The Iron Age 1929-04-18: Vol 123 Iss 16

IRON AGE New York, April 18, 1929 ESTABLISHED 1855 VOL. 123, No. Drill Bits Faced With Hard Metals Stellite and Tungsten Carbides (Borium and Blackor) Used Oil Fields and Cement Industry Resist Excessive Scour and Abrasion BOUT five years ago the well-drilling fraternity California became interested the possibility improving the performance rock cutting tools facing them with hard metal. Churn drill bits had been made high-carbon alloy steel, sharpened forging, and hardened quenching and drawing. was apparent that, worn edge could rebuilt fusion welding, there would little wastage tool steel, that desired toughness the bit need not sacri- ficed hardenability, and that exact heat (impossible portable forges) would unnecessary. According Haynes Stellite Co., Kokomo, Ind., that organization first developed proper methods for putting layer hard alloy softer backing. this the steel base first ground clean, and preheated carefully and thoroughly dull red heat. oxy-acetylene flame having slight excess acetylene then directed spot until the metal begins rod Stellite has meanwhile been held the flame and the hot surface “tinned” completely with thin layer the hard metal. subsequent layer Stellite then welded this prepared surface; the end the hot rod kept “Increasing the Footage Drilled per Bit Use Hard Facing Place, mining engineer, Los Angeles, Engineering and Mining Journal, March 23, page 486. Fig. 1—Comparative Appearance Wearing Edges, Flying Shear Knives. Top One Hardened Chrome-Vanadium Steel After Cutting Six Heats; the Lower One Machine Steel After Cutting Heats under the surface the puddle, and the molten area gradually worked ahead the necessary thickness attained, always protecting the puddle with the enveloping flame. Finally the piece slowly cooled ashes. Stellite alloy principally chromium, tungsten and cobalt, intrinsically hard. The hardness such prepared surface approximately equal (mineral- ogist’s scale, equivalent scratch hardness topaz). the best the older bits. The above mentioned facing process was rapidly adopted for well-drilling tools. Its use has also extended other industries, especially cement manufacture. Conveyor flights, bearings, and spouts contact with hot clinker have their life prolonged indefi- nitely Stellite coating. The facings have also been applied successfully metal working dies, swing hammer crushers, and other parts. Other Hard Alloys Stoody Co. Whittier, Cal., soon brought competing alloy into the market called Stoodite, hard chromium- iron alloy with some manganese.* has hardness be- tween and (i. e., will scratch quartz but not topaz). Other proprietary alloys now being exploited for similar purposes and welded similar methods are called Fig. 2—Rotary Drilling Bit, Mounted with Bori- um, After Running 856 Feet. particles re- tain position and softer steel between gouged out abrasion rock particles 1065 any — | Spartanrod and Diamondface (mainly iron and tungsten) and Plmite (an alloy iron, chromium and tungsten). entirely different class hard inset materials represented “Borium.” McCorkindale the Stoody Co. authority for the statement that Stoody and Stoody originated this, the first the diamond substitutes, 1927. Borium has hardness between and (will scratch corundum sapphire but will not scratch diamond). tough enough with- stand shocks drilling operations and Mr. McCorkin- dale’s opinion marks advance over the above mentioned hard facing metals, least far rock drilling tools Fig. 3—Core Drill, Mounted with Borium, After Cutting 120 Feet “Tube borium placed along the edge covered, and the torch played directly the tube. The mild steel melts and cements the Borium the bit, after which ready for the hard metal facing. all applications, the flame the torch should have ‘ragged’ edges (that is, flame with excess acetylene), and the bit warmed red heat the point where the Borium run. The electric arc should not used, will slowly oxidize the material.” The illustrations show the appearance rotary tools after hard usage. The hard particles remain place even after the scour rock particles has cut deep chan- nels between them. addition Borium, several other diamond substitutes have been placed the market. Among them are Hastellite, Thoran, Titan, Sulamite, Dia- monet, Duridium, Tungsite, Vulcanite, Anglite and Redor. While they are all made “secret” processes, prob- able that the principal material tungsten molyb- denum carbide. third class facing material, which covers the Fig. 4—Blackor Powder Scattered Over Wing Six-Way Bit, Preparatory Fusing with Carbon Arc. Opposite wing shows appearance com- pleted weld Fig. 5—Bit Shown Fig. After Digging 1,115 Feet 15-Inch Hole are concerned. its use from times the amount hole may drilled with hardened steel. “Borium sold either pea size (small irregularly shaped pieces that run through 3/16-in. screen but remain screen), ‘tube borium’—the same inclosed 5/16-in. cylindrical jacket mild steel varying lengths suit the requirements the user. “Application always carried out with the acetylene torch. applying pea size Borium, the pieces are set the cutting edges the bit with high carbon rod. After this, Stoodite applied surfacing metal hold the particles place. 1066—April 18, 1929, The Iron entire cutting edge and yet said hard the above-mentioned insert particles, known recently developed Blackor Co., Los Angeles. Its properties and method application have been described Place. “It tungsten carbide alloy marketed black granules, which crumbles between the fingers and breaks down water black fine powder. does not melt the acetylene torch and has applied with the carbon electric arc. has hardness ranging from 8.6 9.2 (about equal corundum sapphire), according the amount intermelt allowed the welder between the base and the hard-facing metal, and the number coats applied. Due allowance must therefore made for the skill the welder. Too much facing metal makes for brittleness.” Mr. Place’s opinion, insert particles such Borium are held place either slight cementing alloying effect, the shrinkage the overlapping surfacing metal. “Unless great care taken the welding oper- ation, cracking the bonding material may occur, and the insert