The Iron Age 1929-08-15: Vol 124 Iss 7

(ts New York. August 15, 1929 ESTABLISHED 1855 VOI 24, No. 7 =. e ” O arm jor industry in a SUT eae . f * / eserve 1 ; (7 x « 5 BY VIRGIL JORDAN HE action of the New York Federal Reserve Bank isiness men uneasy. but which the tock market is dete. Aug. 8 is probably far simpler and more consistent mined to ignore. This fact is that money is abnormally in its purpose and effects than are the rather far high, which means merely that credit is scarce in com- fetched and abstruse attempts to explain it. I do not parison with the demand for it. This is true the world think the large and sudden raise in the discount rate and vel It has been increasingly true in the past two years, the equally large cut in the rate on bankers’ bills should and will remain true as far ahead as one can see, unless be regarded as another attempt to scare, break or control there should be a radical change in banking policy and the stock market, or to discriminate against it. If th business philosophy. market chose to regard it as such, that tells more about the market’s state of mind than it does about the Federal Rediscount Rate Does Not Fully Reflect Money Tightness > *vwoa’e r 1 1 1 . } Reserve’s. The central banks of all important countries (except . . : : . : France) have raised their rates and will raise them fur- Reserve System Is Not Specially Interested in Stock : ther if the present situation persists. Here even a 6 per Market ; f1) f cent rediscount rate does not fully reflect the tightness of As I read the record of Reserve policy and practice in money, for the collateral loan and even the commercial recent years, I do not find that it is specially interested in paper rate in the open market are higher than that and the stock market at all, or much less that it has been en vill probably remain so. gaged in any sinister strategy to curb it. The Reserve It is useless to blame the stock market and its enor System today is not controlling the money market in any mous demand for credit for this tightness of money, or to such narrow sense; it is merely responding and adjusting hurl epithets like “speculation” or “inflation” at the new itself to conditions that have arisen through great and methods of financing industry and trade which have given far-reaching changes in industry and trade, domestic and rise to this demand. They have come to stay, and their international, and the methods of financing them. That, demands are probably going to be met. The banking sys I believe, has been its position and policy ever since 1923 tem will ultimately have to adjust itself to them. The “in The changes last Thursday are merely a recognition or flationists” and “new era” philosophy are in the saddle or symptom of an important fact, which has made many trying to get in, in almost all countries as well a ere. On Aug. 8, 1929, the directors of the Federal Reserve Bank of New Y ork unexpectedly id vanced the rediscount rate from 5 per cent to 6 per cent and reduced the rate on acceptances from 514% to 5% per cent. The securities’ market response was first one of alarm. Then bankers appeared to greet the action as a constructive step As an important item in the whole matter of the relation of high money rates to business activity, THE IRON AGE asked Virgil Jordan to dis cuss the question for industry Responding under a title, “The Federal Reserve Hews to the Line,” he supplements in the accompanying article his contribution in THE IRON AGE of May 30, emphasizing that the new methods of financing industry have come to stay and that the central banks, if left alone, will probably adjust themselves to the existing pressure with safety, on the score that credit re sources are adequate for considerable industrial expansion. Mr. Jordan, who has been chief econ omist of the National Industrial Conference Board for upward of nine years, reiterates that the Federal Reserve Bank is not trying to control the money market in any narrow sense 393 { i‘ S en eives ) é é edit res irce espe ( i l ( nsiadera ex ne a ( ssing tmosphere of - j I I ACU } nportance of Open Market Credit on General Business Steadily Diminishing r} ty. ’ “yy Y } C i \ViT¢ ' ate ny a vers rioimna ? rin? + . > y +} “+ + ) , g +17 y hy ? In) I) llé ( ( I ( > YT al&, , = nable in tha eid. said E.G n il aper er ‘ ‘A Surve f the Pul Ir n (hy ) y P] no é 1 re f +} ‘ ] — ' som ; . be ! he Electroplater and Wepositors lechni- S Birmingham, England Some selections ddress follow: + on +3 f . } + : 7 : +} ] > a< - The ncentration of sulphuric acid in the solution has ! ixed relationship to the chromic acid content verage working conditions one part by weight of huric acid is added to every hundred parts of chromic 1. Variation in that proportion causes a reduction of cathode efficiency, a low concentration of sulphuric d being particularly detrimental to the deposit, which ered with a brown film. Describes a Typical Bath \ typical bath solution contains 40 oz. per imperial gallon of chromic acid, and 0.4 oz. of sulphuric acid. No her added substance is essential for satisfactory work- ng, but it is obvious that chemical changes take place luring electrolysis. The most important of these is the eduction of a portion of the hexavalent chromium to the state. Some workers, therefore, favor deliberate nitial production of part of the hexavalent chromium to the trivalent state by chemical or electrochemical means. It is, however, important to limit the concentration of alent chromium, for that element reduces the range current densities for satisfactory deposition. Chromium plating differs from most other metal de- ‘ocesses because of the high current density essary, the low current efficiency obtained, and the onounced differences in character of the deposit that ts from variations of current density, temperature and composition of the solution. In general, with increas- ecreasing temperature, the effi- hanges from a bluish relatively poorly organized and which is more and n getting the short end of the credit rope. The devel ment of large, well capitalized marketing organizati or “stabilization corporations,’ such as has been be inder the stimulus of the Federal Farm Board, change this materially. In