The Iron Age 1930-05-15: Vol 125 Iss 20

THE IRON AGE New York, May 15, 1930 ESTABLISHED 1855 Business Gets Back Sound Basis Industrial Effort More Effective When Not Diverted Call Loan Profits and Merger Possibilities—Wages Must Maintained JAMES FARRELL course, when drive over smooth piece road, sooner later come place where get little bump. think place these obstacles the road ourselves for the purpose getting little reaction occasionally. There nothing the matter with the steel industry. doubt the real business situation was affected the speculators and the people who were loaning millions call per cent. Our business has solid back- ground. Mr. Schwab has said, you over period time you will find, taking everything into account, that our business good. Here and there, some particular lines, business not good. often think that perhaps here and there little check luxuries and other things that are not permanent helpful. Much Pipe Tonnage Sight Take our business can say that our busi- ness very good. The production most the said other occasions, were take our capacity *President, United States Steel Corporatio: Abstract address before American Iron and Steel Institute, May James A. Farrell today and compare with our two three years ago, would all running over 100 per cent. There have been the industry situations that sometimes night. have one the moment. For month two the manufacturers pipe have been wondering what they were going with their capacities and their plants. think within days every pipe manufacturer the country will have his capacity filled until the early part next year. occur over And then the building business. What the matter with the building business? Every fabri- cating plant the country has got four five months’ work, but there one feature the fabricating tion which causes concern from time time, and that what going become the small fabricator, who has been one the greatest consumers the past iron and steel. not going make speech this morning the question initiative the question the elimination small manufacturing companies; but this country was built with small companies. were all built with small companies. The corporation that connected with has potential capacity today 25,000,000 tons steel. 1447 VOL. 125, No. 4 When came into the presidency years ago were making 7,000,000 tons steel. through the industry. And goes all Everything runs big. Smaller Manufacturer Ignored Lenders the question mind that perhaps things are going too big. You all know that small manufacturer today not astically the banks wants borrow $15,000 $20,000 000 run his busi- Some the institutions are getting large that they make in- quiry when small manufacturer comes the door. does not get see the man that lends the money any more, because the man that lends the money now interested 10, and 100 million dol- lar propositions and not loans back the great potential power the country which, after all, the consumer, who the gate accounts for immense tonnage. received very enthusi- ness. small companies. our business. other things. tion other countries. have got give some thought the recrudescence the smaller manu- facturer this country, are all going get big that after while there will only half dozen concerns half dozen utilities the busi- ness with each other. That phase this question that might given careful thought from the economic side things. When were here year ago great many people were telling each other how much money they had out call Wall Street. John would say “We have not going say which John, but John would say had millions call any more names, but another man would say, have got millions out Everybody had money out call. Where it? not call now; plant and machinery. Bloom Off Merger Rose that has not anything with the steel business, excepting that think that are now beginning—and bears this question good management, Mr. President—to give our undivided attention our business. For several months past people’s minds have been other things. Once while have been asked had any Iron Age, May 15, 1930 must give some thought the recrudescence the smaller manufacturer. This country was built are beginning give our undivided attention For several months past The bloom off the rose the merger business. Wages are not coming down. can compete any market the world except where there arbitrary tariff. Short-sighted tariff tinkering hobbies. read Shakespeare quite good deal, and was reading our old friend “Hamlet” the other night, and then saw something that immediately para- phrased mind, and ran like this: “To merge, not merge; that the question: whether finally came the conclusion that the best thing could all the steel industry would emerge. think the bloom off the rose the ness. think that our friends the steel business will attend their own business they will make much money out what they have they will out what they expect get want say that think that the time, the thought and the strategy that have been put the merger business have adversely affected industry during the first quarter this year. think that, settle down solid basis and work out our navigation and know exactly what course are pursuing, can ahead and sail the course and get back normal business again—because there enough business this country for the steel industry keep going normal basis. people’s minds have been Wages Will Not Come Down want mention another thing, and not wish anticipate anything that the com- the Board Directors, and that the question hours and the seven-day week—and another thing that our committee not delegated make inquiry about, and that the question wages. have had experience one locality where know that, the policy the institute had been fully carried out, there would have been unemploy- ment that place. Well, can show clean bill health very large extent. not anticipating the combined report the committee, and have never made minority report life any question— that not only applies here but applies the com- pany that employs president its business. The companies the individuals that operate plants, either wholly partly hours day and wholly partly seven days week, ought made known (Concluded page 1501) - Divers Heat-Treating Machines routine, con- ducted