The Iron Age 1930-01-23: Vol 125 Iss 4

THE IRON ACE New York, January 16, 1930 ESTABLISHED 1855 125, No. Training Foundry Apprentices Boys Should Taught Make Molds from First Day Foremen Essential NSTEAD being trained with the idea qualifying for executive position, foundry apprentices should taught good shop work reasonable cost. Some, course, will eventually become foremen and superintendents, but they must first become good me- chanics. *Superintendent, foundry and pattern shop, Newport Ship Building Dry Dock Co., Newport News, Va. For this reason believe good investment teach them every detail connected with the trade without trying encourage them telling them they are all going often used effort interest boys the molding what often does start the boy dreaming about the time when will “boss” and soon be- comes observer instead worker. There are three important things essential the training apprentices. First, must be- lieve it; that is, must not doubt the value the work the results are going obtain. must not half-hearted manner, but must feel that well worth the time and money spent. Second, HREE Young Men Sitting This Pit Liner Cast- ing Made This Mold and Many Other Similar Castings Under the Guidance Instructor. This casting, ft. diameter, piece and split was made one | 215 persuaded against our will try out for while. Third, must interest the boys their work. When believe and want and have the boys enthusiastic frame mind, training apprentices becomes not only simple matter, but interesting and enjoyable work. Foremen Must Cooperate Before company can get results from its apprentice- ship training program, its foremen must sold the good instructor may charge the work, but does not receive the hearty cooperation the fore- man charge the shop his efforts will The foreman can show his willingness help giving the instructor all the work needs for his students, allowing him free hand directing his boys and assuming friendly attitude. also must realize that get the benefit every properly trained hanic mecnanic. Selection the right kind instructor important. should good mechanic with progressive ideas and must not afraid get his hands dirty. must full zest for his work, because will have live gang take care of, and consequently must the job all the time advise and instruct the boys. must answer numerous questions daily, and the same ones many times. his job keep the boys interested and en- thusiastic about the trade they are learning. Some foundrymen believe that the best way start new boy foundry work let him watch the activi- ties around the shop few weeks before giving him any special work do, that will become interested and also learn great deal observation that will value him when begins mold. believe this mistake, because the boy will learn very little watching others. However, start him making molds with his own hands the first day the shop and will 216—The Age, January 16, 1930 Boys Molded This Casting Dry Sand Rammed Flask Three Days. generally takes two molders two weeks make similar casting loam interested immediately and will able learn quickly what others are doing around him. this manner will have desire know more about the trade. Start the boy molding. not let him shovel sand for another boy, but give him his own pattern, his own flask, his own sand heap and tools and show him how make mold. Then there will danger his becoming lazy, losing interest finding something else easier learn. have found that the first three weeks boy’s time spent the shop are the most important and therefore should full interesting work. The way start the boy has great deal with how much enthusiasm shows and how well gets course, cannot force him think, but can encourage him giving him something think about. can this the first day having him work with his own hands. all right prepare the boy’s mind for what are going teach him, but not safe much preparing before does any actual work that may lose his interest. This point aptly illustrated the manner which man learns drive automobile. not taken around see numerous automobiles for week order prepare his mind for what going learn. Instead gets into the driver’s seat once and his instructor sits beside him and teaches him every move. The result that one hour learns more about operating the car actual practice than would learn two weeks observation. The same thing applies time teach him all about the materials going use before permitted use them. What must first create desire the boy become good molder. immaterial whether knows what molding sand is, how plumbago made, and whether ramming should called tamping, packing jolting. want start him molding and teach him the other details later —_ ‘ when gets the point where wants know about them. Boy Makes His Own Mold good example how this works out the case young man who recently began apprentice one shop. the first day the instructor made smal] mold for him while looked on, explaining each operation performed it. Next the boy made the same mold while the instructor stood and watched him. When the boy forgot something, the instructor would stop him and give him several moments see could recall what was neglecting do. most cases remembered the proper procedure, but one two times had told what do. After the mold was made under the instructor’s super- vision, the boy was told make the same mold with one watching him. This usually requires considerable time, but about min. the boy reported the in- structor that had completed the mold with the ex- ception “cutting the ditch.” had learned how make the mold, but had not been the business long enough learn that the channel leading from the down gate the mold was called gate. But what did make? properly cut ditch will run mold just well properly cut gate. excellent way interest boys their work and create spirit pride have photographs taken castings they have made with them standing by. venture the opinion that they will prouder photograph showing them standing beside the marine cylinder they have made than any other picture they possess. Not Put Boys Production not put apprentice boys production. This ex- pression not always understood, some getting the idea that means that effort should made teach them work fast