any case, the credit n available through the lower bill rate for this season quickly liquidate itself as the crops are finally market It will not float about in the money market for sp rs to use for very long, and when it is paid off mor will continue as tight as ever. Only Continued High Money Rates Will Force Business Curtailment We have seen in the past two years that tight il not necessarily affect business quickly, for re: which I have pointed out elsewhere. In the long however, continued high money rates will force eit business expansion or credit policy to give way. TI! pressure will show itself first in increased costs of g ent financing, higher taxes and retarded borrowing agencies compelled to de pend upon the bond mat price deflation sets in, slow and chronic. Th lready evident in some countries abroad, and even yme extent here, in the persistent refusal of the evi » respond normally to the sustained vigorous s expansion. t\ British Survey of Present Status of Chromium Plating th bright matte surface, to one with a bright JUS appearance and finally to a dark iridescent dé posit, often described as “burnt.” The blue matte is thin to be of commercial value. The bright lustrous dé posit is extremely hard and decorative, and needs little o1 no subsequent polishing. The dark matte, though ex- tremely hard, can be polished by the normal methods The current density should be kept moderately hig! (100-300 amps. per sq. ft.) Some Difficulties of the Process The nature of the cathode material, and in particular its hydrogen over-voltage, is an important factor in d« termining not only the initial deposit of chromium but also the ease with which the cathode may be covered with the deposit. In metals of low hydrogen over-voltage, such as iron and steel, the minimum current density at which chromium can be deposited is higher, and the range of current densities in which bright deposits may be produced is both different and more restricted than in the case of metals of high hydrogen over-voltage, such as copper. As nickel has a lower over-voltage than copper, it is not so satisfactory in this respect, but as an undercoat nickel has much to recommend it from a cor- rosion standpoint and it is now common practice to de- posit a layer of this on steel articles prior to chromium plating. Lead anodes of high purity are very satisfactory and the gradually formed insoluble lead chromate has no detrimental action on the bath. Electro-deposited chromium is distinguished from other metals by its resistance to corrosion, resistance to oxidation at elevated temperature and its extreme hard- ness and low co-efficient of friction. As deposited, the re- flectivity is only 65 per cent, but in contrast with other metals, that figure is permanently maintained. Chromium is unattacked by salt water, ammonia, nitric acid and hy- drogen sulphide. Dilute sulphuric and hydrochloric acids only vigorously attack the metal after it has been ren- dered “active” by cathodic polarization, namely, by contact with zinc in the acid. ‘etisalat athe cer TNE aan ' Conveyors for Molding Operations Large Use of Mechanical Equipment for Handling Ma- terials in Automotive Plant—Feeder Lines for Sand and Other Materials Reduce Labor Costs HARGING methods fo. cupolas in the Oakland the Molds are carried around to a secondary coolins foundry at Pontiac, Mich., were covered THI ne, which conveys them to the shake-out. IRON AGE issue of July 25, page 207. This ha | do primarily with the matter of preparing the charg Unusual Construction of Conveyors for the cupolas, getting it weighed and transporting it Five of the conveyors are of a new roller type. In to the place where it was to be used. In the following these the general practice of using conveyor truck pages the molding and core-making operations are de perating on rails is reversed by having rollers on a scribed, and handling of the castings on cooling conveyor stationary frame and the mold trays equipped with in and thence into the cleaning department. verted rails fastened to their bottoms. Thus the rails There are seven conveyors for continuous molding move on the rollers. The trays are “44 x 54 in These and pouring, with room for one additional molding unit. cover the rollers and driving chain, the latter on the inne One unit is for cylinder blocks, one tur cylinder heads, side of the frame. It is claimed for this type of conveyor one for manifolds, one for fiywheels, one for gear covers that a smoother action is secured and an accumulation and some other parts, one for transmission cases and on of sand on the rails is prevented. The conveyor for mis for miscellaneous castings. cellaneous castings is of the sliding type and has smaller All but the cylinder block mold conveyor, which is 200 trays. ft. long, are 180 ft. in length. The cylinder block conveyo1 The conveyors are on the usual oval plan, except that is of the ordinary drag chain type. Cylinder block molds that for the cylinder blocks makes a complete circuit. are made on five drag and five cope machines. The drags The cooling or return line of each is hooded and provided are handled from the molding machines to the conveyor with an exhaust system for carrying away the smoke with jib cranes. The copes and cores are handled with and gases. Cleveland Electric tramrails and the pouring done with Copes of cylinder molds are shaken out half-way down f ASTINGS and - S Are and Dropped from the Shake out I nto Tumbling Mills in the Basement Thence the cast ings pass en to the conveyors at the left, which carry them out of the foundry and de- liver them to the cooling conveyor (Below) ISCHARGE End of Two of the Conveyors Which Carry the Castings from the Basemenr. Castings are dumped into basketshanging from the cooling conveyor (Above) The Iron Age, August 15, 1929—395 ? } Stom sha it bail r i at blocks are carried on the cooling conveyor approximately ~ I flasks are placed 2 hr. and other castings 90 min. for cooling, before they nd pe machines reach the cleaning room, on the same conveyor line. tl Cylinder blocks move on the conveyor through a c& from the drag tached knock-out building, where they are cleared of sand nt ’ ! As this na Stoney knock-out machine and