The Iron Age 1929-12-05: Vol 124 Iss 23

THE IRON New York, December 1929 ESTABLISHED 1855 VOL. 124, No. Meeting More Rigid Specifications New Heat- Treating Equipment for Bolts Designed for Accurate Control and Large Output— Plating Room Flexible FRED PRENTISS* effect close its heat-treating operations the manufacture bolts, produce product uniform quality and meet the more rigid specifications consumers physical properties, the Lamson Sessions Co., Cleveland, recently placed op- eration new heat-treating department equipped with electrically operated drawing furnaces, which all cold- headed work except stove bolts are heat treated. esting features this department include compact and *Resident editor, Cleveland. efficient arrangement the equipment, automatic quenching machine designed assure uniformity and quality product and the provision roller tables and overhead handling equipment reduce labor mini- mum. The company has added plating department which shares, with the heat-treating department, the fourth floor new 140-ft. manufacturing building. While the two departments are separated partition, they are connected roller conveyors for carrying the EAT-TREATING Department Con- veniently Arranged for Large Con- tinuous Production. center are two batteries drawing furnaces; left, the automatic quenching machine. The inclosed tank for quenching water back the furnaces 1503 | plating department, after drawing and quenching, work More exacting demands consumers steel vari- ous forms have spurred manufacturers bolts well other steel products improvements processes and methods. the same time competition has been incentive for introduction better manufacturing meth- ods reduce production costs. Bolts regarded satis- factory not long ago not meet present specifications many buyers, particularly the automotive field. Formerly buyers were satisfied with bolts having tensile strength 45,000 50,000 per sq. in. Now there tendency demand product with tensile strength 80,000 lb. and higher plain carbon steel, and 125,000 per sq. in. alloy steels. Buyers have become more particular, also, respect toler- ances the other physical properties, particularly hard- ness, resulting specifications that hold closer range Brinell numbers. Some consumers are interested mostly strength, others Brinell hardness, wanting high low, depending their product, and still others the elastic limit. Although tensile strength and hardness are the two physical properties given most importance exacting buyers, some have strict requirements respect all three these properties. Some also include speci- fications covering elongation and reduction area. addition, and perhaps less important, the demand for closer dimension limits. This necessitates avoidance scale. Gas Furnace for Hardening Hardening, the first heat-treating operation, done the Lamson Sessions plant gas-fired rotary furnace the basement. The bolts are kept the fur- nace from min. 1450 deg. 1600 deg. Fahr., depending the steel and the customer’s requirements. 1504—The Iron Age, December 1929 furnace used also carburizing furnace for bolts which are case hardened and not subjected any further heat-treating operation. electric fur- nace the continuous conveyor type, will installed shortly the heat-treating department, supplement the gas-fired furnace for hardening high-carbon and alloy steels. Bolts after heating for hardening are brought from the second floor the heat-treating department shop boxes automatic lift and dumped into containers roller conveyor that passes along the side the furnaces. They are drawn Homo furnaces, which there are eight kw. capacity arranged two parallel groups. Space provided for eight additional furnaces this type. Another roller conveyor leading from the auto- matic lift will placed parallel and back the one Quenching Machine, the Bolts Pass Down the Gravity Conveyor Background Automatic Unloading Device. This shown dumping tainer. The bolts pass through the hopper into shop boxes and gravity conveyor left packing and shipping now passing front the first row furnaces. From this the boxes work will lifted over the second conveyor, and dumped into the containers which they are charged into the furnaces. Each row furnaces served crane with 16-ft. span and carrying electric hoist. The crane has electric drive for both movement the hoist along the span and movement the bridge along the crane runway. Current for the longitudinal movement supplied three rails suspended from the ceiling. The containers, circular buckets in. diameter and in. deep, have capacity 800 which the usual furnace load. The drawing furnace temperature ranges from 1100 1200 deg. Fahr. and the work kept the furnace from min., depending the grade steel and the physical properties required. From the drawing fur- nace the hoist carries the container the quenching deep, with automatic mechanism with push button control for handling the container and out the tank. The i on quenching solution soda water and small percentage soluble oil. Quenching Automatic Lowering Device Lowering the container into the quenching tank controlled variable-speed drive. When the bucket work reaches the solution its speed materially re- duced; when lifted out the same speed main- tained until the container out the solution, the speed then being about doubled. Because the slow dipping the quenching solution instead rapid im- mersion, the liquid slowly seeps through the work, not causing large amount steam and insuring uniform quenching. The quenching solution heated the morn- ing minimum about 130 deg. Fahr., means steam coils, and kept normally approximately 180 deg., although the heat from the work sometimes brings the boiling point. The function the soluble oil give color the product. The temperature the work high enough carbonize the oil and the work comes out with at- tractive black coating, which will prevent oxidation for some time. The supply oil replenished occasionally dumping bucket fresh oil into the quenching tank. The cycle for immersing the work the solution, quench- ing and raising from the tank takes min. the bolts are handled large quantities, there little surface exposure the air during the short time 4 PLATING Department, Showing