The Iron Age 1930-03-20: Vol 125 Iss 12

IRON AGE New York, March 20, 1930 ESTABLISHED 1855 VOL. 125, No. Plant Operates Mutual Aid Society Has Long Record Success Providing Employees with Medical Attention and Disability Compensation Low Cost operated the West Allis, Wis., plant the Allis- Chalmers Mfg. Co. Membership this not com- pulsory but records show that less than half per cent the employees have not availed themselves the ser- vices offered. Annual dues are low, view the character and scope medical and dental work and con- sultations which are open members. There also are advantages resulting from low and standard charges for drugs and hospital services. years successful mutual aid society has been Membership dues are now year, and for this sum employee entitled day for days for total disability resulting from sickness from accident; hospital and medical attention, also services spe- cialist advisable; necessary prescriptions; X-rays, and death benefit $100. the basis 50c. month per member, plus equal sum contributed the pany, this mutual aid society always has been self-sus- taining without resorting assessments, even the years when “flu” epidemics greatly raised illness and death rates. When man employed effort made sell him membership beyond explanation the functions the aid society. The organization consists president, vice president, treasurer, secre- physicians, the executive committee empowered take action alleviate the condition. All decisions the board appeals are binding upon all parties. Membership Cancelled for Arrearage Dues Any member leaving the employ the company account disability, and not entering the employ any other concern, not going into business for himself herself, may continue member the aid society, provided all dues are paid regularly. But, any member shall become arrears for dues, his her membership shall cease the last day the month for which dues have been paid. Membership dues must received the officers the society not later than the last day each month. Any member who practices attempts practice fraud deception any form secure attempt secure any aid benefits from the society subject suspension for such the executive committee shall determine, but suspension ordered without first affording the accused and his witnesses opportunity heard. The plant divided into units, each which elects committeeman. These committee- tary, the three members board appeals, also committeemen. The treasurer and the secretary are each required post $1,000 bond, the premium being paid the society. The constitution states specifically that all cases where the provi- sions the by-laws cause hardship injustice, the opinion the ex- ecutive committee, either members ALLIS-CHALMERS MANUFACTURING Co. MUTUAL AID SOCIETY APPLICATION CLOCK No.__ MARRIED 0 THE UNDERSIGNED HEREBY MAKES APPLICATION FOR MEMBERSHIP IN THE ALLIS-CHALMERS MUTUAL AID SOCIETY. WHEN GRANTED SUCH MEMBERSHIP HE DIRECTS THE ALLIS-CHALMERS MANUFACTURING COM- PANY TO DEDUCT THE SUM OF 50 CENTS PER MONTH FROM HIS WAGES AND TO PAY THE SAME TO THE SAID SOCIETY TO COVER HIS DUES. AID sociery | SIGNATURE witness Employee Who Signs This Membership Application Blank Does Voluntarily 843 men and the officers the society meet executive commit- tee. The president, president, treasurer and the three members the board ap- peals are elected annually popu- lar vote the members. The sec- retary elected the executive com- mittee. em- ployee must have been member the least six months 4 7 AGE being eligible hold office and committeeman eligible for reelection unless has attended two-thirds the meetings during the previous year. committeeman elected ballot the members from each unit district the plant. The president for the current year has served the company since 1895, first journeyman machinist and later shop executive. The secretary has been with Allis-Chalmers Manufacturing Co. since 1902. The secretary the only officer who receives compensation from the society and none the officers devotes full time society work. Physicians Chosen Jointly the Society and the Company The executive committee, working with committee appointed the Allis-Chalmers Mfg. Co., chooses the physician, who has full control the medical work the society, subject supervision the executive committee and trial relations committee the company. The physician holds office the will the executive committee and may removed from office after days’ written notice. respon- Income sible for full medical and Members’ dues ......... surgical attention members. must retain Interest assistant, who must ments qualified render the same contribution Comparative Revenue Statement Some the Principal Income and Expendi- ture Items Interest from bank ac- medical service the phy- count sician, who must pay the salary Also, associate physician selected the same man- Benefit checks unclaimed, cancelled Benefits and expenses Sick benefits ner the physician, and he, too, must have quali- Death benefits fied assistant whose salary paid the associate physician. salary Other physicians eye, ear, nose and throat specialist similar- selected. His duty render general service, but not required per- form surgical operations for the relief eye, ear, nose and throat ailments. The the physician and the associate physician given sum per member per year. One surgeon has served the aid society this way, for years. Cost dental work not borne the aid society. Ar- rangements are made with several reliable dentists, each spend hr. day the plant, where first aid ad- ministered and advice given. Dentists not receive pay from the aid society, but receive their compensation from the practice which they derive from the members and their families. The society provides dental X-rays and pays sick benefit dental condition factor illness. Formerly dental X-rays were made outside the plant, but recently the mutual aid society purchased X-ray machine now operated the company and the society- machine now operated the company and the society longer bears its expense. What Member Entitled Now then, what member entitled for his 50c. month? For total disability resulting from sickness receives day for days for any one illness. Other specialists ....... X-ray examinations