The Iron Age 1929-03-28: Vol 123 Iss 13

ESTABLISHED 1855 THE IRON New York, March 28, 1929 VOL. 123, No. Ascendency Alloy Iron Castings Survey the Foundries the Country The Iron Age Shows Quantities, Kinds, Industrial Uses and Methods Making EDWIN CONE some time alloying ele- 1900, which close 49.5 per ments have been gray iron castings im- prove moted, not initiated some years ago the research department the International Nickel Co., the development has been equally encouraged the Bethlehem Process Used. Steel Co. promising outlet for its pig iron (which contains nickel and chromium). Active also has been the research staff the Union Carbide Car- bon Research Laboratories Long Island City the interest chromium, though largely course chromium for special steels and high-chromium iron alloys. Sponsoring vanadium for gray iron has come from Castings. 3.—Principal What Was Asked American Gray Iron Foundries (approximate) Alloy Iron Castings Made 1928, and All the returns were not 2.— Quantity Each Grade Alloy Which Castings are Put. Use Treatment Applied (if any). cent the total. plants were included which make special al- loys, such heat and acid-resist- ing castings, which contain high percentages other elements. when this article was compiled. others, including some special plants which have been solicited, contribute facts that warrant fur- ther comment, supplementary article will published. Following analysis and Such summary the facts obtained: The Alloys and How They Are Introduced HREE alloying elements con- Vanadium Corporation Amer- ica. More recently, for benefitting gray iron castings, molybdenum has been advanced the Climax Molybdenum Co. and others which have pushed investigations this ficld with notable results. That some decidedly important metallurgical facts have been ascertained these various agencies and the foundries themselves and that there fairly wide use alloy iron castings have been known but quantitative way. was, therefore, decided survey the entire gray iron castings industry. The results have been eminently gratifying, largely the noteworthy coop- eration the foundries. The extent the use alloy iron castings has been revealed larger than believed. The results the canvass are given the following: Scope the Survey the iron foundries the United States, with the few making pipe and number others (about all). received the questionnaire repro- duced this page. There were 3818 these, listed Penton’s foundry list. Replies were received from nearly © tribute the bulk the alloy These are nickel, chromium and molybdenum. smaller amounts castings are made which contain vanadium, sili- con, manganese and copper. alone, combinations nickel and chromium, large quantities. Only recently has molybdenum been used any extent and this usually incorporated itself the product. Vanadium reported combination with nickel one two companies, and copper being used one foundry combination with nickel. Vanadium used alone one case alloying element large steel company, which makes its own alloy iron castings. This company, which makes nickel and chromium and vanadium iron castings, uses them for pig machine wheels, hydraulic cylinders for tube mills, sizing and welding rolls, and for air compressor parts. Some companies use nickel Melting Processes Used Three processes are used producing alloy iron cast- ings. Predominant among these naturally the cupola. few cases the electric furnace the melting medium. The air furnace also extensively used, principally, how- 861 ever, the manufacture alloy iron rolls. One company makes its castings duplexing with the cupola and elec- tric furnace. Various Ways Adding the Alloys Fairly complete information furnished most foundries the method the alloy into the iron. Where the cupola used melting medium, Mayari pig iron quite extensively used, the number companies reporting this its source nickel and chromium numbering over 25. the cases where pig iron not the source nickel and chromium, ickel shot largely employed. ‘This introduced into metal, either into the spout the cupola into the which form fairly high There also Chromium obtained from added, usually the ladle, arbon ferrochromium, which melts easily. onsiderable application the special alloy, nichrome, hich added either the spout the ladle. ferromolybdenum calcium molybdate used ntroduce molybdenum. the iron being supplied from cupola, the molybdenum added ferromolybdenum the ladle the alloy casting made from air furnace Principal Uses Alloy Iron Castings Automotive Engine Parts. Rolls for Rolling Mills. Wearing and Other Parts Machine Tools Special Pipe. Iron Dies. Heat Resisting Castings. Stokers. Glass Molds. Pump Castings Withstand Pressure. General Machinery Castings. Electric Resistor Grids. Gear Blanks and Pinions. Ingot Molds for Special Metals. Vanadium, silicon and manganese are added the iron the ladle, usually the ferroalloys the the interesting features the use number npanies considerable steel scrap the charge. rap ntroduced the same way making semi- and either nickel chromium sometimes added This resuits what may called alloy -steel casting. One two companies make prac- using scrap alloy steel containing nickel, chromium, vanadium and sometimes manganese and molybdenum, and depend upon this for producing alloy Composition Some the Castings Wide variations are reported the composition the For straight nickel castings, the percentages run anywhere from 0.50 3.50 per cent nickel. various types alloy iron castings. Where and chromium are used combination, the compositions run anywhere from 0.15 per cent nickel and 0.15 per cent chromium per cent nickel and per cent chromium. The use molybdenum alloy iron castings is, stated, development comparatively recent date. Very little has been published concerning the results thus far obtained. can stated authoritatively, however, that good number companies are using this element 862—March 28, 1929, The Iron Age their product and that the application expanding rap- idly. Our reports indicate that, particularly the manu- facture rolls for rolling mills, and also certain types castings for automobiles and airplanes, the use mo- lybdenum iron has gained foothold and has passed the stage. Percentages