The Iron Age 1929-09-12: Vol 124 Iss 11

AGE New York, September 12, 1929 ESTABLISHED 1855 VOL. 124, No. Lacquer Department Conveyorizec Studebaker Doubles Output, Saves Per Cent Labor and Reduces Rejections Per Cent Installing New System BURNHAM FINNEY HEN the Studebaker Corporation decided re- chanical conveying system reaching into many depart- cently concentrate all manufacturing activi- ments. ties South Bend, Ind., was faced with the The conveyorizing the lacquer department was in- necessity greatly increasing its output there take cluded the expansion program. means the new care the volume automobiles formerly made system, production hoods the department has been Detroit. Instead constructing additional units increased from 400 800 10-hr. day and the output high cost, examined ways and means which opera- sets sheet metal parts has mounted from 125 tions might carried more intensively its present 350 the same working period. Concurrently, labor buildings, and finally decided install extensive me- saving has amounted per cent and rejections have declined per cent. *THE IRON AGE, New York. | OODS Are Carried Department Overhead Chain Conveyor 659 § j Be Sheet metal parts going through the lacquer depart- ment consist the running board splash apron, radiator splash apron, fenders, gas tank covers and They are brought from final inspection the stamping depart- ment the lacquer department overhead chain are transferred hand two men another overhead chain conveyor. The department served two conveyor lines, one for hoods and one for other parts. Both conveyors are constructed 4-in. I-beams teel angle supports. Running I-beams are two-wheel trolleys with standard ments connected No. 458 drop forged chain. they move along the conveyor line, the running aprons, radiator splash aprons, fenders and gas tank covers (hereafter referred the “fender line”) are cleaned with Rex Pamco Reducer remove spots and are sprayed with Rex Cleaner take off all grease and slight rust from previous handling. aying booth individual unit with air- pressure tank located outside the booth. The cleaner forced air through two hose into the booth, where workman sprays the sheet metal parts. Fenders Baked Drying Oven Passing out the spray booth the conveyor, fend- ers are air-dried while moving toward the oven, 660—September The lron Age where they are baked from min. 400 deg. Fahr. This oven, manufactured Young Brothers Co., Detroit, standard panel design, with the oil heating unit situated pent house the roof the building. Heat forced through ducts from the heating unit the oven and drawn out there means exhaust fans. the oven the Rex cleaner flakes the fenders, that the first operation after emerging from the oven the scuffing off this material. This done rubbing the fenders hand with steel wool, after which they are Hinges, Corner Pads Have Been Riveted, Hoods Are Put Special Slat Conveyors Where They Are Striped with Strip- ing Pencil (Bottom). The strip- ing operation shown above = wiped down with alcohol cloth make sure that rust has accumulated. For spraying the prime coat, fenders are carried through booth which the Floco system automatic shower bath used. This booth contains series shower spray heads, some which are turned upward and some downward, that all parts the fenders have the spray paint turned directly them. The spray heads are adjustable suit local con- ditions. number drain pans form the floor the booth. Through these pans the paint returns the stor- age tank, where ready pumped again into the Floco system. The supply tank for the Floco system located service elevator tower the third floor. From this tank the material pumped second supply tank, the sawtooth the fourth floor, which small capacity » 4 4 FTER the Lacquering Operation, Sheet Parts Are Taken from Conveyor, Put Special Rubbing Bucks and Rubbed Down Hand with Oil, Pumice Stone and Water (Upper Left). Hoods are dipped tank for the priming coat, the paint the tank being specially agitated the top bottom (upper right). Booth which Rex Pamco cleaner sprayed fenders and other parts in- dividual unit with air agitated pressure tank located outside booth. Cleaner forced air through two hose into booth (lower left). Prime coat sprayed fenders Floco System automatic shower bath (lower right). Booth contains series adjust- able shower spray heads. Several drain pans form the floor the booth The Iron Age, September 12, and designed the pump constantly primed, thus giving the spray heads proper pressure. Fenders Pass Along Conveyor Bank Coming out the Floco booth, fenders pass along considerable bank the conveyor for dripping purposes. The bank special glass-inclosed room, offering against dust and dirt, where the floor made series drip pans. From this room the con- veyor leads into drying oven, where the prime coat ked for period hr. temperature ranging from 370 400 deg. Fahr. Coming from the oven, the fenders are cooled for min. and then are lightly sanded. this point they start journey through number spray booths and drying ovens, during which they are sprayed outside with from six eight coats lacquer, are air-dried for min. between each coat, and are oven- dried for min. 170 deg. Fahr. They are water- sanded, mist-coated and retouched. They are then sprayed inside with black paint, again oven-dried for min. 170 deg. Fahr., removed from the conveyor for Parko- Rub, and polished. After being polished, they are hung conveyor and are delivered the final car assembly line, passing route through finished stockroom, where they can removed for storage, desired. Hoods through similar process, except that they are dipped tank for the priming coat, the paint the tank being specially agitated the top and bottom. Moreover, after polishing operations, hoods are sent overhead conveyor the assembly department, where hinges, corner pads, and handles are assembled and riveted. They are then put slat conveyor which they are striped with striping pencil. Finally the two halves each hood are assembled and are placed overhead I-beam conveyor delivered the final car assembly line. Ovens Are Constructed Wood Ovens which lacquer coats are dried are economic- ally constructed wood framework with plaster board sides. Since