societies Building, New York. The first section was pub- lished Feb. 28. spout, skulls transfer ladles, and when pouring into furnaces. far the largest part produced skulls. The amounts involved will vary different plants, rang- ing rule from 0.20 1.00 per cent the hot metal, the average being approximately 0.50 per cent. Unless practice light-weigh ladles, error yield will ob- tain, proportionate the amount such iron scrap pro- duced. Such recovered and later prepared for either blast-furnace open-hearth use. therefore does not constitute actual part the charge which normally shown against the furnace. For great accuracy, one should not consider elimination metalloids this por- tion the hot metal. However, the error involved small when such scrap amounts 0.50 per cent less. provision made for this factor normal calculation, but where this scrap greater and particularly high metal charges per cent and over, should con- sidered. Moreover, where this obtains, the high scrap production should investigated. Spillage and Other Losses handling hot metal mixer and open-hearth furnaces, mechanical losses the form shot, spittings and splashings occur, which can accounted for only metal (hot) received, less that charged open-hearth furnaces—the difference being made scrap and losses. These losses, together with those which occur the mixer, normally amount 0.50 per cent hot metal. Therefore, the consideration losses hot metal, this factor applied. While such losses would slightly lower for plants which can charge the de- sired hot metal one ladle than for those which re- quire more than one ladle, for practical purposes 0.50 per cent used standard all cases. exception made only the case plants using large proportions blown metal, basic duplex operations, which may require four more ladles such metal, which case 0.80 per cent for spillage allowed. Loss Iron Due SiO, and Steel Scrap Table III, “Losses Components the Charge,” loss 0.09 per cent appears against steel scrap due the 0.10 per cent steel scrap. figure 0.10 per cent allowed arbitrarily, and examination condi- tions discloses this conservative. For example, per cent the total metallic charge pit scrap, then per cent scrap charge, pit scrap constitutes per cent the total scrap charge. the pit scrap, even though carefully prepared the skull cracker, contains much per cent slag weight, equal 0.40 per cent slag total scrap charge. the slag analysis approximately per cent this equal total 0.06 per cent total scrap. Larger amounts will increase this proportionally. view The Iron Age, March 14, TABLE V—FREE METALLIC IRON BASIC OPEN- HEARTH SLAGS (PERCENTAGE) Slag No. Tapping Ladle Composite 0.85 0.30 2.67 2 0.77 0.99 5.97 2.50 3 0.88 0.91 1.55 1.95 4 1.00 0.82 2.71 2.14 3.63 1.60 7 0.40 2.46 1.45 0.87 2.20 10 ar 0.60 0.80 0.65 TABLE VI—EFFICIENCIES OF ALLOYS AS DETERMINED BY VARIOUS AUTHORITIES Per Cent—— Manga- Sul- Chro- Vana- Molyb- nese phur Silicon mium dium denum Nickel Test No. 2.... 64.6 a 72.5 79.6 86.2 eee Test 3.... 70.6 92.1 94.6 91.1 Test No. 5.... 87.7 95.6 Test No. 6.... 63.4 80.5 71.6 Test No. 8.... 66.1 $0.1 81.5 79.0 65.9 es 87.8 97.0 56.0 65.5 Ses 86.0 93.5 66.0 70.1 80.0 85.0 Plant average 79.4 77.5 Plant average 70.0 74.5 72.5 Plant average 68.0 74.0 the large losses due introduction careful preparation pit scrap desirable, but the extent which this should carried remains for investigation. addition, dirt and sand will found attached many forms light scrap and the poorer forms mar- ket scrap. Therefore, assuming 0.10 per cent ap- pears within reason, especially since many types scrap contain silicon which small amounts are not reported analyses. Where silicon scrap known analysis charged, the ratio should calculated accord- ingly. For the SiO. content assumed, and with the ratio 1.85, the loss slag per unit steel scrap 0.10 0.4667 1.85 0.086, called 0.09 per cent. Loss Additions Loss additions, which refers pure manganese, silicon, chromium, vanadium, etc., the ferroalloys used, varies practice depending slag conditions, presence other oxidizable elements, temperature, time allowed « TABLE IX—LOSSES COMPONENTS BASIC OPEN- HEARTH CHARGE (DUPLEX OPERATIONS) TABLE VII—VARIOUS TYPES MISCELLANEOUS SCRAP PRODUCED, PROPORTION METALLIC CHARGE Plant No. Pit Scrap Iron Skulls Steel Skulls Total 2.97 0.21 0.25 3.43 2.51 0.28 0.12 2.91 3 2.76 0.43 0.28 3.47 1.70 0.30 0.62 2.62 3.12 0.59 0.25 3.96 2.73 0.41 0.25 3.39 2.97 0.56 0.25 3.78 TABLE VIII—COMPARISON YIELDS Difference Difference Between Feto Between Suc- Suc- Ratio Kinney cessive Ratio cessive Yields Yields Method Slag Standard iron-low High manganese iron- low ore...... 90.92 0.12 89.75 0.14 Standard iron high 0.34 89.39 0.36 1.81 high ore....... 90.39 0.19 89.20 0.19 1.44 High-phosphorus iron. 0.28 88.94 0.26 1.73 Excess limestone..... 