The Iron Age 1930-08-07: Vol 126 Iss 6

THE IRON ESTABLISHED 1855 New York, August 1930 VOL. 126, No. How One Progressive Foundry Increased Outgoing Tonnage between employers and men has won many hard battle for business. one the good things which have come these post-war days—born the good feeling engendered having plenty around. But eyen more essential when there not plenty. And this article tells such case, and how well has worked out for all concerned NCREASED production per unit equipment, with its associated advantages workmen and management alike, always problem inter- est its application modern jobbing foundries. Usually these developments have been noted when times are booming and when plants are operating maximum capacity. This because they have been necessitated the urgent demand for more output than the ordinary capacities the plants permitted. especial interest now the story how the Standard Foundry Co., Worcester, Mass., succeeded intelligent application these methods keep- ing the plant operating the highest rate its history during period when the tonnage trend other foundries was decidedly downward. There denying the fact that, when the gen- eral slump business struck the country and the world large last fall, its effects were felt the Standard Foundry Co., along with the rest. But, fortunately, the management this foundry had the vision see what the far-reaching effects the threatened crisis might mean—not only its show- ing the profit-and-loss ledger the company but also upon the many employees whose means for live- lihood would discontinued. 341 This was time which required business nerve and prompt action. the other hand, certainly would prove mighty fine break for the work- men if, modern methods, they could find ways and means, not only holding their jobs but actually increasing their earning capacity time when work was premium. Analysis Showed High Cost for High Quality Following conference with the George May Co., New York, analysis was made ascertain what ways quality could improved and costs re- duced. The analysis showed that the quality the product being produced was the highest grade, but that much the work ordinarily done skilled molders and coremakers did not require men this degree skill. was felt that some this work should done others. This plan would save con- siderable the time the skilled workers for the more difficult molding and coremaking operations. And, thus relieved, they would able work more efficiently. further showed that the high quality product was attained very high cost the company. The results the analysis clearly indicated that, the applications methods recommended, the ca- pacity the foundry could increased about per cent with its pres- ent buildings and equip- ment. jobbing foundry, take supply only the number customers which can taken care business conditions. considered bad business take more customers, when times are slack, than can properly serviced normal times. But, with the increased capacity now assured, became evident that the number customers could increased. the sales department could secure the additional customers, the workmen would kept busy and con- tented during the slack period. The new customers added, however, were not secured price-cutting basis but, the contrary, the basis higher quality product, which would result from the new methods. Taking the Men into Partnership Formerly, the customer and the company were the only sufferers from bad castings produced—the former from delays delivery the requisite number good castings, the latter excessive cost. But the new method the workman also suffers the extent that receives remuneration for bad castings produced. This plan, therefore, makes him equally respon- sible with the management the production high- quality work, while also, the other hand, shares equally the economies effected. The plan, conse- quently, step the right direction, since brings about healthy factory organization wherein the in- terests the workmen and the management are mutual the rapid production work, with mini- mum spoilage. The method paying the workmen, introduced, essentially that the bonus system, although known the name “ability system.” This name was adopted because implies that ability recog- nized and justly rewarded. standard time for each job set, not hit-and-miss methods, but scien- tific methods, the time set being what average workman would expected working under straight day-work system. Then, the workman succeeds doing the job assigned shorter time, the saving time divided equally between the workman and the company. illustrate, suppose the time set for job was hr. and the workman’s day-work wage hour. does the job hr., makes saving one hour $1. Half this dollar goes the com- pany, the other half the workman. The result that, hr., the workman earns $4.50 instead and the company pays the workman for doing the job $4.50 instead $5. Certainly, this nice profit for both parties. The analysis was made February and the in- Iron Age, August 1930 stallation began immediately thereafter. writing, considered completed, and working sat- isfactorily all parties concerned. has made the company and the workers partners the common job making quality castings fair costs. Standards Set Are Fair All Around The success attained attributed, more than any other factor, the accuracy and fairness with which the standard times were determined, the time for each job having been arrived actual time studies. This left little room for arguments and mis- understandings, unfortunate conditions almost sure arise when hit-and-miss guess methods are used determine this fundamental factor. With the time studies basis, charts were prepared show the necessary time which any job molding, core- making, other work should completed. The rates for all operations were set minutes. From the outset, the workmen were made real- ize the justice requiring the worker fault making any spoiled job obliged replace his own time. The importance this primacy quality due the fact that this foundry does job- bing work exclusively, most being done for the great high-speed machine-tool builders Central New England—that is, for concerns whose product well known wherever machinery used. The