The Iron Age 1930-09-18: Vol 126 Iss 12

THE IRON ACE New York, September 25, 1930 ESTABLISHED 1855 BUSINESS—What ERTAIN economists confidently declare that they can prophesy moderately ahead unerringly the astronomer foretells eclipse the moon. Rather than with astronomy their analogy ought with meteorology. The science prophetic down the knowledge that this hemisphere most storms originate the West and generally move eastward and may outstripped few days the telegraph. But they not always follow regular course and besides that one knows just what starts them. are almost ignorant the starting economic depression, until long afterward the historians review conditions. For practical guid- ance know scarcely more than that they occur every now and then and later dissipate more less the same way. Our optimism the present moment chiefly based such historical prece- dents, and the statistics that eagerly scan are examined for symptoms rather than reasons. NDUSTRIAL depressions may start from over- building, from adversities nature, from over- straining credit, from warfare, from general bad habits living, from political discontent, from social movements, and probably from other causes, two more which may acting conjunc- tion. the present time are passing through world-wide depression from which France alone among the major countries appears have es- caped. dismiss Russia, which trying new kind economy. Thinking only terms the United States, believe that our troubles arise from over- provision goods, which follows from overpro- duction, which may follow from overmechaniza- tion, and like the house that Jack built, all which may true without getting the roots things. VOL. 126, No. Factors Condition Its Recovery? exploring for them come always con- sequences the Great War, which still enmesh the world many ways. More immediate roots are found the turmoil the Orient and the unrest South America. The trouble brew- ing India has played the mischief with British trade. The quarreling China has brought Japan the verge ruin and has had serious, direct effect American export trade. national economy complicated and subject derangement only slight altera- tions conditions. the aggregate probably carry about ten-month supply goods. plus minus one-month supply may have profound production permit depletion occurred 1921 and 1930, and there may subnormal em- ployment workers the extent per cent. After the liquidation stocks has been completed replenishment them inspired low prices. This merely explanation the historical observation that severe depressions run about months their downward movement and perhaps another months the return. frequently cause minor domestic depressions, 1924 and 1927. When there superimposed the effect concur- rent foreign adversities, affecting our export trade, there aggravation, and 1930. While, therefore, may now reasonably ex- pect early restoration our domestic balance, plus the benefit our natural growth popula- tion and increase consumptive demand, should not anticipate regaining full measure activity until situations abroad have materially improved, which will involve adjustments quite different from our own. 831 7 4 , POLLISTER president and general manager the Busch-Sulzer Brothers-Diese! Engine Co., was born Portland Institute Tech- nology, entered the engineering the New York Edison Co. His first professional contact with Diesel motors took place some four years later with the National Light, Heat Power Co., for which supervised the construction power plants Illinois. the war Mr. Pol- lister served two years the Army, and was captain, 319th with months over seas service. INTELLIGENT COST WORK WILL AID RECOVERY 1 j 1 lat | | ula ne patn ms ne erhea tin oOlurme i the in reauction ofl op t eet the reduced dGemand For other n t th, Loe i ct etn cost o¢ ore rtant n pt making, und in 1 14 I tries is ours, where we build ratner Lan ture L;] lor mal while consider past costs more yr iess water over the d im, we care fully compte and se these costs to guide toward lower cost designs. In we use historical costs to create in advance This use past costs compels why costs are high and imposes the e obyective costs. 32—The lron Age. September 25, 1930 competition during dull periods may wisely met meet price cutting. ligation of meeting a reduction in such costs betor ] OrK Is undertaken Herein lies the greatest value cost data. y establishing lower future costs advance oundly . Unreasonably low price compet tion will then the urge for effort toward greater pro ductivity and build economically sound basis greater value for the merchandise dollar, which will the manufacturer who stays closely cost finding more firmly established after a depression than before: vhile his competitor, who has thrown costs the four 1 . 1] winds seeking for volume without regard cost, emerge weakened condition return prosperity. compete the — > | \ | . j this Cost Work Shows Its rofit Possibilities JOHN VAN DEVENTER Industrial Consultant ihe ivon ive XISTING will not serve under present-day which began over lepartment provide ards are not sufficient. The cost and the possibilities new economy. vear ago has produced cer- tain effects the machinery and metal-working industry. riodic report covering which rela most obvious these this end progressive companies the general reduction shaping their cost work toward ume, resulting difficulty maintaining margin. secondary effect the stimulus managerial effort caused the need taking steps meet this situation. required routine. roperly maintained, rate and date tions trends things, however, are what more effective executive control; equip- ping with personnel having suitable initiative and plant experience and de- manding suggestions and surveys be- expected that yond and above what was formerly the cost record files shall intensive period questioning policies the result this new competition introduced But much greater constructive inagement today. The cost decreased volume. Execu- tive thought now centered the reduction manu- facturing costs and general nitiative overhead rather than building big production routine volumes and quickening the capital turnover. Profit The experience today must made through the skillful