The Iron Age 1929-11-07: Vol 124 Iss 19

THE AGE New York, November 1929 ESTABLISHED 1855 VOL. 124, No. Revolution Machinery Design Affecting Industrial Machinery Particularly, Represents Breaking with Tradition and Economic Rather Than Technical WALTER appears about take new lease life because epochal changes that can now forecast. The industrial characteristics the nineteenth century, how- ever, are beginning less evident factors shaping social development. Evidence apparent that economic values are shifting, that new appraisal close hand. New factors are shaping that will accentuate and hasten the action present tendencies toward low cost produc- tion and its invariable concomitant, higher wages. Since time immemorial, power, whether was ox- power, horse-power, water-power, steam-power, the first all, man-power, has been used make machinery pro- ductive. Note clearly this fact: power that makes *Consulting engineer, Boston. Mr. Kelley draws from ex- perience in mechanical design dating from about 1890 and in electrical design from 1906, becoming chief engineer in that year of an electrical manufacturing company. STUART machine productive, regardless whether humanly directed, automatic its operation. The machine itself powerless produce. This point emphasized affords clue what follows. has been necessary the past apply power stereotyped manner, after certain inescapable fashion. Because this fact and the handicaps inseparable from it, machines now built will retrospect appear clumsy and inefficient, therefore expensive build and operate. overcome the mechanical handicaps far humanly pos- sible has been the province the designer and the in- ventor. Two considerations, one objective and one subjective, have determined the type, character, mechanically any machine, every machine. The latter changed, has been invariable since machinery, now know industry, was first made. This was because fixed, inescapable condition, that is, the character the Electricity Will Responsible for This Century’s Advancement orient readers the sweep- ing character which ascribes the new epoch machinery con- struction, Mr. Kelley contributed the following historic background: Industry, defined labor employed any manufac- dates from the improvement the steam engine Watt the latter part the eighteenth cen- tury. Then for the first time power could developed any- where that fuel With increasing industrial devel- opment water power likewise be- gan assume prominence. With advancing civilization the domes- tic manufacture commodities became insufficient, and with the advent the steam engine fac- tories sprang populous cen- ters. The spinning wheel gave place the “spinning jenny,” and that turn the “spinning the hand loom the power loom, and the machine shop ap- peared supplement the work the blacksmith and the foundry. Early the nineteenth century the necessity for transportation for the increasing output fac- tory products brought the steam locomotive into being, and railroad construction went steadily forward vice satan.” the case each these twin agents civilization, transporta- tion and manufactures, the steam engine was and still the domi- nant factor; is, however, one those things which reference was made the outset whose in- fluence beginning wane. Steam controlled and put work was mainly responsible for the re- markable industrial development the nineteenth century. tricity controlled and put work responsible for what will prove more remarkable economic devel- opment and much greater ad- vance civilization. f | | | if | | « | 299 1226 wal power, that made necessary apply definite point, with definite movement direction and speed. Factors Initiating Design the first the two considerations: person given the task designing machine that will take material certain sort and deliver certain definite product. The one machine may take raw material and deliver finished product, the machine that receives paper from roll and turns out envelope, gummed, folded and stamped, and printed with return card; monster printing press that also fed paper from roll and turns out newspaper, printed, folded and counted, almost incredible speed. the machine, more isually the case, may one series, each performing certain process, with textile machinery. the man- ufacture ordinary cotton cloth the material passes through machines from the raw baled cotton the bale cloth, each machine representing separate and dis- tinct process. starting out design any machine essential for the designer know (a) The material worked, its character and tex- (b) Its condition and the form which enters the chine (c) The condition and shape which must deliv- re d; (d) The weight mass material worked hile passing; and finally, (e) The rate production, which fixes the speed different parts the machine. Before putting pencil paper the designer must study the problem from must make mental estimate the different movements and changes motion, the number parts, their general shape and size. assem- bling these into connected whole the machine takes form his mind’s eye. When his mental picture has taken definite shape, takes his pencil and makes free-hand sketch, usu- ally several before one satisfactory; then with this tarting point begins more particular sketch, which each feature takes its proper position, with some attention riven proportion; this point the separate design each begun. drawing details seale, determining the number parts, the shape, size, strength, movement and speed each part, the designer continually meets the ame handicaps, change speed direction rotation, character motion. With the details each part settled the machine whole drawn but not infrequently there results impossible combination and the design must revised. Inhibitions Providing for Power the second consideration: Heretofore, working out the details any machine, the designer has re- peatedly been obliged devise means overcome the inescapable condition that power and motion came from source. Therefore, must initially applied single point (except rare situations) and fixed speed. The power, usually with rotary motion, may applied the machine means belt, chain, gear shaft. Within the machine may necessary vary the speed several points, change