Prescriptions Outside hospital expenses Outside nurse Iron Age, March 20, 1930 Eye, ear, nose and throat eee does not, however, receive pecuniary benefits for the first week disability due illness. The member entitled day for days the disability the result non-industrial accident. will receive not exceeding for disability due any one in- dustrial accident. the case one accident compen- sation under the State laws, the member does not receive pecuniary benefits from the society during such time compensation provided law. But for such periods the law does not provide compensation the society pays day the limit days. Under the present State laws, compensation for accident for one week following the first two weeks disability. However, the mutual aid society pays day the time when compensation provided law, when ceases payment, again resuming the day when the duration compensation under the law has expired. Compensation paid once month follow- ing the monthly meeting the executive committee, which must approve all ben- Year 1928 1927 efit checks. Average per Accidents members Member per Member per when outside the com- Year pany plant are considered $5.400 for the society and all 5.739 5.400 benefits specified the by- laws are extended the 0.061 0.053 injured member. 0.068 0.065 All hospital expense re- sulting from recommenda- 0.028 0.044 tions the society’s physi- cian are borne the society for period not ex- 3.753 3.729 ceeding eight consecutive 0.618 0.750 weeks any single case. 2.436 2.250 The society has ward bed rate understanding with leading hospital; however, 0.750 0.750 physician recommends private room and day and 0.059 0.048 night nurse, the expense 0.197 0.181 hospital other than the one 0.008 0.006 with which the has 0.013 0.009 made arrangements, the so- ciety will compensate 0.009 0.009 the price paid for ward bed the hospital with which the society has wishes, may secure private room paying the hospital the difference between the ward bed rate and the charge for the private room. All medicine and incidental charges made the hospital under the orders the physician are paid the society. cases which are certified physician the so- ciety require the services specialist, the society will furnish the first examination and first treatment specialist selected the society physician, provided that the work the specialist performed under the super- vision the society’s physician. The society does not any event furnish the services specialist for opera- tions. All authorized prescriptions for use members issued society physician for filling authorized druggist the society are paid for the society. Prescriptions issued other than the society’s physicians are paid for the society only they are approved the aid society 1 ii 7 ii i ti q | physician and filled authorized druggist the so- ciety. Prescriptions for treatment traveling members are paid the society only upon certificate signed the attending physician. All for injuries sickness not ‘caused resulting from accidents within scope any compensation law which the company subject the time the accident are paid for the aid society. Ar- rangements have been made with certain drug stores for standard price prescriptions. The cost held down the use small bottles, which may refilled necessary. Ambulance service provided contract made the society, the expense being paid the society. ambulance cab provided, depending the char- acter the case. Traveling Engineers May Become Members Members, such erecting engineers, who are sent the road the company, also derive certain benefits, such The society pays benefits any one such case total $90. The society has entered into contract with under- taker, who arranges funeral for $100. The death benefit paid the society $100, this figure having been set cover the cost contract funeral. plan this kind there must necessity certain limitations benefits. Benefits are not paid for disability death for which compensation provided under work- men’s compensation laws any State. pecuniary hospital benefits medical service will paid rendered member for disability which caused, directly in- directly, immoral conduct, intoxication, use narcotics, performance obstetrics, fighting. Benefits will not paid for disability death reason injury illness caused acute, subacute, chronic essentially recurrent disease contracted prior the date which the member joined the society, though member entitled during such. disability regular medical and surgical service after has been the employ the company continuously for days. mem- ber may receive only once during his membership benefits for disabilities resulting from chronic recurring ailment. The work the mutual aid society entirely outside the scope the welfare and medical and hospital service rendered official act the Allis-Chalmers Mfg. Co., either its own efforts promote the welfare its employees carry its obligation far the State are concerned. must not construed that be- cause the existence this society the company has any measure neglected promote safety, provide first aid extend welfare activities the employees and their families. These are highly developed activities carried the company. Any service rendered the company open equal terms all, regardless whether membership held the society. The mutual aid society’s service addition all this and intended relieve and financial worries and render first-class service moderate cost times when its members are most need. this respect must not overlooked that the structure the society flexible, and welfare extended may, and often does, beyond the strict interpretation its by-laws. Alumina Affects Slags Steel-Melting Furnaces view the efforts made from time time intro- duce the use alumina material for furnace construction, important investigate the influence slags which contain, contrary the usual basic slags, fairly high percentage alumina, says Mars article Archiv fiir das Eisenhiittenwesen, August, 1929, pages 103-115. Accordingly, trials have been made ascertain how far practicable (1) dephosphorize steel; (2) desulphurize steel; and (3) deoxidize steel with highly aluminous slag. The experiments were performed 3-ton and 6-ton electric arc furnace, and 30-ton open-hearth