The Iron Age 1929-05-02: Vol 123 Iss 18

THE IRON AGE New York, May 1929 ESTABLISHED 1855 VOL. 123, No. Semi-Permanent Molds for Castings Production Greatly Increased and Costs Heavy Sections Hydraulic Plungers Are Made This Method ASTINGS can designed manner that will allow their removal from the mold without totally destroying the formation the mold, typified the example shown Fig. This represents cast- ing which section hydraulic plunger. number these castings bolted together, one having blind end, form plunger for hydraulic lift lock, and each section with the shrink head weighed over tons. These cast- 29799 2723 Monroe Street, Toledo, Ohio. ings were formerly being made with pattern dry sand molds and, after changing the method molding, made them three times quickly, with only half the number molders and laborers. make these castings according the method shown the accompanying illustrations, hole dug the floor depth equal the height the casting and about in. larger diameter, that, after the outside the mold bricked up, there space around the brick wall that can securely rammed with sand Fig. for Hydraulic Plunger Fig. 2—Sectional View Finished Mold, Ready for Pouring Fig. 3—Sweep for Forming Outside Part the Mold and Seat for the Core Lifting Plate Fig. 4—Sweep for Forming Inside Mold, Core Fig. 5—Core Lifting Plate 1203 \ Fig.4 prevent any possible strain when the casting being poured. bottom plate, shown Fig. made with spindle socket cast it. This set down solid level bed the bottom the hole. The spindle with the outside sweep attached, shown Fig. placed the socket and all ready start laying the brickwork. Good hard fire brick are used and, the shrinkage the casting leaves space between the casting and the outside the mold, the castings can lifted out the mold without disturbing the brickwork, which will last indefinitely. All that has done this part the mold, after Prickers Tapered Spaced Apart Fig.6 Loam Fig. 6—Bottom Plate Fig. 7—Sectional View Segments, Which Form the Core Barrel Fig. 8—Top view Segments Fig.9—Top View Wedge Segment Fig. 10—Covering Plate Fig. 11—Top View Assembled Core Barrel, Show- ing Method Used Securing the Wedge Segment the first casting made, scrape off the burned loam, put the spindle and sweep back place and put fresh coat loam. Very little drying required, the bricks are always warm and there only the half-inch loam that applied each time dried. build the core, permanent “false shown exact dimensions the seat attached the outside sweep, Fig. because, after the core completed and dried and the mold being assembled, must fit into the seat formed the outside sweep. The core lifting plate, Fig. then set this false seat and the segments, Fig. set around place. These seg- ments are machined the sides where they fit together 1204—May 1929, The Iron Age and the bottom flanges. The portion the lifting plate that these segments rest also machined. They are held place, while the core being made, with pins shown Fig. which are left until the core set the mold. One these segments like wedge shape, shown Fig. its purpose being make the core barrel col- lapsible and also allow the casting shrink the use cores shown Fig. 11. Steel hooks shown Fig. are cast two the segments shown Fig. 11. Steel bars, are dropped over the hooks, with wedges, between the bar and the “wedge seg- ment” which holds this segment place. After the mold poured and the casting set and cooled sufficiently, the wedges and bars and are knocked out. This allows the “wedge segment” fall in, after which all the other segments can taken out without any trouble. Being able bare the inside the castings, while they are still very hot, has helped make them very close grained and, machining that had done them was all the outside and ends, made ideal way molding such castings. Japanese Scientist Studies Impact Tests difficult task determining the stress-strain re- lationships specimen broken almost instantane- ously Charpy impact machine has been attacked Yamada the Japanese Research Institute for Iron, Steel and Other Metals. His experiments and conclusions are described Science Reports the Tohoku Imperial University for December, 1928, page 1179. lenses and slits, and then interrupted this rapidly rotating disk with slots the periphery. This interrupted beam made series lines photographic plate at- tached the side the swinging hammer (the equip- ment being mounted dark room). The distance be- tween these lines gives the velocity the hammer; from the change velocity and the location successive lines figured the energy absorbed the specimen and the deformation. The total energy required break specimen, figured such way, within per cent that found the upward swing the hammer. Stud- ies were also made notched bars when bent slowly under the head Amsler tension testing machine testing). Izod test pieces were used. Among other results, Yamada found that the energy absorbed test pieces various sizes proportional the breadths only when the thickness relatively very small; the notch the same depth and shape, the en- ergy absorbed before fracture more nearly propor- tional the product the breadth and the square the effective thickness. Toughness Low Temperature Brittleness temperatures down —80 deg. was also investigated. Izod test pieces, made quenched and tempered steel with 0.1 per cent carbon, abruptly lost nearly all toughness —30 deg. (either slow rapid test), the absorbed energy falling from similar but less pronounced effect noted between —20 and —40 deg. for 0.3 per cent carbon steel, quenched and tempered. quenched and tempered nickel-chromium steel, and annealed 0.5 per cent carbon steel (the latter unnotched) both showed gradual decline energy absorbed under impact fracture the temperature decreased below zero, but the energy absorbed slower loading nearly constant down —60 deg. Thus “brittleness” low temperature more pronounced hard steels when tested impact than under “static” testing. Chain Steel Requires Special Qualities Weldability Affected Composition Steel and Non-Metallic Inclusions, Nature Atmosphere Welding Fire and Type Hammer Die JOSEPH MILLER* OST chain now made from basic open-hearth steel, extra fine welding grade. Bessemer steel longer