the element vary from 0.30 per cent. vanadium, where used combination with nickel, itself, the amount found the final alloyed iron varies from 0.05 per cent 0.10 per cent. introduced one company means Norwegian pig iron contain- ing 0.50 0.60 per cent vanadium. Ferrovanadium also depended secure the metal. The effects these various alloying elements the final product are pretty well known. Nickel and chromium both increase the molybdenum. They contribute wear-resisting properties the metal. Nickel and chromium both produce fine grained material and nickel augments the hardness without detracting from the machineability. Moiybdenum also increases the hard- ness without impairing machineability. counted step the hardness and the resistance heat. Uses for Alloy lron Castings PPLICATIONS alloy iron castings have attained large proportions and the resu!ts this survey are illuminating. Over have been enumerated, some them important and calling for large scale production. The diversity great that only account the more im- portant ones may given here. Automobiles and Rolling Mills Lead Heading the list are the automotive and the rolling mill industries. Large quantities alloy iron castings, principally nickel nickel and chromium, are incorpo- rated cylinder blocks, cylinder heads, pistons and piston Molyb- denum also being used and investigated. claimed that the alloying elements increase the resistance wear and contribute greater strength and longer life. Even brake drums and flywheels are being made alloy iron. rolls for rolling mills, there pronounced ten- dency substitute, for the ordinary iron roll, alloy iron roll containing nickel chromium, but particularly mo- lybdenum. Advocates molybdenum claim that bette wearing surface imparted the roll, which turn produces smoother product, such sheet. iron rings, well bushings, for automobiles. castings for general use, molybdenum said bestow both greater transverse and tensile strength, well hardness. predicted that the use alloy iron castings automobile engines will make for reduced weights and lengthened life, and will have important bearing engines for aircraft. Important Machine Tools Next importance the use alloy iron castings When wear resistance important fac- tor, the sliding members, these castings are gaining increased application. They are also used for the strength factor. Such castings are reported being adopted machinery builders general, for special parts cer- tain types machines, notably paper mill machinery. recent development the production large company small sizes pipe, down in. diam- eter, alloy cast iron containing and chromium. Expectations are voiced that pipe this kind will widely adopted for water, gas and other building purposes. Various types alloy cast iron are going into die blocks, such form sheet metal for automobile work. One company reports the production alloy iron drop hammer dies. Another making stokers quantity, and machine tools. tal, calcium molybdate usually the source the several foundries report the production glass molds certain compositions alloy iron, some these for export Europe. elevator company using molybdenum alloy castings large scale for wear resistance. There fairly large application alloy cast iron gear blanks, sheaves, wheels and pinions, number foundries reporting. Numerous other applications include the following: Certain types heat-resisting castings, melting pots for metals, railroad journal boxes, marine piston rings, mine car wheels, cylinder heads for Diesel oil engines, grinding balls for use mining operations, metal housings for roll- ing mills, casings for pump castings and certain parts compressors and pumps the oil industry where resistance high pressure required, various parts implements and machinery, impeller castings, ball races, grids for electrical resistance cylinders for paper drying equipment, etc. One foundry making alloy iron cams replace malleable castings. Heat Treatment Not Generally Used the question heat treatment alloy iron cast- can said that general very few them receive any sort heat treatment the time they leave the foundry. possible, however, that some are heat-treated the user. respect what heat treat- ment practised the foundries, the following comments may noted: Annealing Practised Several Foundries large motor company heat treats its nickel-chromium die iron castings before machining oil quench from 1550 deg. Fahr., draw the furnace from 900 deg. Fahr. heat treatment practised after ma- chining. Another gray iron foundry heat treats some its castings, and annealing the mold the practice one foundry. plant which produces liners and gears states that these are artificially aged annealing 900 deg. Fahr. for hr. producer sprockets makes the general statement that these are often heat treated. large maker gives these regular annealing treatment. producer silicon alloy castings for lock parts oil-combustion furnace anneals these times. founder nickel cylinder castings accustomed giv- ing these special heat treatment. large foundry pro- ducing open-hearth castings, semi-steel castings and gray iron castings anneals 850 deg. Fahr. its high pres sure alloy castings and its alloy iron dies containing per cent nickel, and also per cent and 0.20 per cent chromium. increase machineability one company heat treated 100 tons last year holding the iron 1400 deg for hr., followed cooling the furnace. Several Founders Give Their Views ECIDEDLY informative and important are some the comments which certain foundries have offered the reply our questionnaire. They furnish different viewpoints the advantages and disadvantages adding alloys cast iron, and they also reflect clearly the trend the future this comparatively new development. What they had say follows: large company which has foundry, machine, pipe, pattern and boiler shops: are very glad cooperate with you securing per cent iron, which, you know, contair nickel and chromium. addition the nickel and chromium the Mayari iron, have added additional nickel various times increase the machineability, Wear-resistance, strength and toughness of the casting other times, when. castings did not have ma- chined and where the abrasion wear was excessive, have made castings with