the temperature the oven never exceeds approximately 170 deg. Fahr., the use such material feasible. After the coat has been thoroughly dried, following the lacquer spraying operation, sheet metal parts are taken from the conveyors hand and are put special rubbing bucks. Here they are rubbed down hand with 662—September 12, 1929. The Age oil, pumice stone and water. Under each rubbing buck drain carry away the drip splash the liquid. The floor the spraying booths mastic deck with drains connected sewer. The mastic deck com- posed material similar asphalt, which laid top the original cement floor the booth. With this con- struction possible wash booths with water and lacquer remover about twice week keep them from collecting thick layer lacquer dust. For use case fire, booths are equipped with automatic sprinkling heads. addition, there are two sprinkler heads the exhaust stack each booth. various points along the conveyor line, and also after final inspection, are repair stations where any work that scratched otherwise marred can removed and put through special process restore its original appearance. The fender painting conveyor 4608 ft. long and driven one 5-hp. motor operating 1200 r.p.m., with dual caterpillar drive. The motor connected OMING Out Floco Booth, Fenders Pass Along Bank Conveyor for Dripping Purposes. Bank inclosed room the floor which con- drip pans Reeves Class Type variable-speed drive, which turn drives two Jones No. double-type reducers from common shaft. The ratio the reducers This turn drives bevel gears directly connected with spur gears with shear pin coupling chain sprockets. The entire conveying system the department was designed and installed the Jervis Webb Co., Detroit. The special conveyor for the striping hoods was sup- plied the Chain Belt Co., Milwaukee, and the lacquer mixing equipment the product the Binks Spray Equipment Co., Chicago. For instrument boards, garnish molding panel units, the layout had made that parts could run grain, lacquer metallic enamel. This was made possible using the same combination ground color and primer for both lacquer and grain. Complete car sets are obtained within 3-hr. period. Parts are delivered the final body assembly line overhead I-Beam conveyor carrying crates, each which contains complete set garnish moldings, door panels and instrument board for one car. The layout utilizes 3166 ft. conveyor, and 32,248 sq. ft. floor space 4875 garnish moldings, 2700 garnish door panels and 800 instrument boards are produced 10- hr. day, with production increase 200 per cent and cost reduction per cent. | ses Universal Heat-Treating Unit Packard Plant Has Three Furnaces, with Pushers and Pullers Interconnected with Time Controls, Forming One Continuous and Automatic Outfit HREE large furnaces and quench tank, set straight line series, that the work can pass progressively through each turn, have been put into operation the Packard Motor Co., Detroit. Inter-connected conveyors and automatic temperature controls make this unit continuous and automatic oper- ation. can adjusted for four operations once such normalizing, heating for hardening, quenching and drawing—or can divided that one class work can annealed normalized being hardened and drawn. while ancther MANKER various units, all sizes work, from small forgings treated interchangeably. Parts being treated regularly this installation include front and rear axles, connecting rods, transmission gears, dif- ferential knuckles, knuckle levers, etc. That, this range size possible large axles, can steering steering due the fact that standard grid-type tray, alloy steel and in. the wide, used carry the work through furnaces. Only two operators are employed, one load the work the trays the charging end the first furnace the charging table altering the time cycles and temperatures the and the other reload the work comes out the 6190 OMPARISON HARGING End Shows the Advantage 140 ing trays the cor- rect position and of the Former All 3 1.30 drops them to the Except Very Low gravity conveyor Production Rate which feeds them + Day Hour Z Hours 4 ce 4 HUNDREDS CARS PER MONTH n al e The Iron Age, September 12, quench through the drawing furnace. The trays are returned, oriented automatically and passed into the furnace again without further attention. Packard engineers developed the conveyor System al ther end, well that between the hardening and drawing furnaces. The furnaces and the remainder the conveyor system were designed and built the Sur- Combustion Co., Toledo, Ohio. These furnace walls are made in. firebrick and in. insulation and ire held together with buckstays. cross section each furnace 6.5 ft. wide and 3.2 ft. first ft. long and the others ft. The furnace has eight gas burners close the discharge end, this the most critical point the heat treating tire directly into the heating chamber. the discharge end are two oil burners firing into tunnels, the length the furnace under the hearth, and with which the pusher operates, and this turn con- trolled Stromberg time clock. the discharge end mechanical puller reaches into the furnace, engages the trunnions the trays and pulls them forward. This operated the same time clock, series with relay correct for the time lag between the two movements. The puller used because was not found practicable put all the load the pusher. Work which normalized only automatically dumped, after passing through the normalizing furnace, the normalizing cooling conveyor, pan type. This carries along and then automatically discharges it, about hour, into tote boxes. The trays continue on, not interrupt the cycle for other work. The trans- fer made through chute which drops the work directly cient clearance for gravity drop the receiving end A discharging their products combustion through numer- ous ports. dividing the furnace into three zones—preheating, heating and soaking—a proper heat gradient obtained. Automatic temperature control located each zone and recording pyrometers are provided. Hot gases pass long toward the charging end, giving off their heat the cold incoming work, moving the opposite direction, thereby insuring efficient operation. Waste heat from each furnace discharged through vent the