used, because now made America has tendency cold shortness, due its phosphorus content particularly, and experience shows unsafe for chain. Thus “chain steel” very soft and not much stronger than wrought iron. The carbon content held low possible, with manganese just sufficient indicate thorough deoxidation. Sulphur must kept low, must also the phosphorus. Links the chain are usually formed cold, coiling the rolled bar special machine. The coiled bar cold sheared into the individual links, the cut ends forming This can easily done, particularly the grade very soft. Off-grade steel liable crack during this cold forming, and thus may often detected. Welding Fires Work Better Humid Days After forming and shearing, the individual links are strung into the fire and the ends given welding heat. The links are welded quick hammer blows, sometimes under flat die and sometimes shaped die, the latter being much easier the steel. this welding heat that causes trouble with chain steel. nearly every case investigated the writer more than ten years’ con- nection with the industry, welding troubles are due burning overheating the steel that crumbles under the hammer. shaped die requires lower welding heat seems hold the steel together all parts and makes for quicker welding. Fires are said the smith rainy damp days. The moisture the air seems modify the atmosphere the fire that welding heat at- tained without burning even tender steel. Steam has been introduced into the air blast for this reason, and many workmen believe that steel otherwise “tender” the welding fire can worked that way. The chemical composition (by ladle test) the chain steel made most mills follows: carbon 0.09, phos- phorus 0.025, manganese 0.32 0.45 and sulphur 0.045 per cent. Chemical Composition Should Watched trouble being experienced with the general run the steel when working into chain, carbon may allowed 0.10 per cent and manganese down 0.27. liberties should taken with the limits quoted phosphorus and sulphur, for the safety the finished chain depends upon keeping down these two elements. Chain steel must kept free from oxides and inclusions the sort that favor oxidation the metal welding heats, and from oxidizable metalloids such silicon. Elements that retard welding must kept out chain steel; for instance, very small quantities arsenic, which, while rendering the steel capable bearing most intense heat, almost completely prevents welding. This Cathedral Mansions, Pittsburgh. element has been known come into the steel from the use burdens containing briquetted flue dust. Nature Pig Iron Has Importance Foundrymen who believe that certain troubles their practice are due obscure changes the quality the pig iron will interested know that similar sus- picion was cast the raw material for chain steel over years ago. Certain steel works that had formerly been able make chain steel the open-hearth without spe- cial attention suddenly found themselves unable make satisfactory even under the most rigorous supervision. After going carefully into all details the steel makers con- cluded that some variation the quality the pig iron was responsible, not reflected any chemical anal- ysis. seemed clear that every method had been tried the steel making process better the result. did not seem possible locate the exact source the difficulty without seriously affecting the operations the blast furnaces, the chain makers were forced worry along with material which they were sure was dis- tinctly inferior that which they had been previously getting. Since the turn the century many changes have come about the coke quality and the development blast furnace operating methods, tending toward greater production and lower coke consumption, which are suf- ficient change the quality the metal and the re- sulting steel. This might come about simultaneously even independently change the nature the iron ores. also conceivable that the quality the fluxing limestone may have much bearing such matter the gangue the ore, the coke ash. matter fact the fine quality charcoal iron often popularly ascribed the fluxing action the wood char- coal ash. Heat Treatment Chain Since the welding heat applied locally (to part the link only), there border zone weakness between the hot worked zone and the colder part the link. This must corrected before shipment proper normaliz- ing treatment. Uses which chain put involve over- strain and fatigue stresses; well known that should annealed from time time. temperature just above the critical, say 1650 deg. Fahr., will refine the grain and prevent grain growth the overstrained surface layers heating. These treatments are done some plants feeding the chain automatically through furnace cham- ber and discharging into the air for cooling. The installation line starting motor requires wider pulley and belt than would used with standard motor, according bulletin issued the Chicago Belt- ing Co. Normal load linestart motors should equipped with pulley and belt from per cent wider than for standard motor, and high torque linestart motors should ordered with pulleys per cent wider than for standard motors the same rating. The Iron Age, May | andling Rod and Wire Overhead Sheffield Steel Corporation Finds New Answer Old Challenge Truckless Wire Mill—Bundles Weigh 400 Lb. Throughout URING the last week 1928, the Sheffield Steel Corporation put into operation its billet, rod and wire mills. The plant lo- cated Sheffield, suburb Kansas City, Mo., the Kansas City Terminal, Missouri Pacific, and Kansas City Southern Railroads. Here the cessor, the December, Sheffield Steel Corporation and its prede- Kansas City Bolt Nut Co., have been operating since 1888 plant for manufacture iron, bolts, nuts, track spikes and similar railroad products. 