The Iron Age 1930-05-01: Vol 125 Iss 18

ESTABLISHED 1855 THE IRON New York, May 1930 VOL. 125, No. Castings That Withstand Heat and Corrosion RODUCTION chromium and chromium-nickel castings, containing appreciable amounts these two elements, rapidly this country. Such castings are ordinar- ily used for high tem- perature applications and for resistance corrosion. They might classi- fied, roughly, distinction what are generally called “alloy steel castings containing over per cent chromium, chromium and nickel combined. Some Early Developments Nickel-chromium castings, for use high temper- atures, were first produced commercial quantities about 1914. They were made into carburizing con- tainers and other heat-treating equipment and little later into various furnace parts, per cent nickel and per cent chromium, the remainder mostly iron, was sion Resistance Thirty-five Foundries Now Making Corrosion and Heat-resisting Castings Their Manufacture Requires Great Care Attention All Details Shrinkage Difficulties Are Intensified Higher Prices Justified Longer Service Some Products Combine Abrasion and Corro- Potential Production Far Excess Demand typical analysis. For some time most castings pro- duced contained predominance nickel and were used almost entirely for high temperature service. Later developments emphasized the importance chromium alloying element resist corrosion, including scaling from heat. About 1921 castings were being produced which contained high per cent chromium with nickel. Since that time developments have been rapid. There are probably foundries now producing chromium and chromium- nickel castings various combinations these two elements. general way, castings which nickel pre- dominates are used for high temperature applications (2100 2200 deg. Fahr. being about the practicable upper temperature limit). Chromium-iron castings (with without some nickel) are used for high tem- perature service and also for corrosion resistance. Addition nickel greatly increases the strength elevated temperatures, but seriously weakens resist- ance attack from sulphur gases. High chromium- iron castings resist oxidation and sulphur gases satis- torily high temperatures, but not have the strength the nickel-chromium castings. alloy Furman Vice-president, Duraloy Co., Pittsburgh P 1277 r a : impervious sulphur attack, and with least the high temperature strength the nickel-chromium alloys, would meet real need. Casting Problems Are Many ROM the foundry standpoint, the problems connec- with the production this type castings are many. happens that much the metallurgical develop- ment work has been done with reference rolled prod- ucts. not are re- analysis evolved which may may suitable for castings, and often heat treatments quired which can only applied rolled products. Usual- ly, too, the corrosion resisting qualities the particular alloy have been determined laboratory tests forged rolled samples. Whether not these qualities exist castings the same analysis, whether the alloy can made advantage the foundry, not considered. However, the foundry required make and must either take chance failure work out the necessary variations analysis and heat treatment produce sound castings. then necessary convince the user that such variations are his advantage, often difficult After the metallurgical questions connection with the alloy are settled (and this calls for more expert engineering judgment than found ordinary foundry organization) the sitates Melting done usually actual production castings neces- great care are-type electric furnaces, although duction furnaces are being used some and one plant, least, these alloys are being furnace open- hearth Best Pour the Cold Side The important correct pouring temperatures are and difficult determine. Par- ticularly the case the chromium IFFICULT Corrosion-Resisting Casting (27 Per Cent Chro- mium) for Mine Pump for Coal Mining Company (Right). the top this page the pump which the casting incorporated Age. May 1930 the whiie appearing fluid. when hot, solidifies much faster than iron steel and the same time too large grains and consequent brittleness pour, far possible, the cold side, remembering that too cold stream will not fill out the molds. Difficulties shrinkage, always present foundry, are intensified and the selection sands, proper design castings and correct location gates and risers have carefully con- sidered. Castings should designed there will minimum shrinkage strains and heavy sections located that impossible feed them they freeze. Also the designer should keep mind that these alloys are poor trans- mitters heat. For this reason the shrinks and cracks from hot spots, con- siderably increased, the heat remains longer localized; fact, the producer these castings has meet all the ordinary foundry problems plus many others peculiar his specialty. very from danger spite all these difficulties, castings are being made much better quality than would have been thought possible few years ago. Machining qualities have been greatly improved, proper methods heat treatment have been evolved and many other improvements remains true, however, that castings the same analysis might show marked variation quality, made dif- ferent foundries. Because the severe conditions which these castings are usually called upon meet, they should subjected most rigid inspection the foundry. many cases they are essential part some important process and failure may involve not only considerable monetary ex- pense but possible loss life. unusual responsibility rests the foundry and many castings, which for ordi- nary service would satisfactory, must rejected. Marketing these castings requires different kind organization than employed the ordinary iron steel foundry. For each application first necessary 5 ’ determine the proper analysis. This often difficult matter. The effect various acids different analyses, and the possible pres- ence sulphur gases must considered, and the other factors which might cause failures must given careful thought. Because the higher cost such castings, much more expected them and the producer wise take every possible precaution against failure. also true that many cases these castings re- place