Washing and Pickling Tanks and Their Ventilating Duct Left and Two Rows Plating Tanks. Driving shafts (right) for plating barrels are near floor be- tween rows tanks (below) Rinsing Tanks After Plating, Bolts Pass Through Centrifugal Dryers. The circular containers which they are handled are then set dumping device adjoining dryer and bolts are emptied into shop boxes (above) required for moving them from the drawing furnaces the quenching machine. Thus formation scale avoided and there assurance that the pitch diameter will not changed. The heat-treating methods stated, result product uniform tensile strength and hardness. cup fracture produced tensile testing and the structure has silky appearance. The bolts are held within the National Screw Thread Com- mission’s tolerances for class and fits. The pitch diameter held within 0.002 and 0.003 in. being lifted from the quench the container remains above the tank about min., until the next container The Age, December 1929—1505 brought the tank, that time being sufficient for the work drain. The container then moves roller conveyor which carries short distance auto- matic unloading device, which dumps into hopper. The empty container switched another roller track which moves back position front the furnaces for reloading. From the hopper the bolts pass gravity roller conveyor which carries them 350 ft. through inclosed runway over the roof adjoining building. This con- veyor connects spiral conveyor which carries the boxes bolts down the packing and shipping depart- ment. second quenching tank provided for quenching water those bolts which are plated. The overhead delivers the containers work this tank. After juenching, the containers are placed roller conveyor that leads into the plating department. Efficiency handling the work being increased the use work containers handled with tongs. These are suspended from the hoist. When the latter raised the tongs grip over lug that extends around the top the container. When the tongs are lowered they re- lease hold the container. With the use the tongs containers with eyes and handling device with hooks, requiring hand labor hooking and unhooking, will eliminated. For drawing and quenching small lots the company has devised circular sheet metal boxes holding 150 five these nesting one the standard con- tainers. Control equipment for the drawing furnaces cated glass-inclosed mezzanine room overlooking the furnaces. Each furnace has independent heat and pro- duction control from instrument boards designed the company. Red signal lights and bell are used signal the operator when the furnace turned off. Three Men—9600 Lb. Hour With the eight furnaces bucket holding 800 lb. bolts heat-treated every min. the rate 9600 lb. hour. However, with the efficient handling and other facilities only three persons are required operate the department—a furnace operator, helper and man the instrument room. Freedom from smoke and fumes and the clean appear- ance the room are conspicuous features the heat- treating department. The cleanliness due the unusual attention that has been given ventilation. The furnaces are set through the floor, the bottoms being little below the ceiling the floor below and the tops convenient working height for the furnace operator. The furnaces themselves are equipped with ventilating system for carrying away the fumes. air outlet provided 7-in. duct connected the top each furnace and extending down the outside 8-in. diameter duct that extends along the third floor ceiling beneath. One such duct serves each bat- tery four furnaces and the air through the two ducts drawn out one fan and exhausted the side the building. Air replace that drawn out admitted into the top the furnace, where aluminum slip ring fits loosely around the furnace cover and provides air inlet. One feature the furnaces that does not have with ventilation the elimination the usual cylin- drical the center the containers. The air placed the fan the bottom the furnace forced through the work, instead through the screen. This proving satisfactory method air circulation and the same time the capacity the container increased. Both quenching tanks are entirely inclosed with sheet metal hoods and the smoke and steam arising during quenching are exhausted through ducts, being drawn out 1506—The Iron Age, December 1929 suction fans the roof. four exhaust ventilators extending from the ceiling and The room ventilated connected fan the roof. The room heated unit heaters; when the windows are closed these supply air replace that exhausted the various ventilating units. Face brick used for the interior mason work be- cause, with its tile finish, easy clean. The walls are finished light tan color which, with the brick trimming, gives the room bright and neat appearance. Flexibility Features Plating Facilities only the plating department equipped for plat- ing with cadmium, brass, nickel, lead and copper, in- cluding plain copper coatings and bronzes, but also for Parkerizing and galvanizing. Chromium plating will added. The electrolytic process used for all kinds plating. lead plating the company has found that the coating applied electrically not porous when hot dipped and consequently more satisfactory. Four double-wheel buffing and polishing machines make pos- sible meet any polishing specification. The convenient arrangement the equipment and the location the plating barrel driving mechanism are among the interesting features the plating depart- ment. Work starts the end the plant adjoining the heat-treating department and finished the other end. floor-type gravity conveyor will installed shortly for carrying work through the department. This will de- liver boxes finished bolts automatic lift, which will discharge them gravity conveyor, which will turn carry them the packing and shipping department. The plating tanks are the double-barreled type ar- ranged lengthwise the plant five lines, two for cadmium plating, one for galvanizing, one for special finishes (copper, brass, nickel and lead) and one for Parkerizing. There are tanks and plating barrels. addition, sixth line contains large tanks for the still galvanizing, and nickel, copper and cadmium plating work too long handled the