The Iron Age 1930-12-18: Vol 126 Iss 25

ESTABLISHED 1855 ACE New York, December 18, 1930 VOL. 126, No. Ancient and Modern Metal Work HIGGINS, president and treasurer the Worcester Pressed Steel Co., Worcester, Mass., has established museum, named the John Wood- man Higgins Armory, which devoted the de- velopment the working iron and steel through the ages the present day. The chief purpose was present visual history the art pressed and Mr. Higgins, his years col- lecting, has carried out his intention magnificent man- ner. His collection housed sur- roundings marked beauty. This armory oc- cupies the upper portion the Pressed Steel com- pany’s new office building, which comprehensive example the ad- vance which has been made the use steel ar- chitecture. The ex- terior walls are all steel and glass. There over- material. Aluminum paint provides the Glass and Steel Building JOHN NELSON T 1823 protective covering, giving the building the appear- ance polished steel and making conspicuous feature the landscape over wide territory. The armory will given its formal opening early next year, and af- terward will open free the public daily. wholly unique. Through many cen- turies the evolution the working iron and steel was chiefly the de- velopment arms and armor, and these form the principal parts the collection. Therefore fit- ting that they exhibited, they are, high vault- Gothic halls and galleries. the walls hang fine old paint- ings, some them very valuable, and historic tapestries, each some way illustrating the fashioning steel. Standing about the floors are mailed and armed knights and squires and men-at-arms. Some these noble figures are mounted, their horses, too, fully clad armor, over which hangs rich panoply. Here and there cannon period when gunpowder was new warfare. Heraldic banners their staffs give gay color above. all combines make picture, colorful, beautiful and romantic. Scope Exhibits From the armor and arms which went with it, the armory collection shows the further development the art sheet steel through more recent centuries down the present day. This part the collection will include the products the important pressed steel mills America and foreign countries, each manufacturer having his own plate glass showcase set Provision made keep the collec- tion date all times the future. The scope the exhibit covers many centuries, 1824—The Iron Age, December 18, 1930 glass and steel building recently completed Worces- ter, Mass., house the Worcester Pressed Steel Co. and the John Woodman Higgins col- lection armor and other the modern trend architecture com- mercial structures. Standard emphasize continuous while extensive use glass permits maximum light. Instead seeking conceal the extending back long before Christ was born. stronger contrast could drawn than that between the mounted mailed knights who dominate one great nave and the chassis high power automobile which dominates the other—90 per cent pressed metal, appropriately designed, accurate and efficient. Building Itself Speaking generally, the building mill con- struction with all steel and glass exterior walls. The deeply recessed vertical structural columns are the visible architectural members, together with the cover plates and the abnormally large rivet heads the ar- rangement which gives strong emphasis. The effect the powerful vertical sweep most impres- sive sight. Continuous steel sash set for effect various planes fills the sections between. The exterior crowned 4 riveting, has been brought into promin- ence the use rivets with larger than ordinary heads. The structural steel was sandblasted after erection and painted with heavy coating aluminum bronze paint, touched out here and there with black. The entrance doors and architraves are rustless steel frames and plate glass, with grilles forged steel. The first floor battledeck tion. frieze steel plates having conventional pat- terns perforated metal, and flat metal crown mold which the bands cornice castings, emphasized wrought iron scrolls each point support, serves exemplify the various methods working and joining metals rolling, casting, stamping, punching, forming and forging. The entire exterior was sand- blasted and covered with several coats aluminum bronze paint, which touched out here and there with black. The building consists two wings approxi- mately equal length which form obtuse angle conform the street lines, with central recessed entrance the blunt point the angle. The door- way, under heavily crested marquee steel and wrought iron, framed perforated wrought iron. The doors are plate glass stainless steel frames, with protective grills polished art-forged steel. The beautiful vestibule and octagonal reception lobby give ’ = access stairs and elevator the main offices the Worcester Pressed Steel Co. the second floor, and the armory above. The third floor occupies two full stories the building, permitting mezzanine galleries and lofty vaulted naves. Here housed the great collection which Mr. Higgins has assembled from Europe and Asia well from America. The two wings, one 100 ft. long, the other ft., are occupied each Gothic nave, ft. high the groins. Along the side each gallery aisle. Beneath each gallery another aisle. The two naves are joined lofty octagonal vestibule. The Interior the Building The walls throughout are the soft warm tint caen stone, the ceilings are the color the sky. the farther end each great hall rose window executed design which typical the 14th The Iron Age, December 18, 1930—1825 4 4 x / 4 5 \ \ century and filled with deep-colored leaded glass. The architect has succeeded giving the sugges- tion maze. The visitor will induced wander about bit finding the way this that alcove aisle. The heavy doors and the woodwork, which sparingly used, are all old English gnarled oak, ornamented with semi-polished hand-forged hardware and trimmings Gothic design, all after medieval baronial fortress the Austrian Tyrol, which for five centuries had housed many the suits armor and crusaders’ weapons the Higgins collection. Some the Rare Exhibits the Museum The east wing, ft. long, devoted medieval art craft. contains pieces the stone age, bronze age and iron age, but chiefly the