The Iron Age 1929-10-24: Vol 124 Iss 17

; o3 i 4, Cy Y cz New Y ork, October 24, 1929 ESTABLISHED 1855 G™ Studies on Migration of Industry EVERAL months ago studies were put un- Industrial Methods of Communities 9, "Wee thumb method der way by the Policy- : . ther causes of unscientific ee —Reasons Underlying Location or a “s the Metropolitan Life In A ae : . : he inadequacy of present ee Relocation of Plants—Growth in sont oe with the Civie Development ’ > Poa - cnanyved nait ns Committee of the National Smaller Cities Merge? and consolida Electric Light Association, t ms are doing a great dea with the object of determin- { } +? bocu ittention on propel ing the reasons underlying movement of industries from atior Keen competition, foreign and domestic. ha one community to another and from one gen ral area of aused industry t eek the lowest pi ble costs. both in the country to another. At the same time, the location of production and in distributior It is realizing that strate new industries within given areas or communities wa gic locatior in important factor in lowering costs to studied, as well as the reasons back of the losses, sus the consume} tained by certain communities, in the industrial fabric of Industrial relocat ) nce the World War has had the country. de p larger groups of movement What follows is taken from a summary of the survey, have been that of the cotton textile industry to the South and from an address delivered by William J. Barrett of ern States, the setting up of an immense rayon indust1 the Policyholders’ Service Bureau, which was read befor n the South, development of a large hoe industry in the the Connecticut Chamber of Commerce, Hartford, last st. Le territory, movement of the center of the steel ir May. dustry from Pittsburgh and development of the Kraft Two forces are causing considerable thought to bi aper industry in the South viven to the subject of industrial development (1) Many lo secure their share of gain in these shifting indu cities have come to realize that their social and econon tries many communities have ught to attract individua advancement depends upon the industries within their bo! ants Advertising campaigns, offering freedom from ders, and are beginning to give attention to thos¢ au taxatiol ! e cast providing rent-free factoris for a tries and to the securing of additional payroll Indust? eriod of time, have been among the mear ised on the other hand, has been caused to study intensivel; present location and, where movement ontemplated, t How the survey Was Made arrive at a future location by scientific mear iwo general object f the irvey were: (1) To mea Many of the larger cities, realizing that the. annot a a tw year period n terms of number of plant depend entirely upon past momentum, Nave set about a ind of employees, the extent and nature of certain phas« tively to exploit their advantages of a large market, esta i industrial developments in the United States and Can lished industries, available labor supplies and inte! ¢ ida, (<) to define the ndey ng economic reasons which ral Si e! Ir ng ‘ n e i I a I ¢ VOrKI! i! irticipat } and living cond ng in any one WENT OUT OF tai f the thre NEW LOCAL It has pee! tems mentioned BUSINESS BUSINESSES estimated that n page 1090, to ! nine-tentns of gether with data all industries n the product Piants Gained are improperly manu factured, Plants Lost b | . . 1 - y | by Communities located. They the number of Communities | have been placed mployees, —_—— ————| where they are sources of capital - 1089 a l tre and I is n adait I n ements na l rma reyvart es 4 , ¢ , ine rs dat { ) ) y ‘ | (;rowth of Industr. RC 1) ‘ y | LJ : r ’ T yr the ’ f ~ ‘ ‘ Tr} } ne roe ert \ ( uN 0.000 populat rancne re t ns and one-tent requently ree? t rae | rreque nec} 1090 The Iron mentioned as ige, October 24. Information on plants lost was difficult to secure. Such . develop iway from a given com- communities as have the data do not care to give it out. ng firms which had gone Information was obtained, however, from plants which had th less success moved, of their reasons for leaving their earlier locations nal interview were utilized One plant locating in a small community found it diffi is recognized that there cult to hold a supervisory force. These people had become elopment accustomed to the social and recreational advantages of large city and missed them greatly in the small com- nunit In another case, a gray iron foundry was located in a iall community. The growth of the business was rapid ind a considerable expansion was needed shortly. Investi gating the labor supplies in the community and adjacent erritory, the management found that ‘present require ments were absorbing practically the entire employable ilation. It thus became impossible to make the needed expal n at that point. One small community was found so favorable for indus tries that its industrial deve ‘: opment has gone considerably 100 23 ahead of its size and recrea VY ’ tional facilities. It has started : > =z to provide such facilities, as a ? Y Lu. partial result of which land ¢ t= © values in the retail business n J i section have gone skyward. a = o = One reason tor a recent DU oO —s Lit movement of industries to = > 9D b = < ; small cities lies in the fact _ s Lu 36 that many of them have, with- > OQ a in the past five years, received a 2 : : , . Lit the advantages ol electri a power service formerly en = joved only by the larger com- U munities. This has made it Average Sizes of Plants Gained ee eee saan ae Se cate in these smaller places with full assurance of dependa- le 24-hr. electric service from il ntel mnected system. It I i that the preponderant movement in six of the I ! raph | are ro. he larger to the smallei nt Middie Atlantic States Gained Most ) t ement of ar ndustry trom one communlt} : nother, that between the Middle Atlantic States (New } New Jerse ind Pennsylvania) and New England me intere Practically 86 per cent of the move- e! nto New England was from the Middle Atlantic : States, the principal trend being from New York into Cor : ne ( ersely, most of the plants moving out of , , . N England went into the Middle Atlantic States. Be \ whole, the Middle Atlantic States