The Iron Age 1930-06-05: Vol 125 Iss 23

IRON New York, June 1930 ESTABLISHED 1855 125, No. Home Modernization—A Way Out for the Construction Industry ONSTRUCTION far reaching its effects that all efforts stimulate are interest the business world. The main purpose the Hoover conferences, following the stock market crash, was set motion maximum amount both public and private work. Public utilities and large industrial organizations were appealed particularly, since many those companies have long-range programs that are planned without regard temporary fluctuations trade. The railroads and other utilities responded way that exceeded expectations. Capital expenditures Class railroads for new equipment and additions and betterments totaled $223,772,000 the first quarter, $11,772,000 excess the esti- mate submitted President conference December, and $96,653,000 above the outlay for the first three months 1929. Residential Building One-Third Normal These and could be, undertaken because they were needed and the carriers were financially able carry them out. mere exhortation “build now” suf- depression. This has especially clear connection with residential build- ing. Easier credit has reviving struction, the face evidences over- building many parts the country and increase real estate foreclos- ures and tax sales. Normally the value residential construction equal that all other forms building combined. has been only one-third its normal vol- ume and about one-half large that for other kinds construction. With the door closed early increase dwelling house construction, the outlook for manufacturers mainly dependent that form activity has been anything but bright. However, business recession puts men their mettle other periods. not surprising, therefore, that human ingenuity has found what seems way out this dilemma. Modernizing Campaign Started May May the American Radi- ator Co. inaugurated home modernization campaign. out- lining the program, Herske, director sales promotion, said: “From time time intermittent and sporadic efforts have been made obtain our share the business available this mar- ket (home modernization). How- ever, consistent, intensive ef- fort has yet been continuously applied convert this market into immediate sales Sixteen Million Homes Without Radiator Heat pointed out that there likelihood gain home build- ing even dupli- cation the 1929 vol- ume. “That leaves,” concluded, “only the modernizing field immediate increase total dollar sales.” Census reports, the company found, q show that 16,000,000 homes the United States are without radiator heat. one out hundred were equipped with radiation, the total would 160,000 homes. Estimating the average investment materials $300, the expenditure for the 160,- 000 dwellings would $48,000,000. While the conversion high percentage homes radiator heat this year improbable, the American Radiator Co. lieves the sale improve- ment projects 1930 one out 500 the 16,- 000,000 home owners means impossible task. Will Call for More Labor ceeds. and Materials Instalment This plan, will represent resultful method allevi- ating the current business depression. materials whose trade will sion. stimulated include man- ufacturers iron, steel pipe, pipe steel sheets, cast iron soil pipe, lumber and, course, the radiator company it- self. Materials, esti- mated, will account for per cent the total cost the job. subsidiary. Employment will increased, both among sup- pliers equipment and materials and among those installing the work. Direct labor the job, mated, will represent per cent the total cost, while per cent esti- vill taken contingencies and profits. Needless say, the work will help carry overhead jobbers, steamfitters and plumbers, besides swelling their earnings. Complete Merchandising Campaign Prepared one thing conceive plan and another thing execute it. The American Radiator Co. has pre- pared complete merchandising plans, covering adver- tising and the canvassing and selling prospects. Separate instructions have been prepared for the com- pany’s own branches, for jobbers and for plumbing and steamfitting contractors. All accessories the merchandising campaign, including window displays, broadsides, form letters, bid pro- posals, posters, guarantees and contract forms have been provided. Extra compensation offered the com- pany’s salesmen and suggested that jobbers also offer in- ducements their organizations. The combined force the company and its jobbing con- nections 6070. sales sales 1664—The Iron Age, June 1930 Large amount materials and labor will required program suc- selling, feared would accentuate business de- pression, being used ease the reces- Entire cost each improvement job will financed American Radi- ator Standard Sanitary Corporation Complete merchandising campaign prepared for company branches, job- bers and steamfitters. possible means advancing the program has been overlooked. Even em- ployees the company’s manufacturing plants are being called upon help. inducement they will given cash prizes for “tips” resulting the sale prospects. Great been placed getting or- ders soon possible, that some the slack can taken out the com- pany’s dull season manu- facturing. interest- ing note that the instru- ment that counted most bring this about the deferred payment plan —the very thing that had been expected accentu- ate economic distress fol- lowing the stock market debacle. Instalment pay- ments means allevi- ating depression—a new role for plan still re- garded many threat sound prosperity! “The time payment method proved suc- according the American Radiator Co. “It has been used for years sell more pianos, more vac- uum cleaners, more washing machines, more furniture. has even been great success method selling automobiles, which depreciate rapidly value. which many “For many years real estate and homes have been sold time payments. ... Neither the real estate nor the building subject rapid depreciation value. heating equipment and plumbing fixtures are built in—that is, they become fixed part the house and they last for years. Make easy buy! Sell heating time payments.” Company Finances Entire Job finance instalment payment jobs the Heating Plumbing Finance Corporation was organized. subsidiary the American Radiator Standard Sanitary Corporation, and does not, therefore, aim make profits. This company finances not merely the materials, but the entire cost the job. The entire machinery the instalment payments handled the finance corporation. soon work completed, the steam- fitting contractor receives his entire compensation. small initial payment—a minimum per cent the total cost the job—is required the home owner, but further payments are deferred until the fall when begins using the equipment. 