collection consists examples the craft the smiths the centuries 1826—The Iron Age, December 18, 1930 the two Gothic naves the John Woodman Higgins Armory Worcester, which will contain visual history sheet metal. The arch the right opens into octagonal vesti- bule. when men fought armor. There are implements, old paintings, glass and tapestries. the collector, all these are “documents,” because each presents some manner phase the evolution the art. For example, picture statue image may show type armor arms, specimen which known exist. Many the pieces the collection have historic and romantic associations. True tales could told them, some bold daring and adventure and fine chivalry, some bloody cruelty, some the gentler phases human life the olden days. illustration, hanging the end wall the medieval nave, under the rose window, great Gobeline tapestry, which was designed Charles Brun for Fontainebleau order and under the personal supervision King Louis XIV. That royal 4 J ~ ¢ Re 4 J RMOR the Middle Ages from various parts Europe. The glass and steel walls the building the Worcester Pressed Steel Co., which houses the Hig- gins collection, are beyond the deep-re- cessed arches. personage likewise watched the tapestry through its weaving, that might exactly what had set his mind on. Many copies have been made this splendid piece, but that the armory the original. Another striking decoration the wall this nave has equally intimate association with the French court. armoral wall hanging fabricated gift celebrate the marriage Louis XVI and the ill-fated Marie Antoinette. Its design includes the coats-of-arms Austria and France and also the order the Golden Fleece, with its flint and steel and fire and the Golden Fleece itself. The names great nobles are associated with the armor and arms. One the knights who sits astride his charger front the Fountainebleau tapestry clad armor that was worn famous 16th century noble, Count Radzidall, who could boast that had fought twenty duels with this em- peror, history relates, the jousting tournament was golf links are some men today—irresistible. His friendship and admiration for Count Radzidall were great that presented him with thirty suits mail. Presumably, the harness the Higgins collec- tion one these. The Count may have worn his jousting Innsbruck Vienna. The soft-tinted walls with their beautiful and pic- turesque form appropriate background for the knights and men-at-arms who stand about, each clad cap-a-pie plate armor, who sit their horses, lance rest, ready run friendly tilt, or, need be, fight. These mounted figures represent the advance the smith’s art and the successive con- tributions the Gothic, Maximilian and Renaissance periods history. The Iron Age, December 18, 1930—1827 X-Ray Inspection Welds Pressure Vessels DR. ANCEL ST. JOHN NOTABLE development during the past year the industrial use X-rays the routine inspection welded seams pressure ves- sels. brief account typical installation for this purpose was included the paper “The Application Fusion Welding Pressure presented before the American Welding Society Hodge the Babock Wilcox Co.* The present paper more detailed description the X-ray in- stallation and its operation. The X-rays used for the examination heavy metal sections, such these welded seams, are pro- duced when electrons, traveling high speed Jo ul of the American Welding Society, October, 1930, | ~ exhausted bulb, strike heavy block tungsten placed the center the bulb. The trons are supplied heated filament, radio tube, and the speed imparted applying ex- tremely high voltage between the filament and the target. The X-rays thus produced are passed through the wall the vessel including the welded seam and are recorded photographic film placed the far side the wall. Cavities, cracks and inclusions are more transparent than steel and appear darker regions the negative and lighter regions the prints. During operation shop personnel must pro- tected from accidental contact with the high potenial lines means grounded metal shields, and against continued exposure the rays screens absorptive material. important that these screens prevent the escape rays well the primary rays. The X-ray installation thus includes the following elements: power plant capable pro- ducing least 250,000 volts and sufficiently light and compact mounted movable base. | X-ray tube capable op- erating continuously 220,000 volts more. rounding all high-voltage equip- ment. Fig. Wappler “88” X-ray power unit. 1828—The Iron Age, December 18, 1930 lead the equivalent, surrounding the X-ray tube ex- cept where the rays are screens for absorbing any pri- mary rays which may pass the object being examined. Absorbing screens consisting 1/16-in. lead the equivalent cut off all secondary “scat- tered” rays. | pages 93 to 116. welding becomes more general some method determining its soundness essential. The X-ray equip- ment used for this purpose the Barberton, Ohio, plant the Babcock Wilcox Co. here described the man Welded pressure vessels, in. thick, are successfully and rapidly inspected. Added interest attends this discus- sion because the proposed specifications for fusion welding unfired pressure vessels, recently made public, which X-ray inspection mandatory. Film holders cassettes, adapted ular work hand. Means for supporting the vessel under tion proper relation the X-ray tube and for moving the vessel relative the tube and film without disturbing this relation. Equipment for developing the X-ray for examining the negatives. The power plant which produces the high voltage for exciting the X-ray tube shown the electrical connections are shown Fig. The power supplied two high-voltage transformers, each capable transforming single-phase current from ings are connected parallel with the lin control cabinet, and the secondary windings are con- nected series with the X-ray tube through pair rectifying disks driven synchro- nous motor. this way voltages high 300,000 can applied the tube. This some- what higher than the maximum capacity the tubes present available. The value the high voltage controlled suitable adjustment autotransformer and rheostat connections the control cabinet. The supply electrons and hence the