The Iron Age 1930-02-06: Vol 125 Iss 6

THE IRON AGE ESTABLISHED 1855 New York, February 1930 VOL. 125, No. Build 100 Car Bodies Hour Murray Plant Laid Out for Scheduled Rate Output— Lacquer and Paint Handling Are the Roof automobile body-building plant recently erected the Murray Corporation, Detroit, laid out for fixed production schedule 100 bodies hour 900 9-hr. day. With departments for manufactur- ing the stampings, assembly and painting, well for receiving the stock and shipping the finished product, this plant complete unit within itself. keep work flowing through all departments the proper speed equipment was provided maintain the scheduled rate output the various operations. The time element was used also basis arrangement the painting department, the location and spacing spray booths, ovens, air-dry sections, rubbing docks, etc., being carefully planned allow the proper length time for each operation and drying period, with uniform conveyor speed. One Side the Stamping Plant, Showing Line Presses the Sides Which Are the Central Compressor Reservoir the Lubricating System. section the overhead body going through the various coating operations takes hr. min. from the time reaches the cleaning department until ready for installation the trim. Quality not sacrificed for speed, because the standard set the company calls for high-quality work. The painting department divided into two sections occupying separate floors. one cleaning done and the under coating applied. This takes hr. min. the other the lac- quering done, well other work incidental finish painting. takes bodies hr. min. through this department. Bodies move through the painting depart- ment for the various operations cleaning, priming, sur- facing and lacquering uniform speed 8.8 ft. min. This new body manufacturing unit includes stamping plant 200 425 ft. and adjoining L-shaped seven-story assembly building 525 and 350 ft. long, 100 ft. wide. conveyor for carrying finished stampings from the press room the foreground 427 Space Saved the Painting Department Having Double-deck Drying Ovens cally. addition the mechanical lubrication the bearings, the air cushions 109 presses, grouped into systems, are lubricated mechani- cally with average six eight points lubrication each press. stated that lubricate all these bearings hand would require eight oilers each shift, but with the mechanical system one man per shift suffices, making saving oilers day when the presses are operating two shifts. The lubri- cating equipment, which said the largest installation centralized lubrication the world, was installed Lubrication Devices, Inc., Battle Creek, Mich. How the Plant Arranged Extending the full length the plant the side the press shop steel storage and loading and unloading bay. This served two 15-ton traveling cranes. Cranes deliver the steel from the cars the gether there 540,000 sq. ft. floor space. The plant storage floor and from the storage floor the front fully equipped with conveyors various types for han- the rows presses. Two presses for blanking are located dling parts, assemblies and bodies the various manufac- the side the storage floor. turing processes. The one-story stamping plant equiva- lent height three-story building and its sawtooth roof provides exceptionally good lighting. The press shop arranged for large output and for convenience handling and routing work. The presses, 175 number, are arranged rows with from ma- chines row, with one more rows machines for making single part. They are arranged for progressive assembly that the piece, panel, leaving the last press the end the row completed unit with all moldings, window reveals, win- dow flanges, etc., stamped place and ready for assembling. leaving the last press the panel hung overhead conveyor which carries the proper floor the assembly building. The press bays are served five 15-ton electric traveling cranes for handling dies. Dies not use are stored mezzanine floors, which there are five located intervals above the press shop. One the cranes provided with movable cab, which found great convenience handling dies. After the crane spotted over the press the operator moves his cab along its runway the crane point that brings directly over the press, where can look down and control his operations setting removing die, without depending signals. With the convenient facilities for handling and storing dies stated that all dies line presses can changed from one two hours. centralized system lubrication pro- vided for all the presses. Between 5200 and 5500 points are lubricated while the presses are operation 240 systems, each which takes less than min. operate. valve each bearing delivers the bearing pre- determined measured quantity lubricant under high pressure and shuts off automati- 428—The Iron ‘Age, February 1930 Two railroad tracks extend through this bay. Sheet The Compressor the Lubricating System for the Large Toggle Presses Located the Left Under the Large Bull Gear. This press has points lubrication, which are located moving parts. All lubricating points are reached flexible hose and copper tubing UB-ASSEM- BLIES Are Welded with Type Spot Welders with Flexible Hose Connections Over- head Welding Ma- chines EZZANINE Floor for Die Storage, Above the Press Shop, Has Movable-Cab for Handling Dies steel received flat cars and scrap carried out the inner track. Finished bodies are loaded box cars the outer track. conveyor brings the bodies the loading dock from the fourth floor the assembly building. ma- chine shop for press and die repair work located mezzanine floor the side the steel storage building. Scrap metal from the press operations carried 30-in. belt conveyors, one the side the first row presses and another extending the length the press room front the presses. These conveyors discharge the scrap other conveyors the basement, which de- liver baling press. The bales scrap are elevated level above the loading bay conveyor which dumps them into flat cars. Parts are carried from the press room two lines conveyors, one for parts that are trimmed and the second for completed stampings. Panels are stored and doors assembled the first floor the assembly building. The door frames, panels and reinforcements