The Iron Age 1930-01-16: Vol 125 Iss 3

THE IRON New York, January 1930 ESTABLISHED 1855 Molybdenum Steels Gaining Favor Survey Present Applications Shows Large Tonnage Being Absorbed Heat Treated Steel Parts and Case-Hardened Pieces Requiring Maximum Toughness and Uniformity HILE molybdenum alloy steels were made toward the middle the last century, the rarity the element pre- vented systematic study their characteristics and their commercial development. During the Great War sud- den demand for the metal arose, the price bounded up, and intensive prospecting for mineral several the western States. Thus has developed that the “rare molyb- denum reality available any quantity, after the necessary time had elapsed order develop the mines and build the reduction plants. This changed situation encouraged the utility molybdenum structural engineering steels. These researches led since been verified practi- cal experience, namely, that molybdenum most valuable when less than per cent added steels containing other common alloying ele- ments, such and chromium. was immedi- ately apparent that such com- binations had superior resistance While higher molybdenum alloys had been made com- mercially the crucible process many years before, first electric furnace heat low molybdenum steel was made December, 1917; open-hearth production started May, 1918, both events taking place United Alloy Steel Corporation, Canton, Ohio. Use the steel during war times was confined those parts where the maximum shock and sudden load. THUM taining molybdenum used annually. Case-hardened pieces (either car- burization nitriding) such Gears Camshafts Wrist pins consume considerable fraction the tonnage. Parts high stress, such Connecting rods Steering spindles fuselages are made the heat treated alloys. Large objects, requiring extra tough- ness and uniformity, like Crankshafts Hammer rams Die blocks Gun tubes Armor plate are made these steels, together with other items such Corrosion resistant sheets Soft steel for deep pressing Hand tools cente! reactions; 141 (where it cools how rapidly the surface sized pieces harden effectively when cooled air. (b) Quenched alloy steels containing molybdenum hold their hardness after higher drawing temperatures. Longer toughness was required, namely, light armor for hel- mets and tank armor, armor piercing projectiles, and Lib- erty motor crankshafts. Uses since the war, which have largely increased lage, have been due the more complex combination properties listed below, ex- ploitation the metal, and marked reduc- tion price. Molybdenum marketed ferromolybdenum, calcium molybdate, denum silicate; least 250,- 000 tons the low alloy steel now popular was made 1928 the United States. American mines monopolize the situation; the 1918 price has steadily declined about one-fifth that figure. Effect Adding Molybdenum Alloy Steel Experience has developed the following facts about al- loy steels containing little molybdenum: (a) The most prominent and unmistakable ability induce air hardening and hardening depth. mas- sive piece such alloy steel will hard even the comparatively slowly matter cooled); furthermore, moderate times heat are also required complete the proper sluggish rate grain growth also prevents coarsened, brittle structures after relatively long heatings. VOL. 125. No. > ganese with Molybd 100 Dian tre ited to nell and afte: Quaid-Ehn respe nter? re eyregates or dirt an n t e tne Virtue can it re ROM the above properties steel—which for the and di re ni vine 1 the sense that between steel with without molybden ( ri en } It part the tonnage has been used { hey | ‘ y { 5 { 7 ) | “ | { } ; ina enr ort } } | ~ } 1 - | ‘ ly I te } y I + rive ence endurance limit (as det characteristic of any high t i] free from s irf: HYSICAL Properties Core 1-in. Rounds, Case- Hardened Nickel-Molybdenum Steel, Single Heat 142—The Age. January 1930 Izod impact repeated alternating stresses A high r Draw na "er nerat+ure Dea Fahr. EDIUM ganese 100 Diameters. ». treated 269 Bri- Quaid-Ehn test, respectively carburizing anti-friction bearings. both cor races. Piston pins, steering knuckk ns, camshaft gears and other carburized parts for the aut machinery industries have also been made great tity this material, S.A.E. steel 4615 0.10 0.30 0.50; 1.25 1.75; 0.20 0.30). ommended heat treatment is: forge 2100 220 Fahr., finish forging relatively high temperature, malize 1650 Brinell hardness about 160. chine, and then carburize 1675 deg. Fahr. Oil quen 1 from the carburizing pot about 1500 deg. after cooling the pot, reheating and quenching) gives good strength the core, shown panying chart; this comparatively mild treatment quenched from 1600 1625 deg. Fahr. drawn indicated ra HYSICAL Properties Aircraft Tubing and Sheet and machining and carburizing usually sufficient and the ring part may ground precise dimension immediately and may given 30-min. draw about 300 deg. Fahr. relieve internal strains. any event this relatively simple 20; treatment avoids nearly all the distortion which accom panies multiple heatings and coolings necessary harden the case and properly refine the core carburized hromium steel. Such “single treatment” carburizing steels exist virtue their property resisting grain growth, even (01 when heated considerably above the minimum then required for complete hardening, and therefore avoiding com coarsened and brittle core. the carburized parts are ifter imple shape, like wrist pin, they can quenched case sclero cope hard. Ring gear made from S.A.E. 4615, carburized, cooled the pot, reheated above the critical temperature the case, quenched oil press, and then tempered deg. Fahr. should within 0.003 in. flat and round (80 per cent should more than 6.0015 in. out flat 0.002 in. out round). Reheating for quenching nide bath liable give file-soft surface layer; oil ienched from the furnace carburized gears should hardness 755 0.010 in. below the sur This high surface hardness associated with treme toughness; impact bars carburized and heat treated regular gear-making routine have strength double the figures for carburized nickel steel gears for heavy trucks and buses, gear for superchargers, where high surface hardness and tough- required, would