current through the X-ray tube controlled the heating current sup- plied the filament from auxiliary transformer insulated for 150,000 volts. Fig. diagram showing the gen- eral arrangement X-ray tube, vessel, photographic film and lead shielding for the examination welded pressure ves- volts 150,000. The primary wind- X-F ate]! Tube Transformer lam Spark Rectifrer High Voltage A.C.Line Cycles and Filament Ground Line rity Rheo Fig. Diagram electrical connections. partic- sel and Fig. photograph made during the inspec- tion longitudinal seam drum ft. long, ft. diameter with wall. The power mounted truck frame within grounded metal housing. The X-ray tube mounted within lead- covered metal “safety” drum provided with suitable window permitting the X-rays reach only limited region along the welded seam. Auxiliary lead shields fit snugly against the outer face the vessel and extend for several inches from the region exposed primary rays provide effective protection against scattered rays which are absorbed these shields the wall the vessel itself. examina- films and Fig. and alternating The film placed film carrier which covered and provided with auxiliary shields fitting snugly against the inner face the vessel. Personnel through Safe Drum Secondary togra phic Film Wall Fig. Diagram arrangement. The Tron December 18, | | ty JTartin | = / Fig. installation. hus amply protected. The vessel placed with its ixis parallel guide rail attached the steel fram pair guides the truck frame maintain the X-ray tube fixed distance from vessel the truck moved longitudinally portions the weld. The film carrier mounted tramework which likewise moved ngitudinally that during exposure the film the window the safety drum. For exami- nation girth seams, different shape window another type film carrier are used, and the . essel rotated about its axis. routine, pictures are made for each foot j ing! ‘ P ‘ ‘ } . seam and each deg. girth The extent girth seam that can one time depends upon the diameter the drum the rays toward the end the film have pass diagonally through the wall and traverse con- iderably more steel. The seams are marked off into regions these dimensions and each region as- gned reference number, which marked alongside the seam, together with reference mark the center the region. different type reference mark indicates the boundary between adjacent regions the inner sur- Perforated metal markers are placed upon the reference marks and another perforated metal marker carrying the vessel number and any other pertinent data are fastened front the film holder. this way each film carries its own identification marks and proof that the X-rays have penetrated all parts the region examined. typical radiograph longitudinal seam hown Fig. The weld itself not distinguish- able because the excess metal both the inner and uter surfaces has been removed, and the weld metal perfectly sound. almost impossible locate the weld difference the appearance weld and plate zones the film. The weld zone can only definitely located its relationship the images the reference markers which were placed the drum definite distance from the center the welded oint. density determinations this weld metal gave value 7.83, which only 0.2 per cent 1830—The Iron December 18, 1930 less than the theoretical density steel this composition. Gas holes, whether large small, appear sharply defined rounded spots Fig. The welded zone this case can readily located. Fig. slag inclusions extending along the walls the joint are indicated more less cloudy elongated areas. determine the exact location de- fects, exposure made with the X-ray tube displaced short distance, say in., transversely the weld. The tube then shifted the same distance the other side the weld and second exposure made the same film. From the relative displacements the outer surface mark- ers, the defect and the inner surface markers, the depth defect below the outer surface can calculated. typical double exposure radiograph shown Fig. the defect marked “D” being the one located graphically Fig. The radiographs are made with standardized technique which all the exposure conditions affect- ing the character the pictures are held constant during the examination each vessel. These condi- tions are: Distance from source X-rays, the “focal the target, the photographic film, usually in. film from inside surface vessel, Type film used, usually double-coated safety X-ray film. Type fluorescent screens used for intensifying the photographic record and shortening the time exposure, usually Wappler combination screens. Intensity X-rays, governed the current through the X-ray tube, usually milliamperes. Wall thickness vessel. Penetrating power X-rays, determined the voltage applied the X-ray tube. Time exposure. Fig. Radiograph longitudinal seam; sound metal. | q aa! The voltage applicd the tube and the time exposure are chosen suit the wall thickness. For walls, in. more thick, the maximum voltage that can safely applied continuously the X-ray tube used—about 220,000 volts. Excellent pictures are secured through in. with min. exposure. For used and reduced voltage chosen give satis- factory result. Excellent pictures have been made through in. 160,000 volts min. Under these conditions cavities having depth per cent the wall thickness are readily detected those small per cent can observed care- ful study and some small per cent have been detected. desired, calibrating device, consisting perforated sheet metal per cent the wall thickness, can used record upon each film the difference photographic density due such cavity. The correct exposure times reduced voltages are tabulated plotted calibration curves. The installation also adapted the examination castings, well diffraction analysis the high-voltage pinhole method originated the author’. tion analysis the pinhole diffractometers tached the safety drum convenient locations which with weld castings in- spection and the exposures are made simultaneously with inspection exposures. Castings are mounted front the safety drum, below it, has been rotated into the horizon- tal position. Movable lead shields are placed around the casting protect per- sonnel from scattered rays. Ancel St. John, “High