com- mercial organizations exclusively for jobbing work, quite different from that found subsidiary departments large automobile factories, the topic frequent articles this subject. Commercial heat-treating plants have always faced the handicap great di- versification operations, each batch work having different specifications be- cause every customer has his special requirements. This demands more furnaces than necessary for the same tonnage the production shop. the former, furnace conditions might changed every hour, whereas the production shop may run furnaces hr. day one class work and able keep the furnaces loaded capacity, all one temperature and one setting pyrometer control fuel system. ceases matter skill the production shop, while the commercial plant demands all skill and personal *Dayton Power Light Co., Dayton, Ohio. Commercial Plant Installs Furnaces for Metal Parts Ranging from Small High-Speed Tap Welded Assemblage Alloy Tubing for Aircraft By. FRED knowledge—so that automatic controls and new devices are fre- quently frowned upon reflection the “art.” has become apparent, however, that automatic control produces the most beneficial results furnace that must quently temperature and operat- ing conditions. All that necessary merely move the dial indicator the control instrument. accomplish result hand regulation burners means many adjustments and close attention the part the operator for considerable period time. Any laxity results poor work and accompanying loss rejected product. When the time and effort in- volved maintaining proper temperatures few fur- naces through constant manipulation fuel and air valves has been eliminated, man can usually released for other work, that the control equipment pays for itself comparatively short time. The question recording instruments for commercial heat-treating plants has required some study. Some Double-Ended Furnace Has Burners Arranged Two Banks. Automatic control may set entire hearth uniform temperature, one end much cooler than the other for preheating through charge The Iron Age, May 15, | have maintained that without careful routing the sep- arate pieces and complicated marking the chart and record cards, the latter lose any reference value when number pieces for different customers pass through the furnace overlapping times. Too much depends the conscientious performance clerical work the oper- However, when controversy between the maker the piece and the commercial heat treater, the ator. arises chart, backed proper card records, becomes the referee. Where single pieces groups are involved each charge the furnace, sections the chart may filed with the eard, keeping the history the part Dayton Forging Heat Treating Co., Dayton, Ohio, has adopted such policy. When moving new quarters, was decided that complete automatic control should installed and full records maintained. This has proved most economical and satisfactory. The investment re- cording control equipment expected return many times the cost years come. removing the new location, usable furnaces were reconditioned and obsolete equipment replaced. tematic study fuels—cost, controllability, handling and made. This resulted the adoption natural gas instead the fuel advantages and disadvantages—was oil formerly employed. Old style burner equipment (noz- zle mixing oil burners firing through open ports with air infiltration) was replaced greater number sealed tunnel gas burners. The latter were manifolded and sup- plied means air-gas proportional mixers with auto- matic gas governors requiring but one valve control the temperature well the air and gas flow. number gas jets along both sides the furnaces simultaneously fed from one source give almost perfect chrome-molybdenum airplane tubing, and landing gear axles for the Air Corps, United States Army, Wright Field. Conditions for such work are especially exacting and require high degree uniformity temperature throughout the long pieces thin-wall alloy tubes. Test pieces are wired the fuselage intervals that condi- tions all parts the furnace interior may checked. These test pieces must show almost identical physical characteristics; example the close tolerances per- mitted, every test piece, say for 800 deg. Fahr. draw, must have ultimate strength between 175,000 and 180,- 000 lb. per in. Heat-treated aircraft tubing must scale free, that the furnace atmosphere must correct all times. This accomplished means automatic gas-air propor- tioning devices. The furnace also designed for two- zone heating other service, such continuous straight through operations. Each 11-ft. zone individually and automatically controlled temperature and atmosphere. The other hardening furnaces have been similarly designed and equipped. Three the old furnaces were enlarged hearth area that the wall thickness was cut the width one brick, in., which would seem elim- inate all insulation, vital economy and long furnace life. using expensive and special refractory brick combination heat resistance and insulation was se- cured wall almost equivalent that 9-in. wall composed half firebrick and half insulation. Such thin-walled furnaces operation are nearly cool the outside, and hold their heat overnight shut- downs nearly well the more conventional types, and the investment high priced refractory has more than paid for itself. The same general design was applied the pot fur- uniformity temperature even furnace in. wide naces, consisting number lead, cyanide and salt and ft. long. Such fur- baths shown the left rear nace shown one the the general view. Mani- erate Size. Quenching tanks (oil and urners were utilized, with welded assemblages water and oil tempering equipment gas and air pre-mixing, and foreground 1450—The Iron May 15, 1930 4 | these gave excellent results. Longer carbonizing and hardening furnaces, varying from ft. hearth, are notable for the uniformity with which the correct temperature can held. Each these furraces requires about 1500 cu. ft. gas per hour for the 2-hr. heating period, but after has reached temperature 1700 deg. Fahr. requires but 300 cu. ft. per hour hold the charge this temperature. Correct insulation, multi-burner firing and proportional gas-air mixing, with automatic