happy culmi- nation this endeavor that the workers, bearing strong and direct financial penalty for the production bad castings, have become full partners quality maintenance. Not the least the advantages resulting from the plan the effort made the workers find ways and means improve the quality the castings. Now that their financial return affected the quality the product, they are free with suggestions. And they will willingly long way provide im- proved and better methods for doing many jobs which established custom had decreed should done certain routine methods. Intensive cooperation has become reality. The equally direct and immediate incen- tive has also made the employer interested more production per dollar. The men now are earning little over per cent above their hourly rates, their production having been increased over per cent achieve this result. The largest amounts are being earned the molders, many cases production in- creases high per cent having been made. Each man, being time-rate basis, has become business man whose interest both quality and cost are con- current with those the com- pany. Auxiliary Departments Share Profits Even the service gang has become interested business unit under the plan. This group delivers and removes flasks, patterns and rigging for molders and where helpers are not used. Their allowed time based the work done and they, their own initiative, have worked out plans expedite their work. They are making considerable savings for the company and participating mutually the savings made. Likewise the cleaning and chipping are time rates, giving the men these departments oppor- tunities make savings and participate them. Here consider- was encountered the start meeting the rates set. But, with the help the men them- selves, the work was soon hum- UPERVISORS’ Bonus Chart Used Foundry Work. Dot- ted line shows how used. With per cent departmental efficiency and per cent bad castings, 4.5 cost, the bonus 4.4 per cent. The horizontal line from left reaches the vertical line, then slopes parallel with the two diag- ming along well onal lines until reaches 4.5 cost, above the mini- after which runs horizontally mum rate, allow- the bonus scale ing profit for all concerned. Windows are now washed this plan, but the windows along the craneways are washed the crane opera- tors. This part the plan was adopted because >) Vv w c v = S the bare trolley wires the crane system are located just be- low the sills and, owing the traveling the cranes back and forth, safety considerations were prime importance. Each crane operator was given con- tract maintain the windows his area trans- parent condition, and thus participates the new system. example how improved methods result from the system, mention made the stack gang finding difficult meet the rates set, for period several weeks. Concentrated effort eliminate waste effort won out, however, and the rate was more than made. This was achieved improvements the bottom drags and other simple improvements. Now the stack gang participates considerable extent the savings effected. Knowing What Castings Actually Cost Another vital factor associated with the high- quality production decreased cost that the exact cost the company every casting made predeter- mined. This accomplished merely adding the costs each operation, for the nature the sys- tem these costs cannot exceeded. This knowledge the exact cost every casting has shown many glaring and almost ridiculous disproportions the blanket tonnage selling prices that still plague the gray-iron industry. now known the Standard Foundry Co. which items are profitable, which are non-profitable, and the extent which they are one the other. Comparisons between the costs different methods molding, and between small orders benches, machines and floors, are easily made setting the rates both ways and then choosing the lower the two. The value combining small pieces the most efficient-sized flasks similarly determined. Tonnage per man partments has increased over per cent. But, while the work- ers were achiev- ing this result, the management conducted active and suc- cessful campaign increase the business equal amount, obviate the hardship lay- ing off men. spite adverse political tions, the addi- tional per cent still needed counter- balance addi- tion increase like amount, expected as. the system gets into smoother operation, now assured. should noted that the workmen are not the only men who work the new system. The plan has been extended apply the supervisors well. For the utmost good achieved, believed all should participate the system. How the supervisors may earn the bonus determined the supervisors’ bonus chart, reproduced herewith. Bonus Cent = on * o @ NF E Supervisors’ Bonus Based Their Service Their bonus automatically determined, shown the example and dotted line the chart itself. Cost figures are different for each department, depend- ing the ascertained reasonable cost the part the work done each department. noting the bonus earned, the chief executive and directors can evaluate each supervisor’s services. scrutiny the figures necessarily compiled use this chart, complete picture the effectiveness every depart- ment obtained. The supervisors are paid pro- portion their worth, and they know, and the com- pany knows, their efficiency. keeps interest un- failingly quality and cost. Ogden Mills raised the question, recent address, how long per cent the world’s popula- tion can continue consume per the coffee, per cent the rubber, per cent the silk and per cent the automobiles the world. The Iron Age, August Uses Chrome-Nickel Alloy Shown Special Exhibit STRIKING exhibit Nirosta steel has been assembled the New York ing, 230 Park Avenue, New York, the Krupp Nirosta Co., Inc. The exhibit room pletely paneled with high-chrome-nickel-alloy sheets, satin finished, and the products displayed widely represent the melting, conversion and cast- ing licensees the process. Double doors the room are built central panel, cast one pair and etched pressed metal frames. Border- etched tiles with background. Sheets the ceil- ing have been applied modernistic design and there star the cen- ter. ing the ceiling are Iron Age, August 1930 Displays