The Iron Age 1930-04-24: Vol 125 Iss 17

ESTABLISHED THE IRON ACE New York, April 24, 1930 Shop Training Fits Boys for HEY succeeded from the very start, and once became leaders and teachers other mechanics, suggesters new methods work and new means for its accomplishment.” Thus the partnership Francis Pratt and Amos Whitney, established 1860, characterized Prof. Joseph Roe his treatise English and American Tool Builders. These founders the Pratt Whitney Co., Hart- ford, Conn., had served apprenticeship under able masters, and, like the Colt Armory, their shop became, turn, the training school for many men since promi- nent the machine tool and allied industries. The roster those who have worked the Pratt Whit- ney shops includes Worcester Warner, Ambrose Swasey, Foote, William Gleason, Bullard, Positions pointe, Gardner, John Johnston and many more. Apprentice training such plant naturally deep rooted. Noteworthy also the present congenial environment. Many the skilled mechanics, fore- men and other executives with whom the apprentice daily contact are graduates, while the president the company, Clayton Burt, out- standing product another great training school, that the Brown Sharpe Mfg. Co., Providence. Thus, the concrete examples around him, ambitious boy can see the future possibilities his training; being associated with men who have traveled the same route, may feel that his training under sympa- thetic and authoritative guidance. For many years the company has had from 1269 4 { | apprentices the shop all times, and planned increase this number. Three- quarters the boys enroll for the machinist apprentice course. From their ranks hoped ultimately recruit foremen, inspectors, produc- tion men and other execu- tives. Having skilled mechan- ics, familiar with the com- pany’s methods, standards and products, available various key positions the organization is, course, immense advantage the company. Training includes varied shop experience, supple- mented classroom instruc- tion four hours each week the Hartford Trade School. The course for machinist and molders laid out cover period three years; the pattern- making course covers four years and the core-makers’ course, one and IG. 1.—Applicants for Apprentice Must Pass This Stenquist Mechanical Aptitude Test. The cover page this test and that the Otis test the opposite page—both copyrighted—are produced permission the World Book Co., Yonkers, 1210—The Iron Age, April 24, 1930 Narne STENQUIST one-half years. the completion his regular course the young man desires more intensive experience any branch, for example tool mak- selected. The system organized around supervisor apprentices. being Pratt Whitney graduate, and hav- ing served the company various executive and other capacities, the present supervisor well qualified, both through thorough knowledge and experience the trades taught. Careful Selection Applicants One point emphasized de- scribing this apprentice system the care exercised selecting applicants for training. the first place the boy must have sufficient education and must, upon test, reveal mechanical aptitude. must give evidence definitely knowing which course wants, and show promise going through his training the finish. The boy who will not study, who has MECHANICAL APTITUDE War TEST DIRECTIONS Part 1 belongs with, is used with, orisa part of one particular Part : rs with Letter H in Part 2; so His written beside 1 in Letter D: so D is written beside 2 in the list of answers. No. 3 of answers. No. 4 belongs with Letter C; so No. ¢ ongs with Letter P; so P is written beside ¢ in wkict. If you are not sure, guess. Try all * gy cr Stare Total T Score I STEM ~ 7 th Part Thus, N it st ot N I \ \ | position continue his high school college postpone starting his practical shop training. character qualifications. The company wants train normal, healthy minded young men who have some ambition, and especially glad enlist boys who may ultimately qualify for positions responsibility with the company. From past experience the company has de- termined upon the ages between and the best for starting apprentices. rule, boys older than are not sufficiently adapt- able, while those under usually have not enough education. Preference given high school graduates who have had mechanical drawing, mathematics and voca- tional branches; about one-half the appli- Enlist Boys from All States Applications are received from boys all parts the United States. waiting list maintained, and when one more apprentices are wanted SELF-ADMINISTERING TESTS MENTAL ABILITY the applicants are notified. with one his parents his INTERMEDIATE EXAMINATION: FORM tance receive application Read this page. what you blank designed give infor- open this paper, turn over, until you are told these blanks, giving your mation regarding their edu name, age, Write cation, employment, alth Name and other matters that might aid the supervisor sizing Teacher Dat 192 the applicant. Grade School City prospective appren- tices receive copy the sample question already answered correctly, Notice how the question answered Trade Pratt Sample: Which one the five words below tells what apple This booklet, attractively answer the questions ship, living conditions many views the shop de- A foot ist ia toa how many cents will pencils cost 2.