The Iron Age 1929-12-19: Vol 124 Iss 25

DEC THE IRON Seventy-fifth Year DECEMBER 19, 1929 American Steel Wire Company the Yuletide, with its inspirations good cheer with us—the New Year approaches—and sincerely WIRE Rolled Strip Steel Wire fer extend you our best wishes for very Merry Christmas and Premier Wire Serew Stock Piano and Odd-Shaped Wire Happy Prosperous Nineteen Thirty Wire Cables aad Wire for all Purpeses American Steel Wire merican Wire Company 208 Salle Street, Chicago Church Street, New York Other Sales Baltimore Birmingham Boston Buffalo Cleveland Denver Detroit Kansas City Memphis Milwaukee Minneapolis-St. Paul Oklahoma City Philadelphia Pittsburgh Salt Lake City St. Louis Wilkes-Barre Steel San Los Angeles, Seattle, Honolulu Export istributors: United State eel Produ urch St., New York City ACE Joseph Ryerson Son Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Camden, Jersey City THE IRON AGB, published weekly by the IRON AGE ne CO., at 239 W. 39th St., New York. N. Y at the Post Office at New York under the Act of March 3, 187 1879, THE IRON AGE ate December, and again the holidays put forth restraining hand check the few days will forget busi- ness for while—but not the thousands friends with whom have worked and those who have Forget Business helped make this most successful year. the spirit the season take this opportunity greet our many customers and friends and convey our most sincere wishes for Merry Christmas and most prosper- ous New Year. December 19, 1929 A. Entered as second class — im 8, U. . $6.00 a year in U. S.: Canada $8.50; Worcign® $12.00. Dec. 19, 1929. Vol. 1234 o. 25. Editor Managing Editor THE IRON ADVERTISING STAFF Cc. 8. Barr General Advertising Manager I F. Warne Chicago Emerson FINDLEY Cleveland R. A. Fiske FP. L. PRenTiss Buffalo Chicago H. Pittsburgh R. G. McIntTosx Cincinnati Cleveland L. W. Morrerr Washington FRAZAR oston Published Every Thursday the IRON AGE PUBLISHING CO. W. C. New York New Jersey 239 West Thirty-ninth Street, New York New York Frank, President Griffiths, Secretary EDITORIAL STAFF A} I. FINDLEY W. W. Macon Thorough Studies Lower Shop 1647 Bonus, Premium Other Wage Incentive Not Always the Only Cure Making Aluminum Aircraft Careful Heat Treatment and Temperature Control Melting Are Features Strength Zinc-Base Die 1655 Discussion Gravity and Pressure Methods and Types and Merits Alloys High Speed Cupola Melting 1659 Many Metallurgical Advantages, and Most Are Slow River Shipments Gaining 1660 Ten-Year Increase 339 Per Cent Ohio River Tonnages Iron and Steel Shallow Cuts High Speeds 1663 Experiments Turning Include ance Mechanical-Spring Characteristics Radially Tapered and Behavior Spring Materials Considered Iron Mining Revival 1667 Region Develops Into One Largest ‘Iron- Ore Reserves, with Business Like Years Ago? 1673 Output Basic Materials Off Mote Than Retail Trade, Then Now Contents for December 19, 1929 Production Control and Materials Handling Education and Training for Industry Engineers’ Place American Life Book Reviews New This Week’s IRON AGE Brief EDITORIALS The Week Business Iron and Steel Markets Non-ferrous. Metal Markets Personah Notes Foreign Steel Markets Machinery Markets New Trade Publications The Week’s News Quickly Told Owned the United Corporation, 239 West 39th Street, New York. A. C. Pearson, Chairman. F. J. Frank, Pres. Musselman, Vice-Pres. Fred Stevens, Secy. and Treas BRANCH Otis Building. Pittsburgh: 811 Park Building, Boston: Room 230, 80 Federal St: P 1402 Widener Building. Cleveland: 1362 Copyright, LONDBERG Philadelphia mcs Lewis Detroit Cincinnett C La CHAUSSER St. Loute 1654 1703 1668 1670 1678 1681 1682 1699 1701 1707 1710 1716 Building. Detroit: 7338 Woodward Avenue. Cincinnati; 409 Tractioh Building. Buffalo: 616 Ellicott Square. Washington: 536 Investment Building. San Francisco: 703 Ma Street. Subscription Price: United States and Possessions, Mexico, Cuba, $6.00; $8.50; Foreign, $12.00 per year. Single Copy cents Iron Age Pul ng ¢ and THE IRON AGE December 19, 1929 HARTOMETER MODEL ‘ screw thread gage for use the operator the machine. screw passes this gage will enter the nut tapped hole. Furthermore, will strong dependable screw, because the lead and pitch diameter JONES LAMSON JONES AND LAMSON MACHINE CO. SPRINGFIELD, VERMONT IRON New York, December 19, 1929 ESTABLISHED 1855 VOL. 124, No. Thorough Studies Lower Shop Costs Review All Problems Incidental Production Costs Necessary—Bonus, Premium Other Wage Incentive Not Always the Only Cure CRIS BERG* many efforts made reduce costs are not themselves sufficiently broad and complete attain re- sults which are possible. Fur- ther, often happens that cost taken finality, with- out regard thorough coordi- nation men, methods and ma- chines through which further lowering cost may sible. manifestly unfair the equipment manufacturer the whole burden cost reduc- tion placed his machine, separate EFINITE benefits accru- ing from rational appli- cation bonus premium system paying for work done are outlined this arti- cle. Specific analyses for three departments show daily output. But these are not haphazard results; they accrue studies the entire shop prob- lem. The old-style preinium system the structural shop had been put into use without study surrounding conditions. Conse- quently the average saving re- sulting from the new plan was higher the case the struc- tural shop than either the ma- chine shop the foundry, where day work had continued prac- similar, but unequal, gains tice. This demonstrates the need for complete study shop con- ditions, and also shows the fruit- lessness applying wage in- when the same time the flow material, instructions em- ployees and other unfavorable conditions virtually strangle the machine, and keep from doing the reward thoroughgo- ing study the problem for each individual operation and for the shop whole. centives without first rectifying many possible the bad practices which tend offset the advantages wage incentive scheme. work the manner and the quantity for which was de- signed. Wage incentive schemes plans, whether piece work bonus, cannot considered cure-alls for all the evils high cost production. First all necessary that the wage