multiplica- plant executive typical progressive tion small economies. Cost and expense reductions new attitude toward work aid meeting form the managerial keynote today and will today’s competitive condition continue pursued with keen executive interest Shortl market breal tor some time come. executive, “our volume dropped level that logical that cost work and the cost depart vipe all profit und exist perating condi ment should receive more executive attention toda tions. Seeing likelihood immediate upturn, under these conditions than they did during the decided over our organization, artment “boom” period. The cost department the one pla department, and what found the industrial plant which all operating ffset the shrinkage production gravitate. Cost saving ideas and suggestions Our cost department, from the statistical stand flow out just operating statistics flow in. was probably well equipped such depari could and its records were good order. usable ideas depends what the management asks intorma and how well equipped, initiative and abil “Here was department our which materia big lumps that woul control call attention jobs which stood out and were reported the proper past averages, and labor have run above below The Iron September 25, 1930—833 g = executive. should have been wonderful source help but strangely enough was unable get new and usable idea out it. found also upon in- quiry among our department heads, that aside from the customary reports and notifications cost excep tions sent them our cost department, there had not been one instance during the preceding several months where usable suggestion had been made possibie ways cut costs reduce expenses. “Our cost department had been living what expected the way routine reports. But when you are faced with unusual conditions mergency nature, statistics and routine devised meet normal conditions will not necessarily give you When established stand irds performance will longer serve, initiative imagination must come the rescue rather than routine reports. the kind help want. “We not expect that the cost department shai! furnish the executive brains our organization, but think every plant has right expect that with all the available it, this statistics should made produce cost saving ideas. Our cost department been under the jurisdictior the comptroller and cam inder what ve call our administrative | ontro It was wrongly } ke from its statistics vas evident that must intro- duce additional initiative into lepartment. put under the factory manager and assigned 2 i ry) rh +} + ; + + + ‘ 3 ems | | t as t establis] ind had hou AGEME Every item exper put aete! Wi thought verhead for but that man gr Jumps had to be broken down good deal more before uld find +} ‘ } nothing like breaking down find what inside it. Our power charges againat departments Was one such case. &34—The Iron Age, September 25, 1930 SUGGESTIVE How many suggestions for cost and expen reductions are getting from our cost partments? Have got the sort initiative cost department that can expected duce ideas well statistics? ment rather than help it? Have split our overhead expense item into small enough pieces for control and duction? know what our power losses are each department? thought had this down pretty fine with recording instruments showing the exact against each department. “As matter fact, this told how much pow were paying for but not how much was going int actually consumed with our machines and compared this with what were putting into each department check-up from this angle showed losses that ran into real money and would have kept growing had not run them earth. “Investment work process was another ite: that found susceptible the analysis treatment When volume preduction falls off, the relative work process, per unit production, usually up. Splitting this item according department showed that two these, out total were responsible for per cent the total. lieve the principle first hitting the heads that stick the highest made drive the process account these two departments. one them, found that rearrangement our machines gave better flow work and prevent: stock piling between operations. the other, installation simple overhead stock conveyor sulted from our studies. These two things gave even more favorable ratio for this item work process than had formerly had for our normal out put. the other five departments, were able make substantial reduction keeping after the foremen and making them realize the importance not keeping material and labor dollars tied “These are only two the leads economies were the results our insisting that the cost depar ment should generate cost saving ideas after had initiative and technical knowledge. Similar possibili- ties for cost and expense reduction are now uncovered nearly every day. These are put down paper an‘ ire gone over twice week committee our executives. ay | the coming six months and | ‘éiésS IVE ESTIONNAIRE Are sure have taken all the slack out our work process account? know the idle time supposedly busy machines—and why? Are getting the idea cost and expense reduction over the foreman? our cost reports find and check high costs before the job completed? 10. put repairs and extensions under cost control let them “go blind”? “Once week the assistant factory manager who charge this cost analysis study has meeting vith our foremen, get the cost and expense saving idea thoroughly into their heads. Once week, meets with the sales executives, order keep touch with price competition and find out where cost savings can most readily interpreted terms increased sales and markets. more than one in- stance, this has led complete redesign one our products; initially favorable cost being secured through incorporating, the new design, parts and materials that were developed comparatively “We were driven into our new attitude toward cost work the business depression and the necessity for ircumventing it, but now that know what can accomplished the way worthwhile savings shall never back our old way being satisfied with routine records and reports.” The experience this metal-working executive not uncommon one today. Hundreds manufac- turers faced with the need waging vigorous cam