chromium high per cent. have not had any experience with refer- nee to heat treating of these castings * * *. We realize our experience has been very limited compared to other foundries, but would like say this time that we have had very great success with these two alloys and we feel that if anyone is going to stay the foundry game, he must make a high grade cast ng. We believe, and it has been our experience, that where quality considered well price, the is far ahead to buy a properly alloyed casting We have told our customers that we stand ready, and we solicit ir order ‘ hat basis, t study the uses to which intend put isting, and then furnish them vith an alloy casting that in our judgment will be heaper for them in the end than to buy an ordinary) Large company, which has foundries several impor- tant industrial centers: At one of its plants it is making ar lloy cast iro aining 0.50 per cent chromium and per cent kel for melting pots for aluminum, melting kettles ] d, zg ne and bath tubs for the die-casting stry nd gi mold f ‘ t ing of vat is al another plant, nickel-chromium mine car wheels are made, having nickel content 0.08 per cent and chro- mium content 0.11 per cent. the same plant, high tensile iron made the addition per cent Alloy Iron Castings States Tons \ 1,9 M i i 4.40 Delaware d 2 | Ok! oma 150 Geors Ore 114 Ind 17 Rhode Island (ve | La } i Ma ichusett L0,266 ‘ Michigan West Virginia Minne ta 1.793 Washington Total tonnage mixture and 1.5 per cent nickel, the product being used for mill housings. There also made this plant steam-jacket outlet chambers containing 0.35 per cent nickel used equipment for certain types cars. large manufacturer machinery castings, having oth iron and brass foundries New England: exper } j f We ind t I wi it! f hed bet it d We the ex] mented th usi! hot ina terre l * TI nent e perhap t ter than h tl I ! im, | t not iff tly satisfactory hat w nt ‘ furth Lastly w ed ng | h nich nd ! i the I rk we varied the percentage from 7.50 to & per ent of tl iron down to 2 per cent of our mixture ] believe the best result were obtained through thi emeée In this, of course, the metal w: melted in eee Al output goes into machinery pract the machine tool trade. would probably ife figure that have made the t ir if to 1200 tons of alloy iron castings I he- eve today we are making a better iron casting, using last proces have made for some prominent foundry Middle Western State: Alloys, such nicke omium particularly, nd chr come into such prominent use during the last year (Concluded page The Iron Age, March 28, = Educated Foundry Engineers Neede Plea for Course Engineering Colleges—Decided Lack Trained Men—A Curriculum Suggested foundry engineer and where such course taught this country the present time? Only years close connec- tion with the foundry industry man educated, practical experience, the rank being foundry engineer. This educa- tion usually obtained through the expense the employer industry whole. Lack Foundry Engineering Education HERE are approximately 366 colleges ties the United States accredited institutions learning. these 366 institutions, 168 have en- rineering curricula mechanical engineering, electrical ng, civil engineering, railroad engineering and great many other branches the leading engineer- the 168 engineering colleges, there have enrollments more than 1000 students With enrollments excess 2000 students 1927 ZS Of the 168 engineering colleges only / are elementary course foundry work ndry courses are generally very short and nanual Usually the students ire required spend from hr. week pattern and foundry course during one semester. Naturally, the benefit derived very limited, because the lack time part the students noted, because the subject ! red 1 r than elective The enrollment engineering colleges 1927-1928, tated United States Department Interior, Bureau Education, was Nov. 168 colleges engineering with total student enrollment 65,520. These 168 engineering colleges have less than lifferent engineering curricula, including the more out- tanding subjects previously mentioned, well the ‘ollowing very specialized fields engineering such petroleum engineering, textile engineering, art engineer- ing, geological engineering, fire protection engineering, sugar engineering, and flour mill en- Not one the 168 engineering colleges has foundry engineering curriculum and only them short course general foundry operation. Second Place for the Foundry Industry? Does the foundry industry take place second the many other branches engineering? not the foundry industry important as, for example, sugar engineering flour mill igineering? These two branches en- ngir gineering are taught, but not foundry engineering. *Foundry ratory engineering, department n engineering, University of Illin s, Urbana, Il EARNILL not need engineers the foundries? the foundry industry going continue accept anybody, with any kind engineering education, and continue pay the penalty financial losses educating these engineers, because lack understanding the problems that confront them, due the improper tech- nical training? The foundry industry just much need well trained technical men need skilled workmen. Demand for trained technical men much greater to- day than was ten years ago, and going even more the future. The foundry has realized the im- portance replacing the old-time method guesswork with laboratory work. {dvertisements Reveal Need for Trained Men following quotations are from industrial periodical publications, which show only too plainly the need trained technical men the foundries. Who are capable filling these positions men who have spent years and years the foundry industry, and are about retire because old age. studying the re- quirements, experience and knowledge requested these advertisements, the need plainly evident for real foun- dry engineering course one our 168 engineering col- patter? molding, melting practices and modern plant nect with brass and gray foundry Must specialist 1 his lit 1 have the at ty t ven modern foundry. Apply let- age, education, salary expe ted and details of xpe X¢ 1327 Here the need real foundry engineer. must have thorough knowledge pattern making, molding, melting practices, and