iron steel castings. Designs and patterns suitable for iron steel are use and often necessary make drastic changes meet foundry limitations conditions peculiar the job. This all calls for expert engineering service. Many failures have resulted from ill considered recommendations analysis accept- ance faulty design. This has bad effect the industry whole, but felt most acutely the producer responsible for the fail- zation men with sufficient technical background and practical ex- perience give weight their The difficulty making and marketing this type casting, to- gether with the cost the alloying elements which enter into them, makes them considerably more expensive produce. This higher cost can only justified proportionately longer service life. The pro- ducer often called upon guarantee this longer life and has make the choice between losing sale and giving guarantees which, from several standpoints, are not very satisfactory. Contingent liabilities are established which are upsetting the financial stability the guarantor. Responsibility case failure hard fix; the producer has control over operating conditions his customer’s plant and sometimes cannot even learn what the exact conditions were. Not even the pressure competition can excuse many the guaran- tees which are being made. stated above, the first im- for carburizing boxes. Manufac- turers automobiles and automo- bile parts are the largest users carburizing boxes. The expansion chromium carburizing boxes were first available, gave large outlet some extent, cyanide and lead pots were also made well floor plates, rails, for heat- treating furnaces. Castings EVELOPMENT chro- mium-iron alloys opened the corrosion resisting field. The high chromium-iron al- loys are almost completely resistant nitric acid well most the organic acids. The chemical industry took advantage this property, particularly the con- struction ammonia oxidation plants and for handling nitro-cellulose products. The total investment chromi- um-iron and, more recently, alloys for this purpose, has been large. Most this has been for rolled products, but great many castings have been re- quired. These have included pipe fittings, valves, manhole covers, connections and converters. with the Castings Resist Mine Waters WIDE Use for These Steel Castings Recuperators Where High Temperatures Are Involved. ator and how installed lead pot the Willard Storage Battery Co.’s plant Cleveland shown pump manufacturers order accommodate pump designs the eccentricities their alloys. has been fairly well worked out and several pump manu- facturers have been supplying chromium-iron pumps real commercial basis for some years. But this For many years serious problem existed the coal fields because the presence acid water many mines. some cases, the corroding action this water was extreme that so-called acid-resisting bronze pumps would fail after three four weeks’ service. was found that these acid waters attacked the high chromium-iron alloys very slightly. Chromium-iron mine pumps, service for several years, still show the original tool marks. was necessary for the casting producers cooperate closely Other important applications such alloys have been rabble arms and blades zine and copper ore roasting fur- naces, supporting members, tracks, carriers, etc., enameling furnaces, skid bars, troughs and shoes billet heating furnaces, saucer valves for open-hearth furnaces, recuperators and preheaters, and tube supports cracking stills. recent development has been the making appa- ratus for handling sulphite pulp paper mills. This almost entirely corrosion problem and chromium-nickel The Iron Age, May | 4a alloy has proved very sat- isfactory for the purpose. While rolled products con- stitute most the equip ment used, considerable number castings are also required. Marine hardware, where the need for alloy castings based their resistance at- mospheric corrosion and their preservation high polish, offers another use. These qualities suggest possible applications, limited only the present cost the castings. Some these alloys are remark- resistant abrasion and are replacing, some ex- tent, manganese steel and white iron. The advantage sion and corrosion resist- ance is obvious. Continuous Normalizing Units Need Such Castings For sheets for automobile use, continuous furnaces sev- eral different types have been developed. the most generally used sheets are carried through the furnace rollers disks. These disks are mounted shafts which are either water-cooled dry, depending the severity the ser- vice. Disks and shafts are made from chromium-iron chromium-nickel castings. erable tonnage constructed. Because the pressure most these furnaces are being operated higher tem- peratures than was originally intended. Operating tem- peratures between 1900 and 2000 deg. Fahr. are now com- mon and impose severe strain the operating parts. Alloy castings have stood remarkably well, considering 1280—The Iron Age, May 1930 such furnaces have been built long 200 ft., can realized that consid- alloy castings required for each one production requirements EAT-RESISTING Castings (Below) Are Part the Equipment This Large Heat-Treating Furnace for Forgings. The supports for the forgings well the side plates the car botrom are UPPORTING Beams Plates Heat and Cor- rosion-Resisting Castings for Oil Stills (Above) the severity the condi- tions. fact, wherever tem- peratures run over from 1000 1200 deg. Fahr., and particularly where strength these high temperatures essential where corro- sion problems are involved, there very real need for alloy castings. Many im- portant industrial develop- ments have only been made possible ability. Solve Low Temperature Carbonization Problems Processes and methods which tend waste industry are be- coming more and more im- portant. Many such proc- esses have been theoretical- possible for long time, but their commercial devel- opment has been retarded because the physical lim- itations available mate- rials. The production these alloys has changed this situation and engineers are now able proceed with such projects, the knowledge that materials secured which will give satisfactory service high temperatures against various acids. typical