grains will lost during Channel- ing the bit therefore avoided the use hard- facing material like Blackor, since covers the entire edge. cites comparative test two wells, one drilled 2071 ft, with two faced bits costing $150; the other required sets hardened steel disk bits cost- ing $1,350. Such materials also have distinct possibilities for metal cutting tools. The Vanadium-Alloys Steel Co., Latrobe, Pa., has conducted tests lathe tools pointed with Borium (see THE IRON AGE, Feb. page 429). ° > = > = 5 \ | Testing Compressed Gas Cylinders Volume Expansion Measured Two Pressures Determines Wall Thickness and Machine Records Data for Each Cylinder GLEN BAGLEY* capital the compressed gas industry, and conse- quently means must devised determine their condition, not only purchase but any time thereafter. The walls must thick enough with- stand the maximum working pressure safely, yet thin enough avoid exces- sive freight charges. The elastic limit must high enough prevent exces- sive stretch during proof test, and low enough insure maximum ductility and insurance against rough handling. The past records the extremely cylinders the United States have shown such small number failures indicate that these desirable quali- ties must have been achieved. However, the consequence single cylinder fail- ure may serious that pertinent inquire whether anything more can done still further safeguard produc- tion and use. represent large part the invested Government Specifies the Test GLEN Practically all cylinders have been made under Interstate Commerce Com- mission regulations; the principal fea- tures are: Every new cylinder must withstand test pressure equal times the charging pressure deg. Fahr., with permanent expansion not greater than per cent the total, and without any previous pressure greater than one-third the test pressure having been applied. In. addition, one cylinder from each 200 must stand crushing test six times the wall thickness without cracking. Tensile test specimens from this cylinder must show elongation not less than per cent in., with elastic limit less than per cent the ultimate strength. fair criticism hydraulic test made under these conditions that, while shows that the wall stress not greater only very slightly greater than the elastic limit the steel, does not give any information regarding the value the stress the wall. thin-walled cylinder with high elastic limit would pass the test equally well with thicker cylinder which had lower elastic limit. develop additional tests which would give more information with regard each cylinder made without harming it, number cylinders were studied large overpressures. Subsequently, the cylinders were burst under pressure, tensile test specimens were cut *Union Carbide Carbon Research Laboratories, Inc., Long Island City, Excerpts from paper read before the Compressed Gas Manufacturers Association. Whose Extended Re- searches Cylinders for Compressed Oxygen In- dicate That Present Ac- ceptance Tests Can Improved from their walls, the hardness the steel was determined and the microstructure was studied. When this work was completed, was found that the curves showing the relation between pressure and volume told great deal. These curves (Fig. turned out practically straight lines the elastic limit (or the point which permanent expansion takes place). Beyond this pressure, the curves are different shape, depending upon the hardness the steel. Curves for the softer cylinders show relatively sharp break; the cylinders expand rap- idly when the elastic limit passed. The harder cylinders act elastic manner until higher reached, and have more gradual ex- pansion after has been passed. The slope the straight part the curve indicates the average wall thickness the cylinder, because thinner wall will show greater elastic expansion given pressure than heavier cylinder. While such curves give complete story regarding both the wall thickness and the condition the steel, the de- terminations are tedious and imprac- ticable for commercial acceptance work. Fortunately, since the wall thickness indicated the slope the straight part the curve, single determina- tion may used; was found con- venient use 2500 lb. per sq. in. for oxygen cylinders (commercially charged with 220 cu. ft. oxygen com- pressed 2015 lb. deg. Fahr.). cylinder hav- ing the thinnest wall acceptable would have elastic expansion this pressure 127 cc. The heavy line Fig. indicates the slope the elastic curve from such cylinder. Any cylinder too thin, such represented curves and would give larger expansion than 127 2500 per sq. in. pressure and would rejected. much for the determination proper wall thick- ness. There yet remains the question proper elastic limit. study the upper portions the curves shown Fig. showed that those cylinders represented curves and possess the desirable qualities suffi- cient wall thickness combined with elastic limit suffi- ciently high resist excessive stretch the Interstate Commerce Commission’s test pressure and the same time retain the maximum possible ductility. cylinder producing curve such showing very gradual bend, indicates unnecessarily high elastic limit; this gives the steel greater tensile strength than required the sacrifice desirable ductility. Curve has desirable elastic limit but insufficient thickness. the thickness had been above the specified BAGLEY The Iron Age, April 18, > | | ¥ = { 200 180 > 127 © 190 cv a 100 on 1000 2000 2500 30003360 4000 5000 Hardness Acceptable Hardness Acceptable Thickness Minimum. Too Thin Hardness Acceptable Too Hard Thickness Average. Thickness Acceptable Hardness Maximum Too Hard Thickness Average. Too Thin. Fig. Pressure-Expansion Curves for Character- istic Cylinders During Acceptance Tests among the curves and Curve from cylinder which not only too thin also has too high elastic limit. This cylinder the most undesirable type, since possesses low ductility combined with high wall stress. well this cylinder, der (which also undesirable the basis low ductility, although not the basis high wall stress), would acceptable under the present Interstate Commerce Commission test. Cylinder would re- jected, properly should be, while cylinders and the desirable