89.76 0.35 88.63 0.31 2.63 High-silicon iron..... 1.56 87.02 1.61 2.04 for deoxidizing action and other factors. Any standard for efficiencies must necessarily based normal good practice. Since manganese and silicon constitute the largest pro- portion additions used, their influence shown the assumption per cent efficiency per cent loss. Where they represent smaller part the total alloys, adjustments are necessary this standard. The figures Table indicate efficiencies for various alloys under variety conditions, the efficiencies referring the pure metallic manganese, etc. Net Losses Foregoing explanation the character the losses and the factors used accounting for them. previously indicated, necessary only multiply these the percentage the material used the metallic charge, after considering the analysis the metallic and non-metallic material going into the furnace. If‘the blast TABLE X—CALCULATIONS BASIC OPEN-HEARTH YIELDS (DUPLEX OPERATIONS) Type Losses, Blown Cold Hot Steel Lime- Dolo- Percentage Losses Percentage Per Cent Metal Iron Metal Scrap stone mite Spar Materials Charge Loss per Metalloid losses: Used per Ton Com- Ton Total 4.12 0.07 Materials Metallic Charge ponents Metallic Charge Blown metal .......... 80.0 1.296 Manganese ..+0.05 0.65 065 0 28 Hot metal ee 12.0 11.64 1.400 Phosphorus 015 3.3 11.14 0.368 Iron loss in slag Steel scrap cece eseseces 4.0 1.65 0.066 rati 4.17 0.15 3.0 7.35 foreign Limestone 5.55 1.51 0.046 losses ..... 0.80 0.50 0.40 1.53 3.00 0.084 Miscellaneous 0.15 7.35 0.011 losses ..... 0.75 0.75 0.75 0.75 3.446 Less metallic recovered slag........... (a) Total losses.. 1.62 11.14 11.64 1.65 1.51 3.00 7.35 Scrap recovered: Miscellaneous scrap..... 2.00 TABLE XI—PRACTICE DATA FOR DUPLEX OPERATIONS Condemned ingots and ingot butts....... 1.00 Se in eleac } 0.66 0.72 0.77 0.82 0.88 0.93 (a) and (b) Compensate for each other. Miscellaneous scrap (Bes- 0.66 0.72 0.77 0.93 TABLE XII—PRACTICE DATA FOR STATIONARY OPEN- Open-hearth miscellaneous HEARTH FURNACES Ope n hearth condemned in- Pig Iron, Per Cent 40.4 46.6 53.1 57.5 gots and butts.......... 1.00 1.00 1.00 1.00 1.00 1.00 90.82 90.04 88.96 88.27 4.32 4.44 4.54 4.64 4.76 4.86 Scrap, per cent........ 3.95 3.98 4.02 4.04 8.86 9.09 9.29 9.52 Loss, per cent........ 5.23 5.98 7.02 7.69 734—March 14, 1929, The Iron Age furnaces consume some part the open-hearth slag, the metallics thereof are credited the open-hearth and thus regarded scrap credit, the percentage de- ducted from total losses being the amounts used per ton metallic charge, with due regard for the metallic con- tents. The latter usually set figure for any plant, based the average analysis such slags. For example, plant produce per cent slag based metallic charge, and the total metallics includ- ing included shot are per cent, and the blast furnaces find convenient use about one-third the total slag produced, there results credit per cent per Ingots from Charge, per periods time. Since cold iron plants would show credit for iron skulls, miscellaneous scrap for such plants proportionally lower. For plants appears that aggregate per cent miscellaneous scrap can used for stand- ard. This would infer good practice. Higher percentages appear deserving investigation. Cold iron plants should rated lower, proportionate difference iron scrap produced for equal percentages pig iron. When deal- ing percentages materials, amounts actually in- volved over period month year are usually not apparent. For example, were 50,000-ton plant produc- Percen Total Pig Iron Charged, per cent. Total Steel Scrap, per cent. Blown per cent. NGOT Yield Duplex Basic Open- Hearth Practice, with Varying Propor- tions Blown Metal, Shown Fig. (upper left). Characteristic basic open- hearth yields with varying percentages pig iron the charge are shown Fig. (upper right), taken from many years experience under all conditions. Fig. lower right, indicates basic open-hearth yields, all other things being equal, affected differing proportions pig iron used cent 1.35 per cent the metallic charge, which should deducted from the total losses give net losses. Miscellaneous Scrap addition credit for scrap the form open- hearth slag recovered blast furnaces, miscellaneous scrap, ingot butts and condemned ingots constitute part the scrap recovery. Miscellaneous scrap includes iron scrap, pit scrap, steel skulls, mold splashings, ete. far the largest part contributed pit scrap, which usually amounts per cent the total. Pit Scrap Production pit scrap varies considerably. Table VII gives typical pit scrap production per ton metallic charge for several hot-metal plants. These figures cover long 5.0 905 Pig, per cent ing 0.50 per cent higher than such standard, this the equivalent approximately 250 tons times the yield or, roughly, 225 tons. careful drainage furnaces and the use ladles sufficiently large take care over- charged furnaces, one can increase the ingot yield de- creasing scrap production. interesting note further