and economically. What really means that boy has been success getting out order washers pistons, should not continued the same type work. not want train boys become special purpose workers, but rather all around mechanics, and this cannot done keeping them con- stantly washers, pistons drill presses. HIS Boy, Small for His Age, Worked This Year. With little coaching readily grasped the molding idea. The mold sweep- small condenser cover advantage secure apprentice who has good school record, but poor standing should not disqualify him from learning the molding fact, the boy with the good school record should not given the preference unless also good shop work and general aptitude. Frequently boy who has served part his apprenticeship becomes interested his work that takes special courses study night school that will prepared handle the larger problems connected with the trade. would un- fortunate have prevented the boy from starting learn the trade because had not previously realized the im- portance school work. One our boys who has just completed his apprentice- ship had difficult time school and one time were obliged lay him off for several months until work harder class. His school average was gen- erally below per cent, but his work the foundry was 100 per cent. has become one our leading molders. the past have lost several boys, who were developing into good loam molders, account their school work. They failed in. school, after refusing study, but ap- parently were born mechanics. present have young man who has splendid school record, but his shop record poor and, spite all have done, cannot make good molder him. Advancement Should Not Depend Solely School Work For this reason not believe wise make hard and fast rules when specifying who shall permitted learn the molding trade. Neither should decide prentices’ chances advancement solely upon their work, especially they are making good progress the shop. have aroused considerable interest boys athletic competition, that they are proud this good thing, but must careful not create more enthusiasm for the ball game than for the molding | q 4 ; | { | j + a The Iron Age, January 16, 1930—217 trade. must not forget that good ball player does not mean good molder. Another way work interest among apprentices put learning competitive basis. just easy game ball. One group apprentices can matched against another group with the superintendent in- structor umpire. One game can the percentage good another the greatest number intricate good work will qualify the groups take more difficult When these contests are properly managed, they excite great deal more interest than ball game. Everyone player and the best feature that the boys use their heads and their energy trying become good better molders order beat the group opposing them. When real molding contest extending over year put on, the boys often can hardly wait get the shop. They talk about it, dream about and tell their best girls about it. That what makes good molders and men who love their work. weekly honor roll show- ing the standing each man and each group men relative their percentage good castings should kept. This also works considerable enthusiasm. Details Should Not Neglected Many important things often are neglected teaching apprentices. Sometimes they are neglected because they are not considered necessary and sometimes because the teacher does not know about them. such cases are teaching the boy walk before can crawl, and the result becomes imitator instead good me- chanic. Why should boy taught the effects silicon cast iron and the same time not shown how tuck sand around pattern. can make good castings never knows the effects silicon cast iron. want make molders, they should taught place their patterns flask, how riddle the sand, how hold the riddle, how hold the rammer, how ram drag mold, how ram between bars, how place gaggers, how tuck bars, how vent mold, how cut gate, how prepare gate that the metal will not cut, how carry off the gas from cores, how apply facing pattern, how make parting, how hold trowel, how and when use feeding heads and isers, how place cores mold, how hold cores their proper position mold, how secure core print, how make clean mold, how pour mold, how and where ram soft, how and where ram hard, how prevent scab cut, how prevent burn own, how prevent blister, how prevent cold shut, how prevent blow holes, shrinkage holes, and strains, how set sweep, how lay loam brick, how apply loam, how make loam seat, how build runner box, and how build cinder bed. i Boys Taught Work Specified Manner the same time they must taught why all these things are done specified manner and what would happen the work were not done that way. good example how apprentice can astray unless taught the necessary details young man who saw old molder ramming fire brick over the core prints pipe pattern order provide more solid bearing for the core the drag part the mold. The boy thought this was good thing, and later when received pipe pattern mold, decided use similar support his core prints. Unable find couple fire bricks, went the carpenter’s shop and 218—The Iron Age, January 16, 1930 secured two pieces in. lumber about the same the brick. saw reason why they would not hold the core well the brick. They did hold the core, but when the metal came contact with the wooden blocks terrible commotion occurred, and much young man’s dismay his casting was failure. had been under the direct supervision practical in- would have known that melted iron will not Boys Should Not Work with Experienced Molders Good mechanics can best produced having boys ork for the first two years shop themselves part the shop away from the journeymen molders, directly under the supervision instructors. When working with molders, they generally become nothing more than good helpers, because the molders seldom allow them any important work. Moreover the molders not take time explain why they certain things and consequently the boys’ time about per cent wasted. the other hand, when boys are actually working under instructor’s supervision, they are told how the work and why should done that way. safe assume that they learn more one day working this method than