furnace. The results are summa- rized follows: The dephosphorization steel the electric furnace with aluminous slags more difficult carry out than with pure lime slags, while the open-hearth furnace practically impossible dephosphorize with aluminous slags. the electric furnace, order secure good phosphorus distribution coefficient, the aluminous slags must contain certain minimum percentage (about per metallic oxides. The dephosphorization fer- rophosphorus with pure alumina quite impracticable, aluminum phosphate reduced contact with iron, with formation iron phosphide. The desulphurization steel with aluminous slags impracticable, but the electric furnace iron-carbon alloys and sulphide iron can desulphurized with lime- alumina mixtures and also with pure alumina. The lime- alumina slag takes sulphur the amount per cent corresponding per cent sulphide calcium, and the pure alumina takes per cent sulphur cor- responding per cent aluminum sulphide. deoxidizer, aluminum behaves exactly the same way silicon, but has the great advantage that its oxide not strong acid silica, and can therefore used more highly concentrated form than silicon, even the basic electric furnace, without adversely affect- ing the desulphurization and without attacking the furnace lining. New Method Making Steel from Indian Pig Iron NDIAN pig iron generally unsuited for steel manufac- ture, the phosphorus content being too high for acid practice and too low for standard practice. Mathur, article the Journal the Indian Chemical Society (Vol. No. pages 353-355), proposes new method making steel from Indian pig iron. Molten pig iron poured into basic lined converter which certain amount burnt lime and mill scale have been previously added neutralize the extra amount silica, formed from the oxidation the silicon the charge, and the same time produce highly oxidizing basic slag. The metal blown according standard acid practice, afterblow being necessary for the oxidation and removal the phosphorus. The silicon and manga- nese the charge produce temperature high enough for easting purposes. the end the blow, ferromanganese and ferrosilicon are added bring the metal the required analysis. the Mysore Iron Steel Works steel being suc- cessfully produced basic lined converter using direct iron with 0.12 per cent phosphorus cupola metal with 0.14 0.15 per cent phosphorus, the phosphorus being reduced the final metal about 0.026 per cent. The Iron Age, March 20, Shears Strip Mill Provides Flexibility Third Unit Completes Coverage Widths and Gages for Acme Steel Co.—Straight-Line Flow— Efficient Electric Control ROGERS OREMOST among the features the new No. hot- strip mill the Riverdale, plant the Acme Steel Co. the use two-high stands equipped with rolls that are true cylinders. Insteai the rolls having necks, the roller bearings back the rolls the exten- sions the rolling surface. This construction assures ample bearing area and general ruggedness construc- tion. Also, the vertical edgers are unusually heavy de- sign that, when rolling narrow widths, they may used for reduction area the insertion vertical rolls with oval and square passes. This unit one three hot-strip mills the River- dale plant. was installed add flexibility operations and give this company complete coverage the hot- Mechanical Hotbed from the side. The steel, travels sidewise down the furnace skid pipes, moves right angles the roll passes. The peel trough and the billet ejector (the latter consist- ing square steel rod operated between two motor- driven rolls) are mounted the main floor. The furnace fired producer gas through eight burner sets which are supplied with preheated air from cast iron recuperator located the downtake. Waste gases from the furnace pass through flue, beneath the floor, 90-ft. steel stack, which stands foundation outside the building. The damper projects through the floor. This furnace has outside width ft. in. and will take billet ft. long. The design such that the Conveyor Apron Conveyor Pinch Steel Passes Direct Line from Raw Steel Storage Approach Table, Upper Right Diagram, Thence Through the Mill the Finished Product Warehouse strip market. No. mill can roll strips in. in. wide, but cannot roll strips heavier than in. No. unit will roll all ordinary thicknesses widths from in. in. The new No. mill will roll strip from in. in. wide. Thicknesses light 0.025 in. may rolled the nar- row widths and light 0.035 in. the wider. Further, any desired thickness may rolled the heavy range gages all widths. This mill housed main structure 800 ft. long ft. wide. the south end 100 300-ft. extension the west, which used finished product warehouse. The warehouse served 10-ton overhead crane, depressed railroad track and floor space for loading truck shipments. The bulk the product stored corru- gated stee] skids, which may moved either the crane electric lift trucks. Semi-finished steel, bundles tons each, re- ceived and stored the north end the main mill build- ing. Billets are number sizes, ranging from in. square in., and all are ft. long. These 15-ton bundles are unloaded from railroad cars storage 15-ton overhead traveling crane, which takes the bundles from the storage dock the charging dock. The latter equipped with furnace approach table. The same crane runway extends also over the roughing and finishing stands. Rated tons hour, the billet heating furnace, which was designed Oliver Leutscher, Peru, has conventional pusher and charged, and also discharged, 846—The Iron Age, March 20, 1930 width the furnace may increased the event that desired use 40-ft. billets. Fuel consumption monthly basis about 120 coal each ton billets heated rolling temperature. The furnace roof, the flat suspended-arch type, carried girder system en- tirely independent the furnace and resting columns which are clear the furnace and its accessories. Heated steel moves straight line from the dis- charge door the furnace the vibrator. front the furnace door snip shear the toggle type. Then fol- lows the roughing mill, which consists vertical edger, two in. 15-in. horizontal roll stands, vertical edger, two in. 15-in. horizontal roll stands, vertical edger, in. 15-in. horizontal roll stand and finally fourth vertical