paign keep costs down and expenses from climbing have turned formerly neglected cost departments the source timely suggestions. They are becoming convinced that the ideas which can obtained from the intelligent study cost data and from special cost investigations are much more valuable than any rou- tine reports. while does not rule establish new standards, helps maintain those that have already been established. Next reducing costs and expenses the matter keeping them from going up. While not any sense new idea there new timeliness today the thought applying cost rou- tine that excessive costs shall determined and corrected before the completion the work. This locking the barn door before the horse stolen. The methods used exercising this sort must shaped suit conditions the plant which quantity pieces, the first hour’s run operation may carefully checked against standard time, job has been done before against the estimate anticipated, executive attention immediately di- rected that job the end that the remainder the lot may brought within cost bounds. After that once accomplished, daily, twice-daily hourly check- thereafter required will keep the work under control. contract work involving considerable number hours one concern has adopted the practice having the cost department notify the works man- agement when the accumulated actual hours work had reached 25, 50, and 100 per cent the esti- mates. This gives three opportunities for corrective control during the course the job and has resulted considerable cost saving. Plant repairs, maintenance work and extensions are put under similar cost control having careful estimates prepared for each important job. The esti- mates made the plant neer’s office are turned over the cost department checked the work proceeds. Those who have adopted this plan, either auxiliary their general pense budget without the bud get system, have found that definite control feature which helps pull down the over TRANSMISSION head. Special investigations should form large part the work the cost department aid effectively the solution pres- ent-day Some these investigations may lead nowhere, but even one POWE ten should result the uncovering some practical economy meas- ures the effort will probably well spent. Some these investi gations are almost absurdly sim ple their nature and reveal sur prising situations. chinery building plant, walking through one the extensive ma- chining departments, had the idea passed through, the count, number machines that actually cutting metal and com pare this with the total number operation the supposed to be time. did and found that out total some 300 machine tools, posedly active were actually cutting meta! when passed them. Some were waiting for work, others were having work set them taken down, still others had been + the tem shut down because porary absence operators. (Concluded on page Ws) The Iron Age, September 25, 1930—835 | &§ Modern Equipment Saves l | materials are handle d and all major Ooper- convevor, Where cores are set and copes closed ations are performed modern labor and them. the molds are carried along they time-saving equipment the new Charles poured from overhead tram-rail crane that Citv, lowa, foundry the Hart Parr Division the the conveyor. Operators these cranes Oliver Farm Equipment The designers this duct the entire pouring operation from their cal have step forward providing special This accomplished use electric ntilating equipment with modern produc- adle, controlled from the cab. The speed machinery, has made this foundry one whicl ouring crane can synchronized with that conditions are unusually favorable and cost mold conveyor. up-to-date practice From the time molds are poured until the Large castings are made two Beards mold conveyor delivers them the shakeout sta Piper sand-handling, sandslinger and mold-con- tion, they have received about min. cooling units Patterns the shakeout, copes are taken off jib mold machines are and shaken out, placed gravity conveyor ated rotating Molds are rammed returned the ramming unit. Castings are the: sandslinger units the turntable rotates. The lifted out the drag half air motor hoist half placed variable-speed power mold mounted trolley and transferred Palmer-Bee Co. power-cooling conveyor, whic! them additional min. cool befor delivery the cleaning room. Drags are then shaken out second shakeout table and transferred back power mold conveyor and returned the turn When the castings reach the cleaning room, cores are knocked out large stationary- tvpe machines. Castings are then transferred another overhead power conveyor, whic! carries them twin sand-blast room, wher they are cleaned while hanging the passes through the rooms. means Conveyors right carry castings through room sand-blast casting con- veyed (above) from the first into the second room lron Age, September 25. 1930 3 4 ; 7 motor hoists, mounted overhead rail. cast- ings are taken from the sand-blast conveyor, placed gravity conveyor and delivered the chipping station. With this operation completed, castings ire loaded cars for delivery the storeroom machine shops. ORKING conditions made unusually favorable pro- viding special ventilating equip- ment remove dust and gases. Modern labor and time-saving equipment handles all materials and performs all major operations. Cost production lowered. Continuous molding units have extreme flexibility thorough preparation the sand. feature twin-room sand- blast into which castings are car- ried suspended from conveyors. ad Spillage sand from the molding machines the turntables falls through grating apron conveyor. This conveyor also receives sand from the cope and drag shakeout and elevates inclined belt the opposite end the then discharged vibrating screen, all unit. Sandslinger veyor equipment left) contribute low cost production belt conveyor deliv- ers sand overhead screen through which drops into bin which feeds mixer “a 4 thy % wh _ At. — 3 i The Iron Age, September 25, — + through which passes into storage tank directl) over No. Simpson sand mixer. All sand passes through the mixer, where proper additions water, facing, etc., are added. The mixer discharges another inclined belt which returns the