how losses convert- ing pit scrap for use may occur. Assume that 1000 tons pit scrap sent from the open-hearth the skull cracker, which will considered per cent metallic content. preparing this material, handling, etc., much per cent loss may occur, there available the open-hearth approximately 900 tons per cent, 765 tons. other words, there loss tons steel, the equivalent about 0.30 per cent the total metallic charge. This loss will naturally vary with the The Iron Age, March 14, 1929—735 quantity and kind pit scrap produced and with the care with which handled the drop. Condemned Ingots and Ingot Butts Condemned ingots most plants are largely question rigidity physical and chemical specifications. They will vary considerably from plant plant, depending largely the type steel made, the tolerance speci- fications and the standards inspection for quality. average total ingots and butts well-conducted plants amounts usually per cent metallic spection molds, careful pouring and care producing steel, come within chemical can assist keeping such scrap within that figure. Ingot butts are largely dependent the minimum size ingot that can rolled. The length the ingot butt that can handled rolling mills determines this fac- tor. Where plants are held one size ingot mold, there little chance for improvement this type scrap production. Where plants use variety mold sizes, greater ingot butt percentage total metallic charge apparent with larger size molds. Duplex Operations applying the method duplex operations, which are combination acid Bessemer and basic open- hearth, the same system can applied, except that the spillage allowance the blown metal higher because the increased number transfer ladles. This factor 0.80 per cent instead the 0.50 per cent allowed ordinary hot-metal charges. The metal used for blowing, the following comparison, combination low-man- ganese basic and standard Bessemer iron. The Bessemer slag resulting follows: — — Per Cent FeO MgO and TiO, 16.00 2.03 14.62 61.40 0.72 0.75 3.72 The average yield blown metal 91.3 per cent, and for our purposes recovery per cent scrap made, well per cent for slag, shot and spittings later consumed blast furnaces. Therefore, basis blown metal the scrap 1.1 per cent and slag, spit- tings, etc., 1.1 per cent, the loss 7.3 per cent, total loss and scrap 9.5 per cent. While the amounts prac- tice may differ from these figures, they nevertheless serve indicate the degree difference duplex yields with varying amounts blown metal used. Since the same characteristics are desired the slag, 736—March 14, 1929, The Iron Age one can readily calculate the yields obtained the open- hearth department (only), well the combination duplex yield. The losses and scrap for open-hearth are figured and this the losses and scrap per ton blown metal are added. Since none the open-hearth slag consumed blast furnaces, the credit nil, but the total scrap will include the amount slag, spit- tings, credited Bessemer, and proportion the percentage blown metal used. The basis used per cent blown metal, the remainder being hot metal, cold iron, scrap, etc. Influence Proportion Pig Iron Charges Ingot Yields Fig. characteristic curve showing the perform- ance one stationary open-hearth plant with varying amounts pig iron and scrap over period years. will noted that, spite the multitude varia- tions possible, such analyses materials, overloading furnaces, types steel, etc., definite relation exists be- tween pig charge and yield. Such curves can extended further show influence percentage pig iron charged for more equal conditions. such comparison the curve will have definite aspect trend. Fig. represents such condition. “Equal conditions,” the sense which used here, refers the lack ex- treme variations over short periods compared sents actual slag proportions and analyses, analysis materials metallic charge and proportions used per ton metallic charge for period about three months. assumed that for per cent hot metal charge, the standard per cent miscellaneous scrap and per cent condemned ingots and ingot butts obtains. There- fore, the miscellaneous scrap for lower higher per- centages used adjusted take care standard 0.50 per cent iron scrap produced per ton hot metal. The curve demonstrates clearly the influence percentage pig charges yields for “equal conditions.” The same study can employed denote possible yields for any steel with varying pig charges, same charge for different steels. Table XII shows the practice obtaining for various pig percentages. The calculations are made the usual man- ner for slag ratio, etc. [Consideration slags, going into molecular analysis and the basicity ratio, concluded the paper.] Colonel Lindbergh’s Traveling Office special tri-motored Ford transport* “City Columbus,” used traveling office Col. Charles Lindbergh and Major Thomas Lanphier. Special equipment includes stenographer’s