1919, open-hearth furnaces were erected take ad- vantage the large local scrap market. Billet and bar mills were added, well equipment for duction blue annealed sheets, concrete reinforcing bars and railroad and industrial forgings. January, 1928, desiring round out steel-making N ~€ Pe } E id cl WARE — > All Ld | GALVAN/Z/ING MIL operations, the company settied upon a program which involved, the principal outlet for increased tonnage, the manufacture wire and wire products. The Morgan Construction Co. was commissioned consulting en- gineer carry the program into effect. The new wire mill interest being the first instance which the manufacture wire products has been treated primarily handling problem, with uilding structure, layout and equipment coordinated take advantage all economies handling. also the first mill the bundle has carried as_ the tandard unit throughout all erations Raw material for the wire mill supplied new Morgan mills, four-stand 18-in. billet mill and 17-stand 10-in. rod mill. The latter somewhat un- usual design that local conditions required the mill > deliver rods toward the heating combination rod and merchant bar mill | 1206—May 1929, The Iron Age receiving bars from either end, and which serves the new mill and earlier bar mill. The new mill rolls 30-ft. billets 2-in. square into 400-lb. bundles rod No. gage and coarser. Wire rods delivered from the reels pass through covered conveyor about 250 ft. long. Rod Handling Lifts Rods delivered the end the muffle conveyor are transferred telegraph hook onto the arms two “star wheels,” each arm carrying eight 400-lb. bundles. power-operated hairpin hook removes rod bundles 3200- lb. lifts from the star wheels and delivers these rod bundles either into storage direct the cleaning house. Leaving the rod storage building, the hairpin unit crosses Independence Road elevation ft., runs AYOUT the Wire Plant, Including the Rod and the End the Conveyor Lead- Lower plan (page 1207) Entire ing layout the cleaning house and baker, showing move- bundles storage and wire mill. ment between and switch layout the wire mill the side the wire and enters the cleaning Here the load set down one house high level. three transfer trucks running rails. The cleaning house the straight-line type, with rectangular masonry tubes served single-leg gantry crane. The north rail high rail suspended from the super-structure and, the acid-proof cleaning hooks present their open ends this side the building, the trucks can place the rods the hook when the crane properly spotted for this operation. This trans- fer hand job, with provision for motorizing the future. The hooks used the cleaning house are sus- pended two points and have therefore neither swivel nor tilt motion. The cleaning tub concrete vat 104 ft. long, the east end which four acid tubs are partitioned off brick, each tub holding two 3200-lb. loads rod. Be- yond the brickwork are the tanks for water and lime and the sulling space, all commanded the same gantry crane. North the cleaning house service Q | x | 2 O = : = CLEANING HO. | | | be folded back, so an-Connor Machines Return Track for Hooks Deckers Single Holers department with storage for burned lime, and with slaking trays mill floor level, and, basement level, storage and seasoning vats for slaked lime, boiler, compressor, etc. Acid delivered gravity from storage tank outside the building lead-lined measuring tank, from which valved the various cleaning vats. Baker Transit Force Gravity Cleaned, sulled and lime-coated rods coming out the lime tub are dropped transfer truck which moves forward rails about ft. for transfer rods the tramrail system the baker and wire mill. There this point section the tramrail hinged for vertical movement, commanded air hoist. pin hook made welded structural steel, which there are service, runs down the hinged section and enters the coils. means the air hoist the hinged section then raised quickly its upper position and the loaded hook, with other aid than gravity, passes into the baker, whose doors are automatically opened for its passage attachments the hook. Inside the baker, which has six alleys ft. long, the tramrail suspended from the baker roof structure and has sufficient pitch insure automatic operation. the exit end braking device mounted the tram- rail structure brings the load gradual stop. This such design that, through the operation pen- dent switch handles the wire mill side, alleys can emptied completely one hook time. The baker heated natural gas passing through ribbed semi- w cylindrical cast iron flues beneath the rods, and ven- tilated natural draft through the roof panels. Auto- matic regulating sets maintain the alleys uniform temperature. baked rods carried the steel hooks units are pushed hand from the baker overhead tracks along the south side the wire mill where trackage provided for storage, classification and switching. Wire-drawing equipment consists continuous wire machines, double-deck blocks and single-draft blocks. the continuous machines there are nine, six being ar- ranged for either three, four five-draft work and three being arranged for four, five six-draft work. double-deck there are five, each direct motor con- nected. There are eight single-draft blocks with indi- vidual motors. control tunnel runs the length the wire mill just south the wire-drawing units. the tunnel wall are mounted all the magnetic control panels. Each wire-drawing unit has its own overhead switch track sufficient length carry loaded hook. Rods are switched from the storage track hand and ap- pliances are attached the hooks which permit their use flippers, that eight bundles are flipped direct the first die without other handling. recognition the fact that, take full advantage the handling economies inherent large rod bundles, there should complete separation raw and finished material, equipment and layout were arranged that there should normally backward movement ma- terial that had passed through die. the course 4. * Low The Iron Age, May 1929—1207 Return Empty Hooks Acid Storage 7 F AIRPIN Hook Unit Has Picked Standard Lift Hot Rods Assembled the End the Muffle Con- veyor, and Starting Into the Storage Building— (Above) AIRPIN Hook Leaving the Rod Storage Route the Wire Mill, Weighing the Rods Track Scale—(Below) Coated Rods from the Acid-Proof Hook the Hook Serving the Baker and Wire Mill. The tram- tical movement and, when its right end raised, grav- ity starts the load its way the baker. the back- ground are the gantry crane and the concrete cleaning tank a OAD Lime- Coated Rods \rriving Gravity the Baker and Open- Automatically the Baker Door— (At Right) Loaded Hooks Low End the Baker