The Iron Age 1929-09-26: Vol 124 Iss 13

a THE IRON AGE New Y ork, September 6, 1929 ESTABLISHED 1855 VOL. 124, Ni Cas Sr - evelopment More Urgent Than Research = ¢ \ c Small Concern Can Perfect Applications of Facts Made Known by Another s Research [If Engineer of Sufficient Inventive Ability Is Available i T the time when engineering became a r ! tall formation f ! r all the profession it had but two divisions, nam entiones ! f knowledge tary and civil engineering. Civil engineeri eladed all tint was. known ahont cuwineerine But Development Has Made Research Popular scope of engineering soon became so large that it wa , ; wai 4 ‘ a ciate forced to subdivide. At the end of the eighteenth centur wad +t differ fundamentally: in their nature , machine inventions and uses gave rise to mechanical an thi fect thet these ie tivities are new. there al gineering. The rapid development in the manufacture eo 7 . ; re and proper pla of iron and other metals led to the differentiatio = oe - ' clea} unde metallurgical and mining engineering. More recent that ; , / responsil r the popularity of re velopments in electricity brought forth electrical engine: Ae » matter fact. research dite tes o clus ng, and wide application of chemistry produced chemica n industry unless thev can be profitably applied to mat engineering. turing. O ais an ste 1 applying tl During the last decade another differentiation in ar facts are 1 fundamenta fferent functions requirit entirely different plane may also be observed. I te : ,; fF, tion and different typ« on the /rind of ability required in engineering wo1 Phi sults of this differentiation are the occu — ’ it research, tl earch men” an development engines ne / r rtar ly rch engines he¢ ¢ ‘ { } devel pme I ner na passe i EDUCATION Storaae of Knowledae UNOS OF D - yy — t+ my ® F Ds i > Evrensive Recoamc {| o-= |_f : CXTENSIVE NESEARCH rm + le ys ! ‘ + 4 f ons _ ; , sigh koe ‘ tt Is = 2 2 IcaTion Unknown) © 2 a. >. O° D \ _— S az tagram Are q = & ; ] x : < v G he ualities D % 3 2 = | Fo) INTENSIVE RESEARCH | HE eee “O_-— + +- /S NILNO c Cc . : Sampee eT Baer RAS SH (Application Knows ws the Researc! 2 > — S “4 Oo) ‘ n Advance X x , ake — 9 be “\ — Advance) Man, While i oo Ss oO wv >) + cc oo r. +- A fy Cc a= a ne poe eee oe a ee tS ~ ey e e e ma @ Canis « cummeminianeian Semmimmaii at ohe Tins a eh @ =. q an SS —- the Lower Are o! — S LL \ c = ea o r-¥ z | RE DEVELOPMENT | ,. Phose of the De ao nm oO ae <** —~ ah (Tot iC Lc , fe Ee 0 perce tte P- Dt U Sepa 4 RES lOrind DeST OOl- velopome ot - o_o = > : ~ a U ' 4 Fi 4” > w = ~~? Se — c re neer =— oO 0 Pe u TION OT Known a = Yo Y 3 uve D> ' O- >< c C. esearch Data) 30 owe “& =; be TTY: bm {is € wi g 5 b** f \ + uJ Bete? Research Differentiated From Development y y é a y veer } f rar y y ’ viedo , ’ ’ 1 1e8 Ve ) ’ } y ) y } l ’ } ’ i eY Septe mber 26. the fact that research and technique, we have the outline of the kind of education ociated, and functions of de he must have. The present educational systems do not named research. Some have, produce engineers of this kind and there is no source of ndustry needs more researc] btaining them except by accidental selection. 1 elopment engineer \ no dificultic n supplving Mental Equipment of Specialized Workers wnile tnere are as ie diagram may help in understanding the subject we are discussing. It represents graphically thé veneral mental characteristics of the typical researc} man at the top of the diagram: note how they gradually troduced int ndusi from change into those of the ideal development engineer at il mply eans searcn —s the botton een supplying working material In this diagram the amount of knowledge of genera ELACTUVEr EOURG It PrOntAnee to physics is assumed to be the same, and is the minimur n his factories, he dist _ vee that any man engaged in research or development must id previously been conducted It have. The distribution of the balance varies with th: patons Sy wae vere in level on the diagram. Horizontal strip 2 taken in th marked difference be ipper quarter will represent a research man, highl entiie research ckcept im specialized perhaps in one branch of physics, with ver rh entine re on : om little engineering knowledge, possessed by little inventiv: mh paenomer neuire and ability but with highly developed faculties of investigat mmediate practica ng and generalizing. This type of man is best fitted t ther hand, industria! researc! lo research into fields of science, with no immediate pra pecined field with dennite pra tical application in view but with the purpose of expand ing the knowledge on which the industry is based, ex ; caer »y une pecting that proper application will be found in the futur nd nething that alw Strip 3, taken in the second quarter from the top, may vn. The function of PORSRTER . 2 represent a somewhat different type of research mar thing new. It may be a new His knowledge of theoretical physics is not so extensive; elements ne IDSA ' instead he knows more about engineering and he possesses er intormatior rs ae - some degree of inventive and investigating ability. H: en nerefore tne Penceons 0! s best fitted to do intensive research, where the appli- explorer, In- cation of his findings is known in advance. His work should best be confined to a definite field, for the im- U I mediate object of improving, cheapening, or extending efforts for exploring the the application of process or products. A man engaged rofound knowledge of the field n such work must know enough engineering to guide necessal The trainir r re his research in the proper direction, and must possess ' me a nat the nys yme inventive ability to apply in the best way the re tne bi ne rt el and ha sults of his research. research technique The present tion able producing a Development Engineers Are Inventors industry needs rh lower half of the diagram represents develo} eed of capabi en tor applying ent engineers. They solve industrial problems by a} This does not meat hat the re ving known research data. They do some researc! e of applying h findings f themselves, but their chief effort is exerted through thei appens to possess such an ability nventive ability. The diagram should have no precist rforn an at vhich in