The Iron Age 1929-11-14: Vol 124 Iss 20

THE IRON AGE New York, November 14, 1929 ESTABLISHED 1855 Apprentice Training Pays Dividends New High Standards Result Developing Young Men for Responsible Executive and Technical Positions PRENTISS* IGHER standards apprenticeship training and higher goal developing young men for responsible entrance requirements which call for more ex- executive and technical positions modern industry. tended preliminary public school education have With changed conditions production, men with spe- been adopted the Warner Swasey Co., Cleveland, cialized training have large measure replaced skilled its apprentice training school with view obtaining machinists machine operators production shops, editor, THE IRON AGE, Cleveland usually working indefinite time repetitional opera- * wae The Apprenticeship Training Class the Warner Swasey Co. Shown the Upper The lower illustration shows blackboard instruction class room 1293 tions. While specialization, course, has contributed mass production, has frequently been pointed out that the development the man has been neglected except for his own routine operations and has been given pportunity broaden extent that will become potential executive timber. the other hand, with the growth industries there has come increase the de- mand for men capable filling the various supervisory technical positions. successful operation for years, the Warner Swasey training school has made minor changes from time time its standard methods order keep pace with the changing conditions industry. Whatever nes crept the school organization that was re- < garded too much red tape was speedily eliminated, and implicity marks the operation the school. run along practical and flexible lines with low overhead and very little clerical detail. Plant Executives Are School Graduates While the fundamental purpose the Warner Swasey training school—to give good mechanical train- ing stepping stone for higher positions—is not new, being emphasized the raising the standards. Its past success this direction shown the fact that manager, two superintendents, the chief de- signer, metallurgist, estimators, time-study men, several foremen and assistant foremen, some branch office man- agers and several salesmen are graduates the school. Other graduates hold important positions with other com- Formerly applicants who had passed through the eighth grade the public school were admitted the training school. Now the young men enrolled must have education equivalent least two years’ work Cleveland high school. However, majority the new pupils are high school graduates. The age limit has been narrowed, now being years, desired that all apprentice supplement their work apprentice school attending one the various night 1294—The Iron Age, November 14, 1929 schools Cleveland, this being advised whether they are high school graduates not. making curriculum night school studies, the apprentice aided the supervisor the apprentice school the selection studies that will fit well with his work. Night school attendance also emphasized the whole personnel the company. The applicant must physically sound and good habits and character. Extreme care taken the selec- tion apprentices order secure the right type young men those who give promise having latent talent that will make them fitted for the mechanical field. avoid the possibility improper placement, the student who admitted taken for six months’ probationary TUDENTS Are Put Ma- chines the Start, the Shop Training Being Augmented Class Room Work. There shop training room, but apprentices are assigned the various production departments ro- tation, each prentice being un- der the direct su- pervision fore- man. Usually four machines each department are re- served for the use period. That regarded sufficient time judge his adaptability. Probationary Period the Important Test During the trial probation period the apprentice system put important test. The work during that period must training value the purpose the trial period fulfilled. The apprentice given class work that interesting and the same time not too difficult will become discouraged. During this period must decided for the good the young man and his employer whether the former has the ability master the trade. found that has selected vocation for which not fitted, only fair him that not permitted serve the four-year course. report the applicant’s progress and general de- portment made the superintendent the first each month during the trial period. any time found that not qualified for his work, his services may terminated. the applicant found satisfactory the expiration his trial term, engaged regular apprentice and signs agreement remain with the company years longer. While there definite division apprentices their classroom and shop work, under the flexible arrange- ment that prevails they can fairly well divided into two groups based their preliminary education. Those with APPRENTICE WORK RECORD NAME SHOP NO TERM COMMENCED GRADUATED MONTH SHOP WORK SCHOOL WORK DEPARTMENT ABILITY BONUS HOURS ACTUAL EFFICIENCY OEPENDABILITY | TIMES TARDY RECORD gard Sur Ho Abit gs Abilit? ne First Cs mre cal Mechs™ Unusually LEGEND Grade A— Excellent. ..95 B—Very Good. 90 “2 D—Fair 7 E—Poor 65 Name Apprentice SHOP RECORD Quarter Ending SCHOOL RECORD l¢ ls | | | l< = 9 77) | | | THE WARNER SWASEY COMPANY APPRENTICE SHOP DEPARTMENT CHANGES EFFECTIVE THE WARNER Parent or Guardian's Signature (Please sign and return APPRENTICE DEPT EMPLOYMENT DEPT OMPLETE Records Are Kept the Work Done Apprentices. monthly record made the foremen the department which apprentice working, and the data from this shop record are used making another record which includes grades for school work. quarterly report sent the boys’ parents. Still another blank used transferring boy from one department another The Age, November 14, 1929—1295 | — Monthly Machine jr ac | | Months | + 4 — rat only two years high school generally become shop em- ployees and will fill positions foremen, assistant fore- men, inspectors and tool makers. The apprentices who are high school graduates usually more out their apprentice course than the boys the other group and are inclined qualify