The Iron Age 1930-07-17: Vol 126 Iss 3

EDITORIAL STAFF ADVERTISING STAFF W. W. Macon A. L. PInDLEY Cc. 8. Baur | Editor Bditor Emeritus R General Advertising Manager G. L. Lacugr Cc. E. Wricat ee , TAYNE Managing Editor News Editor ESTABLISHED 1855 8. G. Koon G. 8. Herrick Member Audit Bureau Circulations Hartford Cleveland Chicago Cleveland and of Associated Business Papers - B. L. HERMAN CHARLEs LUNDBERG BURNHAM FINNBY GERARD FRAZAR I R oO N A G E p U B a I S H I N G Cc Oo. New York and Detroit and 239 West Thirty-ninth Street, New York Frank, President Griffiths, Secretary New York Contents for JULY 17, 1930 Must Plan the Work Avoid Delays and Maintain Good Morale Minerals Power-Controlled World 158 Making Screw-Driver Handles 145 Electrically-Produced Steam Used Heating Plastic Compound Foreman Must Know His Men 143 Endurance Properties Rail Steel 158 Release Sub-Atomic Energy 161 World Power Conference Berlin 171 New Diesel Aircraft Engine 148 Alloy Scrap Used Pig Iron 156 Tests Show Effect Using Chromium, Chrome-Nickel and Titanium 176 Tunnel Furnace for Enameling 159 Heat Interchange Makes for Economy EDITORIALS 178 Fuel Products Pass Through New Equipment 173 Weight Lb. the Horsepower and Speed 2000 R.P.M. Line Production Aircraft Plant 152 This Week’s IRON AGE Brief 168 Pratt Whitney Main Building Has Work Flowing from Sides Center Book Reviews 169 Correspondence 180 Laboratory Dignity and Beauty 162 Commodious Structure for Aluminum Com- The Week Business 181 pany Engineers New Kensington, Pa. Iron and Steel Markets 182 Business Recovery Not Far Off 165 Despite Current Pessimism, Gradual Improve- Expects Further Decline Production 167 Foreign News 205 Lewis Haney Looks for More Weakness Before Substantial Recovery Begins Machinery Markets 207 BRANCH OFFICES—Chicago: Otis Building 1319 Park Building. Boston: Room 230, 80 Federal Street. Philadelphia: 1402 Widener Building, Cleveland: 1362 Hanna Build- ing Detroit: 7338 Woodward Avenue Cincin- nati: 409 Traction Building. Buffalo: 616 Elli cott Square Washington: 536 Investment Building. San Francisco: 703 Market Street. Division of United Business Publishers, Ince.. 230 West 30th Street, New York. <A. ©. Pear son, Chairman. F. J. Frank, Pres. C. A. Mus- selman, Vice-Pres. F. C. Stevens, Secy. and Treas. Subscription Price: United States and Posses- sions, Mexico, Cuba. $6.00: Canada, $8.50; for- eign, $12.00 a year. Single Copy 25 cents. Copyright, 1930, by Iron Age Publishing Co. j NEW BRITAIN NEW-MATIC CHUCKING MACHINES your chucking jobs are within the range New Britain New-Matics, you will interested the many exclusive features incorporated these ma- chines which contribute maximum daily and weekly production and accuracy. New-Matics are safe, are operated with minimum manual effort, are flexible, and are rigid. Available four sizes: No. 454 Four spindles-8” chucks; No. 452 four chucks; No. 654 six chucks; No. 652 six chucks. THE NEW BRITAIN-GRIDLEY MACHINE NEW BRITAIN, CONN. THE IRON AGE July 17, 1930 EIRON ACE New York, July 17, 1930 ESTABLISHED 1855 VOL. 126, No. Foreman Must Know His Men HERBERT RAMP condemns their sowing the seeds for the same kind crop the minds his men. Work must planned that will not cause delay. Nothing upsets production having one de- partment behind. System the boiled down essence lax, they will past experience. able, but must supplemented the foreman’s initiative. foreman’s first and most difficult duty obey orders. must learn take the instructions given him and carry them out efficiently. Obedience marks him man who may higher. foreman’s experience and opinions may run counter his orders. may even know that his own ideas are better than those the management. such cases his duty knowledge opinion and support his conviction with every argument his com- mand. But after has been ruled against must carry out his instructions, not automatically, not sul- lenly, not with resentful feeling and with hope that they will not work well, but with genuine desire for their success. That the measure successful foreman, for learns that degree self-control difficult see how can failure other things. certain foreman was very energetic pressing his own views the conduct his job, and often caustically criticized the management because would not always let him wished. But later be- came president company himself, and then learned there were larger considerations than the con- duct any one department, that the good the whole organization must considered, before that any branch. learned respect the foremen who obeyed orders and pray for those who did not. foreman will always have certain latitude his work, matter what may be. will always have opportunity de- velop his ingenuity and resourcefulness. can show his caliber even the manner which carries out his instruc- The men under foreman’s supervision are influenced the way carries out his will they be. loyal and obedient, those who work for him will more conscientious tions. the foreman com- plains his superiors, condemns orders issued him, shows spirit resentment against proper authority, sowing seeds for the same kind crop the minds his men. Foreman Must Avoid Delays NOTHER essential foreman that plan his work will time, will not cause delay. Nothing upsets the production factory like having one department one man behind. The failure one man’s work can delay lose the sale thousands dollars the product. dis- appoints the sales force and the customer, impairs the profits the concern. delay may not always disastrous, but there always the risk that may entail serious loss. The foreman may have ample excuse for delays. Machine broken down, men off sick quit, orders wrong, material late! But real leadership and planning will take care such con- 143 e.? Sy 4 tingencies. would easy run department where there were unforeseen difficulties. Foreman Must Plan Work Ahead The foreman must plan ahead. must learn the capacity his department, his machines, his men. must set reserve for machine failures, for absentees, for spoiled work. must these things the start. waits until trouble require particular attention because they not run true any formula. They are influenced various conditions—by the state their health, their