motion from rotary rectilinear, provide reciprocal motion, provide rotary motion with varying angular velocity, etc., and the designer has been obliged devise mechanical (and some- times clumsy) means obtain all these various move- ments that each functions positively and order from the single movement initially applied. designing and constructing new machine original type, manufacturer must start with long purse, 1230—The Iron Age, November 1929 the expense the completed machine not infrequently runs into six figures, occasionally into seven. The de- signing may take months expensive force; much research may required. Then may found neces- sary rebuild the first one finished. Then comes exper- imental operation, which may develop the necessity for additional redesign. Sometimes the whole machine has scrapped and new start made. With the machine perfected and the machine builder’s worries over, the purchaser and user begins have his; first, the machine represents large investment; second, mechanical complications require expert attention; third, maintenance cost high; fourth, the light present possibilities use power inefficient; and fifth, possibly large space occupied. These conditions spell high cost product. Mental Bondage Established Custom The adverse conditions enumerated for both builder and user the machine are due large part consid- eration No. that has rigorously prevailed until lately; yet even date very little advantage has been taken the greater technical freedom machine design, increas- ingly possible. Mental bondage established custom has far proved stronger than technical freedom action. The real badness the mechanical complication here- tofore made necessary the inhibitions imposed that one fundamental condition (consideration No. the method applying power and motion) has never been properly sensed, even the machine builder. There has, till re- cently, been other way, the conditions have been accepted inevitable and little thought given them much said about it. But the time has arrived when the designer machin- ery reality emancipated (if will be) from the neces- sity applying power one point, and motion likewise, single character and speed. Will accept emanci- pation? appears very slow doing so. The inexorable character former conditions governing the application power and motion machine has pow- erful hold—mental attitude with regard has become fixed—that mechanical designers find difficult es- cape its thraldom. Only occasionally will one become emancipated fully and freely motivated the— him—new idea. Another reason for slow acceptance the new freedom that mechanical designers have rarely had any consid- erable electrical experience. They are more less awe the intricacies electrical design and fight shy it. When late there has been indicated close combi- nation machine and electric drive, the mechanician has used standard motor, the electrical feature has been left the electrical manufacturer. Since electric motors became factor reckoned with applications power some years ago, electrical and mechanical designers have followed parallel though, rule, quite distinct courses. Whenever electric drive seemed indicated more desirable motive power, the electric motor has been used the mechanical de- signer, but has applied this form power precisely would have done power directly from engine water wheel. has not sensed the basic fact that elec- tric power (the phrase misnomer) not power all, just means transmitting power, the most convenient, serviceable, flexible and controllable existence. Electric Motor Longer Adjunct Here now the great idea. possible the means electricity offers apply directly one several points, without the intervention mechanical means, rotative movement 10,000 hp. 0.001 hp. through wide choice speed; also rectilinear motion through wide range. ture: And simple mechanical aids these two basic movements can varied obtain other characteristic movements, reciprocating, varying angular velocity, etc. Although not formulating the present freedom sign till quite recently, the extended experience the writer both mechanical and electrical design, made quite natural combine the results such experience more intimately than others have done and then sense the real situation. The design electrical forms and movements longer closed book all but few; they are almost much common property technicians the particular features mechanical design. There therefore little technical character prevent manufacturers machin- ery from combining electrical with mechanical production. Very distinct changes method, however, will take place. These are likely more complete than once apparent. This revolution manufacturing methods will not come day, year, but should much evi- dence ten years. The limiting factor time will the supply competent designers available. There are two wise sayings that will throw light this situation. Pittsburgh Bridge Selected most beautiful steel bridge completed during 1928 the Sixth Street bridge over the Allegheny River Pittsburgh, according jury awards appointed the American Institute Steel Con- struction. This bridge was designed the Bureau Bridges, Department Public Works, Pittsburgh, under the supervision Covell, chief engineer. was constructed the American Bridge Co. and the Foun- dation Co. The structure the self-anchored suspension type and 884 ft. long, having roadway ft. in. wide between curbs addition two cantilever sidewalks. jury five made the selection. Two the jury were named the American Institute Architects, two the American Society Civil Engineers and one the American Institute Steel Construction. This jury was made follows: George Pegram, past president the Amer ican Society Civil Engineers, chief eng Interborough Rapid Transit Co., New Yorl Most Beautiful Built 1928 use doth breed habit man,” and, “Habit with him was all the test truth; must right. I’ve done from youth.” This the point view that—with rare exceptions prevails with experienced technicians. because mental attitude that mechanical engineer, master mechanic, rarely competent organize the most effi- cient electric drive, where only question placing electric motors. This not evidence any lack simply unable properly interpret