for more re- ponsible positions, including those junior engineers. training usually qualifies the apprentices this group old positions other usefulness than shop work and bly would become discontented kept the indefinite time. These apprentices many cases designers, estimators, time-study men into the sales department. Many develop into good designers because their wide shop experience and dvanced technical training accomplished earnest ap- night school efforts. While not graduate engineers, they have rather broad preliminary training engineering, being given good grounding the fundamentals engineering. However, ipprentices, regardless their pre-apprenticeship education, are the same footing. They are given the same opportunity succeed whether they are high eraduates or not. Train Production Experis The hool aims train experts production. The tudents are put machines the start and the shop training augmented class room instruction such subjects are applicable the everyday shop experi- en I tr boy. The curriculum has passed through evolution founded past experience. The week’s schedule includes hr. shop work and hr. the class room, class room work being for weeks the year. This includes such subjects shop mathematics, machine draw- ing, applied mechanics, materials construction and or- ganization. The curriculum follows: p arithmetic ead ig, gearing speeds easuring, algebra with practical applica tice, machine tools care and operation me principles of engineering drawing algebra, shop practice and mechanical drawing he fir yea practic: ind applied mechanics ractical apy ition to shop problems, mechanical draw 2 Fourt metal chen manufacture and physical iter of construction, ete, etallography re m design, gears, cams, ets shop electri the ¢ ! il stud \ 4 = a 1 ee } « _ —_ 1296—The Iron Age, November 14, 1929 feature the system that there shop train- ing room. Apprentices are assigned the production de- partments, where they start production work machines. Each apprentice assigned foreman and always under his jurisdiction. The foreman, however, part relieved instruction shop instructor, who assistant the school supervisor. Apprentices work production basis and are eligible bonus. Apprentices Routed Through Entire Plant The boy routed through the entire plant sys- tematic way order give him opportunity gain complete knowledge shop practice. This accom- plished following prescribed department schedule that was recently rearranged eliminate work departments that would mean repetition work already done and duplication effort and the same time provide logi- cal sequence training various types machines. The method scheduling fits with the arrangement equipment, which grouped according machines. Four apprentices are work time most depart- ments and they spend four months each the de- partments. apprentice divides his time between dif- ferent types machines the same general classifica- tion each department and spends from one two months each machine except turret lathe, which devotes four months. For example, starting the drilling department the apprentice spends two months vertical and two months radial drill. follows the schedule through, being trained the various types machines sequence and the end months reaches the tool room. After leaving this devotes four months miscellaneous work. During the last four months given training along any special line that may wish and may seem best fitted follow. the following page the apprentice shop schedule. Machines, usually four number, are reserved for the apprentices most departments. With this plan ap- prentice always guaranteed machine which work, and with four-month periods the scheduled changes be- come simplified. Apprentices’ Jobs Are Secure apprentice who industrious, shows the proper ca- pacity and complies with the rules and regulations sure holding his job, for never discharged because curtailment plant operations. There established PPRENTICES Work the Planer Depart- ment. This and other pictures show that the appren- given their shop training the best types production equipment : — an Operating Modern Type Sim- plex Ma- chines rule that the number apprentices department limited maximum per cent the total num- ber producers, but the number usually kept below that percentage that the danger avoided exceed- ing the percentage case falling off business. Various activities are provided interest the boys and encourage them show their capacities. annual essay contest held, the boys competing the writing Cash awards and trips other industrial cities are the prizes. This contest has done much stimulate interest, initiative and individual enthusiasm among the boys. An- other activity “The Apprentice,” monthly publication edited the apprentices. Material pared for the most part by, the apprentices and the pub- lication distributed the entire personnel the com- pany. APPRENTICE SHOP SCHEDULE Months Total Ap- Ma- on Months prentices chines Each in Re- Ma- Depart- Department Department Analysis quired chine ment Drilling 4 Vertical 2 2 Radial 2 2 { Screw machine 4 Nos. 4 and 6 mchs Heat supply Heat treating Tool supply 2 4 Milling 4 Horizontal! 2 2 Vertical 1 Simplex 1 l Lathe and grinding 4 Engine lathe | 1 Surface grind ng l 1 External grinding l l Internal grinding | l $ Assembly sub-unit i] Ram type units 2 Saddle type units 2 i Planing Planer shapers 3 x 10 planer 1 1 Horizontal! boring mill 1 1 Assembly—Ram type 4 Main machine 4 Assembly—Saddle type Main machine Turret lathe operation Bar machine saddle type Chuck machine Tool room 4 General work $ Miscellaneous The Apprentice Club organization graduates and apprentices and carried entirely them. Meet- ings are held once month and are preceded supper served the company’s cafeteria. The club’s function both educational and social. Complete Records Kept Boys’ Work complete and accurate record kept each young man’s work. monthly apprentice shop record made cated the time. The data from the shop record used making apprentice work record, which also placed the grades for school work. quarterly apprentice report also made out and sent the boys’ parents. Letters are used for symbols grading similar the plan used schools. Another form provided for the transfer