sur- roundings, companions, habits, home life and many other things. They may represent all grades mentality and character. One may require the harsh- ness the rasp clear his vision that can see his work should. Another may require patience: may slow grasp what expected him. third may only stand the comes, like the ORKMEN represent many velvet touch correction; may locomotive engineer grades ability and men- nervous and high strung—he means who lets his steam right but mistaken, does not run down when his tality and they must handled dif- train late. ferently obtain the best results. Every company know how. There little advantage dismissing Some men require prodding, others man unless his case hopeless. One gives its foremen patience. Frequently the mildest does not cast aside tool because does some kind sched- The average man does not make planning, any other name. the boiled mistakes purpose. essence what type suggestion all that nec- not fit, the temper wrong. Men are like tools; they need reground and retempered, not cast into the scrap heap. foreman knows the failings and Nine times pacities the men has. knows out ten needs help and not rep- their good and bad points. New em- the and fail- quantities, and change ures thousands good morale high- one’s force likely operations. important. One never for the worse. nows what man can ments. points the until one gets him shortest the right frame mind. route points. plant with- out system would like railroad without time- table. absolute necessity any manufacturing plant, and yet matter how detailed, elaborate perfect is, can never take the foreman’s place, release him from his responsibilities his duties. System Futile Without Foreman’s Initiative System inert, lifeless. has initiative. built upon the well trodden road successful achievement. does not invent. does not stimu- late ingenuity, because does not reach after the un- tried. not resourceful progressive. System like street signs and house numbers. gives you your bearings, tells you how reach known ob- jective. But doesn’t guide you into uncharted territory. The foreman must have the brains, the flexibility, the adaptability supplement the system. Systems may give him 10-hr. day with min. the hour, but may have stretch the hours that gets min. work from each order fill his contract. That his job. The development and progress forces changes systems. Finding new tool new device, different method doing things means laying out and paving new streets for system name and record. Foreman Must Study His Men foreman must know his men. must learn their strong points and their weak points. They are his tools, and his most important ones, and they 144—The Iron Age, July 17, 1930 Workmen Need Help foreman who cannot get along with his men, with tions, cannot get along with his work. have all seen foremen who felt their duty was simply walk and down the gangway, orders and look wise. That the smallest part fore- man’s job. His greatest work serve and help those who are responsible him. The average man does not make mistakes pur- pose. tries his work well (even though does not all can). realizes that hold his job must give service. may have faults and shortcomings, but nine times out ten needs help and not reprimands. foreman may quarrel with his superior abusive his equals, but should always courteous his men. When not, losing money for his company. must maintain the morale his department. His influence should such make every man take interest his work. should make them feel that their work important the company, that they are essential part the organization the same is. must not expect more enthusiasm from them than possesses himself, and must not disap- pointed because some are sullen and stupid and in- different, himself lacking spirit. The foreman should not measure the poor man the good man, but rather what did and what does now. foreman devotes much time and thought inanimate things, like tools, machines and jigs, (Concluded page 204) ! | i} | if Screw-Driver Handles Made With Electric Steam Cleveland one the largest manufacturers mechanics’ hand tools the country making wide variety wrenches, hammers, pliers, screw-drivers, and the like. Three years ago the management came the conclusion that there was need for high-grade screw- driver which could sold for reasonable price, and gave the problem the research department, which experimented continually with many different types compositions for screw-driver handles. Recently compound was perfected that met exact- ing demands. This compound, when applied steel blade make complete screw-driver, dielectric strength, tough, strong, durable, and remains slightly “tacky” even continued use, that the handle has slip the hands. The com- pound, which has proved factory, very ingenious and re- quires careful handling order produce the de- sired results. Raw material for the compound placed batch mixers equipped with high pres- sure steam jackets, and thoroughly mixed and kneaded for about three hours under the action heat. Since the material sensi- tive heat changes, the tem- perature must held within close limits. After mixing, batch the ma- teria! carried BENNINGHOFF engineer, Illuminating Co., Cleveland. LECTRIC Steam Generator, Entirely Automatic, Installed One Corner Screw-Driver Department. Temperature close- controlled source. one operation requires lower temperature than neighboring equipment, fed with steam through pressure iron reducer. case. press, where squeezed into slab approximately in. square and about in. thick, indented divide into small in. These slabs are then allowed season certain length time. After this curing process the briquets are broken off and placed steam-heated platen oven order bring them temperature which the material becomes plastic. This temperature must also closely controlled, because too low temperature will not permit the material flow properly the next operation and too high temperature causes effect similar burning. This platen oven was designed the Vichek Tool Co. meet exacting conditions. The oven, illustrated con- sists seven platens, which are each block steel in. square thick. this block are drilled holes every in. along dimension, and each end drilled similar hole