— Fitness the with the Prescribed School time basis, the test also boy’s interest his fur- ther education The Age, April 24, view, which largely matter sizing the applicant, the boy requested solve few mathematical problems check-up his claims schooling. The application blank sent prospective apprentices living distance accompanied letter which invites further correspon- dence. From the filled-out blank and the ensuing corre- spondence the supervisor determines whether arrange for personal interview the plant. after the personal interview the boy proves accept- ible, sent the shop hospital for physical examina- tion. passes this successfully sent the Hart- ford Trade School for Stenquist Mechanical Ap- the authority the foremen, supervisor, are disciplined. the apprentice progresses through the shop the Progress Record card, Fig. maintained the super- visor from information received from the foremen. This rating card serves mainly detail record the appren- tice’s progress, but also believed have beneficial psychological effect all concerned. acquaint the boys with the products the shop they receive bulletins and other trade publications issued the company. the completion their apprenticeship, the graduate gets two diplomas, one from the company and another from the Hartford Trade School. pocket card and part, Fig. 1), and the Otis Self Administering Tests for Mental Ability (Fig. 2). The Otis test intended show fitness ahead with the school sis, and therefore lack interest may reflected any dawdling the part the boy answering the questions. The appli- cant’s interest carefully determined all stages his hiring and training. the boy passes these tests placed the waiting list notified start his trial period the plant, the case may be. with the company. Having been accepted ind started his course, the boy, parent guar- lian enters into formal Apprenticeship Agreement. The guardian required pay the sum $25 the expira- ion the trial term three months. The company agrees that upon the completion the term apprentice- ship give the apprentice its equity one-half the cost the box tools given the apprentice upon signing the agreement, certificate apprenticeship and the sum $125, this being refund his initial deposit $25, plus bonus $100. Although this agreement exe- cuted after probationary period three six months, apprenticeship actually dates from the beginning the probationary period. The apprentice starts his school work two weeks after his matriculation. Before the apprentice taken into the shop, re- ceives instruction safety practices, use measuring tools, shop rules, pay periods, etc., from the supervisor. From the beginning until graduation the supervisor keeps constant touch with the boys training. visits the boy his work several times week, talks with the fore- man assistant foreman, follows the Trade School progress the boy and, when necessary, checks the living quarters and general environment out-of-town apprentices. Each quarter the foreman makes formal report each boy the supervisor, who enters the record card, Fig. This later sent the Trade School for entries the school marks; report, accompanied letter, then sent the boy’s parents guardian the director the Trade School. the case poor marks, either school shop- work, the boy required report the apprentice supervisor. Boys who neglect their studies their work because slump interest, those who fail observe the rules the shop, who fail respond 1212—The Iron Age, April 24, 1936 Pratt Whitney plant, which has been training apprentices since its founding 1860, has graduated many men since prominent the machine tool and allied industries. Great care exercised selecting ap- prentices. The applicant must show very definite interest the particular training for which applies. cally fit, have sufficient preliminary edu- cation and upon test show mechanical aptitude. Character carefully considered; the company wants boys that will stick, and especially de- sirous enlisting those who may ulti- mately qualify for positions responsibility sented the company; this serves certifica- tion, convenient form, that the boy has duly com- pleted his apprenticeship with the Pratt Whitney Co. the completion his course the boy, now journeyman, taken meet the president and other major executives the company. meets men who, having served similar apprenticeship, can heartily congratulate graduates with having the backbone necessary complete their three four years practical training. And, through their own first-hand expe- rience, these men are able outline some the fu- ture positions which the graduate may aspire, providing his ambitions are backed continued determination through with what undertakes. must physi- requirements are Machinist Courses Comprehensive RRANGEMENT the Pratt Whitney shop spe- departments, such the milling, planing, grinding, etc., the parts all machines being routed pro- gressively the final operation, assembly. Machinist apprentices start one five departments, steel turning, drilling, milling, screw machine cast iron turning department. the course their training they through departments, spending practically three months each, and halfway through their course they put period the foundry. They work under the direction the various foremen and assistant foremen. The first piece every new set-up which the apprentice works taken the inspector the department, who inspects with the boy and shows him the reasons for any changes made. the first year the course the machinist apprentice may work the cast iron turning department, drilling and boring department, screw machine and the steel turn- ing department. One the first things learns the grinding tools proper shapes and angles for various work. The second year finds him the milling, thread milling, planing, hardening and the assembling depart- ments. the third year works the gear cutting and gear grinding, general grinding, assembly and the tool and equipment departments. Apprentices work all types lathes and, when skilled enough, they are permitted perform thread cut- ting and some the other finer operations that make toolroom practice. Drilling includes work single and * multiple-spindle machines and radials. Use jigs and fixtures part their experience, well the proper grinding drills, proper speeds and feeds for various ma- terials and the proper tapping holes. Instruction given hand screw machines includes set- ting up, the boys being required adjust the machine for PROGRESS RECORD MACHINIST APPRENTICE First Name Initial Jig and fixture work Deep drilling Unusual uses of the machine ( Company Number Company Last Name Performanc Ope (Pr BENCH AND VISE WORK | Filing | Hand Polishin — —— Reaming Fitting keys | Winding Springs | | Babbitting | Scraping to bearing _ Chipping oil ways Rem. broken sti ids & ‘taj | Scraping to to master late Fitting | | Laying out | Soldering _ DRILL PRESS WORK — permitted much grinding, because grinding usually being the last operation piece, spoilage can very large. For this reason grinding generally one the last jobs apprentice receives his course. Before doing much the assembling department the apprentice must