roof, close the charging end. the vent recuperator. Fresh air for combustion forced through the coil this recuperator, heated some 600 deg. Fahr. and then delivered the burners. Inspirators the gas burners regulate the gas-air ratio. Thus reducing, neutral oxidizing atmosphere can obtained will, and automatically maintained. Trays work are pushed through, pusher, three alloy-steel rails. This pusher motor driven, through link drive. The time the work the furnace controlled through the frequency 12, 1929, The Iron Age UTLET End Hardening Furnace, Right Side Picture, with Quench Tank Below over Conveyor Above It. The conveyor for bringing parts from the quench is at lower left corner | this conveyor commences point below the floor. may seen coming through the floor one illus- tration. If, the other hand, hardening follow, the trays travel along the conveyor which bridges the gap between the two furnaces, and into the hardening fur- nace. This roller conveyor ft. long, this distance giving the work the proper cooling before enters the hardening furnace. with the normalizing furnace, the hardening fur- nace divided into three heating zones, automatically controlled temperature. There are the same type pusher and puller. This furnace has ten gas burners and two oil burners, operating the normalizing furnace. the discharge end the work dumped through chute into quench tank. the normal- izing furnace, any desired heat gradient can main- tained. Dumping done unique manner. The trays have trunnion each end, the advancing side, but are supported the rails underneath. These rails end UTLET End Drawing Furnace. the quench chute and the trunnions ride another set rails the sides the furnace. the tray leaves the supporting rails upsets, swinging the trunnions from the side rails, and the work drops off into the quench. this point the puller reaches in, engages the trun- nions, and pulls the tray out the rails the pass- over conveyor, over the quench tank and the loading table the drawing furnace and places The 23-ft. dog-chain cooling conveyor foreground sufhces for Parts drop from into tote boxes and are then passed through the cleaning room air cooling receive the work again. The parts are brought this point out the quench slat-type continuous conveyor and operator reloads them into the trays. The drawing furnace similar the others except that heated only two burners. After the work has passed through the proper heat gradient, pulled out dog-chain cooling conveyor, ft. long. When finally the tray cooled pieces dumped, the work drops into tote boxes for removal the cleaning room. ISCHARGE from End Normalizing Furnace Appears Extreme Left with Chute (A) Normalizing Cooling right this conveyor rises from the receiving position and runs alongside the furnaces Conveyor. The Iron Age, September 12, 1929—665 ~ | | ‘ A i | q | | This conveyor then makes turn with the tray and ides edge and between two guide rails. This con- veyor runs the length the three furnaces and delivers the tray “turn around” conveyor front the harging end the normalizing furnace. the tray tipped over this “turn around” lies flat but with the trunnions pointing the rear. correct its position the conveyor, which consists two parallel traveling chains with Handling Steel Tubes into SING combination overhead carrying device and permanent stacking rack, steel tubes loads tons are handled from unloading platform storage and from storage point use the plant the Spicer Mfg. Co., Toledo, Ohio. The system was Cleveland Electric Tramrail, Wickliffe, Ohio. The permanent stacking rack consists, one photo- graph two U-shaped steel bars for each load handled. The illustrations show tubes such rack ing taken from the platform alongside railroad car and dropped position the storage pile. This method ndling permits intensive use the storage necessary. the same ana ecincatior il bove the other, and may operator does all the trans- porting from that point into storage and again out storage and into use. needs assistance beyond carrier running the standard overhead rail sys- tem. can pick and store carload tubing one-half day, and, depending « Raising a Load from Low-Level to High-Level Track 666—September 12, 1929, The Iron Age Picking Up a Lift from tween, makes complete turn with and drops down short gravity conveyor which feeds the load- ing platform the normalizing furnace. Production has been greatly excess that from the furnaces formerly used. The output this installa- tion equal that box furnaces, and two men only are required, contrasted with men the box fur- naces. Due atmospheric control, scaling and pitting has been almost entirely eliminated, and spoilage has been reduced considerably over the entire range. torage with One somewhat upon the distance has move the loads, can keep two men the car busy unloading and stacking the platform. One photograph shows the transfer between the low- level rail used the platform, which passes through the door, and the high-level rail within the storage and man- ufacturing building. The section which operated push-button control. Safety devices installed this equipment prevent the load from running off the section being raised and also prevent the load from run- ning over the end either rail when the connecting system not position receive it. pin and socket device used produce proper alinement between the elevating section and the up- per and lower with which functions. the doorway through which the load passes from the platform has automa- tic fire-door conform with Underwriters’ regulations, the section track passing through the doorway fitted with swinging link which operates automatically the contact with the throw-out mechanism. This permits the door automatically, case fire, manually, the end the day. Incoming Platform Depositing Lift Tubing the Pile a aterial Handling Applied Nitrate Chilean Industry Revolutionized Labor-Saving Equipment Much Nitrate Recovered from Ore with Sharp Cut Cost STERLING MERICAN material-handling machinery success- fully replacing labor, even where cheap. the Chilean nitrate industry, Guggenheim Brothers have introducd completely mechanized and highly effi- cient system handling nitrate ore and extracting the nitrate saliter. The