The Iron Age 1930-07-24: Vol 126 Iss 4

EDITORIAL STAFF ADVERTISING STAFF J D. C. WARREN SMBPRSON FINDLEY Chicago Cleveland and Associated Business Papers, Inc. LUNDBERG FINNBY IRON AGE PUBLISHING CO. end Contents for JULY 24, 1930 . . . . | Polishing Stainless Steel 213 Metals for Coins 216 Gleaming Luster Brought Out, Required How Much Buy 217 Analysis the Factors Governing the Economic Quantity for Purchase Exceptionally Large Galvanizing Bath 229 Heat Treating Motorcyle Parts 221 Continuous Furnace with Chute for Quench- ing, and By-Pass for Other Work New Equipment 236 Control Mixed-Ges 225 This Week’s IRON AGE Brief 240 Automatic Regulation Air Supply for Burning Different Fuels Simultaneously Personal Notes 244 Attachments for High-Lift Trucks 230 EDITORIALS 246 Use Standard Unit with Home-Made Appendixes Solves Vexing Problems The Week Business 249 High-Pressure Steel Drums 232 Method Manufacture Germany, with Iron and Steel Markets 250 Tests 350 Atmospheres Non-ferrous Metal Markets 266 Combines Casting and Forging Making Alloy Steel for 269 Tools and Other Uses Foreign News Dr. Haney Sees Little Chance Business Comeback Inside Three Months New Trade Publications 276 BRANCH OFFICES—Chicago: Otis Building Pittsburgh: 1319 Park Bullding. Boston: Room 2230, 80 Federal Street. Philadelphia: 1402 Widener Building. (leveland: 1362 Hanna Build- ing Detroit: 7338 Woodward Avenue Cincin- nati: 409 Traction Building. Buffalo: 616 Elli- cott Square: Washington: 536 Invest ment Building. San Francisco: 703 Market Street. Division of United Business Publishers, Inc., 239 West 39th 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 year. Single Copy cents. Copyright, 1930, by Iron Age Publishing Co. July 24, 1930 THE IRON AGE ~Z = ~ Machined ice BILLINGS The err grinding, polishing, filing. extra Operations: may add slightly the cost the forging, but subtracts greatly from the cost the finished part. The price that high-grade forging, machining. You may cut from machining expense; THE BILLINGS SPENCER CO. HARTFORD, CONNECTICUT New York: Warren St. Chicago: 565 Washington Blvd. RGING give you the figures before you give the order Send for the man—or send your samples direct THE IRON New York, July 24, 1930 ESTABLISHED 1855 VOL. 126, No. Polishing Stainless Steel Sheets Bring Out Their Gleaming Luster ABRICATED work for use monumental buildings, now made rust-proof metal, given its char- finish. has come what might acteristic brightness surface special polishing processes, here described. includes about two score designated polishing industry, which ap- pears still its develop- ment stage. Leaving the hot mills with customary finish, and lacking the desired finish for the various uses which the product applied, the sheets receive series polishing operations before the metal has the bright surface the finely finished product. separate and extensive department for polishing low-carbon nickel-chromium stainless steel sheets large production basis has been fitted the Re- public Steel Corporation the plant the Central Alloy Division Massillon. Here the sheets are routed from machine machine for successive polish- ing operations until the metal has been given the final Various kinds fin- ishes are produced meet requirements. The equipment sheet-polishing machines. Sheets special polishing specifications, now being made the Re- public corporation, include material for the automo- bile, food, petroleum, building, hospital equipment and other industries. Sheets for exterior use the Empire State Building, New York, are being produced. the construction this building over 400,000 stainless steel will used, which being furnished this corporation and other producers. nearby plant Canton the sheets are being fabricated for the Empire State Building the United Metal Products Co. With plant equipped for making metal doors, trim, partitions and other metal New Type Polishing Machine Used for Polishing Stainless Steel Sheets. Polishing done with grit-covered rollers which, addition revolving, have oscillating motion 213 | | 4 | A | 1 work used the building field, this company able make stainless fabricated work for the Empire State Building with little addition its existing equipment. Electric Furnace Melting for the Steel The stainless steel made and the sheets are rolled the Republic works Canton. The steel melted electric furnace, the furnace charge being high- and metallurgists the company. they are brought temperature 1950 deg. 2100 deg. Fahr., the time and temperature depending the gage the material. Light-gage sheets are air cooled; but, rapid cooling necessary annealing stain- less steel sheets, the heavy-gage sheets are quenched water leaving the furnace. After annealing, the sheets are pickled remove the scale, solution hydrochloric acid, washed Special Type Annealing Furnace grade steel scrap having very Used Giving the Sheets the low carbon content. Proper amounts ferrochrome and pure nickel, produce the de- sired analysis metal, are cast into the ingots when they are poured from the ladle. These are rolled into slabs which are usually ground, but sometimes chipped, remove pits and other de- fects which, left the surface, would not weld during the rolling operations following. Then the slabs are reduced sheet bars, which are either sand blasted pickled remove the roll scale and bring out defects, which are removed second grinding. The sheet bars after this grinding are pickled and cleaned remove the scale. Heat Treatment Continuous Furnace General hot mill practice rolling sheets fol- lowed, with some modification, rolling stainless steel sheets. The sheets are given two four rollings and one five passes through each mill. They are re- heated between each rolling and the next. The rate production only about one-third that common grades sheets, because more reheating and more passes through the mills (and consequently more handling) are required. The hot-rolled sheets receive the Strauss heat treat- ment continuous furnace designed engineers The Age, July 24, 1930 Treatment After Hot Rolling clear water, then put through standard type scrubber and dried. Sheets subjected this treatment are designated pickled, finished sheets. high