sand the turntable end the unit, discharging aerator and into the main storage tank. Features these modern continuous molding inits the Hart Parr Division the Oliver Farm Equipment Co. are extreme flexibility operation ind thoroughness sand preparation. For example, these units employ two shakeouts, one each for the ypes and drags. Two shakeouts mean less con- gestion each station. the cope the drag shakeout has capacity handle the entire pro- duction the system case one the other should down need repairs. Both shakeouts are thoroughly ventilated, thus removing objectionable rases and dust that otherwise would accumulate Two shakeouts reduce the necessity hutting down the entire should one the ther fail function. The successful continuous sand-handling system the one that properly prepares and controls its id. the Hart Parr Division plant the sand-con- trol laboratory performs important service regulating the moisture, permeability strength the sand. From the results an- alyses taken intervals during the day there are determined the necessary recl; laimed sand required keep the unit sand the desired condition. new sand added the slinger units. Fines, are taken out means pneumatic system, thereby meability. + preceding paragraph mention was made how the castings are delivered overhead power cooling conveyor the core knockout station the cleaning roon Here the castings are transferred oak machine. Sand falls through grating apron conveyor, which turn discharges Iron Age. September 25. 1930 belt where rods and tra metal are moved magn separator. then de! ered into for the breaking all lumps, finally vated into dola cars transport core room ling units. use sive pneumat system, nished poration, erstown, Md., all fines are removed vari locations the knockout system. claiming equipment makes possible save reuse all sand, whereas old methods this cor sand would used but once. Each core room has its own independent sand handling, preparing and distributing the small core room sand prepared mixer: which discharge into bucket suspended from tram-rail electric hoisting and traveling crane. Thi: crane equipped with double suspended hoists raise and lower the bucket the mill and hoppers above the core makers’ benches. Sand delivered this crane hoppers over each core benches. the core maker completes the filling his plates, places them rack suspended from overhead conveyor, which carries the cores throug! three-pass, oil-fired, Young Brothers conveyor-type core oven. Cores are then delivered unloading station, where they are removed fron the racks, sprayed, jigged, set and conveyed molding units. Core Oven Mounted Overhead, Allowing Storage Space Underneath The core oven 170 ft. long ft. wide, ant the insulated panel-type construction. mounted overhead, allowing about ft. underneath which space utilized for core making, core and space for wires and supplies. note that this core department core makers may employed, plus helpers, jig, set-up and spray ing crews, with oven, oven conveyor, core benches and hoppers and core storage all room 200 long ft. wide. core room No. all large cores are made jolt rollover machines and baked car-type ovens After baking, they are taken from the cars, sprayed. jigged and delivered gravity conveyors continuous molding units. Sand prepared 4 3 q 4 uy TT second floor two mixers and distributed screw conveyors hoppers over machines which are ser- viced jib cranes and overhead traveling cranes well. the charging floor, iron handled with electromagnets into buckets, which are weighed charged directly into two No. Whiting cupolas Four men now the work the charging floor tha previously required ten more. All the iron from the cupola run into ceiving ladles where additional mixing takes slag comes the cupola run into ladles suspended from carrier mounted tran rail track, which conveys the pots out the found building and discharges their contents into which take the slag dump. Ventilators (right) remove dust and im- prove working condi- tions. example tion core knockout Arresters for the ven- tilating system (oppo- site page) mold stations are mounted framework the foundry yard. Low-Temperature Coking Process METHOD making coke low-temperature process, which the physical sembles that making iron blast furnace, has been developed the Meier Coke Retort Co., 1315 West Lockwood Avenue, Kirkwood, Mo. The coal carried from bin through conveyor which preheated waste gases. passes then into re- volving retort, which either insulated water jacketed, according local requirements. Coke coming out the bottom the revolving retort carried another conveyor the bin. This conveyor accomplishes the quenching, the hot gases being carried off hot stoves operated conjunction with the equipment. Fuel for coking gas, which has passed through the hot stoves and enters the | retort from 1000 1700 conjunction with the exhaust plant, obtain the oils and tars and other ingredients the gases coming off from the top. Advantages claimed this process are maximum yield especially the light oils, and ab- sence cracking these gases, oils and tars the retort, flexi- bility operating rate and gen- erally simple operating conditions. The plant said low in- stallation cost well opera- tive cost, and uniformity claimed both heating product. stoves and considerable amount carbon black thereby recovered. The Iron Age, September 25, Bi: | oller Chains Industrial Applications Chief Engineer, Duckworth Division, Chain Corporation methods, and the othe Block chains consist assembly are available the transmission B-shaped steel blocks drilled bot! here positive velocity ratio must ends receive rivets which they are attached Chair links. Such chains are suitable only for light tan work, where the speeds are less than 800 ft. minut: rate rree required for the chain stretches, due wear. This increases thi listance between shafts the pitch the links. The mating sprocket wheel, the the shaft other hand, wears with very little change pitch. son and higher the backs the teeth they round the sprocket, the load carried single tooth, the marked ef- wear becomes excessive and noise develops. drive with its inherent advantage Objectionable features the older block chain led need, not the