boy from one department another. This, signed the apprentice and employment depart ments, gives complete authority for the transfer. dition these records, written reports the workman ship, fitness and deportment each apprentice, with recommendations his future work, are made the superintendent quarterly during the entire term apprenticeship. The boys are paid 25c. per hr. during the first six months their apprenticeship and their pay raised per hr. the end each six months’ period, that during their last six months training they are earning per hr. They receive pay for the time spent class room work. completing his four years’ training each boy receives gratuity $100, graduation pin and four years faithful service. School Pays Dividends Production Two questions frequently are asked connection with apprenticeship system. One is, “Does pay?” and the other is, “Does sufficient percentage the apprentices remain with the company after graduation?” The Warner Swasey Co. school paying good dividends produc- The Age, November 14, 1929—1297 | tion. The work the boys satisfactory both quality and volume. Apprentices having average three training are showing shop efficiency per cent. fixing the bonus for regular mechanics the shop efficiency based per cent. The second question also answered the affirmative. the graduates the school since 1915 more than per cent are still the employ the company, and surely important fact hat nearly all these hold responsible executive tech- nical positions and very few are the ranks machine operators. the graduates since 1915 who are still employed the company, four are makers, are in- rs, one assembler, three estimators, one sales cor- six foremen, three assistant foremen, five ma- chine operators, four designers, four demonstrators, two pattern makers, one tool room clerk, one purchasing clerk, one production clerk, six sales department, one cost epartment and two time study. The fact that the Warner Swasey Co. has continued the practice training apprentices for many years itself evidence the soundness the policy. There ample room—and indeed great need—for increasing the business apprentice training throughout the metal- working industry. Apprenticeships, one form another, have existed throughout the ages. Manufacturers have experimented from time time determine the most efficient way training men for given industry. the present time many seem believe that mass production has eliminated the need for trained men other than the specialized types. But, permit business become active, and the lack trained men becomes the same old complaint. Chromium Plating Brass Iron Chromium, when plated brass iron, often faulty through errors the preliminary deposition nickel and not the subsequent plating with chromium, Chemiker Zeitung. hydrogen during de- position chromium and its absorption the metal cannot avoided. the hydrogen readily diffuses from the chromium into the nickel, the capacity the latter for the gas may easily exceeded. This results brittleness, non-adhesion and peeling, either during the plating chromium soon afterwards. deposit coating low hydrogen possible, the au- thor recommends the use baths which give ciently strong and ductile product, low which adaptable for subsequent chromium plating, even with the use high current densities. Insufficient re- moval grease from brass before application the nickel also causes blisters the chromium plating. Armstrong Seadrome Will Require 15,000 Tons Steel Armstrong seadrome, floating landing field aid transatlantic air navigation, will require about 15,000 tons structural steel and plates. About 9000 tons pig iron other able ballast material also will used. Esti- mates are now being taken the cost building the first the Armstrong sea- lromes. possible that work will divided building Co., Chester, and the Works, Philadelphia. accompanying illus- tration shows working model the seadrome. This model has withstood tests which heavy storm conditions have been simu- lated. The drome will 1100 ft. long and 340 ft. wide. Its legs, which are for anchorage, will extend downward 252 ft. The platform will ft. above the normal During the tests, some which effected condi- tions waves 180 ft. high, the seadrome model remained practical- level, without pitch roll, according the in- ventor, Edward Arm- strong, engineer with 1298—The Iron Age, November 14, 1929 Co., Wilmington, Del. Henry Gielow, Inc., naval arch- itect, New York, has worked the plans for the anchor- age. anchorage cable 21,150 ft. long will used. When the drome has practical, others will built that chain will provide landing fields about 400 across the Atlantic Ocean. The first one will an- chored midway between New York and Bermuda. These seadromes will equipped with various facilities such hotels, gasoline filling sta- tions, repair shops, They will also have radio apparatus, enabling them keep touch with air- planes sea. The designers say that these seadromes will re- main virtually stationary during the heaviest storms sea. Airplanes will able land their decks, refuel and take off again. Mr. Armstrong has been working for years and has had the advice and cooperation such organizations the General Electric Co., Ra- dio Corporation Amer- ica, John Roebling’s Sons Co. and the Sperry Gyroscope Co. { ~ SAAN 4 Lubricating Problems Rolling Water Introduces Detrimental Factors—How Various Types Mills May Adequately Greased ISCUSSION lubrication the presence water occupied the September number Lubrication, published monthly the Texas Co., New York. Essential characteristics lubricants were outlined and then their application various types equipment, with water splashing over the bearings, was entered into some detail. What was said about conditions steel mills covered the following paragraphs. Water Roll Drives Causes Trouble steel plant service hot water steam conditions will frequently prevail the blooming mill well certain other rolling machinery. This because often found necessary run water constantly over the rolls and roll necks for the dual purpose cooling and blowing off scale ingots, bars billets are broken down. Some mills, addition, blow steam directly the ingot during its first pass through the rolls, remove the