incentive applied the basis studies which should follow the correction miscellaneous factors, all which will have important bearing whether not the net outcome the wage incentive plan will successful. How One Concern Attacked the Problem Three tables herewith show data prepared from three departments one manufacturing concern. will noted that, the cases the foundry and the machine shop, comparisons are drawn between wage incentive plans and day work. the case the structural shop the comparison between new premium system and old premium plan. each case the new plan, figures for which are given the right-hand columns the tables, the following pages, was put into use only after *Consulting engineer, Chicago. Thorough Study Essential Thus the one adequate and thorough study all conditions which have bearing manufac- turing cost. often extends beyond the shop doors the stockroom, and even the clerical force the office. Any accomplishment the way cost reduction should taken incertive search further under the as- sumption that work this character never finished. There remains only find the way which leads still lower manufacturing cost. Sometimes this ac- complished the purchase new equipment; often speeding old machines; the rearrangement manu- facturing units; wage incentives; handling orders and materials, and proper method routing. Always, however, the best results are obtained when all the above factors are developed far possible, and synchron- ized that one aid the other. Finding the the Bottle” ROM plant where new equipment recently was installed, with the expectation that further effort would necessary increase production and cut cost, 1647 Table I.—Gray Iron Foundry Work Weight Work— Increase Time Timein Pro- Casting Hours Hours duction, per No. per No. per Per ¢ Piece Pi Piece Pieces Piece Cent 20 Ib. 15 0.70 15 0.50 40 500 Ib. 1 6.00 1 4.00 50 900 Ib. 9.00 100 40 Ib. 6 0.33 10 0.20 65 330 Ib. 3.50 2.20 0 Ib 12 4.00 12 2 00 100 100 lb 6 1.70 10 1.00 70 238 1.00 0.50 100 *Total and 136.68 78.20 the following illustration taken. The burden was placed wholly the new equipment. Neither effect was realized except small way, because the flow ma- terial formed the neck through which, without readjust- ment, greater production was impossible. new drying oven was installed, with many distinctive improvements over the old ovens. Ahead the oven were two chain conveyors, the first one feeding the second, which carried the product through the oven. After trial operation many weeks, the only benefit derived was that lower fuel cost. The oven could not worked capacity, simply because the conveyor was not loaded heavily enough. The conveyor could not fully loaded because raw material did not move from the storeroom the manufacturing department properly proportioned lots. The stores department was blame only part, because the order department took recognition the problems involved the actual manufacture the product. was the practice the order department tabu- late incoming orders until (arbitrarily assumed) suffi- cient number pieces each kind had accumulated that order should given the shop. When this stage had been reached order was issued the fac- tory, way the material storeroom. There the store- keeper, without knowledge shop conditions, used hit- and-miss judgment sending material the shop. often separated items order, sending first the shop that material which was easiest for him handle take from stock. The results were two-fold. Work went through the shop slugs, and parts order often remained the storeroom for month, delaying shipment the complete order far beyond even the unnecessarily long time required get the first part the order through the shop. This unsystematic method handling orders and materials, which resulted the unbalanced loading the conveyors, hampered this plant that was able ship finished products only about one-half the working days each week. Correcting Bad Conditions The remedy was simple. The expenditure for the new oven having already been made, the only further outlay necessary was few hundred dollars whereby the two conveyors were mechanically adjusted cover all neces- sary conditions loading. There was established also scheduling department which was responsible for loading the conveyor that properly correlated assortment parts passed through the oven each day. This solved the problem the shipping room, from which finished ma- terials started move every day. Purchase orders are now forwarded without delay this scheduling department. There analysis made and material ordered out stores such quantity and such sequence that the conveyor will neither clogged nor only partly loaded. The schedule such that finished parts will reach the shipping department such quantity and assortment that orders may promptly filled and promises delivery kept. result the new management methods, the oven exceeds the rating given its manufacturer. Above all, the output the shop was more than doubled, with only small increase labor needed load and unload the conveyors. Three Departments Show Large Gains ONDITIONS similar the above are not confined any one phase manufacturing. Recently per cent increase production was made possible the jobbing foundry referred early paragraph simply rearrangement working space and equipment and installation wage incentive. Before changes were made the men were paid the day. Molding machines were available, but they were poorly located with respect the shop whole. Molders, after having finished job, left the floor search new one and the pattern necessary for it. One the first steps taken revamp methods this foundry was study the flask situation. The assortment was, generally speaking, satisfactory for the run work hand. However, the storage space was unhandy with respect the molding floor and flasks were piled with regard type size. Hence much expense was incurred sending them storage, digging out the flask needed and again returning the shop. handy storage space and orderly stacking overcame this difficulty. Table Shop Work Time Time Piece Work Per Cent No. Machine Hours per No. Machine Hours per Premium Increase é Kind of Piece Pieces Used Piece Pieces Used Piece Work Production i3-in. cast steel gear with clutch