made 1.5 per cent nickel molybdenum steel. Where gears maximum strength needed, carburized per cent nickel steel preferable. From steel maker’s viewpoint, nickel-molybdenum desirable because none the alloying elements are lost during melting remelting. Practically recoveries recharged scrap may effected. Manganese-Molybdenum Steel Medium manganese steels are being used for carburiz- ing. has been established that 0.25 per cent molyb- denum will improve the Izod impact values (representing toughness) medium manganese steel least per cent, change associated with fine grained microstruc- ture after carburization the McQuaid-Ehn test. Molyb- denum also appears improve the uniformity response heat treatment, decreasing the number rejects beyond specification limits when medium manganese with- and out molybdenum carburized. Comparison the physi- + cal properties fine-grained electric steels both with and without molybdenum given the table the next page. The Age, January | 720000 re ~ ( | 700 800 900 1000 4 With With Molybde: Molybde Hi \ Mec l ingal | \ en it ) nt | narden a l; har nfer quenct haracterist i <4 at « and re re i Hardening Ammonia (ras hos ntainin i pe cen aiumi num) acquire HYSICAL Properties ens he eater Or 1 90 hi phe |: ny NX é nir eq i ‘ } icine elr ] metal ompoun Tor hose re. Such patented aluminum alloy exploited under the trade name “Nitralloy,” chromium other alloy steels which may also case-hardened the same manner, become quite brittle the core trouble has been largely the addition about 6.20 per cent molybdenum the analysis. Larger addi- tions molybdenum seem also increase the speed the nitriding reactions. Chromium steels with molybdenum for case-hardened articles have not been used very much. The rapid and deep hardening propensities induced molybdenum inten- sifies the natural hardness the chromium steel. and therefore the core lacks the toughness required, for Mi ) f hr would be expected to be due te the wor ar Wit tamnara tin 144—The Iron January 1930 stance, for clash gears, except after complex heat treat- ment comprising normalizing, oil quench from the pot, double heat treatment and final draw 385 deg. Fahr., timing each operation carefully. Such extreme precaution will not necessary when extremely hard case main consideration, and tough core minor Chromium-Molybdenum Automobiles and Aircraft AJOR fraction the molybdenum produced year goes into chromium-molybdenum into the S.A.E. specifica tions 4130 4140, making automobile necting rods, axles, ing highly stressed parts. interesting high grade jaw and soc} sufficient strength and hardne can had heat treat ment avoid the neces sity case hardening The chemical limits S.A.E. 4130 Carbon- 0.25t0 Manganes romium Molybdenum 1 0.15 to 0.25 0.15 tot The first mentioned steel water hardening; the latter must oil Brinell, although hard ness range 215 will permit very rapid machining. Heat treat ment includes 4130 After Quenching tively high draw for Drawing long time—see (b) above. Physical properties are shown the adjoining chart. indicate the fact that close adjustment quenching temperature chemical analysis un- necessary—a matter importance mass production the following tests %-in. rounds, all after quenching water and drawing 1050 deg. Fahr., may cited. The teel was S.A.E. 4130, with chromium and molybdenum on the high side. | Yield Kelonga Reduc Point tion tion Brinell Izod 140,000 62.7 319 139.500 17.0 63.1 321 138,400 17.5 61.7 321 1900 16.8 57.9 317 quenching temperature 1550 1650 would get the maximum physicals with the minimum amount heat. Draws should 1000 deg. Fahr. more insure good toughness (high Izod figures). slightly different analysis than S.A.E. 4130 very (Continued page 201) tance. More Alloy Steel Made Increase Over 1928 Perhaps Per Cent—Most Forms Steel Show Substantial Gains—Motor Cars Take Five-Eighths ETURNS from nine alloy steel producing ear, the bars have gone per cent, sheets have including all the large producers, showed rolled creased per cent, tubes and pipe, about per cent, and steel amounting 897,514 tons 1929, with strip steel, per cent. cember estimated. These returns not include certain There has been sharp reduction billets and slabs large tonnages covered the figures reported alloy steel reported, production which, according the American Iron and Steel Institute. Prominent among the returns, dropped approximately per cent. The the missing items are copper-bearing steel and figures for the companies reporting show increase other alloy steels which the alloy constituent below about per cent, which little greater than the certain minimum percentages. per cent increase total steel production 1929 com the table shown the distribution the alloy steel pared with 1928. reported the nine companies, not only among the dif Subdividing individual products, seen the table ferent types steel, but also among the consuming indus that the automotive industry took the largest tonnage tries. About per cent the total comes under the seven items listed (not counting “miscellaneous” heading bars. Sheets accounted for nearly per cent, undistributed uses). More than two-thirds all the billets and slabs, including forgings, for like amount, irs, four-fifths the tubes and pipe and nearly three tubes and pipe for something less than per cent, strip fourths the strip steel went into motor cars. steel for little over per cent and plates for less than roportion the distributed tonnage black sheets and per cent. billets and slabs and more than one-half the distributed About Five-Eighths the Alloy Steel Went Into build Automobiles bution, the basis the returns nine companies, Widely varying views what constitutes alloy shows more than per cent going into automobiles and teel account for the failure many compilations automobile parts. other industry listed absorbed cord closely with each other. Totals reported the much more than per cent. Agriculture went 3.1 per cent, American Iron and Steel Institute for 1928 amounted forging steel, separate from the individual industries, gross tons ingots and 169,684 tons casting about 2.5 per cent, and machinery and tools, about 2.3 per With the considerable loss from cropping and scale the cen little over per cent