example, the possibility low temperature carbonization coal subject which has, for long time, interested some the leading engineers the world. The advantage distilling the gas from the coal the mine, piping the consuming centers, and, the same time, separat- ing some the other coal derivatives, obvious, pro- vided the initial and upkeep cost not too high. While there are engineering problems connection with these processes yet solved, their successful development depends essentially the availability alloys materials stand under the severe conditions involved. (Concluded page 1359) 7 | a | a = L = 4 ast Refuses Step Aside POTTER* AST iron has run the gauntlet the ages and has survived the combined efforts innumerable alloys and materials replace and still remains one the important engineering rials, spite the fact that there has been concerted ef- fort made the foundrymen, roads other materials its field. Surely any material that can withstand the test time such manner has some in- herent qualities able value. The physical properties any alloy are dependent its structure, the various constitu- ents present and their arrange- ment. The structure cast iron greatly influenced the presence silicon, manganese, carbon, etc., and the melting and cooling conditions. as immeasur- vary the physical properties thorough knowledge these conditions necessary, but this brief discussion can consider only some the more important properties themselves. Compressive Strength Great let consider the strength The compressive strength greater than that any the more common materials and alloys, ranging from 80,000 200,000 per square inch, depending its structure and chemical composition. Compare this with wrought iron about 90,000 lb. per square inch and ordi- nary carbon steel This makes cast iron useful where compressive stresses properties. about per square inch. are great, such bases and beds for heavy machinery and columns, and for heavy bearings. This property not considered often might be, since most designs are figured with tensile strength basis. The tensile strength values given many handbooks and tables 15,000 25,000 lb. per square inch out date and should changed. Properly made cast iron for castings requiring strength will seldom run under 25,000 per square inch and ranges and over 60,000 lb. per square inch, depending its chemical composition and structure. Therefore, table needs drawn up, which will correlate strength with chemical composition structure. new and The properties shearing and torsional strength are generally not considered all cast iron. Recently con- siderable work has been done shearing tests and some European foundrymen believe better indicator casting properties than the transverse test, which used generally this country. Cast iron classed brittle alloy with practically *Assistant professor, College of Engineering and Minnesota, Minneapolis . Architecture, fact, however, that gray cast iron relatively thin sec- tions can punched readily without fracturing the casting. Experiments Moldenke show what plastic high tempera- tures. The writer also recalls instance stove job where little slide draft was placed stove casting and, instead using bolt rivet hold the pieces together, round pin was the slipped over and the pin ham- mered form head, and the complete. This job little comment the time and the iron was called job was caused some has also been known for long time that red hot cast with These properties are mentioned not because their present value but because their latent possibilities. Has High Rigidity property rifidity one that often misunder- riveting cast iron. iron can sawed ordinary wood peculiar an saw. stance resist change shape, the resistance de- formation.” This property depends much the elasticity material. Cast little ticity and therefore not shape readily. Cast iron condemned many its brittleness and the fact that breaks warning, while the more ductile materials will distort considerably very iron has very elas- does change its cases because without before rupture. This argument for the more ductile alloys somewhat inadequate, since all materials must function their elastic limit. designers the and the the various materials little more thoroughly, casting failures will greatly Too figure, and, when failure occurs, too many times they change below will study stresses properties reduced. many designers guess instead the material cover their mistakes. good example the rigidity cast iron has just recently the castings were replaced Difficulty was come writer’s attention. Certain iron built-up steel welded forms. encountered trying machine this Then was found that the welded forms were quite easily sprung out shape handling, which resulted considerable difficulty the and found necessary back iron castings number first assembly accurately, because its springiness. throughout whole operation, cases. Built-up welded sections, doubt, have dis- tinct advantages for some work, but this case where overstepped their field tne Has High Resistance Corrosion non-corrosive properties cast iron have long been known, but they have become commonplace that they have been frequently overlooked. Cast iron The Iron Age, May 1930—1281 4 | corrodes about one-half fast the ordinary steels, and only slightly faster than wrought iron. Cast iron pipe and fittings stood the test time and testify the resistance cast iron the ordinary corrosive actions. Certain cast irons are quite resistant both alkalis and acids and result are used extensively the chemical industry. Recently cast iron has been used exterior ornamental slabs large buildings, replacing ornamental stone and terra-cotta. This possible be- cause the non-corrosive properties cast iron, along with the ease and perfect reproduction which duplicate ornamental figures can cast, compared with the cutting and shaping stone. Considerable trouble has been encountered from time time many parts the country from the corrosive action sewage and sewer gases. some places they have been known seriously attack the tile, brick, con- and steel, and cause disintegration rapidly that f failures have occurred, entailing little expense and } ; trouble. Cast iron has very adequately helped remedy this