itself lemarkation between the research man and development rom researcn, and } be Col engineer, but we may assume it to be somewhere about word iInventior The distinction ne AA. Thestores of knowledge and the qualities of mind nvention lies in the fact that the are distinctly different. eu on mes int er Triangle BCD approximately represents the immedi r the mind lherefore, we maj ate financial returns from investment in research and enginee! n “industria levelopment. This triangle is similar to the one repre enting inventive ability. It illustrates the fact that both mvest research is of value to industry only as it is applied. Liat ul ertor? the I I n and the development engineer Small Concerns Can Do Development Work dustry the scope of each activity ) show the proper place of development departments a becon umeult and ake two examples, one of large industry with a con ten nh functions t me perso! Both iderable variety of products, and the other of small in nt departments may therefore b lustry with only one or two products. As mentioned above, the writer The former can afford to maintain research depart- nere difficulty ir roducing ents where both scientific and industrial research aré esent college done, because such industry, covering a wide field and levelopn tC engines ve ade variety of products, can usually get direct financial re- Lb which, it imed, turn on the research budget. There must also be a erienct een to sl that development department whose chief function is to find ige of general physics makes the best applications of the findings of research. This n than a physicist specialized in ncludes conceiving ideas of solutions or applications, re man who knows the funda experimenting, designing, constructing, testing and ad neering branches is better than an vising production. wledg f development The small industry cannot afford to maintain research 1929. The Iron Age departments and has to be content with published data ible information on certain nar? h of physics mati la ain narrow branch of phy This cannot be properly considered as a great hand s not always sufficient cap, because, as we know, all new findings of researc] Even a superficial observatior f irious industria become known after their first practical application rganizations strongly indicates the tendency toward which is never the best. Proper development departments lefinite separation of development departments from re | of any small industry may and usually do find better us¢ search departments, assigning functions to each of then f another’s discoveries. If this were not true, small as indicated above In other words, we are erving a industries with no research departments would pas it further differentiatio n the engineering profession; of existence; as a matter of fact, they do not. levelopment engineering now at the place where it Therefore, small industries with a limited variety of iting f attention from the lleges. Before the ce products should have development departments for th: ege in he ndustry, however, tl functions cha purpose of enlarging their sales, through the best a} terist f development engineering must be early s¢ plication of published research data The functions of forth, and the technique of development work must ery these departments should be the same as those in the tallize itself Then the eg vill be enabled t elect large industry. There will even be a little researc nd trai é f t rofe f development e1 carried on in a small plant because existing and gineering El 7 in P ectrochemists Meet in Pittsburgh YW ww XY > Annealing Brass and Copper—Symposium on Electrochemistry in | Aeronautics—New High-Frequency Furnace Described MONG its many successful general conventior the xides and no inclusions Crucible life with care can be annual fall meeting of the American Electrochen 0 to 150 heats on a single lining Practically no slag cal Society at Pittsburgh last week, Sept. 19 t 5 necessary The furnace is as nearly airtight as p: was one of the most important and most largely attended sible and ingots are poured straight from the furnace It was the fifty-sixth general meeting, held under the In cost and power consumption the furnace is ay auspices of the Pittsburgh section at the William Pem proximately equal to a 3-ton arc furnace Size for Hotel. Registration was over 250 with actual attendance: ize, says the author, it will compete in cost and produce at least 350, many not registering. metal of better quality The crucible magnesite witl , This society has an enviable reputation for the s lay bond. posiums it has arranged. This fall the feature wa ne In melting brass, the power costs are not so low as fe on “Contributions of Electrochemistry to Aeronauti the Ajax furnace. It has been used at the Westinghouss Nine papers were presented and the discussion was ampl plant for 2% years and has melted 1,000,000 lb. of bra Many new developments were brought out and future na graphite lining Highest temperature is 1600 deg | trends outlined. The symposium is reviewed on othe ( It has melted pure iron and deal for refining witl pages. ig Round table discussions of live electrochemical topix Electric Vacuum Furnace are also a feature of this society’s work. It originated S the result of vears of studv on rendering metal the first meeting of this nature at its Dayton, Ohio, spring A vapors luminous by “temperature radiation,” tw meeting in 1924. Another one, devoted to “Recent De types of electric vacuum furnaces have been developed | velopments in the Annealing of Non-Ferrous Metals,’ These were described by Arthur S. King, head of the was on last week’s program. There were also for the first nhvsical laboratorv. Mt. Wilson Observatory, Pasadena time parallel sessions on two days at which many mis Cal., in a paper “The Design and Operation of Vacuum cellaneous papers were scheduled. In all 36 papers were Furnaces with Carbon Resistor Tubes.” High temper ; delivered and discussed at five sessions Several wer: ture alone appear to be necessary to produce th yn the subject of chromium plating. large variety of spectroscopic phenomena observed No Furnaces for Velting and {innealing oe Poet nen een on et ce os ceo J ‘ ary The cylindrical and the hooded type