Caught the Tramrail Brake Prevent Bumping the Door Open—(Below) a. IME-COATED Rods from the Baker Being Stor- and Switched into Wire Ma- chines. Nothing this wire mill floor except the opera- tors’ feet tions the Plant the Sheffield Steel Corpo- ration, Kansas City, 400-lb. Bundles Are Uniformly Used where Throughout the System a | 4 ATTERY Continuous Morgan-Connor Wire Machines Served the Left Loaded Rod Hooks and Delivering 400- lb. Bundles ished Wire the Skid Trucks (at Right) Tramrail Carrier Picking Buggies Nails Going the Rumbler form RAMRAIL Car- rier Nail Mill Arriving Platform and Weigh- The operator steps off the caband parks and dumps the bug- gies into the rumb- lers 1210—May 1929, The Iron Age 4 » » af 4 \ | a continuous machines this arrangement course inherent. the double-decking and single-draft units spacing has been such permit the stripping and loading finished wire the back side the drawing equipment. The stripping cranes cover space the back instead the front the drawing units. take care emer- gencies and disturbances normal schedule, these stripping cranes are permitted cover few feet the front the blocks, that process wire can dumped reels and multi-draft work handled these units. The stripping cranes load finished wire bundles pressed steel skid platforms which are mounted standard truck bodies. These loaded skids are distributed gasoline truck the low-lift type, pass- ing over the platform scale and going either the nail mill the galvanizing department. feature this plant the handling wire 400-lb. units throughout every operation. The nail mill was laid out carefully with this view. The machines are arranged two rows facing central aisle. Back the machines are parked the loaded wire skids and the transfer bundles the reels traveling crane and mechanical hoist. sawdust bin two-carload capacity mounted the roof trusses and discharges the rumbler platform. One continuous annealing furnace serves vanizing unit. the two-pass type and arranged for wires, being open chamber design, and burning natural gas. The acid and fluxing tanks wooden structure and the fumes are vented through the roof. The take-up frame divided into three 12- block units, each with adjustable-speed motor drive. Blocks are 28-in., 22-in. and 16-in. and are sufficient length carry bundles. The double-deck reels serving this unit are commanded traveling cranes and are loaded with 400-lb. wire bundles from skid trucks parked under the same cranes. Similarly, the take-up blocks and the skids receiving galvanized wire are commanded cranes. After passing over platform scales the transept, skids loaded with galvanized wire pass into bay from which wire distributed north the field fence south the barb fence machines. This bay served traveling crane with one-ton electric hoist carrying hairpin hook. Galvanized wire loaded edge and may picked off the skids this hook one-ton lifts. the crane interlocks with tramrails running be- Rods Flipping from Hooks Into Two-Draft ire Machines the Wire-Drawing Department Over the center aisle mono-rail carrier means which the operator, riding overhead, can pick any nail buggy spotted the center line. The carrier sets down the nail the elevated platform the rumblers, passing over tramrail scale transit and recording the weights. The cab clears the rumbler plat- form only few inches, that the operator can dis- mount park the nail buggies and fill the rumblers. Rumblers are 30-keg capacity, and are the hex- agon type, made welded steel plates. means hinged butterfly valves, sawdust and whiskers are shunted the sawdust bin behind the rumblers and nails can dumped directly the sorting plate. The usual keg shakers are provided. novel feature these rumblers that the hexagon shells have trunnions gears. Mounted each shell are two large steel tires, which rest two sets chilled iron rocker wheels, through which the rumbler driven friction. Each rumbler has its own motor, which the push button control well the brake and the butterfly lever are mounted operating plat- form convenient level above the sorting plate. tween the reel sets the field fence machines, the wire can stacked edge floor racks adjacent these reels and rolled and them without lifting. Simi- lar arrangements are provided for feeding the barb fence machines. Equipment for bale ties and for blued and galvanized nails and other specialties are now installed the galvan- izing room space reserved for future galvanizing unit. cooper shop with capacity serve the nail mill well the existing bolt departments the Sheffield plant located beside the nail mill, delivering kegs the nail- cleaning department conveyor. Warehousing and de- livery into cars now handled lift trucks and skids. The general layout provides for expansion cleaning and baking facilities the same building, ex- tensions both wire-drawing and nail-making depart- ments and westward extension the fence and ware- housing bays. Morgan Construction Co., Worcester, Mass., was consulting engineer the entire installation. All crane and tramrail equipment the rod storage and wire plants was supplied the Cleveland Crane Engineering Co., Wickliffe, Ohio. The Iron Age, May ¥ 4 | | | | | 7 = | = J Low-Cost Production Jobbing Shop Steel Foundry Uses Gravity Conveyors, Comprehensive System, for Displacing Man-Power —Great Flexibility Operation Eastern Steel Castings, Newark, J., re- its plant, seeking lower cost pro- duction and greater output from the same floor space, was detailed Campbell, chief engineer the plant, dinner meeting the Newark Foundry- men’s Association held the Downtown Club, Newark, the evening April 24. The plant doing jobbing business steel castings, more than per cent the orders being for quantities less. was admitted the speaker that probably foun- dries general could not follow, the same extent, the line development which his plant has undergone. There were many worthwhile suggestions the sys- tem, however, that believed that most foundries, how- ever local however strongly the jobbing side the business they might be, could benefit putting por- tions such equipment, save labor costs certain operations. Application labor-saving equipment, production methods and wage incentives has been made this company