control throughout, sponsible for this economy fuel and the same time produces excellent uniformity temperature throughout the whole furnace chamber. Equipment Quite Diverse ROM the following list will seen that the equip- ment installed the Dayton company capable great diversity operations. Two double deck hardening furnaces, each chamber wide in. high in. deep, for hardening and temper- ing smaller parts temperatures 1600 deg. Fahr. These are the left-hand pair the smal] furnace group. Three furnaces, in. wide in. high in. long, for use 1850 deg. Fahr. One equipped with Carborundum hearth, for pack hardening high-speed steel. One preheating furnace for high-speed steel, in. wide in. high in. long. One hardening furnace for high-speed steel, in. wide in. high in. long. One furnace, in. wide in. high 120 in. long for general purposes. One furnace, in. wide in. high 168 in. long for general purposes. One carbonizing furnace, in. wide in. high 120 long. This and the above two are the right foreground the general view. One furnace, in. wide in. high ft. long, with two zone control; for aircraft and general hardening. Pot furnaces, line along the left-hand wall, follows Two cyanide pots, in. diameter in. deep. One cyanide pot, in. diameter in. deep. One salt bath, in. diam- eter in. deep. One lead bath, in. diameter deep. Tank furnaces, toward the center the building, Two oil tempering pots, in. wide in. long One oil tempering pot, in. wide in. long in. deep. Quenching tanks, front the furnaces, follows: oil tank in. wide ft. long in. deep. One water tank in. wide ft. long in. deep. Two water tanks are in. wide ft. long in. deep. Two oil tanks are in. wide ft. long in. deep. addition there are minor auxiliary quenching tanks, s follows n. deep View Dayton Forging Heat Treating Co. Plant designed han- dle tools, machine parts, castings, and aircraft tubing —- well complete oil cool- ing and recirculating system. Furnaces with are equipped recording pyrome- ters operating Martin elec- tric control valves conjunction with proportional gas- air mixers and light signals. Pot furnaces are supplied with indicating pyrometer with switchboard for con- nection hot ends each pot. Oil tempering furnaces have their individual thermometers. Combustion air supplied four Spencer turbo- compressors and two North American blowers arranged dual piping for interchange when necessary. Gas piped from nearby high-pressure feeder line and reduced the plant normal operating pressures. All distri- bution piping under floor supported the side walls out sight. Causes Blisters Enameled Iron ECENT investigations have been made the Bureau Standards three samples cast iron intended for enameling which gave serious trouble regular pro- duction. Samples from one plant showed under the micro- scope spongy texture the iron immediately under the blister, recognized mechanical cause the defect. second plant was using steel-iron mixture, melted electric furnace such way that the resulting castings contained only 1.2 per cent silicon, and showed eutectic structure with excessive amount very finely divided graphite. was believed that this carbon was readily oxidizable during firing into gas which caused defects the coating, and the trouble was corrected reducing the amount steel scrap and increasing the sili- con content. The third consignment iron was normal chemically and sound when examined under the microscope. Never- theless possessed certain surface condition which caused blistering when enameled under variety condi- tions. discovered during extended research recently completed the Bureau Standards, this was entirely cured sand blasting and annealing the castings before starting the enameling operations. The Iron Age, May 15, 1930—1451 ar Bending Conditions Galvanizing How Produce Coatings Good Bending Avoiding Excessive Iron-Zinc Alloy Layer Essential DR. ING. HEINZ OOD bending qualities galvanizing coating are much greater importance for the rust-proofing iron (or steel) than generally pre- sumed. Especially for galvanized sheets and wires this quality the highest importance, because the former are bent when used for roofing, just the wires are bent when used for telegraph lines and fencing. If, due the unavoidable bending, there should IG. 1.—Showing the Elements Bending Coated Sheets, Being the Iron Base, the Iron-Zinc Alloy Layer and the Pure Zinc. the extent lengthening, the bending radius and total thickness the galvanized sheet peeling off the zine coating, cracks appear it, the protection which such broken coating offers the iron below very problematical. Results experiments deal- ing with the question the protection zinc coatings discontinuities the coating have been published recognized authority the subject. far the experiments show, the very small discontinuities—for instance, zinc holes—can afford pro- tection when there (as was the case the experiments) electrolyte very good electric conductivity. These experiments show, however, that this protection af- forded the main only when two conditions exist. The first that the discontinuity very small and the second that the zine coating thick. must thick because there considerable consumption the process this protection, and the coating only this much, +} + near the discontinuity quickly eaten away and very short time there more anodic metal protect the iron. Compact, Metallic Protection must recognize the fact that rust protection can given coatings only when compact, metallic layer pure covers the iron base. What have Iron Age, May 15, 1930 replace the sensitive iron surface one which much more resistant atmospheric attack, the cir- cumstances were any way such that the electrochemical protection the cell became effective, there would more protection expect, because the exist- ence such cel! would cause the rapid destruction the coating. view the foregoing, examination the interest- ing experiments Ulick shows unequivocally that there thicker coating zinc the specimen pos- sibly begins rust later. must bear mind that, however strong the attack the experimental period was, was short duration comparison with natural con- ditions, when even the thicker coatings would time eaten away under the influence the electrochemical cell. The experimental attack lasted only days, which period not long enough for the zinc eaten away, would the case during period atmospheric attack. Interesting experiments made Bauer show that the protective operation becomes evident only cur- rent density least 0.0000106 amp. the square centi- meter (0.0000684 amp. the sq. in.) the surface the iron produced this cell. Daily experience inspect- ing cracked galvanized coatings shows that such protec- tion practically never occurs. further fact regard zinc coatings that use they are much greater extent bent than the speci- mens the experiments. The result this treatment that the discontinuities practical conditions are greater than was the case the experiments. therefore clear that larger uncovered iron surface can longer pro- tected the zinc, except close the border the zinc covering. IG. 2.