days working with molders. tried working one our apprentice boys with molder large loam job. passed him one day saw him standing around apparently doing nothing. asked him what was doing. twisted his face disgusted sort way and said, “Oh! doing the heavy looking on.” This was true. The molder was all the work himself while the boy stood around getting more disgusted and more discouraged every hour. Spirit Practical Joking Objectionable The spirit practical joking the part molders another objection doubling apprentices with them. Molders are inclined the boys. Probably this spirit fun, but such things tend decrease the seriousness the work. Many apparently harmless jokes they play hurt the boys making them afraid things for fear they will make mistake and ridiculed. instance, shop where the apprentices work with the molders, one day found young man painting the outside his snap molds with plumbago, because said molder told him that that was the way pro- duce smooth castings. Another time found boy look- ing all over the shop for clamp stretcher which the molder wanted. Another young man just starting was very much worried because one the molders had told him had the sand his first flask upside down. have successfully trained apprentices the pattern shop and foundry because have been able enlist the aid our foremen. This cannot done one day, but only keeping everlastingly after the foremen until they are interested point where they want all they can help. The instructors apprentices have big job and need all the help they can get. plan furnish the in- structor with list operations for each kind work and list suggestions that will help him teach each operation. must study the list operations and suggestions, not because does not know them, but order that will not omit anything. must bear mind that there are many little things connected with making mold that are liable consider too incon- sequential teach. This wrong, for the more details teach the more complete will our work and the greater will the knowledge the apprentice will have the molding trade. | 7 | ixing Gases for Industrial Use Major Economies Had Through Enriching Gases Too Lean Used Alone— Modern Mixing Devices competition the life trade, technical progress the life the productive end all industries. stand still impossible the modern race progress and competition. industry realizes these obvious facts more than the iron and steel industry, where capital investments are large, turnover low and margins profit often small. depends frequently the ability reduce manu- facturing costs taking advantage every possibility the complex technical processes. Economies May Made Fuels Undoubtedly one the most important opportunities save money the manufacture iron and steel products offered fuel. Heat applied every step the production from coke pig iron, from bloom wire, from slab sheet. Heat applications are many fold, from the coke the blast furnaces the fuel the open- hearth furnaces; from the tar oil the forge oven the powdered coal the pair furnaces; from the stokers the boiler rooms the electric heat the refining and special alloy departments. The diversity the item fuel nothing short amazing. B.t.u.’s today are more re- stricted one form; means heat variety forms solid, powdered, liquid, gas (raw refined)—and the practical engineer utilize the most profitable form best advantage, depending supply and applica- tion. Industrial gaseous fuels have taken new importance during the past ten years, due the realization the above economic fact and all gaseous products any proc- ess are looked upon valuable assets. Coke oven gas, for instance, longer by-product the coking coals, but one the main products, par with the coke itself well the tar compounds. Blast furnace gas longer waste product; positive source rev- enue the ore reduction process, with definite market value similar the pig iron and the slag. New Era Calls for Mixed Gases Utilization the industrial gases has made rapid strides and the broader aspects modern heat economy demand further developments. This second phase ushered the art mixing gases into the picture. date all gases are used “as is,” and their applications are subordinated their own characteristics. Gas mixing devices are invented and perfected blend the available gases into mixtures which are more economical, which have superior characteristics and give greater heat efficiency. This vision the advantages the art mixing in- dustrial gases opened new possibilities and review the foundation and developments this new branch en- gineering most timely this moment. *Smoot Engineering Corporation, 136 Liberty Street, New SHADGEN The major industrial gases are: Blast furnace gas, pro- ducer gas, blue gas, coke oven gas and natural gas. Five Industrial Gases Analyzed Blast furnace gas one result the ore reduction process the blast furnace. Enormous quantities are available; its density about 0.08 lb. per cu. ft.; its heat content varies from 105 B.t.u. per cu. ft. Typical dry analysis gives CO: 12.5 per cent, 25.4 per cent, per cent, 58.6 per cent. requires about cu. ft. air burn ft. gas with excess air. date blast furnace gas mostly burned under boilers here America. The tendency clean greater degree and use metallurgical fuel and offers the greatest possibilities mixing agent temper other richer gases. Producer gas made producers the incomplete combustion coals coke; the result trans- formation dirty unsuited solid fuel into refined and better suited gaseous product. Its density about 0.065 0.070; its heat content varies between 135 and 165 B.t.u. per cu. ft. Typical dry analysis reads about per cent, CO. 1.5 per cent, 12.5 per cent, per cent. Its composition varies with coal used and method running producer; not clean and should used immediately. Cold, clean producer plants offer difficult problem. Theoretical air required for complete combustion 1.5 cu. ft. per cu. ft. gas. Producer gas used largely open-hearth fur- naces the hot, raw state and offers through high pre- heat the realization very high flame temperatures. Coke oven gas the result the high-temperature bituminous coal modern by- product coke ovens. Its density about 0.4 0.5 per cu. ft.; its B.t.u. content about 450 