The Iron Age 1930-04-17: Vol 125 Iss 16

THE IRON New York, April 17, 1930 ESTABLISHED 1855 125, No. X-Raying Die Castings ECENT X-ray studies die- cast test have shown that the interior conditions depend largely upon the construction the die. This was emphasized also recent the users X-ray equipment production and inspec- tion work. Some time one the authors made brief statement the application X-ray inspec- tion and since that time this method has made rapid and successful progress. Three Methods X-Ray Examination examining die castings means X-rays are concerned with three ways this: 1.—Radiographic inspection with photographic film. 2.—Radiographic inspection with photographic paper. 3.—Visual inspection fluorescent screen. Radiographic inspection with photographic film the most sensi- tive way ob- tain permanent record and like- wise the most *505 Fifth Avenue, New York. Proceedings, Amer. Soc. for Testing Ma- terials, Vol. 29, Part 200, 1929. Tool the Metal Industry,” Fink and Archer, Aluminum Co. America, Cleveland convention the Am. Soc. Steel Treating, Sept. 10, X-Rays Indus- try,” Herbert Isenburger, The Metal Industry, June, 1928. 1135 Locating Defects Before Production— nique the Process—Concrete Cases DR. ANCEL ST. JOHN AND ISENBURGER™ X-Raying Zinc-Base Die Casting rapid these three, but the most shows defects which will not show the photographic paper nor flu- orescent screen. This holds specially true for die castings which are less transparent X-rays than aluminum castings, since the atomic weight zinc much higher than that aluminum and the pene- trating power X-rays decreases with increasing atomic weight. Where longer exposure time can tolerated, the less expensive method radiographic inspection with bromium-silver paper satisfactory, especially for aluminum castings. Besides being slower method inspection, there are not many details ob- tainable with films, though the permanent record can Technique the Methods The technique for both these methods sche- matically shown Fig. The objects under in- vestigation (B) are placed be- tween the focus (X) X-ray tube and close possible the photographic film paper (F). The tube mounted within lead-lined d | | | | | 2 i; > -_ Film Method Fig. 2—Technique the Fluoro- scopic Method In- spection (Right) X—Focus X-Ray tube D—Lead-covered steel drum B—Specimen under investi- gation F—Film backing drum (D) prevent the escape X-rays except through predetermined openings; the film paper protected against secondary radiation rather heavy lead back- ing (L). The appearance the various defects almost the same for different materials and can raised per cent precision radiographic inspection with film record, about per cent with bromide paper record and not better than per cent visual inspection with fluorescent screen. This holds good for blowholes which lie the direction the rays. Visual inspection mostly employed for checking production and special value where die castings are supplied certain permissible percentage poros- IG. 4.—X-Ray Picture Part Alumi- num Cooking Utensil (Below) Fig. 5.—Portion the Side Wall Loud Speaker Case (Zinc-Base Die Casting) Under the X-Ray (Right) Iron Age, April 17, 1930 IG. 1.—Technique Photographic Ray Examina- tion (Left) X—Focus X-ray tube D—Lead-lined steel drum B—Objects under investigation S—Fluorescent screen A—Lead shields M—Lead glass mirror ity. This method rapid but relies the momentary judgment the operator and there permanent rec- ord. Fig. illustrates the fluoroscopic inspection. Fig. (B), are the objects examined which can arranged slowly moving conveyor belt, desired, (X), the focus and (D) the drum. After having passed through the specimen, the X-rays excite barium platino- cyanide screen (S) effective fluorescence radiation which observed lead glass mirror (M) the viewer (V); (A) represent protecting lead shields against stray radiation. The visual inspection aluminum propel- ler schematically shown Fig. will noticed the illustration that the lightest spot the screen corresponds with the thickest part \ | { | the propeller. the same propeller had been X-rayed photographic film and print had been made, the very same region which appears light the screen would the darkest the print. with ordinary photographs, lighter regions the negative (fluorescent screen) darker regions the print mean that less X-rays have passed through the object that point which indicates that the object less transparent there. Hence cavities will show the prints light spots whereas heavy impurities more dense metal will appear darker. With this mind there should difficulty understanding the following X-ray pictures. X-Ray Pictures Castings Fig. depicts aluminum cooking utensil, submitted for examination because suspected. excellent example what die casting should not be. Besides numerous cracks, there are large gas pockets and consid- erable general porosity, the latter showing the flow the metal itself. part the side wall loud-speaker case (zinc-base die casting) illustrated Fig. addition general porosity, the darker area indicates denser metal, the white spots are gas bubbles, the dark spot the lower half impurity and the line through the center represents the parting line the die. The number T-7650001 cast in. Fig. shows what can done with proper casting technique: perfect zinc casting, photographed Fig. Detecting Defects Before Production Defects die castings arise prin- cipally from two causes: (1) Incor- rect specification die casting pro- cedure. (2) Departure from specified procedure. The former leads char- acteristic chronic defects, the latter occasional. order improve the quality die-cast products the following pro- cedure should adopted: Select least three specimens cast the same die and X-ray these. Any defects characteristic the casting tech- IGS and 7.