connecting the many holes drilled right angles. All open- ings but two are then plugged with screw plugs, and these open holes steam lines are connected, the result gridiron steam heat with live steam coming contact with the material heated. The platens are placed one above the other about in. apart thoroughly insul- The Iron Age, July 17, E € = wa wok q } a q J a Briquets Organic Compound Are Heated Plastic Con- dition Platen Oven. Each tray steel slab, through which holes are drilled form gridiron steam passages. Briquets, after being heated the previously de- scribed platen oven for certain length time, are then put into hydraulic press, where the compound pressed around the screw-driver blades under 50- ton pressure make complete screw-drivers. The press equipped with dies, through the bottom which are thrust four six screw-driver blades, depending upon the size, held jig. The dies used are high-strength special and are chrome-plated insure long life. the compound placed the hollow die and plunger die lowered, forming the handles. Presses Have Unusual Automatic Control The presses have unusual automatic control insure absolute uniformity and finish the screw- drivers. After the bare blades are jigged into the hollow die and clamped, green light the top the machine indicates they are spaced and clamped properly. Improper clamping apt break the expensive dies. the green light does not light, steps are taken immediately remove the cause improper clamping. After the green light shows, pressure applied and the plunger descends into position. the proper pressure applied white light flashes and, not, steps are taken remove the cause improper pressure. the green light and white light both show, then time clock started which runs for prescribed length time and then flashes red light. Complete screw-drivers are then removed and the process repeated. Each cycle repre- Iron Age, July 17, 1930 plete screw-drivers. addition the light control, separate electrical sys- tem actuates 10-point recorder, each press controlling one point, giving graphic record the length time each batch screw-drivers has been held under pressure. platform above the presses placed the mechanism, consisting motor-driven oil pump for each press, air compressor for supplying air clean the dies, and water pump furnishing flow hot water through the dies order keep them operating the proper temperature. Accurate control the tempera- ture the mixers and ovens intro- duced problem planning the lay- out. The existing boiler plant was too far away and did not have suffi- cient capacity pressure. Circulat- ing hot oil was considered for heat- ing medium, but since the tempera- ture these operations might changed possible improvements are made the compound, this method was discarded since two different tem- peratures could not obtained from the same source. was then decided use electric steam generator for these heating processes, since the tem- perature the superheated steam could controlled very closely, and means reducers different temperatures could easily obtained different parts the system. The steam generator installed has connected load kw., 440 volts, phase, but was built take 240 kw. care for future expansion. (In order increase the capacity will necessary only insert more immersion units.) The generator ft. in. long between heads and in. diameter, with central steam dome having two steam outlets. each end plate are twelve 2-in. tapped holes for the electric immersion heating units; for the present operation nine openings have been fitted with General Electric standard 10-kw. immer- sion heating elements. The electric steam generator was designed and built the General Electric Service Shop Cleve- land. The generator shell was built for 200-lb. pres- sure accordance with the American Society Mechanical Engineers’ code. After the generator was installed was run for about ten days without any insulation, order observe any possible defects that might have been overlooked the inspection. After this ten-day test proved that the electric steam generator met all specifications and inspections, was insulated with 3-in. magnesia asbestos. The electric steam generator equipped with various standard safety devices and indicators. Close regulation steam temperature and pressure had pressure regulator with steam gage, control switch and contactor panel. - | | | | | One the features the operation this elec- tric steam generator the unusual close control temperature. mixing the compound the steam pressure held between 115 and 120 which equivalent 347.2 350.1 deg. Fahr., differ- ential plus minus 1.45 deg. Fahr. the platen oven pressure reducer used and here the temperature held between 335.2 and 337.9 deg. Fahr., differential plus minus 1.35 deg. With the above described apparatus 15,000 completed screw-drivers are made hr., operating only six presses days and three presses nights. With this production only 530 kwhr. were used the electric steam generator. This unique steam generator installed adjacent the operations where steam needed, corner the frame building housing the screw-driver de- partment. stack, boiler settings fireproof build- ing needed, thus keeping the installation cost The first cost the equipment also low and the maintenance negligible. Furthermore, there labor YDRAULIC Presses for Making Vichek Tool Co. have made possible the mass produc- tion new type high-grade screw-driver low price, which would not practical with any other type equipment. Heavy Hollow Rolled Drums DENSITY tunnel for aircraft investigations was recently made the Atlas Works John Brown Co., Ltd., Sheffield. consists cylindrical cham- ber with hemispherical ends. The cylinder made four hollow rolled rings and the ends, steel castings. Each ring, measuring 17% ft. inside diameter and ft. long, was rolled hollow and seamless from steel ingot weighing tons. Machining, internally and externally, reduced this weight tons. The wall thickness in. The four rings combined with the end castings make structure about 250 tons weight and ft. long. Assembled unit, the rings are held together and the end castings forged steel needed, since the equipment entirely automatic operation. The accuracy flexibility, economy