The Iron Age 1929-09-05: Vol 124 Iss 10

THE IRON AGE New York, September 1929 ESTABLISHED 1855 Marked Savings Obtained Studebaker Corporation from Operation Transportation Department Employing 200 Men and Like Number Equipment Units JOHN SULLIVAN the Studebaker Corporation, production car- Today the department consists approximately 200 ried number separate buildings. Bodies men and similar number equipment units. Among for example, are made five-story factory the types carriers are steam locomotives, Fordson located some distance from the assembly building tractors, gasoline trucks, trucks, electric-lift Body stampings are turned out another structure trucks, hand-lift trucks, side-dump trucks and various while other parts originate the foundry, forge shop kinds truck trailers. and power plant departments, each which occupies its The use hand-lift trucks minimized. Wherever own building. addition, there are still other buildings possible they are service only for short hauls de- that contribute their share toward the manufacture liver material power trucks, and for moving parts Studebaker automobiles. from one floor another the building. little wonder, under the circumstances, that effi- Wherever power trucks have been installed, electric trucks cient and economical means transporting materials are employed for transportation inside buildings, and and among the many buildings major problem. For gasoline trucks and tractors for outside work and for its solution the company created some years ago trans- interdepartmental portation department, the growth which has paralleled effort made move materials between depart that the company’s production facilities. ments the ground floor outside buildings that power equipment can used. the body department, Studebaker Corporation, for instance, there are several stations which hand ff 5 eit ODIES Are Transported from Body Plant Assembly Building Flat-Type Railroad Cars with Specially Constructed Double-Deck “Uprights” VOL. 124, No. elevators the main floor, haulage tractors operating bring material Handle Overflow from Conveyors rin irts machining, stamp- spring departments the the transportation department must coordinate its hos mechanical conveyors, which have rs ( ves tne pressure To C1UE a specine ib-assen ents irts conveyors imulate raplaly create congestion ] s n ranuers tnet re ised to take off some ) delive its destination « } » he le ] possibie each operator has routine dally ile. Generally traverses his route number during the day, recording the time arrival ery trip department has central all telephone calls pertaining ae”. SA _ [FT Trucks, Capable Handling Dies Weighing 30,000 Lb., Are Used material The routing mat lls special chart, turning them whose schedules are light the moment. done through working gang bosses, who keep pecial the operator receives from the slip giving information about the task. mpleting the work, delivers the slip back routing clerk, who records the closing the trans- Schedule Based Number Cars Produced cle tment’s daily schedule based the num- finished automobiles produced each hour. the departments supplying assembly lines with deliveries are made every half hour. However, points the time reduced min. This fact that there practically stock certain parts for the assembly hat veries must made the assembly build quickly parts are produced The lron Age Since there storage space for finished parts, except small bank, which soon would disappear unless frequently and regularly replenished, any department falls under its scheduled output tie production the entire plant. The same con- dition would created the transportation department which much meet its responsibilities. Incoming and outgoing freight cars are handled the yards the Studebaker industrial rail- road, which operates the same manner independent carriers and under the supervision the Interstate Commerce Commission. has personnel men track. Four locomotives are service, each having crew five men, including switchman and conductor. Four New York Central, Pennsylvania, Wabash and Grand Trunk—have receiving tracks the entrance the company’s yards and this point deliver freight All incoming and outgoing freight cars are weighed weighmaster and are routed yardmaster. The railroad handles ap- proximately 9000 carloads raw materials and finished automobiles each month. and owns miles fireman, cars the company’s railroad system. The duty maintaining its locomotives devolves upon the railroad, and special crew three men, two during the day and Track maintenance, however, taken care the maintenance depart- ment. Sixty Per Cent Saved Hauling Refuse Sand Marked savings have been made the cost hauling refuse cinders and sand from the foundry dumping ground outside the city lim- its South Bend. few years ago the department contracted with hauling company have this ma- terial removed, but installation own equipment for this purpose has reduced the Equipment expense per cent. comprises various types refuse side-dump wagons, ramps, tractors. The which amounts about 300 daily, handled train consisting gasoline tractor and side-dump wagons. One the most important tasks the department the transporta- bodies from the body factory the assembly This accomplished means locomotive and four flat-type railroad cars with specially constructed double-deck “uprights.” chutes refuse, cu, vd. tion building. Each car has capacity bodies, six the lower deck and six the upper. Bodies Lowered Loading Dock the end the body assembly lines the sixth floor the body factory “lowerator” elevator, which delivers bodies the loading dock either the mezza- nine the main floor, the delivery point depending upon whether bodies are loaded the upper lower Each loading dock equipped with electric hoist, which lifts bodies trucks. The trucks operate rails extending from the dock the door the railroad cars, which bodies are pushed hand. When filled the gates the sides the car are closed and the bodies are automatically locked position. When cars reach the assembly building, bodies are unloaded manner similar that which they were decks the railroad cars. 4 gular schedules. » if tt y 4 Are Carried From Manufacturing Departments Assembly Build- ing Trailers