showed thé _ a greatest gains ie to relocations of industry, with New Kngland second. The Middle Atlantic States led in new inch factories, with East North Central territory se in Small Places nd The Middle Atlantic States are substantially ahead establishment of ne ocal plant New England stand +} elites do respe ’ law can 7 pee ee Cold Worked Gun Forgings east insportation al The forgings for guns manufactured during the past mmur offers the ad ear have all been cold worked, according to Major-Gen t its disadvantages eral C. (¢ Williams, chief of ordnance, United States n re more than on¢ Arm) At a meeting of the Army Ordnance Association, ed, more than one-sixth of Oct. 10, he said that 165 forgings have now been pro- f the ne cal industries duced by this method and not one has failed in service. reasons tor this movement Watertown Arsenal has continued to make minor improve- Markets, labor, transporta ments in the process and equipment, but the process is now standardized and is highly satisfactory. 1929 Evolves New Beehive Coke Proces Humphreys Coal & Coke Co.. After Long Experiments, Obtains Product Meeting New Speci- fications of Foundries ORE exacting coke specificatiohs from foundry nitation there wa pl 1u marketabie at a pren consumers and growing competition from by-prod- a quality uct coke producers have led the Humphreys Coal & Coke Co., Greensburg, Pa., to evolve a process for manu facturing beehive coke comparable with by-product coke it \ better understanding of the pre both physical characteristics and chemical analysis. Th he Humphreys apes? eh Geuee oe Humphreys company, a subsidiary of American Radiator —— Cet the tt I ee Co., with mines and ovens in Westmoreland County, Pa., fouowring OS: CS SARS ee operates in the famous “Old Basin” Connellsville seam today with those of a few years ag During the many years of its history Humphreys be Old Specifications hive foundry coke has enjoyed a good reputation, both fon its chemical and physical characteristics. Until recently \ however, the coke was manufactured from coal that r ceived no preparation or refinement prior to coking was any effort made to control the porosity and shatter qualities or weight by formule in the introduction of air into the ovens. As the coke requirement of der , foundries became more exacting, the company realized that, if it were to supply satisfactorily the foundries of S the parent company, as well as a large outside trade, in provements in beehive coke would have t e introduced The Humphreys situation was complicated because the New Specifications company’s production f coal is limited under it lease hold to a comparatively small tonnage, equivalent onl) the requirements of its battery of 145 ovens. With th ( er he new spe NENERAL View of Surface Plant, Showing Pang- born Dust Ar- resters and Classifiers on Right, Prep- aration Plant in Center, and Ovens on Ex- treme Left The Iron Age, October 24, 1929—1091 im price What Foundries Now Expect of Coke ige 1091, the company installed a laboratory i engaged a chemist and metallurgist. : we lieve | he first of its kind ( W itl | iborato! ! Y l t el! ’ ! of nree i ( expel nts tne col t ) »f mecnar I i I De S1Ze of ( I flicis separatio1 é I irthe lesulphur I ( al metnods ! e} rove ! assu i S el ae Nea . te ering I er e ct hich the I has been suc I ems ~ es ustrated | tt p s of its foundry coke Shatte Index Pneumatic Separation Utilized Aiter the coal 1s Drought to the TY I ning tis first crushe é assed ove! pne ll! a rat {] Struc | ture of the Coke Before Hand - Drawing from a Beehive Oven Is Clearly Shown in This View 1092—The Iron Age, October 24, 1929 preparation ito a prope separators, plant r fine fur- nished by the American Coal Cleaning Corporation. Here a novel arrangement has been introduced by giving al! the coal a primary treatment and a portion of it a sec- ondary treatment over the separators. This is done to insure uniform chemical quality. With only one treat ment, which is customary, an extra quantity of refuse in the feed coal may not all be eliminated, but with a sec ondary treatment complete elimination to a predetermined standard is assured. After the coal has been run through the separators, it is given a treatment of acid to reduce further the sulphur content of the resultant coke. After the coal passes into the ovens and during the entire coking period, operation is regulated with extreme care to insure the proper porosity, weight and shatter in dex. The porosity and weight per cu. ft. can be and are varied to suit the requirements of the various customers. This diversification ranges in porosity from 49 to 56 per cent, and in weight per cu. ft. from 28 to 34 lb. This effort on the part of the producer to meet the require- ments of its customers is another recognition by the Hum- phreys company of the economies in foundry operation to } be derived from the use of the proper kind of coke. Sea Coal Produced as By-Product During the process of coal beneficiation by the pneu- matic process, considerable fine dust is produced. This is collected by means of Pangborn dust arresters, which have been erected adjacent to the preparation plant, and is classified into two sizes which are marketed as sea NE of the Pneumatic Sepa- ( rators in Cleaning Plant. Here all coal is given a primary treatment, and a portion of it a secondary treatment over the separators to insure uniform chemical quality AND .