are brought the assembly jigs and flanging presses overhead con- veyors. After assembling, the doors are placed plat- form type conveyor for metal finishing and then overhead conveyor which transports them the body paneling line the third floor. Nearly all the trimming operations are done with trimming presses, but, parts trimming done with metal band saws, this method found more economical. Saws for trimming are ar- ranged two parallel lines; back each line belt conveyor which carries the scrap the baling press the basement. Spot Welders Gun Type Are Used floor, well the trimming that done with band saws. Practically all the welding the body sub-assemblies done with special spot-welders the gun type developed the company. The welding guns are attached ible cables connecting the welding machines, which are suspended overhead and may moved along the assembly lines for convenience operation. The seats, side panels and back panels are butt welded into single piece large butt-welding machines. The piece leaves the machine continuous panel the formed body from door door and from sill roof. The cowl panel welded the same manner. The units are then placed platform type conveyors for the metal- finishing operations, after which overhead conveyors carry them through openings the floor the body paneling line the floor above. special revolving punch used the assembly department place standard type punch for making and countersinking very small nail holes. This unfluted tool the ends which, instead being flat, punch, have 5-deg. angle. This tool being spun into the piece cuts out slug the same punch. The objec- > URNTABLES Connection with Platform Welding and finishing Conveyors Add Convenience Moving Bodies The Iron Age, February tion the use punches -the very small diameter required for this class work that they break fre- quently. The use this tool obviates that difficulty. Framing and Assembling Third Floor The body framing and the final body assembling are done the third floor. The wood parts composing the under body, roof and frame are received from the com- pany’s mills fully machined and ready for assembly. These units, together with the all-steel front end assembly, are assembled body-framing jigs which hold dimensions close limits. The wood body frames are carried convey- ors through spray booths, where they receive sealer treatment prevent dry rot, variation the moisture content and the ravages insects, and then the six body paneling lines the moving platform type occupying the rear end this floor. When the body reaches the end ONVEYOR lines for Paneling (at Right) Away the Scrap from the Metal Band Saws fot Trimming Stampings. found more econom- ical those parts which are not made quantities (Below) one these lines completely paneled with doors fitted and hung, and ready for painting and trimming. The painting department located the sixth and seventh floors. The body after assembling carried the sixth floor vertical conveyor operating eleva- tor shaft. Several carriers this type connecting differ- ent floors are used, some for conveying bodies and others down, including one for taking the bodies from the fourth final assembly floor the loading dock. The regular freight elevators are used only for transporting workmen and for handling small parts such reinforce- ments, brackets, hinges, ete. These elevators have speed 400 ft. minute, four times that ordinary freight elevator. 430—The Age, February 1930 reaching the sixth floor the body hooked overhead conveyor, which elevates the ceiling after various operations and down the working level for suc- ceeding operations, well for carrying through the ovens for drying. Some the drying ovens have two chambers, one above the other, and some save floor space being elevated several feet above the floor. The bodies are thoroughly cleaned the Deoxidine process and re- ceive two coats metal primer, the putty glaze and two coats surfacer. After the final sanding operation the body goes the seventh floor for the color coats and the installation the roof deck material. Safety Served Location Paint Work having the painting departments the sixth and seventh floors, volatile and inflammable liquids are kept where they not endanger other parts the plant. the same time, this arrangement permits the use the roof for handling the lacquers and paints. Located the roof are mixing vats equipped with agitators which keep the lacquers and paints constant consistency and the colors uniform. Rotary pumps be- neath the mixing tanks keep the lacquer continuous cir- culation pipe lines which serve the spray booths the two top floors. The spray gun lines are connected these pipe lines, thus eliminating the fire hazard caused open containers lacquer. Air contaminated fumes ex- hausted from the spray booths the roof and replaced fresh, heated air delivered through heating system the roof. Cushion and seat backs and trim panels are manufac- tured the fifth floor. The sewing machines are placed rows facing each other, with wide belt-type conveyor running between them. Light overhead conveyors handle the trim panels from operation operation. The cush- ions and seat backs are trimmed moving lines, the cush- ion line having upper rail equipped with rollers for compressing the spring while being trimmed. The fourth floor used for the installation glass, cushions, trim hardware, etc. Here are conveyors the platform type with ingenious turntables the corners, permit the bodies shunted about necessary. Over- head copper feed wires supply current the trimmer’s portable lights. The plug ends light cord are attached contacts wooden trolley block, which slides along with the conveyor. When the trimmer has finished, and steps out the body with his light, lifts the trolley block from the feed wire attached wood handle. Stripping and final inspection follow the trim installation, after which the completed body transferred the ship- ping a That Resist Heat Suitable Material Not Simple Four Classes Alloys Available—Corrosion and Heat Resistance Same Problem HOLLAND NELSON* and rustless steels and the various developments which have led the variety such alloys now available, much has been written the value certain chemical combinations