difficulty, and result cast iron liners for man- holes instead brick, cast iron ladders instead steel, and cast iron ducts instead tile and concrete are being specified number municipalities throughout the country. This development opens very promising field for cast iron. ast iron silo door frames proving the only material that will withstand the silage juices and fumes. this field proving much more satisfactory than steel concrete. works well for frames, the whole silo out cast iron? could sections any desired height diameter. would permanent and fireproof construction and dismantled and moved quite easily, and, when had finally served its purpose, would still have nominal scrap value, which not the case with present silo materials. Cast iron has also been used limited extent for culverts, and the only reason has not been sed more extensively because bulkiness and frequent breakage transit. With successes being tained the manufacture centrifugal cast iron pipe, i appears that cast iron culverts may soon find Used Holland Vehicular Tunnel would not fair this discussion the proper- ies and uses cast iron did not mention its part greatest engineering feats the age, the construction the various tunnels under the Hudson River New York. Cast iron was one the most im- portant construction materials used, because its high compressive strength, its non-corrosive properties and its cheapness. the Hudson River vehicular tunnel alone ised 81,000 tons cast iron segments Hardness Important Factor abrasiveness and hardness white cast iron make especially adaptable for carwheels, brakeshoes, chilled rolls, chilled plows, balls for ball mills and numerous arts for mining and crushing machinery. Alloy and heat-treated steels have made some inroads this field, but cast iron still predominates. Cementite the hard constituent white chilled cast iron and the same constituent that brought out the hardened steels, but because the higher carbon content cast iron there greater concentra- tion this constituent, which makes more resistant abrasion. Cementite the hardest the ordinary iron-carbon constituents and reported 272 times hard pure iron (ferrite), measured with Jagger — *Metais and Common Alloys. Hoyt Iron Age. May 1930 microsclerometer. comparative table hardness given follows: White cast iron 418 Hard steel (quenched) 275 and over Alloy steels (heat treated)... 160 to 500 The table shows how favorably the hardness white and chilled cast iron compares with that the heat- treated high-carbon and alloy steels. This extreme hard- ness accounts for the high resistance abrasion. The chilling property cast iron particular value, be- cause makes possible harden parts casting and yet keep other parts soft enough machine. get this same effect steel necessary resort rather elaborate system heat treatment. Cast Iron Withstands Heat Well heat-resisting properties cast iron are very important. has been shown number in- vestigators that the strength properties are unaffected temperatures 800 deg. Fahr. Between 800 deg. Fahr. and the critical temperature (about 1360 deg. Fahr.) there some change structure but great change physical properties. When gray cast iron subjected repeated heatings and coolings and the presence certain gases, the very objectionable property growth exhibited. White cast iron does not exhibit this property and should used where such conditions prevail. used with success for such castings grates, stoker bars, annealing pots, and melting and heating pots and vats. Most other alloys when used under these conditions either melt, warp corrode rapidly that they soon become useless. recent survey the railroads this country shows that practically all the grates used locomotives are cast iron, although some are experimenting with other alloys with the hopes getting longer-life grate. Thus far other material has been found that gives the all-round atisfaction that cast iron does for this purpose. Some experiments have been tried with alloy cast irons and the results seem indicate that still greater heat-resist- ing properties are possible. Cast iron demonstrates its ability resist corrosive action and heat the same time such burners for gas and oil stoves and the various parts water heaters, heating stoves and furnaces Its Bearing Properties Are Superior RAY iron’s bearing anti-frictional properties are more valuable than generally understood. Gray cast iron probably the only alloy known that can func- tion bearing without lubrication. This particu- larly valuable property when lubrication runs dry, the will function for considerable time without causing serious damage the machine. There are two reasons for this, first, some the graphite flakes break out and act lubricant, and, second, the minute formed when the graphite flakes break out, lubricating oil lodges and acts reserve when the lubri- cating system fails function properly. Cast iron bear- ings have replaced non-ferrous bearings numerous cases and have stood very satisfactorily. The high compressive strength cast iron make possible for use bearings carry heavy loads. Only recently has cast iron been employed some cases instead steel for tailstock spindles machine tools. Steel spindles tend score and freeze themselves place, and continued hammering loosen them soon spoils them. The points the cast iron spindles stand better too, because they not burn themselves out readily from excessive friction. general use. run the gauntlet the ages.” preference other materials. specifications. The most important use cast iron account this property cylinders all kinds, and for pistons and piston rings. For castings this type materia! alloy has yet been discovered, regardless cost, that functions satisfactorily gray cast iron. special grade gray cast iron, known “gun iron,” being employed extensively for bearing parts railroad equipment and heavy machinery. used bushings, sleeves, cylinder liners, slide shoes, crosshead guides, gears, sheaves, Because the excellent bear- ing qualities and the uniformity gun iron, users are pay- ing considerably more for than for the ordinary cast iron. Tests alloy and low-carbon cast irons (high-test cast iron) also reveal improved wearing properties over the ordinary. Freezes 150 