Speed, High Voltage X-Ray fraction Analysis Transactions the American Society for Steel Treating, 1928, pages 485-492. Fig. Radiograph porous weld. Fig. Radiograph weld Fig. Double exposure radiograph for localization defect. The entire cost such installation, including transportation charges, local construction, engineering fees and thorough train- ing personnel the technique and interpreta- tion metal radiography should not exceed $15,000. The operating cost will! depend upon upon which ment written off, upon the labor rate, the over- head factor the amount use. With fa- vorable conditions should brought low per hour, plus the cost film. Under these cost per foot welded seam can low as: containing slag inclusion. Plate thickness, in. less $0.40 in. 0.75 234 in. 1.00 in. 1.50 in. 2.75 Thus the cost X-ray inspection for vessel about ft. long ft. diameter with 3-in. wall, having two longitudinal seams each ft. long and two girth seams each ft. long, would $150 less. For similar vessel with 2-in. wall, would under $50. Practice Germany X-ray inspection welded pressure ves- sels economical well feasible. Germany, the X-ray machine used right the boiler house and the vessels are inspected after installation and possibly after having been service for some time. doing this, the X-ray tube mounted through the inside the vessel and the films are placed against the outer surface. Modern developments electric arc welding and the experience with large pressure vessels will eventu- ally convince the purchasers and operators that struc- tures and pressure systems, welded under correct pro- The December 18, 1930—1831 < — Lower on of X-Ray be Fig. Diagram for localization defect double exposure. edure control and proved the X-ray perfect, are eminently safe and desirable. present, infair and intemperate say that all welds are bad say that all welds are good. Means are avail- able for separating the good from the bad, and any user metal fabrications, who fails use them, blinding himself opportunities which are being grasped his competitors. Influence Cold Rolling Various Kinds Steel effect definite degrees reduction cold rolling physical properties subject recently investigated Greulich (Stahl und Eisen, Oct. 1930). Plain carbon steels, nickel and chrome steels, and monel metal the following compositions were tested: Ca n steel 0.12 0.00 0.40 0.017 0.024 Carbon steel 0.29 0.06 0.40 0.020 0.013 Carbon steel 0.34 0.18 0.57 0.024 0.017 0.46 0.30 0.75 0.021 0.028 Carbon steel 0.61 0.34 0.838 0.022 0.016 steel 0.18 0.26 0.49 0.020 0.021 ate D.14 me steel 0.08 0.42 0.34 0.008 0.024 0.39 12.56 0.15 0.62 0.46 0.042 0.021 0.94 15.36 0.19 0.56 0.45 0.019 0.010 0.56 14.50 n 6.37 0.00 2.02 0.028 0.033 .... 35.20 10.50 1 0.15 0.02 1.82 0.020 0.015 30.40 66.80 .. The plain carbon steels contained spheroidal cementite, the carbon the corrosion resisting pearlitic steels was almost entirely the pearlitic form, while the austenitic steel contained minimum precipitated carbides. The materials were received the form in. billets. These were first rolled square sections and then annealed for hr. follows: The carbon steels 1200 deg., the nickel steel 1130 deg., the monel metal 1470 deg. and chrome steels 1650 deg. Fahr., followed slow cooling 1290 deg. and then air cooled develop pearlitic structure. The austenitic steel was an- nealed hr. 2010 deg. Fahr. and then quenched water. After pickling and cutting 2-ft. lengths, the test pieces were ground exact dimensions (0.495 in. square). Comparisons with the original materials showed negligible changes hardness preparation the specimens. The test pieces passed between pair smooth rolls operating ft. per min. Before the second pass, the work was rotated about its axis deg. produce approximately square sections. The re- 1832—The Iron December 18, 1930 duction amounted about per cent, but means additional passes was possible reduce the and nickel steels and the monel metal about per cent. After month’s aging room tempera- ture, the degrees reduction were measured, and the tensile strength, Brinell hardness, and Rockwell hardness were determined. The hardness was found throughout the cross sections. The following table shows the effect varying reduction the hardness soft and hard materials: Reduction in Area, Per Cent Average Sample No. Rockwell-C Hardness 1.5 —1.2 49.3 21.4 6 1.4 13.2 6 $7:8 27.6 1.4 —1.9 48.9 25.3 1.54 20.6 33.8 The hardness well the elastic limit increase rap- idly with corresponding decrease elongation re- ductions exceeding per cent; the strength and re- duction area under tension show little change per cent reduction. Above per cent reduction all properties change less rapidly, the hardness in- creasing slowly, and the decrease reduction area under tension being the most marked change. The change these properties for all the materials tested was found directly proportional the logarithm the per cent reduction cold rolling, per cent reduction. The same proportionality factor between tensile strength and log. per cent re- duction held for all the common steels, independently their carbon contents, and also for the alloy steels with pearlitic structure. The increased value the proportionality factor for austenitic chrome-nickel steel and for monel metal indicates the influence composition and space lattice. Upper X-Ray Tube | D. D2 F, “Film 7 q 7 TRAIGHT LINE production and me- chanical handling materials have made the St. Paul, Minn., plant the American Radiator Co., low-cost unit. From the raw ma- terials the product everything ar- ranged with view minimizing hand labor and expediting the flow the work. fact, the lay- out and equipment have proved satisfactory that they have been du- plicated large extent the company’s new works Neuss, Ger- many. Trolley-Type Molding Machines The outstanding feat- ure the foundry unit comprises hangers suspended from track. weight the hanger, while four guide rollers engage the side the rail. cable, which passes around Straight-Line Output and Mechanical Handling Radiator Plant LACHER ONTINUOUS suspended molding ma- chines, continuous sand handling and continuous washing, painting and drying radiators are features manufacturing system arranged for economical production large