are then returned indry, the casting the conveyer The molding sand passes through a riddl ( lding the core through a crusher; all the sand goes over the cast magnetic pulley to take out the metal. ire shoved by a Then the sand is discharged into a pit, where it 1, after the sand made fluid by being mixed with water. The sand and ng mach water are kept thoroughly mixed by being agitated by nder bl a spray of water. The sand is carried away by a hy ind t] istings dropped with lraulic pump, being delivered to a dump through a 5-in. lime Dust collected in the cleaning department is handled ng rr 1 oi in the same way, being delivered from the dust arrestor ng, tl iter circumference of on the roof to the same pit that receives the knock-out t Lt ind passes throug! sand an inclined apron Cylinder blocks, on reaching the cleaning department n i he foundry, the yn the cooling conveyor, pass on the same conveyor ng in a straight through a Pangborn double sand-blast machine. Then ng they are ground with a swing grinder, tumbled and given a water test. For testing they are placed in a revolving Castings Cooled in Open Air fixture placed on a roller conveyor so that the blocks can harge the castings into a hoppet ve turned over, permitting the testers to see inside thi I t int basket that is barrels. ! r ited above the dis- The bottoms of the baskets that carry the smaller : angles to the flight conveyors astings on the cooling conveyors, instead of being flat, ; ng I fy 900 t OU irn up at an angle of 90 deg. on each side, making it ! ! nder blocks previously easy to dump the contents. The castings are dumped into ( ! 1 ds and flywheels, one kids, which are handled by electric trucks for the tum- ngs ant ( re ransmission bling, chipping and grinding operations. The tumbling ng The baskets of cast equipment consists of 40 Whiting tumbling mills with nter Cylinder blocks, 36 x 80-in. barrels, motor driven in batteries of six. t Cylinde) The cleaning department is well arranged and equipped. It is entirely free of belts and piping, all pipes for exhaust lines from the tumbling mills being Se (7 Side of the Foundry, Showing the Ends of the Molding Units and Sand Hoppers. The pipes are for ventilating the basement (Below) x * 396 1x sat 25, 1929, The Iron ige under the floor. Air drawn through the dust arrestors, after cleaning, is returned to the building during the cold weather. Otherwise, with a large amount of cold air being brought in to replace the heated air removed, it would be difficult to heat the building. Gravity con veyors and electric hoists are provided wher- ever needed to facilitate the handling of work through the cleaning operations. The tumbling mills are served with electric hoists. Core Ovens of Vertical Type Efficiency and saving of space are effected by the arrangement and equipment of the core- making department. This is provided with 16 vertical core ovens 8 ft. 6 in. square and 45 ft. high. These are oil fired and have auto- matic control, which maintains the temperature at ap- proximately 450 deg. Fahr. On their downward cours the cores pass through a cooling chamber and, when they reach the floor level, they are ready for inspection and assembly. + Cores for each oven are supplied by a group of 4 to 12 core-makers, who work around the oven. The core maker sets his own cores in the oven and takes an empty tray back to his bench to be loaded. This eliminates the use of racks and the provision of aisles. Owing to the use of vertical ovens, it is stated that the core department takes only about one-fourth as much space as otherwis: would be required. A new design of hydraulically operated vertical oven is provided for drying cores after pasting. These art carried on 26 x 42-in. trays which are raised by a cyl- linder operated by a motor-driven pump. One pump and one motor serve the three ovens of this type. The cy! inder located beneath the oven raises the loaded trays 15 in., at the same time pushing up the stack of trays above. When the cylinder descends, a catch holds the the tor if the trays in position. As each tray reaches the top ven it moves automatically over to the opposite or re- turn side of the conveyor. The cores remain in the oven about 25 min. An advantage claimed for this type of! IX TURE in Which Cylin- der Blocks Are Ro- tated While Being Water - Tested Af- ter Final Opera tions in the Clean ing Department p° JIRING Fly wheels on One of the Mold Con veyors oven is that, as the trays do not turn on sprockets at the top or bottom, they can be spaced closer together. The core sand is delivered to overhead hoppers and distributed on monorails to hoppers above the core-mak ers’ benches. Core sand is prepared in three batch mixer: supplied by the Standard Sand & Machine Co. The foun dry makes its own sea coal, using a Grindle multi-stage pulverizer for pulverizing the coal. The sand prepara tion equipment includes two Simpson mills Three sand-handling systems serve the molding units: One for the units making cylinder blocks and heads; one a third for the transmission cases and miscellaneous casting Room for the flywheel and manifold molding units; ‘ provided for a fourth sand-handling system. Preparing Sand for Various Uses Sand from the tumbling mills in the basement, which eparate the sand and castings, is conveyed on a belt con ver a magnetic separator to a bucket elevator that aeliver tt a re volving screen above the foundry floor The screened refuse sand is discharged to boxes on the floor. The good sand from the screen goes to a primary tempering belt and thence to a paddle mixer, which de- ivers it to a circular storage bin of 100-ton capacity. \ revolving table feeder takes it from this bin to a The Iron Age, August 15, 1929—397 } e a final tempering I ring 1ai¢ { I sa ! t So! ! pe I Afte ring the ! a lirrel cag ! hen de ! flight distribut I i cit ered to niy Strike ff and spill m the foundry floor to reciprocating con- leliver it back into the system. N ! ntroduced automatically and uniformly with rev ving plate feeders. l block and cylinder head p I ul ‘ ration room in floor ( evated and dis , + n le ny 1! te ty gy n he overhead sand ng ligh I mpart l ? ? ’ Sand is stored in concrete bins in the sand stora building, which has a capacity of by an overhead crane. 