—A Perfect Die Casting and Its Appearance Under the X-Ray q - neers are able find easily the causes for interior de- fects. The necessary changes form position gates and air vents other parts the die, such can made without requiring new dies, are determined and made. Have another group castings, made the new technique, X-rayed, and proceed this way until satis- factory castings can secured from the die. should not take more than two X-ray examinations order obtain perfect die. This procedure should especially applied pilot castings before new die put into production operation. most the cases where X-ray inspection has been employed, has proved cheaper and ever much more satisfactory, saving time and money, than the ordinary and old-fashioned way cutting castings and all simi- lar ways checking production. The X-ray picture shows the conditions throughout the piece without destroying any way harming and gives permanent record. After defective conditions are cor- rected once, they tend stay cor- rected. X-ray equipment, however, should not installed until the problems hand justify the purchase outfit. This would seem make the tool un- available the organization with small problem temporary diffi- culty. But, fortunately, some the pioneers have installed equipment take care such cases, that possible evaluate any proposed use X-rays without great expense. believed that the advantages gained the field here discussed, well other branches, particu- larly steel castings, will justify present necessary expense some nique will likely appear all FIG. 3—Schematic Plan Vis- cases. There are reasons expect, three pictures. comparing the pic- ual X-Ray however, that operating costs can tures with the die, die casting engi- Aluminum Propeller reduced efficient methods. The Iron Age, April 17, 1930—1137 | | | \ | Foundry Operates Production Units RODUCTION the Kenosha foundry the Nash Co. has been tripled the installation modern molding machinery, compiete system conveyors, improved method charging the cupolas and the group system casting production. Labor saving noteworthy. The original foundry structure stood ft. from the sidewalk line. This waste area, ft. 700 ft., has been covered leanto, which the only addition made the building. this space has been concentrated the cleaning department, which equipped with con- veyor along the outside wall, for delivery finished cast- ings the shipping department. Storage bins for sand, coke, pig iron, limestone and Each Group Has Own Sand-Handling and Sand-Tempering Outfit —Sharp Reduction Labor Cost scrap have been roofed over, improve working conditions bad weather. These bins stand along the north wall the foundry structure and are served 5-ton overhead electric crane. Opposite the four cupolas have been erected overhead bins for coke. one side these bins steep ramp which the crane unloads pig iron. This ramp and the coke bins feed gravity two electrically operated truck cars which travel parallel tracks that extend from this loading station into the building point under the charging platform. The table each truck will accommodate two drop-bottom charge buckets. After charge bucket has been loaded, the truck spots charge bucket which has under the charging crane. and Shakeout Magnetic Separator Mounted over ¥ 4 4 \ A\ \ \ 1138—The Iron Age, April 17, 1930 Screen, Screen been unloaded cupola lowered the crane and deposited the truck. The loaded bucket raised the crane, spotted over the center cupola and dumped. soon the loaded bucket removed from the truck the empty bucket transported the bins, where again loaded. Before this system was installed men were required handle the charging op- erations for 150-ton melt. The plant still new and has not yet been worked capacity, but has been demonstrated that six men can now handle the charges neces- sary for 250-ton melt. This charging equipment was manufactured the Paw- ling Corporation, Mil- waukee. worthy note that the cupolas were raised that 6000-lb. mixing ladles could permanently set opposite each cupola spout. Distribution the hot metal means smaller ladles, suspended from overhead monorail system which reaches all major pouring stations. The saving floor space this foun- dry the use vertical and overhead core ovens was described THE IRON AGE May 31, 1928. The present capacity the foundry made necessary that another and Pug VERHEAD Conveyors Pick Castings Shakeout Sta- tions for Delivery the Cleaning Department (Above). The draw- ing shows how one the units was laid out and how sand handled and delivered. The mold conveyor makes closed loop 7 q 4 a a ray | i ~ vertical core oven installed, and also overhead core black drying oven, both which were designed Young Brothers Co., Detroit. Sma!l Molding System Placed Inside Large One HERE previously had been installed this foundry two sand- and mold-conveyor system for six-cylinder engine blocks. Later flywheel molding system was installed. When the group production plan was adopted was decided move the flywheel unit from its old location and spot inside the ellipse formed the cylinder block conveyor. This move made use otherwise waste space and cleared part the foundry floor for another molding operation the group plan. one end the old engine block conveyor has been installed second conveyor loop. Cylinder blocks, after having been shaken out, are conveyed mezzanine floor, where the cores are removed. They are then conveyed the new conveyor loop, where they are progres- sively ground, sand blasted, shipped, cleaned, re-sandblasted and put under hydrostatic test. The blocks now made these units are for the 8-cylinder engines which into cars built the Kenosha works. After the hydrostatic test the blocks are put conveyor which delivers them the machine shop. The Iron Age, April 17, » | ™ general picture the foundry this point dis- closes core ovens the west end and part way east along the north wall. The four cupolas and the 8-cylinder motor block and flywheel operations occupy the rest the floor space along the north wall. The remaining floor area con- sists all the center portion the building, most the south bay and all the newly constructed leanto. previously pointed out, the leanto has been given over cleaning and testing operations. was most con- a units being used for the production small castings. Adoption the group plan does not mean that pro- duction not flexible. For instance, the unit which ordinarily transmission castings may used for the production intake manifolds and exhaust pipes. Some Cleaning Operations Performed Mezzanine Floors Most castings made the floor area which has been described pass directly the