ones, would accepted. Information Given Two Readings means these curves, complete specification for hydraulic acceptance test 220-cu. ft. oxygen cylin- ders can stated follows: 2500 lb. per sq. in., the elastic expansion must not greater than 127 and the total expansion must reach value 220 cc. between the pressures 3360 and 4000 per sq. in. Such test can easily made setting the pressure 2500 lb. per sq. in. and reading the elastic expansion; does not exceed 127 cc. the wall thickness the cylinder satisfactory. The pressure can then gradually rise until expansion reaches 220 cc.; this point reached Expansion 2800 x onnn Ann 1000 2000 3000 4000 5000 5500 6000 00 Range 5500 6950 Fig. Curves Carried Bursting Pressures 18, 1929, The Iron Age between 3360 and 4000 then known that the steel that cylinder has satisfactory ductility. While such test appears logical, does not conform exactly the present Interstate Commerce Com- mission regulations. Thus—take cylinder minimum wall thickness; would expand elastically 127 cc. 2500 pressure and (at the same ratio) 170 ce. 3360 pressure. But suppose the proportional limit were passed before the higher pressure were reached and the total expansion actually measured 220 cc. 3360 pressure; the permanent set would then 220 minus 170, cc., which per cent the total (220). The present limit per cent. But does such permanent expansion harm the cylin- der? little computation shows that per cent perma- nent expansion (say cc.) cylinder whose total vol- ume 44,000 will cause permanent set the metal the cylinder 0.02 per cent, assuming that all the stretch takes place circumferential direction. Even the greatest permanent expansion possible under the proposed test, would only cause the metal acquire set 0.05 per cent, fraction very small that could not possibly harm the cylinder. matter fact the first per cent the perma- nent expansion under internal “rounding-out,” and occurs the first time pressure applied. not caused true stretch the steel, since experience has shown that necessary exceed per cent perma- nent expansion order sure that the true elastic limit has been reached. For com- mercial reasons, therefore, would desirable increase the allowable permanent ex- pansion limit per cent the total test pressure order facilitate the opera- tion the test. There does not seem any valid objec- tion this increase. Fig. Diagram obtain further informa- Testing Jacket tion this point, the expan- sion several cylinders was measured the bursting point apparatus sketched Fig. Results obtained with this apparatus are shown the curves Fig. Total expansion varied from 2800 6500 cc., thus show- ing that the maximum permanent expansion cc. encountered the proposed acceptance test negligible percentage the permanent expansion available, even the less ductile cylinders. These curves also show how the ductility cylinder decreased its elastic limit and ultimate strength increased, since the cylinders which require the higher bursting pressures show less total expansion. machine has also been developed which will auto- matically draw these characteristic curves for each cyl- inder (Fig. 4). consists corrugated steel pressure element, which operates drum carrying the sheet paper which the curve drawn. This pressure element connected parallel with the cylinder that the same pressure applied the cylinder. The volume element connected piping vertical tube and float; the pressure applied, the float moves the registering point vertically the same time that the pressure element rotates the drum. This machine provides permanent record the characteristics each cylinder the time purchased. } q minimum, the bent portion the curve would have fallen 6000 f 5000 | —_—S The second phase cylinder testing attempts de- termine what happens cylinder after placed service. Extensive investigations have shown that bar- ring accidental damage the cylinder service, the only factor serious consequence the life initially satisfactory cylinder internal corrosion. occurs only occasionally, but presents external evidence, and highly important find some means. Internal Corrosion Chief Danger During Use The elastic expansion the cylinder, which has been described above means determining the average wall thickness new cylinders the acceptance test, can used for this purpose. extra measurements are needed, since the present Interstate Commerce mission regulations require the determination the total and permanent expansion each cylinder every five years. Sometimes has been found that excessive corrosion can occur less than the prescribed five-year test period. safeguard against this possibility, each cylinder tapped with light hammer each time received the plant for refilling. Any cylinder which does not ring clear given jacket test immediately, regardless whether due for the five-year test. the elastic expansion not above the limit, can cleaned out and returned service. Conclusion conclusion, has been shown that simple non-de- structive tests are available which make possible Fig. Autographic Device for Acceptance Tests determine the wall thickness and condition the steel every new cylinder which placed service, the time the cylinder delivered from the steel mill. addition, the present five-year test affords data from which the wall thickness cylinders service can determined during life, they may discarded before becoming dangerous. Hammer tests give additional safeguard which can applied every time the cylinder refilled. Steel Frame Fabricated the Field buildings using the all-welded steel arch have recently been built the Florida fruit-growing districts Arch Engineering Construction Co., Orlando, Fla. They range size from 74-ft. span 217 ft. long 117- ft. span 202 ft. long, the latter requiring about 200 tons structural steel. shown the view, which represents fruit pack- ing house built for the Seaboard Airline Railway, the steel arches are made short lengths structural channels cut form arch when butted end end. They are then fabricated into one piece electric arc welding. Entire fabrication completed the ground; then the arches are raised into position, anchored the footing and tied together channel purlins welded the arches. rivets, bolts screws are used the fabrication