150 cars and is se) Dimensions of the principal buildings are: Found) 260 ft.; core department, 160 x 247 ft.; cleanir room, 120 x 350 ft.; service building, 60 x 360 ft.: sa 247 x storage building, 80 x 225 ft. Adjoining the cupola partment is a chemical laboratory in which the heat On the second floor of tI service building are a pattern shop, pattern storage roo: and raw material are checked. men’s lockers and women’s rest room. The foundry was laid out and built under the direct of J. E. Linabury, the foundry manager, being design: and built by the Austin Co. The mold conveyors ar those for handling pig iron, scrap and briquettes to tl} weighing scales were supplied by the Link Belt Co., tl cooling conveyors by the Palmer-Bee Co. and th ovens by the Detroit Sheet Metal Works. Makes Steel Casting Requiring 360,000 Lb. in the Rough I hamme} astings and ng I I t pi lreda it! ne stra I n icr ned V¢ ent Ol tU lt 4 ng, W nwa ucie y tne W g M « 1 ( Wheeling, W. Va 01 ! now ng built by the Chambers Engineering Co., Chambersburg, Pa., for shipment to nal acturer in Italy, required unusual care n because of its size and specifications. It mild steel of the following analysis: Carbon, ent; silicon, 0.30; sulphur, 0.029; phosphorus 034, and manganese, 0.90. The heats from three open- rth furnaces were required to pour the casting, a total ght of 160 tons \ second heat of 20 tons was re- red 16 hr. later to take care of furnace was built around the sink head, which is lined with Sil-o-Cel brick and properly fired to delay of the casting proper until all of the steel was and also to maintain a liquid situation while shrinkage. In the was cooling in the main body of the casting. The block was cast with the working face down in a 398—August 15, 1929, The Iron Age 1 dry sand mold set in the floor, the bottom of the blo being level with the floer. Small cores were not « sidered, owing to the huge volume of metal, but cores were used successfully in each end lightening The blo« k entirety and the was too large to remove from the pit in it riser was cut off by means of an ox acetylene jet. This cut was 28-in. deep all around the riser, leaving a final core 4-in. in diameter, which was knocked off. As the crane capacity of the foundry was not larg: Abarat p~ enough to handle a casting of this size, unusual problems of moving had to be met. Temporary trunnions were cast 01 the ends to facilitate handling in addition to the permanent ones on the sides. The end ones were later removed. I order to move the casting from the pit, ways were built and the block was turned around and skidded on a truck bed on skids. It was then moved about th: foundry on a 150-ton truck on a turntable. The problem of transferring the casting to the customer also involves difficulties as only one or two railroad cars are large enough to carry it. greased When the block is prepared for th« ocean voyage to Italy, special bulkheads will probably) have to be built in the ship’s hold to prevent shifting. HIS Anvil Block, on Car Ready for Ship- ment, Has the Record - Breaking Weight of 240,000 Lb. It is 156 in. long, 95 in. high, 84 in. wide at bot- and 55% in wide at top tom Cae » > , j | Steel Which Is Sound in Blooming Precautions Necessary for Best Results — Preferential Range of Temperatures— High Manganese Content BY JOSEPH VERY mill rolling the regular grades of common A A carbon steel has made some study of the causes of seams and slivers. It is safe to say that no- where have these causes been so well and so definitely located that control can be applied with fully successf results. Widely divergent ideas regarding particularly the proper procedure in teeming, handling, charging and heating the ingots have resulted from studies and ob- servations made. The difficulty lies in interpretation of the facts observed and is due to the complexity of the conditions surrounding the entire sequence of operations. It is not uncommon, therefore, to find that the full burden of the elimination of seams and cracks has been shifted to the steel maker. In such cases it is assumed that if a good quality steel is teemed properly into prope1 molds other features may be neglected. This applies i a general way; that is, good steel making will lessen the problems of the blooming process. It applies, however, to such grades of steel as no peculiar characteristics that involve hot-short quali ties at one or another temperature. These latter grades tend, in rolling, to break up into seams and slivers, and steel-making skill does not operate to change the condi tion. Also, in general, if the sulphur content cannot be kept down the general tendency of the output will be toward greater trouble in that direction and here, too, the steel maker is handicapped. Assuming a careful practice in steel making and a good soaking pit operation with proper pass design in the blooming mill, there still remains the question of steel compositions and their appropriate rolling tempera- tures. Preferential Range of Rolling Temperatures Everyone is familiar with the fact that ingot iron has a decided preferential range of rolling temperatures. It is a fact, not so well recognized, that the common grades of steel have such preferential temperatures, al- though to a much less marked degree. However, mostly, the range of unsatisfactory rolling is extended, pushing the most satisfactory range up toward the burning point of the steel. The writer had, at one time, arranged a series of tests to compare different compositions and to bring out the suitable temperature for each. An electric heating element was placed in refractor) in such a manner that special test specimens could be heated while held in the grips of the tensile-testing machine. A thermo-couple gave the temperature. With this apparatus it was possible to break specimens at the various temperatures at which steel might be rolled in the blooming mill. It was found that, when specimens broke off short in the test, poor rolling was observed on that steel at the temperatures so represented; but wher specimens necked down to a sharp point, or nearly so, good rolling was observed on that steel at those ten peratures. That