edger. Each edger driven separate variable- speed, direct-current motor. The first four horizontal roll stands are pairs, each pair being driven through reduc- tion-gear set variable-speed, direct-current motor. The last roughing horizontal stand has separate motor. Between the roughing and finishing mills elec- trically driven flying cropping shear which controlled ope: ‘or the shear. Crop ends fall the basement, where are easily removed wheelbarrows. The finishing section the mill consists five two- high stands, each driven separate variable-speed, direct-current motor. The first two motors the incom- ing end this unit are connected with the stands through reduction-gear sets. The remaining three are direct-con- nected. The main pulpit, which are located the controls for the roughing and finishing mills, conveniently lo- pens Charged into the Side the Furnace and Worked Forward Battery Pushers (Above). The recuperator located the back end the furnace setting, beneath the pusher rods hand corner draws hot air for combustion from cast iron recuperator Roof Suspension Members (Below) Are Unusually Heavy. The blower the lower right- The Iron Age, March 20, P cated the side and above the level the finishing stands. Coils and Straight Lengths Made Will This mill coil hot strip such thick- nesses can coiled. Also, there 230-ft. hotbed for straight and cut strips. this score special equip- ment has been provided, the different units operated depending whether straight coiled strips are produced. rotary flying shear has been placed after the last finishing stand. This shear has only one blade and makes one revolution each cut. used cut cool- ing-bed length strips which are run out the cool- ing table. Between this shear and the hot-run table gap which placed either section hut-run table, for straight strips, pinch rolls and guides and vibrator, the strips are coiled. There are rolls, driven individual motors, the removable run-out table. This ment for the hotbed transfer crane, which travels across the building over the hotbed and cold-run tables. This electrically operated and handles its loads means series magnets spaced cen- ters. means this transfer crane strips may lifted from the shuffle bars and dropped any one the four cold-run tables, strips may transferred any part the table which empty. All the mechanical equipment for this hot-strip mill was furnished the United Engineering Foundry Co., Pittsburgh. Overhead electric cranes, both the main mill structure and the finished product warehouse, were designed and built the Whiting Corporation, Harvey, Twelve Motors Drive Fourteen Stands Complete electrical equipment for the main rolls and mill auxiliaries was furnished the Westinghouse Elec- tric Mfg. Co., East Pittsburgh. laying out this mill, was desired able produce wide range strip, INISHING Section This Mill Consists Five Two-High Stands, Each Driven Separate Vari- able-Speed Motor. Rotary flying shear appears left foreground removable equipment can changed min. means the overhead crane. With the vibrator place the strip passes the take- section apron conveyor and then the apron con- veyor proper. Two reels have been installed, with kick- off mechanism and device which loads coils the charg- ing end coil which extends along the east wall the building the finished storeroom section the structure. This apron conveyor, the kick-off and the coil are operated from control stand located near the reels. previously outlined, straight strips are wanted, the section run-out table put place the vibrator and auxiliary mechanism. The strip then cut the rotary flying shear and passes down the hot run- out table, which extends the full 230-ft. length the hot- bed. the opposite side the mechanical hotbed are four parallel cold-run tables which are the same length the hotbed and which terminate four shears. special interest connection with auxiliary equip- 848—The Iron Age, March 20, 1930 hoop and fiat sizes, and also able change quickly the mill set-up from one schedule the next, operate the mill economically orders relatively small tonnages. The required flexibility was attained the installation direct-current adjustable-speed mo- tors drive the ten horizontal and four vertical roll stands, thus giving individual control the speed all except the first two pairs roughing stands. The motor characteristics are follows: Stand No. Motor H.p. Motor R.p.m. (Edger)..... 150 400/1200 (Edger)..... 150 400/1200 600 450/900 OTBED Transfer Crane 230 Ft. Long. travels across the building and serves the hotbed and run- out tables, lifting the steel means numerous magnets The four 150-hp., vertical-roll edging stand motors are located the mill, and are flexibly coupled the reduc- tion-gear sets. The three 600-hp. motors driving the five horizontal roughing stands are located separate motor room, apart from the main substation. The five finishing stand motors are located the main motor room substa- tion, together with the large motor-generator set and switchboard and equipment. All the roll motors are provided with rear inclosing end bells and are arti- ficially ventilated with filtered air. Power for operation the twelve 600-volt roll motors, and for auxiliaries and excitation, provided single large five-unit synchronous motor-generator set. This set consists two 2000-kw., 600-volt generators for main motor power, 300-kw., 250-volt generator for auxiliary and crane motor power, and 100-kw., exciter generator, all driven 6350-hp., per cent power fac- tor, 3-phase, 60-cycle, 12,000-volt synchronous motor. Com- bination all generating equipment into one large ma- chine permitted compact arrangement the substation and also resulted somewhat more efficient operation than with two more smaller units. Also, the selection the 12,000-volt synchronous driving motor, made feasible only the installation one large set, permits connection directly with the supply lines the Commonwealth Edison Co., thus simplifying the switching equipment layout and improving the efficiency, due the elimination trans- former losses. The vertical-roll edging stand motors are controlled resistance-type magnetic starters, that they may ERTICAL Edgers, Which Form Part the Roughing Mill, May Fitted with