erection these buildings (other than anchor bolts for holding the frame down concrete foundation) nor any work done the shop. According information furnished Lincoln Electric Co., one these buildings was under construction when the two hurricanes spread disaster Florida last August and September. the first hurricane the wind blew down the front and rear masonry walls, but the welded super- structure remained intact and unharmed. The second and more severe hurricane left unharmed this and the several other buildings the same construction. Fruit Packing House Seaboard Airline with Welded Arches The Iron Age, April 18, q 4 “2 ay € Rolling Bar Plates and Hot Strips Continuous Mill Eleven Stands Uses Flywheels Four Only—Close Speed Regulation Needed the Others placed service the American Rolling Mill Co. Middletown, Ohio, was described Ink that company before Cincinnati meeting the Amer- ican Institute Electrical Engineers. What follows taken from that paper. The new mill produces ingot iron and various grades steel strip gages down 0.093 in. and widths in., also plates in. thick and in. wide 75-ft. lengths. These products are rolled from 6-in. thick slabs, in. long, and the width required the finished product. For ease handling and storing, the strip steel coiled leaving the last stand the hot strip mill. CONTINUOUS bar plate and hot strip mill recently From the above follows that stands No. No. are independent regards speed while No. No. and No. No. are interdependent. Independent stands No. No. are each driven wound-secondary induction motor and are equipped with flywheels. The motor horsepower varies from the total rolling horsepower, the remainder the rolling energy from the flywheel. The output the motor limited automatic liquid slip regulators which introduce resistance motor secondary the motor pri- mary current increases and permits the flywheel give stored energy. Characteristics the first four stands, all with rolls The mill consists stands. The first seven consti- tute the “bar mill” and normally reduce the sheet about in. thickness. The last four stands are the “hot strip mill.” Between stands and are runout table, transfer, and bar piler for taking off sheet bar other heavy-gage product. Close Speed Control Essential While the initial length slab when enters No. stand in., the length has increased about ft. No. stand, and about equal the minimum spacing between stands possible with this type mill. Thus the remaining stands, economically spaced both for con- servation floor area and heat, must centers less than the length the piece. result the piece, after leaving No. two more stands the same time. This requires very close control speed, any change speed draft one mill must accompanied cor- responding change the other stands the train. rolling wide strip, wearing rolls makes frequent changes draft necessary. 1070—April 18, 1929, The Iron Age in. diameter, are shown Table following page. Interdependent stands Nos. inclusive are driven 600-volt d.c. adjustable-speed motors. Owing the necessity for close speed regulation, and the fact that the piece the stand considerable length time, fly- wheels are impracticable here. The motors, therefore, must provide maximum rolling torque. These stands are all 4-high in., with working rolls in. diameter, backing rolls in. diameter, and have roller bear- ings. The seven motors are heavy-duty type, with low pedestal bearings and fabricated structural steel bases. The four 3000-hp. motors, being very low speed, require forced air ventilation. Automatic Control Coiler Speeds Three coilers (working successive pieces) take the strip from the last stand the mill and form into coils about in. diameter. The sheet red heat when enters the coiler and cooled water before be- ing discharged. The coilers are driven 75-hp, adjusta- d.c. motors, which actuate the coiler rollers through multiple-spindle gears. The rollers bear the surface the coil and the coil grows are expanded cam driven 5-hp. adjustable-speed motor. The strip steel forced into the coiler pinch rolls. The machine started automatically when the strip completes circuit from ground the surface insulated roller. TABLE I—SPEEDS INVOLVED STANDS NO. NO. Speed Motor chronism, wheel Gear Mill, Speed, R.p.m. Hp. Sec. R.p.m. Ft. Min, 800 514 30,000 14.42 121 800 514 30,000 35:1 14.42 121 1000 600 40,000 29:1 20.18 169 1200 40,000 29:1 24.3 203.5 TABLE INVOLVED STANDS NO. NO. Gear Mill, Rolling Speed, Stand Hp. Ratio R.p.m. Ft. Min. 2000 300-500 37.1- 61.70 174.7-291.0 7 2000 300-500 5.32 :1 56.4- 94.1 266.0-443.0 3000 180-360 59.6-119.2 280.5-561.0 3000 180-360 79.7-159.4 375 -750.0 3000 180-360 96.3-192.6 454 -908.0 3000 180-360 104.8-209.6 494 -988.0 2000 1800 1600 140 1400 1200 1000 800 600 400 200 STAND STAND Curves shown illustrate the relative value different variables each stand the mill. The drop tempera- ture between stands and represents the critical range ingot iron, between 1922 and 1562 deg. fahr., which range the material may not rolled. From the test data the power consumption per ton steel rolled kwhr., which must added the idle 2250 2200 TEMPERATURE 2150 SPECIFIC w x w oO mo” ENTERING Cooling Rolls Relative Values Each Stand Roll Speed, Specific Power Consumption, Thickness Metal and En- tering Energy ture. (above). power consumption equals horse- Used Rolling power-seconds Time, Seconds Friction Load STAND Showing Effect Flywheel Providing Heavy Energy Which Drawn Upon the Metal Entered Between the Rolls. Only small part the energy used displacing metal supplied the motor the moment that metal being displaced About sec. suffices coil, cool and discharge strip No. 12-gage steel 180 ft. long and in. wide. Power Requirements Affected Many Variables The power required roll steel sheets varies with tem- perature, per cent reduction, speed rolling, kind mate- rial and diameter roll. probable that large part the input the old type mill with brass bearings consumed friction the bearings. This fact dem- onstrated comparative tests made the four-high stands the mill herein described, which are equipped with roller bearings, and another mill making similar product and having brass bearings. these tests was found that the specific power