plating barrels. Shaft Lines Along Floor Driving shafts for the plating barrels, usually placed overhead, are here located few inches above the floor. One shaft along the wall drives the barrels the first line tanks and the other four lines are driven two shafts, each located between rows tanks and driving the barrels two adjoining lines. There are two wash- ing and pickling tanks, one each the head one line, and these serve the adjoining line the same bay, crane with short runway being provided deliver work for the second line. From the end the crane runway, monorail tracks equipped with electric hoists extend over the tanks the length the building for handling work and out the barrels. Fumes from the pickling and washing tanks are drawn through ducts around the sides the top the tank and carried outside the building through ver- tical duct leading the roof, where they are exhausted suction fan. Two rinsing tanks, one for cold water and one hot water, are located the end the line plating tanks. After rinsing, the bolts are placed centrifugal driers, one which located the end each plating line. Here they are dried blast hot air. Adjoining each drier efficient dumping device designed the company. The circular container that holds the work during drying placed fix- ture the dumping mechanism and turned over hand-operated spider, bolts being dumped into chute, from which they pass into shop boxes. Then they are ready the packing and shipping department. ig Molybdenum Cast Iron Strength and Hardness Increased Much More Rapidly Than Machinability Results Achieved With 1.5 Per Cent Molybdenum usual, steel has led the iron industry the use alloys, but recently they have been successfully introduced into gray iron foundries—particularly the use nickel and nickel with chromium. Other alloys have been tried with varying results, but yet have not been accorded wide use. these, molybdenum, has received comparatively little at- tention the past, despite its availability from many mines within the United States. Gillett and Mack, their recent book “Molybdenum, Cerium, and Related Alloy Steels,” state that four alloys are most used steel mium, vanadium, and manganese; the most these alloys are imported. “The de- velopment domes- tic alloying element which can, whole part, replace sup- plement these foreign elements, obvious importance American steel makers and users. Molybdenum such element. The United States has the largest potential supply molybdenum ores any country world.” Any large me- tallic deposit na- tional asset and this particularly true molybdenum. There are number deposits, mostly the Western States. The present price about one dol- lar per pound con- tained molybdenum re- stricts the use this material but seems very probable that the price can reduced when molybdenum used larger tonnages. Molybdenum has earned *Metallurgist and as- sistant spectively, Stockham Pipe Fittings ham. tions, Part 1920, page (b)O. Smalley, The Iron Foundry, supplement Metal Industry, Jan. 19, 1923. Stahi und Eisen, Feb. 26, 1925, page 294. alloys. One the most promising reported improved tensile making, these being nickel, chro- parted gray iron Brinell Hardness 200 Strength Strength Molybdenum, Per Cent ORTY Crucible Melts Cast Iron Uniform Composition, Except for Molybdenum Content, Were Tested Standard Methods, and the Most Im- portant Data Plotted Above definite and increasingly important place mak ing, and may have even more essential part the development high-test gray irons, especially case national emergency should make difficult obtain other Little Information Now Available Surprisingly little has been published the subject molybdenum cast iron, although there are numerous articles molybdenum steel. strength and molybdenum. (a) data before the stitute British Foun- drymen special cast iron. (b) that molybdenum valuable strength- ener, toughener and grain refiner and that- 0.50 per cent, ma- chinability not fected. noted one the most striking molybdenized gray iron, i.e. its strong tendency toward putting graphite into the nodular form. Piwowarsky, his notable article alloys gray iron, (c) finds increased strength due molybdenum. Recently there has been considerable work molybdenum cast iron but yet little has been published. Data Crucible Melts planning this se- ries experiments was desired follow practical foundry con- ditions closely possible. work demonstrated that was difficult effect complete solution high percentages molybdenum when such additions were made the was also considered the small but unavoid- able fluctuations The Iron Age, December i | | | é\ TANDARD Cast Iron Containing Molybdenum. Unetched Micro 100 Diameters Shows Fine Graphite Flakes. Etched micro 500 diameters shows compara- tively coarse grains, with graphite, pearlite and phosphide composition iron produced the cupola commer- cial scale. Therefore all charges were melted crucibles, which means the usual fluctuations chemical con- stituents could rendered negligible. check the results, molybdenum was added the ladle, especially the lower ranges, these results being comparable those obtained the crucible melting. order have uniform composition, identical charges were made for the whole series crucible heats, forty number, varying only the size molybdenum addition. Cast scrap (42 per cent each charge) was obtained from one large casting uniform dimensions, while pig iron (50 per cent) and steel per cent) were from carloads unusual constancy composition. Molyb- denum was used two forms, ferromolybdenum and lower melting point molybdenum alloy. (Calcium molyb- date seemed unsuited for these experiments.) Analysis test bars was follows, there being little variation: Per Cent 0.060 Total Carbon ... 3.32 Graphitic Carbon ......... 2.67 Combined Carbon...... 0.65 Molybdenum ........ addition Gas was used fuel, crucibles being carefully covered. Tension tests were made bars cast accordance with the recently recommended pattern for gray iron for pipe flanges and fittings. Transverse tests were run American Society for Testing Materials arbitration bar. Brinell hardness was determined the lower end the arbitration bar. Machinability Determined Drilling arriving comparative values for machinability, used modified Keep test, having been found 1508—The Iron Age, December 1929 give satisfactory results the past. Equipment consisted direct-connected, motor-driven drill press travelling 400 Suitable weights were placed the press (which was free move vertically) that the total weight the point the drill was 130 %-in. high-speed drill was used, care being taken that sharpen- ing between experiments was uniform. order test for machinability, the end trans- verse bar was ground depth in. and the drill point rested the bar, the exact point being located center punch. The drill was then operated for one minute, and the depth the hole Machin- ability was reported penetration— millimeters per minute. Duplicate determinations checked closely. The authors realize that one test can measure all kinds machinability, but believe that the drill test gives good average results. Physical Properties and Structure Results are summarized the graph showing the physical properties determined and the micrographs showing the structure. Owing the method melting the variations, which are reasonably consistent, may ascribed primarily the influence molybdenum. percentages molybdenum decrease machinability, measured the drill press. However, machining did not become notably difficult, until molybdenum had reached 1.5 per cent, which point also marked the attainment maximum strength. per cent molybdenum, drilling was difficult. bar, not shown graph, with 4.40 per cent molybdenum, could not drilled. hardens cast iron, even small amounts, but apparently hardness increases more rapidly than machinability decreases. maximum strength, with 1.5 per cent alloying metal, the Brinell ~ TANDARD Cast Iron Containing 0.65 Per Cent Molybdenum. Unetched micro 100 diameters shows large nodular graphite. Etched micro 500 diameters shows somewhat finer grain than the iron without molyb- denum. Constituents are phosphide, graphite and pearlite , = number was about 260, but the bar could readily bar with 4.40 per cent molybdenum showed 418 Brinell, and could not drilled. Transverse with unalloyed bars having transverse strength 3200 lb. per sq. in., strength increased rapidly, reaching maximum 5000 per sq. in. with 1.5 per cent alloy. Tensile tensile bars plotted similar curve that for transverse strength, maximum 45,000 per sq. in. being found with 1.5 per cent molybdenum. The micrographs, both etched and unetched, explain the effect molybdenum the physical properties cast iron. the first place, the usual long, heavy plates graphite are absent, and most the carbon the from nodules. This naturally strengthens the iron. Very fine pearlite sorbito-pearlite, induced the alloy, also tends towards strength. The fact that the molybdenum great extent solid solution the ferrite toughens the matrix, pro- motes shock-resistance, and also inhibits grain growth. Both the solid solution and the sorbitic structure harden the cast iron, shown Brinell tests, and the higher ranges molybdenum, make the castings less ma- chinable. Increasing hardness the iron not due increase carbides, there little increase combined carbon shown analysis, and microstructure. This absence excess carbide, coupled with the strengthened matrix, also helps account for the high resistance shock. Practical Conclusions Molybdenum far from being remedy for all foundry troubles, but strengthener has definite use, especially where low costs are not primary importance. With molybdenum one dollar contained pound, two TANDARD Cast Iron Containing 3.10 Per Cent Molyb- denum. Almost all the graphite nodules; the grain size small, and the pearlite tends strongly toward sorbite 4 ~ TANDARD Cast Iron Containing 1.77 Per Cent Molyb denum. Unetched micro 100 diameters shows flake and nodular graphite. Etched micro 500 diameters shows that increasing amounts molybdenum fine the grain. Structure comprises small amount graphite, very fine pearlite tending toward sorbite, and phosphide per cent added cast iron would add about $40 per ton the cost, the tensile strength being increased from 26,000 45,000 per sq. in. addition one per cent will raise the strength from 26,000 40,000 per sq. in., cost $20 per ton. Obviously, the increased strength would permit lighter sections. The statement has been made that molybdenum acts desulphurizer. The present experiments gave evi- dence such action, although first the addition alloy apparently reduced sulphur. This effect seemed due interference with the usual analytical methods. limited number impact tests indicated that iron containing 1.77 per cent molybdenum had almost double the shock resistance the unalloyed iron. seems probable that this property molybdenum bearing cast irons will prove value. Preliminary experiments also indicated that small percentages molybdenum have little effect the repeated heatings, scaling. Maximum values for transverse strength 5000 per sq. in., and for tensile strength 45,000 per sq. in. were found, but obvious that these values hold only for the type cast iron used. changing the other elements such carbon and silicon, higher strengths could undoubtedly obtained. summary, the results our experiments show that moderate amounts molybdenum have beneficial effect the physical properties cast iron, but the increased cost detriment. However, where decreased weight, increased strength, shock resistance are im- portant, molybdenum can used decided advantage. The Iron Age, December EAMLESS Tubes are Loaded Into Re- tort. Calorizing compound then placed uniformly inside each tube means the split pipe, and small diameter pipe placed each tube prevent the charge from mov- ing endwise and leaving some por- tions bare. Com- pound also placed channels between tubes alorizing Resist Corrosion Rotating Retort Contains Steel Tubes, Granular Aluminum and Hydrogen Atmosphere—Alloy Forms Surface Which Resists Oxygen and Sulphur SAYLES* ALORIZING, well known, process whereby practically immune oxidation maximum temper- aluminum driven into the surface another atures 1650 deg. Fahr., and entirely resistant the metal, usually mild steel, form aluminum corrosive attack gaseous sulphur products. The process alloy. This alloy, where mild steel the base metal, has thus extended the use inexpensive construction material operations which could not previously *President, Calorizing Wilkinsburg, successfully employed. 