- Drawing of the Coke Has Little Effect on the Size Because of Its Tough- ness | | i coal, or as an alternative can be re-introduced into the of the coal preparation plant, the No. 1 grade is compara coking coal. ble with the highest grades which are manufactured. The analyses of the two grades of sea coal are: Each cdr of foundry coke is tested for shatter index, porosity and weight per cu. ft. and analyzed for volatil No. 1 Grade ci ea " ae - matter, moisture, ash, fixed carbon and sulphur. Through Per Cent i aaall, Ciaae 69 the laboratory close control is maintained over the prope Through 100 Mesh 4 Ash 7.00 functioning of the coal crushing and coal separation Through 200 mesh 62 Sulphur plants, as well as the proper formule for air control of No. 2 Grade ee a = the ovens. In fact, the laboratory is used to exercise con Through 100 mesh 60 Aah oe - te trol over the coal from the mines to the finished coke in Through 200 mesh 20) Sulphur ys cars. Every active working place in the mines is ana lyzed at stated intervals, and an inactive place is mot ré While this sea coal might be termed as a by-product sumed until a complete analysis is made. Enlarge Old Motor for Reversing Blooming Mill Drive BY G. P. WILSON EVAMPING of a motor driving a reversing blooming The increased horsepower rating of the motor required mill at the Indiana Harbor, Ind., works, Youngstown new generators which would have a combined rating of Sheet & Tube Co., to accommodate larger equipment, was 6000-kw. and a 5000 hp. driving motor for these gen recently accomplished by increasing the size of the moto1 erators. The speed of the mill motor was raised from 40 from 5000 hp. at 40 r.p.m. to 8000 hp. at 50 r.p.m. The to 50 r.p.m. by increasing the voltage of the generators old motor, installed on the 35-in. blooming mill in 1918, from 600 to 700. The new set and the revamped motor was supplied with power from a 3500-kw. flywheel motor- are provided with a new control, and a foot-operated generator set with two 1750-kw., 600-volt, d.c. generators. master switch replaces the old hand-operated master Increasing the power of the motor necessitated the witch. The field relays for the motor and generator ars replacement of the present armature copper with greater of the latest improved type. This new control] will in cross-section, to allow for this increased rating. To im- crease the performance of the set enabling faster a prove operating conditions further on the motor, under celeration and increased over-all performance to be made. peak-load conditions, tapered inter-poles were provided on The old flywheel set and control will be left instalied the machine and new compensating and commutating as a standby, so that the motor may be operated from windings. The old shunt field coils were removed and either the old set or the new, thus assuring available new field coils with improved insulation were provided power for driving it. The motor has a spare armature New end bells and baffle plates were installed, which also, so that this arrangement of the two motor-generator will improve the ventilating condition of the machine. sets will make the power supply conform to the spare that Redesigning the ventilation of the motor in line with is available for the motor. present-day practice, and increasing its horsepower to When completed the installation will be the only one 8000, necessitated increasing the amount of air to the of its kind operating in steel mills, and will be the second motor from 40,000 cu. ft. to 80,000 cu. ft. a minute. largest reversing mill installed. Comparison of the op- eration of the new foot-master control with the old hand- *(j;eneral engineer Westinghouse Elect & Mfs East Pittsburegl operated control will then be possible. The Iron Age, October 24, 1929—1093 eat Treating Woodsmen’s Axes Lead and Salt Baths, Electrically Heated and Automatically Controlled, Improve Output and Cut Costs Made by Semi-Muffle Furnaces N opportunity to appraise the over-all costs of heat treating carbon steel tools, and to show that reduc- tion in collateral costs may overbalance an increase iel cost, occurred in the plant of Warren Axe & Tool Warren, Pa., manufacturer of high-grade axes and As described Electric & Mfg. Ce... Mansfield, Ohio, in a paper before the meeting on fuels, 1f Mechanical Engineers, Philadelphia, Oct. 7, the body of an axe is forged from low-carbon eging tools of some 33 years’ experience. Wirt S. Scott, Westinghouss lis is welded the cutting edge, consisting of iigh-carbon crucible steel. Only the blade or cutting bit needs to be hardened; hence it is unnecessary to heat the ntire axe except for obtaining a blue temper color, which a characteristic and advertised feature of the company’s iighest grade tools. In the past, in order to secure the best results ob- tainable from fuel-fired furnaces, each axe was individual- hardened and tempered. Despite the utmost care in eat treatment and testing, the necessary free replace- nents of tools sold under an unconditional guarantee be- ame an appreciable item, and one to be eliminated if yssible. This resulted in extensive investigation of new ‘as and new methods of heat treating the parts, par- larly as applied to tempering. Prior to electrification, the axes were heated in semi- wuffied, gas furnaces. Individual treatment was thought produce the ultimate quality. The possibility for error n judgment on the part of the heat treater was appre- ciated, but this was minimized by the employment of ex- penienced heat treaters. 1094—The Iron Age, October 24, 1929 To secure the dark blue color of tempered steel was the aim of the heat treaters in the final operation, but the accomplishment was a matter of judgment, subject t« many variables and resulted in different shades of temper- ed steel and different degrees of hardness. To improve the quality of product, and to secure the most dependable uniform quality, it was decided to eliminate some of the variables, and reduce others to a minimum, through the use of electric heat, regardless of the operating cost. After electric furnaces were put in operation, the entir« method of heat treatment was reversed. Equipment i: 2 ALT Bath, with 29 Tempering Single-Bit Axes in the Bath. Hot axes ars replaced by cold ones at regular intervals Steady operations and unique current con trol hold temperature of bath within clos« limits cluded batch-type, semi-continuous operation, bath-typ« furnaces in place of hearth type; separate hardening anc tempering furnaces; one hardening and one tempering furnace in place of five combination hardening and temper ing furnaces. The electric furnaces are of the rectangular bath- type, consisting of a steel plate shell, lined with heat insulating and refractory brick. Heating elements formed of return-bend coils of nickel-chromium resistors are sus- pended from hooks anchored in the side walls, and also placed in the bottom in suitable refractory spacer blocks. The vessel for the bath is made of cast nickel-chromium alloy, supported