scale more effectively. Such conditions, coupled with the extreme heat which constantly encountered, place most exacting requirement upon the roll-neck and gear lubricants. These must, therefore, compounded prod- ucts, inasmuch straight mineral lubricants cannot with- stand the continued washing action hot water. The usual procedure compound the gear lubricant with definite percentages certain substances which will give the final product the desired adhesive properties. Any rolling mill gearing, however, which does not come con- tact with water can readily lubricated with straight mineral gear compound, viscosity ranging from 2000 5000 sec. Saybolt, according temperature conditions and the manner lubrication. The pinions adjacent the roll necks the blooming mill are usually inclosed oil-tight casing. this event they are run bath specially prepared gear compound high adhesive characteristics, having vis- cosity about 2000 sec. Saybolt 210 deg. Fahr. some installations, however, these pinions may only covered with shields which are not oil-tight. Where this done there often bottom the gear case; therefore, bath lubrication out the question. the lubricant must able stick tenaciously the pinions over the periods which intervene between applica- tions, and maintain sufficiently protective film. vis- cosity about 5000 sec. Saybolt 210 deg. Fahr. has been found necessary make the resultant lubricat- ing film able withstand the terrific pounding and ham- mering which occurs, especially when the mill reversed. Continuous Mills Rolls continuous mills are usually driven herring- bone pinions and set relatively heavy gears. These pinions such mill are often constructed make necessary lubricate the bearings with grease and maintain continuous flow cooling water over them. Naturally this water will splash the pinions (where exposed), involving condition and requiring grade lubricant such was mentioned discussing the blooming mill. Certain mills, however, may built with oil-tight gear cases and suitable shields which will permit bath lubrication. This, course, the admirable condi tion, for the utmost protection afforded both the lubricant and the gear teeth. Table Rollers Bevel gears which drive the table rollers nearest any rolling mill frequently operate exposed. They are, there fore, subject water conditions, flying scale and the heat which radiates from the hot metal its course through the plant. Here the gear lubricant difficult apply, the first place, and, furthermore, after has been plied, there every obstacle put the way its tioning effectively. Centrifugal force will tend throw off, especially where has suffered any extensive duction viscosity, due overheating. The washing action the water which splashes such gears detriment also. addition, excessive con tamination solid foreign matter can hardly avoided, unless precaution taken guard such gears effectively. Ultimate protection can attained, therefore, only frequent applications lubricant which has been refined withstand these detrimental conditions. Usually the same product recommended for the blooming mill gears must used, having viscosity from 1000 2000 sec. Saybolt 210 deg. Fahr., according weather and temperature conditions. should plied pouring the teeth the point mesh while the gears are running inward. Salt Plate Mills Detrimental Plate mills present additional detrimental condition, from the quantities de-scaling salt which are thrown the plates during rolling, and also from the red hot plate passing directly over bearings and gears table rollers. Often water sprayed the rolls addition. These factors, coupled with flying scale and dust which driven with considerable force when the hot gases ex- plode, tend destroy any lubricant used the roll necks, table roller bearings and gears. Gear compounds specified above, however, have been found withstand these detrimental elements quite satisfactorily, applied frequent intervals and sufficient quantities. Here additional property which the gear lubricant must possess ability resist being thinned out the oil which used the pinion bearings, inasmuch good deal this latter will often work out and the gear teeth, especially older types mills. Roll necks must lubricated with specially com pounded roll-neck grease that will not carbonize nor wash off when contact with the water run over them keep them cool. Lubricants used such roll necks are termed cold-neck greases. general, they are tallow-mineral oil compounds, often being prepared emulsify con- tact with water. Frequently, however, water not used. where is, the necks may run hot melt down cold-neck grease. such cases hot-neck grease must substituted, despite added friction and wear. The Age, November 14, 1929—1299 7 3 OF, | | te j = q Hudsen River Bridge Column (Half Dimensional Size) Testing Machine Ready for Test XTENDED use so-called structural silicon medium manganese structural steel the Port New York Authority has already been noted THE IRON AGE. Approximately 33,000 tons the former has been bought for tower, floor and anchorage members the 3500-ft. suspension bridge over the Hud- son, and 5500 tons the second named will into the 1675-ft. arch built over Kill van Kull, nearly all into the bottom chord. Extended studies of these steel (as well as other more common materials construction) are being made the bridge department the Port Authority, including tests destruction half-size fabricated members. Some preliminary results the strength large columns fabricated three types steel are now available, and give direct comparison the different steels they would expected behave bridge. For this work the 10,000,000-lb. testing machine the United States Bureau Standards, Washington, was used. Six columns were ft. long, about 160 sq. in. cross section, and dimensionally one-half size specimens the base columns the towers the Hudson River suspension bridge. Two others were dimensionally one- half size representative member the lower chord the Kill van Kull arch bridge. The six first mentioned were identical size and make up, except that two were *Aug. 25, 1927, page 466, and June 13, 1929, page 1643 1300—The Iron November 14, 1929 Test Large Structura fabricated ordinary structural steel, two the