cleaning department. RANSMISSION Cases Are Made Molding Unit venient, therefore, (Above). Tempered sand handled means Cylinder heads, how- make use the foun- dry floor space such way that certain loca- tions would given over for definite mold- ing operations and, therefore, the instal- lation overhead conveyor system, cast- ings would ported only short distance the cleaning department. Accordingly, four Beardsley Piper Co., Chicago, sandslinger units with loop conveyors were installed—two near the west end the building and two near the east end. These units were placed pairs, back back, speak, that pouring stations the adjacent conveyors could reached single overhead monorail system. Six-cylinder motor blocks are made one unit; cylinder heads another; transmission cases the third and either transmission castings exhaust pipes the fourth. Open floor space between the two pairs these Iron Age, April 17, 1930 belt conveyors Sandslinger Molding Systems Are Installed Pairs, with Pouring Stations Adjacent Each Other (Top, next page) then chuted the fin- Castings Are Delivered the Cleaning Room Over- head Conveyors next page). The platform con- veyor along the wall the left transports cleaned castings the shipping department ever, are conveyed mezzanine floor, where they are cleaned and ished casting conveyor, which delivers them the shipping room. The four molding units are interest be- cause each self-con- tained and, further, sand handled belt conveyors, rather than elevators. Each unit consists platform loop conveyor, shown the diagram, furnished the Palmer Bee Co., Detroit, inside which, one end, sandslinger. The shakeout station the opposite side the loop from the pouring station. Copes and drags are handled hoist stationary grid, from which the casting picked overhead conveyor which deliv- ers the cleaning department. Sand falls through the grip hopper. apron conveyor takes sand from this hopper and delivers = | j | | 1141 — rs J * a ¥ The Age, April 17, 1930 f ‘ belt conveyor, which also carries spillage from the re- volving grill turntable (14 ft. diameter) the sand- slinger. This spillage fed the belt conveyor strike which sand through slot pan located beneath the turn- table. This belt conveyor then follows incline pass- ing under separately in- stalled magnetic pulley mechanism, which removes iron and chutes one The belt then carries the sand still higher point, where unloads vi- brating screen. The sand then drops pug mill, from which discharged second inclined belt conveyor for delivery above rotating The sand then drops into overhead storage bin, from which delivered the sandslinger apron feeder. The bin has capacity tons and the unit has capacity tons sand hour. Summation the molding stations for large castings discloses that there are seven sandslingers use. one unit men make 500 six and eight-cylinder block castings hr., using 28-in. 48-in. 13-in. copes and drags and 30-in. 56-in. 15-in. copes and drags. this unit, others mentioned, the number men designated in- cludes supervision, core assemblers, core setters, molders, clampers, pourers, runner box makers and shakeout men. another unit men produce 900 flywheel molds daily. Twenty men working another unit produce 450 standard six-cylinder blocks. Fourteen men produce 600 transmission cases day and seven men make approxi- Iron Age, April 17, 1930 HAKEOUT Sand Passed Through Vibrating Screen (Above) Pug Mill All Cleaned Castings Come Conveyor Cen- tral Point( Below) the Shipping Room mately 500 manifolds each working day. has been previously mentioned, the overhead conveyors, made Palmer Bee Co., reach all shakeout stations. They deliver cast- ings short distance across the building the long and narrow cleaning depart- ment, which laid out sections handle the type conveyor given point. Grinders, tumblers and sandblast equipment are mounted where needed near the north wall the clean- ing department. Extending along the south wall Chain-Belt Co., Milwaukee, conveyor, which delivers fin- ished castings the west end the structure. Those castings which must under- hydrostatic pressure are tested and, passed, are replaced the conveyor for immediate delivery the shipping room the far end. Castings Are Distributed Motor Trucks means overhead crane serving the shipping room, castings are loaded trucks for distribution various departments the Kenosha plant, for delivery the Racine plant, the one Milwaukee. Trucks going Milwaukee are designed that, for the return trip, they can loaded with bodies from the Seaman plant for delivery Racine and Kenosha. Underneath the floor the cleaning department belt conveyor which passes under the floor grids and then passes under magnetic pulley. This conveyor meets like unit which serves the 8-cylinder block line. Waste sand gathered delivered hopper three-car a | capacity which stands the yard. Sand blast equipment used this foundry was furnished the Pangborn Corpo- ration, Hagerstown, Md. interesting sidelight the outcome the use conveyors that two electric trucks now operate the day turn the foundry and the cleaning department; eight were used. Electric trucks are longer needed the night shift, whereas previous the installa- tion the new equipment four trucks were kept opera- tion night. present the foundry cleaning room and core depart- ment occupy 20,900 sq. ft. floor space. The daily aver- age melt hr. 290 tons. The casting loss, including machine shop scrap, has been cut and the core loss has been reduced. One hundred and fifty tons core sand used daily. Piecework has been discarded and group piecework plan introduced. Each group men has leader. sched- ule set for each group and when they complete their schedule they may leave for home. Each leader con- stantly alert carelessness and laziness the part the men under him, and quick make changes when necessary, because paid only for castings which are accepted the shipping room. The new rates have been set that the men earn more than they did under the straight piecework system. British Ideas About Welded Pressure Vessels probable that the (British) Institution Mechan- ical Engineers will appoint committee formulate rules for the design and inspection unfired pressure vessels, and for the certification