finish desired, the sheets are cold rolled after pickling and scrubbing. Sheets for deep drawing are reannealed and repickled. Pickled, finished sheets designated No. finish, material that goes the trade for forming and polish- ing, are closely inspected show their surface con- ditions and physical properties. Each lot given cup test determine the character the surface will have after deep drawing, and whether has the required polishing properties. Some the sheets will show pebbled surface after the cup test. that case the material would require extra amount polishing after drawing, obtain the proper finish. Physical tests are taken each lot show the tensile strength, Rockwell hardness and elongation The best deep drawing grade Enduro KA2, the trade name for the stainless steel made the Republic corporation, has tensile strength 90,000 per sq. in., elastic limit 40,000 45,000 per cent higher elongation in., per cent higher elongation in. and about per cent elongation in. This compares with elongation per cent in. for the best grades | common deep-drawing sheets, and shows the higher ductility the stainless steel sheets. Grinding and Polishing Successive Stages The grinding and polishing department laid out for progressive polishing opera- tions. The polishing machines are grouped rows. one room are about machines arranged four rows, two lines for coarse work and two lines using the finer grits. Starting with relatively coarse grit, then successive steps finer abrasives are used, depending the cus- tomer’s requirements. Polishing fol- lowed soft buffing with buffing com- pound made grease and chrome oxide. Polishing done with fine bristle Tampico brushes. Often special finishes are specified. When scratch brush finish called for brush made fine stain- less steel wire used. This gives the sheet satin finish. The sheet laid the table the polishing machine, which travels and out under continuous canvas belt coated with the artificial abrasive. Located another room group special polishing machines for the final fine-finish polishing. These have grit- coated rollers which pass over the sheets and, addition rotating, the rollers have oscillating motion. The two polishing departments are located sep- arate rooms, segregate the coarser and finer polishing and avoid danger hav- ing coarse dust the air dropping the work during the final polishing. Con- siderable pains have been taken elimi- nate this possibility. The final operation consists dipping the sheets solution nitric acid, which they are kept from min. The sheets are kept motion these pickling tanks means mechanically — One the New Types Polishing Machines operated agitators. After this cleaning they are washed water, dried with hot air, wiped and finally cleaned with whiting take off the finger marks. After this final cleaning they are usually handled with gloves. Sheets for the Empire State Building are given special Tampico brush finish and are individually numbered with stencil. coupon cut from each sheet and stenciled and the coupons are E =, - + f J 3 Battery Standard Type Polishing Machines, Which the First Polishing Operations Are Performed The Age, July 24, 1930—215 $ a iid} 7. Section Pickling Room. right given 100-hr. salt spray test. Edges the Empire State Building sheets were honed remove raggedness. Sheets not perfectly flat reaching the polishing department, and those which any buckles may develop during polishing are flattened stretcher leveler having combination electric and hydraulic operation. Sometimes the flattening done between polishing operations and sometimes only after final polishing. Fabrication the Sheets Stainless steel sheets being fabricated for the ex- terior the Empire State Building the United Metal Products Co. include the pier and trim sections, made 18-gage material. Forming done brake which bends deg. are made. The larger pieces formed the brake are 151 in. length. Four five forming operations are done this machine, and eight sets dies are used for nine die changes. Operations include offsetting work some the members, well punching out piece the bot- tom the stock, which done with blanking die punch press. Chrome-alloy steel dies are used the brake. The dies are covered with paper and with lubricant, lithophon compound. This done prevent deposit iron from tools and dies, which would give the erroneous impression that the material rusting. The lithophon compound brushed the dies causes the adherence the paper. When members are made with offsets, the two sections forming the unit are arc welded together. Then the joint filed and buffed. Sections not having offsets are not given any mechanical polishing opera- tions the fabricating plant. The members after fabrication are cleaned and polished with whiting, dried with hot air, cleaned with gasoline. Then they are again polished with whiting 216—The Iron Age, July 24, 1930 the tanks the operating mechanism for the agitators, sheets motion the pickling tanks surface. which keep the and coating whiting sprinkled protect the The final operation spot welding angle iron spreaders the back the formed sheets, these spreaders being used for fastening the sheet members the structural work the building. After this welding, the pieces are again sprinkled with whiting and then they are packed corrugated boxes for shipment. Fabricating being done floors, starting with the material for the first floor. this method, material for each floor kept separate and shipped required under the erection schedule the building. Metals for Coins Claussmann and Billon and presented recently the des Sciences, Paris, note Urbain, had for their object the investigation the limit hardness obtainable with certain metals for making coins and medals stamping. desirable that metals employed for these pur- poses should soft reheating, but hard after cold rolling hammering. shown that the com- pression obtained cold treatment the determin- ing factor regards hardness, and that though the degree hardness rises rapidly the beginning the compression, the limit appears obtained with all the metals and alloys investigated when the thick- ness has been reduced about per cent the original dimension. With reduction about per