550 per eu. ft. and required times volumes air for theoretical com- bustion. considered rich, fuel, cleaned for wide and easy transportation. Its analysis varies with coking time and the following limits are averages: per cent. Advantage Offered Blue Gas Blue gas water gas is, strictly speaking product the commercial gas industry, made from coke coke residues (lately also from mixture coals) so-called water-gas sets, with periodic cycles air and steam jection. Blue gas weighs about 0.043 per ft. heat content varies between 290 and 310 B.t.u. per requires about three times its volume air and its typical analysis reads per cent, per cent, 3.5 per cent, 4.5 per cent. Blue gas offers remarkable possibilities. me- dium gas, neither rich nor poor. cheap make, study the cost figures the gas industry will prove The Iron Age, January 16, conclusively; its method manufacture flexible. of- Gas Association are full data and instructive sug- fers great opportunities the mixing gases, either gestions. Table shows interesting comparisons. lengthen” rich gases such natural gas coke oven The practical problem mixing gases consists gas, blend producer gas and blast furnace gas into development reliable mixing and apparatus. ‘icher mixtures. Attention here drawn the possibili- is, strictly speaking, control problem. Two gases ties this gas the iron and steel industry. often brought together the right amounts and nore profitable make blue gas with coke breeze than correct proportions produce definite mixture pre that residue stokers under boilers. determined B.t.u. content per cu. ft. Outstanding feature Natural gas is, course, the peer all industrial any gas-mixing device are: Range, and B.t.u. cor ases; was made nature’s laboratory the centuries rection. the Dark Ages. Density 0.046 per cu. ft. Com- Range—The mixing apparatus must deliver the gas sition cent, CH, per cent, 3.5 mixture needed the quantities demanded cent, 0.5 per cent, per cent. Its B.t.u. furnaces other consumers. The mixture may not ntent 950 1100 per cu. ft. and the air re- right, but the gas quantity needed must supplied, times its volume. Its composition not interfere with production. Therefore, hanges often hourly and depends largely source base the operation the mixing and control devices rigin and distribution system. Natural gas rich, the quantities delivered, which means flow control. ‘lean fuel. Economically aking, has only one draw- Flow (cu. ft.) gas plus flow gas gives flow too good. The art gas mixing tries correct mixture the foundation. more suitable mixtures with Flow control means measuring the volumes and cor- gases recting the quantities needed through accurate flow certainly stands reason that natural gas not metering devices. The range determines the limits the ideal fuel for low-temperature operations. too accuracy. Practical considerations such multiplicity ncentrated for that purpose. burn 1000 B.t.u. val furnaces, Sunday banking, etc., require wide limits, such uable gas where 350 B.t.u. gas would fit the bill sim- meaning 150,000 15,000 cu. ft. hour, 63,- ply extravagant and offers possibility for saving. 000 6300 cu. ft. hour. The flow control must ac- curate and must flexible, follow rapid changes, Gas-Mixing Devices Being Developed the sudden shutdown one furnace unit. Re- This can done suitable gas-mixing device which this last specification, obvious, but often ffers attractive investment returns. All over the country task account the climatic considerations engineers are realizing the truth the above facts and outdoor service. mixing stations are operating enrich blast furnace ith coke oven gas; lengthen natural gas with blue gas; Proportioning for Desired Analysis gives the right analysis the mixture. That is, expressed large variety combinations are possible and en- gineers interested should make comparative studies Vol ties, flame temperature, pyrometric factors and colorific Volume iti the books covering the subject, such the case may be. This can also written Volume information available and the pamphlets the Ameri- Volumes for Volume third method express- 5 OLUME Control Gas Mixture With B.t.u. Cor- rection Had Use the Layout Here Pictured rate Gas Exhaust Volume Regu! ator Pressure Gas ted € 220—The Iron Age, January 16, 1930 7 Valve Bie | Gas | | | To C ntactor oF B] Analyser IAS LXMAUST & _ | J VV. UK 7 Supply | | | 7 | Ratio Ad /usTor M, Jar Volume Control Gas Mixture with Pressure Regulation Provided the Equipment Shown Here, Wherein the Two Gases Meet Right Angle the Mixing Chamber ing ratio form percentage mixture, such 100 per cent Mix per cent plus per cent 100 per cent Mix per cent plus per cent 100 per cent Mix per cent plus per cent Once the metallurgical calculations have decided what mixture best suited, the ratio can determined ap- proximately and the control device must give those pro- portions between limits. For instance, mixture coke oven gas (500 B.t.u.) with blast furnace gas (100 B.t.u.) desired have 340 B.t.u. content per cu. ft. That re- quires volumes coke oven gas and volumes blast gas per cent blast furnace gas. The control device must allow the setting ratios between limits 3.5 1.5 and 2.5 2.5 (70 per cent and per cent), corresponding 380 upper limit and 300 B.t.u. lower limit mixture. These ratio are very important determine the accuracy the control device. The settings must not only simple and easy make, but also permit rapid checking. B.t.u. Correction—For ordinary industrial gas mixing the problem solved accurate flow control (quantity) and accurate ratio (quality), but there often necessity step further. This condition exists, for instance, with gas company which bound contract deliver definite B.t.u. gas community for gen- eral distribution. none the constituent gas has Table I—Qualities Industrial Gases Blast Furnace Producer Blue Gas Gas Gas Gas B.t.u. per cu. ft...... 165 295 Air required, volumes 0.75 1.35 1.90 Cu. ft. mixture... 