have shown himself good machin- \ aamirted School Number Date _ Employed__ y drills for hard and soft metals ar per turning I | Precis jon work to gauge an d micromete measurement | Thread cutting External Right Hd. U.S.S Acme Square | } | + Buttress _Internal Multiple ~ Left Hand ; Chuck work |} ace plate work Drilling unusual substances such as glass, | marble, tik | —t + + LATHE WORK | Eccentric work | Fits ng tools | Running acing | Press traight turning | | Shrink given job from the blue- 3—The Formal Report Card ist and familiar with machine print. Working knowledge automatic screw machines also available and opportu- nity given later build this knowledge the desire. milling, the boys start with the rougher and simpler tration) Made Quarterly. The shop record furnished the foreman the department which the apprentice working. With the Trade School marks entered, the report sent the boy’s parents guardian IG. 4—The Progress Record (lower illustration) Serves Mainly Detail Record the Appren- tice’s Course Through the Shop. maintained the supervisor apprentices tool operations. this de- partment the apprentice gets his best experience ma- chine tool design and meth entire machine the process assembling and the rea- sons for every dimension, jobs, and constantly re- turning the milling ma- chine various departments throughout their training, they receive comprehensive training this class ma- chine tool. Proper clamping the work, grinding tools, removal casting strains proper roughing cuts and the correct method finishing, are taught the plan- ing department; use the square and bevel protector and other planer work measuring tools. Experience the grinding department includes work cylindrical, internal, surface, cutter and other types grinders. general the boy must fairly skilled before rather than merely having follow blueprint instructions. also takes part the “running in” machines before their shipment. Toolroom work includes making jigs and fixtures, experimental machines and special small tools and gages. working limits 0.0001 in. and better the machinist apprentice learns the meaning close accuracy. applying himself his work, the apprentice may ob- tain unusually thorough training that will serve substantial foundation for advancement positions re- sponsibility the mechanical industries. The Age, April 24, 1930—1213 St or RECORD KEY \ RECORD A | o x. ist Quartet | 3 “308 | _ Quartet [Ag | | | = | mall Parts Heated Time Schedule Electric Furnaces Automatically Held Heat Receive Stipulated Number Parts Rack Fixture, Which Are Quenched After Scheduled Time WIRT ORTABLE tools, electrically driven, require the heat treatment numbers small parts. For example, addition the line accessory tools, portable electric drill requires the hardening and tempering armature shaft for electric motor, armature pinion, first intermediate gear and pinion, second intermediate gear and pinion, spindle gear, and numerous small parts such keys, washers and dowel pins. For such operations, Black Decker Co., Towson, Md., formerly used gas furnaces. Production consists porta- ble electrically driven tools very high quality, such drills, bench and pedestal grinders, valve grinders, valve refacers and stands, and tools for such equipments. Dur- ing period years, the old furnaces have been replaced electric furnaces, until now the heat-treating depart- ment per cent electrified with small electric furnaces, admirably adapted multiplicity small parts. One-half inch electric drills constitute approximately per cent the total production the Black Decker plant. average monthly production 1370 complete units this size involves 11,000 pieces per month heat treated for this item alone. The total cost the heat treatment for the parts for one these electric drills, including electric power, labor and overhead, $0.188, while the total factory cost the same parts $1.64 per tool. The total weight heat treated for all variety *Special representative, Westinghouse Electric Mfg. Co., Mansfield, Ohio. Iron Age, April 24, 1930 SCOTT tools approximately 25,000 lb. per month, 200,000 pieces with average weight oz. are available the power consumption the electric fur- naces, hence estimate was based upon furnace perform- ance, radiation losses, idling periods such heating the morning, well door losses while charging the furnaces. the basis hardening temperature 1550 deg. Fahr. and tempering 400 600 deg. Fahr., the monthly consumption for the 200,000 pieces would not in. excess 9600 kwhr. the power rate per kwhr. obtained from the Consolidated Gas Electric Co., the cost electricity would $115.20 per month. This approximately per cent more than the cost gas fuel for performing the same operation, with gas 70c. per thousand cu. ft. Therefore, will interest ob- serve why electric heat, the face increased fuel cost and added investment, considered the most economic form heat treatment. matter fact, the cost fuel electricity relatively small comparison the total heat treating cost the total factory cost. The cost electricity only per electric tool unit, whereas the total heat treating cost and the total factory cost $1.64, 6.6 per cent and 0.76 per cent respectively. Equipment Heat-Treating Department Parts heat treated consist mostly chrome-nickel and chrome-vanadium steels (S.AE. 3140 and 6145). Heat treatment consists hardening and tempering all parts, | | plus certain amount carburizing gears and pinions. Equipment comprises the following: Two 5-kw. preheating ovens, operating 750 deg. Fahr. maximum. Two 8-kw. hardening furnaces for heats 1475 1625 deg Fahr. One hardening furnace for heats 1475 1625 deg Fahr. One 15-kw. hardening furnace for heats 1475 1625 Fahr. One 40-kw. carburizing furnace operate 1650 1700 deg Fahr. One oil tempering bath, operate deg. Fahr. Une gas heated tempering bath (melted trate), to operate at %00 deg. Fahr. maximum. One Crescent washing machine using caustic a maxmium of 400 ni- soda solution. Much experimentation has proved the Black Decker Co. that for its particular product, with the best alloy steels obtainable, there are four conditions heat treatment that must met and accurately duplicated order obtain the maximum results from the steel, namely: definite