Deg. Below Melting Temperature relative ease casting important considera- tion with all the casting alloys. The melting and setting temperatures, shrinkage and fluidity are the most important factors influencing the ease with which alloy can cast. The melting temperature the average cast iron approximately 350 deg. Fahr. lower than that for the average steel. This means easier melting, less chance for oxidation, smaller amount superheat necessary and less “burning in” and cutting the mold. This ordinarily results smoother castings and castings truer pat- tern, well lower melting cost. Gray cast iron has peculiar property that exhibited other alloy its melting temperature higher (about 150 deg. Fahr.) than its freezing temperature. This valuable from casting standpoint, because automatically about 150 deg. Fahr. superheat. This greatly aids the “pouring off” the alloy and reduces the losses be- cause cold metal. provides Shrinkage Low AST iron has the lowest shrinkage any the com- mon alloys, shown the table. This property low shrinkage greatly reduces the formation shrinkage cavities and cracks, which are always serious problems any casting job. Shrinkage cavities and cracks greatly reduce the strength the casting, and the strength the material not the strength the casting. Some sort strength test actual castings would very desirable, and would doubt show that the lower the shrinkage the higher would the ratio the actual strength the material strength. POTTER presents brief for old material, one that “has Cast iron, finds, has many properties that commend for certain uses has suffered mainly because poor foundry practice and inadequate predicts that cast iron will now move forward, because organized effort study its properties, classify castings, set specifications and standardize and improve both product and methods. Porter Cast iron generally very fluid, which favorable property easy casting. cast iron especially fluid and, addition, has the property ex- panding slightly soon after sets while the metal yet more less plastic condition, thus forcing the metal into the minutest cavities the mold, giving most per- fect reproduction. mental castings. This property made use orna Another phenomenon that aids the casting intri- cate shapes the property cast iron stretch when cooling from the molten condition. This another evi- dence the plasticity cast iron high temperatures, and affords automatic adjustment casting strains due shrinkage and contraction, thus preventing rupture and the formation cracks. This property makes cast iron more adaptable the casting intricate shapes with varying metal thicknesses. Gray Iron Easily Machined machining important factor for all machinery parts that must finished. iron can machined faster and less cost than any other our common alloys. Gray cast Greater speed machining possible, less. power required, there less tool wear and accuracy finish easy obtain. Then, ad- dition low machining costs, requires less machinery investment, reduces the pro rata floor space required and makes the machine shop generally more flexible. The annealing cast iron facilitates machining; often cuts the machining time half and greatly reduces tool wear. The machinist has always been interested soft cast iron, and has been the practice too often sacrifice strength order obtain high machining speeds. Europe more attention has been given the strength Comparative Shrinkage Materials Shrinkage Per Foot in 64ths of an Inch Heavy gray cast iron ‘ 6 Average gray cast White cast iron ‘ . 12 to 16 Cast steel ; 16 to 20 The Iron Age, May 5 : : A : Aluminum Copper ; 14 Zinc, lead and properties, while the machinability more less sec- ondary consideration. Endurance Limit Not Uniformly Low iron’s resistance shock and impact and its fatigue properties have generally been taken for granted being very poor. only very recently that any actual research any magnitude has been attempted determine these properties. Work done Prof. Moore the University Illinois, and Prof. Kommers the University Wisconsin has given first real data these properties. Some very unexpected results have been found these Kommers says discussing some his tests*: “The fact that series which gave the lowest present series, had endurance limit lb. per square inch, and that series gave value lb. per square inch indicates that cast iron need upon uniformly low-strength material. The strength cast iron can evidently controlled imi least that steel.” According cast iron exhibits marked increase endurance limit with repeated stresses, which not gen- erally the case with brittle materials. Both reports show that the notch effect cast iron practically nil, while steel any kind greatly reduces the strength. This means that irregulari- ties shape, machining marks, mars, nicks, have practically effect the impact and fatigue strength cast iron. This very desirable condition for any material working under stress. Other investigations have also shown that these properties can greatly improved proper heat treatment. Segregation Can Largely Overcome done much give the reputation being very unhomogeneous material. This due the many differ- ent elements and constituents and, while cannot eliminated entirely, can controlled and reduced minimum fixing the chemical composition and es- tablishing uniform melting practice. has also been found that this condition can greatly reduced the addition certain alloys and heat treatment, that with knowledge conditions and careful practice, this objectionable property not serious handicap. The unit cost castings always vital factor. The cost cast iron parts the lowest any the cast parts, but just because commodity cheap indication that inferior quality. This false idea values often robs part its rightful field. Heat Treating and Alloying Offer Great Possibilities alloy steels and heat treatment have brought about many new properties steel that have been great boon our mechanical and metallurgical develop- ment. Metallurgists agree that cast iron essentially steel with excess carbon. Experiments have shown conclusively that alloy additions and heat treatment offer great possibilities for improving cast iron. Nickel and chromium are being used with gratifying