100-ton electrically operated testing machine has been installed the College Art and Technology, Leicester, England. Specimens long can stretched and wedge grips will take 3-in. pieces. 10,000 Automobile Frames Day EARS ago, when first saw automatic wire- fence machine, with its processing parts moving with the precision German soldiers parade, was much impressed with the possibilities and the potentialities automatic machines. Each part han- dling one the small sections wire—vertical the erected fence—took from coil the cutter snipped proper length. The little pieces wire were then swung around, put into position across the longi- tudinal wires and the ends quickly coiled around the longitudinals, thus forming the completed fence. All this, course, was done while the longitudinals were moving slowly and uniformly through the machine. Such equipment that, however, presenting merely few moving parts single machine, suffers once contrast with massive group machines several production units, such are employed the automatic frame plant the Smith Corpora- tion, Milwaukee. The impression one gathers after watching that plant work, turning out its product the rate 450 automobile frames hour, may perhaps expressed statement made the guide who showed through the works. said that professors mechanical engineering universities within striking distance Milwaukee are handling psychological problem with their stu- dents the following manner: the seniors ap- proach the end the course—as, indeed, they see the finish short distance ahead and believe that there nothing more for them learn—their bumptious- *Associate Editor, THE IRON New York. Conveyors and Coordinated Ma- chines— Processing and Assembly Timed Split Seconds = ness taken out them visit this plant. groups dozen, score, more, they are passed through the plant, where they see the array automatic, synchronized machines operation, many them without man anywhere near. And, with chastened spirit, they depart, with the idea that per- haps there may something left learn, after all. Naturally, such plant did not spring into exist- ence over night. represents the result some years development, from the time when the first automobile frame pressed stee] was made, 1903. was not, however, until 1920 that this plant was completed. And, course, has been subject re- vision much the detail since that date. fact, constantly being revised, within limitations, improved methods performing certain operations are developed. Manufacturing Employed UCH what follows taken from paper read the Chicago meeting the American Society Redlin, assistant works manager. THE IRON AGE pub- lished brief description this plant the issue March 22, 1928, page 794, which several illustra- tions showed the main operating units. Other illus- trations, from changed points view, are those here- with. While the plant has eight manufacturing units operation, the four principal manufacturing esses, taking place one large room, are the items The Iron June especial interest. the first employing six large presses, the lengths strip steel are cut, punched and finally formed side-bars, rights and lefts alternately. this press line the steel passing through the four operations handled entirely conveyors. First the straight strip “kicked up” edgewise for the contour the side rail. Next the numerous rivet holes and other openings are pierced, the rights and lefts separate Then the blank- ing press trims the out- presses. distance (sidewise) for the operation performed. man places hanger other part proper posi- tion, drives one two rivets home with hammer and the carriage withdraws the two parts. Then the whole machine moves the carriage forward another space. this next location, soon the members have been carried sidewise the fixtures, automatic mechanically operated riveting machine comes into play, forming the rivet head single crunch. All this movement taken care the mechanism back the machines, the which then are fed into riveting heads being the two forming ma- ELECTING and opened like jaws suffi- chines, right and left, for ciently (after acting) folding the flanges that the carriage fixture channel section. Every through pickling line without fouling any vats, forming into side-bars, at- taching hangers and clips, assembling rights and lefts with their transverse members, rivet- ing all into completed automobile frame, cleaning, painting and drying —all hours—these operations performed mechanism, are de- other blank goes into the first machine, the alter- nate blanks being auto- matically turned over be- fore reaching the second machine —thus forming the rights and lefts. the second group machines, Unit No. these rights and lefts are machinery. the operation goes on, station after station— all—a hanger being attached here, there, rivet (or two them) driven this station, the end the bar clipped off final form fitted with the various spring hangers, brackets attachments which they are carry frames hour. the completed frame. The ends are clipped off close tolerances and additional holes are pierced—those which certain scribed here. Each piece sec- onds behind the next one, for the plant geared 450 finished Fractions sec- onds count here, everything must fit exactly where belongs, the whole works not suffer. another station, until the last the the two side-bars are com- pleted. Here they are discharged automatically, the rights one side, the lefts the other, for in- spection. Meantime, the trans- must come very close. Meanwhile, the four rows Unit No. the cross bars bers are made and similarly fitted with their clips and other This again entirely auto- matic, timed operation. or transverse mem- attachments. Unit No. the