—Straight Length- ening Coated Sheet Changes Condition from That Left That Right, Without Peeling the Coating. Here the iron or steel base and B the layer zinc | \ N B \ IG. 3.—Unequal Lengthening the Base and Coating, Caused Bending, Leads Peeling. and are the base metal and zinc coating; the lengthening the neutral zone, and the differing lengthening the two zinc layers Nevertheless the fact must again and again stated that, the protection should affected the existence the cell, the zinc would eaten away too rapidly. there defect the zine layer, protective film zine salts produced, and this way the zinc capable withstanding the attack the atmosphere for some time, Coating Must Not Break Nor Peel What therefore imperatively demanded galvan- ized coating that should not break nor peel off under the bending conditions use. The opinion largely held, dealing with this matter the literature the subject, still that thick coating cannot have good bending qualities, and that they can obtained only very thin coatings. The same opinion expressed also the standard A-93 the American Society for Testing Mate- rials. The classification threefold: coatings bend- ing qualities, medium bending qualities and good bending qualities. these classes the coatings are further divided ac- cording the thickness the iron base. The inference deducted from this that coatings good bending quali- ties are thinner than those bad bending qualities. Fur- ther, may note that the coatings are have good bending qualities they must correspond some extent the thickness the iron base; other words, the thinner the iron base, the thinner the zinc layer. The explana- tion this fact have found follows: Fig. are shown the conditions for hot-galvanized coating when bent. There great difference lengthening the three layers hot-galvanized coat- ing. Especially interesting the lengthening the IG. different Zinc Co. bending; the lever paratus method used Washington Navy Yard. method, used New York Navy Yard, United States Standards and New Jersey In the latter T is piece ready for 135 deg.; compression over man- ready for 1.75- in. mandrel the lever drel for first bend; the oper- ating lever for spindle used hold the mandrel its work and B, blocks of outer pure layer, view the neutral zone the iron base. From the calculation given, the lengthening the pure zinc layer dependent the bending radius and the thickness the sheet. the calculation shows that the lengthening follows that the lengthening becomes greater the sheet thicker and the bending radius smaller. course can imagine that the danger the peel- ing off the coating increases with the increasing the lengthening. must also stated here that numerous experiments have repeatedly established the fact that, any lengthening galvanized sheet, the coating peels off only when the lengthening iron base differs from that the coating. the iron base and zinc coating are lengthened equal extent, there likelihood the coating 5.—Four Layers molten zinc into Sheet Are Shown iron-zinc alloy and Magnified Diameters. the pure zinc coating the base metal, the dif- breaking before the iron base. lengthening after the manner Fig. will therefore never result coatings peeling off. the case bending, the lengthening the iron base differs from that the zinc coating, that the two layers are stretched side side and concurrently different lengthening. The result that they are forced apart, shown Fig. This explains the well-known fact that galvanized coat- ings when heated peel off. must remember that there great difference between the expansion qualities iron and Under ordinary conditions the expand- ing zinc nearly twice that iron, Thus there difference the lengthening the two main layers, with Laboratory Ap- Test Bending the right after bending ready for wood or fiber The Iron Age, May 15, e e C- i- ar O- ing and its bending quality. The first thing must clearly understand that the zinc coating sheets consists different layers— different both their chemical compositions and their physical qualities. shown Fig. general galvanized sheet consists First there the iron base itself, and the iron, and may consist solid solution Per Cent Iron position approaching the compound Per Cent Further, this layer, follows usually the Showing What They Are Composed thickest layer, pure zinc. Fig. the dia- gram the iron-zinc alloys, shows the com- positions the different layers. the result separation and further the peeling off (To concluded) Firm Adhesion Zinc Iron the separation the layers, various meth- ave been tried, similar the one known under name “Galvannealing,” with view producing coat- ing good bending qualities more securely fixing the layers the iron base. This accomplished placing strong etween the layer and the iron interesting ago 1.3:..1 wre ape} Vas publsned a snore tin (American Institute Mining and Metallurgical Engineers, October meeting, preprint 1600C) which gives the results many experiments made with view finding out relation between coating thickness and bending qualities. the main arrived at, from this research work, again that only thin coat- ngs can have good bending qualities. Some the results expressed the A.S.T.M.., that thinner coatings are better for bending than thick coatings, and that the thickness the coating must related the thickness the iron base. Testing Bending Qualities will now deal