new system operated Diesel- engine plant aggregating 22,000 hp., and all heat the engine exhaust gases and the water utilized warming solutions used the plant operation. The re- sult, compared with the Shanks system, which has been general use without any essential improvement since its original invention long ago, the recovery about twice much the nitrate contents the caliche the ground, with only per cent the labor, and about per cent the fuel per ton nitrate, and re- duction cost amounting over $10 ton. The story the great Chuquicamata copper deposit, containing per cent copper and considered utterly with- out value some years ago, generally known. The de- velopment Cappelen Smith the Guggenheim interests mechanical means for crushing and leaching the low-grade rock enormous quantities made Chuqui- camata the enormously valuable mine the Chile Ex- ploration Co. Old Practice Wasteful The nitrate grounds, where more than 100 nitrate plants were operating, many them loss and none with more than bare profit, invited similar develop- ment. The practice was break the caliche rock hand, haul the extraction plant small railroad cars mule carts, crush 3-in. lumps and load hand into shallow iron tanks, where was flooded with liquor from the previous operation. The broken rock and liquor were then heated steam about pressure and the liquor was actively boiled for several hours, until the greater part the sodium nitrate contained the caliche was dissolved. The saturated hot liquor was then drawn off into shallow open tanks and allowed cool for six days, which time considerable quantity the ni- trate was crystallized out. The cooled mother liquor was then pumped back tanks full fresh caliche, while the wet crystals were shoveled out the crystallizing tanks, drying floor, and left several weeks drain off the excess water. Waste was evident all along the line; the steam heated tanks were not jacketed, the crystallizing tanks were ex- posed the hot sun day, and the spent caliches “ripio” still contained about one-third the original ni- trate contents, that only about per cent the nitrate contents the caliche was recovered. Further, only about per cent the caliche excavated ever reached the plant, the rest being broken fine otherwise left the ground. Very slight use was ever made mechanical methods for handling the crushed rock; and, contrast with Ameri- can practice, there seems never have been consulting BUNNELL engineer constructing firm specializing the improve ment Shanks-system nitrate plants. Cappelen Smith conceived the idea constructing huge nitrate plant, using the identical system that had proved successful handling and leaching copper ore. tract caliche land containing about square miles, bout miles from the port Tocopilla Chile, the Maria Elena nitrate plant was built. The caliche rock located brought the crusher house 30-ton railroad cars, and dumped revolving car dumper. The rock crushed successively jaw, gyratory and Symonds crush- ers size about %-in., and the rate about 16,000 tons day. From the crusher house, the material transported long conveyor belt, which discharges tripper into movable vat-filling and spreading mechanism, carried cantilever bridge supported gantry railroad tracks, shown one the accompanying illustrations. The loader bridge can thus fill uniform layers any one series concrete tanks about 100 ft. square ft. deep. After filling with rock, the tank flooded with mother liquor, which warmed waste heat from the engines and circulates through three tanks succession, until its nitrate content built near saturation. The strong liquor then circulated through series coun- tercurrent coolers, the last which are refrigerated, that the nitrate caused crystallize out. The cooled liquor returns through the countercurrent coolers, taking heat from the hot liquor coming from the leaching vats and thus conserving all possible heat energy. The condensers the refrigerating machines are cooled liquor requiring heated. New Equipment and Methods Yield Savings When the oldest the three tanks the series gives the last its nitrate, cut out and tank fresh rock cut in. After draining the tank mother liquor, the spent caliche unloaded grab buckets from two cantilever bridges working together the same tank. The wet ripio, which contains only per cent nitrate, delivered hoppers the gantries supporting the un- loading bridges railroad cars and hauled away dump. The gantries and tracks supporting the unloading bridges are located the opposite side the leaching tanks from the loading bridge and constructed high enough pass over the latter, that the operation can proceed regular order from one end the row tanks the other, returning from tank No. tank No. the beginning the line. the large rock-crushing plant, leaching tanks and material-handling machinery, the equipment com- prises elaborate system pipes valves which any the tanks can connected into the system required, pump house with motor-driven centrifugal pumps, the countercurrent coolers, crystallizing tanks, handling The Iron Age, September 12, 1929—667 centrifugals and conveyor belts for the nitrate and delivering the loading platform, am- nonia refrigerating machinery, air compressors and ery complete machine shop with iron and steel foundry plant proper more than mile length. Power Scrapers and Shovels Employed for Mining development Col. Robert Marsh, Jr., suc- ful system using large drag scrapers and hovel ining caliche equally important inno- ition the Maria Elena plant. The practice the Shanks planis has been mine entirely hand, with isting black powder hand-drilled holes. The niner piles his lumps caliche for inspection over- seer, who makes crude test few pieces touching them with smoldering wick called “mecha,” and judg- the percentage saliter the emission sparks. Hand mining expensive and slow operation, requir- large number men, all whom must provided vith housing the cost the plant, the nitrate region desert incapable supporting life except such or- industrial communities. But the application shovels caliche mining was not easy. The lies irregularly distributed lay- from one several feet thick, generally overlain stratum which low grade nitrate-bearing and above that layer “chuca,” fine earth. Below the found rock containing ni- trate, and below this the hard packed earth known - 668—September 12, 1929, The Age Scrapers (A) Remove the Overburden Earth from the Caliche. Mining power shovels. The shovels load the caliche into steel cars (D) the track alongside. Trains are moved electric locomotive (C) operating trolley main lines and storage battery loading tracks. Power for the shovels supplied from portable transmission towers. Jackhammer drilling (B) prepares the cal iche for blasting There may thin salt layer above the ca- liche, and all these layers vary greatly thickness and distribution. only way ascertain the amount and quality the caliche digging holes through the various lay- ers, and sampling from the sides the holes; and the methods use are uncertain that customary apply arbitrary discounts, “castigos,” the official test cutting off two three points from the nominal per cent which near the minimum for profitable op- eration the Shanks system. Economy Payroll Pays for Mining Equipment The mechanical mining operation thus requires the stripping irregular overburden part loose earth, part rock, from irregular layer nitrate-bearing rock, generally less than ft. thick, and varying nitrate con- tent from perhaps per cent one point zero “ | | * . ~~ test hole ft. distant, perhaps again showing per cent hole farther on. the power shovel can- not pick and choose its material, but must take comes, was evident that the grade caliche recovered mechanical methods would average much less than the per cent that would obtained individ- ually hand-picking each lump. The shovel, however, would get all the caliche, the good with the poor, while the hand operation left least per cent the discard. The economy the mechanical mining operation would enormous, over tons would handled per man, against only tons hand. Computation showed that operation the magnitude planned the saving housing and welfare work reason the reduction labor force would amount nearly $4,000,000, enough ALICHE Rock Brought 30-Ton Cars the Crusher House (F). Dumped into revolving car dumper, the rock crushed successively jaw, gyratory and Symonds crushers. then trans ported long conveyor belt (G) and picked loading bridge (H), which distributes series ten concrete tanks (J). the treated with hot mother liquor, which, after becom ing saturated, passed through coolers crystalliz ing vats. Nitrate stock piles above these vats shown upper left. the middle foreground concrete tank partly emptied spent caliche. the distance (E) the rock 1S are Se =; to pay mechanical The system worked out Colonel Marsh comprises for the complete mining equipment. rectangular loop railroad track, crossed loading tracks which are easily movable. sampling test holes with much more care than was ever the practice with hand mining, the depth the overburden and the caliche are ascertained, and any patches worthless ma- terial approximately located, that the mining operation can skip them. The overburden, after being loosened blasting with black powder, using compressed air drills and electric shot-firing, removed drag-line scrapers and deposited the previously worked ground. Follow- ing the drag-line scraper, electric shovel loads the ca- liche, also loosened blasting, into steel cars the load ing track alongside. The cars are moved trains six electric locomo tives, operating trolley the loop track the yard tracks, and storage battery when the loading tracks. Power for the shovels carried overhead electric con- ductors supported steel transmission towers skids. When the strip ground alongside the loading track, the transmission tow- caliche has been exhausted from ers are simply dragged, hitching mule, new position, and the track picked up, steel ties and all, 66-ft. lengths suspension frame attached drag line hook. Thus short time the whole loading track may shifted new position, and regular work may seen town ing can proceed over the entire area. The Maria Elena plant, when put into operation, had = — eee The Iron Age, September 1929—669 | : \ | | | | | } | | | | — capacity; but the grade the caliche proved run lower than expected. The efficiency the extraction was, however, good that nearly per cent the saliter the caliche was recovered, spite the that the caliche occasionally ran low per liter content. should noted that the Shanks- system plants become very inefficient with caliche even content, that all rock running below per ded and left the waste pile. the inevitable operating difficulties new plant were smoothed out, the output the Maria Elena plant reased, until became evident that would have 500,000 tons saliter per year, and would re- about twice much saliter from given area liche ground would possible with the Shanks sys- besides working profitably material too poor for 9000 persons form the community Maria Elena; and this about one-third the number that would produce the same amount saliter Shanks plants, which would take four five the equal the output Maria Elena. Change Great Importance Chile the plant, with the successful solu- lt and } ; . ly +) and the expansion production double the original schedule, settled all doubts the economies effected the Guggenheim system. The op- erating managers Lautaro Nitrate Co. made many visits the Maria Elena plant and inspected its operations thoroughly. They studied the operating costs and pro duction figures, and became convinced that the Guggen- heim system outclassed the best possible Shanks plants. Negotiations were accordingly that resulted the control the Lautaro Nitrate Co. passing the Guggen- heim interests, and new financing for immediate con- struction 500,000-ton plant caliche lands recently purchased the Lautaro company and not yet developed with production system. The wasteful practices the production Chilean nitrate hitherto, which the best spots were mined first and the poor material left untouched, have resulted loss large proportion the nitrate lands already worked, and corresponding loss the Chilean Govern ment revenue that would have been obtained from the saliter. The development the unworked territory and large plants capable producing saliter low cost will great advantage Chile, strengthening industry