quantities. Ingenuity the part the manage- ment has supplemented the layout and equipment promoting efficiency. Cast- ings are cooled unheated sand storage room. Through heat interchange the tem- perature the castings lowered and the sand kept from freezing. Cables attached the controls the cupola charging ma- chine enable one the car men start the elevation charging buckets while the other climbing the stairs the charging floor. This arrangement elimi- nates the need for extra man operate the charging machine. CORE SAND Core Sand Mixer — flat rimmed wheel each end the conveyor, the hangers from one po- sition the next. Power supplied air cyl- inder, which drives broken finger the length the piston, which equal the distance be- tween two hangers. Upon the completion stroke the piston returns normal position, the broken finger sliding over the hanger that en- gaged when moving for- ward. hanger sup- ports top plate and bottom board. Iron Moved Monorail Paralleling the mold- ing machine both sides are overhead monorails from which iron ladles are suspended. One iron group four continuous molding machines. Each pourer serves each conveyor unit, getting his iron the cupolas and moving chain hoist trolley the the top rail the track are two rollers supporting the completed molds. strainer gate core used pour radiator castings, because insures more even dis- tribution the iron through the mold. used TESTING AND ASSEMBLING DEPARTMENT Machine \ ge Tro Ney Type Molding Machines OFFICE WAREHOUSE OFFICE From the raw material yard the warehouse the American Radiator Co. plant planned for uninterrupted flow the work. The Iron Age, December 18, =| — = |= Paint Dip Drying Transfer core Ovens successfully, however, the iron must kept hot. The monorails from all four the molding sys- tems converge into turntable front the two cupolas, that ladle may transferred from any the branches another. The pouring ladles are filled from mixing ladle, which receives molten metal from the cupolas. one of Counting the iron pourer, only seven operatives are required per molding unit. Two men make the the molders pile sand the drag cope flask. Then the rammer moves forward and plow-shaped leveling board scrapes the sand off the mold predetermined level. Ram- mer feet play mold, peaning the sand around the flask bars. second plow smoothes out the trenches made the peaners. automatic rammer simplifies molding. First Each hanger the molding machine supports top plate and bottom board. The hangers are suspended from track and are pulled from one position the next cable, drawn air cyl- inder. drags, setting the chaplets, dumping sand the drag pattern and passing automatic sand rammer over the mold. One these operatives also sets the cores. Another set two men required mold the copes, which are made similar manner. Completed drags are swung the bottom boards pneumatic hoist suspended from the same monorail system that car- ries the ladle hoists. Then the copes are superimposed the drags. Finally, another operative puts the 1834—The Iron Age, December 18, 1930 top plate and clamps the closed mold, the same time turning the valve that controls the pneumatic drive for the entire molding unit. Since performs these operations for two molding machines counts only one-half operative per unit. The top plate each hanger swung coun- ter-weighted cable, making easy lower raise. When lowered, hooks from the top plate are fastened molders pile sand the drag cope flask. Then the rammer started its forward movement. plow- shaped leveling board with straight edge the bot- tom scrapes the sand off the mold predetermined level, following which the rammer feet play the mold. These have peaners each side which pean the sand around the flask bars. The feet incidentally have compression springs, that their action — + a =. » — Two molding machines with molding sand hoppers and rammers shown between four points underneath the bottom board and then the assembly tightened two eccentric clamps. Each Machine Turns Out Molds Hour After the mold poured passed the end the machine farthest from the cupolas and shaken out. The shakeout man unclamps the mold, raises the top plate and then transfers the flask air hoist grating, bumping the flask and down actuating the air valve the hoist. The sand sifts down sand recovery belt beneath the floor, while the sprues are knocked off the casting and thrown into nearby bucket, which later taken away lift truck. loader transfers each casting from the shakeout steel tray. uses fork handle the castings, since they are still very hot, only min. elapses from the time pouring the time shaking out. Lift trucks are used transport the casting trays. Since one loader serves two molding units, count- one-haif operative per machine. Each molding machine makes average molds hour, the number varying above below the average according the size the work. The automatic rammer, which was designed company engineers, machine. First the cushioned, rather than pounding, impact. The ram- mers, moreover, work eccentric shaft, which gives them alternating movement. After the ramming operation, second plow passes across the trenches made peaners and then passes back again, making smooth, firm The machine motor-driven. The whole cycle opera- the lug drives ahead causes the forward operations leveling board, rammers and plow. drives back, carries the second plow through its final move- ment. The safety the operatives been guarded. sheet steel shield front the throws counterweight struck, automatically stopping opera- tions. addition, back the machine, safety finger has been provided, which operates knife switch stopping the motor. The finger most posi- tive safety guard, since operative must raise be- fore the machine can proceed its forward move- ment. Sand System Continuous The molding sand system, like the molding opera- tions, continuous and provides for the recovery and The Age, December 18, 1930—1835 —_ reuse shakeout sand, well the spill sand from molding. continuous steel apron conveyor runs un- derneath all four the shakeouts, carrying the sand elevator. then conveyed squirrel cage rid- dle, where the tramp iron removed, and there- upon dropped into one two 8-ton storage bins. The bins