cent, nickel, and also copper alloy with 8.8 per cent aluminum, showed the greatest degree hardness. These were followed bronze containing per cent copper, 4.6 per cent tin, and 1.4 per cent and gold per cent pure. i | ical buy one time? This question present all purchases. Many factors enter into the decision:—(1) variation price with bought, (2) quantity used consumed given length time, (3) interest the in- vestment involved, worth the money the buyer, (4) cost the buyer mak- ing the purchase, (5) trend the market price, (6) possi- bility obsolescence, (7) cost insuring the merchan- dise after its arrival, (8) cost storing after its arrival and (9) deterioration. These are the most important and most thought of. purchases drop forgings, for instance, the main factors that can mathematically determined reasonably stable market are the first three, that is, variation price with the quantity, consumption per year, and the value the money the buyer. The inter-relation these values may expressed formula, solescence. Here the total number units that should bought one time, the number units consumed per year, the flat charge (or lump sum differen- tial) for the units dollars, the base price the units dollars and 1/100 the value the buy- er’s money per cent (that is, per cent expressed decimal part, 0.06, etc.). Two these terms may not familiar, those rep- resented and Forgings are often sold much apiece, regardless quantity, plus “set-up charge.” the unit price and the set-up charge. Many things are sold under the same plan and are quoted that way these values may derived. The Saturday Post charges $1.50 for one year, $2.50 for two years, $3.50 for three years, and pre- sumably would charge $4.50 for four years, and on. seen inspection that the charge year (equals plus flat charge 50c. (equals *Treasurer, Kilborn Bishop Co., New Haven, Conn. How Much Should One Buy Get the Lowest Final Cost? HOLLOWAY KILBORN* ANY factors have con- sidered determining the most economical quantity buy one time. The problem similar that ascertaining the best quan- year, with extra for any tity manufacture one lot. means the diagram Mr. Kilborn makes possible solve the prob- lem very quickly, once the funda- mentals are known. quantity used year (or month), price differentials based quantity, interest investment, cost buy- ing, trend market price, cost storage and insurance, probability deterioration and possibility ob- were 1500 outgoing calls Ordinary unlimited phone service might cost $50 number calls made. that case equals $50 and equals Another type telephone service might cost $15 year, with charge 5c. for each outgoing call. Here $15 and $0.05. this case, the use were only one out- going call year (exclud- ing incoming service) the calls would $15.05 each. there considers the year they would cost $0.06 each. use the formula necessary able determine what and are when prices are given for several quantities. These may obtained from any pair related values. calculated dividing the difference the total dol- lars cost any two lots the difference the quan- tities the same two lots. For instance, 200 sell $0.13 each, total $26 and 400 sell $0.10 each, making total $40, $40 less $26 $14, divided 400 less 200, 200, which gives $0.07 each for After finding multiply either quantity the value and subtract the answer from the total number dollars for that quantity, which will give the above case 200 $0.07 equals $14, which sub- tracted from $26 leaves $12. the same way 400 $0.07 equals $28, and this subtracted from $40 leaves the same value When three more different quantity prices are given, different may obtained from different pairs values, which case the best result would obtained using each possible pair and averaging the results. Then, taking that value being the most nearly correct, one may find for each quantity and use the average Practical results may ob- tained using the two quantities nearest what considered the most likely amount the pur- chase. Let first inspect the formula general way determine rational, which the mathema- tician’s term for sensible. states first that when the consumption larger The Iron Age, July 24, 1930—217 | A the amount bought one time should larger. That reasonable. states that when the consumption multiplied four the amount bought one time only twice. This not obvious, but any might true and there nothing experience that makes obviously untrue. next states that when the flat charge greater the amount also greater. This seems like good rea- soning, will spread the flat charge over larger quantity, thereby decreasing the unit cost. then states that when the unit price increases four times the amount should decrease one-half. This certainly sensible idea, although that par- ticular ratio not obvious. evens things out like instalment purchase, having one-twelfth the insurance come due each month. The effect change that when in- decreases. This surely sensible, for the more his money worth the buyer the less economy spending it. The entire formula does not violate any fundamen- tals good sense and therefore rational. Let apply particular case the purchase drop forgings. Suppose the price forging quoted follows { 1000 $0.50 each, total $500 (2) 2000 $0.46 each, total 920 3000 $0.44 each, total 1,320 920 500 From (1) and (2) 0.42 2000 1320 500 (1) and (3) 3000 1000 1320 920 (2) and (3) 0.40 3000 2000 The average 4lc. each. From (1) 500— 410 (2) 920— 820 100 (3) 1320 1230 and the average 93. other words, the forgings will cost each, plus flat charge $93. Then $0.41 and $93. Suppose the buyer’s business making per cent the invested capital, and can use his money; then 0.10. uses 2500 forgings year how many should buy one time? 2500(93)2 (0.41) (0.10) and 3370 and the price should about 43c. each. can borrow the money per cent then 4350. his business making per cent then 99 buys only 2380, because can use the rest the money better advantage his own business. the prices had been 1000 $0.50 2000 $0.48 3000 $0.47 would $0.455 and $50. Then the amounts be- come, with money per cent, 2350 per cent, 3020 per cent, 1660 218—The Iron Age, July 24, 1930 indicating that saves less quantity this case, because the prices for the