desk, typewriter and minor office appliances, two built-in berths and refrig- erator. Preliminary ground lay-out work incidental estab- lishment airports along the route the proposed trans- continental rail-and-plane service the first purpose which the office plane was devoted. Transcontinental Air Transport, Inc., cooperating with the Pennsylvania Rail- road and the Santa Railroad organize rail-and-air route cut the running time between New York and Los Angeles less than hr. Ten tri-motored transports have been ordered the Pennsylvania Railroad for use this service. *See THE IRON Jan. 31, page 327, and Feb. page 401, for description methods manufacture. Redesign for Production Welding Methods Outlined Whereby the Process Can Instituted Manufacturers Machinery Metal Products LINCOLN* lem that perplexes the uninitiated. The difficulties EDESIGN from cast iron welded steel one prob- expected them usually are among the following: The best place start. may cause upheaval the factory or- ganization. Our customers may not like it, and stop being customers. may mean much expense for new machin- ery and scrapping old. Our engineers are not accustomed the process and may wrong design. have one who can weld, supervise the welding operation, and judge the quality the work, don’t believe can save money anyway. will start when others have succeeded it. have tried all out and the promised sav- ings have not materialized. The hardest all objections handle are the last two. The manufacturer who says that will when others are successful, the one who excuses himself saying that has looked into and from his small *Vice-president, Lincoln Electric Co., Cleveland. TEEL Frame Work for Punch Press, Made Arc Welding. This considerably lighter than the erly employed, although stiffer and much tougher for Electric Motor Built from Stand- ard Structural Steel Shapes and Tubing knowledge can safely say that there nothing ex- cept propaganda, closes his mind. This always danger- ous. unfortunate fact that competition re- specter persons. The manufacturer who cannot meet disappears these days rapidly changing methods. does not better job than his competitor cannot succeed. Therefore, the successful executive cannot de- pend the development that done his competitor for his shop practice. The process that succeeds for his competitor will not for him—he must get there first. may help cite the experience the Lincoln Electric Co., which started develop and redesign for rather complicated electrical apparatus can redesigned economically and successfully, any other line equip- ment which inherently easier will yield the same treatment without difficulty and even greater profit. The first essential successful redesign arc welding the desire it. know process that will re- sult equivalent profit without some necessity both faith and backbone the manufacturer using it. After the decision has been made use this method, the easiest place begin can determined survey the manufacturing processes and the application en- gineering ability. The following points should borne mind selecting the starting point: (a) Select some part that can made without any complicated forming devices. (b) Select some part that not greatest operative importance that error will not disaster. (c) Select some part that may giving trouble made present cast riveted methods. Experience shows that the great danger, once the start made, that the organization will too fast—the men will want weld everything immediately rather than work out the economics and best design for each part. The application welding manufacture involves more than buying new production tool; means devel- oping new manufacturing process, and should ap- proached the same spirit other fundamental changes have been approached. High-speed tool steel was com- paratively small importance until new machine tools and new standards practice were made available. Alloy steel manufacturing small importance unless the design and heat treatment changed take advantage its high qualities. the same way arc welded steel used the more accurate design possible and the greater utility steel can only benefit the design The Iron Age, March 14, modified take full advantage these inherent vir- tues steel. may seem those small welding experience that there are fundamental principles involved the re- design parts welded construction. There is, how- ever, good deal help which can obtained classi- fying all products under three simple heads—these are bases, containers, and covers. All machinery and all parts machinery can subdivided into these classifications, and for the purpose thinking terms welding, considerably easier think parts subdivided into these Only Bolts Rivets This Steam Shovel Bucket Are the Teeth, Which Are Removed Intervals for Sharpening (above) Derrick Boom (At Right) With all Con- nections Welded classes, than think them individual parts