so- called structural silicon steel, and two new type medium manganese known structural steel. (The main web plates the latter speci- men columns were reduced thickness slightly keep within the capacity the testing machine.) The Kill van Kull specimens were the third type, viz., medium manganese steel. Specifications for the Three Types Physical specifications for the three types contain the following principal requirements: Man Carbon Silicon gunese Steel Steel Steel S0.000 000 6S,000 95,000 nore Yield point, minimun 25 000 15,000(a) 5.000 Reduction in area, minimum(b) i2 30 30 (a)Average for ear group of 10 heats must be at least 17,000 Ib. per sq. in (b) Sect Ver ; in. thick may be slightly less du 2 all types the material, in. thick less, must bend 180 deg. without fracture about pin whose diameter equal the thickness the test piece. Elongation in. must also greater than the figure derived dividing 1,500,000 the ultimate strength, with certain allowances for plates sections thicker than in. for the silicon and in. for the other two varieties. Chemica! specifications for silicon structural steel are follows: carbon less than 0.40 per cent, phosphorus less than 0.04 per cent, sulphur less than 0.04 per cent and silicon between 0.20 and 0.45 per cent. — r + / / } / j } / - A 4 @) + + 1 f f A /B | j | ~ ¥ + An) 0.00 / Train in inchne ch Stress-Strain Curves Large Compression Members half dimensional mode! section Kill van Kull arch, made medium manganese steel; proportional limit model 24,000 lb. per sq. in. and are half models columns for towers Hudson River suspension bridge, identical except for type steel used. medium manganese steel; proportional limit model 24,000 per sq. in. structural silicon steel; propor- tional limit model 22,000 lb. per sq. in. ordinary structural steel; proportional limit model 18,000 per sq. in. -_ —_ Columns Alloy Steel Medium manganese steel analyze follows, for shapes and rivets: Structural Steel Rivets Preferably, not over 0.35 0.30 Phosphorus .... § Ac id steel, not over 0.05 0.04 i Basic steel, not over 0.04 0.04 Check analyses are made the Port Authority from finished material representing each melt. the results such check analyses show excess beyond the limits specified more than per cent for carbon silicon, per cent for manganese and per cent for phosphorus and sulphur, cause for rejection. The sum the carbon and manganese content check analyses should preferably less than 2.05 per cent. Large Columns Tested Failure Cross sections the columns (diaphragms not indi- cated) are shown herewith; also some representative views the tests. One view the test progress shows the steel scaffold surrounding the entire testing machine enable the observers reach any part the column, and special latticed structure built close the column, which served base lines determine deflections and any tendencies toward geometrical distortion during test. Total compression was measured group mi- crometer dials, built into compressometers ft. long, four for each face the Hudson bridge columns. The picture shows two them the edges the outstanding flanges and two the reentrant angles obscured the view). testing, the load was increased increments and held stationary until all observations were made. This routine was continued step step until the total deformation overran the range the measuring instru- (one Hudson River Bridge Kill van Kull MAIN MATERIAL MAIN MATERIAL 4Ls 4x 4x 9/16 al 4 Pls. 9 x %d Cross Section Columns, Diaphragms Not Shown After Severe Over All Test Failure Typical Columns This Design, Irrespective Used ments, which approximated the maximum carrying capacity the column. that time series load-time measurements were made determine whether the “pick-up” phenomena were present. “Pick-up” term used designate progres- sive strengthening column after long continued ing beyond the stress which causes considerable deforma- tion. associated with change the modulus elasticity stresses beyond the proportional limit. these tests the carbon steel columns showed 3200 per sq. in. “pick-up,” the silicon steel columns 3000 and 1900 in. respectively, and the manganese col- umns did not show the phenomenon. Some results the tests are tabulated. Stress-strain curves are shown; curves for duplicate columns are identical. lb. per sq. in. Columns Much Below Yield Tension Specimens Elastic Limit Point will observed that the true elastic limit the fabricated column (or least that load where the linear relation between stress and strain undoubtedly ceases) very much lower than the minimum yield point called for the specifications. The latter figures are more nearly approximated the stress which failure column commenced. These columns were relatively short (ratio length least radius gyration being 28.9 and 23.7 re- spectively), there was marked deflection the The Iron Age, November 14, eee | i a 9 “In | y Ss mary of Results o / e ¢ lu 8 Column Test and Data Dimer Coh Calculated ~ Yield Point Proportional Stress Li Radius From Mill Tests, Limit (b) at Failure(c), per Sq. Lb. per Sq. Lb. per Sq. Hud River Bridg ( I if 159 1. in 10,200 17,000 94 f 159 sq. in i 10,200 18,000 { 159 sq ! 54.900 22,000 ~ ts 24 ft 159 Sq. in. 7 4.900 20.000 53,000 155 sq. in. (a) 9.97 09,300 24,000 61,560 24 155 sq. in. (a) 9.97 59,300 22,000 62,280 Kill van Kull Bridge Chord é ’ 144 sq. in. 10.51 1600 24,000 59,000 I el 1 i t trengtl pet tir 1) ned tre \ t failur t eclure whole until ample evidence had that the column was the point test coupons were taken from each angles and plates used the fabri- the test columns, and the anticipated the whole column, figured weighted average point such given the table. will the carbon steel columns failed per cent the calculated yield point, steel columns about per cent, etter ful observations during the tests indi- I the bridge member to secure maxli- — Buckling Cover Plates Medium Manganese Steel Column, the the present article, primarily written show that the silicon and manganese steel box-section columns ilt members having much greater load-carry- than made the conventional carbon steel. nvestigation was supervised Ammann, Izett Steel HEN the German liner, the Bremen, made its first ippearance New York, statements appeared