also expert architect order erect reorganize the present plant already modern foundry. must specialist and have large ability organizer, both brass and gray iron foun- dries. Foundry Engineer Wanted: man broad experience with record successful accomplishments, with thorough knowledge modern foundry practice gray alleable and steel. Must practical foundryman cupola mixes, sand control, wage incentive. Knowledga non-ferrous I a set reply state age, nationality, education, experience detai ind salary desired. Address Box this case the applicants must have thorough knowledge modern foundry practice gray iron, mal- leable and steel foundry work, molding methods, cupola mixes, sand control, time study, besides good business talent, and also know something about non-ferrous metals. Foundry Engineer: Man have charge all machin- ery in progressive production foundry. Reply, state age, Address Box 392 experience in detail le ges. and know molding methods, 864—March 28, The Iron Age Drawing.—General Drawing, neering Drawing. Laboratory.—Pattern and Foundry Work. English.—Composition and Literature Electives. Non-Technical (Hygiene). Sophomore Year Chemistry.—Applied Foundry Chem- istry, and Routine Analysis Work Physics.—General. Metallurgy.—Applied Foundry Problems. Steel Making. Sug Freshman Year Metallography.—Study Structures Iron and Steel. Chemistry.—General, Qualitative and Laboratory. Foundry and Heat Problems Analytical Geometry. list Mech English.—Business Correspondence Electives. Non-Technical (Language). Electiv es Junior Year Curriculum Foundry Engineering English.—Public Speaking Electives. Non-Technical Electives ( Language Senior Year Engineering.—Mechanical Engineer ing Design Treatment Non Ferrous Metals and Alloys. Laboratory. Foundry Management This man expected know the chinery used production foundry. Steel Foundry Engineer: have pos steel foundry engineer, tion control. Apply letter X5527. The requirement here knowledge besides knowing production control. who familiar gineering education which based especi dry industry, and being graduated from first class ition or Ine produc open gineering college curriculum. with steel castings The Foundry, Chemistry. uantitative and Physi- and Operation and Foundry cal. Electives and Applied. Architecture.—Building Construction Heat into Work. ant Layout Crystallography Applied Non Law, Finance Ferrous and Ferrous and Investment. Laboratory.—Machine Shop, Foun- English.—Engineering Reports drv Experimental WY ork and Sand Electives. Non Technical Electives Advanced Testing (Civics). Iron Ore and Organization Reports.—Plant Visitation and and Management. ports. function ma- terest the foundry industry, selecting their ally the foun with standard foundry engineering Over 5600 Foundries United States Sept. 15, 1928, survey and methods, duties are connection with during the period 1926 1928 follows: efficiency of mechanical equipment, transportation and handling. Give details age and salary ex- United States operation Aug Again, the foundry industry requires foundry en- 1928 gineer with production, efficiency, transportation and me- 6.110 chanical equipment experience. small percentage the great many vacancies that are filled thoroughly trained men, illustrates the need Without doubt, the foundry industry large enough The Iron Age, March 28, 1929—865 ai} errous dept. other shop United States in 192s 1,817 N us uundries dept. of ot} shops it l ed St ( l 192s l \ States 189 ( 28 1 ~ is 19° la ] 24 S Stat it 19 t i I ted Stat 28 7.7 Total number foundries operation the United Canada Aug. 15, 1926, was 6280, com- pared with 6110 foundries operation Aug. 15, 1928. This shows decline 170 foundries two years. How- the tonnage has increased considerably during the past two years, and not decreased might expected. This only goes prove that the foundries are consolidat- ng, that the smaller plants must give way the arger and more efficiently operated the latest nprovements such rapid molding machines and sand equipment are installed, and where chemical and place the old rule laboratories are taking the Code Minimum Requirements for Apprentices The foundry industry much concerned about the prob- securing better molders. This very important juestion. The National Founders’ Association has accom- shed remarkable work this field standardizing minimum requirements for apprentice training, followed the foundries educating our next gen- molders and shop foremen. This accomplish- ent, however, mostly concerned with manual training with the apprentice’s appreciation the important tions the technical the manual work. next step consider the our foun- iry engineers. Who going educate cur Who going teach foundry work our high schools and other technical institutions not even have place where foundry engineering taught? Are the foundry engineers just going taken through ING ineer Students Use Mold M 1e i [ ersity of pag ) ss 1S study esi 1 28, 1929, The Iron Age mill the old fashioned foundry experience? costly the employer and often discouraging the man. many cases only repeating the errors that many others have met with while traveling the road becom- ing foundry engineer experience and observation through number years’ work the shop. Outlined Curriculum Suggested following outlined curriculum should looked upon only example course which would much more adapted the one who intends follow the foundry industry after graduation. this foundry en- gineering curriculum, which itself does not give much detailed information, certain problems, suggested de- tail another page, could studied during the foundry instruction periods. not believed that foundry engineering course will produce perfect foundry engineers, that employing men who have been graduated from will solve all further trouble the foundry industry. However, man who has been graduated from the course would certainly have better understanding the foundry problems that con- front him the shop, because has the foundation adapt himself its conditions easier and more effectively. Not only would the foundries benefit from such trained men, but great many the industries dealing with the foundry industry would employ these men advantage. Blast furnace companies, molding machine and equip- ment manufacturers and sand producers would undoubt- Subjects and Problems Studied Alloy steel 20. Gating. Aluminum. 