the total was manufacture alloy steel—a drop approximately and the unclassified list covered more than per cent—the ingot figures the institute might tran cent. lated into about 1,860,000 tons rolled steel 1928 Comparing the returns with those for practically the Trade estimates for 1929 report increases varying from same companies for 1928 (the difference companies per cent. take per cent fair average, porting being confined two three small units) then the rolled alloy steel 1929 must have been about find that the plate tonnage has almost doubled since last tons. Production Rolled Alloy Steel and Main Channels Consumption 1929 (Gross Tons, Reported Nine Steel Companies) Oil, gas and water companies Mining and lumbering Machinery and hand tools. Bolts, nuts and rivets.... Electrical manufacturers Pressed and formed metal. Jobbers and warehouses The January 1930—145 oom | | i] i] ; | ain Building Prospect Outlook for 1930 for Increases Public Engineering Projects and Upward Trend Residential Construction ind immediate cause this for municipal bond have not yet gone ahead ier financing through bond given the Presi conferences and their attendant publicity, int than amounting practical certainty that flood prevention, sewer milar public improvements will measurably product 1930. Along with these engineering projects vill undoubtedly large increases public and ects, many them long needed and many eady provided for Government appropriations. there een long nditures for public improvements are likely show Commercial and industrial building 1929 the upgrade, and they are consequence less likely have further increase 1930. Recent surveys have approximately equal hown rather more than normal percentages vacancies large office buildings, and this class work seems due for quiet period order that demand may catch with anufacturing facilities are not likely in- wh t + +] great] the comir year, though plant moderni cost-reducing machinery and e industrial and commercial organizations have ample inds plant extensions; apparently they had more than nple funds 1929, addition spending con- for new buildings than 1928, they had hich they employed the call money market. Obstacles Building Resumption Swept Away rather anomalous situation; large accumu- itions funds, available for program very consid industrial expansion, but diverted into speculative ecause full expansion program was restricted tes had and turned fea creating too large surplus manufacturing tru cKed nat, 1 We} vten f i obstacle t extensions public utility facilities. the constructior Sizable Increase Residential Building Expected 1930. one class work that suffers most period stock market speculation residential building, in- cluding apartments, two-family houses and one-family houses built development projects. Not only were invest- 146—The Iron January 1930 — ( 4 7 q 4 4 | q \ *\ ment funds diverted from the usual mortgage loan char nels 1929, but there were even considerable from savings accounts and check the growth building and loan associations. Private dwellings. ticularly the better types, did not fall off se) did residential buildings investment and types. But residential building expenditures decreased per cent from 1928. one respect. good thing. There was some oversupr ny the opening the year, and the reduced ime this class work has brought about lemand. Consequently, sizable increase vork all kinds expected 1930, though not the point equaling the volume the peak year 1928. \merican people keenly desire better houses and ents, with all that best modern conveniences. the cost new 1ildings too for more than small portion de- express itself effective demand new buildings. buildings an only be sold or rented ex- pense rendering buildings bsolete. Itis rather likely that the obso- lescence existing factor residential buildings increasing, but have not yet arrived ways disposing old buildings simply junk present time or- movement for modernization old buildings, particularly houses, under way. 1929 i i progress was doubtless impeded somewhat Apparently there generally unfavorable conditions. excellent opportunity for this kind work probable volume this class work for this year hay run high billion dollars. This the present method which the obsolescence problem residential buildings being met, and good economic But, the question arises whether the long run shall not have invent radically new residential building designs, with simpler and more economical uses mate- rials, order produce housing for larger market lower costs. This, however, looks future more distant than the present year. Per Capita Building Expenditures Less 1929 the chart accompanying this article shown that per capita building expenditures decreased rather se- verely 1929, and per capita engineering expenditures dropped very slightly. This interruption the country’s program construction expansion was more serious than anticipated, due considerably less financial stability 1929 than most people expected. Considering all the indi- cations improvement now existing, reasonable estimate per cent increase total construction expen- ditures over 1929, provided improvement the construc- tion contract record occurs during the first quarter the new year. Since such improvement can usually unted five six months after upward turn the market, bettered first quarter record likely. writer’s estimates for all building and engineering Wol n he Unite: States are as follows: ave raye for years 1925-1928, 1929, 1930, about This last figure just little under average, 1925-1928, and represents ear recovery rather than year expansion. This would differ from the figure for 1925-1928 having Per Capita Expenditures rk, public works and utilities, power developments and ther engineering projects, and modernizations, and habier perce ré aentia Idi Non-residen hould increase from per cent, civil engineering expenditures may much cen figures would indi nstruction expenditures 1930, divided follow $55.92 for building; $13.08 engineer W rt chart show that civil engineering ex- penditure repre sented per cent of total con struction expendi 1929, com pared with per cent the total 1927 and 1928. The estimated for Cnaineey VWIOTK cate 19 per cent ol engineering