would be, of course, on the earlie Pittsburgh. MILLER 4 passes in Diloomuing ming, for, once reduced, the grain re fine- ment begins to strengthen the material. With this method he also started in 1918 to test samples prepared from such ingots as were found to \ contain an accidental high manganese content Thes« usually were observed to roll well. Thus it was deter mined that open-hearth free cutting steel (added sulphur) would roll much better if the manganese specification, ormerly around 0.60 to 0.80 per cent, were raised to i ] L “44 eT ent Rejections Ran High Rejectioz n the old grade ran very high on blooms rr bars for cold-drawing purposes, or for machining ymewhere around 20 per cent average. And often half the blooms would have to be diverted. With manganese pecified at about 1% per cent these rejections dropped to 2 t per cent. Earlier production was sold under a trade name, and was found suitable for free cutting and case hardening purpost Thus a grade of steel which formerly was a source of great annoyance and loss in rejections was changed to ne that was easily prepared and without serious losse The idea that raising the manganese content would induc a brittleness and hardness was shown by test to be e1 roneous, for such brittleness was not encountered to any extent until the composition was well up around 2 per cent manganese. Steel made with 1% to 1% per cent manganese was found to be free cutting and tough; also it case hardened satisfactorily. The first of open-hearth screw steel with this higher manganese was made in 1925, and was used with success It would be difficult to favor, in blooming, a preferen tial temperature. However, by careful heating an ap- proach can be made to the best temperature conditions, and particularly where it is best to start rolling at very high temperatures. It is possible, however, to make composition changes, like that mentioned, improving the rolling qualities without changing the utility of the product. Steel Clean of Oxides Rolls Better Of course, if the sulphur is low, and the steel comes through clean of oxides without excessive deoxidation, it will roll better. Some claim for certain chemical mix- tures that through their use unusually tough metal is produced; and it is sure that, if the materials used in a heat of steel bring it out clean without the excessive ise of aluminum and silicon, the metal will roll better, even in spite of the sulphur. The problem of making steel which is free from seams and slivers lies between excessive care in handling and rolling the ingots after teeming, and the production of a tough metal that will roll without great care. In tonnage operations the latter is preferred, because it allows greater production from the blooming mill. In making 1 special grades which do not in their nature roll well, The Iron Age, August 15, 1929—399 100 fugust 15, 1929, The Iron A : non riven the ingots after the ingot skin. These ao some good, and they simulate t} , } . fluted forging ingot. However, no precautions will produ 1 ntended to favor a result as successful as that attained when a tough ¢ ar stralr put on position of well made steel can be used. ° ~ ~“ | D orging Seamless Steel Drums Difficulties Encountered in Expanding a Thin-Walled Tube—Ends of Various Shapes Closed by Dif- ferent Methods—Limitations in Accuracy APT. RONALD BENSON with flat tools always ng the cor Machining the Inner Bore The machining allowance varies with the furnacs - me of heating, but a rough rule is to allow 1 in. o1 , irfaces in addition to mandrel taper allowance. | ‘here seems to be no reason why boiler drums shi , ne not be accepted with a black forged finish outside—in ibes of this nature have been supplied—but it is necs T Y ‘ The ! specify a tolerance of approximately % in. in the l t I The * + a ngt " re Producing the Hollow Tube i ant t rgemen as “bellying.” rie Nf org y’ in be Carried I 9 nverst Vit the dliametel! . I lir i tk ll thickness KX 9g‘ ‘ ( ndre king fror billet roughe¢ Point of © diatom elds ali se i Collapse y something between 60 Collapse of Wall Flat End Pro- +} 6-in. wa ere being mad During Closing duced by Flang- go on for 90 or 100 mir In a Die ing ng ma eaucet eating tne mar rKking rule t 1i the mandrel does not f« ! The 1 ¢ nomica! ng the mandr emperature as high as thickness of wall. The interior cannot readily be produc Fe o tubs currer n the i ificiently free from scale to obviate machining. ¢ ree } re-heated It usually expedient to bore a straight hole throug! > 3 andrel may isé If a central hole one from end to end, and subsequently to close both ends removed, the ume of mandrel tending Or one end can be closed before machining, leaving on BS caret oN me ving is redu per cent end open for machining purposes, to be closed subs¢ . +1 . rialls ; | . I diff ilty ky vy : ‘ no the yuentiy esigns usually call for a thicker wall on the » . +7 } ‘ etal ina ferent as ny ed + ed end than on the shell allowance must be made Io! y + | y i si Closing the Ends ‘ nar? There are —_ scihle wv sine the ends f : y - I , é i , ( \ ( I metnor i t ind I ( sing em ey ere the proportionate reduction in diameter is small, a it tubes of the kind described would be closed to approx tely one-third the original diameter. It is therefor: mi LD Vet me quite impossible to carry out such a closing eration die, because the pressure required is greater tan the walls of the parallel portion can support. Even if onl) the length of tube exactly sufficient to form the close end were heated, collapse would take place in the parall portion where it just enters the die, as shown the sketch. Yet this portion at least must be heated to enabli closing in a single operation. In practice, a large number of dies of varying angle have to be used, the work done in each die being small, an the expense is too great. The closed ends so made are, however, very well formed and evenly stressed in closing Closing the End by Flanging Method The second method of closing is by bending over, o1 The open ended tube is bored, and ro ign ma flanging. chined outside. The portion which it is intended to bend ver is rough machined for concentricity only, and extra thickness is left on it to suit the design required. The