concept power transmission, not merely different from, but actually variance with, his regular line thought. Therefore, there must time for the demand for electro-mechani- cians develop new crop engineers. The only other supply from the few who have not become rutted the traditions, precedents and methods either electrical mechanical design, per se. [In following article the author proposes more specific regarding the implications herein set forth, with attempt supply suggestions practical interest machinery Dr. J. H ice McFarland, president of the Art Commission of Pennsylvania, Harrisburg, Pa the intention the American Institute Steel Construction decorate this bridge with suit- able bronze tablet, and certificates containing repro- duction this tablet and the names those interested the construction the bridge will awarded. Plans for the ceremonies incident thereto will dis- cussed the annual meeting the institute Biloxi, Miss., Nov. 16. Other bridges came for among them the High Bridge over the Harlem River New York, the Cottage Farm bridge over the Charles River Boston and the Thirty-first Street bridge over the Allegheny River Pittsburgh. The Iron Age, November 1929—1231 ‘ | g } ‘ ino «& \ dricl | ~ > 4 7 4 Welding and the Steel Mil Superheated, Gas-Free Steel Carrying Little Aluminum Solidifies Into Metal Tough Forging—Proper Procedure Necessary for Success SIDE from series illustrations repair work done the well-known thermit process (such worn wabblers, welding breaks heavy axles, crankshafts, frames, cylinders and bed tes) Mr. Deppeler’s paper consisted discussion nature the metal the joint. From this ing abstracted. Ir aering t! pn cal ( ialit thermit tee! first question is, will not the strength the welded nly that similar cast steel part and not that the original forging? matter fact, forgings that have been thermit welded and tested destruction just often fail completely outside the welded Steel, cast, differs from forged worked steel not hemical composition but only physically. Com- ercial cast steel solidifying throws the grain many impurities, and these, forming part enting medium between the grains, are weaker +} » the orair +h ] + nan tne grains themselves so that fractures of cast steel lly intergranular. Forging, rolling, working these grains distorts them, that the strength piece then that the material itself and not weaker grain Weld Metal Quite Different from Cast Steel Thermit steels, instead being refinement rela- tively impure materials, are the result the reduction pure iron oxide pure aluminum, with the result that they, although cast, invariably fracture through Technolo t 1906 with the e of echnani cal en 1eer | Deppeler was associated 1 he N York Central | oad ele ication York terminal rcetvle ne welding and worked research 1 this until 1912, when ‘came a sociated with the Goldschmidt Thermit Co., now the Metal Thermit Corpora- tion. New OrTrkK He is now 4 4 chief engineer and works man- 3 1232—The Iron Age, November 1929 DEPPELER This question was thoroughly investigated during the war, when Lloyds’ Register Shipping was asked approve the use stern frames made welding to- gether several simple forgings. Cast steel frames had been approved, but this request was refused the consideration that, customer was willing pay the extra cost forged steel frame, would not right furnish him forged steel frame with cast steel welds, because this would stronger than cheaper cast steel frame similar design. This contention steel approved Lloyds, some the welds being be- tween sections with free ends and others between sec- tions not free move. The results this test are avail- able detail anyone who may desire them, and resulted Lloyds’ approval the thermit welding forged steel frames. One impact test was quoted; where in. billet welded the center and supported 5-ft. centers was struck tup weighing 3290 falling nine times from height ft. This resulted permanent bend in. but sign fracture. The specimen was then turned over and straightened out continuing the blows. After this, Lloyds’ engineer suggested that the weld sectioned and examined internally rather than con- tinue the impact testing, which might prolonged. Since the approval Lloyds’ Register Shipping and the American Bureau Shipping hundreds stern frames steamers have been thermit welded and, although one two these frames have again broken, the breaks have never been closer than ft. from the weld. This, course, not true test the comparative strength thermit steel and forged steels, beeause the case these ship welds the excess metal the weld usually not machined off; but indica- tive the fact that the metal next the weld not harmed any appreciable extent otherwise. All the common alloying elements are easily reduced from their oxides powdered aluminum, and these re- ductions have been carefully studied determine the efficiency the reactions. properly mixing the various thermits therefore possible produce steel given analysis. such means, have our control the tensile strength, the ductility, and the hardness the resulting steels. The tensile strength can varied from about 50,000 Ib. per sq. in. 110,000 Ib. per sq. in., and the corresponding ductility from over per cent elongation in. down zero. Those familiar with the casting ordinary steels must realize the difficulties encounter the extremely high temperatures necessary for the welding opera- tion. Thermit steels, however, have one very great advantage: they are perfectly deoxidized. fact, all ¥ tne grains. | TER being graduated from ne ‘ ONG Seam 2-in. Boiler Plate. Ordinarily such long thin seam would uneconomical because the volume metal the gates and risers such large proportion the whole, but heavy drums the advan- simultaneously welding the entire seam and thus minimizing the internal thermal strains obvious them show very slight aluminum content. Here again, the steel man suspicious, because excess aluminum him usually means trouble, but the troubles that has experienced are due more entrapped par- ticles alumina rather than metallic aluminum alloyed with the iron. Even though, the thermit reaction, great quantities alumina are formed, the heavy metal liquid water and separates from the lighter slag completely