work. building capita expendi tures dropped from $60.60 in 1928 to $52.08 1929 (due entirely reduced residential build ing), the indicated increase $55.92 1930 seems rea sonable. prosperity continue this country some- thing near the levels the past five years, seems nece ary that proper proportion national income must con tinue spent for new buildings and that per capita expenditures for this purpose the rate $60 per annum vould reached again the next year so, even though ich increase not likely this year Substitute for Hand-Puddled Wrought Iron Studied report, soon published the Bureau Stand ards Journal Research, gives information the com parative properties wrought iron made according the recently developed Aston method and the similar product made hand puddling. Results of the tests indicated no marked significant differences between the two irons. The product made the new process appears have all the earmarks usually associated with the name, wrought iron. The new-process iron, the tests carried out, was more uniform structure than was the hand-puddled product; the other hand, its tensile strength was slightly lower, but the duc- tility was higher. significant differences corrosion resistance the two irons were revealed the corrosion tests carried out. The Age, January | | | 924 1925 1926 1927 1929 Selecting eat for Heat Its Source Economic Problem—Factors Favoring Electricity, Gas, Oil Problems Steel and Non-Ferrous Products persistent leaning the turer toward one form fuel. i years ago was not unusual fin factory using only one sour heat for many different heat-treatir operations. This tendency disappearing, has become mor generally realized that heat suited one operation may not another. Heat Treating Connecticut OCAL economic conditions necticut are favorable electri heat treatment and are becoming in- creasingly favorable the use gas. Most our industries are metal working, and many are highly spe- cialized branches the metal-work- ing industry which quality tne ince f he ii neat treatme! proble decided shown the overall cost the prod- for the different forms heat ere tha unit fuel may cost two three times 11 ich heat unit does not } ] I essarli\ naicate na coa more efficient than coal iower | If t neat-ti ALIT i a pial ( nat ¢ the fuel for heat treating mear } ii > ) Lt ndividual process ecor R.M Items Influencing Overall Cost Among the items which influen cost Fuel, power eanir f product ] raw material and finished the ind rejections raight productior hining and rking condition Mar ndustrial enginee! end to overemphasiz« B.t.u makin naking comparisons various ind, wher nsidering +} n particular pet f } seldom get any Some ] + ; rial electric heating engineer the advantages electric heat. Neither argument - Cal nd p n tl Tact f the overall economi situ Lower cost per B.t nothing inefficient per B.t.u. means nothin +] ilization and greater spoilage result n less profit le operatior ] 1? ed intang { ant ot elec I ! I les f they do not If the n avantage al rea the I Lil ea nosen mu re 1it in tne lowest overa ! Vill ever ally i displaced by ome more econo; ory heat r vga oO! n furnace if lire? I ilted disregard econon tuat situation ing | i rT nea nic? i carelu ruthful analysis vhole manuf proce . Mic | ni ed p ( t lid produ indicated the first place. momet+time in ne no 7 nomical application results from Lig Power Cx t 148—The Iron Age, January 1930 major importance. only natural that there should local trend to- ward the use electricity and gas for heat treatment, general, eco Electric furnaces are operation for annealing, hardening and tempering steel, the bright annealing copper and nickel silver, and annealing brass. Gas used for hardening, tempering and carburizing steel, for annealing nickel-silver shells, and more for large production annealing brass. Oil furnace: anneal, harden, temper and carburize steel and anneal brass and copper the large rolling mills, and annea! malleable iron. Coal mainly used only for the anneal ing malleable iron and steel, but there are still few coal-fired carburizing furnaces and brass annealing fur naces operation. still have the most ancient fuels, wood, use large scale for the finishing anneal brass sheets the large rolling mills. appears that this may replaced city gas. Ball Bearings and Cold-Rolled Steel production standpoint the two most important plications annealing steel the State are the bearing industry and the cold-rolled steel industry Two ball bearing manufacturers use oil for annealing and the third now does its entire annealing with electricity. This manufacturer now has operation capacity 1200 kw. eight 150-kw. electric all which operate off peak night that the furnaces create additional demand and the cost power mi mills per kwhr. Another very important annealing operation the industries Connecticut the bright annealing cold- rolled sheet steel. The trend from coal oil and electricity shown these plants that three manu- | isis for this trend. | facturers using coal five years ago, two are using both coal and oil and third using electricity entirely. During recent years number coal and oil-fired furnaces used for carburizing have been re- placed electric furnaces. Viewed from general stand- point, seems somewhat difficult justify some these installations economic basis, but the number installations continues grow, evident that the in- dividual manufacturer thinks that getting improved product, there results saving overall cost which justi- fies the investment. Also, many these installations. carburizing conducted only night, which with the form power rate prevailing most the large cities the results energy cost from per kwhr. this basis the heat cost for electric heating closely competitive with oil and probably cheaper than coal, when the labor for coal firing taken into account. Carburizing Rotary Drum Furnaces Interesting results are now available the compara- tive cost carburizing small pieces modern insulated. rotary drum, gas-fired furnaces and rotary drum electric furnaces. each case solid carburizing compound was used with average length heat from hr. and temperature 1690 deg. Fahr. The gas furnaces were charged with 500 lb. steel when operating under the above