RECORD OF TRANSPORTATION DEPARTMENT CALLS MSTRUCTIONS —€ntres made in Garty Dy transporter cor cats as 7 | From Marrs NSTR T T | Calls Received Transportation Depart- ment Are Recorded Sheet Shown Above. Monthly maintenance operating sheet, setting forth all expense items, kept for each unit the department Electric Lift Trucks q The Iron Age, September =— a ‘ J j — ] Bile 4 “ y loaded the body factory and are taken elevator the fourth floor, where they are held temporarily until they the assembly line. Through hole the floor they are lowered electric hoist the chassis the assembly line the third floor. Numerous models cars are assembled the same time one chassis line, and therefore imperative that bodies de- livered the chassis line according the sequence the model cars going through the moment. The lowerator the body factory and the elevator the everal hours +} formar mat) the nel ve keeping he nreccec metnod, the quick Change Keeping ne pre nriy contin uous operation and thus cutting down pro- costs. The labor expense eight men has been Facilitate Forge Shop Operations the forge shop, material process moved from ration the next steel trays carried electric trucks. Trays are various sizes and shapes and iced the side hammers and heat treating where they are the most The department laid out that material passes complete cycle without backtracking and the lift trucks and trays facilitates the for- ird movement. During final inspection the material ransferred from trays trailers hauled ractor the assembly building. Getting into the foundry, the duties the transpor- tation department are well defined other depart- ments. The industrial railroad delivers all raw materials freight cars into the foundry receiving bay. Charges the cupolas are handled specially designed con- ors and trucks operating tracks. trucks trailers are used extensively taking castings from sand, passes from the foundry floor down rough chutes into trailers stationed tunnels running iderneath the foundry. The trailers are tractors the crane bay the foundry, where 596—September 1929, The lron Age EFUSE from Foundry, Such Core and Molding Sand, Passes from Foundry Floor Down Through Chutes into Trailers Stationed Tunnels Running Underneath Foundry. Trailers are hauled electric tractors crane bay, where her ina few refuse material transferred crane large chutes, through which it is dumped into refuse wagons outside building molding floor the cleaning room and thence, after on, the machine shop. Refuse, such core refuse material transferred crane from the trailers large chutes, through which dumped into refuse wagons outside the building. For foundry work the transportation department has men and like number pieces equipment. Men are divided into gangs directed gang bosses. every case the gang boss drives piece equipment, but his duties this respect are arranged that has considerable free time which supervise the activities his men and coordinate them. Incoming and out- ments and less-than- carload freight are handled two Ford- son tractors and morning the drivers the tractors tribute the trailers the railroad freight depots. the return trailers are hauled receiving points, which the materials are delivered. has proved economi cal, because keeps trucks active vice rather than tied for period depots dur- ing loading loading. repair all rolling stock used the de- partment have been systematized that accurate record op- erating costs avail able all times. The department carries its own stores division. Every part piece equipment requisi- tioned out stores and charged against the individual unit for which intended. Incidentally, each unit has number for identification purposes. For each unit monthly maintenance operating sheet and recorded the driver’s wages, re- pair men’s wages and the cost all supplies, such gasoline, oil, charging batteries and the end every month the actual operating ex- penses for the previous days are calculated that the department knows exactly what each unit service costing. For large expenses, such the purchase tires, the amount not charged against single but pro-rated over period several months. Germany Takes Half the World’s Tungsten China dominates the world tungsten market due the possession huge deposits permitting surface mining with cheap labor. the 8000 metric tons ore (basis per cent produced the Orient, 5200 net tons was imported Germany. According Colin Fink, Metal Industry, this almost half the world’s out- put. great many deposits are known the United States, but only few are producing; the total marketed 1928 was 1290 net tons per cent WO. concentrate, valued $761,000. The largest producer the Nevada- Massachusetts Co. Mill City, where the output expanding | issembly building h } anacit : Panels, doors and other metal parts pro- iuced in tne body — — artment ] tric lift 4 pa e1rectrl A ised. The outstanding piece I equipment g ire two Elwell-Parke) f att electri ni-low lift | f dling dies weighing lb These dies ineyvy Mak lange fre not ived this manner. 7 = Assembling Airplane Engine Process Done Twice. with Intermediate Close Inspection —Frame Used Hold Crankcase FAY LEONE interesting watch the assembly Wright Whirlwind engine. the first place, all the parts which manufactured the various bays, after traveling the logical order from one machine another the process progresses, finally, after numerous have been tests and inspections, are carefully wrapped placed sub-divided trays protect them from harm transit, and taken from the stockroom. group finished parts required, withdrawn from here needed, begins the assembly. The bling crankcase set frame—a special assem- device mounted wheels and capable rolled along track from one assembly station another. After putting the crankcase, the smaller parts added it. The crankshaft with its bearings next goes in; then the master rod. The link rods with the pistons attached fitted the the mounted the crankshaft. being are are master rod and The intermediate section the crankcase, carrying *Mechanical engineer, New York In THE IRON AGI Ju . page 148, Mr. Faurote described the Wright airplane ¢ ne in subsequent articles he described various macl f ttions: Aug. &, the connecting reds Aug. 15, the crank \ug. 