great variety miscellaneous work. was the first and second these items that Mr. Camp- bell spoke, illustrating his talk with the use about lantern slides. pointed out that the foundry general has for long time been losing tonnage fabricated steel, steel stampings and welded work. believes, however, that, the foundries clean house and get themselves into good shape cost production, they can make money, even though their tonnage output may not increase. Where Can the Most Money Made? There terrific waste human effort the oper- ation the average foundry. make one ton cast- ings requires the moving from even 100 tons materials (counting such duplicate movements Human labor, effective the extent about 0.1 hp., paid 50c. hour, would represent cost for each hphr. Contrasted with this, electric power can purchased almost anywhere for 2c. kwhr. With proper allowance for the cost the equipment utilize this electric power, allowing for appropriation, obsolescence, repairs, upkeep and all expenses incident running such equipment, the total cost may reach 10c. for each hphr. The difference $4.90 would long way providing profits for the average foundry. Heavy cost disorder was another topic brought the speaker. Most foundries have materials piled the floor, using valuable production space and making the manufacturing area act also storage warehouse. something the bottom the pile needed, the whole pile likely jumbled disorder get out the particular piece. Not only this method wasteful its use area, but also its use man-power keep things going. Any given operating space the average foundry should produce, dollars output, from two two- and-a-half times the present average production. Means taken this end would avoid need frequently for new buildings and plant, which would likely become cluttered the first unit. 1212—May 1929, The Iron Age Taking industry whole, handling costs represent the greatest loss all our manufacturing processes. These costs may attacked from several points view. The arrangement the floor space proper manner believed accountable for per cent the total savings obtainable from the modernization process. All Handling Problems Have Some Similarities Some the problems foundry handling are com- mon all types foundries. Gray iron, malleable, non- ferrous and steel foundries all are concerned for the most part with small castings. They differ, however, their method operation. Malleable foundries, for in- stance, having only one heat day from the air furnace, may said similar those gray iron foundries which operate with only one cupola heat day. Steel foundries using electric furnaces, and therefore having more less frequent heats, may compared with the continuous pouring employed some gray iron plants and with the small-unit heating, giving fairly steady flow metal, non-ferrous plants. With particular reference his own plant, the speaker threw pictures the screen showing what had been done. The main section the plant long rectangle, from which various wings extend right angles the axis. these wings are not conducive the straight-line flow which found most economical and advantageous handling materials, one has been used mainly for the office and another mainly for the pattern shop, thus minimizing the amount wing space covered the general manufacturing process. was emphasized that the mechanical system put into this plant was tied with the production control and cost system, which operated with the aid Hol- lerith tabulating equipment, that reports each day’s castings, the last detail, are available 9.30 the next morning. Straight-Line Movements Used Beginning with the core room, was pointed out with the aid the pictures that core sand does not anywhere cross the path the cores, from the benches ma- chines which the cores are made their ultimate use the molds. This sand dumped into pockets back the men’s benches and within easy reach sweep the arm. Electric trucks are used put the cores into the batch ovens for baking. pneumatic-tired carrier, known colloquially the “ambulance,” used for moving the baked cores the molds. Melting begun 8-ton open-hearth furnace whose product passes then into 6-ton electric furnace, where the refining done. Operating thus the duplex basis, the electric furnace 2-hr. cycle. The bull ladle weighed, both and out, obtain the yield. interesting ladle heater was shown, which employs brick-lined cover for each ladle, with oil fuel nozzle projecting through the center the cover. The ladles are run these covers out-of-date hand- lift trucks which thus perform service preventing them from being scrapped. The cover conserves heat. Various types molding equipment find place this foundry. There are squeeze machines, roll-over machines, well hand operations the floor and — 4 ™ ' | s few cases large molds made the floor, although this latter business being gradually done away with. Each machine and each molding floor placed with regard narrow line conveyors that the molder does not move more than from his machine deposit his mold upon the carrier. Molder Pushes His Molds Away from Machine the case large molds, single line run out the roller conveyors, which operate easily that man can easily push more heavy molds over them. For the smaller molds may placed abreast carrying board, the two ends which run narrow lines rollers they were rails. Here one carrying board after another shoved out toward the pouring station the molder prosecutes his work. Several types pouring equipment are used, varying with the size ladle handled. The bull ladle de- posited the crane upon carriage turntable. can swiveled any direction suit the needs the small ladles which are filled from it. Ladles holding more than 1000 are handled individually from over- head cranes. There are several 1000-lb. pouring units running tramrails commanding the pouring section the mold conveyors. Still smaller ladles for some the smaller work are handled hoists running beams. Reaching the dumping point the conveyor line, the mold picked two men and thrown bodily into large bucket handled the crane. The bottom boards are thrown back line conveyors which returns them the molding stations. For average-weight the two men sometimes dump many minute. The bucket, full castings