conditions and consumed 16,400 cu. ft. gas per ton steel, 8.2 cu. ft. per With marginal cost gas 95c. per 1000 cu. ft., the heat cost for carburizing was $15.60 per ton per lb. the case electric furnace the charge was largcr, being 800 lb. per heat. With other conditions the } same the gas furnace, the production carburized per kilowatt hour amounted 3.24 618 kw- hr. per ton, and the heat cost electricity per ton material carburized was $7.40 0.37c. per less than half that the insulated gas furnace, with marginal power per kwhr. study the overall efficiencies the furnaces this operation, based the above figures, will indicate the reason why the rotary drum furnaces are excellent application for electricity. this case the fur- nace has overall efficiency approximately per cent, and the gas furnace approximately per cent. not one those cases where electricity has been com- pared with obsolete fuel furnace, the gas furnace was modern and purchased within the last and one- half. The comparatively high efficiency the electric furnace due the fact that there are flue losses and also end through metal losses have been eliminated, the drum does not project outside the insulated chamber. recent years large number oil-fired hardening furnaces have been replaced Connecticut gas electric furnaces. some localities there decided trend toward electricity and others the use gas expanding more rapidly. These changes have been par- ticularly true the case industries having large quantity production hardening. Electric Hardening for Ball Bearings After several years investigation electric harden- ing furnaces are being introduced rapidly into the ball bearing industry. Five large plants now either have their hardening departments completely electrified equipment purchased for doing. four these cases electricity replacing oil and the fifth, gas. the latter case the electric furnace eliminated rejections the races for improper hardening this plant, and the complete hardening room now electrified con- siderable saving labor has resulted. This plant also does all its drawing electric furnaces the forced air circulation type, which replaced gas-heated baths. With the exception gas-fired, rotary drum, furnaces purchased short time ago, and which are now being replaced electric rotary drum furnaces, all heat treat- ing this plant performed electric furnaces— hardening, drawing, annealing and carburizing. the plant large spring manufacturer, gas- heated, modern, belt-type furnace operating very suc- cessfully production hardening small pieces. additional unit being added. Gas this case replaces oil. This same manufacturer has large number gas- fired lead pots for the continuous hardening and drawing strip steel. These pots operate very successfully and show considerable saving from the oil pots formerly used, because lower maintenance cost. This concern used oil for large production annealing and for some its hardening and gas for lead pot hardening and draw- ing. Each time new application has arisen, they have investigated electricity well gas, but for their local situation they feel that gas considerably more econom- ical than electricity. This situation accentuated the fact that they are comparatively small power user, but very large gas consumer. City Gas for Annealing Brass Sheets Oil for annealing the breaking down operations and wood for the finishing anneal are the basic fuels Con- necticut brass rolling mills, although some coal used. The most important development the past year rolling mill annealing has been the installation large continuous furnace heated with city gas for annealing oiled brass sheets, replacing wood the finishing anneal. The installation has been successful that the use for the operation may extend rapidly, and under suitable local conditions may replace oil for all rolling mill annealing some mills. bright anneal not being obtained, but the finish the brass superior the product the wood muffles, and the heat cost with gas only slightly higher than with wood. Electricity was considered for this operation, and appears has been rejected, because the finish obtained was not good with gas. One objection was the effect grease and dirt the brass entering the nealing furnace. the electric furnace the dirt not oxidized burnt off the combustion furnace, and tends bake the brass. This becomes rather seriou matter the finishing anneal. The control the atmo phere the electric brass annealing furnace subject worthy much investigation, because with the same surface finish, electricity closely competitive with heat basis many situations. While electric furnaces have not progressed very rapidly large rolling mills Connecticut, there steady increase the number used for the annealing brass tubing and shells specialty plants. The origina! muffle, installed Waterbury 1923 for tube annealing, has now operated daily hr. for without coil burn-out any furnace maintenance expense. Control Atmosphere Bright Anneal Copper Considerable progress has been made the atmo control electric furnaces for bright annealing copper. Oil continues the fuel the eastern roll- mills, but electricity still extending rapidly for an- nealing seamless tubing, coiled sheets and wire. Recently continuous electric furnaces the tube type have been built for bright annealing copper tubing atmo phere steam some non-reducing gas. Pit-type elec- tric furnaces the retort type are now use for bright annealing coil copper sheets atmosphere steam. properly constructed water-sealed electric furnace has little maintenance expense, shown the fact that two in il The Iron Age, January 1930—149 vith A \ \ l nee eX ns¢ ] wou i tr } ratiy a " yy no ror la ui mu } y + I } rn? i y ) T I Investigate } } } al _ ne at 4. ~ 150—The Iron Age, January 1930 industrial work has proceeded entirely logical man- alone economic lines accordance with the require- the industrial world Broad Periods Electric Heating civilization could not have reached its present mechanical development without the product electric furnace. Electric heating its development through three broad periods: 1889 1900, from 1900 1918, electric melting: 1918 date, what now called ng. Starting with prox electric heating has progressed ature range