f graphite S900 important subjects were discussed at the i resistor-tube furnaces each have a temperature rang: formal session devoted to electric annealing of nor ip t 00 deg. ( Steady ynditions of temperature ferrous metals. One was the description of a new high and pressure are quickly reached, after which the light frequency electric melting furnace and the other yme is permitted to pass to the spectrograph An image of data, offered as a printed paper. on vacuum furnaces the interior of the tube is projected on the slit, light fro with carbon resistor tubes. the incandescent wall of the tube being excluded The New High-Frequency Furnace charge in the tube aporized, and the characterists radiations f the vapor excited under closs ontrol of FURNACE was described for the first time D conditiotr A long column of uniformly heated vapor ’ P. H. Brace of the Westinghouse Electric & Mfg. htained \ 1 pectrosco] studie are described b East Pittsburgh, Pa. The smallest unit practicable for ees commercial size which can be used with 60-cycle currs is 750 lb., said Dr. Brace. In this new furnace as low Fuels for Annealing Brass and Copper as 125 lb. of steel has been melted at 60 cycles. Electrical T? pen the informal discussion on electric annealing efficiency is 75 to 80 per cent. It is possible to melt 400 f non-ferrous metals, Robert M. Keeney, Connecticut lb. per hr. of chrome alloys poured as ingots with a Electric Light & Power Co., Hartford, Conn., was s¢ power consumption of 650 kw.hr. per ton. In general, lected. Mr. Keeney presented a valuable resumé of dé . consumption will average 600 to 700 kw.hr. per to elopments in annealing brass and copper with gas, Due to the stirring action in this furnace, melted wood, electricity and so on alloys are nearly carbon free; there are no disseminated In the order of their relative use, fuels for annealing The Iron Age, September 26, 1929—825 Tor Bright \nnealing f26—Se;t 26, 1929, The ember Iron Age gas, wood tion of the local section under the chairmanship of Chur'‘ec: and wood A. Styer pe ? T ] but at a Seeing Tungsten Carbide Made \ ar¢ now LANT visitations ul ( The Westinghouss large delegation at feature of the Electric & Mfg. Co., were a convent n East Pitts luncheon and burg} j ed a con ected the irty through many of its departments \ l members made the trip to the Firth-Sterling ! Ste ( McKeesport, Pa., and were received by the t a re e! Lewis Firth, in his office. In the plant they (1) Re iw it eration one of two Ajax-Northrup high-fre- ( enc) irnaces, making a heat of high-carbon tool stcel nd a large 3-ton Heroult furnace, producing special too teels, and a ton circular tilting open-hearth furnacs ng [The Heroult furnace is located on the site of the second irnace of tl tvpe which was built in the United States ! 10S I} I mill were also visited. {OY LT the nost interesting daepartments was the one ere the pany produces Dimondite, a tungsten-carbid t netal Carbon, tungsten powder and cobalt ar a finest po cylinders to the r w+ . +} v\)° ] nt mall hy } x ir’ S tnen presset into STY Ll ) nel ntered Yr) cre 7 retrac b l r re } iroge! The mater eaiite the proper fort Mi + +} + +} tungsten- } t | ? tT? ‘ x] erimenta stage Sin i Next Convention | nowt > ant y r thy et A il hy ne pal Vay 1930, under the ne t elect ne { In that C1t' | nnu ny ) tne ciety Che n Birmingham, Ala rl riments were carried out with cast iron ( ! ! “ tr tne more n tant are a , that hi When reheated to between 700 and 750 deg. C., followed . to Mr a water cooling, the Brinell hardness of such iron r futur i m 228 1 130, whereas when heated to above 800 ‘ ( nt ge. CC, and cooled similarly the hardness increased witl Co., New the temperature of the treatment to about 270 Brinell ; \ ! ‘ arliti tructure was then evident. <A_ troostiti » ire appeared after a quench from 825 deg. C., and of eg. and above the structure was martensitic with give! i hardne of 477 Brinell ed Furth experiments with cast iron of other composi gir ! ed equally important constructional and me nz har chang. It was emphasized that temperatures to \ n ¢ high or t rolonged must be avoided as well as slow na ( ! is these conditions encourage the development of graphite, while if the re-heating is greatly prolonged me of graphite may be burned and replaced by ox \ les wl gr) a very fragile structure. T cast oO soften temperature heatings therefore recom are 4 ach cet I ar tas 6 4 < NOE ee ests er nose ieee Steel Treaters Study Steel Melting Slag Conditions. Electric Steel Castings and Melting Practice g 5 S and Locomotive Forgings Covered by Four Notable Contributions N both quality and attendance the special sc ! if ar { ! me ae e Ta I al Sept. 10 on steel metallurgy of the American Soci nd mination t n t ng for Steel Treating was highly noteworthy It wa nace ad ew be acti long th four years ago in the same room in Cleveland that t ( tance.” Be Ist ne not accustomed t vacuu first session of this scope was held, instituting a departu: I gy, the eration see trange Vacu melting in the programs of the society. The elevent National Metal Congres conducted | tt TES Fe Making Two Slags Suggested included this metallurgical session, whic} ence of nearly 500 to the ball 1 HH I neart rur! ! Ah tial eememacw of thn vantes end: the many a icing. a conditior ig il eat ile ‘ 1 | | ! ire given in the foll ! irag? 1. | . Slags Govern Steel-Making Processe s the re val ‘ . ne Ul furna PAPER which was pronounced \ everal menta rr ‘ t} thy. } it ’ new re ] ny iv ? tors as an outstanding contribution to the meta ' fiy r t} hea The all ect r) ft } the « t irgv of steel making was entitled, “Slagws Produced i1 Steel Making, Their Effects on the Product and or ’ ; y Tne y Process Itself.” by George A. Dornin. Gathn n | neering Co., Baltimore. } ’ ‘ Y ry n¢ Y na i Particular attention wa alled the author Ver I } } ! eal i nevitable flaw ind lack i ul rn it n | | n steel made by processes tha it | t I \ Y y i? t tee] i no ] ne under slags carrying iron oxid Slag e : . . . e y ‘ ry y y y tended, govern what the isic oper ' r t r ‘ } \ ' ipable of in making clean steel. h } ’ ry ’ nil ( ( ed I yn ly i roces i , ( le t? t { reauell cal 1u il | i ] } re y \ = illat ! eral . 