ring Vert. boring mill 12.00 Vert. boring 5.20 Piece work 130 cast iron brake Wheel Vert. boring mill 6.30 Vert. boring mill 3.50 Piece work 3i-in. cast ste cut gear Vert. boring mill 7.20 Vert. boring mill 2.50 Piece work 188 Cast steel frame 15.00 Planer 8.70 Piece work Drill press 5.00 Cast frame Horiz. boring mill 28.80 Vert. boring mill 4.50 Piece work 203 Cast steel rollers 102 Vert. boring mill 0.78 102 Vert. boring mill 0.43 Premium packing metal Planer 1.92 Planer 0.48 Premium 300 40-in. packing metal rings Lathe 3.40 Lathe 1.14 Premium 200 Cast iron frame Babbitt floor 11.10 Babbitt floor 6.50 Premium Cast iron frame Assembly 24.30 Assembly 16.20 Premium *Total and average 381.36 177.30 115 *Based number pieces day-work column. Iron Age, December 19, 1929 Foremen were instructed watch the progress jobs and anticipate their completion, and have delivered promptly the molder the pattern which the schedule called for next. The layout the floor was planned that products now move progressively down aisles ample width. This relieves congestion the molding machines, making possible for them rated capacity. Piece work was based thorough motion study. The results were that output was increased over per cent; not extra man was employed; expenditure was necessary for new equipment; the cost production was lowered and the men were allowed earn about per cent more day than with the old day rate. Table shows the increase production brought about the new methods. Figures are given for number miscellaneous items, some which were made single pieces, while others went through the shop lots pieces each. The time required make single 56-in. gear was cut half. The saving time making cores showed per cent and 100 per cent in- crease hourly output for the two jobs was accom- plished. How the Machine Shop Was Benefited Table are shown results obtained after putting into practice improved methods the machine shop. new equipment was purchased, most the machine tools hand were recent design. Machine speeds were adjusted; cutting tools were properly ground; ma- chine tools were rearranged with reference the sequence Special attention was given the methods and time for setting jobs the machines. material routing system was put operation and both the men the machines and the foremen were given advance informa- tion, that they could plan set-up ahead time and have tools and material ready start the new job. Time studies were made and piece work and premium system payment supplanted the old day rate. Production the shop was increased the average, 104 per cent. The use piece work resulted gain 135 per cent, and those jobs where the premium sys- tem was used the gain was per cent. Gains Structural Fabricating Shop Basis for establishment premium system may fault, and that, combined with other unfavorable fac- tors, may choke shop production. The structural fabricat- ing shop had for some time made use premium sys- tem which had been roughly based records day- work cost. had been expected that the magic word premium would bring low cost. Little effort was directed that early attempt conditions under which the work was performed. Some time was spent the recent change rear- ranging machinery. Aisles were cleared and material worked was carefully classified and piled orderly manner, convenient the various machines. Then time studies were made and new premium system was built from them. The workmen were instructed now make the best possible use the equipment. Results attained are shown Table III. The average increase production was 106 per cent. noted that the production increase several cutting operations ranged from per cent 300 per cent. This divergence itself was clear proof that hit-and-miss production methods had been use and that improvement was over- When studies were completed, instructions were writ- ten covering each operation. This was done that work- men and foremen could duplicate conditions for specific job even though might not get into production again except long intervals. Standard Speeds and Feeds Important Often there lack interest applying standard speeds and feeds machine shops which are run day work. has been shown time and time again that the use these standards habit-forming among workmen and these habits become especially valuable shops where day work and piece work are mixed. Once the men become accustomed operating given size drill its proper speed they will habit maintain these standards any work which passes through their hands. therefore urged that standard speeds and feeds specified for all classes work throughout the shop. point often overlooked the checking patterns, ascertain whether not the castings will carry extra metal which later must removed unnecessary ex- pense. With reference the attitude the workmen, should impressed upon them that the possibility earning higher wages depends maintaining new con- ditions and following instructions. method long satisfactory which not closely adhered to. Finally, regardless whether new old equipment used, one must coordinate all factors which contribute the prob- lem production. Then the can his best. Table Shop Work New Premium Old Style Premium Work after Work Improve- Condition Had ment Condition Improved Per Time Time In- Hours Hours crease Kind Oper- No. per No. per Pro- Piece ation Pieces Piece Pieces Piece Special Container Size A— Steel Cut 106 0.194 0.160 Punch 106 0.349 0.128 173 Drill 106 0.140 0.070 100 Form 106 0.185 0.112 rivet 106 0.565 0.284 Special Container Size B— No. Steel Cut 108 0.157 0.155 Punch 108 0.155 0.098 Drill 108 0.034 0.034 Assemble and rivet 108 0.290 0.128 127 Special Container Size No. Steel Cut 139 0.223 118 0.107 108 Punch 139 0.060 118 0.060 Drill 139 0.062 118 0.054 Form 139 0.110 118 0.042 163 Special Container Size No. Steel Cut 0.320 137 0.080 300 Special Container Size E— No. Steel Cut 0.410 0.123 233 Punch 0.250 0.064 290 Form 0.292 0.039 645 Assemble and rivet 0.220 0.102 116 Special Container Size Steel Cut 0.250 0.210 Punch 0.345 0.16 110 wa Notch 96 0.193 96 0.053 264 Assemble and rivet 2.040 0.950 115 long pieces flat bars Punch 50,000 0.00372 50,000 0.00340 *Total and average 905 535 *Based number pieces day-work column. The Iron