consumption the brass bearing mills was much higher than the roller bearing mill. This difference increases the temperature the piece falls and bearing pressure increases. friction mills, which make the total 40.3 kwhr. per ton, with production 150 tons hour. this must added the power consumption various auxiliaries, amounting about 800 kwhr. hour, making total 45.6 kwhr. per ton steel from blooming runout coil storage. Brake drums made nickel alloy cast iron with bands having molded linings will operate satisfactorily for 50,000 miles without overhaul, according Dayes, chief engineer, American Car Foundry Motors Co., writing This alloy cast iron has fine, dense, uniform grain, with Brinell hardness 260. Cast stzel drums will either score the molded lining develop alli- gator cracks from overheating. Steel drums and steel shoes, while very efficient and long lived, are objectionable because they squeal. The Iron Age, April 18, 1929—1071 High-Test Iron Made Six Methods Foundrymen Hold Symposium Chicago—European and American Progress Reviewed—Scrap Steel and Alloys Large Aids NEW era gray iron may said have developed the perfection processes make high-test iron. notable symposium this subject filled the room capacity the annual convention the American Foundrymen’s Association last week The session was prolonged three hours accommodate those desiring speak. Under the chair- manship Prof. Moore, University Illinois, Urbana, the seven scheduled leaders were allowed present their papers before any discussion. the papers were preprinted. Chicago. Only two High-Test Cast Defined program consisted review what has been done Europe and America. The subject was intro- “High-Test Cast Iron,” the annual exchange paper from the French Foundry Technical Association. Its more pages were abstracted Prof. McCaffery, University Wisconsin. deals with the actual state the production high-test cast iron Europe and chiefly France. After reviewing the theory high- test cast iron and showing that the lower the carbon, the higher the tensile strength, and after discussing patented cast irons, alloyed irons, electric cast iron, the duplex process, low-carbon and high-test cupola iron, Mr. Lemoine says that the low-carbon cupola process not, technically speaking, improvement the duplex, which certainly the best all the present time. also Semi-Steel the Basis sound basis production high-test cast iron has been the semi-steel process developed during the war [in Mr. Lemoine. Fairly mechanical properties were obtained test bars. But the develop- ment the electric furnace for foundries has made pos- sible the single and duplex processes, affording the first real possibility adopting compositions with low carbon and high silicon, leading not only better properties but also good uniformity, and hence more reliability. interesting cupola process has been established from the careful study melting scrap cupolas for the duplex process, coupled with the knowledge the fact that some kinds scrap are slow carburization. may ve says good possible still further improve low-carbon cast Carbon Content. plished three ways). 18, 1929, The Iron Age Six Methods Making II.—Control Cooling Rate After Casting. Size Graphite (accom- iron “jarring” or, better, “grating” the forehearth. alloyed cast irons, Mr. Lemoine says that special elements are rule expensive and are considered only when necessary further improve given property—the same method which has been applied alloy steels. Alloyed cast irons seem worth con- sideration certain corrosive problems, for resistance wear, etc. far mechanical strengths are concerned, alloved cast iron can considered reserve force used for further improvements. High-Test Europe OLLOWING this general excellent introduction the subject, Dr. Edward Marbaker, director, foundry research division, Whiting Corporation, Harvey, pre- sented abstract his paper “High-Test Gray Cast Iron— European Developments.” The methods, now known, may divided roughly follows: Decrease carbon content. Control cooling rate after casting. Reduction particle size graphite and improvement distribution (a) super heating, (b) rapid cooling high-silicon iron and (c) treatment with calcium silicide Alloying elements such nickel and chromium. 5. Agitation of molten iron. 6. Eutectic cast iron. Each these groups discussed the paper, tables and physical properties being given Eutectic irons are comparatively new. They not pipe, quality which can taken critical test these irons. Methods producing high-test irons are numerous with considerable differences among them, said Dr. Mar- baker. Resulting castings have much the same structure and properties, indicating some underlying general theory, pointed out Osann. The subject still contro- versial but ways and means are now available for making better castings. Despite additional expense, the quality more uniform and certain, and lack interest results. The author supplemented his paper with brief ac- count new development since the paper was written. rotating cylinder furnace has been tried out, one end which the charge put in. fired with powdered coal and tapped the center. When the charge melted, High-Test Cast Iron IV.—Adding Alloying Elements. V.—Agitation the Molten Iron. Cast Iron. Four Contributors the High-Test Symposium MARBAKER OLIVER SMALLEY the furnace rotated completely, coating the walls. The product eutectic composition and high-test. German Opinion These Irons UTHORITATIVE European opinion recent develop- ments high-test iron was offered coming from Dr. Piwowarsky Germany Dr. Fritz Meyer National Radiator Co., Johnstown, Pa. association foundries making this and other special irons has recently been formed, important that less secrecy now prevails and common benefits now result. Among the many strik- ing comments, one was the effect that Europe much emphasis laid upon the fundamentals cupola opera- tion and less non-essentials, whereas America more dependence placed additions the charge ladle, such alloys. Dr. Meyer interjected the remark that addition nickel and similar alloying metals like the use pink pill” cure physical ills. This created much merriment. Germany there considerable demand from foun- drymen for alloy-bearing pig