and sand, then dumped the shakeout screen the crane. Molds too large handled men are taken the crane the same shakeout screen, where they are knocked out. Hand-molding was formerly the worst part the plant, from the point view disorder. now arranged that practically cannot get out order. The molds made are shoved out the same manner for the machine molding, and due course time reach the pouring stations. All molds made between heats into the pouring lines, with their gates the right positions and everything lined like ranks soldiers. said that six tons metal from the bull ladle can put into the molds within min., spite the fact that the combined capacity the present pouring units only little more than half what the bull ladle will hold. Production Easily Graduated Flow Orders Great flexibility operation had from the way some the equipment run. instance this was cited with some high-production molding ma- chines. With ordinary runs orders two men operate pair these machines, one making the cope, while the other makes the drag. After the two lines con- veyors from the machines the straight-away mold con- veyor system have been filled, these same men proceed down their individual lines, set their cores and then, with the aid air lift beam spanning the core and drag lines, they close the molds and then shove them out the pouring line. speed this particular work its maximum, three more men would employed this unit, making total five. would core-setter, while the two other additions would handle the closing the molds. This would get full production out the equipment. certain amount speeding up, course, can done adding one man. And right there lies the flexibility the whole proposition, that number speeds production may obtained from varying methods operating the unit. The mold put the line means turn-table rollers, which may turned with very little physical effort. Can Make Mold Minute Each these two high-speed machines, ordi- nary run work, making from molds hour. They have been speeded mold minute, the shakeout the castings slip down the vibrat- ing screen toward boxes carried line rollers. One man usually suffices rake them off into the boxes; which they proceed the cleaning department. The sand falls traveling belt running incline into the sand conditioning department, which one the wings outside the molding area. elevator takes new sand the same unit for mixing. Two Simpson machines are used, running series, the product the first going into the second and thence the screens. Skids are used large number the assembly small orders preparation for shipment. good deal the sorting takes place immediately after the castings leave the shakeout and the time the sprues and sink- heads are-cut off. This removal operation performed either with acetylene torch sprue-cutting ma- chine, depending upon the size. The sprues and sink- heads immediately into charging boxes another line rollers. Everything weighed, both and out, ascertain definitely the figures for yield, production, costs, etc. Discussion separate lines thought were represented the discussion which followed the presentation the paper. One had with the wage incentive arrange- ment, which part the system the plant. The other had with the relationship between the old method and the new method cost production and overhead charges. With regard wage incentive, this applied pri- marily the group basis, except for individual hand work. Even the craneman automatically member the group. Operators are paid straight piecework. There bonus added, representing percentage the wage and graduated according number factors. Absence defective castings measures one factor; greater production than the standard another. Savings deter- mined from these sources are split half and half between the company and the man group. Analysis the product used basis for bonus for the melter. Physical analysis the sand operates measure the bonus for the sand-handling crew. The cleaning bonus based upon the saving gas from predetermined amount. Grinding bonus based upon the amount metal ground (measured weights and weights out) and upon wheel life. What Return from Investment Equipment? Answering for the author the paper question from the floor, the relation between overhead after the changes were made and that before, representa- tive the General Electric Co. mentioned something which had taken place his own organization. cost $3,000,000 develop machine make electric light bulbs, and get into production. This machine made possible dispense with the service 800 glass blowers and resulted better profits for the company. Unquestionably, the overhead was much greater after the machine was put than before. was not only greater absolutely, but was greater, accentuated degree, proportion wages, because the total payroll was much less. whether the overhead was 100, 300 500 per cent was little moment, long the total cost production, including overhead, was lower for given quantity production. The Iron Age, May Industrial Activity P-V Line Continues Sidewise—Recession May Come Summer—Speculation Continues Favorable Factors Rising trend employment and payrolls. Gain retail trade w spite large shipments; large orders for finished steel, Increase building permits. Increase unfilled steel orders March Large automobile Rampant DR. LEWIS HANEY w YorK UNIVERSITY BUREA or Br ~ SINESS RESEARCI Unfavorable Factors Very high money; collateral loans high and loans excessive; low ratio net reserves loans, and high loan-de- posit ratio member banks. Decline commodity prices; reaction metal markets and grains. Continued decline building contracts awarded. March Gold imports; high Federal Reserve justed). ratio: recovery bond prices. Industrial production peak levels. decline freight traffic { ad- General supply commodities large com- pared with demand, reflected P-} Large stocks manufactured goods Foreign trade less than usual, notably Reparations conference failure. Disturbing possibilities Congressional action tariff, farm relief, and credit line. High average earnings and large divi- hands. dend disbursements leading com- imports. Strong financial position most leading 10. 