with the question, how test the bending qualities coating. Fig. shown the apparatus used the laboratories for the researches pub- lished Mr. Stacy. must borne mind that the bending qualities zinc-coated sheet cannot ex- pressed the terms employed for iron sheet. The bending qualities the latter are measured the num- times can bent backward and forward with- breaking. i Zinc-coated sheets, however, must tested such way determine the bending radius over which the coated sheet can bent without the coating peeling off. This radius can expressed multiples the thickness the sheets, or, better, millimeters. This the only correct method testing the bending quality. have carefully considered the opinions cited above the relation between the thickness the zine coat- 1454—The Iron Age, May 15, 1930 Welded Construction Recently Built Ships list notable instances recent welding the shipbuilding industry, issued the American Welding Society, includes the following: Sister ships Pennsylvania, California and Virginia, built Newport News Shipbuilding Dry Dock Co., each utilized much welding that 45,000 lb. electrode was consumed each hull. The same yard has two merchant ships now under construction wherein the inboard shaft alley bulkheads, bilge keels and masts will completely welded. 272-ft. yacht, Viking, utilized welding exten- sively, which said have assisted materially obtain- ing the desired graceful lines. The Fore River yard the Bethlehem Shipbuilding Corporation delivered two colliers 350 ft. long with trans- verse seams their tank tops welded and with bulkheads wherein two rows rivets were replaced one row and continuous weld. The Federal Shipbuilding Drydock Co. Kearny, J., has completed five all-welded channel type scows about 116 ft. long, ft. wide and 10% ft. deep, and constructing two scows similar type that are ft. no Ofl The Truss-Weld Barge Corporation launched 8000- barrel gasoline tank 134 ft. long. Also, the Electric Boat Co. has just completed 1000-ton cargo deck barge, 118 10.5 ft. all-welded design. the construction this barge some 150 tons steel was used, and required 18,000 ft. welding and 3500 lb. welding wire. Lastly, there now under construction the Charles- ton Dry Dock Machine Co. completely welded 120-ft. oil tanker, and the Standard Steel Shipbuilding Corpo- ration, Los Angeles, Cal., 65-ft. yacht. Five-Year Corrosion Test Chromium Steel XAMINATION samples 13% per cent chromium steel, which had been hardened, ground free from scale, polished, and exposed under various circumstances five years ago the (British) Institution Civil En- gineers, shows that the bar which had been exposed the atmosphere above high-water mark was perfect condi- tion, and that which had been submerged fresh water was stained and slightly rusted but otherwise perfect condition, and the part embedded concrete was thor- oughly preserved. The bars which had been contact with sea water either continuously intermittently had been severely attacked. the coating. prevent Steel Plant Lubrication Problems Consideration Methods Used and Difficulties Anti-Friction Bearings Gaining Favor tests reversing mill engine have proved that about per cent its power em- ployed the actual rolling process; about per cent overcoming friction the engine parts; another per cent combating roll journal friction; and some per cent overcoming pinion and spindle friction. The re- maining per cent used producing acceleration the parts this analysis indicates, only per cent the total power shows usefully the product, while absorbs per cent. Some Modern Methods Lubrication some form other, modern lubricating systems and methods are rapidly replacing older methods. One the most outstanding these the so-called “circulating system.” includes main supply line, with branches the various elements lubricated, common return line take the individual returns from each element, suitable tank for receiving and cooling the return oil and separating water and heavy impurities from it, and means cleaning and purifying the oil, well storage capacity for the clean oil. One entire rolling mill equipped with “forced feed” system lubrication. This reaches every individual bear- ing motors, drive, roll housings, tables, manipulators and all auxiliaries. The oil circulated, cooled and filtered. Its supply interlocked with main control that the circulation should, for any reason, interrupted the en- tire mill closes down. claimed that this system efficient that make-up oil amounts only about 30c. day, what one oiler might easily waste hour. This system eliminates the uncertainties attendant upon lubrication the older methods. insures the machinery being always ready operate. This same mill, generously designed all parts, although means The accompanying article abstract paper read be- fore the American Iron and Steel Institute New York, May the degree mechanical and mining engineering, James was for several years engaged mining engineering. 1900 joined the Lackawanna Steel Co., then Scranton, Pa., draftsman and 1906 became chief engineer. When the Bethlehem Steel Co. took over the Lackawanna plant Buffalo continued its chief engineer, which position now holds. has been identified with the construc- tion and engineering progress the Lackawanna plant since its beginning JAMES brand new any respect, operated throughout 1928 with total delays chargeable failures equipment amount- ing only min. Roll-Neck Lubrication Bettered great improvement was introduced when babbitt metal was used the construction roll-neck bearings, giving alternate brass and babbitt areas. The result reduce the friction and make the lubricant more effec tive. This type bearing now being widely used steel plants. The brass usually insert, held posi- tion when the babbitt poured around it. partic- ular importance, however, have brass against the shoulder the roll-necks take the thrust. Lubrication vertical rolls has presented some espe difficulties. This has been particularly true their bottom bearings, since these were split open the bot tom, enabling the lubricant run out. Use bushing type bearing, closed the bottom, now effectively prevents this. Grease, applied through pressure fitting the bottom end the bearing, and able work out only