end to be produced is approximately as shown in the sketcl The length of parallel tube required to make the end fro to b can be determined only by experiment. The usual process is to support the drum from below, i prevent it from kicking back, and bend a small portion of the periphery downward at the top by pressing on it with a suitable tool. The tube is then rotated slightly, and another portion of the end bent over, so that by the tim: the tube has been completely rotated the end has beer flanged over somewhat, and the opening in the end reduced Successive applications of pressure must be small and iniform, or an irregular and crinkled surface of the flat end may be produced. It is not possible to close the end ompletely by this method. Swaging the End The third method of closing is by swaging. The pro ess is essentially a series of small compressions of the walls of the tube in two places. The effect of one squeeze, with the tube in the position shown, is to thicken the wall at a and b and to reduce the portion of the tube which is being worked upon to an ellipse, the major axis of which is the original diameter, the minor axis being reduced by the amount which the press has traveled. If now the tube be rotated, and a s« ries of squeezes be applied, the ultimate result is that the wall is thickened and the diameter decreased. There is a tendency for the portion of the tube which is being worked upon to increase in length. The ratio of circumferential flow to longitudinal flow depends upon the design of the tools and the method of manipulation; wit! . insuitable tools the wall thickness n evel e diameter has been reduced than it w ! This ratio, however, must be knowr \ idinal extension of the dome portior t be a so that the drum shal] be of the correct lengtl r ng 1s completed. It is us ial to allow a tolerances I n the overall length, and it has been four work within this tolerance for a drum 45 ft ng Special tools are needed to shape . I IN i¢ ( nsidaerabd. i unt f mac ning S to aqaone on tft extel r after « sing It is not pra ible to produce a drum with a flat « : > rnt! sned I { Ss metnod The easies napes are elther hemispherical or conical, with a_ protruding spigot which 1s machined inside to form a seat for the mannole er, UI engt! f spigot desirable being 3 i 4 in. with a 4-ft. drun rh 1 thickness of the domed end car ( ncreased ! ( oul Ir ict, the thicke mie are LA a b Liable aaacaii waging Tools ghtly easier to produce, so the designer can call for a nd which he sure is much stronger than any other par tne oiler. Seamless vessels intended for oil cracking. with a 2-ft re, have been produced with one end swaged down ti + lur Or - ne only trace ol } the original bore was a small line which lid not extend beyond a circle 2-in. diameter, and the end were closed, afte lameter. ‘r boring, by a screwed plug only 3-in Sheffield University Opens Cold-Working Steel Laboratory laboratory for res NEW A steel was opened on July England, as the co Sheffield, the Worshipful Co. of Ironmongers of earch on cold-working o 6 at.Sheffield University nsequence of a gift from London. This company has made a grant of £800 a year for seven year to endow a fellowship and two scholarships in the cold working of steel ‘ have presented Through the Cutlers’ Co. of rms connected with the university The laboratory will be att and engineering a { und the nd iniversity Dra or Vn ! ecnar ’ neo r Lt T rift ' ~ t} TT ‘ ng Y \ I ert n& ‘) T aia ed gear ng ’ neg aepartments the professors on which the ustry will be wing, rolling : ich research wo al equipment arawing p (leckneator ‘ f y ‘ ‘ , ant ' ) ( Lt Bed mie I in ] na y peed Tron The Iron Hallam the cold-working industry with the necessary plant ached to the metallurgical of the university and will of those subjects, assisted Ironmongers’ Co., Cutler represented, as well as the ind pre ng are among the rk will be done f the laboratory include ant nstructed b Georg: Ha ne 1 two-speed. gear y drawing peed of TY ‘ re ind wire in I r j ‘ ! nd rod l een eonstructe W.H j It } harder { tes y T ‘ ri I tea ‘ ur Adi peed I to! KIVINE ao + 200 ft a mir Phe ' { r i { ige, August 15, 1929 101 lachining the Wright C rankshaft BY FAY LEONE FAUROTE Processes in Making the Whirlwind Motor Crankshaft OR the Wright Whirlwind crankshaft, steel forgings are purchased from an outside vendor. These are first heat treated, then inspected for flaws or de- and stamped with a serial number. Spots are ground for the hardness test. The forgings are then inspected for hardness and delivered to rough stores. Preparatory to machining the crankshaft forging, the aft end and pin end are cut off and both ends centered. The shaft side of the cheek is then faced, chamfered and irned to outside diameters. The cheek faces are next gh milled, and the outside diameter and cheek are crankpin is igh ground Che faced. The then centered, turned rough milled on the pin er which the pin is finish turned and faced, and mfers and groove are formed. The rough grind the pin and form the radius. The cheek faces are next opera- gh milled, and the serial number is the crankpin is drilled, rough and finish counter chamfered, rough and finish reamed and tapped : cheeks is milled, also the radius on long eeks and the angle on cheek. \ 1%-in hole hen drilled and gun-drilled through. The nterbored, bo reamed and faced, the g I finish rean nd th whole i 102 fugust 15, 1929, The Iron ige Converting the Forging into a Standardized Product aaah Trueness and Checking for Alinement on Crankshaft of J-6 Series “Whirlwind” Engine The slot on side of cheek is then milled, and the opera- tion is repeated for the opposite slot, bringing the two slots into alinement. A %-in. x 45-deg. chamfer is milled on each side of both slots. The web in slot is rough milled, and the sides of slots are then finish milled. The next operation is to drill four holes through both sides of cheeks. The alinement then drilled through the center of cheek. Burrs are removed and the slots are hole is filed to gage. Next the cheek is shoulder and radius are formed. pin side of cheek is side diameters finish crankpin side of faced and the After this the crank- milled, the cheek is faced, the out- turned, and the undercuts chamfered and formed. A hole for screw is then drilled, counter- bored and tapped. A %-in. hole is drilled through the rankpin wall at a 30-deg. angle, reamed and chamfered; and another %4-in. hole is drilled through the bottom wall of the crankpin at a 40-deg. angle. The crankshaft next goes to a plain grinder, where the shaft side of cheek is finish ground and the radius formed. The outside diameters are also finish ground. The next operation is to mill a 314-in—16P thread on the pin side of cheek is ground and the radius formed: afte shaft, near the cheek; then a 2%-in.