22, the cylinders, and Aug. 29, the crankcase ULLING Dismantled Production Engine (Right) Back the ondary Assembly Line. All Army and Navy engines after primary assembly tested for hr., then completely torn down and inspected and re-assem- bled. Then they are given secondary run-in test for hr. FAUROTE the valve tappets, then added. The camshaft, the cam driving gear, next. Finally, the cylinders with the valve rockers, valves and springs are bolted the crank- The push-rod housing, the push rods, intake mani magnetos added. and spark plugs are next After wiring, the engine timed, the magnetos syn- hronized, the carbureter and the manifold assembly and the rear section the crankcase attached; the rocker-box covers screwed on. The engine then ready for test. hr., driving four-bladed pro- peller (see test chart). measures established standards, then disassembled, thoroughly washed, minutely inspected and examined for flaws, then taken hack the assembly line and carefully reassembled delivery the purchaser. After being weighed, then greased and oiled, taken the final testing room and run for hr., where final record its per- formance must meet the same standards. Then retouched and coated with slushing oil for protectio., numbered, registered and crated for delivery. Nowhere the slackened There always ever present the knowledge that here piece oT line close vigilance along mechanism upon which man’s life may depend Whirlwind Engines Left Shown at T he Ir mn” Inhibitors Pickling Process Experiments Show That Only Enough Acid Consumed Remove Scale—Hydrogen Evolved Reduces Inhibitor Rather Than Replaces Metal ALLISON well known fact inhibitors have two-fold pur- pose the pickling bath, namely, prevent the reaction between and metal and reduce acid ration from the surface the bath. Generally peaking, the latter result the first mentioned. Steam cannot entirely prevented from issuing from ling bath; would against the laws aqueous tension and vapor pressure. the protective coating that forms bath containing inhibitors will stop much the steaming. The comparative vapor tensions the ospheric layer immediately above the blanket cannot equilibrium with the attenuating layer the kling solution found just beneath this foam coating. The coat frequently punctured, acid being carried over the steam bubbles, action which can compared k-down overcharged condenser. more stable condition may indeed secured lutions are indirectly heated, i.e., closed pipe made non-corrosive metal. Shooting pickling vat causes dilution the acid and reates eddy currents that sweep the inhibiting from the surface the metal. Inhibitor Should Not Proportioned Make-Up Unless a correct balance is achieved between the in tor the conditions that influence the cleaning, efficient ion cannot expected. The amount acid added from time time frequently but erroneously iken criterion the proper quantity necessary prevent the actions mentioned the first agraph. This misapprehension responsible for gives only more less satisfactory results. her factors that should taken into con- instance, the diameter the steel rod cleaned has distinct bearing the amount in- hibiting substance, inasmuch the surface area the metal governed the diameter, and the action de- sired surface effect. When steel rods are cleaned in dilute acid, the oxide cale first succumbs; after the metal laid bare the steel to corrode. Hydrogen gas evolved, which the surface the metal become embrittled. This ac- more intense when the percentage acid low, necessitating long cleaning periods. Rough, embrittled irfaces offer ample secretion for occluded hydrogen, which left the metal will cause breaks the draw- dies because the ineffectiveness the lubricant. passing, might remarked that imperative that kept out all wire drawing greases soaps, the dry drawing process. dilute acids having inhibitor, the greater the irface pickled, the greater the metal lost. Curve the evolved hydrogen gas that accompanies over- *]} I Produ E neerir Depar ent, Northe Ele Montreal, Canad 598—September 1929, The Iron Age TURNBULL picklirg various sizes rods for min. per cent solution sulphuric acid (by weight) 187 deg. Fahr. Pickling Without Inhibitor Forms Hydrogen When one ton rods having diameter 0.207 in. are overpickled for period min. 4.21 per cent sulphuric acid solution 200 deg. Fahr., lb. iron dissolves, according the following equation: For each pound ferrous iron dissolved there 0.036 lb. hydrogen gas liberated. (If the solution highly oxidizing the change from the ferrous ferric sulphate occurs almost irstantaneously.) Hence the case under consideration 0.036 times 0.108 hydrogen was set free. Similarly overpickling No. gage (W. 0.090 UNIO 0.070 ) 060 4 | | | + T — W.and Gage Amount Hydrogen Evolved During Min. Overpickling Three Per Cent Sul- phuric Acid 187 Deg. Fahr. M.) wire rod, which incidentally has smaller surface, 0.100 lb. the gas was liberated. These calculations follow curve very closely. Curve pictures what happened the above pickling bath where the lb. iron were dissolved. For the first minute two the acid not affected because the metal absorbing heat from the solution. three minutes the acid was rapidly attacking the oxide scale, continuing for another min. this time all the scale was removed and the acid concentration had fallen from 4.21 3.4 per cent, loss 0.8 per cent. After > this the curve still droops, indicating that acid was being onsumed. min. the rods were removed: the bath had only per cent acid. (The stock selected for the test was medium carbon steel, having moderate scale.) This example shows the utter waste both meta! and acid that accompanies improper pickling. The rods were practically free any oxide film min. but a 3 Dd) iN Lv Lo Minutes Consumption Sulphuric Acid When Pickling 0.207-In. Rods 200 Deg. Fahr. few spots remained, necessitating further immersior during which time the acid was free attack the stee! the rod well the spots oxide. Pickling With Inhibitor Forms Water Compare this with curve solution that properly inhibited. case follows: FeO H.SO, Instead the harmful hydrogen gas being produced, water only formed. representing The action such FeSO, case point, steel rods the type usually classified “white