results, but the field has hardly been scratched and more attention should given these possibilities the foundryman and the casting user. concrete example what can done with alloys cast iron was demonstrated job during the war, when very little was known about the effects alloy additions. certain shell forging plant was having con- siderable difficulty with die liners for the forge presses. Steel liners warped and jammed the presses and pro- *“The Static and Fatigue Propertic« f Some Cast Tron.” by Kommers, A.S.T.M., 1928 Iron Age. May 1930 duced shell blanks that were out shape. Cast iron liners solved the problem warpage and distortion, but the start considerable difficulty was encountered be- cause breakage. After some experimenting, chromium low-carbon cast iron (semi-steel) was produced that gave very good satisfaction, producing consistently thousand shells before replacement was necessary. Today, with much greater knowledge alloys, why are they not used more? Cast iron, like all materials, has number unde- sirable properties, some which have already been men- tioned, which prevent its use for certain types work. Its low-tensile strength, compared that the steels, along with its brittleness, prevents its use where high- tensile stresses are produced and where excessive shocks and vibratory stresses prevail. There are many conditions, however, where the stresses not great enough exclude cast iron and both the casting user and the foundryman have been fault not applying the proper specifications give the desired properties for the job. matter fact, large part the tonnage cast iron has been made the past without any definite specifications all. was machined had soft, and the softer the better, but, was not machined, any old thing would do. Instead discarding cast iron should study its latent possibilities little more diligently. How Cast Iron Can Hold Its Place must learn pick their field and stay it. The idea making everything from toothpick locomotive the same shop all wrong. One can- not make heavy and light work, hard iron, soft iron, stove plate, ornamental iron and cylinder iron all under the same roof and out the same cupola and expect get the best results. This has been one the great mistakes the foundry industry. Europe, rather common practice have separate cupola for the different kinds iron, and that principle right. the foundryman will stick his field, study the properties desired and how control them, and constantly strive improve these properties, and furnish uniform and reliable cast iron, will automatically enlarge his market, improve the reputation cast iron and more firmly entrench against the inroads substitutes. The designer and the buyer, the other hand, have frequently been unfair cast iron. Many times have seen cast iron, malleable, steel and even non-ferrous cast- ings made from the same pattern, showing clearly that the designer didn’t take into consideration the different properties these various materials. until few years ago mechanical engineers were not required study metallurgy and, therefore, did not know very much about the properties the engineering materials. What needed more complete cooperation the part the casting user, engineer and the foundryman determin- ing the true properties cast iron and setting proper specifications for the various castings. The foundrymen have already realized this need organizing the Gray Iron Institute, through which they are going study the properties cast iron, classify castings, set specifications and work for standardization and improvement properties and practice. Through this organization they will put cast iron into uses where rightfully belongs and take out places where does not belong, and thus assure the casting user better and more reliable product. This move the part the foundrymen already showing results and the future holds out great promise. Cast iron not only refuses step aside, but already stepping forward. Modern Plant for Malleable Castings Annealing Tunnel Kiln Pro- ducer Gas from Hard Coal FEW torical facts are the following story describing most interesting malleable iron foundry. Prior 1917, Zifferer, inventor new types expansion bolts, trad- ing the United States Expansion Bolt Co., with offices and assembling plant New York, purchased his mallea- ble castings from small foundry located Columbia, Pa., then owned and operated George Cooper Co. Mr. Zifferer’s requirements for malleables grew rapidly and the source supply became inadequate. was during the dark days the world war and all foundries were oper- ating maximum capacity, making extremely difficult place patterns with another foundry, mention nothing the exorbitant prices asked. Why New Plant Was Needed continue business, Mr. Zifferer had one alterna- tive—that owning and operating his own malleable foundry. relatively short time, this was accom- plished taking over the Cooper plant Columbia, and incorporating under the name the Columbia Malleable Castings Corporation. Immediate action was taken scrap the antiquated equipment put into effect what was then modern foundry practice the purchase new equipment, employment skilled assistants and adding the facilities general for the manufacture more and better malleable castings. After plant operations were going along smoothly, the inventive mind Mr. Zifferer again became active and type distinctively new pipe hangers was developed and found immediate acceptance with the automatic sprinkler industry, greatly increasing the business and necessitating larger plant. Additions were built intermittently required, until all available ground was used. Further Air Furnace Fired Alternately with Oil and Coal demands were made for increas- capacity, re- sulting the large tract land along the Lincoln Highway, just east Columbia, for expansion and Landscape Beauty Combined monument his efforts, the layout and detail all buildings and equipment were under the personal supervision Mr. Zifferer. Combining un- usual architectural and landscape beauty with modern design and equipment malleable iron foundry, the new home the Columbia Malleable Castings has attracted much favorable comment. Corporation Approaching the plant from either direction the Lincoln Highway, the