opera- tion and installation the elec- tric steam generator the Composition Handles. Four water- heated dies are mounted each bed plate, and into the base each die five through tightly fitting holes. plastic compound, dropped into the re- cess the die, then squeezed into proper shape form five handles simul- taneously. clamps, set tightly with large number heavy bolts. The joints are packed with leather and with metal, and the internal pressure with- stood about 350 the square inch. The Iron Age, July 17, firplane with Packard Diesel Power Plant. The late Capt. L. M. Woolson, designer of the engine, is at the left, and Walter Lees, pilot, is at the right. May 14, 1929, the following telegram was received the Packard Motor Car Co., Detroit. was signed Capt. Woolson, and came from Old Point Comfort, Va. (Langley Field) "Arrived after hours and minutes uneventful flight, ing $4.68 worth furnace oil." Thus was the world’s first long distance flight Diesel-powered airplane announced. Since that time numerous tests both the laboratory and the air have verified other predicted results. The Diesel aircraft engine beginning regarded with favor automotive engineers everywhere, especially for use where continuous full-load operation demanded. Motor coach and truck owners say that the Diesel offers great possibilities. Because able burn its fuel ordinary furnace oil instead gaso- line, and because such oil costs less and not inflammable, airplane operators are watching Diesel developments closely. Weight Brought Down 2.26 Lb. per Hp. Another interesting characteristic the design developed for aircraft the manner which the weight has been brought down about one-tenth that formerly thought possible. Diesel engines formerly weighed about per hp. but this new Packard weighs but 2.26 lb. per hp. Furthermore, while stationary engines used marine service run from 100 300 r.p.m. and the so-called high-speed 148—The Iron July 1930 The New Diesel FAY LEONE FAUROTE Diesels have maximum speed 1200 r.p.m., this new aeronautical power plant has been speeded 2000 r.p.m. has compression ratio 16:1, air compression 500 per sq. in., compression temperature 1000 deg. Fahr., and fuel pressure 6000 per sq. in. develops 225 hp. 1950 r.p.m. and weighs 510 lb. Airplanes equipped with this engine have climbed altitude over 18,000 ft. without any special equipment. The engine has nine cylinders with bore 13/16 in. and stroke in., producing dis- placement approximately 980 cu. in. radial air- cooled type, the outside diameter roughly in. Superficially looks like many other radial air-cooled aircraft engines. Upon close examination, however, will seen that much simpler. There ignition system. Neither there Each cylinder has only one valve, which although oper- ated push rods the usual manner, serves the Diesel for both inlet and exhaust. Operation Diesel Engine Intrinsically, the real difference between the opera- tion the Diesel engine and the conventional gasoline type, lies the introduction and the burning the fuel. the ordinary type four-stroke cycle engines, combustible mixture gasoline vapor and air drawn into the cylinder the suction stroke. This then compressed. When near the end this operation, fired electric spark. Then the piston moves forward delivering power the crank- shaft, and ultimately returning, scavenges the cylinder. Aircraft ) | | | | this type engine, considerable amount wast- age may prevail. Mixtures run from 10:1 20:1 wider variations are not uncommon. Dirty spark plugs and such inefficient mixtures may reduce the effective power strokes quite appreciably, especially cold weather. the Diesel cycle, however, instead making use such unreliable mixtures air and fuel, the gasoline engine, air alone introduced into the com- bustion chamber. This air compressed ratio approximately 16:1 and reaches temperature 1000 deg. Fahr. This far above the spontaneous ignition temperature the fuel oil used. The fuel then injected highly atomized condition just be- fore the piston reaches the outer end the stroke. Coming contact with this highly compressed and heated air, the atomized fuel burns instantly. Thus will seen that the Diesel engine generates its own heat and starts combustion means this highly views Packard Diesel aircraft en- gine. Notable are the features which have reduced the weight 2.26 lb. per hp. This was secured elimination carbureters and magnetos and intensive simplification de- sign. The latter includes light-weight one- piece crankcase and the single valve arrange- ment which halves the number parts re- quired for valve operation. The engine de- velops 225 hp. 1950 r.p.m. The illustration below Ford three-mo- tor airplane equipped with Packard Diesels. compressed air. outside electrical ignition sys- tem needed. course the fuel must well- atomized condition, and its quantity and time in- jection carefully measured. The Diesel engine has another advantage over the conventional type that small quantity fuel burned just efficiently full charge. Because the air used Diesels compressed such high temperature, liquid fuels with very high ignition temperature may employed. Such oils correspond more nearly the crude, and cost much less than gasoline. Fuel oil ignites only relatively high temperatures. The fire hazard which really very grave the case gasoline-operated airships thus very materially reduced. fact, the Diesel offered more advantages than those arising from this reduced fire hazard, its development would well worth while. was the good fortune the writer have The Iron Age, July 17, Captain Woolson, the designer this power plant, conversation held only few weeks before his fatal flight, outline for him the three basic principles this design. “First,” said he, “the engine must enough withstand maximum cylinder pressures, two three times great those obtained ordinarily gasoline aircraft engine; secondly, high degree turbulence must maintained the cylinder permit all the fuel combining with all the oxygen present the cylinder during the extremely short time allotted for combustion high engine speeds; and thirdly, the fuel pumps and nozzles must de- signed operate over much wider range speed one-piece crankcase construc- tion eliminates heavy flanges