having 0.04 per cent carbon, were pickled for min. per cent sulphuric acid bath. The inhibitor was very cheap substance found suit the average pickling vat. can seen that acid concentration dropped 0.5 per cent min. and min. from the start was 3.45 per cent; remained constant until the batch rods was removed One infers from this that the scale was practically re- moved the 15-min. period; after that time the acid remained dormant. Vats used for all these tests were the standard groove fit, wood construction. The capacity each was exactly 1006 imperial gallons. Although live steam utilized for heating, all steam valves were tightly shut during the trials. Before the test was made the accurate weight the batch rods was taken, viz., 2144 lb. During the pickling the loss weight was exactly lb. 1.67 per cent. The gravity the bath before and after the trial was 1.08 and 1.0836 respe tively. The total percentage drop the acid was 0.55 per cent and the consumption was deg. acid. Theoretically, the amount 100 per cent acid neces- sary remove ferrous oxide 49.1 which equivalent 51.5 lb. deg. Baumé acid. The difference between the theoretical and actual usage 3.5 which creditable indeed. When considered that there was some evaporation and that tub 100 per cent efficient, the figures are remarkably Proof That Steel Not Attacked was previously stated, scale was removed further show that the acid did base, check can made the before the rods were immersed is: Similarly the weight the solution after the test ifference in the two values 10901.0 — 10864.8 36.2 b., the amount iron oxide removed from the rod com- bining with acid form ferrous sulphate and water. Inhibitor Essentially Cellulose The question now arises, just what inhibitor? Inhibiting action undoubtedly due organic substances the compound. Carbohydrates having high radical, such as carbo-hydrogen starch have good inhibiting quali- sugar ; sich y n P ar < ties. might further the scale and say that the supposedly existant Hs. the formula true While the process formation all the free ack the metal. Pure cellulose could used pickling solutions, providing that there was correct amount the substance placed the bath. Too little would inefficient, while too much would wacte Wale. What takes place pickling bath when present? Many theories have becn advanced. Observa Consumption Acid Containing Proper Inhibitor tions taken over period eight months, using four different classes inhibitors, lead the writer believe that highly reducing condition must created the solution. Numerous bodies with sluggish reactions are capable chemical combination the instant they break away from another compound. Speaking generally, when chemical change occurs between molecules, there is, first all, decomposition the molecules and then re- arrangement the constituent atoms form new mole- cules. But appreciable amount time necessarily elapses while the atoms are falling into the new arrange- during this momentary freedom nascent state, The Iron Age, September LiUse, not attack the following manner: acid which hydrogen from metal, the follow ar o 3 0 4 4 4 4 4 4 + 4 j- 9D + + + + + + + + + + + 4 + + + + + > + + 4 the atoms act individuals, and enter into combination But there happened 0.108 lb. hydrogen evolved more easily than held restraint the forces bind- 0.108 1.31 this process, necessitating 11.5 in- ing them into molecule. the case inhibitors the hydrogen acts re- hibitor. ducing agent actually entering into the molecule. From experiment was found that lb. the Carbohydrates like dextrose and glucose are highly substance was necessary give the results obtained lucing. For instance place quantity starch the second trial. will remembered that this was the nto dilute solution sulphuric acid 120 deg. Fahr., test where the acid did not react with the metal after alkali neutralize the acid, have the oxide was removed. Consequently, practice bears out solution. This fact utilized metal plating, the theory. Inhibitor Added Decreases With Age Returning the example previously considered, Solution ‘id ranging around 4.21 per cent 190 deg uppose add measured quantity sufficient quantity the substance must added grade associated with “mill (sucl from time time order make for being capable releasing per cent cellulose and losses sustained when the rods are removed from per conditions). seemingly dissolves. vats. was found that once the salting charge was and i.e., 11.5 tapering amount was necessary reafter particles ferric oxide and ferric sulphat continue the protection. Usually one pound was added can observed floating the surface the bath. with each ton charged. Such additions were made five aginous character the inhibitor binds these sub six times. Following batches then receive amount hick, reddish brown coating. The bath that varies from down per ton reducing condition. sample the solutior The last two batches not require any inhibitor. vhen examined under polariscope shows distinct rota average consumption over period say one month the plane polarized light, nearly always ranges between and per net ton rods pickled. ndicating that dextrose has been formed, but Curve shows the fact that the gage the rod there has been formation glucose, since decreases, the hydrogen gas capable being evolved from ime indication (both these are com that rod also decreases. This curve true for all siz ition wire and rods when they are overpickled noted, fferent properties, since the atoms are located dit for min. 3.0 per cent solution heated the 200 deg. The real criterion determining the amount inhibitor the square feet surface metal What Happened When Rods Were Overpickled cleaned. During average month, using the inhibitor unde hydrogen tends oxidize the dextrose, hence discussion, 2594 tons rods was cleaned Exactly 132 capal le of plating « it on the metal, and hence the 100 lb. of 66 deg. acid was consumed doing this work. tal does not dissolve. average 50.9 per net ton. Pains were taken Consider again the first example where ton 16.5 secure accurate data regarding the amount oxide was overpickled for approximately average rod, the result being 1.7 per cent. Theoretically iT AE ) of i n Was dissolve a The hydrogen | b- 1S. lb. of acid would he