are show cases, the metal parts which are formed Nirosta, and wall cabinets with doors the alloy. There are samples cast, rolled, drawn, spun, welded and etched Nirosta. Corrosion-resisting seamless pipe shown for use oil cracking and two Nirosta steel drums demonstrate its deep drawing and welding qualities. Sections tubing the display range from in. down hypodermic needles and there are samples wire from ordinary sizes those less than 0.001 in. While the room ample the dec- orative possibilities the metal, the display shows both and at- tractive uses. Among the etched Nirosta panels background colored lacquers. Quality Steel Bar Today Result Long Period Evolution ALTEMUS most universally used steel product the bar. ago this writer sat obscure desk not obscure steel mill western Pennsylvania, won- dering the variety steel bar grades the day. had just read the fol- lowing paragraph from small pamphlet issued April 13, 1843, Messrs. Hird, Dawson Hardy, proprie- tors the well-known En- glish Lowmoor Iron Works: “Messrs. John Finch Sons Liverpool are now, and have been for many years, the sole agents Liverpool for the sale our iron, and having given them further commis- sion extending the United States America and Canada, Mr. Finch induced wait upon you our request, and trust the reputation which our fabric has acquired among engineers, boiler makers and railway companies the highest standing Europe will induce parties residing America favor Mr. Finch with trial order, which feel con- fident, when worked, will give satisfaction and insure further commands.” Then was added list iron and steel grades they were prepared furnish, among which were specifications, called, follows: steel making.” Bar Iron Steel Ordinary Merchant Scotch Swedes Staffordshire Spring Best Rolled Best Hammered Scrap Rolled All that the manufacturers claimed for their iron and early steel products was further established the flattering testimony from such honorable users the Royal Mail Coach Factory Gray’s Inn Lane, London. Single Shear Double Shear Early Attempts Classification Evidently these grades met the manufacturing de- mands Europe and the world the 1840’s. The The many purposes which put have set exacting and varied require- ments which the steel mills have endeavored meet through painstaking work the labora- tory, the steel department and the rolling mill. The author traces the developments which began before the days steel show the in- dustrial influences which have kept steel makers everlastingly it” produce steel bars dependable quality meet all requirements. Whether your experience goes back the days the iron bar more recent, there much interest the user bars this brief narrative the progress the “art pamphlet indicated at- tempt classification. another interesting side light intermediate developments, quote from heavy volume entitled “American Locomotive En- gineering,” Weissen- born, published New York about 1875: “Boiler making now process rapid trans- formation, and the use iron soon cease alto- gether. Several important announcements have con- duced this: the first place, Messrs. Corning, Winslow Co. Albany Iron Works have advertised their ability supply semi-steel warranted tensile strength 90,000 Ib. the square inch, price Lowmoor plate. Then Howell’s homogeneous metal and Firth’s puddled steel begins imported; and finally the Bessemer process has been perfected and applied the manufacture large quantities the metal. The experiments regard the Bessemer process com- menced 1856; after meeting with much opposition and ridicule, the subject took hold the attention the public, and finally, being ascertained that the plan was successful and satisfactory was in- genious and beautiful, the Bessemer steel fast taking its place first-class material the markets the world.” Bessemer Process Amplified Uses But years had passed and many changes, some revolutionary proportions, such the Bessemer proc- ess, had wrought wonders the steel industry and greatly amplified the several uses steel bars. For his own information and satisfaction, the author wanted classify and define the growing diversifica- tion important uses which this branch the mills’ product was rolled serve. The general classi- fication was, course, “merchant bars,” called be- cause they had with more less success passed all producing and finishing operations within the me- chanical capacity the mill and were then ready for The Iron Age, August the merchants’ manufacturers’ racks for further sale manipulation, one rather liberal composition serving purposes. This classification naturally led divisions and even subdivisions and the diversification still goes on. that time manufacturing requirements were relatively narrow and bars were ordered accord- ing somewhat general use. The wagon and buggy manufacturer, except for axles and springs perhaps, could take liberties with phosphorus and sulphur his bar orders, and could the agricultural implement maker, but somewhat less degree. The doubtful purchaser asked the manufacturer for reliable quality steel suitable for given purpose and the manufacturer would suggest grade which, his opinion, was best suited for the service intended. This suggestion was based wholly the nanufacturer’s careful observance the past per- formance his the same our English friends had done years before, through the tedious but sure method “trial and error.” Based such experience, how could some defi- nition made for general trade purposes? After reviewing all files, indulging much correspondence and holding many conferences, accompanying tabulated classification seemed offer fairly reliable division. Bessemer Bars First Sinews Machine Age This was attempt define known requirements and suggested guide for prospective customers follow the purchase proved grades steel. Since then the elimination many harmful manufacturing practices and more definite metallurgical reactions has gone steadily forward. During this period the United States the gradual change from the use iron steel had been brought about without serious difficulty. Government engi- neers, railroads and industrial concerns began insist that their requirements should met every respect, thereby compelling the steel