—12P thread, about which the crankpin is finish ground and the collar halfway to the end; then a 2-5/16-in.—12P thread at the ground. Radii are then drilled and formed and_ the outer end. rankpin end is chamfered. \ radius is then bored in After the cheeks have been ground on both sides, the the crankpin, these two “radii” forming the spherical splines are finish hobbed and burred to gage. The crank or cup-shaped surfaces inside the crankpin 9 HESE Draw- | ings of the | ; 1" 8 Diteh US Stal Forr Crankshaft Give | yy 416 Spline ; Rear Crank Section t £72. a , "> 7 Cd 4 72 » Cheek Some Idea of | the Dimensional Exactions' of Manufacture . ~ Eight holes, equally spaced and 17/64-in. diameter, are drilled through the thread end of the shaft. Burrs are removed, sharp edges broken, and the holes tapped. The end of the crankshaft is then faced to remove cen ter mark. Finally, the radii are polished and the crankpin lapped. The crankshaft is washed in gasoline, inspected and delivered to finished stock. Open-pit methods of mining, by which coal or ore is mined from the surface by the use of steam or electric shovels has been devel LADO ME an ~ olan ena oped to a point where approximately 19,000,000 tons of coal, 24,000,000 tons of copper ore, 32,000,000 tons of iron ore, 150,000 tons of bauxite, and 2,700,000 tons of pebble phosphate are mined annually in the United States in this manner. These quantities total 78,000,000 tons, and, according to the Department of Com- merce, at least four times that amount of over- burden is stripped to expose these minerals for mining. The power shovels used in the strip- z : eee ee te ee “alah d ping operations range in dipper capacity from 3 to 12 cu. yd., weigh 125 to 850 tons, and may cost $100,000 or more. A list of 1000 American books, pamphlets and publications on various phases of inter- national business has been compiled by Na- s : tional Foreign Trade Council, New York. Of — Crankshaft for Propeller Hub on Gould these, 170 have been marked as those currently & Eberhardt Hobbing Machine in use by active foreign traders. A five-foot shelf of 40 books has also been selected by a consulting committee. The Iron Age, August 15, 1929—403 f + 4 sing Electricity for Galvanizing Accurate Control and Uniformity of Temperature, Assured by Electric Heat, Lower Costs of Hot Galvanizing M. CHERRY sfully applied to hot r more localized sections, while the remainder of tank may be in good condition. Temperature of Heat Source Low t galvanizing rangt When electric heat is used, the temperature of 2 ni 1 nding upo! at source (heating element) is relatively low—appro nhign a nately 150 deg. Fahr. above the chamber temperatu: the case of galvaniz- The heat is applied uniformly throughout the heatir I tant ! nt hamber, there being no hot spots. Moreover, elect r heat readily lends itself to easy automatic control. | At ery accurate temperature control, a two-point tempe ! ture control instrument is used with a thermo-coupl " de the tank set at the desired temperature and a ther é \ I < ; F } } i ist } effec Py I perature n¢ (Ss? 0) y I ) l¢ rate I ill cor I ar I na Sl 7 < I ! l ll S per I t JoU ‘ ] I } ( the ibil high 20 time Ir a I nt I I a urce Or Y VI I e evel i out \ rculatior I not gases Naturally, when the heat t ‘ ! 1 pot there 1s er-} g ( nk. This explains I ! iel-fred tanks at one 860 880 900 920 940 960 980 Temperature of Z nc, Deg.Fahr. ELATIVE Solubility of Iron . in Zinc of Three Different . Steels as Determined by E. Diegel, of Julius Pintsch Corporation, Re- ported in Zeitschrift des Vereines Deutscher Ingenieure, May 1, 1915 TRUCTURAL Steel and Cast Iron Parts Are Galvanized in the Plant of the Delta Star Electric Co., Chicago, in a Tank 36 in. Wide Inside, 36 in. Deep and 15 Ft. Long. It is rated at 194 kw., taking 220- volt 3-phase 60-cycle current oat 404—August 15, 1929, The Iron Age | OR Galvanizing Trans Parts, mission Line the Southern California Edison Co., Los Angeles, Uses a 70-kw. 220-Volt Electrically Heated Tank, 5 Fr. Long, 3 Ft Wide and 3 Fr. Deep couple in the heating chamber set for the required tempe1 underneath the tank shaped as to accumulate zine ature gradient. it one or more points where the devices are located. The Accurate control of the temperature and uniforn molten zine closes the electric alarm bell circuit, thereby temperature throughout the tank insure maximum lifé warning the operator for the tank and a minimum amount of dross. The ir The power consumption of three size f electrically creased tank life, lower dross, and elimination of firings heated tanks operating continuously, as determined by labor result in a substantial reduction in the cost ictual tests, given in the following tables. The figures galvanizing. nclude the heat required to melt the make-up zin In many cases the major portion of the heat for a N fank—Inside dime 0 in. wide, 36 in. deep month’s operation is used for maintaining temperatu es = = : ; - ae Fa ' or for supplying stand-by losses. In a fuel-fired tank, thé Stes Lt Kwhi Cost of Power “age ce ae vat ace ot cea Galvanized Galy ed Per Tor Per Ton at heat losses consist of those through the walls, th mas tae Bert Galvanized ic. Per Kwht ; from surface of zinc and those carried out by the gases 6 188 In the case of the electrically-heated tank the stand-b +t losses are those through well-insulated walls and the loss ad ae } from the surface of the zinc, there being no stock losses ng ted 19 " ) volts, three phase : . . ( ' , t r t 1) t t af ae I } Since the walls are well insulated, the largest source o 4 heat loss is that from the surface of the zinc. Since