traveler attracted first life- size portrait molder pouring mold. night these signs are illuminated that the molten metal pictured running from the ladle into the mold approach veritable reality. The buildings, which are faced with full range red tapestry brick, laid Flemish bond and trimmed with Indiana limestone, are set back several hundred feet from the highway. The entrance from the highway consists broad curbed driveways, encircling court, which flanked either side large lawn, decorated with box- wood, flowers and fine shrubbery. The general appearance more that country club than foundry, the latter usually being regarded about the least attractive all industrial plants. General Plant Resembles general arrangement the buildings consists three parallel wings bays, shown plan drawing, connected such manner give straight Architecturally the New Plant the Columbia Malleable Castings Corporation, With Its Landscape Gardening, Sur- rounding Its Approaches, Presents Imposing Appearance from the Lincoln Highway. Illuminated signs (above) add the attractiveness the front lawn The Iron Age, May 1930—1285 é line fiow production from raw materials finished product. The molding bay, comprising about 35,000 sq. ft. floor space, double monitor construction give good lighting and ventilation. This bay traversed longi- tudinally concrete gangway with clay molding floors either side. Other bays are similar monitor construction but have high roofs and are well ventilated and lighted large windows. The interior all buildings painted with aluminum give maximum reflection light. All depart- ments the plant are equipped with white enamel Frigid- aire water coolers and sanitary drinking fountains. The entire plant heated Thermoliers, industrial heating apparatus, furnished the Grinnell Co., Providence, I,. these being thermostatically controlled keep the tem- perature all buildings constant all times. Each ther- nolier equipped with motor and fan which serves keep the air constant motion. Steam for heating sup- plied two 170-hp. twin tubular boilers, fired oil, with total capacity 11,000,000 B.t.u. per hr. These were furnished the Smith Twin Tubular Boiler Co., Phila- delphia. Equipment Most p-to-Date Available the way foundry equipment, the policy the com- pany has been toward standardization the most up- to-date and approved apparatus available. While the man- agement has not seen fit adopt conveyors and contin- uous molding, apparent that care and expense have been spared procuring high-class equipment for all departments. The cost electric power being prohibitive, the present melting equipment consists two 25-ton reverberatory 1286—The Iron Age. May 1930 type air melting furnaces. These are equipped with Grindle unit coal pulverizers for firing and also for alternate firing with oil. President Zifferer has worked out combination system oil and coal firing which claimed possess virtues not had individually with either oil coal firing. Process patent has been applied for, information which not available this time further than say that this system melting from cold charge will produce metal low sulphur, with minimum oxidation and metal free from contamination dirt, slag and other impurities which impair the quality castings. Melting Done Two Air Furnaces Two air furnaces each have hearth about ft. long ft. wide. The melting time for 25-ton heat from Plan oftheNew Plant Laid Out Similar the Let- ter The two air furnaces, with their stacks outside the foundry wing, are easily located rate, only one heat per day cast from each furnace and the contention the management that faster melting rate from this type furnace not desirable for economical well metallurgical reasons. The charge consists from per cent pig; from per cent steel and the balance remelt, sprue, gates, etc. Only pig iron made from all-ore charge the blast furnace used, traces certain alloys used steel and high-test cast iron may seriously affect the annealing malleable castings. Likewise, only steel rail ends, known source, are used for steel scrap. small amount charcoal pig used adjust analyses and give better and more uniform quality product. The coal used the unit pulverizer for melting mechanically cleaned and screened. This comes from the Worden mine the Pittsburgh Coal Co., and one the OUNDRY BUILDIN C | PATTERN BUILDING | ~ = e j R T 4 > L F | > coal drier highest quality bituminous coals available. not used, and the coal stored under cover prevent excessive moisture. Molding Done Jolt Squeeze Machines molding department will accommodate about molders. This equipped with Osborn jolt squeeze molding machines for small and medium work roll-over and jolt-squeeze-strip molding machines for heavy work. The metal handled from the furnace the molders 600- lb. ladles, transported hand power trolley operated American monorail track. the molding floor the metal transferred hand ladles for pouring into molds except Demmler Core-Blowing Machines, (at top page) Operated Two Girls and One Boy, Make the Cores. There are 35,000 sq. ft. space this (above) large molding department. One the two air furnaces can seen the left background P the larger castings which will poured bridge trolley ladle direct. Only solid metal slip flasks and cast metal jackets are used. Each molder’s bench equipped with adjustable light socket, which permits proper lighting any part the mold. Cores Made Blowing Machines The core room equipped with mixer; five No. Demmler core-blowing machines, sev- eral International jolt machines, five sections Coleman core ovens, gas-fired, and suitable racks, trays, trucks, for handling cores. impson sand Castings are handled from the molding floors the — atl = | The Iron Age, May 1930—1287 cleaning department Yale lift trucks and specially designed dump buggies, which may dumped directly into the sand blast machines without rehandling the cast- ings. These buggies are also used for unloading castings from the sand blast machines, from which they are taken the lift truck the inspection and chipping benches, and automatically dumped. Present sand blast equipment consists two tum- blast machines, furnished the American Foundry Equipment Co., and one large barrel furnished the Sly Mfg. Co. All