different quantities are nearer together. The general formula may used the buyer hardware store equally well with the buyer forg- ings, even though the unit price for the hardware items same, regardless the quantity. There cost connected with any purchase which exists, whether realized not, and that the flat cost the buyer making that purchase. Estimates the cost making the purchase vary considerably, from $0.50 up. Many people use the figure $1, which probably not too little when considered that the more starts with the clerk behind the counter (or from automatic inventory), and the demand goes through the buyer, with the necessary information how much, from whom, and what price, the typist for making out the order, back the buyer for signature, into the mail with postage and paper costs, possible follow-up letter two, receipt the goods the shipping clerk, checking the invoice, entering the account, drawing the check, entering the account again, more postage, etc. The buyer forgings might well add more the value deter- mined the prices quoted, represent the cost the buyer making the purchase. per cent) surprising what startling facts are brought light. the sales are one year and the article costs $0.10, economy buy years’ supply one time, total $1.80 (obsolescence would obviously reduce this). this item were only one ten items the purchase order—in other words, were $0.10 instead $1.00—it would economy purchase six years’ supply six pieces. the article cost and the sales were one year would economy buy six. this case, the item was one ten, bearing 1/10 the purchase cost, would economy buy two. Varies with Unit Price The explanation that costs relatively large amount purchase ten-cent item, but not such iarge proportion for dollar one. the consumption 1000 year ten-cent item and the worth the money 0.10 (or per cent), the most economical quantity buy one time 447. But one- dollar item the quantity 141, even with the same sales 1000 year, and ten-dollar item, the quan- tity but 45. The buyer reacts more less this principle from experience. the ten-cent item might buy six months’ supply, but the dollar item feels that too much money spend once,” and cuts down the quantity. the $10 item would contract for steady weekly monthly supply. Often the quantity buyer drop forgings buys too much time, while the hardware tool buyer buys too little. There the case (an actual one) one buyer whose consumption was 1000 year and who bought 5000 pieces 0.05 each, “to get the cheapest price.” was $0.048 and $10 and, assuming 0.10, pee | | 7° = ovo 4 , ; | | | | | | | | j | | | should have bought 2000 $0.053. Buying 5000 paid $250 $325, $65 year Had bought 2000 $0.053 would have paid per cent $106 for year per cent $106.00 10.60 for year 5.30 $121.90 $60.95 year actually put his money work 1.7 per cent (as can determined solving the formula for and lost $4.05 year for years, making total net loss $20.25, “getting the cheapest price.” Then there the jobber (another actual case) who did not think paid stock certain item, and who regularly each month for the last six months has sent order for one was $0.30 and (his own) $1. Leaving out all question interest the investment, has spent for the orders and $1.80 for the pieces, total $7.80 (excluding postage), which would one order have bought pieces and still allow for the cost putting through the order. Seventeen pieces for nothing, and still will not stock the item. And cost the seller just much! Were his ac- count not otherwise valuable could not tolerated. is, would actually cheaper for the seller send him two dozen and charge him for one piece only; but might then set his cost 15c. dozen and still order one only, the next time. should buy and save his and his clerks’ labor. Another hardware they save money buying direct, they can get extra per cent from the manufacturer. But they are shortsighted they not distinguish be- tween invoice price and cost. quite far apart. angle—many These two values may Since the dealer can buy several items time from the jobber against one from the manufacturer, the value one case several times its value the other. And also different the two cases, re- sulting marked difference the quantity buy one time, which much more the case the purchase made direct, and unless the larger quantity actually ordered quite likely that will actual- cost the dealer much more buy from the manu- facturer, even with the lower invoice price. For instance, suppose his sales are year and can buy from the jobber 20c. each, from the manufacturer 17c. each. Let his money worth per cent and his cost buying equal order. can surely spread that dollar over items the jobber, against one the manufacturer. Then, get the lowest net cost should buy time from the jobber, but from the manufacturer. does his each from the jobber and $0.192 from the manufac- turer. If, however, would generally the case, buys his from the manufacturer, which should not unless his money worth 147 per cent year, his net 220—The Iron Age, July 24, 1930 cost $0.215 each. And this only hard, cold arith- metic, dealing with dollars and cents, and does not set value all upon the service that jobber can give, which far excess what can obtained from the factory. times “tight money” and poor business the values given this formula will seem decidedly too large. The reason that has changed the buyer’s mind. must change the formula, too. His company very anxious conserve its income discount its invoices. That per cent days one the most profitable deals any business. costs per cent keep that money for more days, per cent year. changed 0.36 the purchase will ac- cord with the ability the business invest its money purchases that time. When the bank bal- ance builds up, can lowered again, resulting larger purchases. the buyer’s business headed for bankruptcy and has concluded that the credi- tors will get all anyway, his has reduced zero and will buy any quantity that the seller will let him have; costs him nothing, anyway. This formula can equally well used control production. this case the finished stockroom may considered buying the items from the production department, and the person who controls the size the production orders