and almost instantaneously. For these reasons, thermit steels not have poured low temperatures cause them solidify into dense, sound castings, and the presence absence defects the steels will depend entirely upon the mold itself and the material from which made. avoid contamination from the latter, necessary select the best silica sands and clays and make syn- thetic molding material containing minimum clay thoroughly mulled with the sand grains coat each grain with the thinnest possible layer clay. Such molding material not only generates much less gas when the thermit steel comes contact with it, but also remains porous that the little gas generated easily passes out through the walls the mold and not through the liquid steel. Loose grains sand trapped the superheated steel will completely volatilize. The elimination defects was aided condition inherent thermit welding, that is, that the weld solidi- fies from the inside toward the outside; this, course, tends promote density and soundness the weld itself. Before this fact was thoroughly realized, was customary use large risers, which were not only wasteful but actually harmful. must obvious why this shrink- age different from that ordinary foundry prac- tice; the foundry, the heat from the molten steel passes out slowly through the mold, and solidification the casting occurs first the surface contact with the mold and progresses toward the core the casting, whereas the welding operation the parts being welded act enormous chills the casting and extract the heat the molten steel more rapidly from the center core than from any other point. Freezing, therefore, occurs first approximately along the axis the parts. The realization this fact introduced radical change the design welds, which fortunately the same time greatly lowered the cost the welding operation. This decrease cost turn has increased the applica- tions welding until now more economical weld almost anything the steel mill than substitute new part. Four Precautions Necessary Practice Describing his experiences with thermit welding for steel mill repairs, Coffin, mechanical engineer, Bethlehem Steel Corporation, Sparrows Point, Md., noted four vital factors for success, viz., the set up, mold ramming, preheating, and release the parts after welding. Since many repairs are not simple butt welds, but occur irregular sections partially wholly fixea surrounding metal, the design proper clamps and the provision proper movement consistent with chang- ing temperature are most important. Each repair merit close study its individual peculiarities. Sometimes the supports clamps may mounted rollers; other times the parts must initially jacked apart, and the jacks gradually released cooling. Thermit welding hollow cylinders also requires the best molder’s skill make satisfactory core. For this and other reasons, Mr. Coffin prefers the thermit welding the steel foundry. Lack adequate preheating spoils more welds than any other cause. The joint should uniformly and deeply heated high temperature with re- ducing flame. Cooling after welding should under control. most cases full annealing will justified reduce internal thermal strains. Annealing also in- creases machineability, although the speaker advocated leaving all excess metal place extra factor safety, wherever clearances would permit. David Arnott, chief surveyor, American Bureau OMPARISON the Amounts Thermit Used the Old and the New This reduction greatly lowered the cost the welding operation, but the reason for was primarily the improvement the internal quality the weld : | 6 | The Iron Age, November 1929—1233 cautious approving new methods construc- tion repair. failure sea much more fraught with danger great monetary and human loss than one shore. Tests made years ago and cited Mr. Deppeler are unable explain certain recent failures. For instance, stern frame breaks and repaired, should fail again? one instance new forging replaced part which broke away and was lost; the fracture occurred this new metal. his the paramount consideration the procedure making the weld; there should complete freedom parts move during the temperature changes reduce internal strains the Control such residual contraction stresses is, Mr. Arnott’s opinion, the most important problem now before those who are repairing ship frames and other massive parts thermit welding. Improper design the part sometimes responsible for original fracture, the opinion Owens, weld- ing supervisor, Newport News Shipbuilding Dry Dock Co., Newport News, Va. such cases second frac- ture may expected, since obviously repair weld- ing does not cure the fundamental defect. had found one fracture stern frame immediately alongside weld, but ascribed this concentration stress caused heavy collar weld metal around relatively small cross section. Small Shops Need Superintendent This Official Would Relieve Pressure Manager and Foreman and Increase Production Efficiency ARTHUR +} and die jobbing shops would gain much efficiency sound principles monet industrial management were adopted. Too many them are operated haphazard fashion. The busi- ness transacted owner-manager, shop foreman man the office who combination bookkeeper, pany and usually does the work three four men. makes all important ’phone calls, dictates answers letters that require attention, reads large number his letters that are laid his desk too-hurried office girl man, quotes considerable amount pending rk, makes hurried business calls various parts the automobile, looks over requisitions for material and sees salesmen, goes out after new contracts and shop activities the previous day and ork process. Since the owner-manager most cases former mechanic, generally fills his spare time ying help over-burdened foreman. far salaries go, the owner-manager ing shop employing average men should rank fairly high, for conducts business amounting about $125,000 annually. ich the ast August, the annual business may high 180,000. Thus, would seem that the manager such establishment too valuable man attend any strictly executive duties, omeone eise. During exceptionally good year, Cleveland enjoyed the year ended leaving the lesser activities The foreman, the other hand, overburdened