maker open record, romance steel. Some continue un- rivalled this day, notably screw stock and certain wire grades. Agricultural implements, early railroad equipment and numerous machines and machine prod- ucts were born those bars and still find them many points useful contact. The varied extension manufacture and use this product early showed that the quality the finished bar did not depend solely chemical compo- sition, but that the manipulation rolling forging and the finishing temperatures were factors little importance. This fact gave rise the need sci- entific way defining more precisely the physical and chemical properties the increasing number steel grades meet more and more service demands. Specifications Began Appear Accordingly, “specifications” appeared greater variety. Among the first issue such were the rail- roads, and they were varied the individual engi- neers each road differed training and experience. Some interesting things might written about early specification conference attended railroad en- gineers and steel manufacturers. Many difficulties would revealed and some overcome. What was sought and partly found was “way” method the production reliable physical properties for definite service, properties which could duplicated with reasonable assurance responsible manufac- turers who would follow given formula specifica- tion. idea what was done define the manufac- turing and service requirements these early soft Bessemer bars may gathered from the following specification “To manufactured Bessemer steel containing not over 0.10 per cent carbon, 0.10 per cent phos- phorus, 0.06 per cent sulphur, with ultimate strength not over 64,000 Ib. per sq. in., and per cent elongation in. The bar bend flat cold without showing any cracks the outside give added attention EARLY CLASSIFICATION BESSEMER STEEL BARS FOR bend.” processes all Grad Carbont Man- per Lb. per Per Cent statemen which involved some Rivet ..... 0.08 0.30 38,000 58,000 31.0 65.0 0.10 0.50 42,500 64,000 28.0 55.0 new equipment, re- Soft Bridge 0.10 0.40 40,000 58,000 30.0 65.0 0.18 0.60 53.0 Carbon was the vised methods and 0.10 29.0 60.0 great dictator st. Medium Bridge 28.0 59.0 class distinction the 0.16 0.70 46,000 70.000 24.0 50.0 Common Forge 0.14 26.0 52.0 those bars and the present cen- 0.22 0.95 49,000 75,000 24.0 2.0 Foreign Axle.. 0.16 0.75 46,000 70,000 25.0 50.0 several grades stee 0.24 0.95 51,000 80,000 21.0 40.0 determined, largely agi Tire Steel..... 0.20 0.75 48,000 75,000 24.0 48.0 with definite indica- Toe Calk .... 0.25 0.75 52,000 22.0 46.0 0.35 18.0 39.0 amount present. tions all sides Knife Back 0.32 0.80 55,000 88,000 21.0 40.0 They did not offer coming new 0.40 1.00 60,000 17.0 35.0 new Finger Bar 18.0 40.0 any baffing engineer- ate 0.45 1.00 63,000 15.0 30.0 while 0.48 1.00 66,000 110,000 14.0 29.0 furnac Rail Steel ... 0.45 0.80 15.0 30.0 marketing problems, electric urnace 0.55 1.10 11.0 23.0 other than the usual 0.50 Carbon*.. 0.45 0.80 66,000 105,000 14.0 29.0 spluttered swad 12.6 21.0 premium which all dling clothes. 0.55 0.50 0.85 70,000 110,000 13.0 25.0 rac 0.60 1.10 10.0 19.0 refinement exacts ose 0.60 Carbon... 0.55 0.85 72,000 120,000 12.0 23.0 its caref 0.65 1.10 10.0 18.0 eful produc the first sinews 0.65 Carbon... 11.0 20.0 tion. They satisfied machine 0.70 1.10 82,000 145,000 8.0 16.0 machine age 0.70 Carbon... 78,000 18.0 the demands men its dawn. How well .73 1.10 88,000 155,000 7.0 13.0 and machines up to they their *Plow steel. disks. tPhosphorus under 0.10 per cent; the opening the generation 346—The Iron Age, August 1930 sulphur, 0.06 per cent for the lower carbon and 0.10 for higher. twentieth century, when new day began. The open-hearth furnace was now assuming the role tonnage and quality producer. Its product was much better adapted meet the growing insistence for chemical physical refinements; terms the pig iron, that the ore available. that time the automobile was laboratory product the experimental output abandoned stable. This “new fangled contraption” was revo- lutionize the age-old need and hunger for transporta- tion. Its astounding development rapidly created imperative demand for ever tougher and stronger sinews. The commercial carbon steels the day strove give the early models shape well sub- stance, with what would now term ludicrous success. The highest physical properties the best known straight carbon steels were taxed their utmost meet and successfully sustain many old forces intensified new combinations. These requirements soon created need for physical properties far beyond the capacity the best known combinations carbon and iron solution, nicely adjusted heat treatment, and the structural re- quirements the modern automobile have created “alloy age,” shall say “interim,” which suggests shorter lapse until even greater toughness obtained and confined within lesser areas and weights. But while the service requirements the major and more vital parts auto- mobile can satisfied only the superb physical properties alloy steels, the re- quirements many other parts are still within the service limits straight carbon steels and are proscribed this article their consideration only. Four Factors Control Quality The four factors affecting the quality and physical properties steel are the method manufacture, chemical composi- tion, deformation process and heat treat- ment. Volumes have been and will devoted these divisions; are attempting here generalization only superior modern carbon steel bars. many and varied are the uses such that cannot present detailed description each class but will select one fairly representative and having ex- tended use, namely, 0.15-0.25 carbon, produced under today’s specification 1020. Carbon, 0.15-0.25; manganese, 0.30-0.60; phosphorus (max.), 0.045; sulphur (max.) 0.055. “This grade known the trade 0.20 carbon open-hearth steel and often machine steel. forges well and machines better than 1010 and 1015 (0.10 and 0.15 carbon), but should not con- sidered screw machine stock. can used for very large variety forged, machined and case hard- ened automotive parts where strength not para- mount. Steel this quality can drawn into tubes and cold rolled into forms and shapes for