and their resistance various cor- rosive conditions. other words, while have, during the last few years, made rapid strides the investigation and application materials combat rust and corrosive action, perhaps not quite much attention has been given this particular type far its application the field high temperatures concerned. Not Two Problems But One ROBABLY this due the fact that manufacturers and users alike have chosen regard the field cor- rosion resistance and heat resistance two entirely sepa- rate subjects and this fairly well borne out actual manufacturing operations. not unusual all find that the heat resistant alloys are produced few foun- dries specializing this particular product, whereas the corrosion resistant alloys are more less the product the tool and alloy steel manufacturer, because most the original discovery the so-called stainless *Consulting metallurgist, Widener Building, Philadelphia. This the fourth article series stainless steels and irons and corrosion and heat resistant alloys. The three previous articles were published April 25, 1929, page 1139; May 30, page 1478, and Oct. page 887. them are malleable and are required various fabricated forms. glance the analyses few the alloys advo- cated for use high temperatures, for the purpose. maintaining strength temperature and resistance at- tack oxidation, will immediately show their striking similarity many the alloys used the field cor- rosion resistance. The author this article, after being engaged almost exclusively the study heat and cor- rosion resistance problems for several years, has come the conclusion that, instead regarding these two sub- jects entirely separate fields, much safer regard them almost one and the same subject; classified, you like, corrosion normal temperatures either gases liquid solutions, corrosion elevated temperatures where definite physical strengths are required. ‘Heat Corrosion Domestic Heaters heat resistant problem that quite familiar every- one, whether layman scientist, the do- electric heater and the resistance wire used for this purpose. This material has formed the basis many our so-called heat resistant alloys. not intention burden the reader with de- tails concerning the development the type electric Pressed and Welded Carburizing Pots Made from Alloy Containing Approximately Per Cent Nickel and Per Cent Chromium. This type giving excellent service (courtesy Pressed Steel Co., Wilkes-Barre, Pa.). The Iron Age, February ~ | resistance wire use today, but its use has been well within the knowledge most us, not difficult trace back memory some the early resistance wires which were probably satisfactory from the viewpoint electrical resistance, but subject embrittlement con- tinued service. mention these two facts because they are probably the fundamental principles governing the sub- ject this particular paper. Two Terms the Basis Specifications The development the present high nickel-chromium alloys, possessing they excellent physical properties high temperatures and all the electrical properties de- manded, together with substantial immunity oxidation under atmospheric conditions, are the result years labor and study engineer and metallurgist alike. think, however, approaching the general subject heat resistance, insufficient stress has been given the fact that such heat resistant elements invariably operate under normal atmospheric conditions, and the natural reaction from such state affairs has led the use two terms when discussing the subject heat resistance. These, even the present time, seem constitute the alpha and omega specifications laid down for the selection suitable alloys for service variety fields. The terms alluded are: Physical properties the alloy definite tempera- tures, and Rate oxidation any particular temperature. During the last few years the seriousness attempting obtain satisfactory alloy demanding certain strength definite temperature freedom from oxida- tion certain temperature has been brought home very sharply investigation failures that have occurred from time time, even when the designing engineers con- cerned have made every possible allowance for contin- gencies using high factors safety, etc. Let cite concrete instance. One particular case that was responsible, perhaps, for starting out more intensive study the subject was the use retort estimated temperature 1900 deg. Fahr. continu- ously. designing the original installation reason- able assume that the engineer concerned required cer- tain strength support his load 1900 deg. Because oxidation the most used and abused term throughout the metallurgical industry, equally natural suppose that requested material which would not oxidize, scale, lose gain weight that same temperature. Many attempts were made produce retort with- stand these conditions, but the time the writer ap- proached the subject think fair stating that six eight weeks would have been considered reasonable life for this retort; some cases may have been more, other cases little less. Failure Often Due Chemical Corrosion study this subject pretty soon convinced the author that, this particular industry, failure was not arising from lack strength elevated tempera- ture oxidation, but there was definite evidence corrosion chemicals and gases, which were attacking either some par- ticular element all the ele- ments and their various chemical compounds the alloy. cite this instance because, 432—The Iron Age, February 1930 Cast Carburizing Pot the High Nickel-Chrome Type stated before, was probably the first that stimulated interest corrosion various gases high tempera- tures. There was the possibility producing alloys definite chemical combinations resist such corrosion. Once started upon line thought, not all difficult gather together further information support this substantially. How many metallurgists frequently hear one our colleagues extolling the vir- tues one particular alloy only find that someone else, apparently exactly the same type process, readily condemns the same material. Yet would not suggest that alloy would behave differently because dif- ferent geographical location. Take the case hardening industry example. have mind two the largest installations the