Rolls Grooved for Oval and Square Reduction Passes, Thus Increasing the Flexibility Operation the Mill The Iron Age, March 20, a4 § 4 4 4 started stopped independently other large mo- tors. The eight large stand motors are started generator voltage control, and hence are all started together. Complete control the mill motors, the two 2000-kw., 600-volt main generators and the run- baleony the wall the main substation, overlooking the finishing stands. addition, fine rheo- stats for the seven roughing and edging stand motors are located near the respective mil] stands, the floor opera- tors may regulate operation roughing part mill. interest the lubrication system, installed Bowser Co., Fort Wayne, Ind. consists central filter plant which continuously filters all the oil from all the bearings and gears this mill, with the ex- ception the Timken roller bearings, which are packed with grease. This system, entirely automatic, located basement room that oil returns from the bearings and the gears gravity. designed handle heavy oil 1550 deg. viscosity. Sponge Iron Varies Grades Its Value Steel Making Depends Melting Large Charges—Other Factors Affecting Its Use his paper “Economic Aspects Sponge Iron Produc- tion Canada” Prof. Bradley Stoughton places sponge iron whole price basis with scrap. The author also brings out the fact that particular cases the price sponge iron can, the case with Swedish sponge iron, obtain much higher level than scrap. The writer this discussion paper before the American Electrochemical Society its annual meeting Toronto, 1929, advocated strongly the necessity viewing the value sponge iron differently, when considering “commercial mass production steel” and “high-grade steel production.” was then said: Sponge Iron for Commercial Steel Maker paper presented 1928 the Swedish Iron Masters’ Association, the present period circula- tion steel was found about yr. After reviewing the various factors influencing the returns, the paper predicts that within this century the returned scrap will equal exceed per cent all commercial steel produced. Accordingly the demand for iron’’ for commercial steel mak- ing, whether produced the blast furnace, sponge iron process, might more less than today depending the total amount steel produced that time. commercial steels, this general circulation iron must taken into consideration. Furthermore, sponge iron must compete price with iron from the blast furnace and with commercial high-grade scrap. There evidence, however, that steels pro- duced with sponge iron base will show sufficiently better physical properties demand premium price, and thereby enable the maker pay better price for such sponge iron. Sponge Iron for Fine Steel Maker the maker high-grade steels, such tool steels, high-grade spring steels, wire steels, and vari- ous special carbon and alloy steels, the above given basis for valuation sponge iron not correct. The markets for these steels demand quality, and may safe predict that the specifications physical properties will not become easier, but more and more difficult to meet. While alloys in the scrap may be utilized for some particular group alloy steels, their presence naturally growing objection not only the manufacture straight carbon steel, but Tholand, East Forty-second Street, New York. This discussion paper Prof. Bradley Stoughton, Lehigh University, Bethlehem, Pa., delivered Toronto, March and abstracted IRON March 13. 850—The Age, March 20, 1930 also the manufacture such alloy steels where the contaminating metals the scrap, mainly nickel and copper, are not tolerated. Prof. Stoughton states that the Swedish sponge iron obtains price twice that scrap. The writer wants make this information more specific. The price obtained for the Swedish sponge iron today runs high $60 per ton, delivered the consumer’s plant, while the seaboard price $44 per ton without duty. Different Grades Sponge Iron The possibility regular sales such prices the “high grade” steel trade strongly emphasizes that high value possible sponge iron. depends the quali- ties the sponge iron, more than the price scrap. Sponge iron should never discussed without bearing mind particular properties different grades the material. Vital factors bearing the quality sponge iron are, Prof. Stoughton clearly brings out, uniformity and amount detrimental impurities, and also their physical and chemical existence the sponge iron question. Among the “disadvantages sponge iron” Prof. Stoughton lists that the material liable oxidize read- ily and thus difficult handle during the melting. This only true under certain conditions and three years’ expe- rience from melting per cent Swedish sponge iron (with specific gravity electric furnaces the United States has not brought out single instance such difficulties. open-hearth melting non-compressed sponge iron will readily oxidize when struck directly the flame but, properly protected the rest the charge, such diffi- culty exists. should also mentioned that compressed Swedish sponge iron (sp. gr. has been melted open- hearth furnaces the extent per cent the charge without any difficulties from oxidation. lengthy report “Recent Economic Changes the United States” was published last year and reviewed extenso THE IRON AGE, May 16, 1929, page 1363. Now comes brief summary the major work the form “An Audit America,” Hunt (203 pages, 5x7% in. McGraw-Hill Book Co., Inc., New York. Price $2). The author was secretary Herbert Hoover’s committee which instituted the researches. Having been written during period intensive industrial activity and soaring security markets, the book will doubtless read with interest these more sober times. | | 7 Steel Forgings Containing Nickel Information for Users—Effects Other Alloying Metals—Properties and Trend Heat Treatment CHARLES McKNIGHT* ARGE forgings constitute important and con- stantly increasing field for alloy steel. The informa- tion regarding them not nearly complete readily available the information pertaining other forms alloy steel. For example, the data published the Society Automotive Engineers the properties, analyses and heat treatments alloy steel are standard, but are not applicable large forgings, they are based tests