without relation. Bases Bases cover probably more than per cent all structures, base this connection being any part which used resist bending. This would include its sim- plest form the base for motor generator set, motor driven blower. would also include lathe bed, bridge, the steel work for house factory. The same rules would apply the redesign all these parts which have the function resistance bending. Containers The second classification great deal simpler. Any part which made hold pressure, liquids, solids, container. Examples this would boilers, air re- ceivers, engine cylinders, storage tanks, pipe, and kindred structures. The same rules which apply the manufac- ture arc welding any one these will also apply all them. Covers The third classification still more simple. Any part which has for its function the protection parts against 738—March 14, 1929, The Iron Age the weather, against objects dropping it, such gear guards and similar parts, can thought cover. Redesign Bases Bases are the largest single class, will con- sider them first. Since cast iron has modulus elas- ticity about per cent that steel, the same stiffness steel can attained with only per cent amount material. Generally, possible design the base that the metal placed the redesigned structure much more efficiently than the cast structure. For in- stance, I-beam the best shape which dispose metal order resist bending, but this shape cannot used the usual cast base because the pattern cannot drawn from the sand. However, can easily used the welded base. Brief study will show that most cast structures are the result experience only, and have little with ac- curate design. When the first castings are made shrink- age cracks may develop, the draft the pattern needs changed for easy molding. Perhaps the casting will warp out shape when machined. All these occurrences necessitate modification the pattern and usually pro- duce heavier casting. After all these changes have been made and the design has been finally approved, prac- tice, the fina) shape and cost are different from design based purely the engineering requirements the job. The designer should therefore, redesigning base for welded steel, first all determine the loads that must carry, and, second, what possible allow safely. With this information can design with accuracy and with assurance that the finished product will check with his figures. There will unknown variables, therefore accurate design obtainable. This frequently means tremendous saving itself. Redesign Containers the controlling factor merely the strength cast iron container resist pressure, then redesign simple. Steel can figured for strength very much more accurately and confidently than can cast iron. The rela- tive strength about the ratio the struc- ture previously has been riveted steel, the design the new welded structure should made such way that the greater strength the welded joint will util- ized. Since 100 per cent joint can made proper welding and is, course, impossible with any type riveted joint, this difference joint strength will cut down the needed amount material from per cent. Very frequently, however, the effect corrosion, required stiffness, other factors may enter into the design. With any proper welding process satisfactory results will obtained. Automatic welding both for the longi- tudinal seam and for the head seams should used many containers are made, because lower cost and greater reliability. Instead making large containers ring sections welded together, preferable use longitudinal seams running the length the container. Redesign Covers making covers, the problem merely get the proper stiffness either from inherently stiff sections, else welding stiffeners. However, the shape and appearance such things gear guards and lathe bed pans are more importance than cost; for that reason the design may entirely leave the realm engineering. Frequent Errors When errors are made adopting the new method, they usually are among the following: Delay getting started use the process. Going too fast and without proper design, equipment and training. Buying steel from warehouse cut size in- stead from the mill car lots with plan that will use properly. Attempting make the new part look like the old one. Remember, the old part were right would not necessary change it. Getting frightened when the new design, properly engineered, looks light and spindly. Lack proper engineering. Having accurate cost system show the difference cost comparative designs. Trying use improper size type weld- ing equipment, improper technique, usually the result insufficient capacity machine too small electrodes. The belief that because the plant has foun- dry, castings cost much less than when bought out- side. 10. The belief that the volume not kept the foundry, money will lost regardless other costs. The best machine for any purpose has never been