development the inverted-tooth chain, very also means design which has enjoyed some twenty-odd for notors popularity. Theoretically, with this type ited their most chain, stretching takes place, the links take posi- rrangement that delivers tions farther and farther away from the center the neat compact unit, directly sprocket, this action resulting increase the the posit other units, lengths the sides the pitch polygon correspond ing the elongation the links. broadly classi Each link then remains constant contact with roll hains. its own tooth from the time engagement that B-Block and Block Chains. Showing How They Are Made Iron Age, September 1930 ail a VA — J known silent chains. The author shows the advantages materials, practice, however, the wearing the roller type chain. Mainte- and working + action that takes place nance accurate meshing with pin bearing surfaces the sprockets one strong feature. chain links causes the pins fit loosely. There has been considerable im- lows until becomes event- ually serious cause chain properly noisy operation are working closer tolerances tion, the name mig jumping the sprocket teeth. than ever before. the prod- well applied This condition uct giving better service and running roller ated different ways. The finding wide use | release, and consequently the links seat themselves without any sliding action. Nearly noise- HREE different types chains changes. less operation results. For are available for transmitting improved methods pro this reason, they came power positive velocity ratios. duction, the use tolerances. Thi rathe quiet-running chain provement manufacturing meth- the ods recent years, and the makers chain was Multiple roller chains Baldwin-Duckworth Chain dustries. tructed Corporation, Spring- trands, broaden the extent making the pins hollow and drive They operate with slight split. Thus they same rotative speed act spring cushion, that they close hains equal pitch, with substantial increase slightly when the load applied and release when power-transmission capacity, proportionate the slack side the chain. number strands employed. Actual bearing Roller chains made the Duckworth compan pin and bushing are increased also reat onsist assembly roller links, each which ultimat and longer life. They two hollow steel shafts, called bushings der smoother and operation, due maximum efficiency throughout the entire life both has been definitely established that small pit sprockets and chain. that adopted the multiple, roller chain will sati torily ican Society Mechanical Engineers, the Society load 3500 ft. minute, which con ibou Automotive Engineers, and the American Gear Manu the maximum speed which chain can facturers Association. run results has also quently discarded for high-speed work favor the Rolle hains have been ject the limitations the block chain. The had dency, throug! flexibility variou become known slow-speed chain. During the past “take the the aving few years, however, several manufacturers this from incurring heavy ets may 18 \ h afety search work both the labora- tensile tory and actual field practice, esser yth roller chains, properly made machin and applied, can run the same relative high speeds The roller- Overcome the Troubles ing the last few years several Block Chain Single, Double and Triple Roller Chain Units, Showing Method Construction The Iron Age, September “0; made is For lec equal 3 prominent manufacturers automobile motors have adopted the multiple roller chain for motor crank and camshafts proper ratio Tr Ol Indications ends future. For general industrial purposes T \ wry mi OST any norn power-trans ney may run from a veral roiler-cnain ait 2000 minute. The ruggedness onstruction the roller chain renders are that more equipped with this type suitable where there tean vrit or coal dust Under the +} 445 + cond their efficien ald ] than per cent places where } ] ] niting inflammable material electrical statics, they fire 4 ‘ 1] mber that iner the piten } + ] pre teetgt! 1 larye) ] nalns mpact and resultant noise ] tnis connec chain vidths strand vill aq n ct pro thy, othe ordinary practice ell i oO! drive. na d ! ¢ roe ets mot than SiX oO one althourh 1 some Instances ratios high nine well remember that driving pin ions less than teeth are not recommend special purpose certain installations, this rule may be aban- Iron Age. September 1930 ‘ral a: ++) h eacl With eacn } ‘ doned: but good idea have the opinion the engineering staffs the chain companies befor proceeding with design departing prat tice. Center distances for any chain drive must half the diameter the large sprocket, plus half diameter the small sprocket, keep the sprocket teeth from touching each other. the center the desirable that distance should not less than times chain used the drive. good way establishing the center distance make equal times the diameter the large sprocket plus half the diameter the small sprocket. Whenever possible, chain drives should off the +, used vertical centers. However, many installations are work erse to and giving satisfaction. isting sprockets may the side und driven sprockets. speeds faster than ing ] llar { } rey ( \ 1} + ke ts. vertical plane and are experienciny Very little slack When used the side that contacts with Idlers should not maximum speeds good practice avoid the inless they are absolute necessity. Chains should never run with both strands tight strand must have certain amount slack ving with the center distance. Sprocket align plays important role the success 1 } 2 92 > 10) 7 i3 } ) 1.70 ) 164 4 11.0 6 26 87 117 1 9 71 609 4.48 16 186 144 122 6.52 7.46 8.70 9.40 240 206 } 11.9 0 14.0 14.8 ( 190 ) 328 7 0.0 22.( °6 6 2 38.0 7 6 1252 1096 174 834 14.2 2 2.0 56.4 2 ) 1824 1596 1422 1218 6.72 7.80 8.4 7 24 279 5 216 18¢ 7? 7 9.60 10.20 1 7 9.78 11.19 12.24 13.20 14.1( 528 162 5 360 0 17.79 19.50 20.70 1026 R55 735 5 73 19 8 25.62 28.05 30.00 1476 0 1056 27 S28 TOS 9.9 45.6 49.8 57.0 ] S4 1878 1644 1461 1251 9 7.9 66.3 93 78.0 S 4. 