passing upward between top flange bearing and shoulder roll, now used lubricant. This improved design both provides effective lubrica- tion and keeps water and scale out the bearing. Bear- ings constructed run for months without being changed, contrast with those older design, which often have changed every few days. They offer the further ad- vantage that wear the top flange almost negligible, with the result that their bevel gear teeth run the proper pitch line and their life prolonged. Special Problems Certain Equipment many instances, such ore-unloading and re- claiming cranes bridges, and overhead cranes the open-hearth department, this equipment must necessity operate atmosphere containing large amount 4 DUCATED the public schools Wilkes-Barre, Pa., where was born, and graduated from Lehigh University 1895 with The Iron Age, May 15, | 4 7 | | 7 ‘ 7 = s 5 | dust more less abrasive nature. the utmost importance take this factor into consideration when selecting the lubricant. Anti-friction bearings various types are finding ever-increasing use the steel industry. Practically all rolling stock, such transfer scale cars, hot-metal and cinder cars the blast furnace department, and charging box ingot cars, etc., the open-hearth department, are now equipped with this type bearing, mounted lust-proof housings. addition, the table rollers the most up-to-date blooming mills are now equipped. For lubricating this type bearing light No. con- sistency low-lime-base grease has been found effective warm weather, and cold test grease the winter. Mill motors, generators, mill engines, blowing engines and steam turbines should also lubricated some automatic method. automatic circulating system economical form insurance against shutdown. The correct lubricant must possess sufficient body establish the working surfaces metals film enough strength resist rupture from the pressures im- posed. The most severe pressures occur the engaging teeth pinions, owing the shock loads involved. The correct lubricant should also adaptable for use “circulating where constant reuse the same quantity oil entailed. Cost Lubrication regards lubrication costs, the following division fairly representative well-equipped steel plants: Per Cent Rolling miils.... $1.5 Coke plants 9.5 Blast furnaces... 15.5 Open-hearths Steam, air and water 0 Miscellaneous . 12.0 100.0 these percentages indicate, practically one-half the lubricants consumed steel plant consumed the rolling mills. The cost lubrication this instance has been lowered driving the rolls motors place 1456—The Iron Age, May 15, 1930 steam engines. Such cost for fairly large blooming mills 0.6c. per ton steel produced, when motor driven, and 0.8c. lc. per ton, when engine driven. Discussion One-quarter the power now developed motors engines could saved the best anti-friction and roller bearings could installed rolling mills, the opinion Burrell, general master mechanic, Inland Steel Co., Indiana Harbor, Ind. his experience, about half the repairs now made rolling mills are directly in- directly caused inefficient faulty journals. Condi- tions are much better now than five years ago, however, not only due better bearings and better lubrication practice, but better gears. Indiana Harbor works, centralized stations for oiling and greasing cranes and roll trains have been successful and economical, and con- nection with wage incentive system have resulted the following: Savings oil, per cent. Savings repair and maintenance charges, per cent, Savings bearings, per cent. Increased tonnage, per cent. Mekeel, Jones Steel Corporation, Pittsburgh, said that oils unnecessarily high viscosity are often fed journal bearings. Another general state- ment which might made was that force-feed oil desirable. Special locations require the use grease, such roll necks where water from the rolls would tend displace oil. Grease also used ball roller bearings matter convenience, and many gears which, virtue combined rolling and sliding contact between teeth, require lubricant some “body.” Mr. Mekeel emphasized the fact that journals must properly de- signed and constructed reasonable service had —sharp corners oil grooves are frequently left ignorant workmen and careless supervisors, which are more efficient wiping lubricant from surfaces than feed- ing between them. Makes Talking Picture Rolling Mill Co., Middletown, Ohio, has adopted moving pictures means supplementing special campaigns and presenting facts about its George Verity, chairman the company, shown the accompanying illustration the Metropolitan studio Hollywood, Cal., where made “talkie.” Ba awe fi > 3 Bulldog Slag Related Steel discussing the acid electrolytic theories corrosion, their au- thors not deal with the entire history. They fail state which step the manufacture iron and steel the injurious ele- ments and their compounds enter the metal. The writer Tracing Defects and Corrosion Back the Blast Furnace—Hot Acid the contemplated burden Slag Essential WILLIAM STEVENS The strata coke can figured correctly carry through the combustion zones with the proper cu- bic feet wind. Correct filling the furnace absolutely nec- essary, for quality and quantity depend onit. Any the opinion that the deviation filling reduction zone the blast furnace, relative slag, should considered the culprit. say “relative slag, because lately slag has been considered the cure-all blast furnace ills. ” Ninety-nine per cent the slag, may safely said, will used flux the earthy materials out the furnace. The per cent problematical. Let consider the elements and their compounds pres- ent the burden. know there are certain percentages acid, earthy bases, metallic oxides, etc., with hard soft coke for fuel, which will give certain reactions when fused temperatures high enough enable the fluid withdrawn from the furnace. The influence the ele- ments and their compounds different temperatures should thoroughly understood before starting figure their proportion the burden. The slag temperature, cause its viscosity, important. This indicates the ratio bases acid, which temperature use free-running slag. Wide Influence Carbon Content illustration: one the elements carbon; our finished product depends the influence