AALLY press that the boilers were made new steel nas coined from the German letters and ich stand for the two German The words “immer zahe” mean “always this steel statement was also le tnat under Krupp patents, exclusively the Central Steel Corporation. Outstanding characteristics teel were pointed out that does not become brittle worked and that prevents formation specially rivet holes and rivet heads. Investigation boiler failures was traced aging the field; other words, becoming brittle. iging phenomenon reveals itself considerable the ability withstand deformation. was also found that the failures were aggravated the influence alkaline feed Investigations disclosed that the sensibility the brittleness under the influence alkaline feed closely connected with this aging phenomenon. rocess aging presupposes that steel sensible been submitted cold obviously unavoidable deformation which, the manufacture 1302—The Iron November 14, 1929 Half Size Those Used Kill van Kull Arch Bridge chief engineer bridges, and Robert Johnston, engineer research and tests for the Port New York Authority, with the help the United States Bureau Standards, especially Dr. Stang the bureau staff. What and How Made When inquiries were instituted THE IRON AGE learn just what this new steel was and how made, immediate results were unsuccessful. result further inquiries the following statement states the facts near they can learned: The new product not alloy steel; carefully made open-hearth steel. conjunction with exercis- ing the utmost care making high-grade product, the steel thoroughly “washed” with manganese during the melting process. then killed with aluminum that the final product there about 0.02 per cent aluminum the steel. Samples this steel after rolling are tested tensile testing machine and annealed 200 deg. The test should show stress lines after suitable etching and used show that steel treated has the same notch toughness the same steel untreated, thus indicat- ing that the steel anti-aging. The story goes that when certain German metallurgists heard some American and British boiler steels which had unusual properties cracking and resistance boiler corrosion, comparisons were made these steels with some the German products. distinct difference was found between the German steel and the American and British. result careful studies, the new Izett steel was produced. » i > | Flash Welding Simplifies Production All-Steel Body Made Major Parts Instead 300—Spot Welds Reduced from 125 Coordinating Design New Manufacturing Method GREAT reduction the number welding opera- large flash welding machine; views and the finis hed tions required build all-steel automobile body weld before smoothing are shown. emphasized Joseph Meadowcroft, as- This new construction requires the following manager, Edward Budd Co., Phila- welding for each complete closed body: delphia.* Some years ago his company’s production welds consisted entirely touring car bodies, and the amount Gas welding Electric spot welds 1100 Evolution the center door post from part mad Continual study simplification and adaptation de- and times difficult access the welding dies, the sign constantly improved machinery has changed these modern one consisting two pieces only with flanged figures materially. the present time the whole side edges spot welded and crimped over. The first design sedan body formed from single sheet steel, de- shows the influence the composite structure (wood scribed THE IRON AGE, Sept. 13, 1928. The body. there- skeleton and sheet steel cover) the heavier load fore, consists four major units, viz., right side, left side, ing members and the light sheet metal outside panels rear and cowl. The first three mentioned are joined The latest construction arranged that the highly ished sheathing takes its share the stresses—in fact, Congress, Tokio, Japan. omy the welding and lessens the weight steel. Spacer Bar Arc-Welded é 2 4 , be Spac Cha Spot Weldin s LASH Welding Ma- Tonneau Back and Side Panels Into Single Piece (Above) LASH Metal Along Seams Rear Corners All-Sreel Center Pos: Automobile Bodies Automobile Body from Right) Composite Many Pieces, Thick and Thin, Two Flanged Mem bers Spot Welded and Crimped The Iron Age, November 14, 1929—1303 | | Pane! Spot Outer Vere’ Automatic Unit Three Interconnected Furnaces Studebaker Plant Have Great Flexibility Much Labor Cost ormalizing, hardening, quenching and } | ) Lu la Studebaker Corporation. Sout! e NIVERSAL heat-treating unit separated for various 1 nei been installed recently expanded and modernized plant Bend, Ind., for These arawing. requirements of production. it treatments, wide range heat treatments paral- eled size work. All kinds forg- from the smallest large axles, re hangeably altering the time various units. The range treated inter- 1? size cycles and temperature pos- ible because standard grid type tray, alloy steel and in. wide, used carry the work through. With this method the work will travel through all three furnaces and the quench automatically and continuously, loads the the attention but two operators. nace and the other reloads the work One emer the trays the charging end the first fur- ges from the quench, preparatory going through the drawing fur- This heat-treating unit was developed and built Surface Combustion Co., Toledo, Ohio. Brick construction throughout was used the furnaces, IZING, Hardening and Drawing Furnaces, Line, Viewed from Charging End. overhead conveyor for returning trays, delivering them Iron November 14, 1929 n iniversal h Tue IRON At HEPBURN in. firebrick and in. insulation being used. The drawing furnace ft. long and the other two ft., all three being 6.5 ft. wide and 3.2 ft. high. The heat gradi- ent obtained each furnace dividing into three zones, preheating, heating and soaking. separate auto- matic temperature control located the heating and soaking zones each, with recording pyrometers. These furnaces are fired with both gas and oil, gas burners being used the soaking zone, where accurate control and perfect heat distribution are necessary. The oil burners are the heating zone, where maximum heat input required. The products combustion pass toward the charging end, giving considerable