made without change for very long. This conclusion safe unless all engineering history wrong and all progress has stopped. For that reason the only safe policy for any manufacturing executive lead the develop- ments. There has yet case where the laggard has had long and prosperous life. Are welding not panacea for all troubles, but manufacturing process that believe will eventually eliminate per cent all castings and forgings and 100 per cent the rivets. This substitution will forced all manufacturers, because the change results saving which will usually exceed per cent the previous cost the part redesigned. first much this saving can pocketed the manufacturer who applies this method. Soon, however, this advantage will disappear because competition; the new method will necessary other manufacturers are stay his field all. Standardization Means Cultural Renaissance Does Not Bring About Stereotyped Living Conditions, Says Conference Board—Places Emphasis Marketing factor the recent economic progress the United States, and “cumulative evidence points unmistakably the conclusion that one the most significant and far-reaching methods for increasing industrial efficiency the benefit, properly used, all interests concerned.” “Tangible and trustworthy facts regarding the achieve- ments and economies standardization,” however, “are few and far between,” and “it clear that the achieve- ments the past are but guide posts possibilities the future.” Such, brief, the summing the National In- dustrial Conference Board, New York, its findings study the industrial standardization movement and its effects upon economic life. However, although the board indicates certain reservations evaluating the ultimate economic effects standardization, nevertheless in- clined attribute great potential value the effects standardization upon social and cultural progress, pro- vided the evidence found support the net economic benefits the movement should prove conclusive. Quite contrary popular impression many quarters, that standardized consumers’ goods and standardization in- dustrial and commercial methods tends develop stereo- typed living conditions and habits, the board declares that “if the machine (through standardization and mass pro- duction) able democratize leisure, may opening the way for the greatest cultural renaissance the history the world.” Standardization, the report points out, means many standardization has been paramount things besides the mere standardizing product size, quality, design methods and procedure the productive process proper. applied increasing degree the functions business procedure all its branches, purchasing specifications, distribution methods, transporting and handling, clerical work, finance and communication, always with the immediate aim economizing material, effort and time. “So pervasive the application the principle that have failed appreciate its significance, the extent and manner which being systematically advanced, its relation industry, government and the public, and the prob- lems which has given rise.” “Standardization should regarded tool, method, device technique for achieving certain ends,” the Conference Board declares the concluding chapter its study. Whether not advantages out- weigh disadvantages found depend entirely upon what use made standardization, may retard well promote industrial progress. practice, judg- standardization general must rest upon satisfactory answer the following three questions, the board de- clares: Does standardization have the effect forwarding scientific improvement processes, techniques and equip- ment? Does standardization make possible higher aver- age standard living? 9 Does standardization relegate problems already The Iron Age, March 14, 1929—739 solved their proper place, the field routine, leaving creative faculties free for the problems still solved? Has Stereotyping Effects For evidence that the standardization movement the United States successfully avoiding the stereotyping effect standardization, the board points the fact that ROM study the physical properties more special melts, and analysis other publications complex brasses, Ellis, research department West- inghouse Electric Mfg. Co., East Pittsburgh, Pa., has been able determine the approximate effect each several alloying elements. The diagrams reproduced here- with are taken from his paper entitled “High-Strength Brasses,” read before the Institute Metals, New York, Feb. 20. His alloys were cast 1000 deg. into open-top chill, and the resulting ingot, approximately in., machined into test piece. Nearly all Ellis’ alloys analyzed copper close per cent; varia- tions occurred the other constituents. Some speakers criticized this practice, pointing out that the copper should change with other elements order maintain proper “balance.” However, group special alloys was oO w Elongation, per cent. Tensile Strength, per