general as- sembly line, where the side bars and the transverse members are brought together and automatically riveted each other, making the completed frame. What operation lies particularly impressive about the whole especially the side-bar sub-assembly and the final assembly the entire frame (Units Each these two units operated indepen- dently, but each within itself complete, coordinate whole, having all its movements synchronized defi- nitely and with the utmost precision. Side-Bar Sub-Assembly Operations PERATING stations the side-bar sub-assembly are all equal distance apart, center center. Carriages the conveyor system are moved forward, predetermined intervals time, from the one sta- tion the next succeeding. Each carriage has right-hand side-bar exactly positioned fixture one side and left-hand bar similarly placed the other side. The carriage moved forward one space. stops and the fixtures top move outward definite 1666—The Iron Age, June 1930 verse members, shorter and less complicated, have been made similar lines machines and they turn arrive the same point for beginning assembly. Bringing All the Parts Together SSEMBLY the frame, from the sub-assemblies briefly outlined, takes place three parallel lines running across the building. Each frame traverses all three lines, moving south one line, then north the center line and finally south the third line completion. This contrasts with the side-bar sub- assembly, which was all one straight-away line running lengthwise the building. This general assembly performs two important functions and does both entirely automatically. collects all the required parts for the frame and as- sembles them, and puts all the rivets, finally “set- ting” each rivet forming the rivet heads. One conveyor system with trucks takes care the first function, so-called “nailing machine” assembles the frame and puts the rivets, while another conveying system equipped with other trucks handles the last function—the riveting. All three sub-units are syn- chronized and operated with one single motor. special set carriages, operating different time schedule, and entirely independent the side- bar sub-assembly, functions during assembly. 7 : : : : : : : : : : : : : : : : : : H : : : : : : = H : : : : : : : : : : : : : : | 4 s 4 7 : | : : : d 7 UTOMATIC Riveters Work Final Assembly. Near upper left the loose parts are moving toward the “nailing machine,” shown center background. Thence the frames move toward the observer, second line, and away from observer, line foreground. The riveters approach their work, perform and recede. Then the frame moves next station (above). upper center (below) the end side-bar sub-assembly. Two frames racks center picture are passing from assembly line the final line right. Spare riveting machines appear foreground The Iron Age, June 1930—1667 7 7 7 7 7 right side-bar and left side-bar are placed fix- tures the carriage, both bars being positioned defi- nitely some inches farther apart than they will frame. this assembly rig moves forward one station after another, the various cross-bar transverse members are also put into their respective positions fixtures. Eventually this group related parts reaches the t — A j AINTING Conveyor, Showing Frame Left Being Picked from Exit Cleaning Oven, Through Painting Oven and Return, Right, Dry and Ready for Storage nailing machine the end this first line, moving sidewise into the nailing machine proper. There the two side-bars are shoved against the ends the tranverse members, and thus into final position. Automatic rivet-feeding heads swing into position and rivets are shot into the holes waiting receive them. Air pressure accomplishes this task, about 100 rivets varying sizes, from feed-hoppers below, be- ing put into place accurately, definitely and quickly, one operation. Then, the nailing heads being with- ‘drawn, the whole frame, with the parts now final juxtaposition and held together with unheaded rivets, picked and placed truck the middle as- sembly line, parallel the line which took the frame parts into the nailing machine. 1668—The Iron Age, June 1930 Two trips are made across the room, between rows riveting machines. After the first passage the en- tire carriage with fixtures and frame moved side- wise the next line. then makes the final trip through the last row machines, and emerges the far end with all rivets properly headed and ready for inspection finished frame. Four eight riveters here function each sta- tion, half each side the frame. Having performed their task, their withdrawal precedes, tiny interval time, the controlled movement the car- riage the next station. the great precision with which all the motions such complicated machine are syn- chronized which perhaps most impresses the visitor. defi- nite time element enters, inas- much the entire plant frames hour. This means that, the average, each oper- ation each one the major production lines must must realized that this 8-sec. period covers not only the manu- facturing operation, but also the time interval required for bring- ing into position, withdrawal working tools and movement the next position. From the automatic inspec- tion machine, which straightens and checks every piece strip steel received from the mill, automobile frame into storage takes minutes. During this period the steel passed through the pickling vats, deliv- ered the automatic machinery briefly described the above paragraphs, completely essed, assembled, inspected, washed clear all grease and dirt, painted and finally baked. How the Many Conveyors Operate every conceivable type and design con- used this automatic plant. Under the pressure necessity, inventive skill has here brought out startling variety material-handling devices. Many old and approved means were utilized, but addition great many entirely new devices were invented. The common reciprocating rail feeder found use many instances, for the inspection machine, the side-bar and cross-bar press lines. However, ap- (Concluded page 1728) ARGE blisters the cen- ter one end sheet made from soft steel rimmed heat were reported the chairman the Rimming Steel Quality Control Committee had made analyses such and found the carbon, man- ganese and