completed units. Ex- tended discussion this matter reported contempo- rary journals abroad, centering comprehensive paper Schuster “Strength and Design Fusion Welds for Unfired Pressure Vessels.” Approaching the matter from the standpoint inspecting engineer for insurance company, Mr. Schus- ter analyzed the causes many recorded failures such construction, and assembled the conclusions many tests suggested code which, followed, would have avoided all the casualties known him. The result pro- cedure which quite conservative, and limited ves- sels in. diameter. recommends the use low-carbon plate flange steel quality, which the maximum strength the weld should never considered exceed 54,000 per sq. in. view the Board Trade rule fixing maximum efficiency per cent for hammered weld, the same recommended for fusion welds which are not hammered. Applying, then, factor safety four gives maximum permissible stress the joint 6750 per sq. in., (somewhat higher than permitted the present code the American Society Mechanical Engineers). Experiments with many varieties lap and reinforced joints show that none them improvement plain butt joint, welded from both sides, except the plan used Switzerland welding short transverse straps intervals both inside and outside. For this Mr. Schuster would permit 12,000 Ib. per sq. in. design stress, depending upon other details construction, principally the use circular oval cover strap, welded all around, the weak junction longitudinal with circular seam, and the use specially dished heads which avoid large secondary stresses the end the shell. Special emphasis all the discussion has been laid upon determining the welder’s skill testing sample joints made under works conditions monthly intervals. Test- ing completed vessels done about twice the working pressure (the exact figure depending the de- sign and use), the joints being vigorously hammered the time. Mechanized Details Augmented Foundry Output STRIKING example increased efficiency accom- panying increased production the foundry was mentioned Arthur Tuscany, manager, Gray Iron Institute, Inc., Cleveland, address, “Important De- velopments the Gray Iron Industry,” presented the thirty-second annual meeting the American Ceramic Society and the American Refractories Institute To- ronto, Canada, last month. making automobile engines the crankcase core usually rammed two halves which are subsequently pasted together, said Mr. Tuscany. These cores must very accurate and has been customary rub down the joint the core hand insure satisfactory casting Production, under these conditions, was approximately half cores per man per hour. the Wilson Foundry Machine Co., Pontiac, Mich., machine was built finish the joint between the two halves this core grinding. Two men with this equip- ment actually turned out regularly 125 half cores per man per hour, compared with the preceding method. The hand-jointed cores varied from piece piece much 3/32 in., while the machine-made cores never varied more than 1/64 in. hand the quality the product depended the workman, whereas under the mechanical method depended solely the set-up the machine, which had checked only intervals three four days. another case, the testing bench where the cylinder blocks for Buick cars were subjected water pressure before delivery the machine shop, men working hand each tested sets cylinders per hour. The holes were closed with clamping pads and expanding plugs. After becoming worn the plugs would occasionally blow out, drenching the operator, who, when not under the eyes the foreman, became inclined reduce the water pressure. This resulted some leaky cylinder blocks finding their way into the machine shop, with generally deleterious effects the quality the output the foundry depart- ment. Later semi-automatic test rig was provided which stopped all the holes securely and made impossible for the operator reduce the water pressure. This device was operated one man who was thus enabled handle cylinder sets per hour. Three men were released for other work, but, what was more important, the substitution accurate machine for human frailty not only speeded production but materially improved the general quality the castings turned out. The Iron Age, April 17, | 1 | | Value Employees’ Suggestions RIOR the advent scientific man- agement, industrial engineering, and administration, employers and employees—manage- ment and men—were re- garded and distinct classes, each having nothing common with the other. The ployers management making much money possible their own way, fair means otherwise. The employees workers were concerned only with exerting little physical effort possible earn necessary livelihood. the average worker report expenditures cash balance represents conglomerated mass account num- bers and figures, just the same micrometer caliper appears the average accountant pretty little in- strument serving useful purpose. Nor necessary that the employees sit the council table management and take part the deliberations the board direc- tors, participate the conduct the business. The average worker would much out place there the average director would the bench the mechanic. Valuable Ideas Latent the Organization Any employer who has the desire take his employees into his confidence the question business operation may without disclosing any matter confidential nature. This may accomplished through the medium suggestion, and the benefits derived therefrom can- not estimated. The fact cannot lost sight that all workers are not mere automatons. Some possess un- dreamed ability and some have reservoir knowledge untapped. the ideas these that the employer should har- ness and put work for the benefit his business in- dustry. Some managers not like seek advice and others object having proffered. should remem- bered that all executives are theoretical, but all are not practical. Very often executive conceives idea thoroughly theoretical from every angle, but when that idea put into practice appears hopelessly impractical and abandoned. All employees are practical, but all are not theoretical. Very often employee conceives idea thoroughly practical, but when that idea tried out fails for the *Ind trial neineer Wa