effect the buyer for the stockroom. the sales year, the unit cost production, the flat cost, production quanti- ties what the cost would putting through sin- gle piece only. the same the for the purchas- ing department, and depends upon the net ability that particular organization invest its money that time. The formula can never cure for all errors buying producing. takes into account only three the factors. The trend the market, obsolescence and deterioration are judgment problems, although de- terioration may often expressed percentage which can increased that amount. the pur- chase perishables there would definite time limit imposed; other words, could not more than certain factor times Obsolescence the problem the particular item involved and will affect the value Market trend sometimes uncertain stock market crash and other times reasonably definite. the case prospective small decrease price and large value quite possible that would good economy disregard the decrease. Converse- ly, not well buy too much, even with certainty increase coming. The writer knows one buyer, otherwise appar- ently sane, whose use certain article was lb. year and who was persuaded, account the quan- tity differential and also the certain increase the market which was coming, buy had put the money the savings bank per cent would have been able buy his yearly requirements, twice the price per pound, with only one-half the income from the capital which was spent for the original amount the purchase. Every pound the material cost him times what paid for it. Let hope found out his error, and sold years’ sup- ply so. | | | Heat tt ad Treating Motorcycle arts et te Vice-president, Surface Combustion Co., Toledo, Ohio LARGE heat-treating division, equipped with modern heating equipment, vital part the plant the Harley-Davidson Motor Milwaukee, where motorcycle turned out every min. Batteries large furnaces are lined along the walls placed groups about the floor, with quenches conveniently located. All are served with overhead monorail conveyors and hoists. Many and varied are the heat treatments carried _out here, which fact necessitates all kinds furnaces and baths. For instance, carburizing accomplished batch-type furnaces. carburized include shafts, crank pins, cams, connecting rod bushings, etc., which are made from steel. These are packed boxes with carburizing compound, heated 1700 deg. Fahr. for from hr., removed from the furnaces and cooled the boxes, and then dumped. Depths cases ranging from 1/64 3/32 in. are obtained between the limits these time periods. For refinement grain structure the parts are replaced the furnaces, heated 1650 deg. Fahr. and quenched oil. The final hardening produced reheating the furnaces 1450 deg. Fahr. and quenching water. Selective carburizing used the ball race hub the shell, the whole being first copper plated. Then this plate removed from the ball race machining. The shells are packed boxes, heated 1700 deg. Fahr. for about hr., cooled the boxes, removed and reheated the furnaces 1450 deg. Fahr. and then quenched water. They are tempered heating 425 deg. Fahr. for about min. Continuous Furnace Adds Flexibility The most unique furnace this division one the continuous type, which can used interchange- ably for various kinds heat treating. was de- signed and built the Surface Combustion Co., Toledo, Ohio. The work loaded trays ft. charging table. The trays are pushed through the furnace three rails pusher the motor-oper- ated mechanical rocker arm type. One new feature this installation that the work, after being heated, can either quenched cooled slowly the dis- charge end. When the work quenched, trunnions the trays ride short rails the discharge end and dump the work through chute (A) the hearth directly into the quench. the chute air tight, and extends from the hearth into the liquid, air enters the furnace touches the work. The quench contained steel tank, some ft. long, provided with motor-driven elevator conveyor for taking the work through the quench and out the tank. set motor-operated pullers reaching into the furnace, The Iron Age, July 24, 1930—221 | | Bae - 2 ™ . through the end door, engages the trunnions and pulls the trays out. These turn are lifted hoist suspended from overhead trolley, and thus returned the charging end. the work normalized annealed only, the trays are pulled out the discharge end the furnace shori rails placed over the chute. They ft. long, which sets just veyor, above the quench tank. The work cools travels along veyor and drops into tote boxes the end. the same time trays are put trolley re- turned. ture this in- installation method whereby the cooling rate retarded. This consists ing hood, which suspended from the ceiling when not use, over the first half the conveyor, while normalized annealed work passing over. Pusher, puller and discharge door are equipped separate motors and speed- anisms. The pusher ated from time clock the proper time intervals. When the pusher the forward stroke makes contact which sets motion the motors the discharge door and puller. The discharge door closes automatically, after the The speed-reducing mech- anisms allow wide range time cycles, periods. cycle has been completed. heating Insulation Furnace Inside Steel Casing This furnace built brick in. firebrick and in. insulation) and incased steel. The doors are cast iron and lined with refractories. Gas fuel employed and the firing equipment repre- sents perfected means automatically proportion- ing gas and air. One valve control, constant furnace temperature and maximum furnace efficiency are as- 222—The Iron Age, July 24, 1930 Furnace the Batch Type for Miscellaneous Heat Treating sured, independently the skill the operator. thus possible maintain reducing atmosphere within the furnace, minimize the formation scale. number gas burners the two-stage ve- locity type are arranged along both sides the fur- nace. They fire both above and below the rails, heat and soak the formly. These re- burners low ture range from 700 1650 deg. Fahr. High-pressure gas used the firing system, compressor being used raise the gas lb. pres- sure. Two auto- matic turecontrols, each with ther- mocouple and