21. Gray iron. Annealing. 22. Labor saving devices. Apprentices. 23. Malleable foundries. Bessemer process 24. Mixing metals. Brass founding. 25. Molding machines. Brinell test. 26. Molding sand. Cast iron. 27. Open-hearth furnaces Chemical analysis. 28. Pattern design. 10. Chill 29. Permanent molds 11. Converters 30. Production control. 12. Copper 31. Pyrometry. 13. Core making 32. Safety work. 14. Cost system. 33. Sand testing. 15. 34. Slag. 16. Die casting. 35. Standardization 17. Electric furnaces 36. Steel. 18. Foundry equipment. 19. Fatigue metals Time study. edly find desirable have foundry engineer their organizations, who could solve some the many ques- tions arising through contact with the foundries. All this goes indicate that the opportunities employment and actual need such trained men would far surpass the number men graduating from the course. Foundry Education Other Countries THER countries have long ago recognized this need. Both France and Germany, foundry engineering has been taught regular subject the engineering colleges. The students are required spend part their summer vacations plant gain the practical experi- ence. Some the colleges even require year’s shop experience after graduation and before the students are their degrees. Many the leading manufactur- ing firms are cooperating with the colleges carrying out this and closely supervising the students while the plant, that their experience would repre- sent more than just year spent the shops. Summer employment great benefit the students, and should encouraged the colleges well the manufacturers. gives the students the experience actual shop work, and the same time gives them thorough test their interest and ability follow the foundry industry. Only those who maintain this in- terest and ability would continue their training. Sum- mer employment also interest the manufacturers, because they can during the summer period observe the students their fitness for later employment the or- ganization. Students will, after graduation, more easily adjust themselves into the organization because their experi- ence gained during the summer employment with the firm. Shop visitations during the college training also both importance and keen interest the students, but often neglected feature their training. Library reference, assignments and reports gineering publications are too often overlooked our colleges. recent survey one our university en- gineering libraries showed that there were less than 198 volumes up-to-date books directly dealing with the foundry industry. Malleable Castings Making Headway—Annealing Time Has Been Sharply Reduced ENRIQUE TOUCEDA ITHIN the last few years the manufacturers malleable iron castings have taken advantage the very dull period that has existed improve their plant equipment generally and study plans for more econom- ical production and prompter deliveries against the time when business would improve. The demand for castings since the first this year has increased markedly and comfortable feeling ible state that, any plant not running full pres- ent, reason the fact that when business flour- hes molders are scarce and competition secure them keen, condition that necessarily results increased labor costs. Should business remain the present time, and particularly should increase, the ruinous prices that have prevailed will cease and the manufacturer will able secure least fair return his investment. Such inerease can obtained should more than fair compensated for three years sales cost frequently below it. the manufacture malleable iron, the malleabiliz- ing the hard iron castings has required such long period time and the demand for prompt delivery now great that serious efforts the part the plant or- ganizations and others have been devoted attempts shorten this part the process. Through the use the continuous oven, this period has been considerably reduced. The Industrial Furnace Co., Buffalo, now has the market electric oven that has proved through long practical tests have shortened the period some three days. The General Electric Co. has been working the same direction and understand will have units the market within reasonable time. these units metallurgical innovations are involved, but the shortening time obtained keeping the oven con- tinuously very close desired temperature and charg- Consulting engineer, Albany, ing and discharging the oven through suitable mechanical contrivances, thereby effecting saving time each end the process. With widening the field for the product, the muffle type oven coming into more general use. When very large castings are made, quite inconvenient, and some cases impractical, place them pots for heat treatment. This muffle type oven admits the heat treatment castings large size for which there increasing demand, and enables large tonnage treated time. Provisions are being introduced for more rapid cooling this type oven than heretofore was possible and other features are use expedite the proc- ess, concerning which mention cannot made thi time. Continuous pouring the practice some the larger plants and greater attention being paid the character molding and core sand used. The cupola source hot metal now being more generally adopted accessory the air furnace. The field for the use malleable iron castings ex- panding continuously the peculiar merits the product are being better understood the engineer. Plant organi- zations have been improved and longer the process subject the vagaries the man who was obliged trust the cut and try procedure. The National Foreign Trade Council, India House, Hanover Square, New York, has issued selected index titles addresses foreign trade which have been delivered its conventions since 1927. The index has been compiled classified subjects covering the principal broad topics interest the foreign trader. The addresses themselves are available the published proceedings the council. The Iron Age, March 28, asting Design Yields Savings Careful Study Cast Product Results Better Foundry Shakeout Device Time Saver DAVID MONG steps foundry