metallurgical and indu mple drying and baking low Since the construction the first metalli heat-treating furnaces about year improvements have been made, that uitable local economic condition ind gas furnaces results ts, the economic situation will com the furnace these Heat Treating Gains Importance han ever, metal- rtan heat treating their opera- ore that comparison costs sources thermal basis means nothing without plete investigation overall costs. Even such estigation leads change the source heat, worth while, because invariably results the little realized weak parts the plant prac- roduction costs materially. Selection heat treating economic pending the local shown the overall cost the finished ina cnoice de Carnegie Safety Trophy for 1930 MIPETITION for the 1930 Carnegie Steel Co. safety was started Jan. trophy illustrated the bronzes which have been put into mpetit 1 innua i 1 tne ir1o0UsS Carnegie manu plants seen from the illustration, this miniature rolling mill with housings. was made sterling silver Gorham Co., New York. The base bronze, while iKINg the rolis are statuettes of two men representing steel rollers handling the machinery iderahly | siderably larger scale than the The men are con Both figures were posed for the artist men employed gie plants, one them being roller Farrell, Pa., and the other roller Clairton, Pa. The height the entire trophy in. carries silver plates for engraving the names the winning plants month month, and that the plant winning permanent possession for the year’s operations. installed Waterbury five years ago have 4 } 7 ther main ne? eem, however, that the retort pit furnace using formerly in ntry 7 Vale i 1! l 1 4 | nd nate DICK Costs + iV | ? ney ‘ n > neating roduct with the different forms heat. | 4 + 4 | 4 = — Fabricating and Handling Equipment Unusual Combination Apparatus for Accurate and Rapid Work Special-Purpose Machines Employed ATERIALS handling Was given utmost cor the for beam and column storage and the third tion laying out equipping the fabricating torage angles and plates. Heavy columns and beams plant the Mahon Co., Detroit. whic} are fabricated the fourth bay, which L-shaped, the igned for convenience handling steel from the wer end extending around parallel line with the received from the mills, and through the fabricating ther structural shop. Here connects with covered ind assembling operations. Efficiency has been ading dock, 140 ft., which serves both shops. Rail labor saved the installation latest types dril road tracks serve the new shop, spanning the bays and punching machines with tables controlled form curve, and one track extends along the loading achine operator, and with other labor-saving A large extension recently Was built to the plant, pl \W el ise ordel are handled at the lower end of the ding two separate fabricating shops and bays for the eam and lumn storage bay, for the company does torage steel. The new used for fabricating isines addition fabricating. Here ware eel for the heavier types buildings and the old shop for ise stock cut and classified and shipments are made types structures. Both are served from through doors the side the plant, that the handling ame steel storage department. The two shops are practi warehouse material does not interfere with production ally the same layout and wherever possible the the end the four main bays transfer bay ent duplicate and interchangeable. for handling steel from the storage bay the heavy fabri Work can shifted from one shop the other ating shop. Each bay served two electric traveling I desired. The efficiency the present arrangement ranes, these ranging from 30-ton capacity. Cranes hown the output, which 17.9 tons monthly per man, throughout the plant are the two-hook type. ounting all productive labor, including crane operators. Cutting equipment located the lower end Here steel cut length for 7 t angies and are Si ney t\ The two shops are located righ irranged that material can routed readily into house orders for either the fabricating shops, that shop. Steel kept under cover from the time when reaches one these shops ready for fabri vaded until it is shipped out, except some of the fabri itlo? One crane unloads the stock from the cat to the ated work from the industrial type building shop. shear and the other handles after cutting. the assem ompany plans eventually cover the crane runway fron bly department are two 25-ton cranes for handling and hich some the material now shipped. loading assembled work. Three 80-ft. bays and one 40-ft. bay, all 380 ft. long, Fabricating for industrial-type buildings done the new shop. addition, fifth bay shop 336 ft. long and ft. wide. The industrial shop has heet fabrication located one side the shop. three 10-ton cranes, one for each gang. the end oading. the side the narrow bay along the outer wall used for bar storage, this shop 25-t Plate and mounted turntables for convenience 2 — The Iron Age, January | | | | > Which Are Handled and n le re achit hop 50-ft. bay for production Slabs, which are vith a torch. seams IGHT Columns Angles Punched Multiple Punching Machine. riage The car- the table 1S ing con- trolled by the ma- Cc h ine operator through solenoid brakes 152—The Single from tric Hoists Operating the Punch Operator ind DackKward on trol Vs ou ) nll the Punching Monorail anda i ait at moving or t tram fr Through Age, January 1930 Pun ched Machines Elec- ra [-} { ‘ 1S 17 Cliane ] wor Dp ases, are cut na toren oy t either of the fabricating shops the warehouse. they are warehouse order directly, crane delivers the steel the conveyor table the saw truck for shipment. The shear table the gravity type and has stops that work can measured the table. will hand Four-fifths the cutting bean and channels done with torches instead saws. sections ft. long. Plates are sheared Bertsch Co. shear and Ryerson-Kling shear. Plates are delivered shear gravity conveyor table. The shear for bevel cutting and ripping, the plate always horizontal plane and right angles the setting the machine. The advantages for this ment are that, during ripping, plates always throug! the shear straight line and plates can squared the table without the use squaring shear. set guides the conveyor