that has been operating under great difficulties, and main- taining the revenue the Chilean Government from nitrate deposits, which are the principal source Chile’ national wealth. Importance Good Steel-Plant Lighting Systems NDER the conditions which now obtain steel rgan, Good light cheap—because great advances the art making electric lamps and shades and because the low cost electric power steel plants. Good light the essence safety—because 11 o see well to be safe. light cheaper most cases than the very floor inates; about the same both first cost and toilet and janitor facilities. good interior lighting system may installed steel works buildings for from 5c. sq. ft., depending upon the class work done and the amount light which that work requires. This system may maintained and operated for 2c. 4c. sq. ft. year, assuming that used the hr., which average figure. Exterior lighting harder estimate. existing and poles may used support fixtures and wiring, the cost installation about half that already given. The intensity used much less and the operating cost somewhat less than half, because practically never necessary use outdoor lights during daylight, whereas dark, cloudy day frequently requires artificial lighting interiors. Safety Conserved Good Lighting Good light the essence safety. Sight far the most useful, the keenest and the most important enses which inform obstacles, moving objects other impending dangers; and safety most often de- pends upon quickness perception impending danger. report accident causes concerned with lighting made every few years the Illuminating Engineering *Electrical engineer Carnegie Steel C« Edgar Thomson lant, Braddock, Pa From a paper before Association of Iron | il ng 670—September 12, 1929, The Age Society the Travelers’ Insurance Co. 1910 the re- port showed that per cent industrial accidents were due inadequate improper lighting; 1918 the figure was per cent; 1928 was still per cent, spite the vast improvement effected lighting systems. Better Output Where Lighting Good distinct gain production the usual result increasing the illumination, plants almost every kind, from “fair” that the present standards. reduction the amount “seconds” produced, and less spoiled material due the workman’s greater sureness eye and lessened tendency make mistakes, also usual secondary result. This conclusion the result tests made during the past five years upon shops and even entire plants before, and again after, bringing the lighting present standards. These tests were conducted some cases the man- agement the plant; others the National Electric Light Association the lamp manufacturers. The num- ber and variety tests, the fact that they come from many different sources, and their substantial agreement show that the tendency toward increased production and increased accuracy work with bettered lighting real and forceful one. quote below from several such reports: Light Intensity — Increase in Character of Work Old New Production Making babbitted bearings........ 4.6 12.7 15 percent Heavy machine work. 11.7 percent Manufacturing piston rings... 1.2 18 25 per cent Inspecting roller bearings. . 3 5 20 12.5 per cent good steel mill lighting system will have certain recognizable qualities, chief among which are: Adequate intensity light. Freedom from glare——uniformity. Provision for cleaning. Provision for turning lamps off singly small groups. > considerable We Ca a Shanks plant. 7 Good light powerful aid production—because men can and will more and better work when they can see We ll. | | q Classes for Open-Hearth Furnacemen Instruction Important Phases Steel Making Given Six Months Intervals Pays Big Dividends Improved Furnace Efficiency MARTIN BOUT months ago some careful computations were made contrast the es- timated cost various kinds fuel the open- hearth department the Lukens Steel Co. have basic total rated capacity 1350 tons, and six smaller acid-lined furnaces (total rated capacity 240 tons). the time the in- vestigation these had been fired with gas made battery stationary producers, using western MARTIN CONWAY coal. large running into six figures, could made the use the heavy oil avail able refineries Marcus Hook, Del., the residue after distilling gasoline and lubricating oils from crude petroleum. This was delivered motor truck and trailer via miles improved highway. (It may remarked passing that this method transport has proved entirely satisfactory; several trucks, each with trailer carrying 120 bbl. per load, are service. Costs are materially lower than the railroad freights—whether the latter are much too high another question.) appeared that Classes Instituted Facilitate Change Fuel Oil From engineering standpoint the change from gas oil was not without difficulty. From operating stand- point there were many chances for trouble, for none the first helpers melter foremen had ever run fur- naces with oil fuel. would easy for workman melt down the furnace ports with the short, sharp flame, thus causing greater expense refractories than the anticipated savings fuel. avoid such untoward developments, the manage- ment approved our proposal institute training course for open-hearth operators. were meet certain afternoon each week, immediately after change shifts. Melter foremen and first and second helpers for the en- tire plant came, their own time, convenient and quiet corner the storeroom, where benches, blackboard and other equipment were provided. Owing rotation shifts the instructors, who included the open-hearth superintendent and the fuel engineer, went over the same ground three times succession, and devoted one hour each week the actual work instruction (although many hours were necessary for preparation). Each man *Fuel engineer, Lukens Steel Co., Coatesville, CONWAY came once every three weeks until four lessons were given. all weeks were required. Model Furnace Used Advantage Aside from careful consideration the topics discussed and the method conveying somewhat tech- nical information terms the workmen could understand, the principal work preparation consisted building scale model the furnace, blocks, chambers, flues and valves. This was done the pattern-making apprentice, and the views show