made 1-in. bars. the purpose this paper deal briefly with the manufacture, uses, analyses, heat treatment and proper- ties nickel alloy steel forgings larger than in. di- ameter equivalent section. will not convey any help- ful knowledge the manufacturer forgings, principally because most that contains has been gleaned from them. the prospective purchaser and user may helpful. Fields Application the end last century, when nickel steels first be- gan used commercially, the largest field applica- tion was large forgings, such armor, guns and shafting for naval vessels. Back the there were made for the Niagara Falls hydroelectric generators some weldless per cent nickel steel field rings ft. diameter and weighing tons each—masterpieces then, but small com- pared some modern forgings. while ordnance consumes relatively few forgings, the industrial demand steadily growing pace with the increase the size engineering units. Forged alloy steel now employed for large shafts, turbine rotor and generator drums, gears, flywheels, pressure chambers, die blocks, Diesel engine parts, locomotive forgings, axles, extrusion dies, rolls and parts steel mills, steam-hammer piston rods, hydraulic press rams, etc. *In charge, alloy steel department, International Co., New York. The article from paper delivered semi-annual meeting New York, Feb. American Society for Steel Treating. usually specified that the steel may made any process—acid basic open-hearth, acid basic elec- tric furnace. Each process has some advantages and there not overwhelming argument advanced for any one. The electric furnace, however, does not contribute large proportion, due the comparatively small size most electric furnaces. general practice proportion the ingot mold the size bloom forging produced from it. Forg- ing molds are usually fluted. Most molds are top-poured. hot-top used and generous crop (20 per cent) considered requisite. Deoxidizers are sparingly used the ladle and never the mold. The question reduction from ingot bloom and from bloom forging has been moot point for some time. regards extremely large forgings seems almost satisfied with smaller ratio reduction than run the risks involved the use extraordinarily large ingots with the consequent liability segregation, cooling cracks and dendritic structure. Similarly, there always has been some controversy the relative merits hammering, pressing and rolling. The first two processes are used the production the actual forging; rolling for the production the bloom, inter- mediary between the ingot and the forging. Pressing usually considered superior hammering, but, again, the quality the end product the real answer. Some hold that the rolled bloom superior the forged bloom. There is, however, little dispute one point. Blooms alloy steel destined re-forged should allowed cool extremely slowly avoid internal ruptures. quite general now bury these blooms ashes immedi- ately after rolling forging. Alloys Which Are Used Alloys used forging steels are nickel, chromium, molybdenum and vanadium. Each, added itself, con- Table I—Nickel Alloy Forging Steels Analyses Molyb- Type Carbon Manganese Nickel Chromium denum Vanadium Remarks toughness. 2.5 per cent nickel.......... 0.18-0.35 0.60-0.90 Intended for normalized forgings. Nickel-chromium 0.25-0.45 0.40-0.80 2.75-3.50 Heat treated usually quench and temper. Nickel-chromium 0.40-0.80 2.75-3.50 For higher tensile values. Nickel-chromium 0.40-0.80 1.25-1.75 “Krupp Analysis” for very high ten- sile values. Nickel-molybdenum ........ ........ Suitable for normalizing quenching. Nickel-chrome-molybdenum.. 2.00-3.00 0.60-0.95 0.30-0.60 Suitable for normalizing quenching. Nickel chrome-molybdenum- the accompanying table specifications (Table certain steels are designated and “M” types. Phosphorus and sulphur usually specified under 0.045 per This conformance with the specifications for carbon and alloy steel forgings the American Society for Testing Materials (A18-27). Their analysis not specified. The required physical properties can obtained from any the nickel-chromium other compound steels given above. The Iron Age, March 20, 1930—851 4 4 4 = 4 q 3 : 7 fers certain properties steel. combination one more, where each complements the other, possible produce properties not obtainable the addition any one element prominent metallurgist re- cently observed, adding two and two and obtaining six as an answer. Nickel added steel primarily obtain increased strength with toughness. does not oxidize, does not con- taminate the bath, has impurities, and recov- erable from the scrap. Particularly important the man- ufacture large forgings, has recently been estab- lished that nickel has tendency render steel more homogeneous and lessen segregation. This contrary the prevalent belief. Chromium added primarily harden and strengthen the steel. acts improve the properties, principally through the formation carbides. oxidizes during the process some degree. Molybdenum very similar chromium. more powerful than chromium its pound for pound, and, addition, has the valuable characteristic increas- ing the depth-hardening steel and nullifying “temper brittleness.” acts for the most part through the forma- tion carbides. Like nickel, molybdenum does not ox- idize and recoverable from the scrap. Vanadium acts toughener and strengthener steel. also forms carbides, but has the valuable prop- erty reducing grain size. oxidizes very readily and hence the addition vanadium the form ferro- vanadium must made after the steel well killed Nickel alloy steels for forgings comprise the following group: steels, nickel-chromium, nickel-chromium- nickel-chrome-vanadium; denum. Nickel Steels: Steel containing per cent nickel was the first alloy steel used quantity for forgings and has for years been standard. Its use indicated where carbon steels are inadequate and more strength, toughness and reliability required. used either the annealed, the quenched-and-tempered the normalized condition. While steel containing per cent nickel not much used this country for large forgings, its qualities have made much more popular abroad, where for all alloy steels customary use higher alloy ratio. One the interesting uses straight nickel