1510—The Iron Age, December 1929 URNACE Top Consists Se- ries Bungs. After assembling, joints are patched, and uniform tem- perature given work series gas burners. Heat and mosphere controlled all times | — — OADED Retort Has Ends Tightly Bolted On, and Lowered In- Furnace Casing. End flanges engage rollers, one pair driven, another pair idling, and retort turns slowly while under heat One the major applications calorizing for proc- essing seamless steel tubes for oil stills. Even when such equipment designed operate petroleum products comparatively mild temperatures—say 750 deg. Fahr.— the reactions going the fluid cause the deposition more less petroleum coke. This prevents the normal heat flow from the furnace gases the petroleum, the same boiler scale cuts down the efficiency steam boiler. more serious consideration that the temper- ature the outside the tubes rises, gradually approach- ing the temperature the products cembustion, degree where bare iron steel scales rapidly. Another factor which weakens oil still equipment internal corrosion sulphur-bearing compounds. com- bating this latter difficulty two methods have been vogue. The equipment may built extra heavy, provid- ing sufficient metal thickness withstand corrosion for extended period, the may treated neutralize its corrosive elements. Both these expedients are costly and only partially effective. Sulphur corrogion especially active temperatures above 700 deg. that still tubes are invariably subjected severe attack and rapid destruction. When this combination oxidation and inter- nal corrosion has substantially reduced the wall thickness ordinary steel iron tube, usually swells diam- eter, there being insufficient resist the internal pressure. Reduction the wall the danger point therefore first evidenced swelling, but there assur- ance that the swelling will detected time replacement before rupture occurs. From the foregoing apparent that calorizing serves dual purpose cracking-still tubes, rendering the in- terior immune sulphur corrosion while the exterior protected from oxidation. calorizing the aluminum driven into the surface layer the steel forming iron- TMOSPHERE Hydrogen Maintained Re- tort; Enters Through Pipe at w* Center End 1740 deg. Fahr. Entire cycle takes 5 a sf hind 4 4 q The lron Age, December 3 — a4 | q “am aluminum alloy, integral part the steel, which resists both oxidation and corrosion. The alloy surface much harder than mild steel and under the action the tube cleaner assumes high polish. Cracking-still tubes calorized are preferably speci- fied cold drawn under American Society Mechani- cal Engineers Specifications, hot pickled after annealing the mill remove scale. The steel delivered also thoroughly sandblasted and wire brushed provide smooth, clean surface. The tubes are then placed cyl- indrical retort and packed aluminum compound which uniformly distributed over both the interior and exterior surface the steel. The illustration shows pipe split down its center for introducing powdered compound into the tube, uniformly from end end. The heads the retorts are then bolted and hermetically sealed, hy- drogen atmosphere being maintained during the entire subsequent process. Calorizing retorts shown the illustrations are 24%- in. outside diameter, ft. long. Four furnaces are provided, approximately ft. long ft. wide ft. high, designed and built Surface Combustion Co. Toledo, Ohio. The shell the furnace cylindrical steel plate lined with in. fire brick. Tops bungs are removable ft. and ft. sections. Tops are lined with in. Sil-o-cel and in. fire brick, and are carried steel frame. The lower part the furnace also sectionalized and bound together structural steel frame. base carrying chilled iron rollers located either end the casing; retorts rest flanges bearing these rollers. Rollers one end are driven 5-hp. motor through speed reduction gears permit rotation speeds varying from r.p.m. Rollers the opposite end the furnace are idlers. Each furnace fired with Surface Combustion burners for natural gas located one There are seven thermocouples protruding into each combustion chamber and these are connected with switchboard type pyrometer, that the temperature any point may accurately checked convenient inter- vals. Gas burners are manifolded inspirators which the proper gas-air mixture for complete combustion maintained. Any furnace atmosphere may had with this system, but this application neutral atmosphere vital minimize scaling the retorts the operat- ing temperature 1740 deg. Fahr. requires from hr. bring the retort and furnace operating temperature; gas consumption for this and the 5-hr. soaking period about 33,000 cu. ft. charge the 35-ft. retort will include 3750 steel, 3000 calorizing compound which, with the retort, makes furnace charge 17,750 After shut- ting off the gas takes hr. for the retort cool black. German Version Birth Stainless Steel DR. PHIL. SCHOTTKY* was peculiar coincidence that 1912 the most use- ful the non-rusting steels was just being baptized, while noted authority special steels was publishing his handbook the following statement: The question the rust-resistance certain special steels has been insufficiently everything points the fact that there alloy iron which will withstand the attack rust. Many scientific prediction later contradicted, for err human, and science human origin. However, this case, the contradiction followed close upon the heels the prediction. Corrosion problems had been under in- vestigation the Krupp laboratories Essen since 1909. Two men, quite different nature, were joined the common pursuit: Professor Strauss, physicist, hearty spirit and tireless his search for improvement, and his assistant, Dr. Maurer, metallurgist, slow, yet tempera- mental, profoundly absorbed his scientific thoughts. was fresh from Paris, where recently completed out- standing research under the great Osmond. the same time as, but independently of, the study rust-resistance, Professor Strauss had begun investiga- tions heat-resisting alloys, which were serve pro- tecting tubes for pyrometers. Two high-chromium and three high-nickel, high-chromium steels were prepared for this purpose. was then noticed that piece the steel remained bright the air the laboratory for months, while nickel itself was quickly attacked. Such fortunate discovery, bridging the gap between two independent in- vestigations, was, course, tremendous spur, for here hand was alloy steel which behaved like noble metal. Such was the ancient goal the alchemists, who were wrecked its impossibility. Rarely was per- mitted them find something useful along the way—al- though, according tradition, Johann Friederich discovered the process making porcelain the effort produce gold. *From article Monatshefte, published Krupp company, Essen, Germany. 