coun- try, under excellent metallurgical supervision, with one alloy use one plant and entirely different alloy use the second plant. Each chief metallurgist assured that the alloy use the other installation ab- solutely use him. Carburizing Conditions Hard Meet article such this seldom possible give more than thought, train thoughts, which may lead those interested into deeper study the subject. Much information private nature reaches consulting metallurgist which, course, cannot divulge. But while the subject case hardening, let just for moment realize the innumerable types carburizing compounds the market; their various chemical composi- tions; the variety energizers used some them. Then let turn around and glance for moment the various furnace designs and types. are confronted with gas-fired furnaces, oil-fired furnaces, electric heating furnaces, cyanide pots, etc. When realize how easy say carburizing case hardening and imagine just the transfer carbon the outside case low-carbon material, what small phase the actual problem are really visualizing and how reasonable might assume that, with all these variations, such the by-products from the carburizing compound, the by-products from either the oil fuel gas fuel, the oxidizing, reducing and condition, the case may be, produced any other method heat- ing, may have distinct and definite bearing upon the most suitable alloy use combating these influences. have conveyed thought clearly, not difficult realize that this there may explanation that one user had oil fuel means heating his furnace and the other two employed electricity gas, the varied at- tack the by-products combustion might sufficient explain clearly why one finds different alloy desirable advantageous the given conditions. The same equally true various case hardening compounds. Moreover, not fully realize also how very vague become the terms “strength temperature” and “resistance oxidation.” Alloys for Both Corrosion and Heat Let digress for moment and glance again the alloys that are used the fields both corrosion and heat resistance. those who have the oppor- tunity daily observing these various alloys from the liquid the solid condition, fairly easy prescribe alloy compo- — | é sitions that resist oxidation definite tem- peratures, For instance, some the simple stainless steels resist the formation scale temperatures 1450 deg. Fahr. the further addition chromium, nickel the temperature which this scale formation takes place raised, and possible produce alloys that not oxidize the sense forming disintegrating scale temperatures 2000 deg. Fahr., somewhat excess this. But the in- formation present being handed out the trade really what wanted? Further, can not very misleading? The author realizes that dealing with very delicate subject. practical steel manufacturer and student metallurgy, advancing these thoughts, not arm chair critic, because have very high regard for great deal the work that has been done some our leading metallurgists determining defi- nite strengths temperatures, creep tests, and much valuable information for long- time changes governing the physical prop- erties many the alloys which refer. However, consultant some extent like the medical practitioner who called the hope producing good and whole- some result, the other end the story diagnose the disease and possible either advise aid curing it. With this thought mind apt view the pub- lished literature the subject heat re- sistant alloys, such issued the various manufacturers, with some temerity. definite physical properties with freedom from oxidation definite temperature. Four Classes Alloys ENERALLY speaking, these have been placed about four classes: alloy approximately per cent nickel upward with per cent chromium higher with iron per cent down traces only. alloy varying according dif- ferent manufacturers, with from per cent nickel and from per cent chromium, the remainder iron. 3.—Various modifications alloys con- taining from per cent chromium with from per cent nickel. 4.—Alloys containing from per cent chromium, with silicon from 0.5 5.0 per cent. The usual run sales data published would advocate the use No. for tem- peratures high 2000 2200 deg. Fahr.; No. for temperatures from 1800 2000 deg.; and No. from 1600 1800 deg.; and the physical properties are plotted and offered the trade their varying strength definite temperatures. Special Steel for Valves While the above analyses are typical the heat resistant alloys offered the cast form the trade, there are one two striking deviations from these which the writer feels thoroughly support his conten- tion. Take, for instance, typical chrome- silicon valve steel the following approxi- mate analysis: Per Cent the reader will take the trouble call for catalogs, even those our leading 7.50 9.00 manufacturers, will find that “st Designed Nickel Traces 0.25 ’ 1 a streng to Meet Chemi- ER ee 2 temperature” and “resistance oxida- tion” ‘are the factors around which the various manufacturers invariably advocate the case may be. The thought endeavoring convey becomes staggering the possibility how seriously incorrect application this information can be. Further, many our complicated chemical industries, becomes necessary establish entirely dif- ferent information, because oxidation may not any means the most serious factor, but corrosive attack various gases may sufficient attack the alloy whole attack various elements within it, producing spongy and obviously weak material with, course, ulti- mate failure. Special Dependence Certain Alloys fairly obvious that the production materials with high physical properties elevated temperatures the steel manufacturer the light today’s knowledge sub- stantially dependent upon the alloys chromium, chrome- silicon, nickel-chrome-silicon conjunction with iron, without iron, obtain his results. There are, course, other additions made smaller proportions from time time, such cobalt, aluminum, tungsten, molybde- num, added with the object obtaining varying physical properties increased resistance attack, but the general sense the word the heat resistant alloys avail- able are substantially the chromium, chrome-silicon nickel-chrome-silicon type alloy which the proportions nickel and chromium and silicon are calculated give Corrosion High Tempera- tures the form automobile valves, this alloy This material service tempera- tures which may range high 1500 deg. Fahr. even higher times. Moreover, contact with the by-products motor fuel, This type for the last few years has been practically uniformly adopted the entire trade where internal combustion engines are used. The manufacturer requires the material possess certain physical properties, however, enable him produce the various forms required and these prop- erties enable him make the following claims: 1.