80 2736 2394 2133 1827 n un Where loads are un- lubricated, lower values facto selecting being plan, the time installation, line the sprocket faces with straight chain Oo d edge. Chain guards for advantage the preventing one from ring accidental contact with the chains and Guards any incur- sprockets. made oil tight may equipped with small reservoir oil into which the dips insuring tion. While con- stant lubrication not always nec- essary, adds considerably the ultimate life the drive. cators are front will fulfill requirement one revolu have not found ning well engine room worst operating i) rare ~ chains SELECTION Standard Roller Chain tion finer pitch used 1.1 1.94 to one have ber n ple means lubrication. the case pulsating such are en- countered pumps single action, compres- sors, ete., large factor safety used. Rarely does fied chain break. High-grade roller chains are made the best mate- rials and are treated and strains. However, the life chain great- than its actual pin-bearing area. Consequently, greater factor wear considered any. abnormal the load, pounds, transmitted and the pitch diameter and angular velocity the driver, the velocity the chain and its horsepower are readily calculated. The velocity the chain equals diameter known, the horsepower may determined the formula torque (in 63,025 the load (in pounds) multiplied its perpendicular distance (in inches) from the center-line the shaft. The rated horsepowers and loads corresponding various chain velocities are given accompanying table, for single, double and triple roller chains. New Device Supplies Hydrogen for Welding General Electric Co. has developed equipment component dissociate anhydrous ammonia into its parts, per cent nitrogen and per cent hydrogen such degree suitable for use with hydrogen welding equipment. the use this equip- ment the hydrogen can obtained very economically stated. The dissociator has capacity supply enough drive Roller Chain Power Transmission Drive Modern Heat- Treating Plant, Showing Both and Drives and Also Reverse and Quarter-Turn Drives. the torque being equal dissociated gas, atmospheric pressure and tem- perature, oper- ate elec- trode holder for currents amp. pressure deliv- ery does not ceed per sq. in. The electrical rating 3.5 kw. 220 volts and cycles. Ammonia gas drawn directly from standard tank good qual ity anhydrous ammonia. The tank arranged discharge and not liquid ammonia, into the piping. The kept room tem peratures, will supply gas pressures from 100 150 per sq. in. until the tank emptied and ready replaced. and thermally insulated alloy tube filled with ammonia-cracking catalyst, and connected low- l- high-current transformer, forms the disso- voltage, Device Equipped With Control and Indicating Instruments Suitable inlet and outlet tubes and openings for temperature-indicating and controlling devices are All parts subjected high temperatures are made heat-resisting alloys and are welded all provided. heated joints. Threaded fittings are provided for replacing the catalyst and the thermocouple. Such screwed joints are placed unheated parts the dissociator and will not leak The equipment provided also with suitable tempera specified pressures the dissociator. ture-control and indicating devices, regulator, safety devices, heat interchanger, etc. Gas for Welding Ready Short Time operation, small snap switch pressed. about min. the temperature indicator will show reading within the operating zone. The ammonia tank valve may then opened and soon the arc struck the gas the operator ready weld. will flow and when the arc broken the gas will stop When everything functioning properly the dissocia- tor will need more attention, even though the operator ceases welding for some time. The Iron Age, September 25, rtificial Atmospheres for Ammonia Hydrogen Nitrogen. ft. hour ity about cu. The Iron Furnaces enera rit | tn the ess ? ‘ li ? i 4 i ] ( ~ thi May in + 14 | | | ne e! t Land | } rit nad anneal) operat ns ( | ammo! pre 1 rm A 7 It i ! i (Lidl ce . 100 ammonia, produces 4 1000 cu. ft. dissociated + . The required about or hy . ++ cost, theretore smal] Quantity Gas Required lo vive some tne } } saa qu oO vas ised DV a ‘ + ‘ } | + 4 nace, Mav sald tha Cu an noutl would supply fairly The continuous tur- brazing nace Fig. last week re- quires about 500 cu. ft. mixed gas, and nour. These are very September 1930 tri OTIS Cen Methane with d the and discharge the work. about ft. doors are O welding torch will require about gas hour. anacity how? i? Fig. ‘atus for producing electrolene similar and the operation the equipment ribed its application city gas. Table the analysis typical city gas, and will dissociate the methane into carbon, after which the carbon will any oxygen present form de, CO. insufficient oxygen present, carbon will deposit soot the cham steam added also dissociates, liber and also its oxygen 800 900 1000 1100 1300 Relation Gas q } isers pure! e desi er. 7 4 q REVENTING oxidation through use at- mosphere rich hydrogen, and preventing decarbur- ization small methane content, are two functions controlled atmosphere furnace. Both results may achieved through the use the apparatus described this article and that last week. For many purposes such at- mosphere results better steel and diminished losses from scale. presence the carbon. combine form more CO, which increases The hydrogen total volume ume produced. adds the volume, that the produced about double the volume The process, therefore, breaks down the bons, and builds new gas diff position. Both these gases are hydrogen and carbon monoxide, and are, therefore, strongly reducing. Complete dissociation the methane does take place 1000 deg. because the relation the system carbon-hydrogen-methane, shown the curve, Fig. librium this temperature about per cent, can varied varying the tempera cated. Methane dissociated reversible reaction. CH, 2H, Addition heat required produce action one direction, and takes place the other direction. The heat for dissociating 1000 cu. ft. city pparatus for Producing Electrolene, Capacity 1200 Cu. Ft. from City Gas —~COMPOSITION O} mixed with September 25, | | 4] | ‘ carbon and steam, about kwhr. should remembered the vol that 2000 cu. ft. electrolene thus produced ited als With natural about four volumes are iced gas used its operation has for producing 1200 cu. dissociated gas hou This apparatus can small sizes, wit! largely self-contained automatic steam