rate preheating. maximum temperature held within close limits definite soaking period. definite rate cooling. The first three conditions are functions furnace, and are met ideal manner the electric furnaces. With known mass material each charge, placed within the furnace, the operator knows exactly how long should remain the furnace. his practice mark the time withdrawal the door shelf, chalk, when charge placed the furnace. Definite Heating Cycles Established Advance Complete time-temperature charts have been prepared for the various products Kaspar, the metallurgist, who also charge the heat-treating department. racked up, preparatory heat treatment, that known quantities are dealt with. Preheating ovens tem- perature 750 deg. Fahr. followed more rapid heat- ing the furnaces the hardening temperature has re- sulted decreasing the length time the work must re- main the hardening furnace per cent. This system heat treatment produces the following: l An accurate grain growth of the ste« 2 Definite physical grain structure Less oxidation or scaling of the work i Elimination of decarbonizatior Black Decker believes that when using electric heat, skilled heat-treaters are not required. The personnel the heat treating department now consists one fur- nace operator receiving 57c. hr. (who formerly was helper the machine shop); one helper 47c. hr. (who assists the furnace operator opening and closing the furnace doors while charging discharging, and does most the tempering), and one boy 36c. hr. (who racks the work preparatory heat treatment). fuel fired furnaces are used, would necessary employ heat treater $1.25 per hr., addition the helper and boy, and questionable one man could handle the work. The present furnace operator has his work systematized that can keep going easy gait all day and still handle large quantity small pieces. familiar with the various parts heat treated, and the length time required, all has think about mark the time withdrawal the furnace shelf, and then there that particular furnace that time, for removing the charge. has valves operate and combustion control. fact, judgment required the part the operator whether the work being heated properly. This labor saving minimum would amount the difference between $1.25 and $0.57 for 275 hr., $187 per month. Quality Improved and Cost Reduced Accuracy the electric heat treatment (duplication results) has saved through reducing the number parts scrapped after being partly processed. For example, OUR the Electric Furnaces the Heat-Treating Room the Black Decker Co., for Heat-Treating the Parts Its Portable Electric Tools. Each furnace automatically controlled the correct tem- perature, depending upon the product being heat treated. Each batch the furnace exact length time The Iron Age, April 24, 1930—1215 special cases. Load tests are made each screw driver bit chuck and subjecting overload. Under this per cent the bits used fail, resulting complete loss; failure lace bending the bit end. Through the use the metallurgist has been able atory precision the shop production, with the result that the failure the screw driver bits reduced one-half one per cent, which figure may not al- together due heat treatment, but partly slight irregularities the com- position the steel. Total savings from this source alone have been great that the price the bit has been re- duced per cent, followed increase sales from 20,000 75,000 bits per year. the basis the past production, and minimum value 25c. per scrapped bit, the yearly loss was $5,000, amount itself almost sufficient pay for the new electric equipment the heat-treating department. Tangible advantages electric heating Black Decker Co. may summarized follows: dependable product produced. Laboratory precision heat treatment secured. Rejects due all causes are less than one-half one per cent. The problem heat treatment entirely eliminated. one source great annoyance and con- siderable loss was driver bits. The speed which these steadily increasing year year. For- r.p.m., and 1600 r.p.m. — 4 The metallurgist determines the time- operation and the number pieces per charge for the several parts; after this, the job heat treatment becomes mechanical one. There has been labor turnover the last three years the heat treating de- partment. The furnace op- erator’s helper could take charge tomorrow and produce the same results without inter- ruption any kind. The furnace op- erator says has the best job the plant, and pleased with his working conditions. The heat treat- ing department lo- cated the same room with the rest the plant, without any 15-kw. hardening furnace has hearth 1234 in. discomfort the sur- wide in. long and in. high, and may operated temperatures high 1850 deg. Fahr. sand seal provided the door eliminate air leakage, and thereby produce uniformity temperature within the furnace otherwise very difficult accomplish rounding workmen. 10. Two girls, seated within ft. the furnaces, all the testing Rock- well machines, per- fect comfort. 11. The feeling security the product and the heat- treating department, the dependability results, and the continuity service and flow materials through the heat-treating department would justify the use electric heat the power cost many times what does. Production and Cost Data Net saving labor the heat treating depart- $187 Net saving scrappage per month.............. 