—To produce alloy which malleable and capa- ble being produced bar form ordinary mill practice. quoting one the manufacturer’s own does not scale temperatures 1500 deg. 3.—Metal which capable being forged and upset into valves. Experience also shows this type alloy possess re- markable resistance the corrosive attack the by- products gasoline internal combustion engines. More Nickel Than Chromium Not Essential Another striking instance which would seem upset very seriously the idea which seems have been more less standard that heat resistant alloys must contain, in- variably, more nickel than chromium, has been brought about the demand the user and the fabricator. Take instance the recent rapid development that has occurred the built-up pressed steel carburizing box. This has led considerable saving weight over the The Iron Age, February . 3 | | cast metal, and course the resulting economies are due the fact that the container itself there considerable less metal heat. other words, using lighter car- burizing pot, not only has heat been conserved but time elements have also been capable reduction. make this possible was essential have metal which was obtainable sheet, bar, rivet and welding rod form; and the high nickel-chromium alloys, referred earlier this article, invariably used castings, were not available suitable form for this new development. But have materials the following approximate analysis: Per Cent 15.0 25.0 Within this range analysis alloys are obtainable the various forms required, which are day day demon- strating their ability withstand the many and complex phases the carburizing industry temperatures 1800 deg. Fahr. maximum. will noted that this type the proportions nickel and chromium are very close to- gether and many cases the chrome-silicon content greater than the nickel. What wish point out that this particular instance the deviation from previously established alloys was found necessary produce the material the form was required. Further, that are from time time those modifications which, viewed the light established precedent, might regarded producing inferior article, are many cases producing equal not superior results, all because, opinion, some these alloys are more truly approaching corrosion-resistant materials with distinct resistance oxidation corro- sion elevated temperatures, conditions which have previously casually referred under the broad heading oxidation. (To concluded) Cast Steel Anchor Chain Made 90-Ft. Lengths URING the war consider- able interest was aroused new development for making large steel anchor describing the new method cial type steel was larly those THE IRON AGE July 1918, pages 28. EPARATE In- dividual Links Are Cast, and, After Inspection, Are Molds. The connect- ing links are then cast, producing chain about ft. long aad _ 434—The Iron Age, February 1930 The new method was developed the National Mal- leable Steel Castings Co., Cleveland, and the name given the chain was Naco cast steel chain. This process making chain not only supplied the demand occasioned the war, which could not met the older process making wrought iron chain, but has per- sisted since and regular product that company. late some photographs have been called the at- tention THE IRON AGE which present some phases the manufacture not hitherto noted and are herewith repro- duced illustrating the size and magnitude the chain, the method pouring and testing carried out the Cleveland plant the company mentioned. 90-FT. Length Chain Ready for Test- ing Special Anchor Chain Test- ing Machine. representative pile cast steel anchor chain also shown q 3 Welded Line Joints for Steel Pipe Types Welded Line Joints Used Today, Considered from the Standpoints Strength, Flow Conditions and Economy GASTON* RACTICAL design welded pipe joints resolves itself into developing the full strength the pipe itself, retaining ductility, offering min- imum resistance flow, yet de- signing one that simple de- sign and cheap make. Vee Butt Joint the All-Purpose Joint The open single vee butt weld, Fig. meets the require- ments enumerated above. the type weld most extensively used for steel pipe and the standard welded line joint. easy make, low cost, and compre- hensive tests full-sized specimens all sizes pipe commonly welded have shown the strongest. This type joint can recommended for standard, extra heavy and double extra heavy steel wrought iron pipe for all pressures and services. Pipe joined this weld frequently supplied the manu- facturer with ends machine-beveled shown Fig. Note that the bevel does not extend the inner wall the pipe; flat portion about 1/16 in. wide left facilitate lining and form “bottom” for the penetrating flame. also serves strengthen the edge during transit and handling before welding. Square Ends Preferred Thin Walls When pipe lined for welding, (Fig. should left between pipe ends allow them draw together the cooling metal contracts, thus the possibility overlapping edges residual stresses. Fig. allowance need made for this spacing lay- ing out piping system, the overall length will true within reasonable construction tolerance after welding. add.an extra fac- tor safety, the weld usually built reinforced about one-fourth the wall thick- ness, shown Fig. This reinforcement should slope gradually from the center down the surface the pipe along the sides the weld. The width the weld should ordi- narily about times the thickness the pipe wall. executing this type joint, fusion the depth indicated Fig. should obtained, care being exercised that molten metal reaches the extreme bottom, “root,” the joint. The open square butt