é Iron Age, April 17, 1930 Tact and Absolute Fairness Essential reason that the theory its relationship some Promoting the System Rewards other function was not Should Adequate and Favors taken into consideration. Combining Practice and The ideas practical employees who have knowledge the theory management are the ideas which will bene- fit the employer. They may range from moving the location single machine, means increased production, safeguard- ing and conserving the issue and use expensive mate- rial. the combination the unusual—the practical- theoretical man—that the employer should eager take into his confidence the question business operation. Such men are present every organization, large and small, though not always known. The machine operator day may deep student industrial management Potential managers and executives can found offices and departments business opportunity afforded them develop their latent ability. When production lagging the employees can often furnish the cause which the foreman unable explain. When the finished product being rejected large num- bers, the employees often know the reason when the inspec- tor mystified. When there lack cooperation and coordination management, the employees often hold the key situation which the manager does not under- stand. They are frequently the key-men industrial and business situations within the organization. Men Must Approached Tactfully get the very best ideas out employees—those which are really worth while and have value—the em- ployer must make them feel that really desirous having their suggestions; that his enthusiasm this respect genuine and not passive. contrary attitude contributing factor the common lack interest the part employees suggestion schemes and the cause failure many suggestion systems. the employees get the impression that the osten- sible motive the management subterfuge find out all they can about the inside workings, few suggestions will offered and those submitted will most likely savor criticism rather than constructiveness. The critical suggestion does not want discouraged, for, when at | — | | submitted good faith, very often has some value. proof the employer’s desire make use beneficial suggestions suitable reward recognition should offered, about which more will said later. The entire matter suggestions should brought the attention all employees businesslike way, and thus the employees will have cause believe that the employer’s intentions are other than the best. Foremen should all times encourage the work- men under them offer ideas, and make them feel confident that they will not made public. make this assurance effective the notice should make plain the fact that, should any employee offering sug- gestion desire, his name will not disclosed. such cases the employee should instructed write the sug- gestion and not sign his name. His name, check clock number, and shop, department office which as- signed should written separate paper at- tached the one bearing suggestions, visors should prevented from interfering with any employee submitting any kind suggestion. such action discovered the guilty party should severely disciplined. Often the only employ- the workman knows his immediate supervisor; caters him, and afraid any- thing which might bring displeasure from his “boss.” For this reason foremen and super- RACTICAL ideas wherever originating. Men daily contact with details business often see how things can improved; man- agerial duties may not permit similar observation the part the “boss.” This article tells something the way which suggestion system may worked out, with mutual advantage employer and employee. Also, some the pitfalls are pointed out. the em- the suggestion. All envel- opes should collected stated periods and deliv- ered the recorder the suggestion board who opens them. All suggestions re- ceived should courte- ously acknowledged. When the employee’s name not disclosed the suggestion should given number and record made, together with the ployee. acknowledging the receipt such sug- gestion the employee visors should not allowed take advantage of, coerce, their sub- ordinates. such gestion scheme be- comes the respon- sibility the supervisors and they should instructed. There are still some who dislike giving credit those under them. not question credit, but one better and more economical management. Plea for Cooperation Employees accomplish the desired results there should installed suggestion system and suggestion board. notice should prepared and posted informing the em- ployees the employer’s desire inaugurate suggestion system, and urging all employees cooperate making the project success. The notice should carefully worded, that the employees will have reason doubt that suggestions any kind for improvement the busi- ness are both welcomed and desired. The notice should also make reference whatever rewards the management intends make for any suggestion considered worthy adoption. Anonymous Suggestions Welcomed Particular places should designated and listed where employees can place their written suggestions boxes other depositories. rule most employees not like hand their suggestions foreman supervisor, and not care have their names disclosed unless the sug- gestion has been accepted. For this reason there should place places designated, according the size the factory business, where they can deposit them sealed envelopes. Those desiring should allowed make use the mails. this way the employees will feel perfectly free offer their suggestions without fear prejudice accu- sation from any immediate supervisor. Every means should taken assure them the privacy their number assigned it. The recorder the board the only person who should have knowledge such infor- mation and should not disclosed anyone until the suggestion has been accepted, and then only official way. betray the confidence the employee any such case render the whole suggestion system value- less—the one thing most guarded against. How Handle Suggestions Offered suggestion board should appointed, composed least three executives who are qualified pass upon the value the suggestions offered. There should also recorder the board, and this position should filled