from an upper flange. A nickel-chromium protective apron is placed around the flange, and over this is laid a steel top plate, to protect the brick work from damage, and prevent the molten material from entering the heating chamber. The hardening bath is operated at a temperature of 1405 deg. Fahr.; the vessel is 22 in. wide by 60 in. long and 14 in. deep. The electrical capacity is 65 kw. "TT EMPERING Double-Bit Axes in a Special Salt Solu- That Tempers and Blues the Axe at the Same Time. There are 26 double-bit axes -om pletely tion immersed in the salt bath The tempering bath is operated at a temperature of 580 deg. Fahr.; the vessel is 12 in. by 46 in. at the top, and 12 in deep. Its electrical capacity is 57 kw. Coils in each furnace are divided into two equal « cuits, each operated by separate contactor switches, which are opened and closed by means of temperature recordir x and controlling pyrometers. Two thermocouples are used with each furnace, one of the protected type plunged in the bath; the other is bare and placed within the heating chamber. This double pro tection and control is necessary to protect the heating el ments fully against excessive temperatures, particularly during the heating up periods, and to maintain Fahr of heat be s ip} lied temperature constant within 7.5 deg Theoretically, if minute to a bath, it a definite amount should be enough work through it each minute to each possible to put just hold the temper Some ature constant. means should be employed to in dicate whether or not the operator was working at the correct rate. This may be accomplished by placing threes contacts on the pyrometer, operating three lamps A white light would indicate correct temperature; a blue light, temperature too low; a red light, temperature too high: a white and blue light, a downward swing in temper | OUBLE-BIT Axes Are Being Heated in the Electrically Heated Lead-Hardening Furnace. The bit only is immersed in the lead Note the the wall at the extreme right, with the white showing, indicating proper tempera- ture and rate of brine directly back of the furnace oper- ator After finishing the day's production, the rack for holding | the bath the insulated placed in position over the lead bath, so that the three lamps on light correct The tank is production quench the axes in is removed, and cover is lead is still in a molten ¥ condition next morning iture; a white and red light, an upward swing in temp iture In practice, it is impossible to comply entirely with the theory above outlined. For one thing the weight f axe vary, consequently the rate of heat absorption is not cor stant This condition necessitates a furnace ha ng apacity sufficient for heating the large charge at the given production rate, and, as a factor of safety, an ex ess capacity for unforeseen contingencies. The temper ire iriation of this combined system under the worst ditions was sufficient to hold the hardening temper ire vithin 15 deg. plus or minus In order that the y ! system noted above hould burn continuou im not intermittently, it was necessary to use two rec: ind controlling instruments, one for the bath and one for the heating chamber. The use of two control instruments, two separat« n tactor switches and two circuit n each furnacs pened he way for an investigation for further refineme temperature ontrol. Temperature surges had been re a iced from 30 deg to 20 ade Zz DY the control, on ature of heating zone sary to and off, reduced, the corresponding surges in temperature intermittently, coul controlling the temper If the amount of energy nec: The Iron Age, October 24, 1929—1095 ‘sius 1096 ( sn \ LKING ne Cll . y } . n+ ? . ely I e? a or CC ( re i I I rie tre } rometel ey \ ‘ resu 4 ‘ ; na i y ’ ) f , y t} ‘ in? ‘ ‘ ] é ne tl? I el T y y co ’ f \\ I e, the te! r¢ Fal : eg | x é } S a ) I re tted ( t ne ered ne o nr.) We? ting ‘ } { eg ( l re y , } rrniy The pering nig} y » eg it} erating ? i (r 1) y : 0 eater un 7 é ' } } f ‘ f erore , ; é h¢ ‘ at} , ch in () ° 7 ‘ lead t ry rhor ha the e 1 t I l icing oxidatior g lead g f rom the hot axes T I \ ' e€ tne bat} ‘ ‘ enched i y 1 ? ’ y ’ tT ry t empe! i ' n o one ixe out y ¢ } eY W } y Ww ix ? ve for th r ¢ , ‘ er } ] t o VW } ‘ ee re re ) h Moldinge’—What It Is and How Conducted as ! ling [Ther . ! ! ( ns pro] nded I e! Uf ] re Finally T a ne ng nothing ré know! ry ’ ’ i ] ? n 1 n made tn the ittern \ m ter y ired nt the vy id ting yainst ( Va ibout zs in By irning the mold upside down the re I poured out This leaves a hollow nzed an yr genuine ( in be succe l applied t cast iron, u in In making a kettle, for example, ut e molten iron poured into the é tand ist long enough so that the de knc metal set gainst the mold surfaces, 11 molten iron is poured out. Several ul Y e with the remaining iron so long as i e! ot The time allowed for hot or cold matter of experience é depends upon the rate of cooling ten metal in contact with the green sand of the ! mparative cold and damp mold walls The Iron ige. October 24, 1929 ne Operation of the tempering furnace is substantially t same hardening that the axe is submerged in the liquid, and a double-bit axe requires as the furnace, except entire only one tempering operation, whereas it is run througt the hardening furnace twice, once for each blade. Temper ng 41%-lb. double-bit axes, both points at one time, tne length of time any one axe was in the bath was & mi! The tempering bath holds 26 double-blade axes, or 29 single-blade axes by the changing of the jig. One operator is required for each furnace, working 01 piece work, each man turning out 1450 axes a day. Tw n and the electric furnaces turn out a larger productior Lie | than five heat treaters previously turned out of the fuel fired furnaces, are not rushed as they were in the past to average a certain wage per day, and have better work no conditions. Maintenance Costs Maintenance of the gas furnaces was amazingly small ($14.90 a month) due to the simple construction of the furnaces, and to the fact that the heat-treaters supplied most of the labor at no cost, since they were on plect vork No expenditures for repairs to the electric furnaces have occurred to date, but the vessel of the hardening furnace