weld, Fig. used *Technical department, Linde ‘Air Prod- ucts Co., New Fig. 3—Open Butt Joint, Square Ends, for Thin Wall Pipe for the smaller sizes pipe, with which sufficient penetra- tion, due the melting the steel with the blowpipe flame, can obtained without beveling. general use for pipe having wall thickness from 3/16 in. 5/16 in. The reinforcement usually made much heavier than when the open single vee butt weld used com- pensate for possible lack penetration. Full penetra- tion difficult obtain regularly without allowing the fluid metal protrude beyond the inside wall the pipe, when this type joint made. Open square butt weld recommended for standard pipe in., extra heavy in., and for all pipe having wall thickness 3/16 in. less, for all services. For some services carrying extremely low working pressures, not subject any appreciable expansion, con- traction bending stresses, this type weld may used for standard pipe larger than in. diameter. For such purposes pipe with maximum wall thickness A A QA A N NAAN A AA A AAA and 2—Single Vee Butt Joint, Lined and After Welding min. min. 4—Open Butt Joint with Partial Penetration, Suitable ork. Only for Pipe Carrying Negligible Stresses and Pressures The Iron Age, February i fi 4 min. iy App Yes, AA max. Fig. 5—Closed Vee Butt Weld Handy for Vertical Risers and Satisfactory for Moderate Pressures Fig. 6—Calking Screwed Joint Should Done with the Minimum Amount Filler Metal V4 Fig. 7—Liner Thin Metal Obstructs Flow Material the Pipe Less Than Protruding Icicles Metal 5/16 in. may welded without previous chamfering the ends, sufficient weld depth penetration being secured with the flame answer the requirements, shown Fig. Closed Vee Usable for Low Pressure Work The closed single vee butt weld shown Fig. some- times used because certain advantages, although not recommended the best practice. facilitates lining up, especially when building risers where pipe lengths are simply placed one top the other. also insures against the formation protrusions the inside the pipe and requires less skill the part the welder than other types welded joints, since not required fuse the inside wall the pipe. This type joint lends itself readily forward ripple welding. shown the figure, when the closed single vee butt weld used, pipe ends are butted together with space between, the sides the vee are thoroughly fused and fusion obtained uniformly the bottom the vee. Lack complete fusion the inner wall partially compensated for heavy re- inforcement the outside the weld. This type weld will not develop the max- imum strength the pipe, but does have strength comparable the usual mechanical joints. may used for pipe sizes in., and for pressure and service require- ments the equivalent saturated steam 250 lb. per For sizes above in., and especially for pressure services, reheating the weld, upon completion, recommended. Couplings Sometimes Welded Prevent Leaks Welded couplings, Fig. use ordinary threaded joint. Fillet welds encircle the pipe each end. This type joint not recom- mended. The joints existing screwed lines are often caulked tight welding the coup- lings. Welds are then used mainly seals but also add materially the strength the joint. makes joint superior the threaded coupling, inasmuch stronger and per- manently tight, but costly, requiring coupling, the labor threading, the labor 436—The Iron Age, February 1930 AA Weld reinforcing strip. not weld over circumferential Fig. and 9—Joints May Reinforced Series Straps Split Sleeve tightening and two welds. The inside the pipe not smooth and therefore does not have maximum flow characteristics. the welds are intended merely seal the joint they may very light, but addi- WA AAAS tional strength required, the fillets should increased size until their dimensions are approximately the pipe wall thickness, shown Fig. the filter metal should slope gradually from the end the coupling. down the pipe wall. Use Liners type joint that the process development the open single vee butt weld with thin liner (Fig. 7). This joint consists the standard open single vee butt weld backed with thin, sheet steel liner which fused the welding operation the bottom the weld. This joint has been designed enable even operator limited experience pro- duce weld free from protrusions the inside the pipe, yet thoroughly fused the bottom the vee, and enable operator aver- age ability produce more easily and quickly weld maximum strength. Two types special reinforced joints are shown Fig. and Some authorities maintain that such reinforcements are never necessary with properly made welded butt joints, regardless the service for which they are intended, and such reinforcements are not generally recommended. However, they are frequently used for river crossings and piping systems where the joints will certainly subjected excessive vibration and bending stresses. The bar reinforcement, Fig. ordi- narily used only for the larger sizes pipe. consists straps welded across the joint intervals around the circumference. The straps are either bent ground clear the bead the outside the pipe. suffi- cient strength against bending, the straps should least thick the pipe wall and one-third one-fourth the pipe diameter width. Spacing between straps should not more than in. Welded split sleeves, Fig. are used for the same pur- poses the bar reinforcement shown Fig. but bent over weld shown Section A-A Diam. liner smaller sizes. When this type joint used, flush weld (that is, weld with reinforcement) used for making the joint braced. short section pipe larger diameter than the pipe reinforced split either longitudinally one side and slipped over the pipe end before welding split halves, placed around the completed joint, tacked and welded longitudinally and the ends. The reinforcing sleeve should fit closely and have minimum length times the nominal diameter the pipe reinforced. least in. space should allowed the bottom the vee for the longitudinal weld (or welds) order that the contraction the weld metal may draw the sleeve tightly around the joint. secure maximum strength the foregoing joint designs, all the butt welds should thoroughly fused the joint edges and should extend completely the bottom the vee. All