and bolts and unique also respect the manner which the cylinders are fastened it. The Packard Diesel cyl- inder, cylinder head and valve-operating mechanism housing are shown the right. Below these are front and rear views the cylinders, showing fuel pump and nozzle unit, air shutter op- erating mechanism and rocker arm. than has been found practicable heretofore Diesel engines. “The most interesting aspect undoubtedly con- sideration the features that have brought the weight the engine down practically the same level that gasoline aircraft engines equivalent power. Heretofore, even Diesel engines the so-called light- weight modern type, have weighed around lb. per hp., this engine weighs but one-tenth much. This great reduction weight essential, and not surprising that radically new methods con- struction had employed reach the desired objectives. “Important weight economies have been secured, first, the elimination carbureters and magnetos and, secondly, intensive simplification design. Evidences the latter are found the one-piece 150—The Iron Age, July 17, 1930 crankcase construction extremely light weight and the single-valve arrangement which automatically halves the number parts required for valve opera- tion found conventional gasoline engines. Crankcase Weighs Only Lb. “The crankcase, which weighs only unique, not only because one piece, thus dispensing with heavy flanges and bolts, but also respect the novel way which the cylinders are fasténed it. “Ordinarily, radial air-cooled aircraft engine, each cylinder held the crankcase number studs screwed into the crankcase flange and project- ing through the cylinder flange against which the retaining nuts seat. With this arrangement the ten- sion stresses resulting from the explosion loads the cylinders are carried through the crankcase walls the crankshaft main-bearing anchorage. volves fairly heavy crankcase construction even with gasoline engine, but such structure applied the Diesel principle would require the use very thick sections, since the light alloys used crankcase con- struction have poor resistance properties for this type shock loading. “In the Packard engine, two circular hoops alloy steel encircle the cylinder flanges contact with the the front and rear the engine, and these hoops are contracted means sturdy turn- buckles that initial stress set these hoops which exceeds wide margin the operating stress resulting from the cylinder explosions. Under this system the crankcase subjected initial com- pression which well adapted resist. When the engine running, however, these stresses are substantially reduced and time possible transfer loads from the cylinders the crankcase. “Although the analogy not strictly correct, com- parison may made with automobile wood wheel, representing conventional aircraft-engine crankcase construction the one hand, and wire wheel, rep- resenting the new Packard crankcase arrangement the other hand. The latter construction has proved considerably lighter because the load not trans- ferred from the ground the hub directly through the lower spokes, the case with the wood wheel, but spread over great many more spokes arranged the upper quadrant the wheel. Those spokes wire wheel which are directly above the ground receive load efficient operation, high de- gree turbulence must main- tained the cylinder. addition shaping the inlet port give in- coming air high-velocity spiral mo- tion, the aluminum alloy pistons are made with special shaped head hav- ing eccentrically located pocket assist this. The master connecting rod (shown left) with its eight links, follows current practice. “Equal importance the crankcase vonstruction that enables light structure withstand extremely heavy loads are the arrangements whereby the crank- shaft and propeller are protected from excessively high stresses. “The maximum cylinder-pressures are more than ten times great the average cylinder pressures during the working stroke. This would necessitate the pistons, connecting-rods, crankshaft and propeller be- ing approximately ten times strong they would have resist the average pressure were not for the fact that effective measures have been taken cushion these major parts the engine from the shock-loading resulting from the high explosion-pres- sures. Advantage taken the fact that these peak explosion-pressures exist for very short time each cycle. The crankshaft counter- weights and the propeller are all but rather have their ini- combination fuel pump both flexibly mounted the tial tension reduced, just nozzle unit contributes a great deal to crankshaft SO that, when the the new Diesel engine that sec- operation the engine. Five peak pressures occur, cushion tion the crankcase immedi- the oil fuel pumps are shown the interposed between the crank- ately below the working the group below. the left and those parts which have has its loads reduced rather one the multiple spring valves the maximum inertial flywheel increased time explosion. the Packard Diesel engine (Continued page 201) The Iron Age, July 17, | Line Production the Keynote New Pratt Whitney Aircraft Plant MARSHALL ITH the slogan “there substitute for quality,” and every man working straight day-work basis, quality work- manship may said rank ahead speed the plant the Pratt Whitney Aircraft Co. Opportunities for economical manufacture have not been overlooked, however, example being the layout the new $2,000,000 plant East Hartford, Conn., where Wasp and Hornet motors for the United Air- craft Transport Corporation are built. this shop the departments are arranged assure continuous flow material and parts toward assembly, testing and shipment with minimum amount travel- ing and handling. The old plant the company was four-story building, and while was found that the arrangement the machines did have cer- tain advantages, the feeling de- veloped that these advantages were outweighed arrangement that would definitely reduce handling and trucking operations. Accord- ingly, degree, the old order was discarded, experiments re- arranging were tried, and the re- sults attained proved all that had been hoped for. Consequently, the company grew and the neces- ity for larger quarters became ap- parent, was determined