400 Increased cost electricity over gas.......... Cost electric furnaces installed.............. $6,000 Fixed charges, per cent per year............. 720 Return investment, per 100 Operating months required pay for complete in- Cast Irun with Nickel, Copper and Chromium investigations certain gray irons which have been added nickel, copper and chromium, similar alloys which have recently received attention the United States and England, are reported the October, 1929, issue the Révue Métallurgie. The amount nickel between and per cent, with half that quan- tity copper; about per cent chromium added ferro. These alloys are recognized having high resistance 1216—The Iron Age, April 24, 1930 various corrosive solutions and being particularly stable under heat, while their mechanical properties may varied within wide limits changing the proportions the alloying constituents. Although these cast alloys are much lower order corrosion resistance than the high nickel-chrome steels, found that they resist attack better than any other alloy cast iron, and that the ease with which they may machined and molded makes them economical substitute, cases, for brass and bronze. | ~ Revamped Forging and EMAND for more rapid production, and the same time maintaining the high quality the product and the desired high-luster fin- ish and increased output without adding the floor space have produced prob- lems which have been suc- cessfully met the auto- FRED PRENTISS* lating and Chromium Plated Mass-Pro- duction Basis—Much Labor Saving before being packed for shipment. maintain high standard and uniform quality product, plating baths and operations are under laboratory control. Universal adoption chromium plating for bumpers place nickel plating has been the out- mobile bumper plant the standing change the Eaton Axle Spring Co., manufacture automobile Cleveland. About three years ago this company made bumpers the past two three years. common with various changes and improvements its bumper plant, including the installation new labor-saving machinery, place its manufacture bumpers mass production basis. The plant then reequipped was described THE IRON AGE, May 19, 1927. Other improvements recently have been made this plant which indicate still further important progress manufacturing methods. Thorough inspection plating work regarded the utmost importance the Eaton plant. The bumpers are given very careful inspections satisfy present-day demands for high-quality chromium-plated work. First the plated members are inspected after nickel plating and buffing, this inspection taking place while the pieces are suspended conveyors. second inspection under arti- ficial light regarded best suited for that purpose given after chromium plating. After final assembling the *Resident editor AGE Cleveland. -others manufacturers chromium-plated parts, makers bumpers had difficulties overcome before chrome plating good quality was put production basis. bumper requires not only dense coating plating material, avoid porosity, which causes corrosion, but also that the deposit should thick enough prevent abrasion; for the coating too light, there danger that scratches will made through the plating the hard service which bumpers frequently are subjected automobiles bumping together. Rust-Covered Bumpers Not Result Poor Plating bumpers are common sight during the winter months, but this corrosion rule not the result poor plating. Rather, caused the salt that spread the pavements melt the snow and ice. This has the same effect the plating the salt spray, the use = Bumper Bars Are Carried Through Specially Designed Heating Fur- nace the Conveyor, for Heating Before Forming the Eye Machine Right The Iron Age, April 24, 1930—1217 which the standard method testing chromium and nickel plating. Outstanding features the Eaton plant, the order their sequence, include cleaning electrically acid solu- tion which entirely replaces cleaning tumbling barrels, various semi-automatic operations, automatic polishing, automatic plating anJ improved plating methods which have resulted shortening the plating time cycle. For depositing the plate, min. required, from the time the Parts Are Formed Has Been Increased Combined Unit (Right) Five Machines, Pro- vided for Turning Out One Type Bar Production Basis. Five operations are per- formed these APIDITY with which Bumper Bar chines without reheat- ing the piece work enters the first tank until leaves the final nickel plating bath. series monorail conveyors carries the work through the various operations the plating depart- ment, for the most part grouped racks, and the assembly department, reducing minimum the handling pieces hand. Cleaning electrically chemical solution after form- ing found have decided advantages over the former methods mechanical cleaning. The work comes out the cleaning tanks much cleaner condition than when cleaned tumbling, being free from the fine ground-up scale which adheres the work comes from the Iron Age, April 24, 1930 tumbling barrels. addition, pieces are sometimes dis- torted during tumbling and this danger avoided clean- ing electrically. Bumpers are made high-carbon steel, having 0.80 0.95 per cent carbon. This said show rust more quickly than low-carbon steel, and requires denser coat- ing plating than low-carbon steel. The chromium plat- ing applied thickness 0.0006 in. The combined coating nickel, copper and chromium 0.0096 in. thick. OLISHING Before Plating Done Automatic Polishing Machines (Left). The conveyor under series polishing wheels. The picture shows two these machines con- nected one exhaust system Before the copper coating, usually the first coating electroplating, applied, the bumper bars are given flash coating nickel. The copper plating followed final nickel coating. Then the pieces are buffed give bright finish, after which the chromium applied. The nickel flash coat less porous than copper and provides dense deposit the base metal. the copper undercoat were applied directly the steel, would necessary use cyanide copper bath. But with the preliminary flash nickel coating acid cop- per bath used, permitting the bath operated higher current density than possible with cyanide j F 4 a HROMIUM Plating Unit (Top Page), Where Pieces Hung Racks Are Carried Monorail. The racks are handled and out the tanks electric hoists which form sections the monorail track. The manually operated nickel plating plant has similar han- dling equipment ULL-AUTOMATIC Machine Which Bumper Bars Are Successively Cleaned, Flash Nickel Plated, Copper Plated and Finally Nickel Plated. The work carried and out the various tanks the continuous conveyor which loops above the tanks The Iron Age, April 24, bath. And the coating copper which deposited thicker than would deposited the same length time cyanide bath. Automatic Cleaning and Plating FTER forming, the parts are electrically cleaned hot acid solution which removes the scale. From this they pass into cold water rinse tank and then into another tank containing alkaline solution. This fur- ther cleans the work and