irons. Some blast furnace men are importing Greek ores containing about per cent chromium and per cent nickel, the resulting iron being used make iron rolls. Vanadium and titanium are finding use, also molybdenum ferromolybde- num molybdenum-bearing pig irons; calcium silicide also being adopted. Methods Used America developments were covered four speak- ers: Coyle, International Nickel Co., New York; MacPherran, Allis-Chalmers Mfg. Co., Milwaukee; Bornstein, Deere Co., Moline, and Oliver Smalley, For the first time, the process developed the Inter- national Nickel Co. for making high-test iron was made public paper Mr. Coyle collaboration with Houston. Limitations the place cast iron industry are being removed the use alloys, said Mr. Coyle, made possible special processes. The greater demand for stronger iron will lie between tensile strengths 40,000 and 45,000 Ib. per sq. in. Per Cent Scrap. Steel Used The Nickel company uses charge containing about per cent steel scrap with about per cent iron scrap pig. Nickel added either the cupola FRITZ MEYER COYLE ladle, preferably the latter. Depending composition and other factors the resulting irons have transverse strength 4500 8000 tensile strength 50,000 70,000 Ib. per sq. in., elastic limit 10,000 12,000 lb. per sq. in. and compression strength 165,000 190,009 These irons are claimed have unusual impact and fatigue properties and readily machinable. The authors relate many industrial applications. The use alloys advocated extend the range composition and obtain strength. heat treatment the latter property particular can augmented. Per Cent Scrap Steel Charged Other American testimony came from the experience the Allis-Chalmers company. Mr. MacPherran gave history his foundry’s practice which is, briefly: A 54-in. cupola is used, having six tuyeres in a row Charges of 3000 Ib. are used: 94 per cent steel scrap, 4.5 per cent ferrosilicon and 1.5 per cent ferromanganese Of 63 arbitration test bars, all from regular operation, the following tensile results were obtained bars......47,900 50,000 Ib. per sq. bars 50,000 60,000 Ib. per sq. bars 60,000 70,000 Ib. per sq. bars 70,000 per sq. Aver. for bars 58,300 per sq. heat treatment practiced About per cent nickel is added to the ladle: also a manganese-silicon ferroalloy containing about per cent manganese and per cent silicon. Metal not chilled ladle addi- tions but must handled quickly machines like steel castings. Total carbon runs about 2.40 to 3.10 per cent, silicon 1.60 2.60 per cent, manganese 0.90 with Brinell hardness The secret low carbon and high temperature Iron from Three Cupolas More American experience came from the Deere com- pany. Mr. Bornstein recounted details the use 28-in., 54-in. and 33-in. cupolas from which series casts were made. Charges varied percentages steel scrap, always high, ferrosilicon and ferro- manganese. Shot nickel was used some cases, others Mayari iron, molybdenum, nickel and molybdenum, and alloys all. Invariably the carbon was low—lowest from the 28-in. cupola. Manganese averaged 0.65 0.80 per cent, phos- phorus under 0.10 and sulphur well under the same level. Tensile strengths averaged 70,000 per sq. in. with transverse values from 5300 7000 Machin- ability offered difficulties, though the irons were not The Iron Age, April 18, 1929—107 quite readily machinable ordinary irons. Those casts containing molybdenum, nickel with molybdenum, machined better than plain iron—in fact “to obtain better machinability, alloys are necessary.” Drop tests revealed Use high-test iron means savings weight and sections well possible substitutes for steel and malleable castings. strong recommendation for the use calcium- silicide was made Mr. Smalley. insures uniform regulation the carbide iron content, exothermic, does not contaminate and controls the deposition graphite. From per cent steel scrap used. Analysis the product, known Meehanite, approxi- mates: T.C., 2.80; Si., 1.20; Mn., 0.60 0.70; S., 0.10 0.15; P., 0.20 per cent; with physical properties: 51,000 per sq. in.; transverse, 4800 Brinell 247, annealing 1650 deg. for hr. Lowers the strength and hardness. toughness. General Comment RUNNING discussion, made largely questions and answers, followed. Dr. Richard Moldenke ad- vised the discounting much that now claimed and said that very few the patents would hold water. Pearlitic iron can and has been patented. THE IRON AGE Survey Calling attention survey one phase high-test irons—alloy cast irons—made THE IRON AGE and pub- lished March 28, Edwin Cone, associate editor, New York, pointed out that that survey revealed the use few American foundries vanadium-bearing pig iron from Norway, the pig iron containing 0.50 0.60 per cent vanadium, and the castings 0.05 0.10 per cent with beneficial wear-resisting properties and greater strength. Also that molybdenum being used quite extensively rolls and automobile castings. cited the fact that electric furnace company has rocking type furnace, which now being used few foundries for making small iron castings, the claim being advanced that both the higher temperature and the churning jolting action improve the iron. Mr. Cone also announced that, with the answers received date, return per cent replies 3818 letters had been obtained and thanked iron foundrymen present for their fine cooperation the survey. Shortening Malleable Annealing Periods Foundrymen Learn New Heat-Treating Furnaces and Methods—Causes White Malleable—New Way Control Furnace Atmosphere foundrymen, the annual convention the foundrymen’s association Chicago last week, discussed their problems technical session and round table luncheon. The technical session was devoted malleable iron foundry practice under the chairmanship Frank Lanahan, Fort Pitt Malleable Iron Co., Pitts- burgh, followed the round table discussion which Seott Mackay, University Wisconsin, was chairman. The latter, attended about members, was devoted mostly informal discussion quicker methods annealing, which malleable foundrymen are deeply in- terested. Malleable Annealing Period Reduced was brought out that two types electric furnaces are now being used which the annealing time being expedited heat treatment. The General Electric Co. has