solve 152—The Iron Age, July 17, 1930 the problem “getting the thing done” building the new plant primarily meet the needs straight- line production. Because this new plant out- standing example the complete elimination lost motion and also because designed that ex- pansion can take place without any sacrifice the no-lost-motion idea, particular interest. Main Factory Building 1000 Ft. Long The group buildings comprising the plant con- sists two-story administration building, per- | | | | | | | i sonnel building, engineering building where ex- perimental work conducted, power house, garage, and the main manufacturing unit. The office build- ing faces Main Street. Immediately back and bridge the engineering building. Immediately back the lat- ter, being continuation it, the main unit. The group occupies area acres. The buildings are steel, brick, and concrete. The main factory unit one-story monitor construc- tion with floor area 400,- 000 sq. ft., being 1000 ft. long and 400 ft. wide, with 40-ft. bays. Light received through skylights, facing north and south, conceded the best for manufacturing, and the ventilation secured motor-operation these sky- lights. Daylight abundant every part the building. The line flow material and work centers about 15- ft. central trucking aisle run- ning the entire length the building and two nar- rower feeding aisles located the sides and parallel it. How the material enters the west end the building and flows eastward work process the opposite end with practically lost motion will explained what follows. Flow Work From Sides Central Aisle All the aluminum parts are machined the north side, all the steel parts the south side this central aisle. This arrangement facilitates the handling the cutting oils, which are different body grades for aluminum and steel, and also facilitates the han- dling and segregation the drillings, turnings, and borings. All operations begin near the feeding aisles and work toward the central aisle. Raw materials and finished purchased parts enter the receiving department way siding the RRANGEMENT departments and production equipment assure the most direct flow and maximum economy handling ma- terial and parts notable the new plant the Pratt Whitney Air- craft Co., East Hartford, Conn. The main shop 1000 ft. long and, shown this outline produc- tion sequence, flow material and parts west east, centering aisle and two side feed- ing aisles. west end the plant, the raw steel passing into the receiving department south the central aisle, the aluminum parts into the receiving department north this aisle. From the receiving department the ma- terials, after being inspected, pass into the rough stores. re- ceived material inspection, and rough-stock departments each side the central aisle are inclosed fencing. the steel side, the cyl- inder-barrel department lo- cated next the rough-stock department. the alumi- num side, the cylinder-head department next the rough-stock department. Rough stock fed into these departments through the feed- ing aisles. This stock passes through the vari- ous machining op- aisle along which ment. After being their journey east- ward the central aisle the finished-stock department used needed. similar manner, the master connecting rods, linkrods, crankshafts, crankcases, pistons, and miscel- laneous parts are fed the outer sides their spective departments along the feeding aisles from the rough-stock department, work toward the central aisle machined, and pass eastward along this aisle the finished-stock department. separate polishing department maintained. located centrally between the rough-stock and finished-stock departments. Parts, such connecting rods, polished are fed into this depart- ment through the feeding aisle before; then work, completed, toward the central aisle and travel eastward the finished-stock de- partment. The polishing depart- Depart- ment Adjoins the Rough- Stock Department. Rough stock enters side aisle, passes through machining operations and then goes eastward cylin- der-assembly department The Iron Age, July 17, 1930—153 = ‘ a + — >» Building Dar > (NSPeTT/ON Wind Inenarts 7] \ C D Stark C 7 VYIGCCA OTOCK Wasp DATTO: Assembiy Q 20 sh 7 af 4 PD ne sTcons ~ - ~ — Room ¥) Crib Toolroom and Maintenance Stock Rooms Are Centrally Located, Shown. Receiving, rough- stock, finished-stock departments are inclosed fenc- ing (shown dotted lines) 154—The Iron Age, July 17, 1930 ment equipped with efficient exhaust sys- tem prevent dust getting into the atmosphere and hence eliminate the possibility dust getting into the motors during assembling. Toolroom and Master Crib Centrally Located The toolroom, where jigs and fixtures and special tools are made, together with the master crib, where the tools are stored, and the main- tenance and electrical stock rooms are located group the aluminum side, just west the finished-stock department. This location, the central part the plant, reduces mini- mum the distance and from various de- partments. Moreover, should noted that the plant enlarged, the building ad- ditional sections the sides, these rooms will continue the center the plant. addition the master tool crib, sub-cribs are maintained each department under the juris- diction the various foremen. Tools are sup- plied the workmen the checking system. The metallurgical department consisting heat-treating division and chemical-and- physical-laboratory division located centrally the steel side. Since the steel parts that require heat treating, this department will still centrally located when expansion takes effect. All materials are ordered physical and chemi- cal specification, and are tested the laboratory division the engineering specifications. The finished-stock departments each side the central aisle are inclosed fences. Stock stored these departments the order which will used the assembly depart- ments, which are just east them. Open racks, shelves, however, take the place the fence the sides the finished-stock departments adjoining the assembly departments. The stock fed into tote pans located these shelves racks from which passes sub-assembly benches contiguous them and located the assembly departments. The tote pans are different colors