also. must quote prices and deliveries new work, make material requisitions for various jobs, considerable designing, plan the program for his men, see that the aterial and blueprints are got together the proper place and are arranged that any one man any num- ber men finishing job one time can turn some- must give his men individual attention they need it, plan his work for the night urn, see that the men understand the blueprints thor- oughly, take with the inspector mistakes made the hop and help decide what done about them, and nat is G ev Avenue, Cleveland 1234—The Iron Age, November 1929 assume many the details possible relieve the manager. not surprising that, with these duties look after, the foreman has time for reflection for studying his plant with eye improvements. There should provision for assistant foreman, but the management seldom wants pay enough for this job make attractive, view the great amount detail involved. good tool maker can earn about much money the bench without any responsibilities except those connection with his own work. relieve the pressure upon the manager and the foreman there should superintendent, who ranks be- tween the manager and the foreman. His duties should include quoting prospective business, ordering mate- rials, supervising the work the designer laying out his work, going over the shop inspector’s reports and making decisions regard mistakes. also should act buffer between the manager and the foreman, settle all matters that not demand the manager’s per- sonal attention, interview all salesmen, see that one gets the manager whose business can handle, direct the activities the office force, decide the precedence orders the shop and choose the materials used when they are not specified the customer’s blueprints. this plan were followed, the inspector would not responsible the foreman, but the superintendent. However, would work close cooperation with the foreman. The designer, who would report the super- intendent, wou'd all drafting, relieving the man- ager and foreman this job. Many benefits would result from the operation such system. longer being bothered with details that formerly required about per cent his time, the fore- man could give efficient supervision shop activities, job that should his first duty. Production would in- creased, scrap losses would reduced, savings would come from reclaiming waste matter and the mental and physical strain the manager would not exaggeration say that the superintendent, measured the proper standard, would earn his salary many times increased efficiency throughout the entire personnel, from the manager down through the ranks, Shipping, New York, defended the marine authorities for stenographer and time-keeper. Solid Tests Open-Hearth Slags Condition and Composition the Bath Judged Color, Shape and Other Characteristics the making basic open-hearth steel, process control, ex- ercised the practical furnace operator, gov- erned largely his ob- servation and interpreta- tion slag conditions. Solid Slag JANITZKY Janitzky was graduated metallurgical engineer from the Metallurgical Institute Leo- ben, Austria. has been successively the employ The surface slag samples were dull black color (shade), trated Fig. which shows both types, ing the dull surface and the lustrous black. “Make the slag right and public Iron Steel Co., the steel will right” Lackawanna Steel Co., a, auchl; widely Jones Laughlin Steel Co., Minnesota Steel Co., and slogan, and yet scientific the Carnegie Steel Co., the Re- of the Illinois the some cases, the the slag surface contained the design pattern which the studies slags are Steel where has been webbed, see Fig. this day meager when metallurgical engineer since should here compared with the that the spider-web de- Marion Howe medalist the knowledge gained through research the behavior bath. Such slag studies Treating 1922 American Society for Steel sign varied from very coarse fine web, typified Fig. 2B. The conformation have been published are concerned primarily with variations chemical analysis. applied practical steel making these studies might considered “post mortem examinations” which are little use the treatment live subject, that is, while the heat the furnace. The present study has at- tempted therefore correlate such indications physi- cal and chemical variables are almost instantaneously discernible the experienced practical melter, applied him currently toward closer control steel melting process. Slag control, based upon observa- tion solidified basic open-hearth slag samples, being practiced many European works. Used conjunction with metal tests for red shortness, this practice renders service distinct and practical value. preliminary study has been undertaken the South Chicago plant the Illinois Steel Co., and general correlation made the readily observed characteristic similarly solidified basic open-hearth slag samples respect their chemical analysis, color, surface design, conformation and texture. attempt has been mad yet this preliminary study connect the character- istics the solidified slag samples under consideration with the inherent quality the steel. The data obtained, however, reveal that for steel within similar carbon range and like conditions charge there exists present day practice pronounced heterogeneity chemical composi- tion, color, surface design and texture the slag. Slag samples were taken with the ordinary melter’s spoon, poured into shallow circular moulds in. diam- eter, deep and cooled air. The essential char- acteristics the solidified slag cake thus formed are: S (1) Color surface, (2) Design surface (3) Conformation of surfacs (4 Texture of cake. Abstract of a paper before the annual fall meeting f the American Iron and Steel Institute, New York, Oct the slag cake show considerable variations which are classified concave (note the sunken center the slag cakes Figs. and 2), flat, convex “puffed-up.” All convex and “puffed up” samples contain small gas holes, the former case principally the upper portion the slag cake, the latter, throughout the whole matrix; the flat and concave samples are very generally free gas holes. “puffed- up” slag course very gassy and represents frothy condition