generator. Thu there has become available small, compact and nexpensive equipment for yases for artificial furnace atmospheres, from read ind TABLE A TYPICAL CITY GAS Hi } 7 particular purpose Reliable instru . l's g the ike oven gas pre viously refe rred to) future. Without Steam with Steam able to indicate Oris \ the hydrogen con Carbon monoxide 10.00 Industry record Methar CH, 282 1.00 1.00 dustry, these nealing sheets the thermal conductivity gases. hydrogen without the use pots, and without scale thermal conductivity times higher than carburization. may also possible the other usual gases, the indications hydrogen stacked sheets, such are used for tin plate, ontent are very accurate. example, with considerable reduction time and interesting compare the cost hydro floor space, and possibly with considerable saving produced the various methods outlined. over-all cost. Actual costs, course, will vary with local con Those who are familiar with the methods ditions, but Table will give approximation ployed for annealing sheets will appreciate the the relative costs. transportation cost con vantage gained the elimination pots and tainers not included this comparison. the production clean sheets. Fig. shows ble treatment can readily worked out for gases outline hood-type furnace for annealing sheets various compositions, the basic principles apply atmosphere electrolene. to all Effect Gases Carburization Fig. shows small annealing furnace the evator type served electrolene producer. For steels having considerable carbon content development suitable apparatus there attendant reaction between the hydrogen rotective atmosrheres will remove the and the carbon the steel, tending decarburize obstacle wider use furnaces requiring the steel and form methane the atmosphere, them. may, therefore, confidently expect that similar the reaction between hydrogen and iron will become considerable importance Campbell, and others have investigated the \ 0 > i y | | | 2 } . = i = | SECTION D-D 9—Outline Hood-Type Furnace with Cooling Hood for Electrolene Fig. Annealing Sheets Atmosphere Iron Age, September 1930 7 7 7 ~ 9-4 > ~ 29-2 ar j ay \ | \] f | | | Fig. effect various mixtures hydrogen and methane the carburization steels. (See lron with Mixtures Hydrogen and Methane,” Sykes, American Society for Steel Treating, Vol. 12, page 737.) The curves Fig. 10, from data Sykes, show the percentages methane for hydrogen-methane mixtures necessary for neutrality carbon solu- tion iron for steels three different carbon con- tents. will noted that the methane content required for neutral conditions quite small. For example, with fairly high-carbon steel, 0.59 per cent, 850 deg. C., only per cent methane the atmosphere necessary establish equilibrium and prevent decarburization the hydrogen. The curve showing the methane content equilibrium with hydrogen and free carbon added for con- venient reference. This curve, should observed, Small Annealing Furnace the Elevator Type, Equipped with Electrolene Producer (in foreground) dissociated 920 dey. that the case above cited—0.59 per cent carbon steel 850 dey gas from the dissociator 920 deg. would stable furnace 850 deg. and, being neu the steel, would have effect upon How the Gases Affect the Results therefore, the content lation the product, Stated briefly, the atmosphere prevents and the small methane content prevents decarburiza tion. simply adjusting the operating tempera ture the dissociator, with the methane content for equilibrium with any carbon teel, within limits, can produced. ale have been con For Some tests ducted furnaces using this atmosphere 0.55 per cent carbon wire, heated cale what ample, coils 1300 deg. Fahr. and held hr., show shows ever, and the surface represents the condition saturated and the same the curve for methane produced under the microscope attempt was made dissociating cure bright sur- hydrocarbon gas, face, but the an- shown Fig. nealed wire could other words, the at- TABLE COST GAS VARIOUS METHODS hardly saturated, will Cost original wire, ex- not take carbon Source Cu. Per Cent Per Cent cept that the out- from the steel Purchased pressure 99.0 side turns the Electrolytic coils were slightly flectrolyti yrocess Electrolene 60° 75.0° darker color. per cent methane plate have been an- neces- sary that the gas The Age, September 25, 7 this atmo than required the sphere in a shorter time usual methods, and come from clean. Coils carbon steel rod have and show nearly all reduced, Design Furnaces and the product Flexible Furnaces ded with ar insulated ct ood, a plain sheet steel] may required for the particular stalled the furnace chan { r tnt igh the to celerate normal ‘ad ( ns W I tin } A Inte ! le] in 4 ‘ i irna I 4 all et Al ne » Ma Thi rnact the dist the first kind (ser? t rate 24-h? nd has peen + last September a n 20 1. tral ormer to 380 volts This 150 k.v.a. capacit heating coil ] 4 14 eda 1200 vol 2OOO les In tne plan lavout + ] + +» ] panel nother, and the the contr third. The fur- roon Special ( I Ircuiat COOINY all } ring platforn condensers and genera- T ip ol Wo pleces ol one for the current and one ] Iron September 25, been | normalized the mill scale was being lig, Three 1930 practically Methane Hydrogen Atmospheres for Equi- librium with Carbon Steels Different with large units, over period years, has demon- strated that there are unusual hazards involved, and that when properly manipulated such furnaces are safe gas-fired oil-fired equipment. Advantages gained the scientific use industrial opera tions are manifold, and are becoming better understood practical men. famil- iar examples may cited atomic hydrogen welding, an- nealing electrical taken operating these furnaces. hydrogen, copper brazing, the substitution city gas for acetylene flame weld ing and cutting operations carburizing with gas, nitriding and finally the sub ject this paper, annealing steel products without scak decarburization. conclusion, the write: desires acknowledg portions The portion relating sources subject nace atmospheres from the work Stansel and Dantsizen, put lished General Electric and the reference there cited. The portion lating production gases from the work drawn Contents appearing General Elect Induction Furnace Operates Hr. Alloy Steels ter the cooling water. All purified befor use, about gal. per min. being required. Instru ments are provided the operating floor which shov its pressure the inlet and temperature the out let the furnace coil. Acid crucibles are generally used, and are mad quartzite. They are given slight taper fron about one-third the way down. has been that, although this increases the energy required pe! ton about per cent most, the life the cru cible approximately doubled, with plain cylindrical pot. Erosion the crucibles ries widely with the nature the material melted Carbon steel per cent) the least active, followed the low-alloy and medium-carbon grades. Charges about 600 are made the average. and require about 600 kw.