indicate whether the material for use army, navy, other orders. the sub-assembly benches the various parts are assembled into sub-units they continue their eastward journey through the plant. The sub- assembly benches are generously spaced that the men have ample room for their work. the assembly department east the sub-assembly tables are two parallel main tracks running north and south which travel, one track being for Wasp, the other for Hornet motors. Assembly the engine be- gins the south end. Three-quarters the floor nearest the stock room devoted the assembly, the balance being used for tear- down inspection and rebuilding after the first run-in the assembled engine. Assembly Stands Pass Progressively Various Sub-Assembly Benches the work-benches the aisles, the vari- ous component assemblies are carefully fitted and checked, and fed into the production line paces 1} | | | | | Ss | Finished Stock Finished Stock Assemb/y | Pack and Shippin Spray opray Booth Boott | | | the assembly stands pass. The main heavier as- semblies, which form what might called the founda- tion the engine, consist crankcase parts, crank- shafts and connecting rods. The engines are made five crankcase sections, the rear section mounting the accessories, the blower section containing the induc- tion fan and its gearing, the main section being com- posed two matched forgings, and the nose section, which holds the thrust bearing and incloses the cam. Operations begin the rear section the first as- sembly bench. The cored oil passages are sealed, oil pipes installed and studs for accessory mountings are turned in. This operation fin- ished, the assembly stand pushed along the next assembly bench blower section, which also the mounting section the engine, put together. The Assembly Department, with the Assembly Stands and the Sub-Assem- bly Benches, the Rear, Shown Above. bracket secured, and the general view the main aisle the Pratt Whitney aircraft plant shown induction fan, its shaft and below gear train are mounted this part. The blower then bolted the swivel assembly stand through the mounting bosses would plane and the accessory section put place. Bushings for the accessory drive-shafts are fitted and reamed, the drive- shafts and gears installed, the oil pump and magnetos mounted and the other accessories put on. the next bench, the main crankcases are as- sembled, the rear half the crankcase being bolted the opposite side the blower from the accessory section. When this place, the crankshaft in- serted, the connecting rods fitted, and the crankshaft rear gear with the induction fan clutch added. The front half the main crankcase next bolted on, the oil-bearing cam and cam drive gear with adjusting sleeves are slipped The nose (Coneluded page 202) The Iron Age, July 17, Tests Show Effect Using Alloy Scrap Making Pig Iron alloys steel and cast iron increas- ing extraordinary rate. Hence ferrous scrap metals will soon reach the market bear- ing ever increasing amounts alloys. This problem not nearly acute now will the future, but already the technical sessions our leading asso- ciations are replete with rumblings from foundrymen and blast furnacemen arguing the use scrap the blast furnace. Even among the foundrymen there lack agreement, some favoring, some opposing, the use scrap making their pig iron. particular, the fear has been expressed that alloy scrap will used blast furnace practice the extent that the quality pig iron will seriously affected. Effects alloys added gray iron mixtures have been studied extensively, and results are available the literature. stated above, there has been much argument the possible effects alloys introduced 156—The Iron Age, July 17, 1930 graphite left). Chrome-nickel (left) pig iron Fig. (right) has finer graphite and greater hardness. the furnace burdens, but little direct data are avail- able. seemed the authors that one way ap- proach the subject would study the direct effect alloys the pig iron itself. know more our pig iron, possibly shall able predict advance the effect different kinds pig iron our castings. The foundryman has been compelled judge the quality pig iron long, and sometimes expensive, practical trials. will not satisfied with this method much longer. did not take him long realize the value chemical analysis his pig iron, and what needs now definite informa- tion the quality his pig iron, before melts it. great step this direction has been taken, through the work Boegehold and others, the quality pig iron. the purpose this paper deal briefly with the effects small amounts the common alloys the characteristics pig iron. illustrates least million automobiles are scrapped and the amount alloys which they contain increasing steadily. The large-scale use stainless alloys new development which complicates the problem. The conservation our diminishing ore reserves demands the most efficient use all scrap metals. Therefore essential that the scrap auto- mobiles remelted, and such way not detrimental the resulting pig iron, castings. The problem the worn-out automobile interest automobile manufacturers, scrap dealers, blast fur- nace operators and foundrymen. How the Experiments Were Conducted basis experimental work several kinds pig iron were used. The melts were made cru- cibles, was desired have all conditions uni- form possible, and seemed probable that losses alloys would too variable the cupola were used for melting. Procedure was simply melt defi- nite amount one lot pig iron crucible, then pour standard transverse and tensile bar, 2500 deg. Fahr. Then definite amount one alloy was added and the melt stirred thoroughly. When the pouring temperature was again reached, another set test bars was poured. The amount alloys used most cases was slightly more than one would ex- pect find pig iron made with considerable proportion alloy serap. All melts were analyzed for tained the melt. Results given below are representative the effects common alloys pig iron with following analy- sis: Per Cent Per Cent Silicon..... 1.61 Phosphorus. Manganese. 0.62 Total carbon 3.66 Sulphur.... 