the personnel manager like authority. Once month the recorder should submit the board all suggestions received, and each should carefully considered its merits and the advantages gained its adoption. Upon completion the board’s deliberations report should submitted the head the firm, giving each suggestion full, its number, and the board’s recommen- dation regarding it. the head the firm approves the recommendations the board, the recorder should notify letter the author each suggestion the final action taken. Letters commendation and notices cash awards should signed the head the firm. Trial Deferred Acceptance advisable try out some suggestions before finally accepting them. There will those offered which are impractical adoption the time, yet have poten- tial value for future use. suggestion which cannot used the time offered should not rejected. may discourage the employee from submitting others. When suggestion once offered, contact arises which may result unlimited benefit the future. The employee feels that his interest has been rewarded measure, and incentive created renewed and better effort. All suggestions having merit, which cannot adopted the time they are offered, should kept record. later date the employer may find among them the very idea seeking. Whatever awards are offered agreed upon should The Iron Age, April 17, 1930—1145 paid without limitation, prevent distrust. They should also made the basis absolute equality. The worker should receive the same supervisor. Such fair practice will serve deterrent supervisors from interfering with employees offering suggestions. The nature and character awards depend upon the partic- ular industry business. Some firms offer stipulated amount money awarded each month the employee submitting the best suggestion. Others set aside fixed amount dis- tributed among the employees whose suggestions are accepted. Others promote pay advance position those employees who contribute the betterment man- agement, operating processes, production incentives. The latter plan results the discovery latent foremen and executives. Patent Cases Must Watched suggestion accepted which involves patentable feature, caution must taken safeguard against pos- sible future litigation. this connection two distinct cases arise, namely, that workman who develops valuable invention his employer’s time, using his tools and materials; and that workman who develops the invention his own time and with his own materials home. the first case the employer has the right use the invention his shop. has right, however, use the invention anywhere except his own shop. This right limited that, moves away sells that shop, cannot take the right use the patent with him. the second case the manufacturer has claim over the invention all, since the employee has right his ideas, provided uses his own time and materials develop them. This holds, even though the invention may the line work the employer. the employee hired for the purpose inventing, everything does the line the company work belongs the company. invents something that not the line the com- pany’s manufacture, cannot hold the invention. Written Contracts Often Help avoid pitfalls the employer should, when adopting patentable suggestion, enter into written contract with the employee whereby the employee for consideration agrees assign his idea and invention the employer. this way the employer will relieved any legal responsibility during the tenure employment the inventor and avoid possible lawsuit should the invention used after the employee has left his service. conclusion, the value suggestion measured the desire the employer take the employees into his confidence the question business operation. This may accomplished the easiest and most satisfactory manner allowing, inviting, and encouraging the em- ployees submit their ideas the form suggestions. Knoeppel has said: know greater re- sponsibility man, than that the one—whether worker, supervisor, executive, owner, banker lawyer—who, industry, either accident which inexcusable, design which unpardonable, fails all his power help workers give birth their mental children.” Allow and encourage your employees think and you prevent industrial and business waste. Manufacture and Properties Light Welded Tubing walled steel tubing, made electrical resist- ance welding Steel Tubes (Inc.) Cleveland, has been investigated the Bureau Standards and the findings published Messrs. Whittemore, Adelson and Seaquist Research Paper 161. Method Manufacture Such tubing made mild basic steel; chemical anal- ysis approximately follows: Manganese per cent 0.015 per cent less than 0.01 per cent Box-annealed cold-rolled strip passed through series rolls give tubular form, with edges accu- rately butted. This blank then passed the rate about ft. per min. between two electrodes which make continuous contact both sides the seam. Passage current brings the edges welding temperature and they are squeezed together while this heat proper mechanical fixtures. welded the seam has small irregular burr both inside and outside. The outer surface may smoothed planer tool leaves the welding machine. Diam- eters are from 0.02 0.04 in. greater than nominal. For dimensions higher precision and smooth inside and outside surfaces, the welded tubing passed through swaging machine. This has slightly tapered dies proper curvature for the outside diameter, and the tube hammered stationary mandrel correct inner diam- eter. without the inside mandrel, well cold rolling circular-grooved rolls also produces tube with smooth outer surface, but which retains the slight bulge along the inside the welded seam. Tubing also Iron Age, April 17, 1930 available cold rolled over mandrel, and the annealed condition. Tubing tested the Bureau Standards had nominal dimensions ranging from in. diameter 0.03 in. wall in. diameter 0.08 in. wall. The swaged tubes were quite accurate dimension; per cent varied less than 0.003 in. outside diameter. even higher degree uniformity wall thickness was observed—a resultant from the accuracy with which the strip was rolled. Swaged and rolled tubes have about the same tensile properties when tested full section (figures are given below), and are approximately per cent stronger than the tubes welded: Ultimate strength........ 