10. Light mercantile and VERAGE activity basic indus- tries continues high and likely remain for least another month. long employ- ment and payrolls show continued expansion, and retail trade holds fairly high level, recession can said have begun. Probably, too, decline unfilled steel orders will before any considerable down- develops, and such decline has appeared yet. The improvement building permits during March, though probably temporary, fa- vorable factor. swing STEEL 1929, The Iron Age But the number unfavorable fac- tors large and important. fact, conditions are such that almost inconceivable that some reaction will not occur few months. Only the development final mad burst inflation could prevent it. Money rates are crisis levels, and bank credit inflated. This condition, to- gether with average level in- dustrial activity which, even allow- ing for normal growth, far above normal can expected, makes combination conditions that calls for readjustment. The present situ- TEEL INGOT PRODUCTION ation fits the hypothesis that fairly regular cycles occur business, and indicates that are near the peak cycle that began the bottom reached near the end 1927. Any recession, however, need not severe. The absence over-buying most mercantile trades, and in- flation the general level com- modity prices, suggests that will not be. But the desirability in- creased caution indicated. Such possible developments decline automobile production, increase stocks copper and drop un- P-V Line Has SCALE 90 a\> f or Some Months. production (ad- justed) has gone even higher AC f | 1925 1926 1927 i929 Reached Levels Febru- ary and March. Building has been moving downward since October and INDEX NUMBERS lowest months MILLION TONS 170 Bank Debits, ready Inordinately High, Have Gone Higher, Reflecting BANK ; and far below years ago RAILROAD TONNAGE 1923 Buying Finished Steel Made Fur ther Large Gain March the est Level Ever Reached. Structural steel, plates, sheets participated the advance 1926 1927 1928 > ~ FINISHED STEEL ORDERS AND SALES - | The Iron Age, May filled steel orders should watched for important warnings. Speculation Still Out All Reason TTENTION called again the extraordinary expansion bank debits comparison with such index business activity railroad freight traffic. Taking the average its registering 196, double the average. the same time, freight tonnage only 108—merely per cent above average. Industrial production only per cent above the average for the same period. commodity prices are almost exactly equal the average, the only possible explanation such enor- mous increase bank debits found significant that the period great divergence dates from the beginning 1927, when the most pronounced phase bull movement the stock market began. spite the busi- ness recession 1927, both bank deb- its and stock prices moved upward, and the parallelism emphasized way which the stock market breaks October, 1927, June, 1928 Jal, 5, and December, 1928, are reflected the debits. The point emphasized the inflation bank credit that these con- ditions reflect. There extraordi- nary increase member bank loans compared with deposits. the Same time, the net reserves the member banks are rather low, and are extraordinarily small comparison with their total loans. will noted that, net demand deposits have moved sidewise down- ward, the bank deposits creased sharply. The result the highest rate turnover bank de- posits that has existed many years. estimate the (index) ratio the volume checks drawn the net demand deposits have been over 600 March, which means that de- posits were turned over about six times. The highest rate turnover 1919 was 3.8, and during the years 1919-1925 the turnover rate ranged from 3.12 3.8. This shows the hectic condition that prevails the use bank credit. Bank credit being used excess business requirements and the sit- tremely rapid turnover deposits. This means inflation and the inflation centers the stock market. Business Stability Predicted for Near Future TEEL production, considering the season, increased March and, even allowing for the normal growth the country’s requirements, was high April, 1928. The P-V line, however, has been moving sidewise level which, comparison with the ingot output, somewhat lower than average. The action this barometer line (which ratio commodity prices the physical vol- ume trade) means that the supply comparison with the demand that the level commodity prices main- tained with difficulty. indicates ap- proximate stability business condi- ditions during the near future. Usually the P-V line anticipates the trend steel production about six months. this assumption, may interpret the February-March rise steel production reflecting the up- turn the P-V line last July and August. there anything this hypothesis, may expect the ad- justed curve ingot production decline soon. 1926, however, nine months elapsed before steel produc- tion followed decline the barom- eter. Moreover, the steel output not now much out line was that time. short, large sharp recession steel production yet indicated the P-V line, and the same observation applies busi- ness general. Divergence Greater Between Housing and Automobiles ARCH brought extremely high rate automobile production, which, considering the season, has been exceeded only February, and then but small margin. the other hand, March brought contin- uation the declining trend build- ing activity which carried the index the lowest point for that month since 1925. This the greatest divergence record. The nearest found November, 1927, when the position was reversed and automobile produc- tion was low ebb. Now, within months, the opposite extreme found, with automobile production record levels. must apparent that auto- mobile production rate which, even allowing for normal growth, can- not last long. Already the March fig- ures show slight decline ad- justed index, caused the fact that the increase over February was less than usually occurs this season. The average daily output over 24,- 000 and trucks gives adjusted index 182, against 184 Febru- ary and 120 year ago. The average for 1921-1927 equals 100. the other hand, building con- tracts yield index only 105, against 114 February and 119 year ago. While some allowance must made for motor exports, ap- parent