creditable job. The roofs furnace and chambers can removed, the interior shape and construction the hearth and checkers can observed. The blocks are also sectionalized that the relationship ports, downtakes and slag pockets can studied. One end the furnace was built illustrate the prevailing conditions with gas firing; the other end represented the way the new oil fuel would used. This model proved invaluable. Most furnace men think that all there their furnace above the charging floor—what they see their daily work. Many them, they think the checker work all, think vaguely that part the foundation, just under the hearth. Few indeed would able visualize the various flue connections, and able tell why certain changes should made the valves, flues and checkers cor- rect definite condition the hearth. After the “training course” had been organized and properly advertised all the men fell into the spirit promptly. Absences were rare. Close attention and active discussion was the rule. Ordinarily would talk extemporaneously for about min., covering all the points outline before me. Then the open-hearth superintendent would take about equal length time, developing certain phases the subject shop language, and illustrating his points with incidents which occurred recently the department. Finally the meeting was open for questions, either from the floor from the plant question box. the end the fourth lesson, each man was given copy the lecturers’ notes, neatly bound folder, and group photographs the model. Improves Efficiency Entire Plant Results have been gratifying, even hard measure dollars. The principal object was achieved, that the change from gas fuel 2-in. pressure oil was made without difficulty any sort. course the oil was put one furnace time, after the superin- tendent could sure that the melters were handling the situation properly. But the whole operation the de- partment took different tone. Minor troubles were less frequent, the average time per heat was materially less, the consumption ore and pig iron the finish was cut down, and the maintenance charges lowered. Summing up, the expected economies oil-firing were realized, even exceeded. result was decided continue the course this has been done The Iron Age, September 12, ™ > intervals six months. The broad outline the course remains unchanged, order care for new em- ployees, but emphasis placed phases which the plant records show need attention. For instance, the last course, particular attention was given bad boftoms, 4 Sectionalized Interior Form and Construc tion Can Studied accidental alloy in skelp steel, to proper manipulation ingot iron heats, and the economies melting correct carbon, neither high nor low. Outline Original Course I Furnace Construction KStavs ane bit W nd door I khead port (zg \ ), Slag} Ke 4 ngement of downtak for « firing rat funct Ze onstructic I d valve I e Onperat St n¢g ‘ Ma dott Du f fir ‘ ‘ } r 672—September 1929, The Age Qualifications first class foreman, first helper, second helper Repair furnace between heats Order charging Working period Judgment of temperature Tapping the heat esson III Making the Most Steel with the Least Fuel Low fuel efficiency the open-hearth process 2. Improving efficiency by a. Improving quality of fuel b. Increasing furnace output Burning fuel completely and cutting dow stack temperature Discussion principles combustion 4. Nature of producer gas and fuel] oil Atomizing fuel oil 6. Factors for success in use of fuel oil Influence of checkers: a, Cleanliness b. Period of reversal esson I\ Reactions and Temperature: Oxidation during melting stage 2. Slag formation with lime, magnesia and silica Manganese and sulphur i. Fixing phosphorus in the slag Ore and lime boil 6. Carbon elimination and its effect on slag Function addition; efficiency recovers Slight Adjustment Coupling Causes Failure Crankshaft will recalled that the second flight Graf Zeppelin toward America nearly resulted disaster through crankshaft failures two the engines. the time the trouble was attributed the fact that superchargers were installed after the first successful transatlantic flight. Tests have been made engines the German Testing Institute for Aircraft Berlin and, with the assistance Geiger torsio- graph, was discovered that, when the rigidity the crankshaft coupling was adjusted certain value, torsional oscillation the crankshaft occurred the regular working speed the engine. was demon- strated that relatively small alteration the rigidity the coupling made previous the second flight had been sufficient bring the critical speed within the the working speed. Bending Tests Concrete Reinforcing Bars bend test machine has been developed the Bureau Standards, which bars various sizes and shapes appear undergo approximately the same strain when bent through the same angle. With tests were made concrete reinforcing bars. Unusual tests for this class material consist bending the bars, without heating, through 180 deg. bar. The angle and radius the bend depend generally upon the size and hardness the bar. seems that the tendency suit the specification what the bars different grade will meet successfully rather than the service demanded the bars bending for use rein- forcement. the tests made bars purchased the open mar- ket the bureau, those which did not break the cold- bend test were not seriously affected strength the bending. The apparent yield point the bending test was much higher than the yield point determined direct tension test. The impact test used gave approximate measure the yield point the bar, but none the bars broke the impact test except few which had been quenched water from high temperature. 