57,500 per sq. in. 53,000 Ib. per sq. in. Proportional limit....... 37,000 per sq. in. Elongation in....... 13.5 per cent Elongation in....... per cent Modulus lb. per sq. in. Under hydrostatic tests the bursting strength short pieces was higher than the tensile strength circum- ferential strips cut from the tube (probably due end support). Only one specimen fractured the weld, and this was annealed tube, one group which the others burst outside the weld and lower pressures. Fractures otherwise bore definite relationship the welds. Average bursting pressures are follows: welded with outside burr cut. .60,060 per sq. in. Swaged and annealed........... 47,840 per sq. in. The research paper from which these data have been taken contains detailed information crushing tests, torsion tests, strength and microstructure the weld, hard- ness the tubes, and ability flange. — war. Bridge Wire Requires Fine Stee Outline Fabrication Processes Indicates Necessity Close Coordination All Departments Intent Producing Nothing But the Best FREDERICK WESTPHAL* the most masterful achievements for steel company this era the complete manufacture bridge wire such furnished the Philadel- phia-Camden, Hudson River, Detroit-Windsor and similar suspension bridges. start the open-hearth furnace charge (of course not overlooking the great importance the blast furnace operations) and follow through satisfactorily finished wire ready for shipment, calls for well-experienced, courageous and fully cooperative organ- ization. Making bridge wire involves many different steps and processes, that equipment and organization must united into strong chain succeed the task and make profit. This article will dwell mainly with the processing from the billet through finished wire, but make com- plete, suggestions are given from the start manufacture, that is, from the charge into the open-hearth furnace. Furthermore, the object sought helpfulness for the future and not for controversy. The problem follows: make 0.192-in. gal- vanized wire with the following principal properties: *Superintendent wire department, Sheffield Steel Corporation, Kansas City, Mo. Sometime assistant superintendent wire de- partment, Jones Laughlin Steel Corporation, Pittsburgh, and rope engineer, American Steel Wire Co., Worcester, Mass. The head piece construction photograph the lower deck roadway, Manhattan Bridge. All views secured through the kindness Robinson Steinman, consulting bridge en- gineers, New York. minimum tensile strength 225,000 per sq. in., gal- vanized withstand five immersions the Preece test, with elongation not less than per cent in., and stand wrap around diameters without sign fracture the steel. Other specifications are imposed too numerous mention here. Quality the Steel attaining the above results from the wire the open- may work the following ladle analysis: 0.75 to 0.85 per cent 0.50 0.70 per cent 0.10 0.20 per cent Phosphorus ... 0.04 (maximum) Sulphur . 9.04 (maximum) The six productive methods making steel this country today are: (1) crucible, (2) acid open-hearth, (3) basic open-hearth, (4) acid Bessemer, (5) duplex (Besse- mer open-hearth), and (6) electric furnace, acid basic lined. The best steel could obtained from the crucible and electric methods. Crucible steel is, course, impractical account the very small sized heats and prohibitive cost manufacture; electric the same category this time, but very likely electric steel furnaces the future may developed large enough size han- The Iron Age, April 17, 1930—1147 | | dled practically and profitably for bridge wire. Bessemer the required analysis obviously undesirable, and although some duplex steel may work satisfactorily should not used because inconsistencies segrega- tion, oxides and non-uniformity structure. This leaves two methods for making the steel, namely acid and basic open-hearth. Heretofore acid has usu- ally been specified for bridge wire. known that cleaner steel, and works nicer the various stages the process. Furthermore, comparison acid and basic steel practically the same analysis shows that the long run acid steel little more consistent final phys- ical tests. However, these facts not mean that basic steel cannot used. was formerly believed that cer- tain sizes and grades wire rope had made acid steel, but wire rope makers are now able make good wire rope using basic steel similar analysis they were formerly able produce from acid steel. Extreme care should taken choosing scrap for the open-hearth charge avoid impurities and alloys, such automobile scrap would introduce. Scrap for steel this nature should obtained analysis, such shear scrap, crop ends and high grade melting scrap. plant oper- ating blast furnaces could the extreme furnishing the hot iron from ores carefully selected for Bessemer iron, thereby having minimum sulphur phorus. view the above facts, opinion that basic steel made with the same care acid steel, and par- ticularly well selected raw materials, could used for bridge wire. Ingot Practice Prime Importance RACTICE varies steel works the size heats and ingots used, but the heat should not exceed 100 tons, and the teeming should such speed pre- vent inclusion gases and bubbling. The ingot molds should the hot top type counteract piping and segre- gation much possible. maximum size would lb. Care should taken allow complete solidification the steel before stripping. Uniform and penetrating heating required the soaking pits; temperature should not exceed 2200 deg. Fahr. before blooming. 