slag. Fig. illustrates the “puffy” slag. The fractured slag cake classified dense porous, respect gas holes, and columnar crystalline stony structure. Fig. illustrates the structural condi- tion, being columnar crystalline and stony one. Both are dense. piping present, the shrinkage cavity parallel the base the slag cake and located approximately midway between the top and bottom sur- faces. essential have the slag free from metallic globules; cavities containing metallic inclusions (which have fallen out fracturing the slag cake) are not interpreted gas holes which would classify the sample porous. Slags which contain large steel nuggets are useless, their reaction with the metal during solidi- fication the appearance the slag test changed that interpretation possible. Data Analyzed Twenty-five open-hearth heats carefully observed and slag samples were taken, herein described, just before deoxidizing alloying additions were made the bath. This moment should represent the nearest approach equilibrium the reactions between metal and slag any period the heat. The carbon content the bath for the heats studied the time taking the slag samples varied from 0.04 0.18 per cent. The present study has been confined this (approximately) one grade steel order simplify the interpretation The Iron Age, November 1929—1235 a - | wy | | - \ \ Fig. (A) and Lustrous Black (B) Surface Slag Cake the results. All slag and metal analyses, together with the classification slag characteristics herein out- riven Table llustrate graphically the observed physical characteristics the slag samples noted and their chemical composition, triangular diagrams have been prepared the type customarily employed the charting three-component systems. this way, it has been possible to select at will from the various oxides comprised these basic open-hearth slags, various groups three and plot the observed characteristics the solidified slag cakes relation the variations chemical composition for each these groups. That temperature conditions may materially affect the acteristics the solidified slag test possibility which was necessary neglect this preliminary first choice variables was the total acids (SiO and P.O;), earthy bases (CaO and MgO) and iron oxides (FeO and The composition the slags, given Table was converted give P:O;, MgO, FeO and 100 per cent. The converted values, given Table were plotted triangular diagram, Fig. immediately apparent that the dull slags, inclusive, separate themselves from the lustrous black slags shown the line Thus one the physical characteristics listed has been associated with the composition the slag. can now definitely say that basic open-hearth slags heats 0.04 0.18 carbon containing less than per cent. SiO. P.O; (on converted basis CaO, MgO, FeO, equaling 100 per cent) will have dull surface when solidified sample taken, earlier actor importance its bearing the reactivity the slag the amount excess base carried solution for forming with the acids present those definite molecu- combinations which have been identified typical for Fig. Design Slag Cake (Cake Has Been Broken and Heavy Black Lines Are Not Part Surface Design). medium web; fine web 1236—The Iron Age, November 1929 the ground-mass slags the type here discussed values excess base for the slags are given [in Table the paper] terms molecules excess base. seemed advisable plot this variable against the silica and ferrous oxide content determine possibly different grouping slag characteristics re- lated variations composition. After calculating the FeO and SiO. molecular basis, the excess base to- gether with these were recalculated 100 per cent basis, and the slags were then plotted. Notable Conclusions Possible Several notable conclusions are apparent from this chart [No. the paper]. The dull and lustrous black slags again group themselves Fig. low silica content the slags accompanied high excess base and the ferrous oxide content. found that the lustrous black slags comprised those compara- tively low excess base and high silica content. Thus Fig. Slag Cake, Full Blow Holes Fig. 4.—Crystalline (A) and Stony (B) Structure Slag Cake may conclude that the lustrous black slags are associated with low FeO content. This phase will brought again relation discussion cleanliness. attempt correlate the composition with the “spider-web,” the variables P.O;, and excess base, all from molecu- lar analyses converted 100 per cent these three variables, were plotted. Here find that these slags showing the spider-web design separate themselves from the balance the slags. Thus high P.O; content seems influence the appearance the spider-webbed slag sur- face. important find that the dull and the lustrous black slags are again easily separated, are the col- umnar crystalline from the stony dull slags, showing that slags occur with low phosphoric acid content. Thus are related all the observed physical character- istics the solidified slag cake which seem related the composition the slag. understood that all surface design the slag cakes termed esses, The Faraday Society and the Journal Iron and In- stitute, June, 1925, 203. \ AS lined, ar 4 described. the molten mass over and above the quantities required ay j — *Colclough, The Physical Steel Making Proc- Table 2—Chemical nalyses Slags and Values Converted 100 Per Cent for Fig. 6 Values Converted Slag Analyses, Per Cent 100 Per Cent for Fig. 6 Heat SiO,-4 CaO+ FeO + SiO.+ CaO-+ FeV + l 10.05 54.55 27.95 92.55 10.9 58.9 30.2 2 11.09 49.01 28.48 88.58 12.5 55.3 32.2 11.55 2.00 23.3 86.88 1 ) 26.8 2.63 92.16 21.73 14.6 t 25.1 2.82 18.18 85.4 15.0 63.7 6 13.47 50.26 23.87 $7.60 15.4 o7.4 27.2 7 3.35 55.95 19.41 88.70 15.1 63.0 8 14.10 53.92 21.58 89.60 15.7 60.2 24.1 9 14.96 52.80 21.13 88.89 16.8 59.4 23.8 10 15.23 52.90 19.50 87. 17.4 ot 22 11 15.67 50.94 19.48 86.09 18.2 2 oz. 12 16.39 52.05 16.71 85.15 19 61.1 19.6 13 15.87 53.07 17.45 86.39 18.4 61.4 29.2 14 16.05 53.91 18.15 88.11 18.2 61.2 20.¢ 15 17.06 50.75 18.52 86.33 19.8 16 16.99 52.18 16.85 86.0 19:7 60.7 19.6 17 16.80 50.40 19.69 86.89 19 g 0 99 7 LS 17.47 50.12 17.38 84.97 20 0 19 7.25 48.72 21.29 87.2 19.8 8 24.4 17.96 48.33 20.17 é 21 17.92 0.59 17.50 86.01 20.8 8.8 «0.4 22 17.81 51.59 18.18 Si.o8 20.3 8. 