0.034 Pig irons different analy- ses correspondingly changed effects. That is, irons high low silicon were af- fected the same general way alloys, but differing de- grees. Other alloys than those listed below also affect the pig HROME pig iron, with very shown Fig. (left) still harder than nickel iron. Fig. (right) the chrome- istic whorl structure molybdenum pig iron. IG. Titanium pig iron has large coarse graphite structure. character- iron, but are such small quantities neglig- ible. Such are copper, zinc, tin, aluminum and lead. What Dilatometer Curves Show and show dilatometer curves untreat- pig iron and two the alloyed samples. good deal information the characteristics pig iron either with without alloys can drawn from com- parative curves. From the above will noted that the unalloyed pig iron showed the greatest expansion, chrome pig, slight and titanium pig intermediate. Recent papers Portevin and Cheve- and Lowry’ show that each type pig iron has characteristic dilatometric curve and that these curves are found the resulting castings, although altered form. The authors found also that each type pig iron had characteristic curve and that these curves could modified will the addition small amounts alloys. would therefore possible making dila- tometer curves alloy pig iron predict the ap- proximate effect this pig iron the castings pro- duced therefrom. For instance, the effect given pig iron could predicted least its effect hardness, growth upon heating, and grain size the resulting castings. Conclusions Reached 1.—Alloy scrap should never used making pig iron for malleable castings. Most alloys have very decided effect the malleable anneal; particular, chromium has extremely det- rimental effect even small amounts. 2.—Where used for steel-making and foun- dry pig iron, would great advantage the blast furnace would furnish the consumer with approximate alloy contents together with the ordinary de- terminations. This would en- able the metallurgist take pre- cautions when necessary, Trans. 1929—page Trans. 1926—page 766. Journal S.A.E. Feb. 1927—page 299. The Iron Age, July 17, 1930—157 take advan- tage desirable alloys. schedule showing the maximum allow- any grade pig iron would also j . 3.—The ques- oxidized pig iron, due the effect scrap graphs above show dilatometer curves for untreated pig iron and two the alloyed samples. Unalloyed iron showed the greatest ex- pansion and chrome pig iron the least. furnace erations, out- side the scope this paper. goes without saying that the addition oxidized scrap the ladle would detrimental. general, the effect small amounts alloys intro- duced the blast furnace would cleansers and deoxidizers the pig iron. scrap and plain scrap must used some form. The blast furnace the proper place for much the miscellaneous scrap, owing its desul- phurization and deoxidation. has the additional ad- vantage diluting very great extent any alloys. Such alloy scrap when used the cupola would give highly undesirable fluctuations chemical and physi- cal properties. 5.—Many foundrymen are spending considerable sums for alloys, the improvement their product. other quarters there fear the effect minute quantities these same alloys pig iron. Consider- ing the small amounts alloys found pig iron and their subsequent dilution remelting, the authors be- lieve that there little danger any detrimental ffect the castings. fact, such effect far more ikely beneficial. ilK¢ Endurance Properties Rail Steel determine the endurance properties special rail steel tests have been carried out the United States Bureau Standards John Freeman, Jr., and France. The results are shown research paper No. 182, copies which may had 10c. from the Superin- tendent Documents, Washington. Comparisons were made between heat-treated rails ordinary chemical composition, medium-manganese rail, both with and without zirconium, and manganese- molybdenum rail. Results are given also some tests made steel from rail which had developed trans- verse fissure and from another rail from the same heat and subjected similar traffic but without the fissure. ff the Heat treat- ment rails was found have in- creased markedly endurance limit the steel. Medium man- ganese rail steels were found general have higher endurance limit steel. The manganese- molybdenum rail steel had approx- imately the same endurance the medium- The steel the fissured rail was found have about the same endurance limit that from the unfissured rail. Medium-manganese rails tested averaged about 0.62 per cent carbon and 1.39 per cent manganese. Such rail with zirconium was little higher both elements, containing 0.64 per cent carbon and 1.57 per cent man- ganese, with 0.09 per cent zirconium. The manganese- molybdenum rail had 0.45 per cent carbon, 1.70 per cent manganese and 0.38 per cent molybdenum. Carbon rails included the so-called “comparison” rail, with 0.82 per cent carbon and 0.67 per cent manganese, and two rails which were heat treated and subjected quenches sec. and sec. respectively. These two rails had carbon about 0.73 per cent and manganese 0.60 and 0.63 per cent respectively. More than diagrams illustrate the tests carried out. These are based the number cycles reversed stresses required produce failure the steel. The tests were made varying stresses for different sam- ples, thus giving rise the curves shown the diagrams. Minerals Power-Controlled World the World Power Conference, Berlin, June, Foster Bain, secretary, American Institute Min- ing and Metallurgical Engineers, New York, read paper “The Place Minerals Power-Controlled World.” the questions the distribution and utilization the minerals the world were dealt with interesting fashion. The speaker gave two instances the need for using low-grade ores. About one-third the copper production North America today mined from ore containing less than lb. copper per ton, while the Alaska-Juneau mine, gold ore containing only cents gold per ton produced over $4,000,000 last year. encouraging outlook for the future the world’s mineral supply the large quantity reclaimed metal. Thus, 1929, half the steel production the United States, aggregating some million tons, represented reclaimed scrap metal. Tabulated Results Effect Alloys Tensile Transverse Strength, Strength, Brinell Alloys Present, Number Lb. per Sq. In. Lb. Hardness Per Cent 1—Untreated pig iron