4 ~ Metal Radiator Covers Combine Utility and Beauty NEALEY HILE steel essentially utilitarian, many markets have been won and there are others that could won combining the utilitarian with the beautiful. The manufacture metal radiator covers ample large market that has been created com- bining the practical with the merchandising factor attractiveness. exX- the outset, well now, these covers were de- signed conceal the obtruding radiator, and sometimes Corner the Shear and Brake Department and, Above, the Enamel Spraying > . Wali eliminate for the air and smudge, but was necessary beautify them order them. far has this idea been carried out that interior decoration, woodwork finish and te ncelude a humidifier to sell the wall color treatments individual homes and buildings comprehend harmonious designs and colors the radiator schemes covers. While today there are many manufacturers metal radiator covers, the industry only years old. One the pioneers the Art Metal Radiator Cover Co., Chicago, which, addition holding major place this field, prominent the manufacture bathroom cabinets, clothes hampers and many other steel utilities. Radiator covers are made this company No. gage sheet steel, cut into proper sizes power shears and formed heavy brakes into the shapes desired. Punch presses are used for notching out corners, stamp- The Iron Age, September 12, 4 7 4 | a an | 3 ing out small sections, flanging, etc. Parts are welded DV spot and oxy-acetylene processes. All orders are grouped into schedules according to Hnichk ninisn, wood grain, marble, plain color, inlays, and 250 any one these schedules may carry from different kinds finishes. Any one unit may have rust detrimental finishes, all steel covered with oil, which must completely removed before the finish applied. Washing naphtha removes most the oil, the remainder being taken off mechanical sanders. The prime coat must elastic enough absorb any oil that may left. The cost cleaning some the grilled panels, stated, ofttimes amounts per cent the total cost. The prime coat and succeeding coats and enamel are sprayed on, long line booths being provided for this purpose. Each coat then baked specially constructed gas ovens, after which the coat hand rubbed and smoothed. The baking process one the most intri- cate the entire process the colors will vary with heat and time. When the proper heat cycle deter- mined for the work hand, carefully noted and faithfully followed for the rest that order. Seven gas-fired ovens are employed, each ft. long, ft. wide and ft. high. Swinging doors are provided front, and the work charged racks mounted trucks. Temperatures used vary from 250 800 deg. Fahr., and there also wide range heating periods. machine shop maintained for the making all tools, dies, jigs, etc. preparing for the manufacture recent model, was necessary for the shop make more than dies, which indicative the important part such shop plays work this kind. Superheating Cast Irons Shows Varying Improvement SERIES tests has recently been reported which the physical properties number cast irons were compared after each iron had been subjected three different degrees superheat. The original article was entitled “Die Uberhitzung von Gusseisen,” Peter Bar- denheuer and Zeyen, and was published Mitteilung Kaiser Wilhelm Institute fiir FEise nforschung, No. 130, Diisseldorf, Germany. Higher Carbon Irons Are Improved found that, with normal silicon con- bon irons showed improvement tent, the higher properties the superheat was raised from 1365 1480 deg. and finally 1605 deg. Irons with less than per cent carbon showed improvement definite mpairing these values. however, made susceptible superheating using high-silicon contents, adding part the silicon powder the ladle. Addi- ion alloying elements such chromium also increases towards improvement superheating. High-Frequency Furnace Used making the tests, high-frequency induction fur- was used melt and superheat the metals. For each sample period min. was allowed the Results of Superheating Cast Iro Tensile Analysis Ss h Deflec- Strength Per Cent Mi neat tion Lb. per 8,700 0.57 33,400 0.87 0.61 34.400 3.34 1.21 OSS 60 67 0) 0.28 40,900 2.79 1.82 1.05 68.500 0.50 37.700 >. 97 1.41 0.92 0 5 39.100 2.80 60 7 0.45 10.900 2.59 2.28 7 00 0) 43.000 9 57 2299 «60.97 70.500 O.3¢t 46.600 2.61 2.28 1.01 60.400 0.41 500 9 79 1.0 1480 60.000 0.37 000 273 237 1.04 78.500 0.43 $3,600 | 2.54 0.91 7,100 0.28 9,400 2.92 72,500 0 S200 2 ‘ Ry 55,400 0.41 1.84 0.55 1480 60.200 0.43 4,800 17 Bet 0.51 1A 69,500 0.47 40,700 16 1.81 0.57 12, 1929, The Iron Age superheating temperature, after which was poured into ladle and cast about 1350 deg. into rods for test bars. All the bars were cast dry sand molds. few the many reported results are here reproduced. Melts No. and illustrate the difference between the high and low-carbon irons. No. brings out the effects adding half the total silicon the ladle and No. shows melt very high-silicon iron. Both im- prove superheating. melt No. 18, 0.39 per cent Cr. was added, replacing Mn. spite the low silicon, this iron considerably bettered the high temperature. Promoting Dendritic Structure Harmful explanation the findings, the theory advanced that anything which tends promote dendritic struc- ture harmful. Presumably, the high temperature employed, all the graphite will dissolved. Con- sequently when the iron cools, there more tendency for undercooling than would the case were there few graphite nuclei present the liquid. Opportunity thus given for the sudden formation fairly large dendrites with interstitial network finely divided graphite and ferrite. The purpose adding silicon raising the silicon content with low-carbon irons increase the tendency for the regular precipitation graphite solidification. Great Britain Controls the Chromium Supply The source all commercial chromium the mineral chromite. Commercial chromite, however, contains from per cent the lower grades being used for refractories and the higher grades for steel making and the chemical industries. the early part the nineteenth century Maryland was the world’s most important source chromium. From 1860 until Turkish ore dominated the world market. Turkey was supplanted New Caledonia the period from 1903 1913, and, since the war, Southern Rhodesia has been the principal producer. The rapid development the deposits the Transvaal the past two years provoke some speculation whether not the Union South Africa will some day surpass Rhodesia. spective the relative positions occupied Rhodesia and the Union South Africa, the British Empire will con- trol the world market for many years, says “Mineral Industry, 1928.” | ] + | J Reproduced Secretary, Oliver Brothers, Inc., New York. Iron Age Courtesy Albert Catterall E