operations that offer spe- cial opportunities for the application improved practice, the casting design first importance rich with possibilities. The design must considered not only with eye the ultimate ability the cast- ing, but also with view facilitating foundry opera- The foundry engineer should given opportunity learn and study the ultimate use the casting, that is, part that the particular casting question plays connection with other members machine appa- ratus. can then better visualize how the casting may erve the same purpose another form, which may considerable advantage when casting operations are con- “| Fig. Replacing Bosses with Washers the Core Was Eliminated 4 f New Desian } Sid New Ve Old Projecting Lugs Place New Projecting Lugs Place 868—March 28, 1929, The Iron Age Old Projecting Lugs Removed The changes incorporated usually embody elimination cores, closer approach uniform sections and gen- eral simplification design. Close contact between the foundry and designing engineers questions design often results improved products, made more eco- nomical basis. Washers Replace Bosses good example what can done design the malleable casting shown Fig. its original form, presented for quotations various foundries, this cast- ing had two inner projecting circular bosses, which ne- cessitated process indicated the cross-sectional view the casting and core. The improved design called for bosses wrought Fig. 2—Bosses, Provided Casting Improved Design Shown Left, Eliminated Necessity for Annealing Permit Drilling Small Tap Holes Fig. ous Pattern Design, Providing for the Withdrawal Pro- jecting Lugs Into the Pattern Without Dis- Mold Impression, Eliminated Cores and the Fins that They Produced turbing the Cavity New Projecting Lugs Withdrawn side red. Fig. Sectional View Core Former- Used Large Pressure Casting metal the form washers, thus eliminating the core. The reduction wall thickness this point also car- ried with the advantage presenting practical punch- ing operation, whereas formerly drilling was required be- cause the small diameter the hole and the excessive wall thickness. New Design Eliminates Annealing improved design casting, shown Fig. elim- inated annealing operation. The cast iron part exceptionally thin cross-section, and its consequent rapid cooling rate introduced difficulties drilling the small tap hole the bottom, indicated the cross-sectional views. 1/16-in. thickness boss section was added 6—The New Type Core Per- mitted the Sand Improved Permeability Fig. Type Pressure Casting Core this point, thereby increasing the length cooling rate means the added volume, which resulted casting sufficiently soft tap without the annealing operation. Fig. representative opportunities for economies pattern design. The casting question, with wall thickness, had projecting lugs 3/16 1/4 in. thick, by 7 q 1" Fig. Formerly Used Pressure Casting Core » | ‘a 4 aa Fig. 8—The Bent Rods Now Employed the Core Give Increased Bar Area Support making the molding the part, because the close tolerance, problem mechanize. Ordinarily cores were employed each end, and the The Iron Age, March 28, 1929—869 | | | part could then equipped for machine molding methods. The employment core this part, however, pro- duced difficult parting line, causing fins. These had removed hand filing operation, cost that more than offset the advantages machine molding. will also noticed that the top plane the lugs projected be- yond the common level the top the casting and did not immediately present opportunities for ordinary drawback. The lower views show how this difficulty was overcome withdrawing the lugs the orbit arc without disturbing the mold cavity impression. Improving the Core Pressure Casting Making large iron container casting such struc- ture withstand air pressure, or, other words, producing pressure casting weighing approximately 1000 ft. diameter and ft. high, having aver- age cross-section in. and form shown the cross-sectional view, Fig. requires considerable care composition that would hold its shape while being removed from the core box and being handled its green state. Fig. shows the plan whereby sand required struc- ture was employed successfully and the core was held position what might called steel corset support. This plan was relatively inexpensive, fitted the various heights and diameters and permitted the use sand improved permeability. The requirements were met without much additional cost, and reduction the num- ber defectives was immediately realized. The reinforcing bars used making this core were formerly the type shown Fig. They were found relatively heavy balanced their supporting features and offered considerable difficulty when the study the sharp sand core was being devel- oped. Later the gaggers were replaced relatively light rods bent the form shown Fig. Besides being very light weight, the rods provided considerably increased &) j | \ 2 } 4 M Fig. 10—Old \ Contrasted = | 1. Hook on to flask rH hooks hy the 4. Remove crane h 5 Hook crane hooks 100 and place plate Drop weight castin la = 9. Hook on to flask Flask and ectCasting hooks and remove casting PRESENT METHOD OPERATIONS variou stages of the process of making the molds and One feature special interest, which proved con- importance making castings this type and resulted minimum amount defectives, was The core prob- lem would have been relatively simple had been pos- ible use all sharp sand either the roll-over machine making the cores halves, the employment particular structure the sand core. rier forms. This was not feasible from production tandpoint, the containers were such varied design and size that the investment driers and equipment for the production cores according the usual methods employed was not justified. and ft. high and would necessarily carry high plastic The core, shown Fig. 1929, The Iron Age and New Methods Shaking Out blocks weight casting Joor with crane flask from 7 OPERATIONS rom flask ig to weight Fig. 9—Gas Escapes Readily from the Improved Core | | bar area support, resulting stronger core that was not subject collapse during its green stage. The improved core permits the gas escape readily from the mold, shown Fig. The pouring operation