Age, December 19, — Careful Heat Treatment Needed—Temperature Control Melting Feature—Wood and Metal Pattern Shops FAY LEONE FAUROTE* Bellevue oil-fired furnaces are employed melting metal for castings the foundry the All the melting furnaces are located one room the center section the main floor. The casting floors, equipped with roller conveyor tables made Eastern Steel Castings, Newark, J., have been installed con- venient points front the entrance the furnace room. Aluminum “Y” metal used for cylinder heads and pistons, the pouring temperature the “Y” metal being about 1300 deg. Fahr. For the crankcase castings the Aluminum Co. No. 195 metal specified. pyrometer room equipped with Wilson-Maeulen Co. apparatus makes possible for the temperature each furnace read any time. Here the observer may signal, means three electric lights mounted convenient point the ceiling, when the metal ready for pouring. green light indicates that the furnace coming heat; red, that the temperature ex- cessive; and white, when the critical pouring tempera- ture reached. addition, the temperature the metal *Mechanical engineer, New York. The design and equipment of the Wright aer: a tical foundry, together with an account of the making of engin castings, cores and the like. were covered IRON Dec. 12, page 1587 the ladle each heat ascertained pyrometer inserted just the metal leaves the furnace room. Later each casting stamped with the number the heat, and thus complete check each heat obtained. After the castings have been shaken out they are taken the cleaning room, where the gates and risers are sawed off power-operated band-saws. Later they are chipped pneumatic hammers, snagged, pickled, sand- blasted, stamped and given careful inspection. The piston castings are rough turned outside before being heat treated, that there may uniform heat pene- Annealing and Aging the Castings After the castings are made, necessary reheat them remove the casting strains and also age the castings, improve their tensile strength. This process accomplished electrical truck loading oven, with outside dimensions ft. wide, ft. deep and ft. high. handles two cars ft. wide ft. in. each heat. The oven electrically heated with connected load kw., provided with automatic temperature control, and the range operating temperature from 200 deg. 700 deg. Fahr., depending the particular process under way. The circulating system with which Saw Sander é 1650—The Iron Age, December 19, 1929 OOD Shop Layout Wright Aeronautical Foun- dry. This the third floor the building and, the diagram shows, has excellent day lighting all around. lers protect pattern shops and storage from fire danger this oven equipped provides most uniform heat distribu- tion. All the crankcase parts, the pistons and cylinder heads are heat treated annealed electric furnaces 960 deg. Fahr. The cylinder heads and pistons are aged 400 deg. Fahr., and the crankcase sections 212 Fahr., Gehnrich indirect-heat ovens. All three parts are then pickled immersing hot caustic soda, followed nitric acid solution. The floor the pickle room protected pavement acid- proof brick and the walls are coated with paraffin: After final washing, the parts are taken the inspection room and carefully explored for checks, cracks and other defects. Some castings which are imperfect show blow- holes. After the preliminary grinding these are pre- heated (three) welding furnaces ovens tempera- ture 900 deg. Fahr. and the blowholes then filled welding the hot castings. The ovens are the car type, each oven having outside dimensions ft. in. wide, ft. in. long, ft. high, and handling car in. wide in. long. Ovens are oil heated and operate 800 900 deg. Fahr. The oil system operates from oz. air pressure and lb. oil pressure. There are number stands for oxygen-acetylene blowtorch welding. shrink the finished cylinder-head fin body the steel cylinder, the heads have expanded heating temperature 750 deg. Fahr. This accomplished continuous conveyor running through electrically heated Gehnrich oven. The equipment entirely automatic its operation, that the operator the unloading end, series push buttons, may cpen close the door either end the oven progress the conveyor. Heating entirely automatic, with automatic temperature control, and provides continuous record the heat cycle through which the castings pass. After the cylinder heads are shrunk the cylinders, they are black japanned and this japan finish baked electrically heated, truck-loading type oven having two.compartments. The crankcases and other parts are finished with gray enamel and these parts are baked electrically heated, type oven with three compartments. Pattern Shops Two Floors the second and third floors are found the metal pattern shop and wood pattern shop respec- tively. These and the pattern storage department the basement are the only parts the building equipped with automatic sprinklers. Equipment the wood and metal pattern shops extensive and adequate. electric elevator runs from the pattern storage department the basement the pattern shops the second and third floors. one corner the metal pattern shop are three auto- matic metal band-saw filing machines and automatic band setter. The entire time one man here required keep the supply sharpened band-saws ready for the department below, one saw lasting only about hr., after which must re-filed and occasionally reset. Each bench the metal pattern shop has both air and gas available. present about 250 men are employed the Wright the pattern departments, the remainder engaged sand-mixing, core-making, molding, shaking out, cleaning, sawing, chipping, filing, pickling, heat treat- ing, inspection, supervision and maintenance. The foundry offices, the first floor, adjoin the inspection room. Services Provide Comfort for Men both the foundry proper and the pattern shops, very efficient ventilation systems have been ‘nstalled, that linseed oil fumes, smoke, obnoxious gases, wood and metal dust are almost wholly withdrawn from the air. The ventilating systems for the pickle house consist wooden ducts with wooden fan outside the building, discharg- ing into wooden stack. the heat-treating room equipment for air-cooling the castings, consisting pits