1 : : 4 il nan ney i , ent ; \ ; ; , , R H Pate] Reduc ng lag ire not necessal I Wort I , | | A *} ce It but the finishing slag must carry 1 at ' e t ping. pouril iY ' conditior h fy eT t that the reduction of FeO in th t n t} ' ‘ ( IS¢ ne j ! er shed more cheaply in a large wa DV the 1dditior deoxidizer This must be done so that FeO not fi Double Slags Advocated and Rejected ictvU ‘ ~ iis i> ta ii , ic st A it with the slag. The aim is the reduct f FeO t i lalit tand nt, on f the greatest advar olid or gaseous non-metallics, the formatior f se tage f the ba ectric furnace the ability to mair 1 Ixing nor! metal cs wit! tne pp? r 1 r r wh } yr t ‘ u'ilit ty; } ‘ j ip the process and hence cutting dow! t “Give th tion and degasificatiot € the mete eile . basic open-hearth a chance—it makes about & el ent Thi the ' ’ f H. M. German. metallurgist. lI of the steel made. ‘ al Stes ( _ Bridg: ' Pp a tnat a dit Vacuum Melting Advocated ‘ nt onait y ‘ ; , Slag changes suggested nen-hearth practice. a y the author are logical, said Dr. H. W. Gillett, director Battelle Memorial Institute, Columbus, Ohio. The removal = |: OR Chairman of rel ed and replaced with a the Steel Session, refining slag. The basic open practice, a the ASS I Secured neartn plan f FeO dissolved in steel is suggested by Mr. Dornin, to . |} > ru > 4 ) ] analogou to the removal bi tne Services of Xaqd narate ¢ ste < le analogous to the remov: ) epara ne metal and ag clyffe Furness, Mid ine vale Steel Co., Phila and to finish under a reduc delphia, Who Has ng refining slag. foanibls Had Wide I xperience nd would re ' n hetter in Steel Making Ivy l, but , ether of certain substances from amixture. To avoid the necessity of self-fluxing o1 sa] agglomeration, “let us con der how far we can go to- - vard eliminating FeO by car- ear how he ' ( t on, favoring that by vacuum. eparate slag and meta The best possible reduction That the direction of product of FeO is CO, for this ; — ny ement of present pract The Iron Age, September 26, 1929—827 igs ehandlinge of steel, etc., was not greed to by J. H. Flahert For special purposes and to eet cla naitior nere na ilways be some ad- ntage I ( l ( ags, but because of yperating plication v r mited. For real progress ! rge tonnag of basic open- ents from fundamental re tion which rrelate laboratory find es and results. Typical of ° 1. He ind } associate IF. McFarland, Pennsylvani 7 © {) ia itnor does !t t st $1t1o1 ror tne non ns ¢ Ever } were initially ( FeO would be I I tne ange oO ‘ + . tuat y Th S I eD I I vould be s ib ect é I ugent Si, Mr r A ' nds Wem nd it is I in be avoided as r¢ 7 Double-Furnace Process Not Justified Always e sve a 1¢ ( n g fi 1 small furnace 4 4 l nace process I iS¢ ‘ DY t < T y Y P 2 1 th l - ed S EN Te etl applied in I ning ne te I astings must George Batty, 1 h director: Stecl Castings nt B Philadelpt } paper “Produc- t I ty “Steg for Casting enyr ‘ n tne itr I ne declared b t ser n the ordinat onditions ir I re é cont nate Vit! idhe ent 1 as art the charg n order that fine! et ( eanst ! the ith. Ther nevitable « ination of carbor To kill off f rn; ‘ ‘ ds ‘ — n the eit] ind nor desirabk { Gentle Boil Advocated } I electric melters believe +} \ gentle | l. rather than an excessive 1 1 { R 4 Bu airectoy } lectri ] 17 nh ? (; ] Ih Y r¢ "toy ide 1 too late lting 1 re ild be added later thar f aed Po? n casting me ld nditions than meta OY nted + i the ry y yt y ae mstock, 1! ta re Titar } Vi ( Niagar Fa N. %¥ Frequently it forencs sa hia .suee : due to ficiey l nide l usio? } ng caref n Y sper ey a T } Ss made ef T sion i] T T ? r ’ les roa { ow Carbon Favors Elimination of Inclusions ne of the views expressed, Mr. Batt; &28—September 26, 1929, The Iron A G. A. DORNIN GEORGE BATTY e additions of iron ore or limestone, except in ove! Pin holes are due to immigrant gases from ths How to Make Good Locomotive Forgings NOTABLE contribution to the subject of locomotiv: forgings was the one on that subject by Lawford H. Fry, Works Co., Burnham, Pa metallurgical engineer, Standard Steel Making locomotive forgings which will give good re- ilts in service necessitates the employment of correct methods from the melting to the forging of the steel. M1 Fry spoke of the various methods and precautions for accomplishing this, various steel making processes, and ingot The forgings, and were discussed, as well as the Physical properties whicl nay be expected of steels were outlined. mportance of structure. forging press and ie resulting structures of steel various . - ypes ol forging steels for heat treatment. Problems of producing and handling forgings so as to give constantly better and more reliable results in loco- motive service concern both metallurgical and mechanical engineers and it is only by the fullest cooperation between producers and that made. In hoosing any of the special steels in an attempt to correct definite type of trouble, users progress can be as for example, axle failures ecurring in the journal, all phases of the problem must e considered. If the failed axles show thermal cracks, it evident that lubrication has been faulty, and it will be for engineering to correct this service condition by me- hanical methods rather than to attempt to find some pecial steel which will operate successfully under un- essarily difficult conditions. Locomotive forgings must encounter rough service and ecasional abuse. It is to meet such conditions that the pecial normalized and tempered steels are being de- » eloped. It is now a question whether it is better to us« ’ eel with high tensile strength or with high ductility Both types are being tried. Time will bring further nformatior Accidental Loads Serious Discussion of Mr. Barr, Fry’s paper was consulting chemist, Union Pacific prolific. WwW. M Railroad, Omaha, Neb., said that discussion was not necessary, only em- phasis on some points. ings shor ks due Accidental loads on modern forg- caused frequently by to the breaking of parts. the highest quality of steel obtainable. become enormous sudden There is need for The finest forg- s rep ighveeeelaanctea eee aa N. Y. Most forging blooms i¢ are satisfactory and acid steel is not always the best. Penetration of the heat is equally important