1.75 2.35 B.t.u. factor unit definite, fixed analysis, corrective devices based the measured B.t.u. content the delivered mixture neces- sary. This slow, gradual, small, ment the ratio and operated similar vernier at- tachment rough, approximate setting. The B.t.u. metering necessity slow; takes time meter con- tinuously and accurately the B.t.u. content gas; the instruments accomplishing this are bulky, sensitive and very slow, they must correct for all variables (tempera- tures, pressures, altitude, flow, real com- mercial value. Limitations B.T.U. Measurement ttention drawn here the fact that B.t.u. measure- ment cannot give practical results when used primary control function. operation this solution very slug- gish and entirely too lazy. Volumetric changes pass unnoticed and ratio adjustments take hours make. Controls based temperature characteristics the flames are also unsatisfactory, for similar reasons. They are further complicated the fact that the same pyrometric effect can secured various component basic gases pres- ent the gases mixed. The above engineering anal- ysis can summarized saying: successful and prac- tical gas mixing apparatus must based flow control the constituent gases, must permit accurate measure- ment the gas flow between large limits, must allow ratio settings change the relative proportion the gases mixed, within definite limits, and the whole device must designed permit the incorporation Two years ago the Smoot Engineering Corporation, New York, having its disposal long, specialized ex- perience control problems, such combustion control boilers, flow control water-gas sets and general de- sign governors for industrial purposes, set out study the gas mixing problem along the lines outlined above. The first solutions tried Eastern steel plant had too The Iron Age, January 16, 1930—221 | | } | | \ | | | | narrow operating range 1). 1928 second so- maintained, second pressure regulator the customers and the butterfly such way maintain predeter lution was developed, which satisfied has commercial accuracy between the limits mined relationship between and Then the page 221 diagram the Smoot contro! and are proportional the volumes deliver: volumes, combined with pressure regulation. The handcock MRC permits change ratio The two component gases are mixed tank. from and lowering the pressure operating regu turbulence created changes direction, com ator PR. This can also done B.t.u. corrector impingement two gases, isting the cock ARC, which controls the bleed-off fro: nixture has proved very complete. was point E’. The orifice plate controls the rapidity sired maintain definite pressure these changes > setting at the | nearb Choice of the regulator depends on local condition Press measul The regulators shown are gas operated. Oil-operated against outflow mixture. ernors are supplied wherever responsibilities are large master regulator was installed operate valves reliability operation absolutely required. The natur the line component gases such the regulators independent the basic principles maintain the pressure point within defi the mixing system, and merely means execute (10-in. water pressure 0.1 in.). The volume reg- orders given the sensitive diaphragms and metering lators and measure the volume each com- vices. Several installations this solution are operating nent gas through the drop pressures between points successfully steel plants and gas plants the the volumes delivered. rat the indi These developments are, however, broader signifi- ble through mercur umns. reg ance. They are the result the insistent demand are air operated, and are reliable, simple machines suited progress. One large company reports having used, through outdoor service. The success this solution has been mixing apparatus, millions cubic feet blast fur- illustrated charts, and the plant operators nace gas fuel replacement coal and richer gases have expressed their satisfaction several repeat orders rolling mill and forge furnaces. Savings $20,000 page 220 diagram simple volumetric mixing month have been realized. The investment value sev- vith two regulators. volume regulator eral mixing devices installed figures out 300 per cent rates two volume valves and such manner year, which quite unusual. maintain definite pressure drop between and This new field engineering promises furnish > secured + > through that low flow the valves must important contribution the better utilization the fuels sed and full load pretty wide oper the whole iron and steel industry, and the conserva- make sure that rat and tion natural resources Fabricates Welded Structural Frame with Simple Equipment 100 200-ft. addition the plant Lincoln the web the chord member, without gusset plates. Electric Co., Cleveland, the Austin Co., Columns and crane girders are beams; heavy designed and erected the structure, used electric truss the plane the side walls was necessary welding for the joints, bolts being used merely for as- carry the roof and craneway over two railroad sidings. sembly and erection purposes. This truss was also welded all joints and the end russes are ft. long. Chords are sec- connections. tion, formed splitting 15-in. beams down the center Rapid and economical erection was result using the web. Diagonal truss members are angles pairs, sufficient number field bolts hold the members back back, temporarily bolted and then welded directly correct position until the welding could done. — —The Iron Age, January 16, 1930 Impressions Tokio Japanese Showed Unusual Capacity Promote World Engineering Meeting and Entertain Face WORLD engineering congress, such one convened late October Tokio, Japan, means long period planning for many people. The Japanese representatives traveled over the world, meeting leaders engineering everywhere, and getting advice and cooperation. The product this was well- articulated, gram, the attendance dis- tinguished engineers dele- gates, chairmen and writers papers, and the determination the most acceptable and effi- cient time, place and procedure for the meetings. The Japanese organizers were from the top rank the profession; they made their first contacts the top. the United States, President Hoover himself approved and promised cooperate, but the rank and file the profession everywhere were enlisted the project, opportunity tional undertaking, establish friendliness and interchange ideas among engineers. engineer specializing efficiency course was deeply interested the methods and devices running the con- gress. should