steels that using nickel steel low-carbon content order obtain very great toughness and resistance shock with only slight sacrifice strength. Originally developed one our oldest forge companies for use subway and street-car axles, this steel contained only 0.13 per cent carbon and per cent nickel, thus approaching pure iron-nickel alloy. The heat treatment was the quench-and-temper, and responded very nicely, account the low carbon, with practically danger cracking. Subsequently was (Continued page 902) Table and Physical Properties Nickel Alloy Steel Forgings Specifications Tensile Elastic Inverse Min. Inverse Min. Tensile Elastic ga- Type Treatment Size Strength Limit Ratio Ratio Strength Limit tion Area Remarks Carbon Annealed dia. 75,000 Tens. 1,800,000 20.0 2,800,000 43,860 36.2 66.7 Crankshaft Tens.Str. Str. Carbon Annealed dia. 75,000 Tens. 1,650,000 18.0 2,400,000 40,800 21.2 55.2 Hydroelectric Str. Shaft Max. Wall 90,000 55,000 2,100,000 20.5 4,000,000 Max. Wall 85,000 50,000 2,000,000 20.5 3,800,000 103,050 68,250 23.0 51.9 Cylinder Forgings Carbon Q. & T. 7”-10” Carbon 10”-20” Carbon Normalized 10”-20” dia. 83,000 43,000 ........ 35.0 88,000 47,500 25.0 42.0 Averages Large Locomo- tive Forgings 3% Nickel Annealed 12”-20” dia. 80,000 50,000 1,900,000 21.0 3,400,000 38.0 103,000 65,000 21.2 45.1 Turbine Rotor— 81” Low Carbon 2.5% Nickel Normalized 10”-20” dia. 80,000 55,000 50.0 31.0 60.0 Averages Large Locomo- tive Forging Max. Wall 100,000 70,000 2,200,000 20.0 4,500,000 41.0 130,500 111,250 21.5 55.7 dia. Max. Wall 100,000 65,000 2,100,000 20.0 4,300,000 41.0 29.0 51.0 Ni. Steel Forg- ings dia. Max. Wall 90,000 60,000 2,000,000 20.0 4,100,000 41.0 95,000 67,000 24.0 52.5 Marine Crank 3% Nickel Q. & T. 10”-20” 18x12.5” dia. 5”-8” Max. Wall 85,000 55,000 1,900,000 20.0 3,900,000 41.0 115,000 85,000 21.0 51.0 Press Column 36x24” dia. Nickel Normalized 10”-20” dia. 90,000 60,000 40.0 93,000 61,000 27.5 54.4 Marine Propeller Shaft 14%” dia. Type 3%” Max. Wall 90-110,000 65,000 ........ 50.0 25.3 64.7 mm. Gun Tube Type Max. Wall 90-110,000 65,000 ........ 72,560 24.3 60.4 150 mm. Gun Ni.-Cr. 10”-20” dia. Jacket Type Max. Wall 100-120,000 75,000 ........ 50.0 100,130 76,950 25.0 62.0 mm. Gun Tube Type Max. Wall 100-120,000 75,000 45.0 175,000 185,000 16.0 50.0 Large Gear Forg- Ni.-Cr. Steel 10”-20” dia. ings Type Max. Wall 95-115,000 70,000 ...... 45.0 168,000 149,500 15.5 Ni.-Cr.-Mo.-Va. Type Max. Wall 100,000 ...... 45.0 143,500 110,000 15.7 50.0 Cylinder Steel 10”-20” dia. 18” dia. Type Max. Wall 100,000 70,000 ........ 45.0 151,000 131,500 18.0 16” Forgings B52—The Age, March 20, 1930 4 7 7 q | | | 7 j q J obbing Foundry Uses Conveyors Several Trunk Lines Fed Branch Lines from Machines —Flexibility Operation Equipment and Plant Feature—Large Savings Reported SIDNEY KOON* ern Steel Castings, Newark, J., several years ago was that making the product lower cost. The business almost wholly jobbing, and about three-fourths all castings made are lots less. Evidently the mass production methods largely exemplified automotive work were not wholly suitable here. PROBLEM confronting the East- Nevertheless, after careful study all phases the situation, was decided put into use those features manufacturing conveyors which could adapted the case hand. Analysis showed that the greatest waste which could attacked was that man-power and particularly that involved handling materials. Hence the study centered along the line the use conveyors promote easy flow materials, and save IRON AGE, New York, ENERAL View the Molding Department. The short, inclined conveyor run left fore- ground .takes the mold from machine toward pouring line left the back-breaking work common foundry operation. Along with the mechanical features detailed suc- ceeding paragraphs was developed system planning, routing and cost keeping, forming production control method which has given excellent results. longer are castings cleaned the haphazard fashion commonly vogue, the present physical situation results almost automatically keeping the floor accumulations throughout the plant. This merely one instance the general stepping-up and tone the whole conduct producing castings this organization. attempt was made utilize definite speed the conveyor system pace-setter. Nevertheless does, practice, perform that function. But the diversi- fied character successive molding operations formed here would not lend itself wholly this method attacking the problem. - The Iron Age, March 20, Practically all the ‘ ia ‘ § é G j a § — veyors are the gravity type the hand-push type, will described. Because the diversity character castings, both size and intricateness, the operation the plant divided into several sections. This was based partly the company’s possession, the time the change, various types molding machinery and the necessity use hand-molding methods for certain lines work. The change was made only after long- continued study, following visits many plants all over the country. making it, there was little disturb- ance possible, both the building structure and the existing equipment. Hence, there are the floor molding department, roll- over machines, squeezers, etc., each which requires — 6 wd 3 4 mounted oversize ball bearings for ease operation, and are made precision and interchangeable stand- ards. They are generally level and have power. The molder finds easy shove score more molds along the conveyors. This pushing, however, function the labor gang, which keeps the floors clear and the molds motion. Reaching the outer end this short run conveyor, which has capacity for number molds, the molds are transferred the trunk line means short section rollers turntable. This again ball bearings and operates with the greatest ease. variant this system, the case molds too heavy closed easily one man, found those which the drag and the cope are handled separately Swiveled Pouring Stand (Extreme Left). Pouring station for ladles suspended from monorail and somewhat different treatment the handling the prod- uct. addition the equipment, particular study was given the core room, and large amount time was devoted revamping the system han- castings through the cleaning department, which often