recorder, are pro- vided. These are motor operated valves the gas supply lines and automatical- maintain any desired tempera- ture, the same time giving chart the tem- peratures. The trays are in. long and in. wide. The ca- pacity the fur- nace varies con- siderably with size and shape the being treated. one class work 900 lb. material hour was treated 1520 deg. Fahr. and the same time 1395 lb. trays were heated. The gas consump- tion amounted 1910 cu. ft. 530 B.t.u. gas hour. another class work 840 lb. stock and 1195 lb. trays were heated temperature 1520 deg. Fahr. with gas consumption 1920 cu. ft. 530 B.t.u. gas hour. maximum burner capacity 2500 cu. ft. hour provided, care for any con- tingency that might arise. More than miscellaneous parts are heat treated this unit alone. these parts might mention the generator shaft and side-car axle, which are formed from 3140 steel (nickel-chromium). These are normalized 1600 1700 deg. Fahr. and quenched oil 1475 1525 deg. Fahr. They are drawn 900 deg. Fahr. obtain Rockwell hardness | q Chute leads quench tank. along rails, cool the air Charging End (Below) Continuous Automatic Furnace Wide cation Varying Heat Treatments. Work goes through trays. ISCHARGE End Universal Heat-Treating Furnace (Above). Work not quenched passes ~ The Iron Age, July 24, 35. Transmission gear blanks are 3245 steel and are first normalized 1650 deg. Fahr. After the teeth have been cut these gears are heated salt bath for half hour 1480 deg. Fahr., quenched oil and drawn 425 deg. Fahr. for one hour. Varied Furnaces Used for Miscellaneous Work Several standard Surface Combustion furnaces are used here, including periodics for miscellaneous work, lead pots, cyanide pots, etc. The lead pot in. diameter and in. deep. The cyanide department separate room which opens directly from the main heat treating division. Here are located seven cyanide furnaces, the pots being in. diameter and in. deep and fired with four burners. These pots, arranged around three sides the room, are served with overhead monorail system. The roller bearing retainer, thin section steel (S. heated cyanide 1500 deg. Fahr. for min. for skin hardness, and then quenched deg. Fahr. and quenched again water. prevent distortion, this retainer held pneumatic hard- ening fixture while being immersed. There are number batch type furnaces and quenches placed different sections the heat-treat- ing division. The oil the oil quenches cooled with pipe coils inside the tanks, which cold water circulated. Miscellaneous hardening accomplished ‘ro- tary-type furnace provided with both oil and water quench, that the work can discharged into either, circumstances demand. This furnace con- sists outer steel shell lined with refractories and inner retort alloy steel. There are ten gas burners located each side—20 all—and temperatures are automatically maintained with two automatic controls, the two thermocouples being located opposite ends the retort. Each has recording pyrometer and connected with valves the gas supply lines the burners. The retort provided with screw which rotates and thus causes the work progress through, and motor employed turn the retort. Each these two quench tanks ft. long. Both are equipped with elevator traveling conveyors arranged that both either can driven from the same motor. The furnace provided with swing- ing chute which the work can directed into either quench with minimum trouble. Continental Mills Recover Empty Nail Kegs from Abroad UROPEAN methods packing steel products for export differ certain respects from American practice, but, nevertheless meet with the approval the buyers foreign markets. Many mills have adopted the policy recovering empty kegs, which nails have been shipped foreign customers. The ordinary wooden keg, used for nails Con- tinental mills, about per cent lighter than the American container, being constructed lighter and less expensive wood. While two iron hoops are the usual reinforcement such kegs, many shippers reach agreement with the buyer abroad permitting the use soft saplings fastened with staples. With this type reinforcement used instead the metal bands, reduction the price granted the cus- tomer. When substantial number such kegs are avail- able from single customer, certain port, they are often returned the mill used over again. The kegs are taken apart, the staves bundled together with the bottom and top, still usable, wired the bundle and the dismantled keg ready for shipment the mill. Thousands such kegs are returned the European nail mills usual ocean freight rate $1.80 per kegs. the cost new kegs profitable reship the and refasten them the works. Packing steel bars, shapes and tubing offers point difference between Continental and American methods. While American shippers bars usually bundle the and smaller, Continental mills gen- erally ship and bars unbundled, binding only the 7/16 in. and smaller and flat bars in. Bundling practically always done with bright, not Iron Age, July 24, 1930 galvanized, wire and occasionally with annealec wire. American shippers round and flat bars, angles and beams, well other steel products usually attach label the bundle with shipping mark, bundle. European mills, instead using labels for identification will, rule, paint the ends such products using different color paint for each cus- tomer, different application the paint when the same color must used. This generally considered less expensive than attaching shipping label. The Matter Paper Wrappings shipping the Far East, dark brown tarred paper used for protection kegs cases nails, bolts, nuts and rivets, instead oil paper. This tarred paper less expensive than the oiled product and seems acceptable to, not preferred by, the Far Eastern buyers. American makers wire netting usually wrap oiled paper bearing shipping mark each roll. European mills, however, inclose the wire netting roll brown tarred paper, which equally acceptable the buyers less costly. Shipping wire mesh differs, American sellers packing six rolls 100 ft. ft. single case, while German and Austrian mills pack and rolls, and the small diameters rolls single case, thereby reducing the total packing costs shipment. Galvanized and plain