table holds the plates alinement The angle shear similarly provided with gravit conveyor and turntable. This shear differs from the that has two blades independently one being used for regular production and the other work. The plate shear will handle 84-in. plates thick, and the angle shear There are two sets the plate and angle shears, one set located the plate and angle bay, which used for shearing warehouse stock, and the second set entrance the shop for industrial types buildings. Handling Steel During Punching efficient method handling material through the inches for single and through punching, when spacing table used, provided the industrial building shop. monorail adjustable laterally located over the punches wall. This supported short beam sections projecting from the building columns, which ve rail for the trolleys which the monorail attached. The longitudinal monorail This through moved forward backward chain-operat the machine. inching machine operator moves the the posi required alinement with The steel handled electric hoists suspended monorail. controls located trolleys on bring the work The machine operator has complet: Adjustable is ¢ irried forward sid for doing Ryerson friction saw; from this they ACHINE for Facing the Ends Columns. The blades are the large disk head back the holding-down bridge (at -COLUMNS and Heavy Angles Are Drilled Multiple Drilling Machine, with Turn-over Table Controlled the Machine Operator Through Push Buttons and Levers (Above) control the piece and can handle beam ft. long. Work held the hoists during punching. With the movable monorail track, single and through punching done two men—the punching machine operator and helper. Multiple punching light columns and angles done closed-throat multiple punching machines with auto- matic spacing tables, built the Thomas Spacing Machine Co., Pittsburgh. These will punch 36-in. beams, and both the flange and web can punched with one set-up, flat upright piece can punched the same template. The travel the carriage the table con- trolled the punching machine operator through solenoid brakes. Turn-Over Table for Drilling H-Columns Drilling H-columns and heavy angles done with Baush multiple drilling machine. This provided with Thomas turn-over table which centers the column being drilled the drill head means chucks, each having two fingers that hold the piece place and work automati- cally, except for final close adjustment. The table has ors Are Employed for Handling Ma- terials Locally the Warehouse The Iron Age, January 1930—153 | | | | push-button and lever controls, all handled the machine Work riveted with Hanna riveting machines erator, for travel well for raising and lowering electric hoists Gantry cranes, which have runwa extending the length one the assembly department out The hoist suspended from monorail the erane. allowing 6-ft. transverse travel. The elect ; vet heater mounted the carriage the crane vel the crane well passing Pipe Increasingly Use Increasingly Use Rises Although Total Pipe Shows ittle Change—Easier Money Expected Improve Municipal Buying pit roductior 15,000 tons pipe, ranging from 4-in. rtation pipe was even less factor than 1925 iron itput. est ited hen the total for the year declined about 65,000 ired with estimat from 81,764 tons rifugal estimated than Warren Foundry Pipe Co., Phillipsburg, 1928, which maller than the leading shipper foreign-made cast iron 137,698 tons 1927, and further slight decline from the United States were the only companies proj year 1926, when production reached 1,534,278 ton nstruction and they made but little progress with The year has been one the poorest The Société Anonyme des Hauts Fourneaux the pipe industry nce the war period Pont-a-Mousson Pont-a-Mousson, France, \lthough the mileage pipe laid was undoubtedly ecided establish American plant, undoubtedly in- than indicated the tonnage sales, there the proposed increase the duty cast iron large siz pipe, recommended the Smoot-Hawley Property nging 20-in. 48-in Throughout 1929, inquiri vas acquired Chelsea, Mass., and construction was begun were not uncommon. irgest der, capacity planned for construction this year. largest sizes, was placed Albany, About ame time, the Warren Foundry Pipe Co., tons and iter hich had been considering establishment sand-spun ent igal pipe plant the New England district Buying Smaller Scale property Everett, Mass., adjoining the Mysti With few exceptions, and ist furnace, filled the low ground, and the end ndry about 35,000 tons year capacity. tal for th year in ¢ bout tor World capacity for centrifugal pipe production reg ‘ York, consul ered further increases. The Sand Spun Pipe Corpor nly about tor ers bought on, licensed two British foundries and the leading French paringly, npared heir requirements past producer cast iron pipe operate under its patents. Water Service Co., New York, Canada, Hamilton, Ont., pipe foundry, licensed Gas ment Co., Philadelphia, each bought the fall 1928, entered into full production sand-spun t 10,000 tons f pipe » 22 A) rican | ig] t & Tr t n pe asing development the year pipe production was Chicago the spring, about 20,000 the beginning manufacture 18-ft. lengths cen- and the American Water Electric Co., bought trifugal pipe the leading interest, marking another 7,000 tons. rwari ster from the 12-ft. sections made about producer centrifugal pipe, operating under the sand- rr) nu la 1 mucn |! tnan in previou ears, pun patents, in an effort to cast large diameters cen- were remarkable that quotations Birminghan trifugally 48-in. listrict producers, usually lower than the North, be- lower rav terial and labor costs, were main Better Business Foreseen for 1930 everal dol ton higher. This from the year ended, foundries were still need een mvpetitive tuation amone Jorthern maker tonnage an , 9} j j among Northern makers. onnage and only maintained low rate operation Exports Widely Distributed However, moderate tonnage private quiry from gas and water companies appeared during the Export neral limited small lots + widoel nal month, municipal inquiry showed renewed activity, videly distributed going consumers and with prospects easier bond market 1930, Dutch West Indies, which should