the basement, through which air fans. The exhaust used for heating the basement winter, with by-pass the atmosphere summer. These ETAL Pattern Shop Layout Wright Foundry. Daylight four sides sured, the shop be- ing the second floor the build- ing. The arrange- ment benches and tools the two pattern shop floors much alike, with benches two sides and heavy tools the center = Forge Grinder “Surface Pla and Insp Lathes Millers The Iron Age, December 19, 1929—1651 2 4 ‘=e i Iron Age, December 19, 1929 ment for Cleaning Castings. This largely bench work, because the light- ness the castings YLINDER Head Shake-out have cooled sufficiently they are conveyed rollers over this point, where the mold sep- arated from the casting UTOMATIC Sand-Blast Table (Below) Where Aluminum Castings Are Cleaned ICKLING Where Aluminum Castings Room, Are Passed Through Series Baths Cleanse the Casting and Show Any Imper- fection. Overhead conveyor used for heavier castings J these two pages are parts the foundry the Wright Aeronautical Corporation, the subsidiary operations pieces equipment are here depicted. XPANDING Fur- nace for Cylinder Heads Fit Them for Shrinking the Steel Cylinder. Below metal pattern shop, showing how air and gas are supplied each man’s bench Enameling Ovens, the Enamel Being Applied While Crankcases Held Fixtures, Shown. Japan- ning ovens are sim- ilar these CALLY Heated The Iron Age, December 19, j m™ | = ventilation systems are believed largely responsible for the complete absence the smoky haze usually ob- served foundries. iron casting done—only alu- minum, kelmet metal and some bronze. Interior walls all departments are painted white down shoulder height, below which they are dark. This, to- gether with the large window area, entirely obviates the necessity for artificial interior illumination except during the late hours the afternoon winter. Even the basemen well lighted and clean. con- tains, addition sand storage bins, metal, pattern and general air compressor room, the oil supply pumps, the lower section the electric heat-treat- ing furnaces, large, well-ventilated metal locker room, spacious wash room equipped with Bradley Washfoun- tains, row shower baths and toilets. addition this there ample space for rest room and cafeteria, which may installed later. Aluminum alloy “ingots” are stored the basement sheet steel floor skids, which are handled electric lift truck the elevator and thence the melting furnaces. Along the ceiling the basement runs the piping for the equipment above, such high-pressure air, low- pressure air, fuel oil, gas, water and steam. The main distributing switch room located the basement also. this supplied 4150 volts Public Service current, transformed here 440 volts for power and 110 volts for lighting. Feeders run the different power and lighting panels for all the lights, motors, and furnaces. the basement the partitions the sand bins are wood, but all the others, such those the metal storage and pattern storage, are wire grating. This allows free circulation air and unobstructed pene- tration light. spur track runs along the wall, the full length the building one side. This makes pos- sible for the incoming sand chuted directly the bins portable conveyor. Incoming metal unloaded from cars spiral gravity conveyor which dumps out metal truck frame, which needs wheeled only few feet inside the metal storage room. From there transferred the furnace room the main floor sidewalk-type elevator 3-ton capacity. Heat supplied the building unit heaters. Those the main floor are fed steam high pressure, and the trap discharge low pressure used for supplying unit heaters the basement, which operate vacuum system, the condensate being returned the boiler room. 20,000-gal. fuel oil tank buried outside one end the building, and the oil pumped the core ovens, melting furnaces and elsewhere needed. 10,000-gal. core oil tank the yard, near the fuel tank. Tying Production Control with Materials Handling electric washing-machine manufacturer, before in- stalling overhead tramrail system, had the usual type stockroom, consisting long rows bins which the smaller parts were kept, and four-wheeled trucks cluttered all over the place, which the larger parts were kept. Operation this plant was described before engineering meeting Akron, Ohio, Bennington, Cleveland Electric Tramrail Division, Wick- liffe, Ohio. assembling several models, several thousand differ- ent parts were used, consisting screw-machine products, castings, pressed-metal parts, bars, motors, itches, The material was from stock the usual type tote box size which would hold material his supply was replenished containers this size bundles angles, rod, etc., depending upon the nature the material being used. the stock small part should unexpectedly become depleted, more machines this model could assembled until the supply was replenished. Definite Stock Runs Established This manufacturer took the first step toward success- ful handling his material when established definite stock run for each model machine. then purchased 800 steel containers, all the same base dimensions and varying only height. cubical capacity these containers was fixed that size hold the exact quantity any part required complete the pre- viously established stock order. Assume that the established stock order model machines was 500. The purchasing department would purchase the various parts required, the quantity which provided the lowest overall price. When these parts were received, 500 them would put into one only one piece was used each machine. ten pieces were used each machine, 5000 would placed the proper-size container they were received, and checked the receiving department. Where parts were too large get into one container quantities 500, these were placed two containers five containers, and those containers plainly marked abc out 1654—The Iron Age, December 19, 1929 stock order 1/5 stock order, conform the quantity they held. There were also few cases where several kinds very small parts were grouped into one con- tainer. These were parts which did not require any man- ufacturing operations before assembly. They were placed this container such way that they did not become mixed