neutralizes any acid that may have not been removed the rinse tank. The cleaning done automatic machine. Bars are suspended vertical position hooks chain-type conveyor which loops and down over the lb. The speed the polishing wheel 1800 r.p.m., providing, with 14-in. diameter wheels, peripheral speed 6600 ft. minute. After passing the last polishing wheel the bar re- moved and hung conveyor. The carrier set track the outer side the machine and another con- veyor carries back the loading end. From the polishing machine the work goes the plat- ing department. Plating done both automatic plating machine and manually operated equipment. The machine used mostly for low-camber bars, bars with deep camber are not easy handle the automatic machine conveyor. The tanks the manually operated unit are arranged UMPER Parts Are Carried Assem- bly Department Overhead Con- veyor Right and Are Placed Stor- age Bins Side Conveyor. The bumpers are assembled the side con- veyor, shown center picture, which tanks. The monorail carries the tanks, giving the pieces im- mersion each the three tanks. The conveyor makes cir- cuit the starting point, where the pieces are loaded and un- loaded from the conveyor one man. places two pieces time side side hooks opposite sides the conveyor, and takes off two clean pieces. From the automatic cleaning machine the bars the automatic polishing machine. This consists series wheels in. diameter in. face, various grains, starting with the roughing size and finishing with oil wheel. man feeding the machine sets the bar car- rier which slightly longer than the longest bar and moves four small wheels. shoves the carrier short distance forward and gripped conveyor chain, which carries the work under the grinding wheels speed minute. short bars are being pol- ished two are put the carrier. Wheel Follows Contour Piece Each grinding wheel direct driven motor, the shaft carrying the wheel one end and the motor the other being balanced counterweight. the curved surface the piece moves the conveyor under the wheel, the latter moves and down slightly with the change the contour the piece, but the wheel always held against the bar being polished, with uniform pressure Iron Age, April 24, 1930 delivers the assembled bumper inspec- tion table foreground two parallel rows. They are served monorail and elec- tric hoists, the latter for han- dling the work and out the bars down over one row tanks and, making turn the end, returns over the second line tanks. reaching this plating unit the bars are hung racks which are specially designed for handling the various types bars. The racks for the most part are made copper, thoroughly insulated with insulating lacquer. About bars are hung rack horizontal position. Those that have eye holes are strung rods and held place nut screwed the end. the other end the rod Pass Through Cleaning Tanks Racks After racking, the bars pass through series tanks and operations which give chemically clean surface, pre- paratory receiving the flash nickel plate. They are then rinsed cold water spray, and copper plated. After this they are given another cold water spray, and the final nickel plate then applied. the automatic plating machine the operations duplicates those the manually operated unit, except that scouring with pumice stone omitted. The bars are hung vertically hooks attached the chain-type con- (Concluded page 1266) — More Mills Needed Roll Copper Rods Total Capacity Could Then Supply Demand Single Shift Basis—Now Two Turns Barely Suffice WOOD* OPPER has been intimately associated with man from the Bronze Age prehistoric times, and has since responded his needs and comfort under all conditions development. Whether was the primitive cooking utensil the open fire, the efficient sword, the bronze figure art, the copper sheathing wooden ships, copper made its impress. still retains its place the larger and modern field made possible the experi- ments Faraday and the electric liberation Edison and Bell. The brass and copper fabricating industry this coun- try located Waterbury, Conn., more than century ago and from there radiated the nearby towns Torrington, Seymour, Ansonia and Bridgeport, all within what known the Naugatuck Valley. Naugatuck the *Sometime chief engineer American Brass now consult- ing engineer, 1388 Lexington Avenue, New York. NDS, BILLIONS Montana copper industry what Pittsburgh the steel industry. However, due the expansion demand and better transportation facilities water, rail and truck, the industry rapidly becoming dispersed among the indus- trial centers the country. Until the coming the electrical era, copper and its alloys were used forms castings and the worked forms such sheets, strips, rods and tubes, but had reality limited demand. Actually was seriously cur- tailed when steel ships displaced wood vessels with their copper bottoms and, were not for the electrical develop- ment, copper would have remained minor position and grown only with our regular commercial expansion non- electrical fields. idea the way the electrical industry now domi- nates the copper business may had from the accom- panying tabulation concerning the total copper consumed Maryland | TOTAL MILLS ROLL WIRE BARS Hour Basis) 1910, When Domestic Consumption Virgin Copper Was Satisfied with Production 8-hr. Basis Been Rapid That Mills (with Additions the Years Indicated) Were Oper- 1929 16-hr. Basis. More mills, believed, should built the immediate future The Iron Age, April 24, 1930—1221 13 Y P RE 15' ae” L fabricated the United States the year 1929. total was 2,238,818,000 lb., approximately two and one- quarter billion, divided percentage follows: Copper Consumption in United States in 1929 Per Cent Ingot bars 5.14 Cathodes 10.65 Bessemet! 