that, the automobile and building curves are come together again, there must sharp decline automobile production during the year, for money conditions are such that there probability any considerable recovery building. the two curves not come together again, will for the first time record. Steel Sales Highest Level Ever Reached better indication the great activity industry could found than appears the sales finished steel. Our index such sales turned upward March, thus con- firming gain the rate increase unfilled orders, and reached the highest point record. The 1929 in- crease partly seasonal and resem- bles that which occurred March, 1923, and again March, 1926. (Is this three-year interval significant?) But the total orders and sales for the first quarter were the highest rec- ord any post-war period. The most notable details are the increase sales structural steel and castings and the high level sales plates. All these reflect, part, the improvement railroad equipment buying. the other hand, the sales sheets, though record proportions, increased than usual, might have been ex- pected from the movement auto- mobile production. Swollen Inventories, Overproduction serious tendency toward over- production accumulation heavy inventories noticeable, although trade and industrial activity the United States ended the first quarter the high levels the preceding months, establishing new high records March several instances. However, the March report the Conference Statisticians Indus- try, which operates under the auspices the National Industrial Conference Board, New York, finds that peak seems have been definitely passed and the easing off toward lower levels seems taking orderly course. Existing conditions and developments during the first quarter assure fairly satisfactory production schedules for the second quarter the year least.” decline building construction noted, and marked improvement that field looked for long the current high rates for money ob- tain. Reading Iron Co., Reading, Pa., moving its general headquarters the New York Central Building, New York. prey Schedule the next instalments the Business Analysis and Forecast, Dr. Lewis Haney, Director, New York University Bureau Business Research follows: May 16—Position Iron and Steel Producers; May 30—Activity Steel Consuming Industries. 1929, The Iron Age — Welders Discuss Chemical Equipment Proper Procedure for Welding Nickel Outlined—Data Steel Vessels for High Temperature and Pressure DUCATION welders, welding welding the chemical and process industries were the principal features the annual meeting the American Welding Society, held New York April 26. The Amer- ican Bureau Welding (the research group the society) also heard the reports its standing committees. these the committee structural steel welding far the most ac- tive. securing data whereby the safe strength welds may fig- ured designers. About struc- tural fabricators are cooperating; welders them have already passed the prescribed qualification tests, and test pieces are being pro- duced them. Some laboratories will test the samples. The detailed program has already been given test and approved, the steel secured, and the financing done. An- other months should give large body data the specific problem under investigation. Edwards, chief engineer, American Bridge Co., the chairman this research committee, was awarded the Samuel Wylie Miller medal for leadership the welding structures, the combined fields research, design and actual appli- cation—he having been instrumental the erection several the notable welded structures described past issues THE IRON AGE. Officers the society were re- elected. Llewellyn, United States Steel Corporation, remains presi- dent; Gaynor, John Roeb- ling’s Sons Co., senior vice-president; American Chain Co., treasurer, and Miss Kelly, sec- retary. The American Bureau Welding also reelected its officers, Prof. Adams, Harvard Univer- sity, being director, and William Spra- ragen, secretary. Wilber Miller, Union Carbide Carbon Research Laboratories, was elected the board directors, fill the vacancy left the death Samuel Miller. Welding Aircraft ICHARD MOCK, aeronautical engineer, Bellanca Aircraft Cor- poration, New Castle, Del., said that welding the fuselage ordinarily the “neck the bottle” aircraft production. his company’s prac- tice this has been avoided careful allocation the work three groups: (a) preliminary bench work sub- assemblies, (b) erection and welding side frames complete jigs, and (c) joining side frames into complete fuselage. Individual members are cut length with the exact shape each end. avoid warpage greater than this long skeleton structure the assembly jigs are rigid frames built angle iron; the tubes are clamped into the corners the an- gles. The joints are open and acces- sible the welder, and the jig Filling Hole aati | and AS N N N } N | 3 Borat ng N Yo/UTION N Pot for Adding Borax Acetylene Flame pivoted can easily turned any direction. Such rigid jig avoids the necessity tack-welding, each joint completed one heating. Three pairs side panels are made hr. four welders and two set- men. Final assembly two side panels into the complete fuselage done much lighter jig, which supports the members from the outside. Weld- ing the wing hinges and engine mount comes first; the men work back the tail, and finish with the tail post. Wing hinges are within 1/32 in. correct position, according Mr. Mock, and the overall length within in. Welders are trained the Bel- lanca corporation. Apprentices spend six weeks welding scrap; then six weeks used tack-weld subassem- blies fairing strips, cowling and other minor details. Always under the supervision experienced welder and making test welds every fortnight, the learner spends the next six months welding parts sec- three months welding the primary struc- ture last attains the status qualified workman. Welding Nickel and Monel Metal RODUCTION sound ductile welds nickel and monel metal more matter metallurgy than manual skill, the opinion Pilling and Kihlgren the International Nickel Co. this these metals apparently are similar cop- per. Malleable nickel sheet, for in- stance, contains small but essential amounts the highl