with the temperature in heating forg ings. Epidemics of axle failures are due to improper lets and lack of lubrication klectric Steel Melting Practice N excellent pape n electric steel melting pract Mw was that by H. P. Rassbach, Midval Steel ( Philadelphia, entitled ““Melting Practice for Three Ty} if Electric Steel.” Krom the practical standpoint the melting practi r piain irbon, mpl i \ ! nplex alloy teel discussed 1 nerete example In plain carbon eel the carbor nter I ne hare hould be fairly close the desired carbor n a chrome nadium o1 ! ! neat, tne naryge I ild contal i muct r the de re lloys Ss re ivallabDle tron the ral ! nat t f whicl in be recovered by rope contre I high-speed steel heat the same true In spite of tl LAWFORD W. FRY high alloy contert, the slag in this case can be deoxidiz a to a high degree Melting practice and logs of the thres ae —=* ypes of heats are thoroughly discussed. In general, bat} temperatures should be hot: cold heats often give troub ings can, however, be ruined in machining. “Select your F . “ It is wood practice to tap hot and hold the neats in the steel maker as you would your physician. . ¥ ‘ 7 ' 1 ¢ : : adle for a sufficient length of time ool to the Vanadium increases strength and high yield ratio a well as other properties, claimed G. L. Norris, Vanadium Mod Corporation of America, New York, as controverting the ; low to high voltage were called to attention by H \I « we « . > « ‘ -eortai steel] ) < te orb nro? e ‘ ‘ } ] > ‘ . author’s statement that a certain steel owes its high proy German, Universal Steel Co., Bridgeville, Pa. Some erties to the manganese content. his experiences in this phase Effect of Banded Structures nee ee Restingry owtimes. Those in attendance at this steel metallurgy session There was considerable difference of opinion as to th ibout 500 in all, were fortunate in having as chairman effect of banded structures. Mr. Fry said that 75 per Radclyffe Furness, of the Midvale Steel Co., Philadelphia cent of plain carbon forgings have this structure and that a pioneer authority on steel melting. The meeting w a high-temperature anneal will remove it. Robert Jol f Montreal, Canada, declared that such structures sh not be present. ttingly brought to a close by a few remarks by him ould Mr. Furness said he could never feel that the ba ypen-hearth can produce as good steel as the acid. Slag Macro tests are best suited to determine quality of hanges do not take place at ones The electric furnace alloy steels and others, in the opinion of E. L. Edwards a wonderful tool; with it on in do things that seen chief metallurgist, American Locomotive Co., Schenectady, most impos le . | * + + sures ry Flaws F Rails by Explorat Fissures and Other Flaws Found in Rails by Exploration BY ( W. GENNET, JR ODERN rails consist of a hard and almost brittl ture, crack, which grow into a f ire The onl ‘ steel rolled into a peculiar, unsymmetrical se thing that apparently every one agrees on is that fissure tion. The steel lends itself easily to heat treat develop or enlarge in size, under continued traffic ment, meaning that widely different physica! characteristics oe : i Defect Probably Originates in Mill can be easily produced by simple mean The unsyn metrical section, comprising the large mass of head metal It appears to me likely that the mill fundamentally, and the thin web and base, is such as easily to acquire it quite unintentionally, to blame; for seemingly some internal strains of an unusual extent. This combinatior ondition must occur during the fabrication of rails that is unique in rolled steel products, and it must not be introduces certain peculiarities in various rails from whicl surprising or disappointing if metallurgists and phys fissures later d A } iy i ic velop. Exactly what that evil condition may icists fail to solve quickly all of the problems raised be a highly speculative matter, for, after all, compara concerning rails. tivelv little i ¢ ely little is known of the actual causes for various ef Any discussion of the cause of fissures amounts t fects that occur in rails mulling over the evidence collected, first, by those who For instance, just why should two or three blows of regard the cause as due to a defect inherent in the rails a spike maul on the %-in. web of a rail be apt to start when they leave the mill, and, second, by those wh a crack in the web as service continues? Why is a stand by the metal, but allege that the traffi ver the mall nick in a piece of steel invariably a bid for a break rails is really the actuating cause for an interior ruy later on? These may be trivial questions, but I mention them by way of showing that not only may fractures *Vice-president, Sperry Rail Service ¢ come from trivial causes, This is taken from a paper read before but that the attempt to locate ers’ and Maintenance of Way A t f A tk : ie definite cause of some fractures may often be com The Iron Age, September 26, 1929—829 r ! é ind wnat } t } i ‘ i? é f es I l y y y ‘ y tT + } ‘ y tioy @? ) ? } y y t} ? , trys } ? a Othe rypes of Defects Now Locatec é£50—September 26, 1929, The lron Age rossing, where planking quite shielded the complete rail section from view. There the detector car told of what proved to be a serious crack several feet in length at the junction of the head and web, and which I think it will conceded was nearly as hazardous as a fissure might ometimes be Quantitative Results on “Bad” Track Generally the detector car has been assigned to te suspicious track, meaning track presumably containing fissures because of experience and records. Results fo practically 1000 miles of tested track occurring on dif ferent lines, with different kinds and ages of rail la inder different track conditions, showed 116 transverss fissures, 66 horizontal fissures and 234 other defective rails. Thus there was one transverse fissure in every miles, one horizontal in every 15 miles and one othe id rail in every 4 miles, totaling a defective rail eve [To me the alarming phase of the whole situation th respect to the number of fissures and othe defects found, but especially with respect to the size of ( f the transverse fissures located. A great man ire taken from track and broken