heat the cold incoming work, thereby increasing the efficiency the furnace. Another point efficiency the recuperator. Waste heat from the furnaces passes out through vent the roof, close the loading end, which the recuperator placed. Fresh air for oil combustion forced through coil this recuperator, where heated about 600 deg. Fahr., and then delivered the oil burners. the hearth each furnace are four alloy steel rails. The trays work are pushed through these mechanical pusher, which motor-driven through bell- crank link drive. The length the period the work View Above will noted the left illustration. bustion Co., Toledo, Ohio TI lar in many particulars to the U=IIIZZBe:t eating t in the Packard plant, described in sept. 12 ge 663 4 Drawing, Hardening and Normalizing Furnaces, from Discharge End. right noted the discharge veyor into tote box remains the furnace regulated the frequency with mentioned, when all furnaces are being used combina- which the pusher operates; this, turn, controlled tion heat treatment. time clock. When the normalizer used alone, separately from the mechanical puller reaches into the furnace the other furnaces, the work automatically dumped discharge end, engages the trunnions the trays and traveling cooling conveyor the discharge end. car- pulls them forward. This puller operated the same ried along for about hour, when dumped automati- time clock the pusher, series with relay correct cally into tote boxes for further handling. for the time lag between the two. The puller auxiliary hardening and drawing are follow the normaliz- the pusher, not practical put all the load ing, the trays work are pushed along the crossover con the latter. The pushers and pullers all three furnaces veyor between the normalizing and hardening furnaces, can controlled from the same time clock, with the relays and into the latter. This crossover conveyor the 3 & Discharge End Normalizing Furnace. Several the trays, crossover conveyor, indicate their design, with trunnions leading edge. The cross conveyor, delivering cooling conveyor foreground, for work which does not require hard- ening drawing The Iron Age, November 14, 1929—1305 “al ‘ | 4 Discharge End Drawing Furnace, With Elevator for Empty Trays Left. roller type; its ft. length allows for proper cooling before hardening. the dumped through chute into the quench tank. slat-type conveyor brings out the quench the load- discharge end the hardening furnace the ing platform for the drawing furnace, where operator again the trays. These trays have trunnions, one each end and both the advancing side. The trays ride the rails through the hardening furnace the discharge end; here the trunnions ride short the trays leave the upporting rails they upset and, swinging the trun- rails the side the furnace. nions, allow the work slide off into the quench. The trunnions the trays are engaged, before dump- ing, the puller, which pulls the trays out another onveyor bridging the space between the hardening and drawing furnaces and places them position re- Cooling conveyor foreground Similar the others except that operates lower temperature, the drawing furnace next receives the work, which pushed through described. the unloading end this furnace the trays are pulled out and the work dumped slat chain conveyor for cooling. the end this the work dumped off into the boxes for fur- ther handling. After dumping, the trunnions the trays are caught dogs two parallel moving chains which carry them and over the furnaces, back the charging end the normalizing furnace. Here they are dropped another dog chain conveyor which brings them the charging table. These furnaces are used heat treat such parts connecting rods, steering knuckles, steering knuckle arms, steering arms, etc. Precise control over the material going into these parts and over the heat treatment them maintained through inspection and laboratory checks. Does Overstress Increase Decrease the Endurance HERE eems to be doubt whether moderate over- stressing will will not decrease the endurance steel alternating stresses. Prof. Moore Urbana, has cited tests show that will; Messrs. Smith, Connor and Armstrong described some experiments indi- opposite paper entitled “Correlation and Overstresses” read before the recent meeting the (British) Iron and Steel Institute. The latter authors’ experiments were the “short- variety; specimen loaded rapidly alternating tension and compression, further direct stress then uperimposed upon it, and the relation between this direct tress and the resulting strain measured. increasing the superimposed strain gradually definite yield point can found, and experience with the method for years the authors that this yield point corresponds the limiting fatigue range. Samples cut from 0.19 per cent carbon steel were 1306—The Age, November 14, 1929 placed under various alternating stresses, including those where the mean stress was zero and those where mounted 30,000 lb. per sq. in. tension, and the same value compression. For several such conditions the yield range was established. The work was then repeated samples which had been overstressed 10,000 20,000 cycles, and the yield ranges such overstressed samples were always greater than corresponding results for the steel its primitive state. The conclusion that overstress increases the endurance limit (yield range) steel fortified experiments 6-in. steel railroad axle (0.37 per cent carbon), which failed fatigue each end after about years’ service. Samples cut from the surface had yield range (zero mean stress) plus minus 36,000 lb. per sq. in., whereas samples cut from near the center, where the working stresses were quite moderate, yielded 33,300 per sq. in. Steel Making Practices Reviewec Many Questions Quality Control, Combustion, Mechanical Equipment and Furnace Design Taken Open-Hearth Men ORE than 130 men were attendance the Open-Hearth Committee meeting the American Institute Mining and Metallurgical Engi- neers, held the Hotel Stevens, Chicago, This was much the largest representation steel men which has been gathered together during the five years these semi-annual meetings. Four half-day sessions were held, each devoted “round-table” discus- sion general topic