automotive parts. can also safely used interchangeably HYSICAL defects steel bars, which for- merly existed, have largely been elimi- nated new methods teeming, bottom pouring ingots and the use sinkheads and tarring molds. reduction processes have been vastly improved recent years, and ingot today reduced fine quality merchant bars one-third the time formerly required, and finely graded reductions insure sound physical condition. American mills have spent large sums re- placing obsolete equipment and developing new methods production and research produce the perfected bar use today. day users, however, leave much lenge the genius the younger engineers. with steels 1010 and 1015 for cold worked shapes that not require deep drawing.” one word only could used sum the basic quality all steel might the word “toughness,” but after the neces- sary minimum mill operations have been used produce this basic quality the ques- tion arises: “How shall modified meet particular service?” The answer, course, heat treatment possibly case hardening the matter lower carbon steels. Forging Most Likely Show Defects reasonably established procedure making sound forging steel this speci- fication the open-hearth process with and pig iron charge, which under better control than some other charge com- binations and less violent reactions, condition which should all times avoided the produc- tion sound, dense steel. essential requirement this steel its ability flow freely any direc- tion under the hammer without cracking showing evidence any seams, which turn depends largely very careful deoxidation. defect not always revealed ordinary hot rolling but almost in- variably forging. Having produced bar required soundness under given specification should perform satisfactorily under the hammer and when finally formed may may not subjected heat treatment. From this little additional strength derived the case low- carbon stock except possibly small sections, but very desirable refinement grain structure estab- lished, relieving all internal strains set forging and bringing about more even ferrite distribution. The Age, August And so, response modern demands for perfected steel bar over its forerunner years ago, American mills have spent large sums money replacing obsolete equipment and develop- ing new methods production and infinite care research. Their efforts have produced bar forg- ing grade which meeting the exacting service re- quirements new era and with eyes toward the future, involving host new and finer requirements the realm airplane and dirigible mechanics, they are the laboratory, testing room, field and air an- ticipating tomorrow’s super-service demands. majestic industry, and the progress made every phase since the opening the present century has set pace such the world has never seen, and yet much remains for the future accom- plish. mention just one project: yet predeter- mined properties, measured accepted tests, have not been completely correlated with exacting service demands. Here interesting problem for the younger engineers today. The whole history the art, for steel making art, fascinating medley mechanical and metallurgical challenges, met and mastered. Materials Handling and Storage Foundry Operations increases melt exceeds tons per run, ac- read before the American Foundrymen’s Association. The following are some his contentions: have unit load greater than 400 500 has been our experience that power some sort should employed transport materials. Electric lift trucks leave nothing desired for many foun- dry operations. They will carry heavy loads, may operated with trailers, are free from fire risks and can operated one man, who need not paid ex- pert wages. Roller conveyors are inexpensive in- stall, are operated manually power, and are capable handling loads five more tons. Because molder specialist, commands high wages. Mechanical power and cheaper labor thus should used wherever possible supplement his efforts. not necessary many jobbing foundries install continuous-molding equipment. But feel that all foundry managers should consider the ad- visability mechanical elevation and mixing sand, with gravity supply each bench machine. The two-.or three-story foundry may work out very suc- cessfully connection with sand and castings move- ment gravity. northern foundry layout must include provisions for frost, rain, snow and ice. Coke and iron should held the charging floor least two days before being used. Ample Storage Space Near Cupola Build ample cupola floor and store upon this constantly least two days’ supply charging terials. Let the iron, scrap, coke and limestone flow gravity from bins well above the charging floor into charging buckets; or, case the climate satis- factory, make the charge adjacent the railroad siding, lifting directly the cupola. duce the necessary floor area the foundry per cent. divorcing molders from all duties but making molds and setting cores, may increase their output 200 300 per cent; e., molder who formerly set floor 110 molds may, the new system, make from 300 400. The volume molding sand largely decreased. All castings and sprues are delivered the cleaning room one more convenient points, while night labor abolished. The moisture content sand kept constant, 348—The Iron Age, August 1930 controlled one man who makes several tests each day. The permeability and strength the sand like- wise are checked. Hard spots iron are eliminated through the absence water the molds, formerly added the operator pack the surface. Need Study Cleaning Rooms part the foundry has less attention been paid economical control than the cleaning rooms. These should studied, decrease hand movement. Pass the castings through chipping and grinding de- partments waist high, from left right the re- verse accommodate the workmen, hire men who can naturally handle their work the machines are set up. Systematically, remove daily all waste from the foundry—cupola drop, slag, dirt, broken cores and worn sand. Movement materials any foundry operation should placed the hands competent man, with such assistance needs. should travel exten- sively, see how his friends and competitors handle similar problems. Use gravity flow materials wherever