immediately that the detect ocates a fissure. Thus the awful naked trut often revealed, and hence the frequent surprise tha the defective rail gave safe passage to the last tra Van. i tne nssure found are bright and shiny, “al ght,” 5 tney are called, ana acK ONLY a littl Lrol ne he surface, vet they are ften larger thar llay n ar and unquestionably must reduce tl trength of the rail most seriously. We have found then chiefly during the warm or hot weather, and whether a rail containing a large fissure would have carried the iast tral sale ly in the cold winter weather is indeed a This naturally raises the question of how fast fissures or’ (On that there n re ible data at all, but Ve know that under ordinary conditions of traffic the growt! faster than supposed. We have reason, from i ases, to think that fissures may read e within 60 da of normal traffic, but t! irel\ a randaon statement ea subiect to chan: DD Jame KE. Howard, whos tatements must alway e @ ! e greates espe ! ae in air-tight fissun grow to tl irface comparatively few blows of ght hamme1 Tests are badly needed so that a rule « il formula can be established and, based on the nun r of to f trafi son dea obtained of the probable at { { Removing Magnetic Materia! $s from Conveyor = 1, 45-in. electro-magnets specially : wound for continuous operation are \ shown in the illustration. They are sus- pended over a conveyor belt at one of the Montana plants of the Anaconda Copper Mining Co. They were furnished by the Ohio Electric & Controller Co., Cleveland, to pick out all iron and steel particles from the material moving along the conveyor. By so doing they save the machinery from injury. \" ne er ee 5 | Should Scrap Brass Be Used or Sold? C p Ass DC Sed OTF SOIC: Institute of Metals Discusses Economics of Reclamation of Copper, Brass, and Mixtures of Babbitt and Bronze GROUP of papers on secondary metals feature ’ . na es, and the enti peration 1 the program of the Institute of Metals D a le? techt 1 perv ! \ it 90, the American Institute f Mining and Meta f er wil ire ma la lurgical Engineers, held in Cleveland during Sept. 9. Such concentrated attention in warranted by tl Should Scrap Be Used or Sold increasing tonnage of used but still usabk illoy hic H{ ui. S J n. cl f metallurgist Det { ator ¥ are circulating in the metallurgical industries, and by t} ( Detr na paper entitled “Ut i : dal greatly increased amount ot trained technica Ww I Vet n the ted Bra indy iivanced the ninior being employed in the reclamation process, act t] t e equa le for a te ‘ four having been frequently commented upon in past an t eh grade pre ir tings from reclaimed THE IRON Aart etal, ever ight in the opet rket ih a pract However, not all the problems have ( ( ever. to examine } rav ateria with any means, aS Was developed n tne discu ! t j ipu i} juty WI I int ( il vne! ne asting program directed by a committee of tl \ et 1 t got f) 1 reputabie Society for Testing Materials. Tests report ( { npar In Mr. St. John’s opinion tl portior dicate that small traces of tin, lead, and cad I reir e} vould dit vy be t il nix the permanency of zinc-base die casting t t { fe,”” functior prima to enhance lisproportionate degree. The result that luidit ! t} ind cheap Vay f doins tonnage of scrap castings is now available bu t th buyers, even though the selling price may be it 1 f . for ( ‘ it \¢ { ent of the original cost of the component met iff t pel hou l t in the raw tate; son q , I). L. Colwell, metallurgist Stewart D ( tit ( ! f tor ne nd melting dest1 poration, Chicago, is of the opinion that the market f . | ea that ellaneou e castings can be expanded four fold when the indu tal for direct foundry use, and thoroughly appreciates the effect of mino1 rit ist | bsorbes 1 smelter of secondary etal \ | a the properties of die castings, and learns how t S| etallurgist Bol Aluminum & Bra Cor interact the danger of salting. it Det t, pointe t that 1 \ Wire Bars from Secondary Copper sacs - cca aes ; oe ies \ similar problem has been solved at the Western etal ipply, the complex esidue ld nly be re Electric Co., where wire bars of good drawing qualiti 1 int isabl hape for a dis} portis te ! ind standard electrical conduc tivity are made tron | re ed { vire reclaimed from obsolete telephone equipment, he hairmar f the meeting, T. A. Wright, chief ne wire, and wire-mill scrap. The operation was de he t Lueiu itkin, In New York, said that tl y W A. Scheuch and J. Walter Scott, metallurgica ffect was bel: felt already, for the manufacturer f engineers, Hawthorne Works, Western Electric ( . I be { I ngot ! VY torced ft end 1 a meiter many ago, in a paper entitled “Manufacture of Wire Ban rol rload f ! d scrap because it ntains an un Secondary Copper.” nageabl ntent of some minor metal W. F. Graham, Lead is the principal impurity to be contended with; it O} Bra ( Mansfield, Ohio, also doubted whether enters through wire ends covered witl older not foundrie hould attempt to make their own ingot from arded by the sorters. Every effort is made to keep it etal a1 tl mpete with an established in it of the charge, but melts will commonly analyze 0.01 lust hw an essential adjunct to the foundry per cent lead, and at times even as high as 0.1 per t trade (since ir pinion all red bra melting st This must be removed to 0.005 per cent or | ( e f the ingot) He was ready to admit that a good ! re than this retards the necessary annealing pe tor I nat ] t M mt Joh Va recommending : yn the fine gage wire to be produced Lead ! t t ight tl 1 cost would in nearly every case ated by oxidizing the furnace chargé oug e hig f up a slag with equal parts of lime rock ar ind, and ( lipped to melt, n ind refine the metal properly. lowing the bath with air. This is repeat ] Mixed Scrap May Be Smelted in a Cupola lead is shown by chemical ntervals until the ve reduced to the minimum. Nine hours ! lr paper entitled “Reclaiming Non-Ferrous Scrap reduce 0.030 per cent lead to 0.003. Met it Manufacturing Plants”, Francis N. Flynn, m« Success is ascribed by the authors to severa tor illurgist, M iukee, als ipported the idea that intel ‘ ic! ind SpensSandle I rat the Scra - r rré t T iT T t tre DY? ce ra;r A ‘ ! nly ele scra} opper i harged S r tl ‘ re f