20.8 23 17.64 4.70 18.09 90.4 19 0 20.0) 24 19.21 53.88 13.79 86.358 22.2 61.8 it 19.61 {8.78 19.72 88.11 22.2 22.4 these groupings can explained the basis the min- eral composition the different slags, but has not been possible yet broaden the present work in- clude study mineral apparent that any practical application slag samples entails relating the conclusions drawn from the slag study the properties the steel. One such steel property may mentioned briefly, the matter clean- liness. seems apparent that low FeO the steel will conducive cleaner final steel. Thus low FeO con- tent the slag desirable feature and the furnace operator can control his heat better aiming obtain lustrous black slag surface test cake. also probable that those slags which show the most dense structure respect gas cavities usually represent condition diminished gaseous reaction be- tween metal and slag. not, however, inferred that all cases this dense condition can used for the deter- mination complete equilibrium between metal and slag, but believed that this density which always accompanied concavity taken index dimin- ishing reactivity. For example, well known that the addition iron ore molten steel bath results notable increase reactivity which subsequently decreases and interest note that the solidified slag sam- ples taken intervals subsequent ore addition exhibit \ 4 \ ° 6 > eo ive) ne) < < SO “a Ne Fig. 6.—Relationship surface coloration slag cake the three variables, acids earthy bases and iron oxides plotted chemical percentages. Note separation dull from lustrous black slags. Data given Table diminishing degrees convexity and porosity and further ore additions are made they become relatively dense and concave. Thus these slag tests may em- ployed practically and usefully indicating the degree Table I—Slag and Analyses and Physical Characteristics Slags Slag Analyses before Additions, Percent Steel forel Additions, Percent Physical Characteristics | | The Iron Age, November | 4 | approach toward equilibrium conditions. other words, taking slags during the period after the charge melted one can gather frozen evidence the magma different stages during the process. From the foregoing reasoning one may conclude that slags which show black emphasized that the desirable slag char- acteristics and composition must determined for each plant, local variations the analysis the charge and fluxes used will undoubtedly affect the coloration, surface lesign and texture the slag tests. Undoubtedly scosity test proposed Herty and Gaines, which handy and may also executed the furnace platform, would useful combination with the slag solidification Petrological studies will still further enhance the owledge and define more clearly the variation the texture the slag specimens. apparent that useful information can obtained the study slags solidi- ied form and that much work still required this di- rection. The foregoing notes are derived essentially from observation solidified slag tests, and hoped hat they may found useful actual furnace operation and also promote thought along the lines which this paper has been written. Some Exceptions Taken the Author’s Calculations Mr. Janitzky has presented very interesting paper most interesting subject, basic open-hearth slags, the opinion Dr. Herty, Jr., Bureau Mines, Pittsburgh. The method studying slags much more comprehensive than usually attempted the average operator and should, with some additional information, eat help the open-hearth operator. One common method judging open-hearth slags, not the paper, chill the slag the spoon ind examine the color this solidified slag. this lidified slag is crushed and the color noted, it is pos- ible predict the phosphorus content the metal very ely, provided that the phosphorus the charge not high that abnormally high percentage P.O; present the slag. Deep chocolate browns indicate under 0.010 per cent, phosphorus, browns and light browns indi- cate 0.010 0.015 per cent, and black slags indicate above 0.020 per cent. Many heat steel has been tapped out slag color contradiction preliminary results from the floor laboratory. treating certain parts the slag composition ternary systems and charting ternary diagrams, Mr. Janitzky has brought out several interesting facts. How- ever, safe assume that the originators the ter- nary diagram are groaning their graves the method preparing Fig. [in the original paper]. preparing this plot the author multiplied the percentage P.O; the slag and then divided the percentage each component the sum and excess base. multiply one component ternary system before the ternary composition entirely incorrect, and had the author prepared this diagram obtaining the ternary diagram with the molal percentages calculated and then increased the percentage some multi- plying factor such 10, drawing lines from the apex 100 per cent P.O; the point question, would have ob- tained diagram showing the relations between the dif- ferent types slags more plainly than shown Fig. 10, and, furthermore, would have been correct mathe- matically. this particular case large error was in- volved, but had the percentage P.O; averaged per cent, instead about per cent, very serious errors would have been made plotting. regretted that the author did not include more ideas the effects different types slags, shown his tests, the quality the steel produced. somewhat dangerous group 0.04 per cent with 0.15 per cent carbon heats single type steel, the rate carbon elimination was undoubtedly entirely different heats caught 0.15 carbon and those 0.04 per cent carbon. hoped that Mr. Janitzky will later present papers the correlation the slag tests with the quality the steel produced, this would most interesting every open-hearth man. German Tests Acids During Pickling RGUMENTS the relative merits HCl and H.SO, for picking steel are summarized Dr. Fritz Eisenkolb in Stahl und Eisen. Hydrochloric acid etches more rapidly and more cleanly, operates effectively lower temperature and leaves residue which does not react with ammonium chloride zine chloride. Disad- ges are the necessity for special containers (pottery glass), low content acid per unit weight, and the harmful vapors