up, being separated from each other partitions. Those parts which did not require manufacturing finishing were moved the machines the schedule each department permitted. After the completion the machine operation they would moved back into stock await assembly. This relieved floor congestion the manufacturing department. Better Control Over Operations and Stock Aside from the saving effected handling large units one trip, and eliminating rehandling, the inventory sys- tem, cost system, and record material lost manufac- turing operations could more accurately accounted for. Since tramrail system was employed handle these containers, with special automatic grab that enabled the operator attach detach the load from the cab with- out the aid anyone the ground, these containers were piled four five high, and aisle space was entirely eliminated. The capacity the stockroom was increased about 400 per cent, and the cost new building which otherwise would have been necessary under the old scheme things was saved entirely. Hardness Brinell balls for hardness testing ma- chines has been investigated the British National Physical Laboratory. For these very hard steels Vickers hardness tester using diamond cone suitable. Brinell balls for testing steels whose hardness number does not exceed 500, should have diamond hardness num- ber (corrected for the curvature the ball) not less than 900. For Brinell tests material between 500 and 630 hard, balls should used. file test can also used rough indication the surface hardness balls. ball can scratched new smooth file its corrected diamond-hardness number probably below 850. | Strength Zinc Base Die Castings Improvement Has Been Large Recently—Gravity and Pressure Methods—Types and Relative Merits Alloys Available ROBERT CURTS* the outstanding features the recent development zinc base die casting alloys the remarkable improvement which made relative physical properties. These improve- ments have been brought about through systematic limit the major part the following dissertation the one type which recently has become popular. Gravity and Pressure Methods Compared broad sense, the term die casting includes both study the effect the deliberate addition other metals zinc, and careful study the effects certain metallic impurities which are likely occur the raw materials which sometimes occur because thoughtless contamination. Zinc base die casting alloys are now available which will make strong, sound and permanent castings. Tensile strength from 45,000 50,000 Ib. per sq. in. and initial impact strength well over 100 ft.-lb. per sq. in. can now obtained through the specification the proper zinc base alloys. Inasmuch zinc base alloys are cast several methods, and because the casting method not only deter- mines the type alloy which can used but also influences the physical properties the castings, seems briefly consider these several methods and gravity and pressure castings. implied, the former method relies the force gravity distribute the *Technical Service, New Jersey Zinc Co., New York. Fig. Orna- mental Zinc Lamp Base Made the Hand Poured Gravity Slush Casting Method (at Fig. 2—Automobile Carburetor Made Sev- eral Assembled Zinc-Base Die Castings (Above) Fig. 3—Washing Machine Agitator—a Zinc-Base Die Casting Weighing Lb. and Having Diameter In. Fig. 4—Idler Gear for Speed Reducer Used Electric Hoist. Note the (diameter) gear which has been cast around the axle The Iron Age, December 19, molten metal throughout the various cavities the die, while the latter method employs the application artificial forces, either pneumatic, mechanical, com- bination both. this process pressures ranging from less than 100 per sq. in. and 2000 per in. are used. The higher pressures are usually employed where high rates production are necessary and where the appearance the surface primary factor. Gravity castings are sometimes classified slush cast- ings (Fig. and permanent mold castings. They are usually hand poured and necessitate the use alloys having rather high fluidity. quite common practice use high-grade, unalloyed zinc for this purpose. Cast- ings this type have relatively low tensile strength (8000 10,000 lb. per sq. in.) and are used primarily the production ornamental objects and toys. Stronger castings may made the gravity method using zinc alloys containing aluminum, copper and, Fig. Hoist Motor Housing—(Weight Length in., Diameter in.). Note the design the casting which distributes the shrinkage about the core and which allows minimum weight and maximum strength. The walls are reinforced with eight ribs which are integral part the casting sometimes, magnesium—although the addition these metals the zinc influences the casting properties and often necessitates greater care when used connection with complicated dies. Possibly many readers have not realized the possibil- ities zinc base alloy castings because they have con- sidered castings this gravity type only. Pressure die castings are invariably much stronger because the difference the structure the cast metal, and because the types alloys which can cast this method are very much stronger. Increased impact strengths, together with greater ease and rapidity casting, have popularized the pressure casting method the extent that consumes about per cent the zine and zine base alloys now used castings. order prevent any confusion, and because pressure die castings are far the most widely used, the author limits further discussion this field. The automobile industry consumes well over per cent the zinc base die castings which are now being produced, although the past year has witnessed the in- troduction similar castings into many new and inter- esting fields. Practically all automobiles are equipped with castings made the newer and stronger zinc base alloys. The recently perfected and widely adopted fuel pump, illustrated Fig. made Zamak, the 4-3-0.1 1656—The Iron Age, December 19, 1929 Fig. 6—Automobile Fuel Pump Composed Two Die Castings Made the 4-3-0.1 Alloy alloy, which will discussed detail later on. Car- bureters, lamp housings, cowl lamp brackets, windshield wiper housings, steering wheel parts, radiator caps, mag- neto and generator housings, spark and