the ; irea of that surface has a large effect on the amount heat required, the size of the tank should be given car di n. wide, 4§ les ful consideration before an installation is madé Fo ral uteel gusts . stand-by periods, a well-insulated cover should be used , A tank failure usually starts with a slow leak. Ii i this is detected, the tank can be emptied and replaced It is easy to calculate accurately the electric power without damage to the brickwork. In the case of elec- consumption for a galvanizing tank or for any other heat- trically-heated tanks, one or more alarm signal devices ing process, since the efficiency of the generation of elec are placed in the heating chamber below the tank t tric heat is 100 per cent. A complete cost analysis should detect any leak that may occur. include the maintenance of all equipment, dross loss, — ° ° ° . . . . The device consists of two heat-resisting wires, about labor, fuel and power consumption and working condition I %-in. apart, connected to an alarm bell. The brickwork and quality of product. HE Walter Bates Steel Corporation, Gary, Ind., for Galvan- izing Structural Steel Parts, Has an Electric Galvanizing Tank 22 In. Wide, 4 Ft. Deep and 30 Fr. 6 In. Long, Rated at 405 kw. at 220 Volts 3-phase Current : The Iron Age, August 15, 1929 —405 i“ cl Le Se os) Aluminum Foundry Makes U e ee j ment wt z 4 } ‘ v I Cig a a eans ‘ a + f Y ng tac ne r i rer ind } ao } ‘ } rog a that ¢ + ‘ I T ical SUS al ; > } } > } al) Ca ny f all hea Ih \ ¥ es ga n Tine T ne S ’ sf ts ~ { AL pOoss1D111i ng t a ne I ae ] ended on imp! r y or } ( ] and ne anda all + y + ‘ cio, 7 } ( no i 2 = Bae Ff \ i e an ££ to mak ,] iT King wiace Mi Cones Intricate Sh Are Made in Sand Molds. Thi are assembled roller tables poured right in th core room, whi is immediately jacent to the ben« and floor moldin; rooms I Bench Molding Room, Each Bench Ma- ine I; Backed [ T Against a Low Concrete Wall and L106 fugust 15, 1929, The Iron Age : [ Jobbing Plant of Aluminum . a Co. of America at Fairfield X-R HB , f y q Uu l p mm e n U Conn., Is Also 100 Per Cent Under Pyrometric Control From an exterior point of view the plant is a pleasing, num treads, as well as rails. A n furniture has pressive institution, and in decoration, fixtures and en iint on all ext ind interior ishing’s, a successful effort has been made t : nu us possible applications of aluminum product ‘ I ! I el! ed t gy roon iilding of Old Connecticut brick is flanked on ea 1 Lich 190 ft. long, 70 ft. wide and 33 ft. hig! Prac ving walls in which are inserted cast alu in ons witl ally one end of this m ope ul ! n the name of the company and its subsidiary, the United that the men in eff¢ ( gy su intially States Aluminum Co., which operates this plant Phe main entrance steps have aluminum hand rails. A fer Melting ne by fuel To ea pot f ac ind gates of aluminum alloy inclose the property and to ttached a pyrometer, and on the inner side of the room erve as a test of corrosion resistan nave not I large el te i chambe! vner men are painted. ' tationed, checking the temperatures of the metal All the hardware, which is of Colonial design, is mad: n the furnaces at all times, to see not only that it is not an aluminum alloy, this metal being used also for th erheated, t also that the temperatures established nterior mechanism of the locks, with the sole exception the engineers are maintained. Loud ennunciator bells of the springs. All the electrical fixtures, including a ng as each furnace ready to be ladled out, an illum arge cast hanging lantern in the entrance hall, as well a nated number overhead on the wall indicating the furnac¢ two others on either side of the front door, are made of numbet the same metal. The stairs to the second floor have alun Adjoining the melting room are the bench and floor N the Trimming Room Are Com- pressed Air Chip- ping and Other Tools and, as Shown Along the Far Side, a Battery | of Grinding Wheels. The com- pressed air lines and special saddles for holding the work are shown HE Dry Sand Molds, as They Are Progressively Built Up by the Insertion of Vari ous Cores, Are Moved Along a ' | Roller Table to a | Pouring Space Ad 1] jacent to Which | Are Located Elec tric Holding Fur naces i 1} The Iron Age, August 15, 1929—407 oms, 60 x 150 ft. and 95 x Bd50 ft. re spectively. 1g department is served by seven 1-ton, I n ton cranes; has a monitor type rool S es in the monitors, as well as large windows nch molding 1 rf tootl ? re eacl ( machine is backed up I i st al Le I Ih ¢ vhich is topped by a i neg I I sua clea! ivi g est irtments are pyron s p ! ed a rrect ten $ I ! \ it { times é é ny and lring e 1 ng is col I ndi ws of concrete yrand ¢ e San re -1rex ved Tron I S pl e sliding an if ered t ding floors mmedliate 1 cel t ! nese 0 ft. in p Here is a battery o ’ rack ovens, with one smaller tray ove1 ‘ itt t eac! er in i check Kept \r l i itter T ens 1 T ( y ( nt ite Lye re y These ire poured right lhe etal w h is melted ir e melt » electric holding furnaces in the is made at as low a tempera- and the temperature is brought up to erature in these holding furnaces, thus pre- g¢ at elevated temperatures. 408—August 15, 1929, The Iron Age In t cylinders, are assembled as respects their various cores b passage along a roller table. his department some of the molds, as for airplan: The cores are inserted fron station to station along the roller table, jigs being en ployed for accurate setting and the mud paste used setting is dried by hand torches. The particular casting mentioned has a full fin outside air cooling surface an requires in the molding a generous use of wires for mold sand support. At the end of the roller table th mold is ready for the pouring. The freshly poured mold is carried t ing © a point near the shaking-out room, where is allowed to cool in its sand a matter of two days. The shakeout or knockout room, where the core sand and wires are removed from the castings, partly by vibrat ing air tools, is next to the cleaning room. Here, in addi tion to the standard equipment seen in similar establish ments, are rows of benches, where operators, using rotary files, finish the rough cleaning of the castings before they are sand-blasted. In cl