possible, lifting these bulk mechanically and allowing them pass downward needed. The Government helium production plant Soncy, near Amarillo, Tex., produced during May the largest quantity helium ever turned out one month any helium plant, according the Bu- reau Mines. The plant produced 1,230,350 cu. ft. the noninflammable gas used airships, oper- ation only about per cent the plant’s capac- ity. The net operating costs for May were $9,352, $7.76 per 1000 cu. ft. contained helium. the May costs, helium fill one the 6,500,000 cu. ft. airships now being built for the Navy could pro- duced the Amarillo plant with net expenditure from the Treasury about $50,000. The entire de- velopment production helium has occurred since 1917. Prior that time helium had been ob- tained only scientific curiosity laboratories. Probably the total quantity isolated the whole world did not exceed 100 cu. ft. and the cost pro- ducing was from $1,700 $2,000 per cu. ft. Now rate 2,000,000 cu. ft. per month operating costs well below per cu. ft. How Large Crucibles Are Made NEW JERSEY Plant Produces Largest Graphite Units the World Careful Molding, Drying and Burning Necessary. EFRACTORIES are playing increasingly im- portant part modern metallurgical practice well modern furnace design. Longer and longer service being expected from fire brick, refractory shapes, linings and crucibles, and progres- sive manufacturers are meeting and anticipating the demand. The Bartley Crucible Refractories Co., which be- gan business 1908 the Jonathan Bartley Crucible Co., takes justifiable pride keeping abreast with the changing conditions and requirements modern prac- tice. maintains well-equipped ceramic laboratory under the immediate supervision Walter Shearer, consulting ceramic expert, retained several other ceramic plants Trenton and vicinity. Experimental work constantly progress this laboratory well the plant. World’s Largest Graphite Crucibles Rapid advances are being made the composition and production crucibles and special shapes. The company now producing the largest graphite cruci- bles the world. They are each capable holding 4000 zinc. Also, this plant has achieved the position being the largest single unit crucible plant the country. How Raw Materials Are Obtained and Used The graphite imported from Ceylon and Mada- gascar, and the clays are secured from number sources, both foreign and domestic. The graphite bought under special specifications and then refined the plant develop the particular qualifications re- quired for the processes involved the manufacture RALPH BROWNE Brown Instrument Co., Philadelphia the crucibles. The clays used must carefully blended develop the special characteristics each material. All raw material analyzed before unloaded into the bins and then dry ground before blending. considerable quantity the several blends clays kept available, they must proportioned and mixed and then allowed season before being worked into shapes crucibles. working softened supply also kept ready for the final mixing. When preparing stock for working into crucibles shapes, the blended clay and refined graphite, clay and special refractory, such magnesium oxide, sili- con carbide, zirconium oxide, etc., are brought con- veyor the upper floor where the proportioning and mixing are done specially designed pug mills. These mixers discharge through chute another set grinding mills the lower floor where the final work- ing given the batch. Sweating Aging Process for Mixtures From these mills the prepared product goes what known the “sweat rooms,” where allowed remain constant temperature and high humidity for varying lengths time, the period varying with the character and amount clay the mix. This process corresponds the aging process the preparation fine clay for china and pottery manufacture and serves develop the colloidal matter the clay, thereby materially increasing the plasticity and work- ability the mass. ordinarily takes about month for clay pass from raw material into the finished products. From the sweat room the prepared material The Iron Age, August taken slabs chunks, de- pending upon the mix, the molding rooms for shaping into crucibles, liners, special shapes, etc. Several proc- esses are followed this op- eration, depending upon the material being used and the shape being produced. The operations have been highly developed this plant and experimental work stantly progress. Molds Are Used Form the Crucibles Numerous types molds are used, depending upon the mix, the basic practice being use specially de- signed and treated plaster molds. These various molds are designed give the proper “feed lines” the walls the pots and cruci- bles that they will not break under the stresses set drying and burning. the shipping floor, one may see rows mag- nesia pots 2000 ca- pacity for use electric furnaces; crucibles all shapes and sizes, both acid and basic; liners, and wide variety refractory shapes. Here, too, will seen the great crucibles. These giant crucibles have been brought out during the past two years, and are told that took months 350—The Iron Age, August 1930 Crucibles Stacked the Kiln Ready for Firing Largest Graphite Crucibles Ever Made. Store Room for All Sizes (Below) development work get the proportions graphite and clay balanced, obtain the lines best for the cru- cible, and plot the most satisfactory firing curve. Drying Rooms Are Humidity Chambers After molding, the cru- cibles shapes are carefully moved the dryers. The drying rooms larly interesting they are unique being humidity chambers rather than dry heat dryers. The humidity point. This, course, con- trolled specially devised system heating and venti- lation. result, shrink- age and breakage are pre- vented the drying process, and the ware made ready for firing. From the drying chambers the various units the kilns for firing. First all the pots crucibles must slowly heated and thor- oughly fired. This done stacking them the kilns, shown accom- panying the total time this kiln vary- ing according the size and type unit being treated. When the units are thor- oughly fired, they are either transferred another spe- (Concluded page 400) Rolling Ingot into Billet Carefully Planned Passes plastic materials, Gasche, combustion engi- neer, Lackawanna plant, Bethlehem Steel Co., con- tributed some observations the design motor drive for 34-in. reversing blooming mill. The paper was presented before the meeting Buffalo, June 17, the Association Iron and Steel Electrical Engi- neers. What had say was part follows: monumental paper the theory rolling 1924 was proposed replace reversing steam engine suitable electrical equipment.