throttle levers, emblem bars, robe rail and foot rail brackets, instrument panels, speedometer parts, inside and outside hardware, clock frames and numerous other parts are now made zinc base die castings. Many Kinds Zinc Base Castings Varieties zinc base die castings are also employed the manufacture numerous other articles, such sewing machines, printing press accessories, moving pic- ture machines, check writers, lighting fixtures, fractional horsepower motors, washing machines, gears, vending machines, sun lamps, toys, cash registers, locks, pencil { a Fig. 7—Bronze-Plated Door Knocker Made Zinc-Base Die Casting sharpeners, door closers, weighing machines, spray guns, radio chassis, radio loud speakers, plumbing fixtures, general house and furniture hardware, etc. the foregoing list, once evident that many the applications noted impose rather exact- ing demands relative tensile strength, resistance breakage impact, freedom from growth, and retention physical properties. The improved zinc base alloys which are now being used are meeting these require- ments. Not only they meet specifications relative strength, but they also lend themselves the application great many attractive finishes including enamels, lacquers and almost any kind plating. Nickel, chro- mium, cadmium and other metals commonly used for plating may applied without difficulty. The evolution the strong alloys which may had today not the result chance findings over-night discoveries. has been slow evolution which many factors had considered. Many alloys were made and tested. Primarily, research investigators sought alloys having high impact strength. But having ac- complished this, their job was not finished. Ageing, due intercrystalline oxidation and internal phase changes, Fig. 8—Steel In- Used Connection with Automo- bile Hardwase was determined for the alloys considered, and many them had discarded because they failed stand the tests which they were subjected. Many other alloys “fell the wayside” because they did not have suitable casting properties—for good all-around alloy must not only have great strength, but must free from hot shortness (cracking the dies), and must have good fluidity and liberal casting range. From the standpoint finishing must easily machined, buffed, and plated. Three Types Die-Casting Alloys the present there are three types ing alloys generai use. The properties and merits these alloys are reviewed the following paragraphs: commonly termed “Tin Alloy” contains ap- proximately per cent tin, per cent copper, 0.5 per cent aluminum, and the balance zinc. This one the more antiquated zinc base alloys and has practically been displaced the newer and stronger alloys. has relatively low tensile strength (approximately 24,000 Ib. per sq. in.) and low impact strength (17 per sq. in.). has elongation from 1.50 per cent in. and Brinell hardness from 61. Such physical properties did not invite the use this type alloy for the hundreds applications which die castings are now serving. About the only justification for the use this alloy, scant though is, that quite readily soldered. Soldering and the tin alloy hand hand, for “chain stronger than its *United States Patent No. 1,596,761, Aug. 17, 1926. Fig. 9—A Group Brass Inserts weakest link” and weak soldered joint necessary, weak casting will serve. From the economic stand- point, this type alloy probably more expensive than the newer alloys because, although low grade zinc may utilized, the cost the copper-aluminum-tin com- bination with low-grade zinc will exceed the cost the copper-aluminum and the copper-aluminum-magnesium combination used with high-grade zinc the most recent alloys. 2.—The 4-3 5-3 alloy contains from per cent aluminum, per cent copper, and the balance high- grade zinc. This type alloy has tensile strength ranging from 37,000 43,000 per sq. in. and impact strength about 100 per sq. in. cast. and Brinell hardness about 80. has very good casting properties, being quite fluid and free from hot shortness. can cast with smooth, even, fine- grained surface which facilitates subsequent buffing and plating operations, which frequently subjected. easily machined and can used connection with steel, brass, bronze and other types inserts. 3.—The alloy (Zamak)* composed per cent aluminum, per cent copper, 0.1 per cent mag- nesium, and the balance high-grade zinc. This the most recently developed alloy and, many cases, has replaced alloys the 4-3 and 5-3 types. With tensile strength 47,000 50,000 Ib. per sq. in. and impact strength well over 100 ft-lb. per sq. in., this alloy undoubtedly the best available the present time. should employed when long life and service are re- quired the finished casting. easily cast com- plicated dies, although some care must exercised the gating the die order prevent overheating which may result cracking. affords smooth, hard, fine grained surface which particularly suitable for plating and other finishing operations. can soldered, necessary, although soldering discouraged be- cause soldered section usually weakens the casting unit. The 4-3-0.1 alloy somewhat harder than the tin alloy the 5-3 4-3 type alloy, having Brinell hardness from 90. easily machined and Fig. 10—Chrome-plated Die-Cast Door Handle with Steel Insert Fig. 10a—Same No. After Severe Hammer- ing Points and The Iron Age, December 19, splendid alloy for use connection with various types of inserts. (See Fig. Nos. and 11.) The use inserts quite general the die casting Iinduetry industry. These may steel, brass, bronze, porcelain, etc. Occasionally another die casting used insert —usually prevent soldering operation. Figs. and portray several types inserts and illustrate the manner which they are “keyed” into the casting. The shrinkage the alloy around the insert just pronounced enough anchor firmly that the casting must actually broken the insert removed. And the casting made high-grade alloy such the 4-3-0.1 type, will not break, shown Figs. ll-a and 12-a. Fig. shows commercial automobile door handle which has been cast around steel insert the type Figs. and Screw Inserts Cast the 4-3-0.1 Alloy. Figure 14-a represents one these inserts severely deformed but still firmly anchored the casting shown