the the bottle.” Pouring castings was another feature which received thoughtful attention and which was worked out especially happy fashion. Handling Molds Conveyors ARIOUS sizes molds are made the plant, from flasks in. square and capable making half- dozen small castings once flasks ft. square more, which single large casting made. For small moderate-size molds the procedure simplest, that the mold made the molding machine and then dis- directly line roller conveyors, running right angles the trunk line which carries the molds the pouring station. All conveyor rollers are made seamless steel tubing, 854—The Iron Age, March 20, 1930 two men two machines, side Here again they are run out the pouring line lines conveyors, the row copes one conveyor line and the drags adjacent line. After ten each have been made, the cores are set and then the two molders, working together with the aid air hoist overhead beam, close the cope over the drag and run the completed mold out over the turntable and the pouring line. the other diréction the case the smallest molds, which are placed groups carrying boards holding four five molds. These boards have runners under them, near the ends, and spaced that they fit narrow lines rollers, shown one illustration. After the molder has put his four five molds such board, shoves sideways toward the pouring line and then places the roller rails alongside an- other such carrying board for the next lot molds. Thus, with these little fellows, there may several boards with their molds stored between ing ike conveyor special rig March ideways track eight, The Iron Age, Right. The overhead hoist takes the The pouring line left foreground cal pyrometer Molds Long Bottom Boards. The boards ride Temperatures are controlled opt tings used shown. Close Cope Left Over the Drag OURING Cas ines. Preparing 4 the machine and the pouring line. These again are run out the pouring line convenience dictates, and take their place under the ladles their turn. Still another problem that the hand-molding de- where castings varying sizes and shapes are made molds, and only one two, half dozen, perhaps, may required each pattern. Here again, however, use the feeder conveyor lines made, molds being prepared and pushed out over those lines the same manner handling with the molding machines. Thus this department, which formerly was subject the confusion usually attending such opera- tion, the same basis with regard clearing the ways are the other molding departments. Nothing can accumulate anywhere block full opera- tion long the molds are being poured about fast they are made. happens that the pouring schedule on, roughly, 2-hr. basis, this the time required finish the steel the electric furnace after has been melted the open-hearth furnace and transferred the electric unit. Providing for Flexibility the Work LEXIBILITY these operations provided number ways. the first place, the storage ca- the various feeder lines, from all the differ- ent molding operations, about equivalent five heats steel from the fur- nace. This capacity not utilized pile molds, however. They are kept 856—The Iron Age, March 20, 1930 OLLER “Getaway” Foreground Takes the Mold Directly from Machine. rear left more flasks and bottom boards are arriving. Steel flask storage behind wall the move, that little material process can possibly arranged for going through the works one time. The fact that the excess storage capacity there, however, takes care any probable delays the furnace, without any way interrupting molding opera- tions. Another flexibility lies the control which the the speed operation each group machines the larger type. Mention was made above the closing molds the two molders oper- ating duplicate machines, one for the drag and the other for the cope. Several different speeds can made this particular unit control the number men operating it. described above, this unit was run two men, one for each machine. can, however, speeded necessary the addition one two three more men, mum five. One additional man, who might serve two such units, will the core-setter, whose work would relieve the two molders that operation and thereby get the molds the line that much faster. Two men added such unit would set the cores and close the molds. And the full speed which the machines are capable might utilized expanding the crew five men and using two them continuously molders, one core-setter and two for closing the molds and put- ting them the pouring line. avoid discarding some the old molding equip- ment which this plant had, means had taken a | J q 4 — 7 q fe adjust this equipment the new conditions. where the molds were too heavy handled manual- ly, and was not convenient give them either local other crane service for that purpose, lines rollers incline were run the table the machines, shown one cut. This forms with the machine work unit such that the operator can put the mold out the feeder rollers without too much physical effort. Much ingenuity was exercised some these instances, and good deal experimentation was required plac- ing equipment the best advantage. This remark applies well the core room, where the lines supply sand the benches and movement cores from the benches the arranged not cross each other. number core machines were set with relation the benches make for the greatest ease making cores. Core sand hoppers the back the benches drops sort shelf within easy reach the operator’s hand. Meanwhile the cores are handled from the benches trays which deliver them the ovens and thence either directly the molding stations or, some instances, storage for later use. Pouring Metal from Overhead Track EATS from the electric furnace are tons. Each received bull ladle that capacity. This ladle then taken the crane central position and deposited upon pouring stand resting turntable (as shown). The pouring ladles are filled this point. they approach from two three different directions, the rotating action the turntable utilized and they are filled the tilting the bull ladle means the crane. When more than 1000 required ladleful, these larger ladles are handled overhead cranes, for the Shake-Out, Hauling Hot Castings Off the Grating into Boxes Conveyor Line. All heavy weigh