required to remove this quantit) this instance was 0.108 Referring the scale from one ton stock, leaving difference per net ton between the actual usage and the theoretica H.O seen that for each pound understood that the solutions are not down nhibitor there 0.0123 pounds such weak concentration that long period tim oxidized H.O. Actually the substance used would necessary for the pickling operation, conse- trials was composed 76.4 parts cellulose quently there was always some free acid remaining the must used take 0.0123 Ib. bath when was discarded. This accounts for most the 2.6 surplu Airplane Disaster Caused Fatigue Steel ACTURE under fatigue studs the front big-end the damaged broken parts was discolored heat, ear.ng of the starboard engine is found to be the caus ( t was said. aster the London-Paris airplane which, After careful consideration the evidence, which June 17, plunged into the British Channel, killing severa! dealt exhaustively with the manufacture these studs report, recently issued the British and the suitability the steel used therein, the court Ministry, based formal investigation, states that thi gave out the opinion that nothing that human foresight vas the primary cause, according the London could have done, providing against this primary cause Trades Review. the starboard engine becoming relatively useless, had ing more detail, the report says that this mis been omitted either Napier Sons, Ltd., the described type which unavoidable. part Imperial Airways, Ltd., their personnel. “It eport also the effect that Major detailed case,” says Sir Arthur Colefax, author the report. xamination revealed that the front, No. connecting “similar many with which all who have with issembly was completely ip, machinery are familiar—the metal some part becom esult fracture the big-end bearing studs. ing fatigued for some reason which remains with which the court agrees, the mystery. Evidence was given almost identical mis the front stud being the first fail, followed few other instances studs failing. Such evidence tuds the starboard also failing. None not enabled the matter any further.” 1929, The lron Age q nad tnere: Cal 7 x} 7 = Work Process Stored Skids the Yard 4 = A* the end of article is shown the steel storage yard Handling Forgings, Dies and Stampings Transue Williams Plant presses point where one HAT constitutes the furnace equipment for wide variety size and weight was described row machines for car- rying the forgings and conveyor urpose. running the opposite lirection between the line machines and located slightly above the floor level for handling the scrap. The forgings fall from the trimming presses the conveyor belt and the press operator throws the flashings the scrap belt. the end the press line the scrap belt goes slight incline and the scrap dumped from the belt into the hopper dump body skid which electric truck carries baling press. All the forge shop scrap, ex- cept very heavy flashings, baled. The two belts carrying the trimmed forgings turn incline the other end the presses and then move along horizontal position for short distance, viding ample space for inspection and sorting, done while the work moving. which Various kinds forgings are moving the belts the same time and the inspec- tors throw each type the proper skid. The ing skids are placed row along the outer sides the belt conveyors. sm: mall tote boxes. receiv- The defective pieces are thrown into The trimming presses are individually driven through 14 aa from motors located above the machines. The jority the presses are the Toledo make. ma- Tools and spare keys for setting the dies are con- eniently carried metal tables mounted castors, one table being provided for six presses. Three methods cleaning are used, pickling, shot blasting and tumbling. Trimmed forgings after sorting and experience the Transue Williams Steel Forging Corporation, Alliance, Ohio, for this The present article devoted arrange- ments for handling, three methods cleaning forgings and provisions for storing and preparing steel. are shot blasted ro- tary table machine. For cleaning No. steel grit heat treated used. Forgings intermediate sizes are pickled. This done separate de- tached pickling building, which equipped with 4-arm Mesta pickling machine with 12,000-lb. lift. The building ft., ft. high, with windows all sides extending the eaves. Tumbling Smaller Forgings smaller forgings are cleaned two 60-in. tumbling barrels located the trimming department the end the press line. Each machine served power loader designed that loaded skid placed the loader truck and the skid and its contents, about 2500 directly into the barrel. raised and the skid dumped This nomical handling arrangement. proving highly eco- The forgings are rotated min., and each machine has capacity tons per day. Skids receive the forgings the discharge end the tumbling barrels. The tumbling mills were built Ideal Industrial Machinery, Cincinnati. new arrangement has been provided the handling dies which proving efficient. New dies are now pre- pared for the layout bench the die storage building, which equipped with two planers for that work. dies this and drilling machine Keyways and shanks are also put the artment. Then the dies direct the With this arrangement not necessary The die layout bench. take the new dies the regular die shop. The Iron Age, September 1929—601 rT room 100 200 ft. and contains about machine tools used die sinking. The die storage building 175 ft. are stored 1800 sets dies and there sufficient room for 2500 sets. Dies are stored steel racks, the width which diminishes from the bottom shelf up, hat dies can lifted from all shelves the rack with lectric traveling crane. The racks are numbered and complete filing system kept for the dies. The steel yard conveniently arranged for the han- ling stock. 