furnace operation its Erie works which for some time has been annealing castings lots tons with annealing cycle hr. This company now building another annealing furnace which 6-ton load carried car will annealed and expected that the annealing time will reduced hr. This furnace will have three chambers two which the work will held temperature 1850 deg. Fahr. The high temperature the entire mass will facilitate rapid annealing. The temperature will reduced 1550 deg. Fahr. the third chamber. Air excluded water seal. When the material below the critical point sudden change deg. made the temperature, but not above the critical point. The other annealing furnace being used Buffalo plant and was built the Industrial Furnace Co. this the annealing temperature has been reduced four days, time being saved bringing the castings tempera- ture rapidly and cooling from about 1100 deg. The holding time evidently not changed. The results were said satisfactory. One user the castings had found them easier machine than those annealed the ordinary method. 18, 1929, The Iron Age Three papers were presented the technical session. The “Practical Aspects White Fracture Malleable Iron” were discussed Duncan Forbes, Rockford-North- western Malleable Corporation, Rockford, Ill. the cast- ing not correctly annealed, the author said, will have white, sparkling fracture due the presence non- ductile pearlite cementite, mixed with the ferrite the matrix. Apparently white-fracture malleable due either the weakness brittleness the intercrystal- line cement low temperatures else strengthening ferrite low temperatures, making stronger than the cement. Cause Brittleness White Fracture Malleable material, likely cause white fracture, annealed single annealing oven, the castings will not neces- sarily all white fracture when cold. Analysis and heat treatment both have bearing white fracture. The surest way develop white fracture heat the after annealing 850 deg. Fahr. and then quench air water. This what happens the hot dip galvanizing process and gives rise galvanizing embrittlement. The best way avoid white fracture, according the speaker, avoid the conditions under which formed. The analysis should under per cent silicon and 0.17 per cent phosphorus. The melting operation should normal, excessively high annealing temperature should avoided, the oven should “pulled” over 1000 deg., and the castings should not reheated 850 deg. white fracture encountered, said, can corrected the Flecto process which the castings are reheated 1200 deg. and quickly cooled through the 850- deg. range. Neither Silicon nor Phorphorus Migrates written discussion the paper, Schwartz, National Malleable Steel Casting Co., Cleveland, said that the author has identified the fault caused when mal- leable iron embrittled during the galvanizing operation q and that had shown that the fault, which can pro- duced galvanizing, can also produced under equiva- lent conditions during the supposedly normal heat treating malleable iron. The speaker said that neither silicon nor phosphorus, two elements regarded major im- portance, will rapidly migrate iron. likely, after annealing, that they will found largely the same position they occupied the original iron. If, therefore, either phosphorus silicon films determine the course intercrystalline fracture, the crystal boundaries the ferrite malleable must some measure coincide with the position the phosphorus silicon the hard iron. did not know whether this was true not, but said that Mr. Forbes’s paper had furnished impetus for investigation that direction. Change produced the Flecto treatment, continued Mr. Schwartz, can hardly the formation destruction films, but may only the change properties the film result temperature heat treatment. This conclusion supported the fact that heat treatments, which change the character the fracture from inter- granular intercrystalline and back, have been shown his laboratory unaccompanied changes either electrical resistance magnetic permeability, even when the tests were made the same sample before and after heat treating. Iron Nitride Must Considered There was also written discussion prepared Marshall, Bureau Standards, who said that be- coming more customary for buyer test out his pur- chases. This the producers malleable castings means more frequent asking the question, “When mal- leable iron not malleable?” The general answer is, “When has white fracture.” Due perhaps superficial re- semblance the white fracture that hard iron, com- bined carbon has times been given the cause the trouble. However, has been shown that silicon and particularly phosphorus produce white fracture. The speaker said that, the author had pointed out, should shown that some element combination will develop the characteristics exhibited white-fracture malleable iron. Although silicon and phosphorus seem connected with this phenomenon, there record that they produce such results any other ferrous alloy. However, pure iron containing nitrogen exhibits thermal effects around 800 deg. Fahr. Iron nitride will cause dis- persion hardening room temperature. This nitride tends into solution iron 1200 deg. There suspicion, therefore, that there might some con- nection the two. study pure iron-silicon- phosphorus alloys, with without the presence ni- trogen, would likely throw further light this question. Controlling Annealing Atmospheres New Way new method “Controlling the Atmosphere Mal- leable Iron Annealing Furnaces,” used the Ohio Brass Co., Mansfield, Ohio, was described Graham that company and illustrated with lantern slides. pre- liminary investigations said that was found almost impossible approach neutral atmosphere during the holding period and maintain, the same time, uniform temperatures. The two furnaces more recently instailed are provided with return gas system, some the waste flue gases being returned through the carbureter and burner. The return gas firing applies only the holding period. The furnaces have been operated for some time with satisfactory results control and quality the product. was found that the return gas could brought into the mixing chamber 600 deg. Fahr. and then through the carbureter, producing temperature 400 deg. immediately