sq.in Copper, per cent Fig. 1—Effect Copper Ten- Fig. 2—Effect Copper Per- centage Elongation Simple Brass America’s large industrial organizations which are most active the field standardization also are the ones which maintain the most active and progressive scientific research laboratories and constantly evolve new processes and commodities and cooperate most actively with the various private and official bureaus evolving new standards. Curves for analyzed and their physical properties computed from the curves, and then compared with the actual values found the tensile test. The average error the computed strength was 1600 and the average error computed elongation was 2.3 per cent. example the use these curves one may take alloy containing: Copper, 51.95 per cent; iron, 3.82 per cent; aluminum, 1.88 per cent; manganese, 0.98 per cent. Fig. shows that the strength simple brass con- taining 51.95 per cent copper about 72,700 lb. per sq. in.; Fig. shows that 3.82 per cent iron reduces the strength such brass the average about 6000 lb. per sq. in.; Fig. shows that 1.88 per cent aluminum raises the strength about 26,000 lb. per sq. in. (average) and Fig. shows that 0.98 per cent manganese increases the per cent. Iron Tensile Strength Com- plex Brass per cent. sile Strength Simple Brass = 15 = Iron, per cent. per Fig. 6—Quantitative Effect Fig. 4—Quantitative Effect Fig. Effect Aluminum Tensile Strength Complex Brass Iron Percentage Elongation Complex Brass 740—March 14, 1929, The Iron Age Aluminum Percentage Elonga- tion Complex Brass The board study takes into account the fact that standardization product, through its inseparable con- comitant, mass production lessened production cost, has shifted the major industrial problem away from pro- duction marketing, with the net effect that the ratio marketing costs production costs steadily increas- ing. This creates situation which part offsets the ad- vantage standardization itself, but, the board believes, may part remedied simplifying and systematiz- ing marketing technique. “To the extent that simplifica- tion the channels distribution may handle this dif- ficulty, standardization can used raise still further the purchasing power the daily wage.” Strength Complex Brasses strength about 1400 lb. per sq. in. (average). The estimated strength for this alloy will be: Lb. per Sq. In. Strength simple brass............. 72,700 100,100 Estimated tensile strength............ 94,100 The actual strength this alloy (chill-cast) ob- tained test was 92,200 lb. per sq. in.; e., the estimate strength only per cent too high. percentage elongation, following are the values: Per Cent In. Elongation simple brass....... (Fig. Estimated elongation............ The actual elongation this alloy (chill-cast) was 18.5 per cent. Tensile Strength, sq.in Manganese, per cent. Fig. 7—Quantitative Effect Manganese Tensile Strength Complex Brass Tin, per cent. While certain that tin increases the strength complex brass, its presence more than 0.7 1.5 per cent gives rise the brittle beta constituent, with ruinous effect ductility. and 10.) Mr. Ellis thinks that all the good which tin could can done well aluminum; consequently recommends that should not added constituent high strength brasses. Nickel (Fig. 11) lowers the strength brass when replaces zinc; its effect ductility somewhat like iron (Fig. although not potent. Mr. Ellis concludes that the use metals other than aluminum, iron and manganese complex brasses con- taining approximately per cent copper unwarranted, because these cheap metals can give the same effect more expensive additions. therefore considers these high strength alloys essentially “aluminum brasses which small proportions iron and manganese are added, the former increase the ductility without reduc- ing the strength, and the latter for increasing the strength without reducing ductility.” Elongation, per cent. Manganese, per cent. Fig. Effect Manganese Percentage Elonga- tion Complex Brass Fig. 9—Approximate Quantitative Effect Tin Tensile Strength Tin, 5 2 Fig. 10—Approximate Quantita- tive Effect Tin Percentage Elongation Complex Brass Fig. 11—Approximate Quantita- tive Effect Nickel Tensile Strength Complex Brass Tensile Strength, per Fig. 12—Relationship Between Proportional Limit and Tensile Strength Brass Yield Point, sq.in. Tensile Strength, per Fig. 13—Relationship Between Yield Point and Tensile Strength Brass The Iron Age, March 14, 10,000 5000 \ 10,000 Cleaning Forgings Shortened Time Pickling and Tumbling Combined One Barrel, Followed Soda Cleansing the Second cleaning drop forgings reported the Cleve- land Hardware Co., Cleveland, through the adop- tion continuous process combining tumbling and pick- ling. The forgings are tumbled barrel through which there continuous flow pickling solution. After pick- ling, the forgings are cleaned washing the continuous metal cleaning m