rate them extremely high. The Japanese group had done difficult job well. The usual squad re- porters photographers, who came out meet with “impressions” and “once mores,” took less time and effort than usual, and showed the model considera- tion and courtesy that was evi- dent every Japanese every group, all through our stay the country. Delegates Given Explicit Directions made some contacts with our international group during the day, met the Parliament House for registration. this building was handled the ment both the World Engineering Congress and the Language and Other Obstacles DR. LILLIAN GILBRETH JAPANESE photograph Mrs. Frank Gilbreth, The Iron Age’s special correspondent the World Engineering Congress. Dr. Gilbreth president Frank Gilbreth, Inc., Montclair, J., specializing developing methods and de- vices motion and fatigue study. She carrying the pioneering engineering practice directed until his death 1924 Mr. with whom she had been col- laborating professionally for some years. She has degrees from the University California and Brown University, mem- ber some six professional societies and the mother eleven children nanage- group from hotels building was well handled. fleet guest automobiles was the Imperial Hotel all through the congress. And those who were Yokohama had special cars Railroad and tram passes as- sured free transportation. the Parliament House were arrows, signs, interpre- ters, Boy Scouts—every known means for ease location. Graphic representation, colors, badges—nothing was left used. result, Monday night only the negligent were left without badges, programs, schedules, tickets for every- thing (including excursions and trips all over Japan). fact, full plans and specifications. The World Power Congress succeeded putting informa- tion date, day, time, sec- tion, location section, sub- ject, chairman, vice-chairman, general reporter, technical sec- 16-in. sheet, with some sup- plementary information Jap- The World Engineering Congress sheet, identical size, covered date, day and social well technical events, but left all but mention meetings the supplemen- tary booklets. short, the maximum planning, visual- izing consecutive and simul- taneous events and relation used idle time was done. What Happened Opening Sessions The president’s reception Monday evening, Oct. 28, was the first opportunity get the “feel” the whole congress group. The first impression was one differences—between hosts and guests (this usually true international congresses). The second was, how superficial these are, compared with funda- mental likenesses aims, interests and experiences. The disadvantages differences language became apparent, which was the chief obstacle all through congress our stay Japan. Over against this there was the fact World Power Congress. The routing The Iron Age, January 16, | aa | | 1e ] th: all engineers use the same technic; that many speak understand the French, English and German that take one through any congress; and that the engineer’s ability express himself sketches, formulas and graphs makes for universal language. Most felt even that first evening that English, spoken slowly and distinctly, ming universal language, and that artificial lan- guage not necessary, though perhaps useful and inter- congress had its opening ceremony Tuesday rning, the Municipal Auditorium Park Hibiya. Because the great earthquake and fire, there was grand historic building available, and one missed the pomp and beauty the opening the first World Congress tific Management, for example, held Prague 924. But one was impressed with the smoothness with thousands delegates and guests were han- There was hurry, confusion; everyone had een told what and where go, and the appointed ime the crowd was seated, ready begin. Prince Chichibu, brother the Emperor, who was patron; the Prime Minister, who was honorary president; Baron Furuichi, the president, took their places One young and two older gentlemen, morning coats, very modern dress, and with the dignity ancient civilization their manner. One was impressed immediately with the successful ntegrati gration respect for tradition and fitness with respect for speed and efficiency. Door signs and arrows; plant the speaker’s desk, and large, impressive chairs the sack coats and cutaways; flashlights and the ick still and moving picture cameras. The Prince, model serious, interested attention; the Prime Minister and the president, setting the tone respect him, yet that the business the session put through Baron Furuichi outlined the short industrial history Japan; spoke the contribution the governments, favorable business conditions, and the assistance foreign countries. enumerated the “400- plus papers,” the guests” from “20 countries”; stressed importance research and interrelating in- vestigations. “There national boundary science.” Dr. Sperry, speaking for the United States America, opened the responses. was followed representatives the European and Asiatic countries having delegates. One was impressed with the dignity the speeches, their sincerity, simplicity, friendliness. The chairman made his opening speech Japanese; many the English-speaking Japanese spoke Japanese throughout the congress. This seemed wise. They undoubtedly did themselves more credit than they had used another language less skilfully; they carried their own countrymen comfortably along with them; they avoided translation English Japanese; they made the congress most educative the 2400 their people who attended, especially the students the group. Chairmen the sectional meetings were proposed and elected, this latter being done hand-clapping. These had been selected beforehand, and confirmed the national groups. The names were displayed large sheets read, thus appealing the eyes well the ears the audience. Extra Congress Meetings Were Unusual There were sections the congress. These met morning and afternoon Wednesday, Oct. 30, Thursday morning, Friday morning and afternoon, Monday morning and afternoon, Tuesday morning, Wednesday morning and afternoon. The first Thursday and the second Tuesday afternoon were left free for garden parties. That meant ten opportunities for sessions sections; some sections