-hr. per ton melt from the cold. From cold charge (with the hot) the completion pouring requires 720 790 kw.-hr. per ton. + The average time from charging 7 white. | oe oS Se mx, Hot contact with inflammable. + it elems tary autior Re 4 Working Conditions Feature Layout New Tool BURNHAM FINNEY Plant onstructed MODERATE-SIZED shop with every departn building for its workmen, finding such policy profit that the can removed, the able rather than burdensome; shop wher brick pilasters knocked and the shop extended employees are not surrounded “DON’T” signs and considerable distance either lengthwise width not abuse their privileges; one which minimum and sacrifice light machinery, the best light and ventilation and efficient production practices are bringing good dividends: Designed that all the shop, with the excep This the impression carried away the Inc., tion the heat treating department, full view building the new plant Goddard Goddard troit, designer and manufacturer milling cutters the workmen and their supervisors, the and reamers. Employing average 150 men, thi remarkably free from obstructions. Even the tool company has incorporated its factory many feat crib the center the shop low height that ures seldom found outside companies offers obstruction free vision the its are ial feature the fact that larger. Aside from comforts provided for men, the company has eration bonus system which has resulted increased out- belief that quiet, clean Even this point, interest the plant does not halt. surroundings some its machining meth- have favorable reaction em- ods, which incorporate special ployees was active con- practices original design, sideration designing the plant the heat-treatment its prod- described this article. Care- uct and its handling fully-planned lighting, heating and terials process, commands ventilating, modern equipment and accessibility tools and other facilities contribute—with profit all concerned—to the type, which provides the best comfort, convenience and pro- well progressive move- uctivity men wor Op- attention. The shop proper the one story, multiple monitor and key and not under lock one constantly charge. present only igned attendant is tervals, as he is a Sig duties. Any workman can there are openings posite corners—and help him elf the tools for his work. does not leave condition when has finished with them, puts them back their proper bins them bench for otherwise lays the attendant have them put shape for future use. plovees appreciate that this rangement diffi their convenience and 25, 1930—849 The September 25, >a x 4 | culties have countered following out the plan. All tools i well as waste, and special tools kept which tool possible damage. Mill from the monitors and eliminates the dinginess which ac- inies the use belts, and shafting. nding department cutter-sharpening and other dry il mmon service, supplies such emery wheels, oil, in the tool bins. ‘here are num- innova their tools, and attachments from nachines, Kets front left part base for arm supports and fixtures, are which for the men ave space and special machine have cast ste e] This ment protects the rts from injury table tool racks are another convenience. Equipped with bearing castors they can moved easily. The result that obtained quickly workmen and can transported minimum effort, and the floor kept clean. Inciden- the absence window sills and benches along the walls nts the almost inevitable clutter and dirt which they invite. machine tools have been motorized, thus eliminating over- belt attachments. This freedom distribution 850—The Iron Age. September 25. 1930 height, tool crib cen shop does obstruct free entire attendant stantly and workmen free access 7 tools and supp! 7 w t ~ - For the inspection room, diffused light from the was found able direct from side window Because this th: inspection ment near center sho ver a . i an 4 right) exhausts with dust collect- system The mono- rolley extend- cutting- department the racks and the hand-saws £ | machines have dust collectors connected with main joints each outlet allow flexibility dust collecting system. the suction pipe attached each machine. piping and the dust collector are painted with aluminum paint, The entire thus offering interference with the light. Housed separate building adjoining the main shop the heat-treating department, which equipped with four gas-fired Strong, Carlisle Hammond furnaces two-stage type. High- speed steel cutters are preheated these furnaces tempera 4 Cast steel brackets attached the base milling ma- the overarm supports not use, protect- ing the supports from injury and keeping uncluttered The Iron Age, September 25, 1650 1700 deg. Fahr. and then raised 2250 2400 deg. The material quenched large ircular oil tanks, the oil being maintained uni- form temperature means circulating system the entire volume continually erience has shown the company that this the standardized system cold-water the oil tank. The uniformity temperature density results better hardening the thal by the older process. Steel Hardened Molten Salt Baths salt baths, this method heat advantages not obtain ras-fired furnaces. For example, heat trans matically controiled regulating valves the gas and air lines which are electrically operated Wilson-Maeulen control system. The receiving entrance for raw materials signed for truck deliveries, ramp bringing trucks floor level for easy unloading machines materials. monorail trolley extends