fillet welds should thor- oughly fused the root. All welds should sound metal, free from laps, gas pockets other defects. The bare pipe ends, before welding, should clean, free grease, dirt, scale, rust bituminous compounds. Used for Piles Support Building Made Ground FRANKLAND* ECENTLY Oakland, Cal., contract was let the city for new steel frame building used garage. This one-story industrial type building and built recently-filled tide flats. Commissioner Frank Colburn quoted the effect that this building will supported steel piling. Steel piling usually connotes steel sheet-piling, while the instance above noted find that the piling H-sections such are used for columns steel frame buildings. These H-sections will driven the same manner any other type piling and tested the same manner insure proper foundation for the build- ing. Usually, after piles are driven for foundations, con- crete footing poured form cap which turn sup- ports the column bases. this case, however, the steel column will connected directly the steel pile the same manner that multiple tier column splices are made steel frames. Thus have steel H-column properly spliced and carrying the steel frame the superstructure and this column reaches into the earth secure footing without the aid any other materials. The question will probably arise whether this innovation not. buildings this may possibly true, but system which has been use for bridges for more than years. There can better test for piling than its use bridge where subject con- stantly changing loads, sudden impacts, atmospheric *Director engineering service. American Institute Steel Construction, New York. mill facing right angles the furnace door eight rollers the table were provided with individual motor drive. Type duction motors fur- nished the Reliance Electric Engineering Co., Cleveland, were used, the drive being internal spur gear. All motors are controlled changes, floods and ice jams, and find them coming through these tests with wonderful record. Recently two new bridges have been built Monterey County, Cal., using this type construction—not only sound but eco- nomical engineering. June, 1929, the Bethlehem Steel Co. ran some tests H-piling site the estuary Oakland. After these piles had been driven, two 100-ton hydraulic jacks were placed top one the piles and total load 164 tons was placed it. This caused the pile fail crippling the flanges directly under the jacks. This pile was 8-in., 32-lb. H-section and analysis will show that the stress attained reached the elastic limit the steel. The extra penetration under this great pressure was negli- gible. When one considers that this pile would called carry load not more than tons actual ser- vice can easily seen that steel beam driven pile may used with safety for foundation work. Quite naturally the question corrosion the steel piling will arise. Steel piling immersed fresh water and soil for yr. has shown but per cent decrease sectional area. There are many rust preventives the market with which the piling may pointed before driv- ing, thus retarding corrosion still further. Recently Seaside, Cal., steel piers reaching out far 1500 ft. into the ocean have been built H-column piling. These piers are being built the oil companies support their oil derricks while they drill for oil under the ocean bed. The Iron Age, February | | 3 Relocated Equipment Boosts Output Chicago Foundry Featured Lower Labor Costs and Easy Movement Products—Adopts Methods Specialized Plants ROGERS FISKE* runs have not checked the Jones Foundry Machine Co., Chicago, its determination lower cost and speed production through the adoption equip- ment and methods use highly specialized production foundries. This company has found that over per cent its molds can made with the use sandslinger and molding though seldom that machine will operate full day without changes patterns. fact, the average for the shop three pattern changes day per machine. Ninety per cent the castings made for this company’s products, which are widely diversified, both ultimate use and range sizes. Job work requires about per cent the foundry capacity. The plan rearrange the plant was put operation REQUENT changes patterns for numerous short *Western editor, THE IRON AGE. first the construction 100-ft. extension. Special attention was given the location equipment and the transport products. Improved machinery was installed. method for the control castings needed meet ma- chine shop schedules not only simplified the work assem- bling finished products, but aided holding the machine shop schedules and also made for more orderly flow production orders through the foundry. The net results are now coming light the shape less use manual labor, increased production and lower cost output. Among the first steps taken was rearrange the ac- tive floor space that material would move orderly way without congestion. The core shop, which was located the south bay, was rearranged and additional space was provided. The sandslinger, which formerly stood the tion; Placing Core Ovens Lean-to; Erecting the Dust Arresters Out-of-Doors and Compact Drives for Machines. Symbols Des- ignate Tools and Equipment Follows: Cupola; CO, Core Oven; CM, Core Machine; CT, Core Trucks; Grinder; MM, Molding Machine, 2TC, 2-Ton Crane; 10TC, 10-Ton Crane; TM, Tumbling Mill; SM, Sand Mixer; SS, Sand Slinger | > Storage Space Was Gained 100-Ft. Addi- + Machine Shop | Mo?ror Truck for Castings Industrial Tracks Cleaning Dept. 438—The Iron Age, February 1930 Dust Arrester q Seasoning main bay near the cupolas, was moved down the main bay near the end the new 100-ft. extension. Small molds are made machines placed the side bays. Rough castings all move one direction the cleaning department. Raw materials are centrally located and are prepared for use and transported modern meth- ods. Machine drives were given special consideration the floor area occupied, with resultant saving work UMBLERS Are Driven Pairs Single Motor Which Connected the Two Drive Shafts Through Speed Reducer space. Crane, electric hoist and industrial track systems for moving materials were unified that transfer from one the other most convenient. Flask equipment has been standardized, have