1512—The Iron Age, December 1929 People were more reasonable perhaps the scientific nineteenth century. Still, from its beginnings, from the production crucible steels Alfred and Friedrich Krupp, the company had always been devoted the build- ing from raw materials finished and semi-finished products every description. lay, therefore, the Krupp tradition supply alloy, containing per cent cheap, base metals, which had the enduring properties noble metal. similar steel had already been produced the Frenchman, Guillet, who, however, was unable forge it. This Krupp was able do, and for this reason the Krupp building where the first crucible melts were made has come known the source the “noble” steels. The goal practical utility was still far from reached. The mechanical division, which was prepare tensile specimens, returned the steels Professor Strauss unworkable. fact, resisted every effort turn down lathe and broke bending, with brittle talline fracture. Heat treatment seemed the only answer, but information was available for selection the proper procedure. This delayed the “birthday party” V2A steel for several months. The correct treatment was finally found through scien- tific knowledge the special properties this non-mag- netic steel—by quenching from 1100 1200 deg. C., oil water, the metal was rendered tough and relatively easy work. Physical tests showed favorable values for ten- sile strength, ductility and toughness, while corrosion tests showed superior any other ferrous alloy. large, smooth-turned cylinder, which today exhibi- tion the Krupp laboratories, had hung the open, half under water, for months, without showing trace rust dimming the nickel-like surface. The V2A steel, useful alloy, was thus born, evidenced the German patent, and the reader won- ders its strange and somewhat mysterious name, let him learn that signifies “test steel (Versuchstahl) No. 2,” and that denotes its austenitic character. 7 7 Development Upset Forgings Saving One-Fifth Weight and Great Improvement Output—Uniform Grain Conditions Give Higher Strength RACTICALLY new process forging, known upset forging, has been developed such extent during the past five years that present out- put approximates 350,000 tons yearly. This estimate cov- ers only commercial and automotive forgings; other types forgings such rivets, bolts, nuts and miscellaneous railroad car forgings (hangers, knuckle pins, air brake pins and coupler yokes) make total far excess that mentioned. This method forging has decreased the amount steel actually consumed producers about 70,000 tons—a really great saving. The estimate for all types upset forgings shows per cent saving weight compared with hammer, hydraulic, other meth- ods forging. The upset forging machine has been one the most important factors the tremendous increase automo- bile production, and has been vital factor the decrease cost. This has been brought about not only the sav- ing material entering into the forging itself, but also the great increase production over other forging methods. Much Greater Production Obtained remember producing steering worms for the old Mitchell car 1912 steam hammer the rate 250 9-hr. day. This forging, produced rolling die, had approximately deg. draft. weight about lb. did not include the tong end, which was later cut off the forging and thrown away. *President, American Forge Co., Chicago Present methods produce the same type forging 4-in. upsetter rate 1200 9-hr. day, and the finished weight the same forging saving per cent steel and increase 380 per cent production. This same story applies even greater measure main drive gears and cluster gears. The in- crease production main drive gears averages over 700 per cent and cluster gears from 500 600 per cent. Upset Method Eliminates Tong Holds Another great saving the upset method forging the elimination flash and tong holds. This ac- counted for the difference die construction and de- sign. Hammer dies are made two parts—the top die and the bottom die—and necessary have the proper amount draft, taper, remove the forging from the dies. This draft varies from deg., differing with the design the forging. contrast, the new forging machine die opens three parts: moving die, stationary die, and the head- ing tools. The operator places the stock the stationary dies and steps the treadle, bringing the moving die over direct line and gripping the stock. The headers then come and the necessary upsetting forging operation, then return their original position, leaving the finished forging the stationary die. Neither draft nor taper required for the operator release the forg- ing. recent years new developments upset forgings include the production irregular designs requiring trimming operation remove flash, and this operation € Bars Are Cut Exact Multiples the Metal Needed for Given Forging. bar end heated and forged. The forged end removed hot saw and the cut end the bar then reheated preparatory continued forging The Iron Age, December | generally finished the same die and same heat, elim- inating the need trimming press. Piercing holes, displacing metal, upset forg- ings has been important factor the reduction cost the eonsumer. doubt the piercing holes the upset forging method saves the consumer not only consid- erable money raw material, but also the cost remov- ing additional metal either lathe drilling operations. large holes, in. diameter and larger, material should displaced, pierced, but with enough tolerance allowed the forging manufacturer that