elling it all furna s solidly built with magnesite ' f id, t i deale Mr. Flynn t the ttituds ent salting. Third, ample burner i r i g irtment } f the name would x d e tne charge tr roughly auring ‘ I ! a nab precaut I Keep tne rap eal e th is manipulated according to the i nd prepars ! r for use ir h a manner as t The Iron Age, September 26, 1929—831 — separating hres September 26, 1929. Im pol fant The Babbitt f/uminum T> Iron i From nd Their S { ni ' i } ‘ nee ne a nt n ~ {llovs l VW B Ame? y | ‘ hs ey y ? y [ al y \ | eng ir The \\ ‘\) bronze a table ‘ rf ¢ anutactu y} } { Alloys i bitting Operation.” g and othe emperature in 1 igh-tin alloy cleaned < emailning In general of zinc metallic wastes are “sweated” or heated at by agitating tin-copper alloy i the skimmings, boring a reverberatory furnace and the resultir with stean is added at least f virgin metal to bring it to specificat t eady to cast Into bearings Residues from sweating operations and other dr i vit arbon in a reverberatory furnace, tl ! eamed out and the remainder freed from ox ind non-metallic inclusions by fluxing with sulp osil High lead is reduced by dilution. Borings ar irning mixed Dabbit and bronze from finish nact egregated usS¢ fully DY screening the bal ‘ ( generally coarser than the bronze and may be treated as above while the fi: ! ng may} e absorbed DY the bronze foundry ! h on a favorable market R. W. Drier, Michigan College of Mining and Ts Houghton, reported that a fairly good separat d bronze or brass could be made as follow G1 1 the xture to a uniform fine size and make a bal entrate by an electrostatic concentrator, usin; irre! sut 30,000 volts. The brass tailing can the ned very well in a small flotation cell, and tl due iri and returned to the fn Bright Future for Beryllium Prominent airman, i allovs, the ver \ tainable in aircraft eng All moder dirigibles tne Zeppelin, the ZMC2, and the twe nde1 ruction for the Na wrought alloy And aluminum ded] mportant to aircraft becauss affore iwainst sunlight, moist Bossert, Dr Emphasizes Application of Aluminum anc depend on this lre ana eronautics | 4 Los Angeles, Gra mammoth ones 1 aura pronze powael of the protect 1or 1+ Sait water. feronautical Men Speak B: FORE ealling on Mr. J. D. Edwards tant director of research, Aluminum Co. of Ame} r ’ ° mphasize¢ the appropriateness of such posium in Pittsburgh, where the aluminum industr ts birth in 1888 as the Pittsburgh Reduction Co., and re 11 years, great progress has been made. He ty was honored by the presence of met e! n aeronautics—E. P. Warner, formerly as nt secretary of commerce for aviation, now edito ind Dr. Lewis, director of aeronautical ré National Advisory Council of Aeronautics Bot ends of te have been from w nat? t licensed in this ? ? y @ALUTIII y ever, 3500 tons country, + L really aictate ! ost of fabrication ther things consi dilemma confronting production 1s one one tl + \ j aluminum alloys is are ered, the really he alloys in wing or ood ft only ») to metal in on, said Mr. Warner. In the 5000 airplanes ( onomic alt per cent ar fuselage construction lanes aluminum wing spars predominate. | ? Saving I When metals are chea} industry may be sol solution. session of this serious ived society to such a su Weight the most important factor now facing the industry—th« Lewis. ject was a great gratification to Dr. aim is the greatest carrying power per unit of weight Corrosion problems are serious. An engine now ha ife of about 1000 hr.—it should have more. T oad is about 20 to 30 per cent of the weight of the \ lighter, stronger material is sorely needed. Magnesium Mainly Used in Fabricated Form Se lighter than aluminum, magnesium is used mainly in fabricated forms in aircraft If ar iluminum casting weighs 30 lb., one of magnesium has weight of 20 lb. magnesium has By alloying, as in the case of aluminun been greatly improved. The alloying elements are aluminum (about 7 per cent), zine (about per cent) with some manganese and cadmium Sur alloys as castings possess mechanical properties substan tially equal to the best of the high-strength aluminum } alloys. Alloyed with manganese, remarkable resistance t rrosion is obtained. Machinability of magnesium alloys in general is an outstanding property. Magnesium forging are no longer experimental as they possess comparatively igh mechanical strength. Propeller blades, differing very ittle from wood in weight, are now made of magnesium Harvey, Alu minum Co. of America, Cleveland, in a paper, “Magnesiun ind Its Alloys.” Magnesium alloy propeller blades look very promising, aid F, W. Caldwell, McCook Field, Dayton, Ohio. Th relatively high fatigue values look good—there has beet 1) illoys. These facts were presented by W. G trouble with aluminum alloys. An advantage for mag nesium is a stiffer blade with less weight. Comparative ost was stated by Mr. Harvey to be at about 1 to 2 He also said, in reply to an inquiry, that sheets are hot-rolled first rolled to a finish with frequent annealing because hat Dlilets, and then from dening during cold work is a property Beryllium Has Remarkable Properties Beryllium’s outstanding property is its high modulu declared Dr. H. W Institute, Columbus f elasticity, about equal to steel, Gillett, director, Battelle Memorial Ohio, in a paper, “Possible Use of Beryllium in Aircraft Construction.” This metal will some day be an in portant factor in aircraft construction. The factor of ignorance is high compared with the 40 years of aluminun levelopment and 20 years of magnesium. Its specifi gravity is of the order of the specific gravities of alu minum and magnesium, its melting point is very hig! \ oys high in beryllium have a tensile strength of 100,000 sq. in. in the direction of rolling, and 70,000 lb. ac the direction of rolling. The metal is very hard to work and requires hot working all the way down. As casting pure beryllium and its alloys are hard to handle; the At $200 per Ib. it is out of + +} reach, and yet the metal is more abundant in the ear isually contain blow holes. crust than either lead or zinc. Cost can come down Zay Jeffries has said that it rt} $40 to cut the weight of aircraft one pound. “Many are S$?5 to $50. Dr. pessimistic on beryllium; I am among the many oy] said Dr. Gillett. An entering wedge abroad has been made by bery ium said Dr. Engle. The German firm, Siemens & Halske, mists, s making 8 lb. per day at $100 per lb., and a berylliun —$_$_$_ ~ yronze (2 per cent Be.) is now used by German railroad It has high fatigue resistance. Solution Potentials of Aluminum and Corrosion URE aluminum is electro negative to many alloys and particularly to 17S or duralumin. This fact is of importance in connection with the protectior f exposed edges on duplex metal products, such as Alclad sheet, said J. D. Edwards, assistant director of and Cyril S. Aluminum { of researcn Taylor, physical chemist, nerica, in their paper, “Solution Potentials of Aluminum vs in Relation to Corrosion.’ The potential differences rising fron ntacts between aluminum and its alloys, iS Well as ther metals, in the presence of an electrolyte, ( theoretical interest and practical importance Al gh hese potential measurements show such wide ations that their quantitative significance is limited, ualitatively they are important in explaining the be havior of the metals in contact under corrosion ¢ 1ditions The factor of ignorance in this field was large in 191 uid Starr Truscott stant to Dr. Lewis, who spoke arlier; today it is much less. The aim has been and 5 ne 1! ng tor i I gy meta Wit! wi h to build rigibles Tender now away from wood to metals Piating ninum a wit hromium has not beer ntirely ssfu it it should be considered—it doe 1iot protect as does ne on ster “ appreciate the great ! nat electrocnen ts nave ione tor aeronautk Electroplating Aluminum on Steel Calling attention to the following sentence from the 1uthor’s paper “In general aluminum can be ifely used n ntact with iron and steel, and the tendency is fo1 protect partially the iron and steel against rrosion.”” Edwin F. Cone, associate editor, THE IRON AGE, New York, reiated an experience. Some months ago called to the ‘ attention was claims o ompany tha t was plating aluminum, or an alloy of aluminum, on steel sheets,—offering a substitute fo tl? Late f I ! I ISé€ Sample f the ted nee vere ent ft research iboratori Reports are not complete but are nflicting \ majority state that a very thin layer of aluminum i resent while I re rts an entirely different metal Mr. Cone raised the aquestion—can aluminum be electri tically plated ot ~ Ly | ( Frary, pre dent tT the ociety, aid that aluminum cannot be plated on teel, although there ars il patent for plating f1 iqueou solutior The nu l¢ es water, hydrogen is evolved, pre enting succeé I plating Dy William Blun sureau Standard tate that ab t 2 ears ago a man took a ! eo late the yme rf ne Cit Hall tower it Philadelphia, with aluminun the result wa i iting f Irom the alle f lentil ised Attention wa illed to the fact by Dr. Colin G. Fink lumbia University, New York, to the fact that large il nt I daium are electti vt cally plated or deposited nan aque l itlor and he added that there is n more action than in the case of aluminum. The sodium s deposited on or with mercury and then recovered fron I imaligan DD H. W. Gillett offered the iggestior that the coating be examined with the X ray, whic vould reveal whether it is a covering of metal or oxide et Mr. Cor aid further examination would be at npted with a piece which has a heavier coating lr Ger! he ided, thin eets of aluminum are nov ed or sweated on stee! American chemists have plate the metal from expensive organic salts of aluminum Other Papers in the Symposium LUMINUM ean be given a pleasing dead-white finish by boiling it in a mixture of lime and calcium sul for the product were phate. The process and a few uses discussed in a paper, “Lime Process for Coating Alu ninum” by Leon McCulloch, research department, West nghouse Electric & Mfg. Co., East Pittsburgh, Pa Two other papers presented at the symposium were Iron on the Magnetic Ralph B. Mason, search bureau, Aluminum Co. of America, and “Therm« Electric Tests for Aluminum, Susceptibility of physical chemist, re Manganese and Other AI ys,” by Cyril S. Taylor and J. D. Edwards, research ireau, Aluminum Co. of America. The Iron Age, September 26, 1929—833 utomatic Thin-Sheet Arc Welding Electro-Magnetic Control Necessary for Good Results—How the Flux Operates and How It Is Handled W. L. WARNER 4 rs . t rts 1 né f the weld An arc is struck and maintaine { { i le ! tlor ! ertal! tween a metal electrode and the joint edges. This th nt t f tl moved continuously at the proper speed from one er t nt to the other, fusing the two edges togeth h the fuslo1 It is essential that the joint be backed up tight I ! Ul e mi that I some means to prevent the molten metal from runni through forming protrusions on the back of the }j t tweel rts ft ind also leaving holes in the joint. This backing up d n time lepending on the nature ce must fulfill several requirements. The material mu t nd the eff heating tr e of such a nature that it will not melt and fuse to tl = : Slain ( per bar stock or strip is generally used for t ul nf acking, due to its high heat-conducting properties ar M4 s _- = r 4 4 v . . >> 4 i ' x _ t, zo) + e , Y 7 > L. ,. ns 5 J ee. ; é re r ve ir t Flow co . ° ; \y 1A i a ¢ y ies ‘ > 0 eee — : = L +. a 5S 7 a4 ae ec x - iq a : 7 . . . J yd BOVE Is Shown (Fig. 1) How the L g — ee i Magnetic Pull Operates on the Arc 4 = on — ‘Y rr -r- - a nag Se) JP ‘oe wer , When Butt-Welding Two Pieces of Plate. — af. centage . ¢ age ———_——_, . - — - ee. ee \* ———ee At Lett (Fig. 2) the three magnetic fields . ee ee: ure traced, which are set up by the arc : p Mogne 7 ' in doing its work nstan lurability for this service. The backing up device must wing to ( mewhat flexible, and yet exert sufficient force t , te) t ns; the metallurgist wi When heat is applied to steel or iron, a distortion « \ accust ed t lacement occurs in three directions. As the heat together by a row of s removed the material tends to return to normal. The tnat t tt { int of this expansion and contraction depends upo! k mus M the rate of application of the heat and the length of me over which it is applied. ent In welding, an intense heat is applied at a point or and l laily rit Tine t } netal surface and is then moved rapidly along, caus ore the nt ng a sma