sulphur all higher than called for. attributed this trouble the sheet in- sufficient cropping the bloom. These ingots raised after pouring. Small blisters sheets, which have been cause perennial trouble, are difficult remedy. not know fully what produces them. comprehensive report this subject, however, was made the Youngstown meeting May, 1928. Temperature difficulties differences, particularly too hot temperature, were given one man the main cause blisters. This results too thin slag and other conditions, one leading another. Such steel too slow starting rim. metallurgist reported that blisters seem come occasional doses. His plant had run one time for months without any such trouble, and then ran into lot bad cases. This spotty experience seems have been observed other men present. Getting Away from Segregation man making largely forging steel reported get- ting away from segregation melting well above the carbon for which the steel was made, and then working down stirring with rods. This practice permits him carry, all through the refining period, slag very similar finishing slag. makes ingots all the way from in. in. diameter, and weighing from 8000 200,000 lb. each. His charge per cent iron, with ore used only occasionally and very little. Segregation the 80-in. ingots reported worse than the smaller ingots. These large ones are poured with the large end down, while those in. are customarily poured inverted. All are teemed through 2-in. nozzle. The 80-in. ingots are Rail fractures, one man reported, are caused mainly segregation one more three ele- ments—carbon, manganese and phosphorus. Carbon, says, the worst offender. Both carbon and man- ganese concentrations are blamed for brittleness. Chipping costs were given considerable attention, This follows the first instalment, telling the meeting the Open-Hearth Committee, published last week, page 1601. Control Quality and Combustion Making Steel very complete records having been kept one organ- ization. general, the bottom bloom from ingot has the highest chipping cost, and the figure drops successively through the different blooms. eight nine heats, completely analyzed, the average cost was about $1.30 the ton steel. The average all the low figures these heats was 37c.; the high figures, $2.40 ton. The maximum for any ingot was $4.82, and the minimum 10c. The lowest average for any heat was 55c., and the highest $2.39 ton. Variation from ingot ingot within heat was reported two speakers greater than the varia- tion from heat heat, using average figures for similar grades steel. Attempts were made elimi- nate other variables, such the individual soaking pit which the steel was held. some cases, the high and low-cost ingots were the same pit. All these heats were poured under normal tem- peratures and other conditions. There much specu- lation the reason for this great difference result, and the matter being probed further. Another speaker reported having had results tests examined from different heats steel. Each heat had about ingots, and tests were taken from the second, seventh and fifteenth each case. The cost ratios ran about 3:3:8. This was fairly uniform for nearly all the heats, the highest cost being for the fifteenth ingot. Getting Carbon Analyses Quickly carbometer was reported one operat- ing man give him his carbon determination about min., for high-carbon steels. With low- carbon steels the test takes min. so, because the steel held about minute longer the mold. The chairman reported that accuracy about points claimed any carbon around 0.40 per cent. One operator reported using this method all steels having above 0.12 per cent carbon. uses particularly making steels calling for carbon range about five points, and gets the results reports that they check within one two points the more leisurely laboratory analysis. These test pieces are all killed the spoon with small quantity aluminum wire. Combustion tests take about min. for com- pletion one plant. When the heat nears the stage which reports are wanted, test taken every min. Thus there report every min., but lag min. from the successive tests. Combustion Control ONTROL combustion gives pro- duction, uniformly high, said Joseph Shadgen, the Smoot Engineering Corporation, New York. The Iron Age, June 1930—1669 7 While his discussion was based upon his own experi- ence installing Smoot apparatus, was given general character applicable other types control. Control gives consistency performance whereby today’s record like that yesterday’s and tomor- row’s repetition. Better quality metal pro- duced because the combustion conditions remain set the equipment. This whole matter combustion control still the development stage. application, all comes down education the personnel. The operating men first are not pleased with the innovation. seems discredit their own attainments and take away part their responsibility for making good steel. After week two, much this latent opposition tends disappear. The benefits better quality and higher tonnage make themselves manifest, and pres- ently the men reach the conclusion that the equipment very much worthwhile. After month two has been found that the melters will not willingly operate without control equipment. Meeting Engineering Problem Each furnace proverbially individual. How- ever much alike furnaces may built, they have their separate characteristics and must handled such. The application must along engineering lines; the mechanical equipment must fitted ac- curately and erected properly and the clearances must Much research work needed along this line. There are many variables that considerable study will needed existing and prospective installa- tions before can entirely sure how control can best handled. The one great benefit from com- bustion control that the matter combustion set once for all, and thus this one the many vari- ables eliminated. For proper operation the furnace pressure must maintained definite point. forced draft fan connection with this desirable, because gives ready means regulate the pressure. Also, this makes the operator independent measurement the air conditions and stack changes. Long Tonnage Runs Controlled Furnace Commenting upon this discussion the