the containers used for moving sand and castings. Changes Made Without Interrupting Output These changes were started April, 1929, and August that year the fouridry had taken its new dress without interruption production. significant that this work was performed when this shop was the height one the busiest periods its history. has been pointed out, this foundry produces wide variety castings with reference the purpose for which they are used. often happens that many four different irons are melted day. Therefore, close attention given the mixture pig iron and scrap steel used charging the cupolas. this score Half-Coupler Attached the Speed-Reducer Shaft Will Used When the Sixth Tumbler Installed 4 desirable have pig iron uniform analysis. Accord- ingly, rather than order iron needed, the practice this foundry accumulate its needs and release from contract five more cars time. The silicon content specified within unusually narrow range, and expected this buyer that order for pig iron will filled from one blast furnace heat. This method has its advantages, that the number stock piles different iron held the minimum and thus the danger mixing grades materially reduced. The Iron Age, February 1930—439 i | we —, Re | Further, this foundry does not maintain, day after day, crew laborers who are occasionally called unload car two pig iron. Instead receives iron large quantities less frequent intervals and has the cars un- loaded contract cost about 30c. ton. Large Average Melt Low Cost The average melt 9-hr. day tons. Labor cost the two cupolas held low point preparing beforehand the entire day’s charge pig iron, coke and scrap. Only two men are used for all material handling and charging operations. the first place sufficient number buggies, open-side wheelbarrows, have been Worm Gear Speed-Reducer Drive Saves Valuable Floor Space. Sand Un- loaded from the mixer into batch boxes provided, that complete charge for the day’s run can stored the charging floor before the cupolas are put under blast. When the shop opens the morning, these two men prepare the charge. Pig iron buggies are taken the stock piles, loaded, weighed over platform scales and raised elevatcr the charging floor. Ample floor space provided that the loaded buggies pig iron, coke and scrap may conveniently stored until they are wheeled the charging doors the cupolas. Coke handled containers each with capacity one charge. Each charge dumped into the cupola without rehan- dling. The first cupola charges are evenly spread over the cupola area, but after the filling well under way charges are dumped into the cupola without rehandling. The con- venience this method handling raw materials can appreciated when understood that the charging floor ample size store over charges pig iron and 440—The Iron Age, February 1930 the necessary amount coke and scrap, and that each buggy load charge. Crane ladles 10-ton capacity each are available for spotting under the cupola spouts. Track ladles, 2000 capacity each, are used distribute molten iron pour- ing floors, which are served narrow gage industrial tracks. Special Drive Provided for the Mixer The sand mixer, the standard design the National Engineering Co., Chicago, special interest because Much valuable floor space has been saved con- necting the motor, which mounted footing standing few inches above the floor level, the Simpson mixer through worm-gear speed reducer, one the standard products made the Jones company. Core and molding sand storage provided leanto which convenient the railroad switch track. the case other raw materials, sand unloaded from railroad cars contract. The storage bins open into the foundry room near the point where the mixer stands. Laborers, using wheelbarrows, take sand from storage the mixer skip hoist. After batch sand has been prepared unloaded directly into corrugated steel batch boxes %-cu. yd. capacity each. These boxes stand truck, and they are also designed they can carried the overhead crane. These boxes may also piled one top the other. This feature made use the mixer where number boxes prepared sand may piled and made available for instant use. Ordinarily, however, core sand transferred directly the core makers means lift trucks. The demands the shop are such that facing sand promptly conveyed the overhead crane the molding stations. Floor Space Carefully Conserved When changes were planned the foundry arrange- ment, much thought was given conservation floor space. was found that space was available for two additional core ovens one end the sand storage lean-to. Accordingly the ovens were built this lean-to with their doors flush with the wall the main foundry core shop. The rear, firing, ends the ovens are convenient the switch track which coke received. Each oven ft. in. high, ft. long ft. in. wide and hand-fired. The inner surfaces the oven walls are laid with firebrick and the outer walls common brick. Between the two courses brick are in. cork-brick insulation. The roofs also are adequately insulated. Cores made during the day are baked night, therefore the ovens are full heat for period about hr. Fuel consumption for the two ovens operated this way 350 lb. coke for hr., with foundry melt tons day. Extending into each oven from the coreroom floor track which car operates. Cores are transferred these cars overhead crane bridge, from which hung electric hoist. Dry cores are con- veniently transferred from the hoist the crane the main bay. Flask Standardized was determined some time ago that greater produc- tion and lower cost equipment maintenance could realized flask equipment were standardized. other words, was decided that the future the job would have fit the flask rather than have wide variety flasks suitable closely fit all jobs. All wooden flasks were discarded and metal flasks were substituted. Small flasks were standardized size, design and material. Many are circular section and are made cast steel. > 7 ¢ 4 ‘= q 4 4 4 All Charges Pig Iron, Coke and Scrap, Each Buggy Being Charge, Are Stored the Charging Floor. All raw materials are prepared and the cupolas charged two men Flasks for large work are rectangular and are con- structed heavy cast steel ends bolted rolled steel channel secti