which the carbon has oxides, silicates, sulphide, gases and mechanical properties. Once this influence known, interreactions between elements and their compounds will understood. *4110 Grand Boulevard, East Chicago, Ind. tive slant. HEN not sample, whose fault it? Often the open-hearth man blamed when the root the trouble much deeper. This presentation the the character which blast furnace slags frequently assume. Suggestions for avoiding this condition give the article construc- cause irregular travel, whether caused wrong weights, mix-up stock, top furnace out level, throwing burden one side, changing stock levels and other troubles, too numerous mention here, but with which the experienced furnaceman only too well ac- quainted. Another practice now being tried substituting smaller bell, with the obvious result that the burden reaches the combustion zones entirely different propor- tions. The standard bell distribution probably gives nearer ideal filling for American practice, and also brings the amount wind required the tuyeres. Unless the weight, density and influence the elements the mix passing through the combustion zones are absolutely known, are working the dark, speak. Brassert, discussing the combustibility coke 1914, stated that the early coke produced our by-product ovens burns too slowly, thereby making furnace operations diffi- cult, Joseph, Kinney and Wood, 1928, the same question stated their belief that, although the tuyere action important, more closely related the density the coke, the velocity blast through the tuyeres, tem- perature, viscosity and relations the slag passing through the tuyere zone, than the combustibility the coke. Neither Brassert, Joseph, Kinney nor Wood offers any reason for the fact that some slags not run freely 4 The Iron Age, May 15, 1930—1457 tuyere temperature. estimation the different writers should state that, cubic foot wind burn cer- tain amount carbon the blast furnace, will depend entirely the density the combustion zone. coke carrying heavy burden one side the question, and coke carrying light one the direct opposite.) Every furnace operator tries keep his combustion zone temperature many degrees higher than his slag tem- perature. The penalty for not doing obvious. Know- ing the results, takes chance and changes his combus- tion zone temperature putting stone his sulphur silicon happens above the limit with limy slag. Governing the Soluble Silica Now experienced man, realizing the influence elements and their compounds, would not put the stone. would make the necessary changes which gov- ern soluble silica the presence lime and magnesia silicates, which are formed. Not only are silicates formed, but also excess lime and magnesia, which case the ion will drop its silica. Just what becomes the which was the solution when the stone comes debatable. Will make the slag fluid? may that the first stopping place the silica will the combustion zones, where the obstruction shelf formed. That holds slag. follow the change stone through the pig: the operator’s cast will probably lower sulphur and silicon. physical characteristics pig will scrappy, slow running, with graphite evi- nee everywhere. Graphite, know, retards fluidity. nesses are also evidence, large and Certain weak- grain struc- ture, heavy cinder, and bulldog slag inclusions. This bull- dog inclusion follows through the steel. Its effect can- not removed any known process refining. Deoxidizing Agents Powerless Effects the gases which follow limy furnace pig ron cannot removed any deoxidizing agents. ould possible that the ameeba corrosion gets its start from this type pig iron. of Upon tracing this type iron back the reduction zone the blast furnace, will found that the only justifiable trait limy fur- nace that meets the chemical requirements, regard- less costs. And further, blowing the furnace after the cast, the pressure generally goes higher; short while sloppy tuyeres will noticed and the furnace will hang. perfectly natural question the cause. The slag has changed its free running condition and viscosity shows up, plainly visible, the resulting sloppy tuyeres. The tuyere temperature drops front these sloppy tuyeres spite high blast heat. this time one might try pierce the coke front these tuyeres with pointed steel rod. This interesting experiment will enable one understand the above state- ments. Hot Blast Cannot Pierce Viscous Slag The tuyere surrounded viscous mass acid slag, which the lime has dropped and which the furnace has built up, not only the walls, but front the tuyeres. The chilling starts because the hot blast cannot penetrate this wall; neither can radiation travel fast enough for necessary check the furnace, which results, usually, cleaning the blowpipes. escape from the sloppy tuyere condition easy, must still remembered that the steel almost sure contaminated the bulldog, the writer calls the slag this instance, for stays with the iron through the finished product, previously stated. 1458—The Iron Age, May 15, 1930 back the proposed change lime, the operator who understands the influence the slag elements and their compounds may not have put lime. had other changes made which gave him hot, acid slag, clean and fast running. The pig iron resulting from this cinder entirely different. clean, free from scum, fast run- ning, not scrappy, and has low graphite content. Pig Iron Meet Both Chemical and Physical Needs This iron not only meets the chemical requirements, but its physical requirements are nearly perfect possible, with almost nil amount gaseous and slag sions. The tuyere combustion zone temperature can handled easier with hot, acid slag. absence bull- dog slag practically assured. The obvious results are smoother running furnace and increased production lower cost. Blast furnace men are held, times, within narrow temperature limits make free-running slag. Present day pyrometers, commonly use, are not proficient enough record the temperature adequately. The techni- cal man starting this game could well learn how judge these temperatures from the experienced furnace man. This same condition might also exist with reference the slag. But will take the lead, with his knowledge physics plus geology and its