600 ft. long and ft. wide, its size being sufficient store 5000 tons material. The stock carried piles arranged according types material. The yard served 15-ton gantry crane with 60-ft. span. This unloads stock from cars stock piles and also delivers 4-wheel wagon the entrance the The wagon moved few feet per- the stock picked 5-ton electric travel- ing crane that serves the shear building and delivers the the shear. This building 120 ft. Heavy Stock Sheared Hot HEATING furnace was installed recently the shear for heating plain carbon bars that are too large cut cold larger than in. diameter and heating alloy bars that cut cold would sustain frac- ure. This continuous oil-fired pusher type furnace, ft. long and ft. in. wide. The bars are heated temperature 1000 1200 deg. for hot shearing. They pass - the furnace skid bars and are discharged upon incline leading alligator shear and after shearing pass roller table. This shearing unit arranged that may also used for cold shearing. that case the bars are handled without passing through the furnace. The shear house equipment includes stalled Pels shear with capacity for shearing bars in. diameter, three alligator shears, guillotine and friction saw with ft. diameter cutting blade. auxiliary the overhead crane the shear house has industrial track extending through its center equipped with car for handling stock. From the shears the stock taken skids one the three forging units des- ignated travel card. The forging capacity has been increased the recent addition hammers. The present forging equipment consists 1200-lb., 2000-Ib., 2500-lb., and 3500-lb. board drop hammers; heading up- setting machines ranging from in. capacity and bulldozers. addition replacing some the larger hammers which are becoming obsolete, the company has placed orders for twelve additional new hammers, manufactured from its own design. central storeroom has just been completed which practically all stores are kept. This ft. long and ft. wide and has 8-ft. balcony each side. ELT Conveyors the Cold Trimming Department Carry the Forgings from the after Trimming. The forgings are inspected and sorted they move along the belt and are thrown the tote boxes back the belts Trimming | Press Room and | the Discharge End Conveyor Scrap 602—September 1929, The Iron Age ; = | Dis- charge End the Tumbling Barrels Are Pro- vided with Hoods and Con- nected with Exhaust System for Carrying Away the Dust lighted through monitor roof. The inspection depart- ment consists three divisions, hot, cold and final inspec- tion. Shipping facilities are provided for handling 500,000 lb. finished forgings per day. New departments include chemical and metallurgical laboratory with sq. ft. floor space and hospital new building ft., provided with first aid equipment. The power plant equipment includes five 500-hp. ing boilers fired with Riley underfeed stokers Westinghouse low-pressure turbines, one 1500-kw. ca- pacity, one 750-kw. capacity and one 300-kw. ca- pacity. substation was recently built that enabled company purchase 1000 kw. power from com- mercial power company should breakdown occur own power plant. Stamping Department ‘HE stamping plant for the most part produces deep drawn stampings for the automotive and other indus- tries. overhead endless chain conveyor for handling Tumbling Barrels Are Located the End the Trimming Press Line. The forg- ings after trimming are dumped directly from tote boxes into the tumbling barrels, electric trucks placing the boxes the hop- per motor recently erected this plant. work proce was use resulting reduction handling costs, speeding production and materially cutting down the amount work stored the floor. This conveyor, 730 ft. long, loops around through the press room, assembly room, spection, pickling and annealing departments ping platform. The conveyor has hooks 20-in. centers which the work suspended and moves ft. per min. carries all work process which there are larger than holes, which comprises per cent the stampings. down from the ceiling, bringing convenient level for loading and unloading. are required between press operations nearly all deep various points the conveyor loops pickling and annealing drawn work, some the work makes many three cir- cuits the conveyor. Annealing done continuous oil-fired furnace ft. long provided with chain type conveyor consisting four chains that run alloy steel channels. Work mains the furnace min. The furnace tempera- The Iron Age, September | “= Pickling Department for Forgings, with Its Mesta ‘ 5 — ~ =~ ~ ~ 4 4 = ~ = - > 4 = hy ai 4 ~ P LL, Machine, Located Separate High-Roofed Build ing with Glass All Sides, Affording Good Ventilation and Light (above) =~ ~ ~ Shop Light Hammer 604—September 1929, The Iron Age | Plant Has End- less TAMPINGS hain Convey- = for Material Process or (At Left) Are Con- Anneale Oil-Fire Furnace tinuous c - — Pickling and Anneal- ing Department the Stamping Plant 605 The Iron Age, September 1929 ture, which under thermostatic control, 1450 1700 deg. Fahr. Hoods connected to 24-in. stacks are located at ading and discharge end carry away the heat and Recently construction was started new die room tamping plant. This the most modern day- nstruction, 160 ft. New modern equipment nufacture stamping being installed led with two cranes for been ordered vill installed + 60 ( 606—September 1929, The Iron Age months forgings and stampings for industrial applica- tions other than that the fluctuation auto- motive production will longer affect the output earn- ings Transue Williams. good share the output now being taken the electrical manufacturers, conveyor manufacturers, packing houses, boiler manufacturers, ag- ricultural implement manufacturers, machine tool manu- facturers, golf club manufacturers, etc. The Transue Williams plant occupies site and includes buildings with floor space 262,150 ft. The company employs 1100 Its officers are Gorman, president; Sharp, vice-president and reneral manager; Senour, secretary-treasurer, and Charles Kingston, works SECOND Hudson River Bridge Pough- keepsie Has Reached the Cable pinning Stage. Here shown the gap between one the two piers and the shore anchorage. The bridge will 4000 ft. long, with main river span. will driveway ft. and five sidewalks towers = Fatigue Tests Drums and Shells Riveted Manganese Steel Drum Failed Head; Riveted Carbon Steel Drum Did Not Fail: Welded and Forged Shells Failed Tapped Hole DVENT higher pressures steam boilers has necessitated the use plate material increased thickness for the shells. This has appreciably affected the problems design and manufacture