1148—The Iron Age, April 17, 1930 important keep individual heats steel sepa- rate from one another their passage from the open- hearth the finished wire. Assuming complete records are being kept each operation, reference and study can made any difficulty met subsequent operations keeping heats properly identified and segregated. two-high reversing blooming mill the head roller tempted take too great reduction per pass, thus injuring the steel with telling effect later. Three-high blooming mills are preferable, because the reductions can adjusted the roll setting and are taken more evenly. The bloom, before going the billet mill, should cropped top least even per cent, even though hot tops are used, and this point careful inspection should given insure that all trace piped metal discarded. course, least per cent the bottom back end the bloom should discarded. Some mills have surface scrapers act the bloom some passes the billet mill. This good feature, but the nature high cargon steel surfaces such that this detail should not necessary previous precautions and good practices have been closely observed. Billet and Rod Mills Require Careful Adjustment SSUMING that Morgan rod mill roll the rods, the billets should in. square, ft. length, weighing approximately 400 order give the de- sired length finished wire. Since the future holds forth probabilities that bridge wire furnished longer coils, the majority the latest rod mills are designed take heavier billet than above stipulated. The heavier billet, course, easily rolled present-day billet mills. Before the billets are delivered the rod mill they should put over the chipping beds, all four sides closely in- spected for seams, laps and slivers. Such defects should marked and chipped out, too deep the billets should rejected. Both ends should carefully exam- ined for visible piping segregation. From the open-hearth charging floor through the finished and inspected billet the effort made point out very that detailed line the best steel works practice required for the basis bridge AIN Cables for Long Suspension Bridges Are Usually Spun One Wire Time, But Spans 1200 Fr. Have Used Assemblages Rope- Stranded Cables. This view shows the com- pacting such cables into the main support for bridge across the Rhine Cologne, Germany. the opposite page the recently com- pleted St. Johns bridge across the Willamette River Portland, Ore. Each its cables contains twisted strands | a 7 ; » : & : Message ITH this issue THE IRON AGE passing other hands the responsibilities its editorial direction which have carried for most the years connection with the paper. William Macon, associate for years, managing editor for the past years, has been appointed fac succeed editor-in-chief. What his loyal co-workers have done make great industrial paper greater has been known and read these recent years wherever THE IRON AGE has gone. This not the place enlarge the ideals and the accom- plishments THE IRON AGE the past years, Such comment may better reserved for the 75th anniversary issue eff which will appear the next few months. enough say here that have striven constantly for these four the chief aims industrial journal: publish concerning the manufacture, use the products its industry the largest possible amount essential information that can found nowhere else. cre increase the utmost the use the products its constituency. that end advocate constant improvement the quality all products and new economies their manu- facture; the same time anticipating changes the economic trend and the desire the consumer. Findley dictory. THE IRON AGE and its readers will still have his counsel. has consented serve editor emeritus. relinquishes active editorial direction, but are con- fident that time time his stimulating thoughts will continue grace the pages that have reflected his personality these many years. There are other paths than journalistic that now would travel, but his interest THE IRON AGE and the problems its readers will run on. His successors are dedicated the same principles that has cogently and tersely set forth having dominated his with profound regret that accept the resignation Alvin Findley active editorial head THE IRON AGE. His broad knowledge, sound judgment and penctrating analytical faculties have contributed conspicuously the upbuilding this publication for the past years. man courage and high personal standards, has kept THE IRON AGE high journalistic plane, never compromising principle for the sake expediency. saw his paper powerful instrument for extending the use industrial prod- ucts and thereby enlarging the life and increasing the well- being all the people. idealism has not been vain— accounts for the high respect that THE IRON AGE com- mands throughout the land. Mr. Findley’s policies will carried on. editor emeritus and director the United Business Publishers, Inc., will continue give THE IRON AGE the benefit his counsel. His successor editor his collaborator and understudy for many years, William Macon, heretofore managing editor. engineer, graduated from Cornell University Mr. Macon intimate touch with the many technical develop- ments that have wrought miracles American production. 4 be age Our Readers hold continually its readers their highest aim the advancement the public good. that platform the editors THE IRON AGE have applied its full power the upbuilding our greatest manu- facturing industry, the production and working the world’s basic metals. They have never forgotten their obligation, view the common thought THE IRON AGE insti- tution and the fact that the public mind has long been identified with the commanding place metal working our industrial life. Never has the editorial staff this journal worked good effect this year which rounds out three-quarters century the country’s preeminent publication industry. Never have the editors had such resultful contacts with the men who are making history the metal trades. And never have our readers freely commended our editorial pages. have great satisfaction knowing that the years ahead these most valued associates many strenuous labors will steadily in- crease the enterprise THE IRON AGE and bring new peak prestige. policy for quarter century. If, the course are privileged review achievements comparable some small measure with the advances THE IRON AGE scepe and influence under Mr. Findley’s stewardship, will with full recognition the strength the publication when entrusted our hands. His long association with THE IRON AGE has made him equally conversant with commercial and economic problems. digger for facts training and master detail, also has breadth view and catholicity interests commensurate with the magnitude the industry that THE IRON AGE serves. time when advances technique and output are con- ditioned never before keen competition within industries and