his production will not impaired. should remembered that the piercing up- set forging smaller size stock must used, increasing the number passes, operations, necessary complete the forging. the larger size holes the body the punch heavy enough withstand the heat the con- stant production forgings, and the holes are fairly uni- form. have never been able, however, maintain perfect hole. this mean that constant production day after day will show some variation, 1/32 in. off one side, then the other. was our thought that improper heating caused this variation, thinking the punch would follow along the lines least resistance, and case bar was not heated per- fectly the punch would run the hottest side the forg- ing. test, however, brand new machine (with new dies) and the bars all heated electric furnace, still found variation, amounting 1/32 in. maxi- mum. But should remembered that everything was new and perfect condition. With older dies and equip- ment have found our average variation from concen- tricity 1/32 1/16 in. This variance, with proper allowance for finish the outside diameter, does not in- terfere with high-speed finishing production, and the sav- ing material and drilling time highly desirable. Design Shows Whether Pierce small holes, in. and under, the design the forging has much with the advisability piercing. straight forging, with perfectly plain outside diam- eter, have gone 1-in. hole with difficulty. But certain types gears, cluster gears for example, with three gears one forging, find impossible pro- duce these parts economically with holes. These forgings, which vary length from in., generally have fin- ished hole either in. in. diameter. found this class work that our die expense increased 300 per cent and our production decreased one-fifth. The increased die cost was caused more passes and high-cost material for punches. Decreased pro- duction was brought about the absolute necessity for perfect holes, and case one punch bent broke, the holes were off center, requiring new set-up. discovered, after working this problem out with our customer, that were trying eliminate drilling op- eration these gears where the saving material amounted slightly over pound, and one man mul- tiple-spindle drill could drill and broach one day more than our entire daily production solid forgings. were trying compete, equipment valued consid- erably more than $50,000, including forging machine, furnaces, motors, with crew four men, against multiple drill and one man. Covering period two months, our average running production time these gears pierced was per cent, per cent the time were down for machinery adjustments. Rejected forgings totaled per cent. the same gear made solid our pro- duction time was per cent and rejected forgings 1.2 per cent. While practically all metallurgical engineers insist upset forgings gear work, not only for additional strength account uniform grain flow, but account 1514—The Iron Age, December 1929 increased density that eliminates warpage distor- tion heat treating, the layman sometimes loss understand the changes which have been brought about this method forging. The increased strength upset forgings was brought home forcibly our organization last year. had job that called for delivery 7000 pieces day—a very intricate job, which had six prongs run- ning into the header about in. depth. tried every known die steel, and our average life these dies amounted 1200 1500 forgings. Four headers one machine were split one day and immediate action our part was required keep production schedules. These headers were in. diameter and were made ham- mer-forged alloy steel. set dies was designed produce the same header forging from 4%-in. round. required in. this size stock produce the headers, and our great sur- prise the first one these upset headers produced 26,000 forgings, and the largest run the upset headers amounted 37,000 forgings, from exactly the same qual- ity steel furnished the hammered forgings. From our experience making and quoting thou- sands different designs upset forgings, believe the consumer would save not only upset work, but hammer work well, called competent forging experts over new designs, with the idea mind simplifying die construction and increasing actual pro- duction. cluster gear production, the addition in. spacing between gears results increased production per cent, with corresponding decrease die expense forgings this type. certain types gears with 1-in. finished space between gears, the forging must finished 13/16 in. that point have necessary stock for finishing. This means that insert large in. diameter must take the entire thrust finishing the forging. Rapid production gears this type heats these inserts spite all methods cooling, causing them bend, making necessary stop production and tying expensive machinery change the die equipment. The addition only in. the spacing between gears allows much stronger die designed, result- ing increased die life and increased production, all which reflects back the customer lower prices. After parts have been released for production, small changes are often impossible make account ad- jacent component castings and gears, all which must redesigned agree with the change one gear. Another factor designing that causes considerable grief all forging concerns the use very thin sec- tions. have found our practice that, forgings re- quiring thickness less than in., necessary set our headers flush with the dies, letting the spring the bed casting produce the desired thickness. This method, course, dangerous. Production forgings having flange excess in. diameter and under setting machines, due the tremendous strain put the bed casting and crankshafts. How the Large Demand Grew The first real demand for drop forgings came from the industry, and after the advent the automotive industry the demand for forgings became great that forge plants were unable meet it. This led the larger automobile companies install their own forging equip- ment insurance against delays deliveries their specifications. Thence came excess capacity, and after several periods depression the World War created such demand for forgings that perhaps one industry the entire country expanded