used all ten; others needed less. All day the second Thursday was reserved for closing ceremonies. Apparently, there were from 700 800 overseas dele- gates, and about 2400 Japanese attended the technical meetings. has been stated that there were social affairs available. The Municipal Auditorium Tokio Was Taxed Capacity for the General Session the World Engineering Congress 224—The Iron Age. January 16, 1930 engineers, ~~ Prince Chichibu Japan, Patron the World Engineering Congress, Made Address the Opening Ceremony the Municipal Auditorium Tokio, Oct. 29, 1929 Japanese who were accustomed and liked European dress, put Japanese dress. The wives and daughters the Japanese delegates participated the entertainments. even the social dances. Both Japanese and foreign food was served, etc. Many treasure most highly the times when were welcomed the home fireside, finding the “foreign style rooms” specially heated, tea foreign style, milk, sugar, cream and hosts too busied about our comfort sit eat themselves. Hosts who had been busied not only attending, but preparing for and directing technical sessions and the social program luncheons, dinners, excursions, garden parties, teas, dances, Activities Succeeding the Congress The week succeeding the congress was devoted ex- cursions and four the Yokohama Day the first week, when Nagoya, Kyoto, Osaka and Kobe acted host. The entire congress group was invited each, and every facility the city was available. typ- ical day consisted greetings the municipality, mspec- tion and sightseeing, and entertainment, more inspection and sightseeing, tea, dinner, entertainment, farewell. The “inspection” covered the business, industrial, educational and other institutions; the scenery, palaces, gardens—all the available beauty spots. many cases opportunities were given rarely enjoyed Japanese foreigners, evidenced the fact that many prominent Japanese informed they had never had chance see things now opened for us. The management this week furnished problem— the large group must divided into smaller groups, which could handled that everyone could see everything, yet have free time shop, accept personal invitations lecture entertained, When remembered that some fitted lectures into the days were Japan, with others asked for that could not done, some idea the complexity the “time and effort” problem given. The ten days Nov. were provided for excursions more outlying parts the Japanese Empire. Many went from these other parts the Orient and their homes. spent this time Tokio and Yokohama, trying fit the inspections had missed while tech- nical sessions the congress, visiting factories, depart- ment stores, offices, social service work, settlements, hos- pitals, colleges and schools—endeavoring see much possible the 24-hr. day every member the com- munity, but especially those industry. had every facility, but time was short, distances surprisingly great spite planning, expert guidance and every transporta- tion facility. Farewell gifts were added the many gifts already received—gifts from cities, industries, colleges other groups whom one had spoken, and from friends flowers, tree trays, fruits, every lovely product the country. Steel Mill Expansion Russia neers the Freyn Engineering Co., Chicago, re- ported Gordon Fox, electrical engineer that com- pany. Some high spots Mr. Fox’s observations follow: The present production pig iron the Ukraine dis- trict about 3,000,000 tons year. expected double this tonnage, more, within the next five years. Expansion this general area planned require new blast furnaces, several new steel works, both Besse- mer and open-hearth, six seven new blooming mills and variety finishing mills. Owen Rice, metallurgical engineer the company, re- ported upon visit group blast furnaces the Ural district, the border between Europe and Asia. Here square brick shaft built 1753 found the work being done Russia the engi- perfectly good cast iron running with only 0.02 per cent sulphur. pair cast iron pipe stoves was use. Blast was provided means old water-wheel driv- ing line shaft connected cranks battery wooden blowing tubs with wood and leather valves. the top the furnace group women were charging with hand buggies. Other features mentioned are trough ft. long and ft. wide which the cinder accumulates during the whole the cast, later spooned out like taffy the end bars and loaded horse-drawn wagons. There are seven blast furnaces here single line only 100 yd. long. They have cast iron tuyeres and elliptical shafts from hearth hopper. Serving them, way con- trast, brand new electrical-precipitating gas cleaner. The Iron Age, January 16, 1930—225 q q Alloy Steel Side Frames for Trucks Superior for Withstanding Excess Strains—Types Steel, Manufacture and Heat Treatment Parish Pressed Steel Co.—Other Pressed Products ITH the average life modern side frame for such vehicles. the claim auto-truck about 500,000 600,000 miles, large Pennsylvania pressed steel company that has suc- 100,000 miles per year, something better than cessfully solved the many difficult problems making steel, heat-treated not, has been found such frames and that its plant the only one the world necessary for side frames. addition, the tendency where such frames are successfully made large scale. This company, the Parish Pressed Steel Co., Reading, Pa., ers, comm has been four ver- says that not only must the itself unusually has certain parts high grade, but also the forming presses and the method rbon strained beyond forming well the heat treatment during process- efore the end the ing must carefully regulated. Special attention the nary passenger car the average carbon frame usually lasts the methods used this company are outlined this lif the automobile. article. demand has therefore sprung up, the weight the past, when the making alloy steel frames has loy been attempted, has been done various plants dif- LARGE 40- ing Furnace Large Side Used for Treat- Frame Blanking ing the Sheets Presses (At and Plates Be- Left) fore Forming 226—The Iron Age, January 16, 1930 i —— =, — FEW the Many Power Forming Presses (Above) EVERAL Brinell Hardness Ma- chines Measure the Hardness the Frames After Heat Treat- ment (at Right) OME the