Fig. 11. This door handle was placed vise and severely hammered, resulting appreciable de- formation without breaking. (See Fig. 10-a). Another example the toughness good base die castings illustrated Figs. and this case one the machine screw inserts was hammered flat the without coming loose from its anchor- age without cracking the casting. Although the inserts will obviously increase the cost the casting, frequently possible prove economy the finished product due the elimination machining and assembling costs. Inserts are used impart greater strength elonga- tion localized points—affording the properties of.a wrought structure where cast structure would not serve satisfactorily. Door handle inserts exemplify this use. They are sometimes used give hardness special wearing qualities (Fig. 4), and are also employed afford the special bearing properties the bronze alloys. Specific electrical properties pertaining either resistiv- ity conductivity may also had through the use inserts. Laminated pole pieces may made integral part the casting used the manufacture electric appliances. this connection, the use zinc-base alloys offers excellent material which may given special prop- 1658—The Iron Age, December 19, 1929 Fig. 12—Tensile Bar Die Cast the 4-3-0.1 Alloy Twisted Through 360 Deg. Without Fracture erties local points without influencing the general economy afforded the use die castings. matter fact, the die casting process much more versatile this respect than many other production methods which involve welding, soldering, brazing, mechanical couplings. The author frequently asked compare the physical properties zinc-base die castings with castings made other materials such brass, bronze, iron and alumi- num alloys. Due the wide variation the figures given for these materials rather difficult make ac- curate comparison. study the various possible sources available data reveals that the tensile strength the 4-3-0.1 alloy least per cent greater than sand cast brass bronze, while the impact strength lower than that cast brass and about the same that cast bronze. Compared with cast iron, the 4-3-0.1 alloy least twice strong with respect tensile strength, and greatly superior impact strength. Sand cast iron has impact strength from ft.-lb. per sq. in., compared with well over 100 ft.-lb. per sq. in. for the 4-3-0.1 alloy. The toughness and ductility zinc base alloys are quite well illustrated Fig. which repre- sents die cast tensile bar twisted through 360 deg. without fracture. estimated that the production pres- sure die-castings consumed well over 60,000,000 high grade zinc 1928. The consumption for 1929 will exceed that 1928. New fields are presenting themselves every day. Many complicated parts which were not economically possible with other methods production are now being made strong, high-quality zinc-base alloys the die-casting method. Fig. 13—This Well-Known Pencil Sharpener Made the 4-3-0.1 Alloy. was dropped ft. concrete floor without any evidence fracture. could not fractured the application 21.57 force, which was the capacity the testing machine. — High Speed Cupola Melting Metallurgical Advantages Are Many—Average Speed Over 200 Foundries Slow—Conception Composite Cupola HAT the economic advantages melting iron cupola the best speed obtainable are evident all foundrymen was the contention Truxell, research engineer, Potter Coal Coke Co., Greensburg, Pa., address entitled “The Metal- lurgical Advantage Higher Melting Speed,” delivered the December meeting the Philadelphia Foundry- men’s Association, Manufacturers Building, Wednesday evening, Dec. 11. The attendance local foundry- men was large. his extemporaneous speech, Mr. Truxell said that the aim most foundrymen melt iron the cupola’s rated speed better, and pronounced his purpose point out some not obvious, but none the less real, advantages which follow such practice, properly carried out. His arguments and deductions melting practice were collected from personal observation over 200 foundries Canada and the United States, east the Mississippi River. Average Cupola Operation Only Per Cent begin with, said the speaker, has been found that the average cupola operated approximately per cent its rated speed, although there are few which are and even higher than the rated speed, while others are considerably below the average. obtain extremely hot iron has long been contended that speed necessarily must reduced. has certainly been learned that hot iron and rated speed can obtained readily with the speed even increased. When iron melted slowly and high tempera- ture, the charging excessive coke found the usual practice; but this term, excessive coke, requires some explanation. Most foundrymen think coke weight ratio iron rather than comparison air, that, the case excessive coke and slow melting, one finds the hot area the cupola limited height and with poor conditions for combustion. Hot iron may obtained this way, and being done quite frequently, although many other factors enter in. evident these cir- cumstances that the iron has quite period time and favorable opportunity undergo changes such losing silicon and phosphorus and picking carbon and sulphur. Careful comparisons, however, show that iron melted this way will vary greatly from the iron which charged almost unrecognizable. Loss and Pick-Up Elements HEN cupola melting capacity speed better, that is, tons hour for 10-ton cupola, and delivering equally hot metal, the difference between the analyses metal charged and metal poured shows likeness that encourages the melter his conviction that can deliver iron the spout which will meet speci- fications. Many foundries are losing 0.20 0.25 per cent silicon and phosphorus while picking 0.10 per cent sulphur compared others with silicon and phos- phorus loss 0.10 per cent and sulphur absorption 0.05 per rather significant that these figures vary directly with the melting speed. the picking carbon, several large foun- dries are melting high percentage steel en- deavor obtain high tensile strength, aiming low total carbon, and are obtaining per cent carbon and under regularly operating high speed. should sufficient encourage small foundrymen least in- vestigate the possib