value combustion control equipment, one operator who has installed such equipment told getting 536 heats from his controlled furnace the first run. Then the furnace was taken off for repairs, not because the roof had gone, but for another reason. There was still in. thickness left the 15-in. roof. There was little difficulty found this furnace, the down-takes and slag pockets and checkers being good condition. Oil consumption during the entire run averaged about gal. far with the succeed- ing run the average has been gal. the gross ton Burnt lime used Another operator reported upon (25-ton) furnace put 1927, insulated with Sil-o-cel and sheathed with steel plates over the necks and regen- erators. The furnace has 12-in. roof. After run- ning 500 heats this was shut down because obstruc- 1670—The Iron Age, June 1930 Add Add Ore Per Carbon Bath Units Time Fig. 1—Building Iron Oxide Content the Car- bon Drops, Showing Influence Ore and Silicon Additions and the Reboil tion the regenerators, which resulted closing the flues. The roof was found burnt only about in. Regenerators Need Absorptive Powers rebuilding, the regenerators were redesigned, but proved not have enough absorptive capacity for heat, resulting the stack temperature running 1350 deg. Fahr., place the previous 1150 deg. The furnace was shut down after 1080 heats take care clog the regenerators, caused water leak. All this time change was made the roof. Starting again, the furnace reached 1500 heats and again had trouble from water leak the re- generators, the bottom which was about ft. below the ground water level. 1975 heats the same trouble again had remedied, after which the furnace ran total 2532 heats, and then was shut down for repairs. This acid furnace. During its first 500 heats used about gal. oil the ton. The figure went gal. after the checkers were redesigned, because insufficient heat-absorbing area. Its aver- age over the entire run 2532 heats, lasting from January, 1928, until April, 1930, was 29.9 gal. The tonnage charged this period was 64,205. Ran 2532 Heats One Roof During all this period there were repairs the roof the backwall. There were new front arches required, mainly because damage from charging boxes. Draft was entirely natural, the stack, having in. damper opening. this furnace used steel foundry, where the yields run from per cent, the fuel consumption was based upon the charge. One steel-works operator an- nounced that the figure given would equivalent about 34.5 gal. the ton ingots, ingots had been poured. Another operator using different type control for combustion reported that the furnaces having that 040 | 020 7 7 Rate Carbon FeO Fig. 2—Temperature Has Influence Product Carbon and Iron Oxide for Given Rate Carbon Elimination control have better production rate about per cent than the furnaces without it. The fuel rate has been improved, the control, about per cent. Steel Melting Progress Report EVERAL topics were introduced the report the steel melting committee, which Dr. Herty, Jr., chairman. There were progress report the work done the study oxides steel, an- other progress report the effect residual alloys coming from the scrap the charge and brief dis- cussion the speaker’s aluminum oxide method measuring steel oxidation. Alloy contamination may come from either the pig iron the scrap. Even trace tin, picked from the scrap otherwise, found fatal the use sheet steel for deep stamping. does not affect other steels badly, but must kept below 0.5 per cent the material rolled into rails. many cases steel will not roll all has much 0.75 per cent tin. ALLOY CONTAMINATION OPEN-HEARTH STEEL December, 1929, January-February, 1930 Plant 0.13 0.11 0.035 Nil 0.090 0.208 0.041 0.002 2 0.33 0.24 0.080 0.001 0.026 0.049 0.004 0.002 3 0.28 0.42 0.024 0.002 0.061 0.196 0.033 0.005 0.30 0.40 0.027 0.001 0.057 0.038 0.004 0.002 0.10 0.16 0.017 0.002 0.028 0.060 Nil 0.001 0.05 0.15 0.004 0.002 0.044 0.081 0.011 0.004 0.57 0.25 0.045 0.002 0.081 0.043 Nil 0.004 s 0.12 0.20 0.003 0.002 0.053 0.063 Nil 0.002 9 0.71 0.35 0.043 0.002 0.006 0.058 Nil 0.001 0.17 0.32 0.027 0.002 0.046 0.117 Nil 0.004 0.14 0.16 0.069 0.003 0.008 0.099 0.016 0.001 0.07 0.11 0.032 0.002 0.045 0.219 0.028 0.005 0.08 0.18 0.006 0.003 Nil 0.058 Nil 0.006 0.03 0.08 0.004 0.002 0.058 0.092 Nil 0.002 15* 0.80 0.26 0.009 0.004 0.066 0.150 0.058 Average ton- 0.030 0.002 0.043 0.099 0.010 Automobile scrap heat, per cent scrap, per cent 0.016 0.010 0.120 0.292 0.053 *Only five days’ sample submitted. With less than 0.40 per cent tin steel may forged readily. With that amount greater, how- ever, the bars become red-short and have re- heated time after time there much forging operation done. Copper Not Always Deleterious There much difference opinion the effect copper. was stated that some the troubles commonly attributed copper are very likely due the last analysis sulphur oxygen the presence copper. steel that has both high sulphur and high oxygen content may very red-short, whether contains copper not. However, with either high sulphur high oxygen the copper may the cause the red-shortness. Fifteen steel companies have been cooperating for several months sending samples from one more heats day, for the purpose determining some the characteristics resulting from these alloy inclusions. strong plea was made for further co- operation, that the results might more repre- sentative. The table gives the result the average returns from the companies reporting during De- cember, January and February. Later reports are process compilation. The companies reporting have annual capacity about 7,000,000 tons steel. Determination Steel Oxidation Fig. represents the progress open-hearth heat after melting about 0.80 per cent carbon. The drops rapidly, shown. takes still sharper drop when ore added the bath, and then resumes something its former curve. the reboil, which takes place after the addition silicon has been melted, the copper drops off increased rate, shown. Meantime, the iron oxide has been going grad- ually upward from light figure the time the charge was melted. Addition silicon drops sharply and holds low level while the silicon melting. Then climbs rapidly, the slope the climb being controlled the