importance stee] makers. Leo Reinartz, assis- tant general superintendent, American Rolling Mill Co., Middletown, Ohio, and chairman the conference, presided. set papers were presented, aside from few committee reports, which were brief. Preference Between Mixers and Mixer Ladles ETAL mixers were compared with Pugh mixer ladles number ways several speakers. one instance two Pugh ladles 125 tons capacity were used open-hearth department making 60,000 tons ingots month. These ladles were running about 50,000 tons iron be- tween linings, and the cost the new lining was from $800 $1,000. Practically skull loss was experi- enced except little around the neck, which amounted about per cent. Preference was expressed this case for mixer, because gives the opportunity get better mix the metal. However, the plant ques- tion has only one blast furnace, the Pugh ladle used, was cheaper than install mixer. Another plant making 150,000 tons steel month uses four 100-ton Pugh ladles and also mixer. The Pugh ladles give much less scrap loss, lb. runner scrap and lb. ladle scrap for ton steel. This plant reported 83,000 tons iron the Pugh ladles between linings. Carrying Molten Iron Miles Three Pugh ladles are used one case transport molten iron mile from 550-ton blast furnace, making six casts day. There very little heat lost and the skulls are mini- mum, being not over per cent the transfer ladle. this must added per cent kish, making total loss per cent. These ladle are running 40,000 tons metal the lining. Another plant using four Pugh ladles gets its molten pig iron from separate company. Scrap loss believed less with these ladles, but the independent iron makes difficult get hot metal 60-ton source of all times when wanted. impos- sible, under these conditions, mix irons different analyses. this case the silicon limits are from 0.80 1.30 per cent. The belief pressed that the Pugh ladle ideal for small tonnages. Cost 650-ton mixer 1916 was reported one operating man $160,000. This did not the building the cranes. another case 600-ton mixer was installed for $150,000, including the building. crane was installed, the arrange C rane RRANGE. MENT Automatic Tongs with Auxiliary Loops and Extra / ment was such that the open-hearth crane could cover the mixer also. Value Automatic Couplers UTOMATIC couplers have been stalled some the plants cause their greater safety op- eration, compared with the open and pin. This applies both charg ing buggies and ingot cars. plants have used the automatic coup- lings from the beginning. Usually standard where the than the one case these are smaller railroad size. scrap charged light, and there great deal switching and use the buggies, the couplers tically necessary getting the work done. having gone back the use link and pins, after having used cars some years ago with coupler them. was found that the types would not work well together another plant where gave some trouble was found that they were too long. The difficulty overcome use shorter links With automatic links ingot cars, customary lay wooden block across the couplers take care the possibility trouble from run ning stopper. however, repo! ted two Use Automatic Tongs EVERAL plants reported using form another automati tongs, similar those used stripper, for picking both ingot and molds. some cases special crane hook employed which both the sharp bits for handling gots and loops for picking mold the ears. This available for setting the mold ground the ingots are stripped, turning molds over clean them and then for setting them back the stools. This device saves lot labor both molds and gots, but not fully automatic general, the arrangement will shown the sketch. The hook motor and capable handling 14, 000 Ib. The loop for molds sets low the bits used for gots, and the way when ingot are lying flat the ground. Hence second pair bits inserted bottom the loop, take care thi emergency. The cable coming down the center disengages the bits found the been the loops after they have done thei work. One plant reported that the men would not use automatic tongs, cause the time required swing was felt bet ter use helper put light tong into place. Another plant, however, stated that the automatic tongs absolutely essential for handling red- hot ingots which happen knocked them into position. The Iron Age, November 14, over point outside the where men cannot get close them. Best Size Mold for Large Slab Ingots size mold best suited for mak ingots rimmed about steel, one for man reported the section for ingots. There more less segregation good practice on these ingots. always immed steel, but not enough cause beyond that noted above. These have and 2-in. taper two sides, and corner radius. Another plant making ingots ngots are very heavily cropped and more segregation obtained than ordinary practice. Corrugated ingots came for ention, one speaker reporting the use 24-in. molds for this purpose, with 3/16-in. corrugations. said these ingots clean much bette with flat and that are free from cracks. This was variance with privately made from another source which the opinion was expressed very forcibly that cracks and seams are both almost sure present corrugated ingots. They were said follow the line angularity tween corrugations. those sides Furnace Control Equipment the most important sub- jects before uperintendent today that proper represented one speaker has only one furnace fitted with automatic equipment. believes, however, that the operating men the other fur- naces have been helped the perience obtained this one case. Proper amount air for the burned cuts the cost operation and results better steel. guess work need employed with fur nace properly balanced. essen- tial have fan supply the and this should driven vari- able-speed motor. Under these con ditions, analyses for show that there very little excess oxygen present. This method operation reduces the fuel consumption and, with less excess air, there much less waste gas, less scouring the outgoing end the furnace the outgoing gases and better furnace life. stack damper works automatically con- nection with the air supply bal ance the condition the furnace. Waste gas analyses are made for for and The samples taken fro