permit Japan and all the Central municipal borrowing lower interest rates than has been possible during 1929, pipe The heavies producers foresee the possibility considerable im- which placed orders provement business for Iron January 1930 i the piece Work is handled to and from the table D\ 1b crane, rar new facing machin the oma ra Machine \ )) Lit} | q W = | 4 | | — Die Casting Moves Toward Stabilit Extended Study Cast Test Pieces. Are Factors Which Improve the Outlook This method manufacturing iden tical parts large quantities low cost has achieved its great- est advance during year the standardization certain alloy compositions When Charles Pack defined American Institute Mining Engineers “metal castings nade forcing molten meta under pressure into metallic mold the industry pos Harvey Anderson sessed very and the operators considered major assets their exclusive possession the know] edge how cast parts successfully the desired size and shape. Today have considerable number ducers cooperating the recently organized American Casting Institute, and both producers and consumers pooling their knowledge alloys suitable for die casting through large committee the American Testing Materials. Die casting, method production, tremely competitive business. the one hand replace forgings and metal stampings effecting savings the cost machining and frequently also the cost obtaining the required surface finish. the other hand, must justify the expense large investment machines and dies offering economies over sand castings, slush castings, and permanent mold castings. Therefore die casting essentially industry suited the production necessities country where the suming capacity for such things automobiles, radios, vacuum cleaners, electric washers, telephones, adding ma- United States. Europeans, when advised the economies the die casting process, immediately inquire what could done with the rest the week’s output machine capable producing ten thousand speedometer cases one ten-hour day. America the consuming capacity sufficient justify the cost multiple dies and die cast- ing machines which make such high production rate possible. with The pressure die casting process comparable automatic screw machine production its replacement man power ingenious machine design. has been aptly stated that the extent which difficult shapes car successfully die cast only limited the ingenuity the die designer. The possibility obtaining accurate *Chairman, Die Casting omm Testing Materials. Member, Technical Staff, Laboratories, New York NDERSON and shapes with accurately cast threads, numerou res and inserts various materials for bearings ignetic parts illustrates the possible labor saving re! this process Secrecy Giving Way Cooperation the annual review published THE IRON AGE one year ago, Sam Tour emphasized the fact that secrecy practised the producer die castings was hindering progress. The signs the times point grow conviction ame producers they vill gain great deal more than they give the hange information minor developments and par ticularly the type mistakes which are costly the entire industry. This comparatively young industry een large number producers bankrupt and consider hand-to-mouth existence survivors. Among the factors contributing these failures are unintelligent bidding, neglect proper cost accounting, lack skill die design and insufficient metallurgical plant contro! the other hand, the business certain outstanding producers exhibiting healthy growth with only such interruptions may expected from the operation normal business cycles One producer has increased lant capacity four fold during the past year and general outlook the industry decidedly hopeful for the coming year. The number large users die cast ings who are installing die casting departments their steadily increasing and the larger die casting ompanies appear general ready either supply die casting machines completed die castings nere i demand The American Die Casting Institute under the presi dency Charles Murray has selected the matter accurate cost estimating one its first major subjects for study. This institute making effort intelligent competition for cut-throat competition between the proposals looking this end producers. Amor one that wherever possible business allocated that producer which stocks die for the proposed part. Thi proposal has the merit seeking eliminate the dupli cation expensive dies but has been criticised because the numerous other factors involved production may give competitor real advantage over the die casting company which stocks the die question. The proposal open the further objection that the present member- hip the Die Casting Institute does not include num- ber the larger producers the industry. This illu tration cited show the lines along which the Insti ute working. Accumulation Precise Information Castings The success the Die Casting Committee the American Society for Testing Materials seems already assured the large amount work which has accom- plished with the enthusiastic cooperation its sixty members, representing consumers, the Govern- January 1930—155 The Iron ment and technical societies. The committee will prepare specifications for aluminum and zinc base alloys suitable for die casting after having made sufficient number tests acquire the necessary information. The largest roducers indicated their willingness cooperate cer- tain researches (which offered promise general im- vement throughout the industry) designating their technical men for committee members nal analyses the alloys which they produced nnages aluminum base and nine zine base alloys (Table were first selected being representative referred practice representative new develop- ent the company, which prosecuting most active arch this field the New Jersey Zinc Co.). Nine producers have cast the various alloys into test pieces and have distributed the specimens shown Fig. testing laboratories total number specimens produced for physical, mical and corrosion studies between 80,000 and 100,000 and about 30,000 these have been tested and nformation circulated among the committee members. about variation composition and properties die castings (that is, test specimens) pro- under