rapidly. The post-war period the forging industry left trail bankruptcy, and 7 7 — ag probably line business suffered heavily from ruthless price cutting and keen competition. all trade conditions this kind, after period four years practically profits, the remaining forg- ing concerns looked forward better times, hundreds hammers and other forging equipment were forced out the market. Bargain prices this second-hand equip- ment led some buyers our products believe that forg- ings could made cheaper their own plants. Hence much this old and obsolete equipment was sold and set competition with modern equipment, up-to-date plants and first-class forging organizations. Plea for Adequate Cost Analysis have never been able understand the installation forging equipment plants not consuming tonnage enough warrant the organization necessary produce This Upset Forging Was Made from 3-in. Bar. The pierced hole in. diameter. The rim the flange in. thick and the diameter the flange in. forging competitive basis. Not enough time study put into the proposition until after the equipment installed, and then eyes are closed the constant loss money. Charges that should made direct against the forging department are made against general overhead, and proper basis outside competition can ar- rived at. Some producers would get quite shock, sure, the total steel cost, actual labor, die expense, fue] cost, repair expense and power were prorated over the forgings actually produced, and then compared with com- petitive figures obtained from modern forging plants. our business the steel cost alone certain types forgings often runs from per cent the selling price, leaving small fabricating margin that only high and constant production with high-speed and efficient or- ganizations, not only the forge shop, but the die depart- ment well, can show profit. One our associated companies has had experience this kind connection with the production bolts and rivets. All told, probably produce our eight plants throughout the country 60,000 tons miscellaneous hammer and upset forgings yearly, and all thought were pretty well all types forgings. discovered had seven different bolt and rivet machines various sections. The thought occurred group all k. TCHED Cross-Section of an Upset Gear Forging (Above). Note that the grain parallel the axis the bar and also parallel the rim the gear blank the point where the teeth are to be cut Designed Cluster Gear Forging (Extreme Left) for High- Speed Forging Production, Long Die Life, High Production Machining. its right incor- rectly designed cluster gear forging Note the narrow spacing neck forging, resulting shorter die life, lower production and slower machin- ing these one section and produce all forgings this type one plant. Upon impartial investigation discovered that, even upon grouping these units, our cost this particular product was much higher than the price for which the same commodity could purchased the outside mar- ket. This discovery resulted shutting down all the rivet and bolt machines our plants, saving the company thousands dollars yearly. Abandoning One Type Product Our investigation this proposed change brought out the interesting fact that, connection with the installa- tion all these units under one roof, with the neces- sary buildings, new foundations, die equipment, heat-treat- ing equipment, shear equipment, oil storage, steel storage, steel handling equipment and furnaces, the interest our investment, not including machines, amounted over $12,000 annually, and this figure alone can certainly pur- chase great quantity bolts and rivets. The same true other types forgings and castings. The Iron Age, December 1 4 | wall 4 Conveyors and Ovens for Large Cores Both Continuous and Batch Units Same Plant Make Comparison Handling Costs Reduced ators and boilers are making and baking cores, and molding and casting. The foundry the Bond plant the American Radiator Co. Buffalo uses mass production based straight-line mechanical methods. Molding, pouring and shakeout all center around con- tinuous closed-loop roller conveyors. All materials and from these units are handled roller conveyors, also. The core-making section has been equipped with con- veyors, ovens and machines, arranged synchronize the two operations making and baking. This estab- lishes definite time schedule this department and permits very close control. Four the core ovens are continuous and automatic operation and two them are identical construction and dimensions. Each oven served two jolt, rollover core-making machines, located side side and front the oven. Cores made plates are transferred directly from one machine oven trays the charg- ing table. Cores and plates from the other machine are transferred directly second charging table, from which they are lifted and set down top the cores and plates from the first machine, the top plate being sup- ported above the lower four cast iron pegs. These are then loaded the shelves the oven conveyor. Built steel, its walls filled with in. insulation, *Amer! n Gas Association, 420 Lexington Avenue, New York. RINCIPAL operations the manufacture radi- HARGING End Ovens, Core-Making Ma- chines and Convey- ors Which Carry the Baked Cores and Plates the Oven Crew. Note pneu- matic clamps chine left, sand chutes over core- making machines and air lifts for handling plates 1516—The Age, December 1929 NEALEY* the oven ft. in. long, ft. in. wide and ft. high. The motor-driven conveyor consists two endless chains supporting series shelves carried through the oven, returning the top, with discharge the charging end. There are 279 ft. link chain weighing the foot and supporting carriers shelves. Each shelf weighs about and hangs down in. Two Unequal Burners Used Heating with gas and the following manner: Two ducts for distributing combustion and recirculated products are installed the bottom and run lengthwise the oven. Ports these ducts are spaced distribute the heat evenly throughout the length the oven. one end each distributing duct are one large velocity-type high-pressure burner and one small velocity burner, firing angle the large one and into the same tunnel. The small burner always operated and serves hold the ov