slag conditions, until the end may around 0.20 cent. There fairly well defined band iron oxide content, shown the two lines covering this phase. This band has greater width the heat proceeds until, the end the heat, may two three times the width attained the time add- ing silicon. Conditions Affecting Iron Oxide will noted from the diagram, the building the iron oxide content becomes much less rapid immediately after the reboil. This because there much oxygen taken out the bath the re- boil and there less left combine with the iron. This accounts for the widening the band iron oxide, less and less carbon remains take out the bath. The iron oxide content the bath any given time governed two things: The rate putting into the bath from the slag and the rate taking out the influence carbon, changing the FeO CO. Agitation the bath may vary this The Iron Age, June 1930—1671 0.05 0.04 0.03 0.02 rate enormously—in one case measurements show variations from lb. minute much 300 lb. This agitation controlled almost entirely the rate carbon elimination. there high amount FeO the slag, high temperature and fluid slag, together with much agitation, the absorption FeO into the metal may fast. If, however, these four conditions reversed, will slowly. Relation Carbon Iron Oxide Rate carbon elimination may given the ente an +} maitior sents actual conditions and e represen tne ¢ L1L10F) Fig. 3—Effect Adding Alloy Low Melting Point: Iron Oxide Drops Sharply and Silicates Build Up, Only Drop Shortly Afterward Fig. 4—Effect Silicates Adding Silicon the Bath. After building up, shown the hump, the decline resumed, either sharply (full line) more gradually, de- pending upon the character the heat being made equilibrium. This equation shows the minimum FeO which can obtained for given carbon con- tent given temperature. higher temperature reduces the FeO for the same carbon content, shown Fig. that diagram shows the dif- ference represented the formula above. For example, FeO 0.01, and the carbon 0.10 per cent, this heat will have more than 0.10 0.01 per cent FeO, for 0.10. 0.10 Measurement steel oxidation the aluminum method based upon the equation 2Al 3FeO 2.11 the FeO content obtained. This factor takes account several smaller elements entering into the matter, such etc. Cleaning Dirty Steel Study number alloy heats has been made Doctor Herty, all which showed very dirty Iron Age, June 1930 steel the time the reboil after the silicon addi- tion. other cases, however, when ferromanganese was added the bath just before the silicon, the heats there were found clean the reboil clean rapidly afterward. Indications this are shown the table, for representative heats this character. Percentage Silicates the Bath Min. the Before Reboil Reboil A—Si d alone 0.063 0.061 min. before sil 0.038 0.015 Spe l alloy used 0.070 0.0065 the case heat where the analysis for silicates shows almost the same the reboil min. before, evident that practically all the cleaning the heat occurred after the reboil. With heat however, which the ferromanganese was put from min. ahead the silicon, not only was the heat much cleaner, but much this cleaning had been done before the reboil occurred. The same true the third heat, which special alloy mixture was put which has been designed for the purpose cleaning these heats. (To concluded) Metals Known the Ancients ARLY uses metals were discussed Rickard, Berkeley, Cal., former editor Mining Scientific Press, before the last meeting the (British) Institute Metals. Mr. Rickard brings wealth information bear the subject gleaned from visits mineral deposits all parts the world, from ancient writings, and from the work archeologists. contends that gold was the first metal existed the pure state bright nuggets stream beds all countries—the primitive highways—and easily malleable into ornaments, but too soft for useful tools. Native copper nuggets furnished the first tools; also material widely distributed nature, “its use marks the beginning every ancient metal culture,” and relics pre- dating 4500 B.C. have been found. Native silver ornaments are also contemporaneous. The first iron articles were fashioned from meteorites considerably later date. Discovery means fashion pure metal melting and casting introduced the age metals. later and longer step forward was the ability smelt impure ore. This was first practiced about 3500 B.C. Smelting copper oxide carbonate beads copper will occur any vigorous wood fire; ores containing mixed minerals two more metals were smelted similarly into the alloys now known brass, bronze and German silver. These were valued for their superior hardness, either cast after hammering shape. Alloying making the pure metals and proportioning them accurately crucible art quite modern comparison. Smelting iron ore metallic sponge and its weld- ing and forging into tools requires enormously more knowledge and skill than the making natural brass bronze. The earliest records the use iron tools such quantity and for such purposes suggest manu- facturing operations, indicates that this was started about 1400 B.C. Asia Minor. the other metals, lead supposed have been dis- covered the period 3000 2500 B.C., from its associa- tion with silver. Zinc, due its property boiling and burning such low temperature, was not made direct from ore until the sixteenth century. | | | Y///Cates | | Conveyors for Core Ovens CONOMICAL Pro ress Made from Year Year the cores has been the Efficiency Both Oven and Con- production foundries subject much study. necessary. The earliest type core veyor—Convenience Chief Factor neers needed increased oven was large box core room The room heated baking continuous movement temperature. The cores, HILL placed racks, were transported and from the ovens means lift trucks. Objections this method included: Breakage cores, investment for trucks and truck maintenance, large number racks and the amount floor space and labor required. The first noted was the substitution I-beam monorail and trolleys for lift trucks. The core racks, suspended from trolleys, were transported and from the ovens, and the monorail served storage and cooling space. Meeting Increased Production The advent mass production all branches industry, especially