history silicates. not any way claim that the open-hearth depart- ment can excused for making poor steel. But firmly maintain that, the pig iron used met with the bulldog slag its downward travel globular state through the combustion zones, will gather more impurities than any known refining process the open-hearth bath can remove. Aluminum Alloys for High-Grade Motors aluminum parts automobiles and aero engines made Rolls Royce England are new series alloys developed laboratories Hall Bradbury and patented under the family name “R. 50.” Four grades are made, for general purpose sand castings, for forging, for die-cast pistons and for forged pistons. All fall within the chemical ranges: Per cent 0.5 5.0 Nickel 0.2 1.5 Magnesium 0.1 5.0 Iron 0.6 1.5 Titaniun 0.5 Silicon 0.2 5.0 Aluminum temainder According paper Devereux, read before the (British) Institution Production Engineers and re- ported Metal Industry, sound, dense castings are easily made those modified aluminum- silicon alloys, and, after heat treatment 175 deg. and suitable aging, are much superior tensile proper- ties and toughness. Comparative figures for the various forging alloys were quoted follows: Forging Temperatures Treatment Maximum Minimum Quench Age alloy 500 350 520 boiling water hr. The alloy was acknowledged definitely superior for high-temperature service. Warping and cracking has always been one trouble associated with these high and long-continued heat treatments, especially change section. has been avoided immersing the cold cast- ings crushed mixture sodium and potassium nitrate (equal parts) and heating gradually until the salt melts and attains the desired soaking temperature. — — — Steel Industry Needs Scientific Research Science Has Lifted Steel Manufacture Far Above the Rule-of-Thumb but Fundamental Research Necessary Meet New Demands ARTHUR LITTLE must obvious that, before you can utilize full advantage ma- terial exhibiting properties diverse iron possesses, exact and fundamental knowledge the real na- ture the material itself and not only the con- ditions that properties, but also the ultimate manner which these changes are effected. Having mind the vast development dustry and the imposing array its varied prod- ucts, would not, myself, presume say that you lack this essential knowledge, but shall quote those whom you regard best informed. tomorrow. Two years ago Dr. Hatfield said: over- whelmed when realize how much there that still not know; when realize how many the simplest expe- dients the industry are archaic, and how relatively backward science supplying the knowledge natural law necessary for advancement; with many the com- monly accepted and so-called ‘facts’ which really believe are not facts all.” Sir Robert Hadfield says: science metallurgy, notwithstanding the amount research and investigation already accomplished, still presents many directions practically unexplored field for the investigator.” George Kelley says: “Theories the hardening The accompanying article an_abstract paper read be- fore the American Iron and Steel Institute New York, May DUCATED the Massachusetts Institute Technology, Dr. Arthur Little has been actively connected with many important industrial developments, among which are new processes paper mak- ing, artificial silk, chrome tanning, cellulose acetate, chlorate potash, etc. life member the Corporation the Massachusetts In- stitute Technology, the National Research Council, consultant for Chemical Warfare Service; president Arthur Little, Inc., chemists and engineers, Cambridge, Mass., and director Arthur Little Industrial Corporation New York. past-president the American Chemical Society, American Institute Chemical Engineers, and the Society Chemical Industry (London). the author “The Fifth Estate,” “The Handwriting the Wall,” and numerous essays and addresses FTER outlining the vances made the steel industry the last century the aid the sciences chemistry, metallography, electricity and mechanics, Doctor Little quotes several prominent metallurgists the effect that our ignorance still exceeds our wisdom. points out how scien- tific work responsible for the various markets this, the machine age, and that the steel industry must generously finance the fundamental investigations which will enable meet the demands metals are still process formulation.” Quotations similar import could doubtless multiplied times. Those here are given with thought minimizing the brilliant and results already achieved the many gifted scientists whom problems have been studied. pur- upon you that you have still very far before you can hope have that com plete mastery your ma- terial which only the edge its fundamental character can give you. Science, the Maker Markets Much you may expect from the laboratory the future, the present obligation your industry science extends far beyond its contributions your methods production and control. has created all the major mar kets for your products. your most efficient salesman, and works without salary commission. Mathematics supplies the and the testing laboratories supply the data without which there would great suspen sion and cantilever bridges, steel-framed skyscrapers, heavy guns and armored battleships, huge ocean liners and railroads know them now. The auto mobile the product science; science has immensely stimulated the petroleum industry, your manufacture tin plate has reached its present proportions only because the processes the canning industry are super- Arthur Little The Iron Age, May 15, | | od — vised and its product protected the bacteriologist, and there would science biology except for the optical physics which created the modern microscope. Your good customers, the electrical industries, whom you sell steel for huge power plants and generators, elec- tric railroads, countless motors and transformers, and the towers long transmission lines, trace their origin the experiments Faraday, which, may assume, the steel makers 1831 saw little significant importance. The demands the chemical engineer upon the steel maker are becoming increasingly rigid their require- ments, and they differ many respects from those the mechanical engineer. temperatures The very high pressures and moder