04 Total the period from 1912 1914 the consumption copper per person the United States was lb. 1922 1924 was lb. now lb. per person. Every day are made more and more conscious our depen- dence the use copper, whether the telephone, the electric light, the radio, the automobile, the rapid transit (air, rail and sea), the many household con- veniences. Referring the above list percentages, note that the present consumption copper the wire bar holds position 63.33 per cent. This percentage increasing year year and quite dominates the whole copper indus- try. The wire bar made copper having the highest lytic refining. used for electrical purposes almost exclusively and its production therefore index conditions the electrical industry. The latter absorbs number other accessories made from cakes ingot bars, and which added the figure copper wire bars would make the percentage absorbed the electrical industry 1929 approach per cent. Data the Average Rod Mill The wire bar approximately in. square in. long, pointed stubly each end, and weighs 240 rolled hot initial temperature 1450 deg. Fahr. into rods, principally 5/16 in. diameter. The mills which they are rolled are known “hot copper rod mills.” They are electrically operated, and are fed hand either from both sides with looping devices semi-auto- matic character. Hot copper rod mills have capacities which range from 100 250 wire bars per hour, and deliver the product coils. Twenty-five years ago mills were entirely hand oper- ated and used wire bar weighing 175 making passes rod. The output was maximum bars per hr. The modern mill can reduce 240-lb. bar rod passes much higher speed and with less labor. The accompanying graph covers period years and clearly illustrates the phenomenal growth the elec- trical industry and the meager attempts the manufac- turers copper products keep pace. under certain conditions demand, the steel industry reports percent- ages operation, the graph shows that under any condi- tions, the copper rolling industry 8-hr. shift must produce more than 100 per cent basis. The upper curve the total copper consumed within the United States. Paralleling closely since 1922, and seemingly impervious the effect the violent fluctua- tions other business, the curve representing total electricity production. Lower than these two the curve representing the production wire bars (the electrical industry demand). The lower curve the capacity the mills produce 8-hr. basis; notes new mills the year erection. Recent Additions Rod Rolling Capacity will noted that the wire bar curve gradually reaching toward the upper curve. 1910 represented barely per cent the domestic consumption; now 63; may, few years, become per cent. This seems reasonable when consider that the electrical industry has been approximately doubling itself every five years and outdistancing all other industries using non-ferrous metal. any rate, the relation between the wire bar curve and the curve representing the capacities the mills produce very marked and clearly shows the need more mills. 1910 the two curves coincided. 1913 mill was built New York the peak rising demand for wire bars. Between the low 1914 and the low 1921 mill was built Great Falls, Mont., primarily produce rods and wire electrify the Milwaukee railroad over the Rocky Mountains. This covered the war period and its imme- diate after effect. During the period from the low 1921 the great high 1929 several mills were built, bringing the mill capacities approximately per cent the total consumption wire bar, against 100 per cent 1910. other words, 1910 the mills were 8-hr. basis; 1929 16-hr. basis. There unmistakable indica- tion that more mills should built the immediate future. Such new mills are built should intelligently located water and rail facilities and domestic and foreign demand. The following locations should con- sidered: Camden, J., Houston, Tex., Paso, Tex., Los Angeles, Cal., and Cleveland. Each one these locations has been studied and shows distinct strategic advantages. Electrification programs the railroads will large factor the further expansion the electrical industry. Europe also making great strides electrification, espe- cially Italy. Russia has program large mag- nitude. These are all factors affecting our own copper industry and promise well for the future. Blast Furnace Filling and Size Segregation IZE segregation recognized important factor blast furnace practice because results irregular gas flow. using fine lake ores appears that operators are forced make some sacrifice gas distribution order obtain regular stock movement with fast blowing. definite correlation between methods filling and size segregation should lead more positive means con- trolling gas distribution. The North Central station the United States Bu- reau Mines, Minneapolis, has recently completed series experiments, made cooperation with the Uni- versity Minnesota, determine means small models the trend size distribution that result from Iron April 24, 1930 changes filling. close stock line, larger bell angle, larger charges, greater speed and greater bell drop, fact any change that results more rapid discharge from the big bell onto the stock line, tends decrease the average particle-size the center make the central area more dense. Charging coke the big bell first, alternating ships ore and coke, smaller charges ore and coke and smaller clearance tend produce more open center. concluded that measurements gas temperature, gas velocity and gas composition, all which are indexes gas distribution, furnish direct method attacking distribution problems that must worked out for indi- vidual furnaces. — Other shapes : 2.25 | Deoxidation the Making Steel Consideration Use Oxidizing Agents and What Expected Them—Blow-Holes vs. Pipes JOSEPH may well pay some at- tention understand- ing the methods employed its refinement. Qualities apart from those dependent upon composi- making processes remain there- after with the product. They character which must reck- oned with relation its fab- rication and subsequent service. Thus certain metallurgists who deal especially with intri- cate heat treatments are wont place importance knowing IMITING internal steel minimum, and then putting those cavities which re- main position the least harm, most desirable pro- thus constitute, speak, cedure. This accomplished proper methods for removing in- jurious oxides and easy accomplishment the skilled steel melter. practices steel making which yield melts requiring large amounts various deoxidizers become skillful the applica- tion these agents and can bring out such melts uni- form condition, without irreg- ularities the composition and with passable de- gree