noticeable *Manager, foundry division, Pal- mer-Bee Co., Detroit. This taken from paper read Cleveland be- fore the Association. Unloading Point Oven Shown Fig. Baked Cores. This arrangement permits quick and employed classification cores cores through the op- erations making and delivery molders was suggested progres- sive foundry con- engineers. This method would keeping with the continu- ous transportation molds already adopted. But the wisdom using conveyors for this purpose was ques- tioned many. was thought that vibration would break the green cores before they could baked. The investment for continuous core ovens and conveyors seemed out proportion the work accom- plished. The protection the conveyor chain and mechanism from the oven heat presented problem. The earliest type power-driven continuous core oven conveyor, Fig. was successful enough tify the idea that cores could This oven was brick with conveyor chain placed Iron Age, June 1930—1673 | =a and Simple Type Con- veyor Core Oven above the oven. Slots through the roof permitted the suspension member connecting the trolley with the core rack follow the travel the chain. Objections found this design were: Enormous heat loss due slots the roof the oven and the lack heat seals the entrance and Oven occupied much useful floor space, Loading and unloading spaces limited, Insufficient cooling time, Transporting green cores, due inability group oremakers adjacent loading point. Horizontal Ovens overcome some these objections, the design shown Fig. was offered. The first oven this type occupied comparatively small floor space, due the type cores produced. was designed for ‘ores requiring short baki ime. making 3—Form Chain Make Both short baking time making the conveyor outside the oven sufficient length include cooling period and unloading space, together Vertical and Horizontal Bends UNLOAD IG. 2—Improvements the Early Type Include Inclined Heat Seal, Absence Roof Slot and Provision for Coremakers Load Directly 1674—The Iron Age, 1930 IG. 4—Large Horizontal Core Oven Embodying Necessary Features for Ease and Low Cost Operation UML with the space around which the coremakers were grouped, the objections found the oven Fig. were overcome. Inclination the entrance and exit the oven formed the heat seals. This construction required the use sheet metal ovens instead brick. Plac- ing the conveyor the oven eliminated the slots the roof and reduced heat losses minimum. meet the conditions imposed this design the conveyor engineers had design chain which would operate both the horizontal and vertical planes. This resulted the type chain and trolley shown Fig. and shown page 1299 THE IRON AGE for May Trolley wheels in. diameter operate over double angle tracks and are fitted with anti-friction bearings. The trolley stem, suspended from high- carbon steel shaft, supports the core rack such position that the shelves always remain horizontal. transverse joint junction chain and trolley stem permits the chain travel and down in- clines well horizontal tracks. Rollers the chain joints provide for operation around roller turns and traction wheels, and make action the drive sprocket easier. Trolleys equipped with anti-friction bearings are capable conveying loads one ton the rack, with very little power. The largest oven the horizontal type which have record has 150 racks with gross load one ton each, and 5-hp. motor drives the conveyor. example oven the larger type shown Fig. This oven designed serve bench coremakers conveyor passes between the two rows benches. Core The coremakers face the approaching conveyor and rack, permitting them select location place their cores. half turn the body and step the only movement required load the rack. The con- veyor track inclined that the lower shelves the rack are loaded easily the upper. With this load the rack travels inclined track deg. into the oven proper, traversing its length three times level track fitted with expansion joints. Leaving the oven over incline, the chain con- verges into horizontal track before reaching the drive sprocket. The contraction and expansion the chain are compensated the movement the coun- ter-weighted take-up carriage. This mechanism located adjacent the drive sprocket. From the take-up the conveyor passes around roller turn portion straight track where the racks are un- loaded filing, sorting and fitting benches. From this point the empty racks pass underneath the oven the original starting point. Sprocket and traction wheels are all mounted anti-friction bearings. Present-Day Requirements For continuous conveyor oven successful the following conditions must met: Adequate and accessible loading space. Ample baking time. Sufficient time and apparatus for cooling. Well-located unloading position. Economical production cores. oven having all these features combina- tion shown Fig. This conveyor makes four passes through the length the oven. the con- or Coremakers Dip Tanks 5—Greater Efficiency Than Fig. Had Keeping the Portion Conveyor Not the Oven Posible. Here low fraction the total length The Age, June ‘ \ veyor leaves the oven passes through inclosed chamber. This chamber completely surrounds the drive and take-up mechanism, and supplied with the necessary fans for directing blast air the cores. The cores are cooled temperature that they can unloaded with the bare hands. Cores, together with their plates, are placed gravity conveyor underneath and extending the length the oven. Cores are unloaded and classified, and stored racks transported the foundry. The plates are returned from the gravity conveyor the adjacent the oven. belt conveyor directly behind the makers transports the approximately 100 ft. paralle benches, the oven. Cores are removed from the belt conveyor, dipped into blackening and loaded the conveyor racks just prior entering the oven. This unit was designed bake crankease cores hour, and has been found capable Advantages Continuous-Conveyor Core Oven i ng wm f space The space underneath the oven used for core rack torage, sorting, fitting, blacking, pasting inspecting ‘ores, The ovens many ire supported above roof russes, keeping the floor clear installations the oven extends over areaway between build- conveyor 1676—The Iron Age, June 1930 Conveyor Labor saving.