Special Straighten- ing Machines Specially De- signed for the Work (Below) The Iron Age, January 16, | 4 4, | ferent locations. The Parish company’s plant in- tegrated unit where the raw material, such plates and sheets, proceeds systematically under one roof the fin- ished product. About per cent the heavy-duty frames made this country are produced this company. Three Types Steel Used one corner building 800 ft. long, the raw ma- terial, plain carbon and alloy steel plates, comes in, three time. The building itself has three "loads ata From this they the forming presses, which there are two very large ones—one 4000 tons, ft. long, and the other 3300 tons, ft. in. long. Besides these two main presses for the larger frames there are some crank presses ft. long. new Hamilton press being in- stalled. Most the alloy steel frames have quenched and tempered and two large furnaces with oil-quenching tanks are provided for this. Both the quenching and the tem- pering furnaces are ft. long. All furnaces are, course, regulated pyrometers. Straightening the Frames Expensive After the formed side frames are heat treated, they are sand blasted when necessary and then subjected the most expensive step the whole process—straightening. This and train expert men this work. one the illustrations, takes care this work. Drilling and assem- bling the frames the last step This High-Powered Pneumatic Press Forms Some Alloy Steel Side Rails ays, two them ft. wide and one ft. wide, making the width 200 ft. The types raw materials used are out- lined Table Large Furnaces for Heat Treatment Only the alloy high-carbon material annealed and this done before blanking. One large furnace pro- vided for this—one the largest the kind existence. One them being loaded while the other being cooled and unloaded. One illustration shows this furnace. ft. long, oil-fired, and provided with two cars. The annealed sheets plates are then transferred the blanking presses notching machines. Some the rmer are very large and handle sections ft. long one stage the process, usu- ally after heat treating and sand blasting, all the heat-treated frames are subjected Brinell test. Some specifications require this. is, however, used also the company check heat treatment. which for some reason too hard retreated. the Larger Trend Toward Medium-Manganese Steel One the most interesting features the trend the use medium-manganese steels preference other alloy steels. Table gives the physical properties the heat-treated frames made from the various raw materials. will seen from the data physical properties that the manganese steel superior any the others. particularly high fatigue value essential insure the long life such frames well high elastic limit. This manganese steel has been found meet such condi- tions. some the elastic limit has run high 116,000 lb. per sq. in. with tensile strength 129,000 lb. com- bines high hardness with high strength and elasticity, enabling meet the severe service encountered bus and truck manipulation. el ( of Stee } ( Mr ( } 1® 0.40 I treated 25 0.5 frame t 0.22 t 0.40 H € ed 0 0 frame 0.26 0.60 0.60 1.f alloy frame mr ese 25 to Heat-treated 5 1.60 alloy frame Table Il Physical Properties of the Steel Used Elastic Tensile Limit, Strength, Elong. Red. Lb. per Lb. per in 2 In., Area, Sq. Sq.In. PerCent Brinell Chrome-nicke]l ...... 90,000 100,000 36.0 Medium manganese... 100,000 115,000 45.0 50.0 255-302 Carbon (heat-treated) 65,000 90,000 44.0 Low carbon (unheat- 40,000 62,000 65.0 50.0 131 228—The Iron Age, January 16, 1930 i } 7 5 q 7 7 | | Complete Machine Shop Gallery the Plant Prepares Dies and Other Equipment For some years large electric company has been using reels for winding cable wire, the reels being made or- dinary carbon steel. has been found that the life these has been short because the ease with which the discs bend and get out shape, causing damage the wire and high maintenance cost due replacements. Because greater elasticity and toughness sary, chrome-vanadium steel has been substituted con- taining 0.35 0.45 carbon, 0.50 0.80 manganese, 0.80 1.10 chromium and 0.15 0.20 per cent vanadium. These have proved satisfactory manufactured the Parish company. probable, however, that this heat-treated chrome-vanadium steel will supplanted the medium- manganese steel because its relative superiority for such service and its relatively lower cost. Other Pressed Alloy Steel Products Among other interesting products made pressed steel are axle flanges formerly made drop forgings. Blast Hanger | urnace Finishing Presses Annealing Drawing Furnace Engineering Dept. Pump Room Made several different pressing operations before com- pletion they have the advantage having draft and hence require less machining. These flanges welded each end axle housing. Other products include automobile spring supports and motor supports made 3.50 per cent nickel steel heat- treated, and journal box lines for roller bearings rail- road trucks which are also heat-treated alloy steel prod- ucts made S.A.E. 5150, which are very hard, with some made S.A.E. 1095. was interesting learn that the experience this company attaining success making these difficult heat-treated alloy steel frames, has proved that not only very carefully made basic open-hearth steel neces- sary, but that acid steel cannot worked easily successfully the forming presses where sections long ft. are pressed into rather complicated shapes with- out cracking. Frame Finished Storage Steel Presses c “Receiving Track General Plan the Plant Indicating How the Material Handled The Iron Age, January 16, j | retary, unnineg i ll reratt ‘orporat n, R Metal Wing Ribs Are Strong and Light Moderate Sized Airplane Eliminates Wood Fuselage and Wings, Thus Improving Production Schedules, Durability, Safety and Maintenance transmitted from intersecting mem- This feature shown bottom page 231. The cabin covered corrugated duralumin sheet, heat treated, 0.016 in. thick. This adds considerably the margin strength the structure, lessens crash and fire hazards, and provides excellent wall for insulation and sound proofing purposes. The main cabin exceptionally roomy and accommodates four people. The passengers may stand erect, changing sea