below the burners. While this tem- perature carries certain amount heat into the burner gases, doubtful whether directly represents sav- ing fuel. More Trouble from Hard Than from Tough Castings discussing the paper Bean, president Grindle Fuel Equipment Co., Harvey, said that the purpose the experiment was improve the quality the prod- uct reducing the oxidation the castings. His com- pany had experimented along the same line and has Authors Two Papers ‘ { ww GRAHAM FORBES 200 secured more perfect control the temperature. coal per hr. required bring the furnace temperature. One burner had proved unsatisfactory and they are putting two burners, one bring the furnace temperature and the other hold the heat. They had burned low lb. coal per hr. for holding the furnace temperature. reduction the fuel required for annealing has resulted, being possible anneal 400 lb. per ton coal. The machinability malleable iron vital con- dition, said Mr. Bean, because the automobile industry de- mands castings that can machined rapidly. Most trouble comes not from hard castings, but from tough castings. reducing decarburization the surface better castings can produced. Most recent furnace in- stallations, the speaker said, are using automatic control for maintaining uniform furnace control through the hold- ing period, the control keeping the furnace within range deg. Malleable Shrinkage Determined Temperatures exhaustive, highly technical paper shrinkage white cast iron and including tables showing density and other data was submitted Schwartz. The author, discussing his paper, said that the question tried answer was whether one lot iron casting will shrink more than another. The first problem was find how much shrinkage there is. designed sphere for test purposes and poured 100 200 heats. Then com- pared the apparent density with the real density and from these studies gathered considerable data. tried show whether chemical composition had anything with shrinkage. found that the effect carbon and silicon very small. Mr. Schwartz said that the gist his paper that shrinkage determined temperatures and various variables, the effects these variables being much greater than the effect carbon and silicon. Seott Mackay, chairman the division malleable The Iron Age, April 18, 1929—1075 7 ff iron foundry practice, made verbal report. said that had been suggested that more work that being de- done research laboratories made available. clared that more educational work needed and that faster progress would made there were greater co- operation efforts between shops and laboratories. Light Steel Foundry Problems Different Views Causes Porosity, Convention—New Alloy Steel Castings the opinion competent observers, there has seldom, ever before, been meeting foundrymen during which sessions devoted steel castings brought out much valuable and interesting data, the annual con- vention the American Foundrymen’s Association the Stevens Hotel Chicago, April 11. John Howe Hall, Taylor Wharton Iron Steel Co., commenting the meetings, held that those who took part the prepara- tion the material and the handling the sessions should congratulated the high average excellence both the papers and the discussions. There were three sessions the steel foundry shop operation course, the fourth being merged with the gen- eral sessions sand control. one session ladle prac- tice, the best designs for stopper heads, nozzles, etc., were described, and the subject temperature control pouring was touched upon. Porosity Problem After few members had talked upon these points, the discussion turned the influence mold conditions and the condition the steel upon the formation pinholes the surface castings. sharp difference opinion was evidence, some members holding the view that sand condition chiefly responsible for these pinholes, others maintaining that the steel blame. The influence aluminum checking the formation these defects was brought up, well its influence diminishing the toughness the steel when used too great amount. About 100 men sat down the luncheon presided over Doty, who opened stating that this, the first roundtable meeting steel foundrymen for informal discussion their problems, was hoped that subjects mutual interest would brought and that those present would find the discussion profitable. Porosity problem steel foundrymen, particularly those making light castings green sand, bobbed again the subject most interest the majority those pres- ent, and the meeting was adjourned only when the ap- proach four o’clock called the members the after- noon session sand control. Opinions members who participated the discus- sion whether the steel the sand mainly re- sponsible for the formation surface pinholes were about equally divided between the two points view, and was agreed that the whole question one that well merits some intensive investigation. Relative Merits Steel Melting Processes side issue this question, the relative merits the several processes steel making, from the point view the ease “running” light castings, was brought up, and the qualities the steel made the different processes, which influence fluidity, were briefly discussed. The one technical session devoted the steel foundry, presided over Utley, vice-president Detroit Steel 1076—April 18, 1929, The Age Heat Treating Complicated Designs Casting Co. and past president the association, was well attended, and devoted the presentation two most interesting papers. New Alloy Steel Castings The first, Zuege, Sivyer Steel Casting Co., Mil- waukee, “Alloy Steel Castings,” presented the latest data the so-called carbon-manganese steels, containing manganese the neighborhood 1.50 per cent, the nickel-chrome steels, the chrome steels, and new steel that has recently been developed the Sivyer company, containing manganese, chrome, nickel and molybdenum. The properties the various steels the heat-treated condition, well plain annealed, were given con- siderable detail. DAVID ZUEGE JOHN HALL discussion, various members stated that their own results the carbon-manganese steels were close agreement with those the author. steel manga- nese-chrome-molybdenum was mentioned quite similar the more complex alloy described Mr. Zue