* Oppor- tunity developed for changing the size and shape the ingot, modification the rolls, and considerable alteration the rolling schedule, all for the sake obvious advantages. Appended diagrams show the surface contour the rolls and end view the *See IRON April 15, 1926, page 1051, for description the new equipment. Knuckled Driving End tapered ingot, with lines superimposed thereon where- the sectional dimensions the ingot after each pass were specified. Nineteen passes were required produce billet from the ingot, the last two being straightening op- erations. The section diagram developed that the quarter turning the ingot directly shown, with the consequent section the ingot after the succeed- ing pass was completed. The tabulations give essen- tial numerical values which enter into all subsequent calculations. Establishment such rolling schedule possible through knowledge the requirements mill opera- tions, which will not amplified this time. must not concluded that any fanciful arrangement passes, drafts and roll grooves will allow highly Profile Roll and, Above It, Rolling Schedule for Reducing Ingots 4-In. Billets. Passes are rolled the bullhead 8-in. groove; the 4-in. groove. The groove, idle this case, used when rolling other sections The Iron Age, August 1930—351 t Y sections cannot safely em- Accepting the ployed numerical substitu- quirement, there still the though mean values for torque necessity applying all the 382 1.075 19.0 and work may ultimately judgment that previous con- applied when the service tacts and mill experience 367.5 motor-generator set would make available, as- specified. speeds rolls for each opera- Power Estimated tion, not overlook the domi- was estimated that the nating character the small work required produce bil- time intervals between the 109.3 86.3 1.267 lets from the ingot, all passes and for general ma- specified, would approxi- nipulations the mill and the 56.3 1.354 5.5 mately kwhr. ton, meas- account the taper 23.0 17.0 1.353 4.25 Actual operation the mill, the ingot, the first three after the attendants became passes impose variable re- Blind familiar with all controls, en- sistance the rolls and driv- ening abled the delivery ton ing mechanism. Average billets with 2334 kwhr. Canadian Terminal for British Transoceanic Dirigible Service The British dirigible R-100 the end its transatlantic flight Aug. was moored the new mast built St. Hubert Field, Montreal, for the purpose —The Iron Age, August 1930 successful completion transatlantic flight the British dirigible R-100 has focussed the attention the world this new leviathan the air and its sister-ship, the R-101, both which depart many features design and con- struction from the Zeppelin-type developed Germany. Not only the British dirigibles differ design, but they present departure the materials used, especially the R-101. Stainless Steel R-101 This sister-ship the R-100 now nearing completion Howden, England, and its successful performance the air may portend increasing use alloy steel for lighter-than- air craft, its frame constructed duralumin and stainless steel almost equal proportions, with some austenitic alloy used for the fittings. IRON AGE gave its readers com- plete discussion the structure R-101 its issue June 27, 1929, more than year ago. The Mooring Tower Canada’s share the airship development has included mooring tower the Montreal airport, St. Hubert. The tower, here illustrated, self-contained structure, anchored concrete footings. the base the tower two-story building, cruciform shape, house the mooring winches, heating plant, etc., and provide lobby entrance, retiring rooms and offices. The tower octagonal structure 171 ft. high, surmounted steel plate turret ft. diameter, from the top which pro- jects telescopic mooring arm which the nose the airship attached. The total height the tower the top the mooring arm 205 ft., and the extended ft. This telescopic arm, weighing tons, mounted gimbal bearings and counterweighted, through system cables and pulleys, swing deg. from the vertical and any position the compass. operated compressed air. the center the tower, there elevator and stair shaft ft. square. The searchlight platform, 142 ft. in. above ground, equipped with searchlights which are used spot the anchorages the ground, and, generally, facilitate airship moorings night. Canadian Vickers, Ltd., Montreal, fabricated and erected the tower. Bil, / Polishing Chrome- Requires Care and > high chrome nickel al- loy for products which were formerly given final coating, such tin, zine enamel, has brought the metal-working indus- try the problem cleaning, polishing and buffing the finished article. Formed and drawn shapes are proc- led sheet, sheet that has been given the addi- tional processing grind- ing remove defects the surface, such mill marks, open surface, pits, slivers, etc. the article being drawn severely worked must annealed during the processing, pickle finish sheet usual, ground finish likely become scratched galled the dies, would scaled an- nealing, and the original finish would advan-. tage. deep draws has been found that pickle finish sheets handle easier the dies and not show the orange peel pebbled surface often the case with the ground sheet. For flat work, where operations are confined bending light drawing, table tops, cabinet work, drains, panels, and trim, ground finish sheets may used advantage. Such sheets are obtain- able with the exact finish desired, and following fab- rication all that necessary clean the work thoroughly any one several methods, depending upon the ultimate use the article. When the finished product intended for use where will exposed the atmosphere, all possibility bleeding rusting sheared edges should elimi- nated and all dirt and foreign matter that