drums. the United States, riveted drums are service for steam pressures approximately 800 per sq. in., which seems about the limit for this type con- struction. For steam pressures the order 1500 For have per sq. in., solid forged drums have been used. other than steam drums been built with welded seams quite heavy plates. view the highly satisfactory service obtained from riveted drums, has direct experimental comparison strength between riv- eted drums and other types drums, and also make tests drums with riveted seams using plate material greater tensile strength than that ordinary boiler plate. Realizing that ordinary static pressure test de- struction gives only limited measure the value the construction used, the Babcock Wilcox Co. for some time been making tests drum shells various types under repeated applications pressure. These periments are still progress, but seems desirable present certain results already obtained for information, with the distinct understanding that the conclusions here given are tentative and that further results pected the tests proceed. The apparatus described this article and the ods test developed have been designed and developed the laboratory force the Babcock Wilcox Co. The writer has served consultant the conduct the fatigue experiments The specimens tested were full size boiler drums, shells full size drum diam- eter ft. ft. in. inside). The expense and time necessary for mens and making the tests was great that comparatively few specimens tested. making ordinary fatigue tests, six more small spec- imens each metal tested are subjected various stresses, and usually some tests for each metal are run pressure vessels boilers, seemed desirable have has exX- may ex- t} Barberton plant so *Research professor of ngineering materials, University nnection with these test special consulting engineer with the Babcock Fig. 1—Diagram Apparatus for Repeated Stresses Boiler Shells and Drums MOORE least 10,000,000 cycles stress. this manner possible determine the “endurance limit” for nearly every metal below which the metal question will with- at stand indefinitely large number cycles stress with- out fracture. This method was not feasible for the tests full size drum determine the relative length endurance specimens (that is, the number repetitions stress failure), although this means the best criterion strength under repeated stress. However, the ordinary service boiler the cycle stress the shell repeated most few thousand times, and the stress not reversed, varying from zero maximum with slight fluctuations near the maximum stress. Thus was feasible run the tests numbers cycles stress greatly excess the number cycles was decided expected the normal service boiler. well known fact that very slight change the stress. above the endurance limit metal, will make large change must imposed cause fracture. perience with fatigue testing, the writer believes that the stress might mean would seem, then, the number times that stress From his general per cent conservative statement that if, under test, boiler drum shell without fracture 150,000 cycles stress varying from zero stress per cent above working stress, might concluded that similar drum material would not fail fatigue decrease withstood the same under normal length service working stre The tests herein described were planned applying repeated cycles shell this basis, tress cent above the per working stres shells, and length fracture, to spec- drum noting the before and the character imen ation and the frac- pparatu diagram a Fig. photographs the set the the Co. are shown the accumulator-controlled the plant. This water goes and Barberton L Babcock and under ure 1600 lb. per taken in in. from pressure mains through reducing the pressure desired the test, and then through a valve produce Co. The Age, September € 7 ml «- Recording! ure bh be “al lest Deum if ne Test Swe 4 4 > eee | I M« tor Dr ve al d Link chanik lly ‘ ] wate! inde hy ting } ist i re dadrive thi i li lution l i plied pevel | ts 0 re OT ited by tne one and several test drum shells tested one time. The pre Bourdon gage directly the specimen, and als The equipment was ordinaril erated so as to give six repetition per tect incipient fracture test shell leakage fine isually shown water), careful irements the minute changes under load were made. Some 2-in. Berry strain gage and others eans micrometer dial gages at- + ch + framework drum shell. utility the measurements to a irom the cipal supported test The prin- strain was whether any marked permanent dis- tortions the specimens occurred the tests progressed. 608—September 1929, The Age tor Operating Hydraulic Valves Two types test specimen were used. The first, which was used for riveted construction, consisted shell with standard heads riveted it. This type specimen referred “test drum.” The second type specimen consisted the test shell with inner shell smaller diameter, leaving between the two shells into which water under pressure was ad- mitted. Figure shows the general arrangement this type specimen, which referred “test shell.” space Drums and Shells Tested One the specimens was man- steel test drum. The plate material this specimen showed analysis 0.29 per cent carbon, 1.95 per cent 0.025 per cent phosphorus, and 0.036 per cent sul phur. Physical properties yield point 83,500 Ib. per sq. in., sile strength 106,500 per sq. elongation in. per cent, and reduction area plate granese manganese, were: per cent. The material for the remaining specimens was ordinary carbon steel and both the chemical analysis and the physical properties showed thoroughly boiler plate, sults for the metal each specimen. The designation each test spec- imen, ruling dimensions each test specimen, the type joint, the range test pressures and resultant com- puted stresses, the number cycles ‘ig. which stress for fracture, and the character the fracture, the test drum are given Table Comments Each Test manganese drum trouble steel test with the gaskets the manholes occurred was \ y\ i lrum shell to be re These mechanically work elec The and the link work Slight > Fig. 3—Hydraulic Valves for Testing Several Drums Simultaneously an | 4 ™ 4 4 ~ 4 = Fig. Drums Under Test during