will have an average life of 6000 hr. Tempering vessels have been in use for 13,000 hr. with no signs of depreciation. If a vessel costs $800 installed in the fur nace, and is used 200 hr. per month, the monthly deprecia- tion is $23.20. Two hundred eighty lb. of lead and 28 lb. of tin are used each month in the hardening bath to make up the loss of metal, which amounts to $31. One ton of granular carbon will last 9 months, and costs $50 deliver- ed. Average monthly cost is therefore $5.60. One barrel of special tempering salt costs $75 and asts three weeks. This item amounts to $100 a month. Recapitulating the total maintenance per month fo the two electric furnaces is: It also essential that the metal have a fairly wide ranges f temperature from the liquid to the solid state. A ricl gray iron has this when high in silicon In the case of aluminum the metal sets practically all at once and slush moldit annot be employed. Measuring Open-Hearth Temperatures Accurately NE rather surprising fact in connection with gas O temperatures in the open-hearth furnace, has re ind EB 19 in five different cently been reported by A. Schack in Stahl sen, (1929), pages 1196 and 1197. This is that the of temperature the furnaces is no higher than (2930 deg. Fahr). the outgoing 1610 furnaces limit in upper gases at ends of the deg. ¢ Measurements were made with the “Durchflusspyrom- so arranged that a stream of gas the hot junction, thus minimizing eter,” a thermocouple is drawn rapidly ove errors due to radiation from surfaces hotter or colder than the vas. Temperatures of outgoing gases measured in this way at the top of the checkers were some 120 to 150 Fahr. hotter than those obtained with the ordinary couple. With at the tempera- tures were from 180 to 270 deg. Fahr. lower than those incoming air, same location, the “true” found by usual procedures. aan oma a —— et Unusual Uses of Magnets in Handling Materials we E electric magnets have tor some years een Ty smal magnets d 7 t i spreadet ean standard equipment for handling hand rf quit landling scrap, pig iron used tor handling pipe, as shown 1n a third istra und many other items of iron and steel, both in ste: Chese gnets k up a muls and foundries and in scrap yards, there are a I several sizes a Save 1 labor in s g. Opa ber of uses to which magnets have been ved als ecausé ‘ e racks in some plants which may suggest other uses ice ‘ ‘ ogether e s to other plants. Some of these out-of-the | where this method ordinary practices are shown in pictures from : I ese { ugnets the Ohio Electric & Controller Co., Cleveland g be ur sed in indling plates ‘ Picking up a box of tin plate without break plant of the Newport News Shipbuilding & ing out contents has become common practice Irydock Co., Newport News, Va The « in some plants. One illustration shows this iny has six such sets, taking plates as h operation wherein one side of the wooden box ) ft. long 8 wide, and from ies between the magnet and the magnetic ma ; in k terial contained within the box. This magnet This par r i vas lertak« 18 in. in diameter is suspended from a 3000-lb connection w 1achining plates to form 9 jib crane on an electric industrial truck miles of water pipe 6 f n diameter, for use Another view shows a 20-in, round n California There were 514° magnet, also on an electric truck with jib carloads of these plat t crane attachment, lifting a pair of railroad handled The carwheels with the connecting axle, for the Indiana Harbor Belt Rail- way at Indiana Harbor, Ind magnets unic ide The Iron Age, October 24, 1929—1097 onveyorsReduceFactory Accidents Growth of Mechanical Transportation, However. Has Created Special Hazards from Which Workers Must Be Protected BY W. S related t ndustrial progress in metal-working nis n alle t! ige of conveyors reased use of mechanical means of rge measure enabled the metal ants of the nited States to make such pro rld-wide production and efficiency records. f the most important benefits coming from the veyors is in lessening industrial acci- \ n « ‘ S e seldom installed wholly to ( ( sually replace hand labor, and working force tends to cut down the so! ‘ ise of the decreased mar ire ) Vvny factories have been able ‘Tr : ror ! ons in accidents is be B ASKET Guards F Should Be Placed n | Over- hain I lerneath head ( to Prevent Ma- Con- veyors 1 terial rrom I alling upon Workmen (at Right) 1098 The Iron Age, October 24, 1929 DEAN KEEFER ause of the displacement of dangerous operations by th ise of conveyors. This is one form of engineering revisio1 which has become closely associated with sound safety work. irritating delays due other form of industrial waste are being minimized by the engineer to accidents and many ing application of mechanical principles in handling ma terials. However, mechanical conveying systems _ introduce special hazards which must be recognized, for the reaso1 that accidents resulting from them are usually quite severe. A conveyor represents a mass of moving ste¢ inder the control of power. It is not surprising, thers fore. eyors are likely to be serious, probably resulting in broken that most injuries to men who become caught in con arms or legs or a crushed body. For this reason no con- veyor can be system considered complete until it is pro- T RANSMISSION Cases Are Loaded On and Discharged from This Conveyor Automatically, There- by Reducing to a Min- imum the Possibility of Accidents to Em- ployers (at Left) Fatigue, cluttered-up working places, congestion, oe AIL Guards Protect Workmen at the Point Where This Core Conveyor in an Automobile Foundry Passes from One Floor to An- other (Below) LONG This Chain Conveyor a_ Rail Guard Has Been Erected to Keep the Drive Shaft Housing from Flying Up and Possibly Hitting a Worker If the Chuck Holding the Axle Should Break or Fall (Above) vided with every possible mechanical device for safety, to conveyor and removing the stock when it has reached lessen such accidents and hazards. the assembly line. Some additional help must be employed to maintain the equipment, “but this,” as Mr. Thalner ’ ‘av avs Icehecce « S; sty \ ee rs . : ; Conveyor Hazards Discussed at Safety Meeting states, “is usually of a higher caliber than ordinary labor Conveyor accident hazards are always important topics and consequently can be relied upon to protect itself of discussion at regional and national safety conferences Proper mechanical safeguards over gears, chains and For example, one of the outstanding addresses at the 1926 belts, as well National Safety Congress Was on “The Hazards of As veyor, \ ill make this equipment almost ‘fool proof.’ ” sembly,” by R. F. Thalner, safety director of the Buick Motor Co. He indicated as his experience that a large as a number of stop stations along the cor As another protection for a conveyor system, the motor equipment should be completely inclosed. This is needed percentage Of the hazards of assembly was in the use of not only as a safety precaution, but also to protect th conveyors. He listed them as hazards in transportation system from | ible damage, for shutdowns are alway from machine shops to assembly plants, in sub-assembl) costly and in main assembly. Under the latter he listed hazards | with conveyor lines, chains, motive power and stop but Repairs Should Be Made While Conveyor Is Stationary tons. Additional hazards occurred in connection with ap- It is a go ds ifety rule that no adjustments or repair purtenances to conveyor lines, such as in frame-riveting, of any kind on a conveyor system should be made whil ventilation, furnaces and hammers and hazards with cab! the conveyor is in motion. Through the use of modern and their inspection, lighting, stock bins for small parts, pressure oiling and greasing devices, however, the oiler belts and gears, steaming room, painting and drying, sub may be able to reach out-of-way places without special conveyors, hoists, pit work, punches, drifts and chisels. hazards Extension pipes on oil and grease cups are also Mr. Thalner is of the opinion that conveyors are prob a good protective device. Automatic gravity oilers are in ably the most efficient and safest method for transporting wide use, and a central oil reservoir or container is not stock, provided the equipment is properly installed. only economical but removes accident hazards. Conveyors which require attention only at the loading Conveyors should not be started without first giving and unloading ends eliminate to the highest degree pos warning to the men who may be making repairs or ad- sible the human factor, because in the entire process of justments or oiling the machinery. Every repair man transportation the only help required is in feeding the should be provided with a lock or a warning sign, which The Iron Age. October 24, 1929—1099 ild pu e starting lever or control switch be ‘ s work on the conveyor. Rules forbidding ne t emove a lock or a warning sign, except the ed it, should be rigidly enforced. In tl] ise of long conveyors running through two o1 r in one room to points from which controls s sometimes a good plan to sounded by the operator ‘e the machinery is started, thus happen to be in a National Conveyor Safety Code Being Formulated f prote ting convevors 1S considered of rtar to demand a national conveyor safety S 1 e is being worked out under the auspices Ame n Standards Association, with the Ameri- S f Me I Engineer al the National f Casualty and Surety Underwriters as sponsors ght groups and organizations, with 42 special s re rating formulating it. Thess nclude tl American Society of Safety En- \ ! I e! Associatior American Eng ( \ ition, International Belting Con National Safety Council, Society of Industrial ‘ SS s Bure l f Standards, factory rth e groups. Their purpose 1: I ‘pate eratior ind maintenance ol 1 t ket, apron, screw and jigging eways, vernead trolleys I ely assoc ted wit t iards, shafting, coup ! ins Hooks and I I } ectrical quip! lent | ul ssible hazards it f I I } Wiring and Il! fastening overhead cay riers of different sorts are also important, and wire rops There are special hazards at regular cross-over points of conveyors Proper methods of securely and cables should be frequently inspected. unless protected by elevated bridges or tunnels with prope guard rails. There is always danger in the practice ofte: seen in factories of boys and other workmen riding kinds of conveyors. Such a certain practice should bh: strictly prohibited; it usually can be done by the estal lishment of guard rails at proper points. The Chevrolet Motor Co. has made novel use of one of its overhead traveling conveyors to carry safety messages This conveyor travels slowly and safety signs are so ar ranged as to appear about every 5 min. at a given point “Even a busy bee uses safety” is one of these slogan: Others “The safe “Safet ways prove safety pays,” “Safety ways bring happy days,” are: way is the best way,” and “Today is safety day.” Many factory accidents are due to falls and therefor loading and discharging it is suggested that stations conveyors be protected with anti-slip floor surfaces. Overhead Conveyors Need Special Protection The efficiency of many small plants has been great ncreased through the addition of suitable conveyors, mar of which are of the overhead type. These conveyors dé nand special protection with nets or flooring underneat} them. Where there is such overhead flooring there shoul always be foot-boards, guard-rails, and the like, to pre vent material from falling. Extension of conveyors from one floor to another has troduced a special fire hazard, permitting a fire, unless there is proper protection, to spread quickly between floors Two methods have been devised to eliminate this hazard one to inclose the chute in a tower of steel, concrete o1 masonry and the other to provide fire doors (draft checks) where the floors. chute passes through the iccompanying illustration i. shaft shown nthe eigns tU.O00 Ib with a maximum finished diameter n. and an overall length of 32 ft., and is thought be one of the largest ever built It was forged by the 1 an octagonal Nicetown, Philadelphia, from 82 in. in diameter and weighing 290,000 Ib., 1100—The Iron Age, October 24, 1929 and was machined in the shops of the Westinghouse Elec tric & Mfg. Co., East Pittsburgh. It is designed to be supported with the rotor on two large bearings, 30 in in diameter and 60 in. long. The shaft will be used in the rotating part of a 60,000-kva. 