thor- oughness Many such melts have the individual sources the steel, addition knowing its chemical analysis. While the sources these character- istics are many and complex, one the important factors that represented the deoxidizing procedure the finishing the melt. Since there great diversity practice with regard the amount deoxidation considered necessary and the means effecting this required cleansing, natural that there should interest taken the effects upon the product, and criticism offered the steel makers’ methods people outside the mills often not well in- formed. Remove Injurious Forms Oxide The legitimate function deoxidizing agent fin- ishing melt remove injurious forms iron oxide residual from normal steel-making process. Steel may made, certain methods, carefully that the re- siduum minimum, and thus very small amounts any deoxidizer will required for such melts. This procedure, however, difficult and expensive, both the time required and because the high quality the raw materials which must used. Steel may regularly made that requires not more than normal amount deoxidizers, and this condition which sought after general practice. Frequently carelessness manipulation, the em- ployment processes making the steel which not permit normal reactions, result steel that requires excessive amount the agents for deoxidation. Two dangers exist under such conditions: First, that suf- ficient amount the deoxidizers may not added that the action may not properly take place; second, that the products the deoxidation (viz., the oxides the elements the deoxidizers) may themselves, such large quantities, prove detrimental the steel when used for certain purposes, general way lower the quality the product. Those who have habitually deal with methods and Melwood Street. Pittsburgh. been made passed all the requirements material subsequent fabrication and service. However, while the elimination the oxides residual from deoxidizing reactions highly desirable, doubt- ful that ever brought about any thorough degree, regardless the nature the oxides produced. For this reason where such oxides, the interspaces from their occupation, are detrimental definite way for any cer- tain product desirable that the steel made that normal amount deoxidizer may sufficient sat- isfy it. Recognizing this fact, the steelmaker diverts from such requirement any melts which require much deoxida- tion. Also apt bring out such special orders furnaces where preferred practice can followed out. this feature most particularly which makes de- sirable that the maker informed the uses methods fabrication connection with his product. Formation Blow-Holes the mild “rimming” steel the gaseous oxides are partially eliminated effervescence, which process aided sometimes rodding. However, the ingot freezes certain greater less amount the gas entrapped, resulting blow-holes, the distribution and size which determine their importance. These reduce the density and continuity the steel fabric and under certain con- ditions arising subsequent working become defects the product. Blow-holes, however, operate reduce the central cavity pipe and thus more the ingot may con- sidered sound. Practice teeming regulated seat these blow-holes well within the outer skin the ingot, that they may not appear surface defects rolling later machining operations. addition these there often solid residuum from The Age, April 24, 1930—1223 additions for active deoxidation, necessary besides that anticipated from the natural effect decarbonization. properly made rimming heats this mostly absent usual cases. better have this condition, excess blow-holes more detrimental than amount the solid oxides. capping top freezing, often practised, at- tempt made reduce the size the blow-hole means pressure. Thus similar result attained without effervescence (or elimination the gaseous oxides). Top freezing usually accomplished the use necked top molds and keyed caps, but sometimes powdered silicon shot aluminum used the top quarter the ingot and the caps then need not keyed. either case dependence placed the use greater amounts active deoxidizers than customary with steel. The higher carbon steels are often full killed, that gaseous elimination takes place. that case the solid oxides must reckoned with rather Thus deeper pipe results and less sound steel from the ingot, but with fewer blow-holes. The contribution made certain procedure, fin- ishing and deoxidizing, the character the steel produced largely that involving the nature and size well the amount the oxides left entrapped the steel. These particles also produce certain effects the crystallization the ingot. Certain these effects upon crystallization are persistent the presence the blow-holes and sonims. Disadvantages May Overcome That the bad effects these characteristics can grossly exaggerated witnessed the fact that steel often made under adverse conditions, requiring exceptional amount deoxidation, and has been applied successfully for practically all usual purposes. remembered that, when not deoxidized one way another, the ingots will not roll the mill; also, that much the steel which actually bad stopped the point blooming, because the development defects. Here sifting process which automatically throws much the burden upon the steel producer. the same time study these oxides and peculari- ties the crystallizations, they exist the steel when subject fabrication and test, would properly made yield most valuable information, particularly for guiding the mills the proper and economical application melts orders. will better attack the problem from this angle than try set standards which judge melt, without knowledge how was made, would seem that many are not sufficiently familiar with this phase testing make proper decisions. Rail Breakages, and Experiments with Heat-Treated Rails BOUT 500 rails 127 136-lb. section were heat treated during 1928 the Steelton plant Beth- lehem Steel Co. and laid tracks six East- ern railroads. These were taken singly from the last pass during regular rollings and quenched water for sec., and immediately drawn 1000 deg. Fahr. for min. the year previous few dozen 130-lb. rails were heat treated the Edgar Thomson Works Carn