wire reels and wire rods are usually shipped unprotected, but the exporter from the buyer certificate release from responsi- bility for rust. Packing black and galvanized sheets the same the United States and there simi- larity packing most other steel products. | HERE are two methods burn several gases one furnace: The gases may mixed before entering the furnace, the individual gases may fed individual burners groups burners into the furnace, and not come contact with each other before entering. both cases the compound effect the several gases must controlled, that the resulting heating value corresponds with the re- quirements the furnace. For the first method the mixing process the same for all burners. usually controlled ob- tain certain predetermined heating value the gas mixture. Furthermore, the use and control the mixture differs way from that when using only one gas. Maintenance constant heating value has decidedly advantageous effect the efficient opera- tion the furnace. Gases lower heating value can mixed with gases higher heating value and thus burned under equally good and economic combus- tion conditions. the second method separate supply for in- dividual gas mixtures, and combustion takes place simultaneously the combustion chamber. This has the advantage greater adaptability the flame action the individual thermal requirements; i.e., times small heat requirements—as long the charge cold—or during periods maintaining cer- tain temperatures without great heat consumption, poorer gases can used, which, when there demand for high-heating-value gas, richer gases can added. Efficient Operation Requires Exact Air Proportions The great economic advantages this type op- eration are well known. Its efficient operation, however, much handicapped, the introduction this method for general use, because requires almost *75 West Street, New York. This mainly translation paper Dr. Karl Loebbecke, which was published Feuerungstechnik, Vol. 17. Only minor alterations and additions have been made, eliminate European complicated methods explanation. The System has been successfully used European installations. Control Mixed-Gas Furnaces Automatic Regulation Air Supply for Burning Different Kinds Fuel Simultaneously KARL scientific adjustment fuel and air. Without ex- tremely careful supervision and control the process, easily possible that just the opposite eco- nomic effect may the result. importance also, for small industrial installa- tions, the use additional gas, e.g., stoker firing. The volume coke oven gas continuously increas- ing and long, distributing gas lines are coming more and more into general use. Steel plants could easily obtain the necessary temperatures means addi- tional coke gas and, times higher heat demands, almost immediate increase the flame output possible. The simplicity lighting and the immediate availability this fuel are particularly valuable from IG. Two-Gas Regu- lator. The arrow shows the direction movement for increas- ing amounts air. Photographic view the instrument appears top page The Iron Age, July 24, Gas ’ ‘ the other sole use coke gas existing furnaces, originally always operating point view. hand, the which were not designed for this type fuel, not economical. And, due the effect the high flame temperatures arches and durability the furnace, highly undesirable. Under variable operating conditions proper ad- justment the combustion air difficult. only one gas used the mechanical (automatic) control al- ways results reduction fuel costs and increase output. When using two more gases, supplied individually mixed, the problem much more com- plicated and only mechanical control can secure their advantageous combined use. One Method Used Germany The Arca multiple-gas mixed-gas control se- cures automatically the supply the correct amount combustion air the operation single damper for two three different fuels used one combus- tion apparatus. also permits operation with pro- portionate constant amount excess air. The operation simple, only the amount gas need adjusted according the heat demand. necessary burn the The air ras follows automatically. This apparatus consists hydrometer with differ- ential floats for gas gas and the air for combus- tion. The movements the float gasometer which correspond the amount gas passing through the meter, are transmitted lever roller mounted the other end the lever. The arms the lever can adjusted according the relative heating values gas and gas The move- ment transmitted from the roller via chain and relay, which held the fulcrum edge springs. One end this lever influences the opening nozzle for pressure fluid. movement the lever 0.002 mm. (0.00008 in.) positive negative direction, measured the nozzle, suffices start the operation the control apparatus, which shows the extreme sensitiveness the relay. How the Apparatus Operates increase flow Gas the roller downward and, means lever opens the nozzle the Arca moves and weight, relay. This sets the 226—The Iron Age, July 24, 1930 IG. 2—Control Combustion Air for Combination Coke Oven Gas and Blast Furnace Gas Firing (each gas measured individually) Adjustment: cu. ft. air for cu. ft. coke oven gas cu. ft. air for cu. ft. blast furnace gas Conditions A-B 23:10 o’clock (10:10 M.) Gas, cu.ft. Necessary air, hour cu. ft. hour Coke oven gas 44,100 176,400 Blast gas 70,800 Total 247,200 Automatically adjusted and indicated 247,200 hydraulic servomotor into operation, which turn opens damper tion air. meter and increases the supply combus- This results lifting the float the air- and raises the fulcrum the lever until the nozzle the relay again median position. increase flow gas II, the relay nozzle opened manner such described above, with resulting increase air The movements, how- ever, the intermediate lever are different amount, according the heating value gas and gas Hence increase gas e.g., four times the amount air flow adjusted would pro- vided increase the flow gas II. The regulator automatically totals the several gas flows, with simultaneous consideration the indi- vidual heating values, and adjusts the necessary total air flow. The flow plotted recording drum the upper part the apparatus. Heretofore