514-r.p.m. horizontal generator in the Westinghouse company’s test laboratory Possibilities of High-Test Cast Iron Need of Classification and Proper Test Bars— Use of Alloys and Special Melting Processes IGH-STRENGTH cast irons offer possibilities to t} n analy t} tre? gray iron foundryman not only to increase his field of range of 25.000 to 13.000 vhen the licon raise operations but also to regain some of the tvpes of work from 0.75 to 2.25 per cent It bviously quite wrong now being placed in other iron and steel groups Ar t dg ist iron at a 14,000-lb. strength whet essential point to be remembered is that n the present na practice 25,000 II al e readily obtained condition of development of high-strength cast iron, this material is still in the experimental stage, and, further, as lest Bar Needed Which Can Be Correlated it develops, it will be necessary to classify or grade cast Test ba ean vel ttle under their present a pt irons according to their merits, said E. J. Lowry, consult nce Their use mited t mpat ns for the pt ing metallurgist, Detroit, in a paper, “High-Strength Cast obtai1 by varying the analyses and the ns used it Irons,” presented at the National Metal Congress, Cleve <ture he cannot be used t mean the actua land, in September. treneth of ‘a casting eads to doubt by the eng European investigators have perhaps been more fo nee? There e, there nmediate nec ty rt ward in the development of this material than om v1 levelopment of test bar which may easily be correlate research and production men, said the autho his 1 to the pl al propertie f a casting. When th doubt is due to the fact that American foundrymen aré¢ mplished it wv be easier t inderstand the action ¢ faced with the problem of mass production, whereas it new processes developed Europe more time can be given to technical development Production of high-strength cast iror vy the of processes surrounding the production of cast iron of : has long been known, but to produce strength new physical properties. 60.000 to 65.000 . per a n. ha led to the use of pecial ' ' ‘ ‘ vith the ipsequent 1ddait n of A Various Types Should Be Classified P ‘ ¢ Such ethods have not generally been acceptec f When one considers the nomenclature, “high-test cast irvme! It must be rea ed that a change ‘f met iron,” it is apparent that the cast iron industry has not re re rage, whereas a simple method of Introd taken full recognition of the possibilitic Ss existing in the tion of i be generally accepted Any change ! industry. Instead of departing from empirical standards, the method of melting requires a re ng of the u it is continuing in the same vein. It is essential that the production process¢ Varying types of cast iron be properly cla fied This It h; heen generally thought that alloys may be i apparent when one considers the trade name “sen teel.”’ ‘ luced int nferior OY with the resulting effect t This term will allow a foundryman to make his product high-strength cast irors wv be produced. Such is not t with as low as 1 per cent of steel in h mixture and a Ase \ ct merelv as an aid to the bettermer f high as 100 per cent steel melted in his cu; This car When all re prope ised it nnect not be taken as a condemnation of the product, but mers it} ect section and analvs¢ ‘ ne I I shows the latitude with which this kind of cast iron ma atter to produce high strength without special procs be made. r] eal that when a foundryman has adjusted n Another illustration is afforded by th: ise of alloyed tures. he ul e regular cupola metal and, with the add cast rons. In this instance claims may e made where ‘ . f on fF the know? alloy ncrease h iveras alloys are ised put no full percentage s give! It must treneth fron ~ OOO Ih. t 15.000 | , and even a nigt be admitted that it would not be an easy task to classify 65.000 ne ’ The known alloy ire nickel, chi cast irons under such methods as the S.A.E. uss n des mium. 1 denu unadium and titar ignating various types of steel for definite uses, for irons are more complicated in their structure, physical Special Melting Processes and chemical analyses than are steels. If, howev: the I tt ttention ha een paid t ethod engineer is to be enlightened, cast irons must e cate lure al asically so because of the apparent init gorically named for him with subsequent ting of what t When. however ne oY ler the use of spe might be expected in cast irons in these classes ting proce , plus the e ota n compa! nt Quite often the engineer is guided solely by text books , combinatior f alloy vith regula n. the resulting with an exception here and there of actual experience. It osts are apparentiy the ame It easier to work wit! is often the case that data in text books are based on as- the latter method than to apply the former in productior sumptions of strength obtained under varying circum foundry work stances 20 years ago. They further are based on inac- There are st further possibilitis n the productior curate determinations in comparison with those made t high-strength iron when the question of annealing i o1 z day. It is quite usual that engineering text books quoté sidered. A process may allow a casting to be made harde the tensile strength of cast iron as a maximum of 14,000 and stronger By proper annealing the hardness and lb., and more usually at 12,000 Ib. per sq. in. Such physi trength are little affected and yet the machinabil cal properties are ridiculous on their face value unless increased to the point of the lower strength, softer ca the specimens were cut from 2%-in. sections made from iron. Continued experiments with varying analyses and analyses of too soft a chemical composition. As an in- later heat treatments offer great possibilities for the pr: stance, keeping the section the same and using a different duction of high-strength cast iron. The Iron Age, October 24, 1929—110! ~ ; 9 ° ° & orld’s Largest Nitriding Furnace Over Two Tons Can Be Treated with Ammonia Gas—Preducts 11 Feet Long Hardened in It A platform of three that melt at low temperatures. \ t nia is or nitriding the l x 4-in. strips running lengthwise is built up in the ( Alloy Steel Corpora bottom of the box to support the material being nitrided, ! UT , Diant, lt wnat S Sala to Dt