coming from the bath. Furthermore, the ferric chloride formed increases the action the steel. hould also pointed out that the waste liquors are use- and their annihilation therefore matter consid- the case sulphuric acid, favorable factors are its igh degree concentration, absence noxious fumes, ron. Baths may thus used nearly the saturation oint. the other hand, the bath must heated give sufficiently rapid action. The cleansing action not marked due the lower solubility oxides than HCl. Baths which have been long use tend deposit ulphate crystals when cooled down, and these must removed washing. Most harmful impurities acid baths arsenic. Iron Age, November 1929 Acids rapidly lose their strength the presence arsenic and the steel covered with arsenical deposit. The tolerance arsenic 0.01 per cent in66 deg. H.SO, and 0.005 per cent deg. HCl. qualitative test can made diluting and deg. respectively and adding few cubic centimeters per cent solution. The formation yellow colloidal precipitate indicates only traces arsenic. yellow flocculent pre- cipitate indicates larger quantities and the sample should analyzed. greater importance operation pickling baths are periodical data the temperature and acid strength. While thermometers serve adequately for temperature measurement, the determination free acid the pres- ence iron salts presents certain chemical difficulties. method now use Germany consists, principle, allowing definite amount the acid sample react closed vessel with weighed amount potassium carbonate. The volume thus liberated read off burette calibrated directly per cent free acid. The taking tests 2-hr. intervals recommended. also pointed out that the analysis the waste liquor this same way will frequently disclose the wastage considerable amounts useful acid. lustrous and concave surface are the most desirable. vcs . aste Prevention and Salvage How the Steel Industry Can Save Inventories— What Costs Carry Larger Stocks Parts FRANK PARRISH ERTAIN railroads and other large users iron and steel report impressive salvage (equivalent from the disposal scrap. Iron and steel scrap not incidental item steel making. rather nec- essary and very important raw ma- terial. Even assuming that steel works could not itself use the scrap produced, its volume would such that could not regarded anything other than regular prod- handling scrap, however, there opportunity for prevention ex- pense that unnecessary and con- sequently wasteful. Furnace plants must keep this expense mini- costs, but detached outlying operations not making ingots heavy steel products, the handling scrap does become somewhat in- cidental. Industries represented mem- bership this institute consume yearly total not less than 25,- 000,000 tons scrap. Much its journeys from the pick-up points, way scrap yards, cars, etc., Corporation, the steel furnaces. Each ton scrap entering into ingots cast- ings probably handled, the first position Frank castings, nor regularly handling Parrish was American plant the Ameri- can Bridge Co. Chicago. was associated with this com- pany Chicago and Pitts- burgh until 1917, his last po- sition being assistant purchas- ing agent. From 1917 1921 was purchasing agent the has handled several times Ojibway, Ontario. Since 1921 has been supervisor inventories, United Steel — Utilization of unused laboratory samples of fuel, etc. ; Unnecessary telephone telegraph Waste of office supplies; | Use of discarded forms or the backs of old reports for scratch pads, rather than new paper; Reclamation of broken or worn t Salvage of containers, packing ma Elimination reports failure to combine into one report in- formation required by several different flicials or departments, thereby making one report for all. Among the suggestions either offered developed during the cam- paign, and dealing with the some- what larger operating processes more less peculiar the steel in- dustry and its allied affiliated raw material, transportation service companies, might mentioned the following: Cutting down hot saws used for certain operation in., whereby the production saw chip was reduced 2000 tons annually; | Platform between two blowing en- 1893 the gines, allowing one man to run both en- gines Estimated saving $5,000 a year; Reduction labor required for tak ing and preparing samples s Estimated savings $3,500 a year for Corporation, wor} mii Certain change in limestone re creening r plant, which would make a return $8,250 yearly; Broadway, Installation distant secondary gnals, connection of additional switche with interlo« average, much three times. 5c. ton for each handling could made, the aggre- gate annual saving would nearly $4,000,000. Parrish told campaign conducted last year the Carnegie Steel Co. effort avoid waste along many lines. Among the common items waste which could mentioned are: Leakage pipe lines: Extravagant use of lubricants, waste and other mill supplie ind failure reclaim such materials when profitable so; Unnecessary burning of lights, use of heat, or running of water Saving of fuel in cleaning furnaces Unnecessary use power, failing turn off motors, to use belt shifts: Unnecessary delays locomotives, trucks other motive equipment This article is an abstract of a paper read Oct. 25 before the American Iron and Steel Institute, at New York locking plants and other prac tices leading to fewer slow-ups and stop of heavy trains carrying ore. Annual saving difficult to estimate perplexing salvage problem the steel industry the economical disposal machinery power plant units which have become obsolete for economical use where in- stalled. many cases such equipment could put years useful life some other place, where its economical capacity would meet the requirements. But, for various reasons, often hard get any dismantled piece equipment released for transfer outside sale. possible that the salvage return quickly available not high that which was estimated when replacement was being considered, and the impulse may wait for better prospect. The superintendent manager may feel that good thing have around, but rarely put back into use the plant which formerly served. The result often that eventually becomes far behind the times, depreciates much reason it