was formerly accompanied explosion the gas, indicating insufficient permeability the core structure. Levers Simplify Removal Casting from Mold The problem removing the casting from the mold was complicated differences heights and diameters and the small amount sand surrounding the casting. The entire operation constituted exceptionally severe handling the flask and castings. The various steps removing the castings were an- alyzed means sketch, shown Fig. 10, and nine separate moves were disclosed. The whole operation now taken care the action two simple levers. Photographic views the levers are given Fig. and Metals Used Hold Gases Pressure QUIPMENT for the commercial manufacture am- monia from atmospheric nitrogen built operate from 100 900 atmospheres (1500 13,500 per sq. in.), depending upon the process involved, but apparatus desirable for pressures 22,500 lb. per sq. in. Circular No. 61, United States Department Agriculture, contains detailed design compression and storage system, safe operate such pressures. Tubing cold-drawn seamless steel, outside and 1/16-in. inside diameter, made chromium-vanadium chromium-molybdenum steel with elastic limit 60,000 lb. per sq. in. This may bent cold without damage. Copper tubing with silver-soldered joints not recom- mended for pressures above 3000 per sq. in. Joints steel tubing are made turning the end 59-deg. cone, and forcing this against 60-deg. cone- Fig. 11—Fasten- ing Levers the Flask Before Re- moving the Cast- ing (at Left) Fig. 12—The moved (at Right) Fig. 12. The levers not only save time, but operate with- out creating dust, which was one the unpleasant fea- tures the previous method. seat cut into machine steel block means threaded collar and gland. (Proper gas passages have previously been drilled the connector block.) Valves are made much like those for oxygen cylinders; the stem has conical tip hardened and ground and fits into seat cut steel block, not hardened. regrind- ing necessary done the softer steel seat. Thi block 0.20 carbon steel with elastic limit least equal 35,000 lb. per sq. in. Gas storage cylinders are 10% in. outside diameter, in. inside diameter and in. long, cut from cent nickel steel gun forgings. limit 63,000 per sq. in. and ultimate strength 92,000 lb. Heads the same material are in. thick, held against flat copper gasket ten 114-in. stud bolts heat treated 70,000 per sq. in. elastic limit. safety precaution, all the apparatus should mounted armor plate barricade, with valve stems long enough extend through that the op- erator can completely protected while the system under pressure. The Iron Age, March 28, ; Hot-BlastCupolainPullmanFoundry Equipment Installed Michigan City Carwheel Plant Includes Skip Hoist—Results Operating Test ROGERS EPLACEMENT two cold blast cupolas single hot blast unit the Michigan City, Ind., plant the Pullman Car Mfg. Corporation has resulted substantial savings coke, power, and man- hours labor. Other features the new installation seldom necessary chip out hanging metal before patching; Bridging over the tuyeres occurs only rare intervais; Lining the melting zone burns out uniformly and never the extent where new block brick required build out the lining; Low blast pressure and the withdrawal gas eliminates flames the charging door, thus facilitating proper leveling the charge; Test pieces are uniform throughout the day ith resultant uniformity casting shrinkage; and, Once the metal brought temperature, its heat can held with blast pressure low oz. operating one the old units, the yard and rces comprised men, and when both old cupolas were blast men were needed. Each old unit had average capacity 135 tons melting period. The hot blast cupola, proved which has been provided with im- material-handling and charging equipment, re- quires men for output 250 tons 8-hr. melting time and its full asserted, has not been reached. The old cupolas were designed with 96-in. shells, 872—March 28, 1929, The Age FISKE which had been lined down The tuyeres were located higher than now considered standard practice. Former material-handling methods were costly. Coke was formerly gathered buggies from yard bins. These buggies were moved elevator, which delivered them the coke charging platform. Old car wheels, they were broken, fell into pit, from which the broken pieces were reclaimed overhead traveling crane. Each 10-in. Tuyeres (at left) Open from Wind Box Into the Cupola. The slag ladle stands the background The Bull Ladle (below) Continuously Filled from Spout Leading from the Cupola. One operator con- trols the tipping this ladle and the movement the conveyor crane load was placed hopper which straddled track scale which the buggies were spotted. After weighing buggy was lifted overhead traveling crane the charging floor platform, which was wheeled either one the old cupolas. Opposite each old cupola charging door was air- operated tilting platform, from which buggy load time was charged into the cupola. mentioned, the com- bined yard and cupola forces for the operation one cold blast cupola was men, and for two cupolas men. With the installation the new equipment chain- type conveyor was placed beneath the old wheel breaker, which has been moved more central location. Broken wheels now fall from the breaker the conveyor for de- livery, without rehandling, iron-charge buggy which stands track air-operated kicking device moves the weighed buggy forward that one man exert- ing slight additional push can place the skip hoist platform. The skip hoist discharges its load directly into the cupola. Coke now loaded buggies direct from railroad cars. coke car not emptied the end the day’s run, unloaded the ground, thus saving demurrage the This coke the first used the next The coke buggy, when loaded and weighed, wheeled the skip hoist platform. also dumped automati- into the cupola. Twelve men the yard and the hot blast suffice. The new cupola was designed with 120-in. shell, which has been lined 84-in. Should become desirable, the lining may removed give in- side diameter in. interest- ing note that according estimates made previous the installation was thought that, with the foundry operating capacity and requiring 250 tons metal day, the 