feed the sand through measuring hop- pers Simpson mullers, which new sand, water and sea coal are added. The mixers (one for each bin) discharge the sand belt, which carries the bottom bucket elevator. Another belt, pass- ing under the floor, feeds spill sand the bucket ele- vator, and the material then raised mixer con- sisting large blades centrifugally driven, from which discharged into large storage tank, hav- ing capacity for nearly two carloads. Sand drawn from the tank carried another elevator and discharged overhead distributing belt. Scrapers along this belt are set different levels that each takes off given amount for molding hopper. The last scraper, course, scrapes sand off down the belt. Castings Cooled Sand Storage Building The new molding sand required unloaded crane through hatches the roof sand stor- age building which situated adjacent railroad siding. Ordinarily supply carloads (for win- ter consumption) such sand kept hand. One the difficulties originally experienced handling the storage sand was that would freeze during cold weather, since the section the building which kept unheated. This disadvantage was overcome when the superintendent conceived the novel plan using the storage room cooling chamber for hot castings. Thus through heat interchange the cast- ings are cooled and the sand kept from freezing. Adjoining the sand storage the same wing the plant room for storing chaplets and bags sea coal and fire clay. « % Be 1836—The Iron Age, December 18, 1930 The raw material yard conveniently located, paralleling one side the building. served spur from the Midway Transfer Railroad and com- manded 5-ton overhead electric traveling crane, built the Milwaukee Electric Crane Mfg. Co., Milwaukee. one end the yard are three storage tanks, one each for linseed oil and crude oil for core making and third for fuel oil, which used heat the core ovens. large space next the core de- partment has been provided for core sand storage, but now planned buy dried core sand box cars, ordering needed. The section the yard used for storing metal and coke bisected scale car track which leads the cupolas. The coke storage consists three bins, with capacity for four carloads coke each. the opposite side the scale car track are three bins for pig iron and two for scrap. The latter holds three carloads scrap each. The former hold considerably more tonnage pig iron, since iron can stored more compactly than scrap. sixth bin the same side for limestone, having two carload capacity. Two Men Operate Scale Car and Charge Cupolas The scale car operated storage battery and has two 4000-lb. Toledo scales, one for each two charging buckets. Coke transferred from bin bucket wheelbarrow, while limestone shoveled and scrap and pig iron are loaded hand. All remelt, sprues, returned bad castings, etc., are brought the yard bucket lift truck and transferred charging bucket chain block from monorail above the scale car track. Two operatives all the work loading the charging buckets, operating the scale car and charg- ing the cupolas. The two cupolas are Whiting No. units. han- dle the slag monorail has been supplied the slag notch side. air hoist suspended from the rail and used both cupolas. However, chain block the same monorail held reserve. Water drips con- The scale car carries two charging buckets, spot- ting each turn under hoisting shaft extend- ing the charging floor. The flanges the buckets engage “wish- bone” the cupola, per- mitting gravity drop the hoisting eye, from which bottom suspended. ore | — Storage bins for recovered molding sand feed the material mullers, which new sand, water and sea coal are added. These discharge the mixture belt which delivers bucket elevator. After being raised another mixer, the tinually into the buckets under the notches, that the slag breaks and doesn’t adhere the receptacles. These buckets are periodically removed refuse dump the yard. The yard crane transfers the ma- terial from the dump railroad cars for shipment. “Wishbones” Facilitate Charging The cupola charging floor equipped with ton Shepard electric crane and charging machine, which swung semi-circular track into posi- tion before either cupola. About tons pig iron, tons scrap and proportionate quantity coke are stored the charging floor, that operations may continued for time the crane should tem- porarily out commission. tumbling barrel, also this floor, breaks old brick into dust, dis- charging into hopper below. The dust used for lining ladles. one side the interior the cupola (at charg- ing door level) attached iron bracket, called “wishbone.” The charging machine rests the top flange the charging bucket the wishbone, per- mitting gravity drop the hoisting eye, from which cone-shaped bottom suspended. This causes the charge distribute evenly around the sides, instead dropping one lump the middle the cupola. Cables Eliminate Extra Operative Cables within reach the scale car have been at- tached the traveling and hoist controls the charg- ing machine, that one the charging men can at- sand discharged into large storage tank, shown the right. tach the hoist the eye one the buckets and start the charging floor while the other opera- tive climbing the stairs. These cables have elimi- nated the need for extra man run the charging machine. the charging level the cupola lined with iron bricks take the wear repeated impacts. Fire brick for lining the remainder the cupola kept storage room immediately adjacent the melting floor and the raw material yard. The cupolas are patched with firestone instead mica schist fire brick. About charges, averaging tons materials per charge, are run the cupolas per day hr. The daily melt the cupolas (in hr.) tons. Core Vent Plate Suspended From Spring Modern material handling methods also are used the core department. Core sand carried bucket elevator riddle and then discharged into storage bin, with measuring hopper the bottom. From the hopper released into mixer, the mouth which can lowered for discharge into wheelbar- row. Core bond and water are added the sand the mixer. The core bond made mixture linseed oil, crude oil and resin. Resin boiled tank, heated light wood fire, located separate build- ing. The melted resin pumped into another tank, The Iron Age, December 18, 1930—1837 = Wa | After being assembled, radiators are hooked conveyor and carried through wash- ing machine (shown extreme right). 