control was used for two three gases whereby the air was individually coordinated each individual gas. Such plant consisted two three control apparatus units, with two three individual air ducts, each provided with damper. addition, four six meters for gas and air flow were required. The multi- mixed-gas regulator controls only one damper and one air duct, and registers individual- and simultaneously the individual gas flow and the total air flow. The diagrams are superimposed 7000 CASE (A) CASE (B) 6000 Cubic Meters IG. 5—Graphic Representation Showing How Measurements Work Out Case (A), Individual Measuring, and Case (B), Measuring Total Gas and One Individual Gas : 5000 a 3—Control Combustion Air for Combination Coke Oven Gas and Blast Furnace Gas Firing (each gas measured individ- ually). Diagram shows conditions during one hour 4—(Bottom Page) Con- trol Combustion Air (One Gas and Total Gas Measured). Load variations are served ad- justment coke oven gas ordinates having the same time abscissa. Individual air ducts and control apparatus and dampers, corre- sponding number with the number individual gases, and the individual and costly measuring ap- paratus are The multi-gas regulator therefore suitable control furnaces fired with two three different gases, and also for controlling additional fuel gas fur- nace using mainly some other kind fuel. The regu- lator also makes the automatic control the air for combustion possible furnaces using combination solid and liquid fuels and also furnaces for sep- arate firing tar, combination gas and oil furnaces, combination gas and powdered coal furnaces, carboni- zation plants. Economical use gas large iron works requires, obtain the best economic heat performance, fur- naces adapted for the use mixed gases. Control these furnaces can carried out means the multi-gas regulator. Figs. and show operating diagrams taken the multi-gas regulator; Fig. covers one day; Fig. covers one hour. Adjustment the combustion air this case was equal four times the amount coke gas and once the amount blast furnace gas. From Fig. may seen how instantaneously change amount fuel gas followed the combustion air. Thrreit impossible maintain definite, constant pressure the gas piping supplying several furnaces. therefore also impossible maintain the amounts gas fed into the individual furnaces, soon one furnace changes its requirements. This effect fur- ther increased the several friction and other re- sistances the individual supply lines, resistances which change with the irregular flow through the lines. For these reasons, control cannot carried out manually, and certainly not such efficient way possible automatic control. wrong ad- justment lasting for only min. would considerably disturb the heat balance furnace, and result production losses. One advantage the twin-gas control should particularly emphasized. the amount heat sup- plied the gas and the amount combustion air are proportion, the regulator, when recording the total amount air, indicates the same time the total amount heat. thus possible base the opera- tion definite amount air, required one the gases. the supply one gas insufficient, the control damper for the other gas has opened until the total amount air, which automatically maintained the multi-gas regulator proportion the air requirements the individual gases, has reached its original value. Control One Damper Suffices Thus the adjustment the combustion air, which theoretically complicated, and the full use multi-gas furnace are reduced the operation single damper. For simplicity usual practice entirely manual-controlled furnace maintain one gas fixed rate and control the furnace the adjustment the air damper only with consideration the other gas. Such operation extremely inefficient. The multi- gas regulator permits the same simplicity opera- tion, and secures the same time the correct adjust- ment the air proportion the individual gas supply. also secures economic operation under all conditions. The losses which occur, the amount combustion air differs per cent from the cor- rect amount, are stated below and will give idea the economic advantage automatic control. The Iron Age, July 24, 1930—227 ] Muuten | inn | control would adjust the gas supply the per cent, the pressure the gas line varies be- tween, say, in. and in. Automatic control can operate with almost theoretical air supply, the burners are good. Ten per cent additional air reduces the CO, content per cent, the combustion temperature 122 deg. Fahr., the actual furnace temperature 104 deg. Fahr., and the furnace output per cent and increases the flue gas loss over per cent. These losses, calculated money, show that the cost for automatic control fully jus- tified. How the System Works Out example how the automatic control can advantageously used furnace supplied with two individual gases, when the character one gas does not permit its accurate measurement, follows. This might the case when firing open-hearth furnace with gas from producer and with one other gas. The generator gas should hot when entering the furnace, utilize fully its sensible heat, and pre- vent loss the tar radiant flame. products essential obtain difficult measure the flow such gas, the measuring apparatus and piping are likely be- come clogged, and rule straight ducts long enough are not available insure correct measurement. Sometimes addition only per cent producer gas sufficient obtain radiant flame. Whereas the measurement the hot producer gas alone would offer considerable difficulties, the measurement the gas mixture, giving the total amount gas supplied the furnace, easy. Measuring One Gas and the Total Gas adjust the proper amount combustion air necessary measure the total amount gas sup- plied the furnace, and measure separately the amount the second gas which fired. The operator then ascertains the amount producer gas subtracting the amount the measured gas from the total gas. then multiplies the producer gas coefficient, such 1.4, and also the other gas its coefficient, and obtains thus addition the two values the total amount air which has supply insure combustion. further air, either fixed amount proportion the total air, make