96-in. melting zone would required. practice, however, that capacity has easily been obtained with the 84-in. diameter zone. This unit operated continuous tap cupola, whereas the old units were tapped intermittently, ordinary foundry practice. bull ladle filled spout ft. long leading from the cupola. This spout designed with the usual built-in puddle, which serves skim slag from the iron. The pour- ing ladles are tons capacity, this being the amount metal needed for pouring two carwheels. The pouring The Iron Age, March 28, TURE the Gas the Charg- ing Sill 150 Deg Fahr. Coke and broken w heels are c h arge d auto- matically from the skip hoist Wheel Breaker, Conveyor, Scale Skip Hoist are Grouped Closely Together (at left) Gas is Collected (below) ft. in. Below the Charg- ing Sill. The tem perature the gas this 1400 deg. Fahr | oa ladles are brought into position front the bull ladle cable-operated cars which run industrial track. this means they are moved opposite the pouring bays, which are equipped with overhead trolley systems. The cars and the bull ladle are operated one man stationed near the cupola. Twelve 10-in. into the cupola. These are arranged and designed standard cold blast tuyeres open from the wind box practice. The centers the tuyeres in. above the base plate and ft. below the tuyeres. annular gas duct attached the shell ft. in. below the charging door sill. Gas ports, 6-in., open into from the cupola. This duct construction and lined with Similarly, the gas duct that leads com istion chamber the heater made welded tes, lined in. the inside; gas welded steel plate in. firebrick. the outside asbestos covering protect workmen who might come contact with it. The temperature the gas leaving the upola about 1400 deg. Fahr. The gas duct connects with header which has three openings into one side the com- bustion chamber. This chamber ft. high from the floor the sprung heckerwork arch. air for com- ustion admitted the combustion hamber the gas ports. Average an- vsis the gas leaving the cupola per cent, CO, 8.4 per cent and 76.6 per cent volume. Special attention has been given the eparates ombustion chamber from the distribut- arch that the arch are arranged even distribution the gas the transfer pipes. The side thrusts arch are taken heavy beam sec- that extend along the outside the istion chamber. bout the same cubic contents contained the combustion chamber. walls these two chambers, con- ted in. brick, form the sup rt for the heater section. ash The lower tube sheet, which ted the high-temperature side, made of cast iron. The tubes, which are lso cast ire spaced 6-in. centers ind fit into tapered holes the tube heet. There are 256 tul ling about 2250 sq. ft. heating sur- face. The hot gas from the distributirg passes vertically through the tubes gas collecting chamber which yunted above the upper tube sheet. The ell the heater made welded plate. The upper tube sheet similar lower one except that not in- walls completely inclose ated. Brick the heater. Within the steel baffle blower enters top near one end the heater and makes three passes across the tubes travels heater are two horizontal Air from the Blower down the outlet, which the opposite end heater. The temperature the gas the com- bustion chamber ranges 1700 deg. Fahr. The temperature above the arch 1550 deg. Fahr. the gas travels through the tubes its temperature drops 874—March 28, 1929, The Iron Age about 600 deg. Fahr. temperature, Air enters the heater room average deg. Fahr., and dis- charged the cupola 450 500 deg. Fahr., which rise 375 425 deg. The drop air temperature be- tween the heater and the cupola negligible for the rea- son that the run very short. Waste gas drawn from the top the heater through flared header which connected duct leading single-end exhaust fan, driven 10-hp. motor. The suction maintained the gas line the cupola oz. This induced draft fan located the charging floor, where readily accessible the operator. The blast fan driven 75-hp. motor and nor- mally takes hp. Air pressure the cupola oz. This contrasts with oz. required the cold blast cupolas. This difference air pressure, well volume required because the smaller air amount coke used, accounts for large saving power charges. Emergency Cold Blast P) /pe Box Annular Gas Duct 4 | Pipe 4 Opening for Charging Car 4 Gate Heated Air Unburned Gas ; Hot Blast Cleanout Door About per cent the cupola gas drawn the combustion chamber. The remainder passes through the upper iron line about 150 deg. Fahr. The tabulated results are typical the operation this hot blast cupola. The figures given are not repre- sentative operation near maximum output, for when the data were gathered the foundry was producing only per cent its rated capacity. Since these fig- ures were obtained melt tons per hour, 245 tons hr., has been obtained. 8-in. bypass and gate are provided that the cupola can operated with cold blast required. The change from hot cold blast means increasing the blast and gate provide means drawing gas from the duct, ahead the heater, direct the exhaust fan. This ar- rangement effectively used control the temperature the gas reaching the fan. The maximum temperature allowable that point 750 deg. Fahr. Bypassing part the gas reduces the rate combustion the heater and thereby lowers the temperature the exhaust gas. Blast pressure the cupola, blast temperature the cupola and gas temperatures the exhaust fan, over the arch and the cupola are indicated control board. Clean-out doors are provided the side walls the combustion chamber and the distributing zone and man- holes are located the chamber above the heater. About once every two weeks dust and soot are removed from the heater. trouble has been experienced from fusion UPOLA Has Skip Hoist and Adjoining, Shown Facing Page, Hot-Blast Allowing for Short Air and Gas Connections — | ‘Dumping Annular \ Gas Duct — Cable Horsting 256 lube Hot Blast Heater Test Results with Hot-Blast Unit Temperature of gas in combustion chamber, deg. Temperature gas leaving cupola, deg. Fahr 1400 Temperature gas above arch, deg. Fahr.. 1550 Temperature waste gas above heater, deg. Fahr. 620 Temperature of gas at charging door, deg. Fahr. 150 Tons melted per day Rate melting,