the first few hundred cycles pressure. Be- tween 3000 and 4000 cycles slight leaks appeared along the buttstraps and one head the rivets. leaks developed 7100 cycles was necessary stop the test replace gasket one manhole cover, and this time the head seam was calked. The test was sumed, and after 45,000 cycles pressure slight leak appeared both head seams. One these leaks in- creased until 65,000 cycles was necessary stop the test and recalk this head seam. Test was resumed, and 92,000 cycles one manhole cover was replaced heavier cover. After 130,225 cycles leak had devel- yped near the manhole opening which was evidently fracture. The test was stopped and examination showed about in. long located shown Fig. The metal around this fracture was removed, thin plate fitted into the hole and the rest the opening filled with weld metal. The test was started again, but after 143 additional cycles pressure the drum head split violently, shown Fig. Examination showed slight fracture extending into the edge the shell. Strain measurements showed considerable variation, but out- standing evidence permanent distortion except the immediate vicinity the location where the crack developed. The standard drum (that is, one designed and constructed according the provisions the code) was riveted the usual way. After 25,000 cycles pressure had been applied minute leaks developed along lower edge buttstrap and both head seams. After 32,000 cycles the test was stopped and the seams calked. The test resumed and after 431,000 cycles very minute leak (about one drop per minute) devel- bottom one head seam. 629,000 cycle slight leaks had developed along the lower edge and the end one buttstrap. The test was stopped and the joints recalked; thereupon the test was resumed, total 1,013,840 cycles pressure was applied without de- veloping any fracture. The measurements strain gave evidence permanent deformation during the test. welded test shell “A” shown, diagram, Fig. The stresses set were practically pure hoop was oped tension. Arc welding was done hand, using ordinary bare welding wire. After 5530 cycles pressure, frac ture developed the welded seam the junction base metal and weld metal. Are welded test shell “B” also shown, diagram, Fig. The seam was are welded hand, using processed electrode). After 163,000 cycles pressure, the longitudinal seam the inner shell the test apparatus fractured. This inner shell repaired and the test continued. electrode (covered was After 417,381 Fig. 5—(At Left) Test Shell for De- termining Fatigue Strength Weld- Forged Cyl- inders Fig. 6—Sketch Original Check Drum Head and Method Repair The Iron Age, September 1929—609 4 4 wi 4 the outer shell frac- tured, not the weld, but the tapped hole where the press- ing the behavior peated stress such seams, and welded joints gen- eral, these few test result seem worthy attention. the case the test shells which fractured th« tap hole for the gage ure gage connection was made This point stress con- centration, and its significance discussed later. During the test the strain measurements showed sign permanent cording the theory elas Arc welded test shell ticity such hole would cause The seam was also welded, electrode. edge amounting three time the computed stress plate. The practical effect ising a processed After 160,000 cycles pres- ire the packing the joint such holes, judged tween inner and outer shells peated-stress tests seems came loose. The test was less theoretical topped and the packing re- value. Haigh and Wilson hereupon the test was have made tests specimen cles the outer shell cracked tensile stress vary- gage connection ing from zero maximum, pipe thread). The failure and they report reduction similar that for are strength due hole only elded test shell “B,” and amount hown Fig. The crack structural rea through the later tests showed larger uter surface, but was several Fig. 7—Long Crack Skirting Edge Welded duction for harder steel with nches long on the inside Jur- - . ‘ ole in it. Tests at the Uni- ng th ; t the strain meas- : versity of Illinois? on speci- irements showed evidence mens soft steel subjected ermanent deformation the steel test shell. cycles reversed bending show reduction strength welded test shell was duplicate shell “C” about per cent due the hole. this connection construction, type welding wire used, and method noted that the “A. standard drum” testing. After 435,883 cycles pressure failure occurred (line table I), which did not fracture, had such tapped the gage connection, the case shell “B” and hole its outer shell. However, owing the allowance for efficiency the riveted joint, the stress the tapped The forged steel test shell was forging without any hole (which was some distance away from riveted seam) ngitudinal «seam. After 20,000 cycles of pressure the was only 13,200 lb. per sq. in.. as compared with 16,500 lb. inner shell the test apparatus cracked the longi- per sq. in. for the stress the riveted seam. tudinal seam; was repaired and the test continued. fair value for endurance limit boiler plate After 446,950 les the outer shell fractured the pres- under reversed bending lb. per sq. in. For sure gage connection manner very similar the stress varying from zero maximum may for arc welded test shells “C” and “D.” The expected that the value endurance limit will rise train measurements showed evidence permanent about 39,000 per sq. This would indicate that practical stress-concentration factor the tapped hole Stresses Concentrated Holes the case the shells tested lay between 39,000 13,200 obvious that, until many more tests have bee ‘ til mor tes have en 1 (J tish) Association for the Advancement of Science, 192 aae, nothing in the nature of final conclusions ean be Report of Section ” lrawn as to the fatigue resistance of boiler seams. How- -_ Bullet l 2 Eng? 1eering Experiment Station, University pages to of A Fig. 8—Plug Specimen Cut from Arc Welded Test Shell Where Broken Tapped Hole for Pressure Gage. ate; center the side the plug specimen, and right the fracture shows open considerable distance each side the hole a ¢ ¢ A \ TABLE Shell SUMMAI Effi- Max. Al- ciency lowable eter, ness, nal Specimen In. Seams Cent Manganese test Two drum, rivete