may have contaminated the sheet during fabrication should removed. The usual method clean the panel with The top the Chrysler Building gleaming needle among the towering buildings New York. CURTIS SNYDER Nickel-Alloy Steel Special Compounds gasoline and then whiting, after which immersed tion nitric acid 130 deg. Fahr. for about with hot water and dried with warm compressed air, and eliminate further marking during transit and whiting. used with protection from atmospheric action, that danger bleeding elim- inated, the nitric acid dip may omitted. When this done the panel should cleaned after fabrication completed and the entire surface should buffed with green chrome oxide rouge, stainless steel buffing compound. Special compounds for buffing have been developed the past year, and within the past six months considerable improvement has been made their quality and properties. number highly satisfactory buffing compounds are being sold com- mercially. Removing Cement and Plaster Stains During construction building has been found almost impossible prevent the rustless steel from being splashed with cement plaster, both. in- vestigation was recently made the research labora- tory rustless steel maker determine satisfac- tory method for removing the contamination the same time cleaning the sheet not impair its corrosion resistance. Samples the investigation were regularly pol- ished Ka-2 sheets, which had been buffed with chrome oxide rouge. They were smeared with cement and plaster, half and half mixtures sand and Portland cement, plaster. The Iron Age, August 4 f ‘ ¥ The accompany- ing table shows the results made with cement and plaster eight samples Ka-2 sheets. The cement stains were re- moved all clean- ing methods except sample proprietary clean- ing compound was and the compound Sample No. was washed with water, dried with cloth and buffed with No. move but were suc- cessfully cleaned from samples and The buf- fing, however, re- moves all the = ‘ y stains. marks which could traced the cleaning buffing methods were ap- parent any the samples. The plaster and cement stains were again visible sample No. following the salt spray test, evident that this method would not prove satisfactory for cleaning. The buffing brings out medium bright luster, the best buffing results the shortest time being obtained the use wheel. Polishing Articles From Pickle Finish Sheets Polishing and buffing drawn shapes possibly greater interest the metal-working trade than any other features the processing rustless steel. The producer finished products concerned with obtain- ing the best finish possible the shortest time. difficult determine just what grit should used start there some variation the surface the sheets from different mills. This, however, should soon change and marked improvements will doubtless appear, even the sheets now considered the best. Much depends upon the shape the article being polished. rounded has curved surfaces that can held fixture and spun, with auto- mobile lamp shells, certain cooking utensils and light slightly finer grit may used the start Iron Age, August 1930 No. Continuous panels rustless steel rise each side the windows the Empire State Building, New York. Rising the full height the building, they required 250 tons high-chrome-nickel alloy, which half was “Allegheny” metal and half Ka-2. than the case when article unsuited spin- ning. 4 lamp shell simi- lar product formed will serve ex- ample. suitable fixture and applied against abrasive wheel No. 150 manu- factured grit, arti- ficial grit being preferable Turk- ish emery. When Turkish emery used should about No. 120 grit. The abrasive wheel should the cessfully and eco- nomically using worn down sec- tions from buffing wheels spacers between the layers abrasive. spacer should put between every two three sec- tions give the desired result. Pol- ishing wheels should run 6000 7000 linear feet per minute, the r.p,m. 14-in. wheel being 1800 1900. High-Speed Buffing Best When all die marks and surface imperfections have been removed the No. 150 grit, the article may transferred grease wheel, dressed with No. 180 synthetic grit, after which No. 200 Turkish emery used with grease. Following this the shell should ready buff. with the abrasive wheels, very soft buff should used, set the same manner with spacers. Buffing speed should faster than for the other wheels, 7200 and 12,000 ft. minute having been found give fine results. While this appears wide variation, almost 5000 ft. min. between the low and high, they are used for actually buffing these speeds. One, using 8000 ft. per min. states that gives the results desired, while the buffer 12,000 ft. claims that obtains better color with the higher speed. Iron Oxide Compounds Undesirable Special rustless steel buffing compounds should used, compound iron oxide, such ordinary red rouge, highly unde- sirable, the metal being likely become contami- nated with the oxide and subject rust tarnish. compounds now the market contain harmful ingredients and salt spray tests 100 hr. buffed rustless steel per cent solution, show staining. Abrasive buffing wheels which have been used for brass ordinary RINDING and polishing high-chrome- nickel alloy steel requires special com- pounds and high-speed buffing obtain the best results. exterior applications the stainless alloy the Tampico brush gives high- desirable finish, which the new Empire State Building New York example. The author has been connected with the United Alloy Steel Corporation, later the Cen- tral Alloy Steel Corporation and recently the Republic Steel Corporation. the issue July 31, Mr. Snyder dis- cussed annealing procedure, methods pick- ling and requirements drawing dies. foreman was that the steel was pitted laminated, had open surface. The real explanation, however, appeared that the presence the brass the wheel, the grease, and the heat generated had caused electrolytic at- tack the Ka-2. this both polisher and foreman were convinced when new wheel was used with re- currence the etched con- dition. steel should never used Ka-2 unless they have been completely redressed. Obviously the wheel which has been run steel might have the same action the stainless steel red rouge.