1838—The Iron Age, December 18, 1930 Following washing, the conveyor carries the radiators through dip tank, shown this illus- tration, through drier. All radiators are given priming coat paint. e & | = mixed with linseed ana crude oil and pumped measuring tank under the core sand mixer. Core makers’ benches are located opposite five double core ovens. feature core making arrangement that relieves the operative the ne- cessity laying down age bin the yard. From the bin the dust dis- charged into railroad cars. After the core sand removed the castings are unhooked from the continuous chain and are slid down which carries them under wire brush and past and picking the vent emery wheel, which plate. The plate sus- grinds the edge the through with it, rises casting past the brush the efficiency the core over and the rame heated plate which der another set brushes smoother, job, edge the casting. Dust since the sand will not ad- from the emery wheels Cores Pass Through Ovens The core racks are After being cleaned flanged wheeled buggies the castings are advanced and are moved tracks the testing and assem- into the core ovens. bling department. the transfer track, equipped first test clamps are put with turntables, permits each side the cast- the buggies switched ing hole and water pres- turned around nec- 110 lb. per square inch. essary, that the re- All castings that show turned empty core driers leaks are discarded. are the handiest posi- the machining de- tion for the core maker. partment all gate ends Each oven takes two comparison the new and old methods and bottoms radiator buggies stacking radiators. Stacking the side conserves feet are ground and all heat being warehouse space. rough between fuel oil burners under brick arch the middle the chamber. The temperature raised 450 deg. when the buggies and then drops back 375 deg. (because the influence the cold buggies). then takes about hr. get the temperature 500 deg. small work and hr. large work. The burners are then shut off and the buggies are left the ovens hr. longer. The buggies pass out the foundry side the ovens, the cores are removed, and the empties are re- turned tracks either side the ovens the transfer and then the core benches. machine files off the rough edges the cores and they are then brushed and carried monorail the molding department. Special Machines Clean Castings The cleaning room for the castings has special equipment. knock out the cores the castings are hung continuous chain and bumped against knockers continuous belt below, which operates the opposite direction. Dust drops through grat- ing the floor and drawn suction pipe stor- radiator bars are filed. special combination ma- chine taps and faces the hole the casting. The holes are tapped one side with right-hand threads and the other side with left-hand threads and the nip- ples used connect the castings likewise have left- and right-hand threads. Continuous Washing, Painting and Drying Radiators unassembled stock carried. Consequently, fast the castings are machined they are put as- sembling machines and then passed gravity roller conveyor second 110-lb. water test. Radiation that passes this test lifted pneumatic hoist and ground and buffed top, following which hooked continuous chain conveyor and passed into washing machine, built the Detroit Sheet Metal Works, Detroit. Here the radiators are subjected continuous hot water spray. The spray hot enough that the metal thoroughly dry soon after the radiators have left the machine. They are then passed through paint dip tank, over drip pan and into drying supplied the Drying Systems, Inc., Chicago. From the drier the radiators are returned (Concluded page 1901) The Iron Age, December 18, 1930—1839 | 4 Precision Forging—the Newer Idea Drop Forgings DEUTE every type moves into new era, entirely new conception ings starting govern. The manufacturing era Which drew close to- vard the middle and end 1929 the era which had inception during war- time conditions. This was particularly true the ase the production drop forgings. During the war years, the need was for quantity production drop forgings. great many drop hammers were hurriedly built and put into operation. With the end the war, this country found itself with surplus drop forging equipment, but after 1921 and 1922 the new demand began make itself felt and, for the next several years, peace time need for drop forgings in- creased rapidly—so rapidly, fact, that much addi- tional equipment was installed. This increase equipment continued keep ahead increased demand—to such extent, fact, that data the Drop Forging Institute indicate that, even during the big years 1928 and 1929, there was more equipment operation than was needed supply re- quirements. result, spite this enlarged demand for forgings, the entire period years closing with 1929 witnessed buyers’ market the forging field. The inevitable result was constant hammering down drop forging prices the part buyers. For this the buyer cannot held responsible, because quotations seemed never, his experience, strike bottom. the other hand, the owner battery hammers felt important keep them work, “eat the burden.” This resulted great studying methods, followed marked improvement production records, that, even the face 840—The Iron Age. December 18, 1930 PENDING little money save larger amount practiced Amer- ican industry number ways. One instance which has had recent expan- sion has with making forgings closely dimensions that considerable than not the result machining cost thereby avoided. This costs more for the forging operation, but the net result reported con- siderable saving. Such process known precision over-supply facilities, most shops made profit. This steady downward trend prices, more often speeding methods, has not, reasonable say, tended make for better forgings. that during year such 1930, from some direction, some way, there should drop forging ideas and re- quirements. During the spring 1930, the Billings Spencer Co., Hartford, began offer new type drop forging, known “precision” forgings. Frankly, the “precision” forging designed create more business for drop shop equipped with liberal supply hammers, but located section which places handicap with reference the center drop forging requirements, namely, the auto- motive market Detroit. short, the underlying thought produce forging worth more money. With the lowering drop forging prices, result keenly competitive conditions, the freight rate from Hartford various buying markets proved serious obstacle the case purely competitive forging. axiomatic that such case either there must further cut price such marked improvement quality that the buyer enjoys saving. The problem confronting the Billings Spencer Co. was: “How can better forgings made than have ever been made before? How can the buyer get more value forgings without ruinous cuts price?” And the answer was: forging not finished product. the case many forgings, the forging just the raw product which money spent for machining. Machining often much more expensive than forging. possible put five cents more into the raw forging, with the result that ten cents forging. | 7 fi > 7 ’ q This combination center head was forged for the Starrett Co. illustrates the superior finish and greater accuracy the pre- cision forging, against the com- mercial product. will saved the machining? That will reduce costs for the buyer, just will lowered prices for forgings, and much sounder manner. will trading the drop forging industry up, and not down.” that premise, the Billings Spencer Co. went work. but efficient re- search department got under way. This research department was given cision forging: That one cent additional used the forge shop may, many cases, save two more cents machining operations, resulting material saving the total cost the finished part. This experimenting has developed many interesting sidelights. For instance, was evi- dent, very early date, that, meet the close tolerances which valuable support through the very were set, new standards drop strict requirements certain air- hammer quality had con- plane forgings which developed sidered. Drop hammers had that time. built which provided greater speed, happens, too, that, the making Billings Spencer tools and golf club heads, machining here, one shop, both problems were evidence. was simple matter work machine shop savings through production forgings with closer tolerances, and demonstrate through case and control methods what actually hap- pens forging operations are put into effect create savings machining. mercial Indicative what was accom- plished the illustration the golf club forging. Instead merely trimming and cleaning, additional operations making for much closer tolerances were worked out, and the final illustration pictures the fin- ished forging. While this resulted added forging cost for certain lot, also made possible reduce grinding cost $4, showing net saving the finished parts $2. And addition there the greater accuracy loft angle. short, there this thought underlying the pre- Pratt Whitney airplane rocker arm; above, the com- forging; precision forging, which must free from surface defects pass microscopic test. that the forging could com- pleted within the narrowest heat range. Secondly, this called for all-around better drop hammer con- struction, the end that the orig- inal forging could made the closest possible tolerance. While precision forging still its infancy, this opportunity work out reductions cost has been quickly taken engineers. promises much, the case the forging which great deal especially the case where very smooth surfaces are desired. below, the already evident that close tolerances, hereto- fore regarded merely laboratory demonstrations, are entirely practical volume production. While this type forging necessity more costly than the rough forging the past decade, can, many instances, show marked savings the buyer. Engineers have been quick see the savings re- sulting from the elimination much costly grinding. (Concluded page 1902) Progressive steps forging golf club head, from the bar steel. The fourth figure the usual forging commerce. The fifth precision forging, set for shape, angles and loft and pro- vided with the semi-finished sur- face. The Iron Age, December 18, 1930—1841 a d “ old Rolling Strip Steel and Its Development STEPHEN BADLAM may defined working, greater than gage accuracy hot-rolled material. material means rolls, All rolling, including cold rolling, affects the dimen- below the critical range. sions the metal worked upon three primary direc- ice, far steel concerned, tions. produces compression the direction roll confined working approximately atmospheric pressure; extension the direction temperatures, any increase over this being incidental, spread the direction right angles the first two rather than intentional. The ordinary temperature directions. for cold rolling steel runs from 250 deg. Fahr. Difference Plastic Deformation Between this and the temperature hot rolling, one respect the plastic deformation metals usually above 1300 deg., though sometimes low the cold differs considerably, degree, from that 900 deg., range which the working steel hot metals. not practiced commercially, and about which know little. not improbable that, the future, When pressure applied elastic material, may find technical applications this wide, unde- steel, the material compressed; but, the veloped field. pressure released, returns its original shape; that is, the material stressed within zone elastic deformation. the pressure gradually increased, Cold rolling strip steel practiced reach point where given pressure causes per- certain inherent properties the finished product. manent change the condition the material and These properties may classified under four heads: does not return its original shape; that is, the Dimensional, gage; hardness, temper; surface, material stressed within zone inelastic per- finish; edge. manent deformation. The boundary line between the The dimensional, gage, factor has two phases: zones elastic and inelastic deformation, the crit- The range gage that may produced cold ical pressure below which permanent deformation rolling extends below that which may produced takes plac