—With the Conveyor makers’ benches, the time spent walking and from distant racks eliminated. The labor used transporting racks from the makers the oven entirely dispensed with. loading rack-type ovens often necessary move the rack several times before placed the oven. One large automobile firm had piece rate for each movement racks. This item alone amounted thousands dollars year. Reduced core Handling cores racks with trucks resulted enormous loss due rough floors, collision with other ob- jects, etc. With the smooth opera- tion the oven conveyor this break- age negligible. Pace setter—The racks, traveling full view the op- erator, enable him time his move- ments with the speed the con- veyor. Take-Up Mechanism (Above) Has Sprockets Shaft. flooring over the space between parallel strands additional loading space may had. Several vertical units are seen, all line cut, which shows vertical oven with belt and roller conveyors serving —one bring raw cores and the other take away baked cores (Fig. UNLOAD Uniformity product.—With each rack-load cores receiving the same baking and cooling time, the product will uniform. This eliminates the human element, which enters into the loading and unloading rack-type ovens. Working conditions—Heat confined the sheet metal oven with insulated walls and heat seals. With this construction comfortable temperature can maintained the core room. Reduction equipment.—With the conveyor re- turning racks, core plates and dryers regular in- tervals, the amount this equipment materially reduced. Increased production per man decreases the number core machines required. Vertical Ovens Because the architectural limitations present core rooms, nature the product and other restric- tions, the vertical-type oven has met with the approval large number plant owners and op- erators. The vertical oven used advantage for baking small cores, drying cores after blacking, drying pasting. Limitations the vertical oven for baking cores are based the requirements noted for continuous-conveyor oven. Floor the production very large often difficult place Mezzanine A IG. 7—A Single Run Conveyor Chain Here Takes Care Loading and Unloading, Well Bak- ing and Cooling. tion lower left shows roller turn, mezzanine floor (in core room) the same conveyor, sprockets being used. Core plates and dryers are returned the racks coremakers +++ — / LOAD/NG | UNLOADING Coremakers the coremakers position for loading directly racks. the core overcome this the coremakers are grouped parallel belt conveyor which delivers the cores from the makers the oven. The belt conveyor usually con- structed gravity carrier idler rolls the carrying side, prevent undue sagging and resultant vibra- tion the belt. the cores reach the oven operator required unload the belt and place the cores the racks. The cores are usually unloaded the opposite side, the plates remain- ing the racks and being unloaded the loading operator. These plates are distributed the core- makers section gravity con- veyor extending the length the bench layout. Two ovens utilized this manner are shown Fig. unusual take-up mechanism used this design. consists U-frame fitted with counter- weights, necessary, and eliminates the necessity shaft and sprockets this point. meets the re- The Iron Age, June 1930—1677 Cor quirements the expansion and contraction the chain, and also provides for loading between the ver- tical strands the conveyor. The space between the vertical runs the conveyor can floored over, giv- ing easy accessibility the coremakers. vertical oven recommended for baking small cores only, because practically impossible ex- tend vertical oven this type sufficiently high incorporate the required amount cooling time and apparatus for large cores. unique design employing the vertical oven, to- gether with conveyor which serves the coremakers, provides ample cooling time, unloading space, and re- turn plates and dryers the operators, shown Fig. The operators this installation, all girls, are placed mezzanine floor and segregated from the male employees. The core room fully inclosed. Proper lighting and ventilation are provided, making this department ideal for this type work. are located adjacent the upper run the conveyor. The conveyor inclined that the top and bottom shelves are loaded without undue ex- ertion the part the operators. The conveyor passes through the vertical runs the oven. the descending side cooling fans are placed that the cores come out sufficiently cooled unloaded with the bare hands. Cores are sorted into tote boxes placed gravity conveyors. These conveyors may given suitable locations either side the lower horizontal run the oven conveyor. The plates and dryers are placed racks, and are returned through the floor the operators the mezzanine floor. This type installation provides for every re- 1678—The Iron Age, June 1930 quirement necessary for the successful operation continuous-type conveyor oven. The conveyor used this and other vertical installations consists two parallel strands steel bar bushed roller chain. The rollers are unusually large diameter, fitted with bronze bushings and provided with large oil reser- voir, eliminating the possibility the conveyor oper- ating without lubrication. The parallel strands chain are connected means cross-rods over which extra-heavy pipe placed. The pipe provides for additional stiffness and, due the fact that easily replaced case wear, has proved added feature this design. Unloading Run the Conveyor Depicted Fig. Tote boxes the gravity conveyor alongside facilitate classification cores The racks are suspended from these cross-rods U-bolts, which provide for easy installation and re- moval. The absence sprockets the mezzanine floor additional safety feature this design. This arrangement may employed with excellent results for large cores well small ones. This due the fact that cooling chamber can cluded the horizontal run, the point un- loading. Pasting, Drying and Blacking Ovens Ovens required for pasting, drying and blacking usually are very small, due the speed the con- veyor. Twenty min. cover the ordinary time required for these operations. The units are u