castings are steel blasted both before and after annealing. From the inspection bench the castings pass the grinders for removal the gates. Present grinding equipment consists four high-speed grinding machines, furnished Safety Grinding Wheel Machine Co. From the grinders the castings pass the annealing the oven, the temperature allowed drop from 1700 about 1400 deg. Fahr., quite rapidly. the third, final cooling zone, the temperature held around 1400 deg. for some hr. use auxiliary burners, after which again drops quite suddenly about 1000 deg. Fahr., when the car removed from the oven. This tunnel type annealing kiln fired with gas, made from buckwheat size anthracite coal which fed mechani- cally into the Dover-Galusha gas producer. The gas washed before delivering the burners and has B.t.u. value about 160. This same gas used for firing the core ovens. Features Annealing Process Outstanding features the tunnel type kiln the accuracy which temperatures, both heating and cool- controlled, resulting not only from the effi- Power, Both Electric and Pneumatic, Generated. There little vibration the foundation the air engine that coin will stand balanced its edge the concrete. Two large twin tubular boilers supply the steam department packed into pots for annealing. These pots are in. in. in. and hold approximately 500 lb. castings each. Quartz gravel used for packing material and this jarred down the pots use Branford air vibrator. The pots are stacked three high car, each car holding six stands, making pots about 9000 castings per car. HESE cars when loaded are pushed into Dressler tunnel type annealing oven 100-ton hydraulic ram. The oven, which 182 ft. long, holds cars. When loaded car pushed in, finished car pushed out the opposite end the oven. When the oven operating capacity, car pushed about hr., making the complete cycle per car about 120 hr. This gives annealing capacity about tons castings every hr. There are three zones heat treating the Dressler tunnel type kiln. the first, heating zone, the tem- perature maintained about 1700 deg. Fahr., when the oven operated capacity. the second, interme- diate cooling zone, which cooled omission insula- tion and the construction special flues, built the sides Iron Age, May 1930 cient construction and equipment the oven, but because the lesser cross-section mass heated and the evenly distributed source heat, which reduces serious temperature lags minimum. Another feature this oven the double protection the castings from the atmosphere combustion, not only are the pots sealed but the tunnel heating zone through which they pass muffled from the combustion chambers, and the actual heating induction temperature through the spe- cially constructed walls the combustion chamber. This protection from oxidation and the fine control cooling through the critical range produces malleable cast- ings free from skin hardness and excellent machining properties without sacrifice strength and ductility. the threading malleable castings, this very impor- tant. important detail too often overlooked the building foundry safe and adequate provision for the stor- age protection patterns against loss fire. This has been taken care the construction fireproof pat- tern vault, with 13-in. concrete walls, located the ground floor the pattern shop and fully equipped with Lyon shelving. The plant also includes small non-ferrous foundry, | with modern melting and molding equipment for the pro- duction metal patterns, special castings, etc. Adequate Provision for Safety and Health protect the health and well-being all employees, first-aid room has been equipped with the finest facilities available for rendering first aid and medical attention injured employees. trained nurse full-time duty the first-aid room and physician makes daily calls render any medical attention necessary. further protect the health employees, and espe- cially the molders, modernly equipped washroom has been provided, with individual steel lockers, shower baths and steam-heated drying racks that molders may always have dry clothing when commencing the day’s work. cafeteria has been provided, where employees are served nominal cost them. The cafeteria arranged that employees may enter from any department the plant without being exposed the weather. encourage athletics and clean sports for employees, the company has provided baseball diamond, tennis court, ground for quoits, and also supports basket ball team. What the Company Produces The principal product the plant consists com- plete line malleable pipe fittings, pipe hangers and expansion bolts, although some jobbing work done. The Columbia Malleable Castings Corporation has ac- tive membership the Malleable Iron Research Institute and the tensile properties its product are follows: Ultimate tensile strength 54,000 to 56,000 Ib in. yield point, 36,000 to 38,090 Ib. per sq. in per sq elongation Personnel the Organization HEN the construction the plant was well under way, Mr. Zifferer’s attention was next turned securing the best talent available assist him building operating organization that would keeping with the general layout and equipment the new plant. His choice ended the selection Deisher plant man- ager. Mr. Deisher, who foundryman, internationally known the malleable industry, having been associated for number years with the Malleable Iron Research Institute shop practice engineer. 1927 was sent Europe the American Radiator Co., foundry expert and consulting engineer. Mr. Deisher has various times contributed, the technical press, articles malleable cast iron and present represents the malleable division the American Foundryman’s Association the ferrous advisory committee the United States Bureau Standards Washington. His wide experience the malleable industry, combined with the creative aggressiveness its president, should make the product this new plant stand out credit the industry. Officers the Organization Associated with Zifferer, president, and Deisher, plant manager, Nelson Albright, vice- president and treasurer. Mr. Albright has been associated with Mr. Zifferer officer the Columbia Malleable Castings Corporation for several years. Rai! Dampers Trucks Burners Burners Track Pyro