ne is IS necessary to have the work well supported tu ng furnace the w d avoid warpage. Other strips, % x 4 in., are placed across f triding large parts { the longitudinal strips, which are of plain carbon steel. end car-type furnac: The hea ! The box rests on cast steel cradles which are bolted ti hree sections—the two ends and steel slabs extending lengthwise. The slabs rest on sand ng element eing located in the bot covered bricks that are laid on the car platform, the sand les. The furnace designed for ope) taking care of the difference in expansion between the ture ip to 1800 deg. Fahr. to permit it brick and the slabs when the box is being heated. g and drawing furnace a ell as for Ammonia is delivered from five tanks to a bustle pips and from that to two outlets, one for connection to the A g e¢ ! h an ¢ box when it is outside and the other for connection when ¢ 1 ft : ft. 9 vide and } it is inside the furnace. Connection from these outlets ¢ f.4 tt. 8 ! The nitriding box is to the box is through heavy rubber tubing that connects nigi ! nted to a bustle pipe. This pipe feeds five %-in. tubes made 8-wheel tor-driven cat of KA2 tubing that serve as inlets. These pipes extend g S few construction, the joints through the end of the box in the bottom of the box and ng gas tight It made of KA2 iinless are of different lengths, their discharge ends being 4 ft. e1 ealed | ead and bismutl ipart permitting the distribution of the gas through the 4 ges Large Nitriding Box (Right) Be rore Being Pushed into the New Nitrid ii¢ n ing I urnace j j ' some | arge ( ylinders (Above) Which Have Been Nitrided 1102 The Iron ige. October 24, 1929 Some Large Sections Which Have Been Nitrided An impeller engine and a ran box. Three 1-in. outlets provide sufficient outlet for the gases leaving the box and to take care of the ba pressure. These outlets connect with a bustle pipe and from this the gas mixture passes into three other outlets which feed into water bubblers. The extent of the am monia dissociation is determined at the outlet before the gas enters the water bubblers. A feature that is unusual is a fan located in the box to insure the circulation of gas through the work. This is direct driven by a motor mounted on the car and con nected to a shaft running through a tube into the box Because of the high temperature, the bearings supporting the lubricated. of of resisting and non-corrosive, all working in a loose fit, The sleeve Is Q fan cannot be A combination steels extreme hardness, heat- used to take the place af lubricated bearings. ing shaft is of Enduro-KA2 The nitralloy and the bushing of a heat-resisting alloy. The roof For checking purposes there are also two pyro driv steel. temperature control is by pyrometers in the furnace. meters in the nitriding box. The work is cleaned before it is placed in the bo» making it as free from scale as possible Then the ( is placed on with a crane and the car runs i the furnace under its own power, the end of the car carrying the Failures in the Brazing of Steel rYwWO general methods for joining thin-walled steel i are in use, according to W. Riede in Stahl und Eisen, 49 (1929), pages 1161 and 1162. These are the torch-brazing process and the dipping process. Objection to the first is mainly on the ground that the flame melts the steel, while the second, although entailing a certain amount of extra finishing labor, appears more rationa and with the exercise of care, will give uniform results. In the dipping process, however, cracks appear in part of the steel which has been exposed to the brass. This appearance is quite the general rule, but may be dimin ished by suitable aging and heat treatment. As a result of experimentation, the following explana offered: vere cold work, tend to recrystallize strongly when sub- tion is Steels, which have been subjected to s« jected to the heat of the brazing liquid. Internal stresses thus set up, accompanied by penetration of the brass be tween the large newly-formed grains, are the cause of the cracks. It is recommended that the brass be kept below 1100 In order to detect the intrusion of brass into the intercrystalline spaces a polished section is etched 3 min in ammonium hydroxide; this shows the brass as a deep block. The grain boundaries are then brought out in the usual way with a 2 per cent solution of alcoholic nitric acid. deg. C two upper products are large piston rods for a ga | shaft are the other two products ‘ oO! remaining outside Lne lurnace n the proper position in the furnace the open end of the furnace is bricked up before the heat is turned o1 The nitriding temperature in 975 deg. Fah Wi s kept in the furnace from 50 to 90 hi Ammonia introduced when the seal melts or at about 300 deg. Fah causing the cover to seat It takes from one hour t 10 min. to drive out the air after the box is sealed and to 6 hr. for the furnace to reach temperature After the heat is turned off the work is allowed to cool dow to about 800 deg. before being taken from the furnacs After the car is taken out, the parts are allowed t to about 300 deg. before the lid is taken off the containe The work comes out with a silver white finish The largest furnace charge to be nitrided far 2 tons. However, it is expected that the furnace would vork satisfactorily with a larger amount of work in the box at one time Work that has been nitrided in thi furnace includes a shaft 11 ft. long and 6 11 n diameter locomotive cross head guides, crank hafts for moto) puses and piston rods and piston pins fo. ya engine The maximum depth of case is 0.035 in The nitriding box, car and auxiliary equipment were built in the Central Alloy plant. The furnace was built by the Electric Furnace ¢ Salem, Ohio. Much Nickel Used in Radio Tubes nickel for screens and plates in the DVANTAGES of for screen grid tubes or other radiotrons are enumerated by (C.C.C Bloomfield, N. J olby, for mesh can be Westinghouse Lamp Co., Inco, Vol. IX, No. 2. It is readily formed into writing pliable, and the any shape desired; it easily cleaned by baking in a hydrogen atmosphere, and relatively immune to tarnishing on standing or han dling; it can be readily spot-welded to other nickel part t has a relatively high melting poin