The Iron Age 1931-04-16: Vol 127 Iss 16

\V W. Macon, Editor 4 |. Finpuey, Editor Emeritus Lacner, Managing Rditor ‘ E. Wrieur, News Editor E. F. Cont G. Koon G. 8. Herrick F. L. Prentiss Cleveland rn. A. Fiske Chicago T. Ii. Genken Pittaburgh SURNITAM FINNEY Detroit L. W. Morrerr Washington GERARD FRrazat Roston kG Gincinnat thon PURLISHING 230 West 39th Street New York, N Y “‘Tronage, N J. Prank, President Grirvirius, Secretar Raun, General {dvert Manage: Address : Division of ren Business New York, N. Y Diatrict Offices ‘ureaeo, Otis Building 1319 Park Buildin (CLEVELAND, 1362 Hanna Building 1402 Widener Bid Derrorr, 7338 Woodward Avenue WASHINGTON, 536 Investment Bldg (INCINNATI, 402 Traction Building RUPFALO, 616 Ellicott Square Boston, Room 230, 80 Federal St SAN FRANCISCO, Bush Stree ind 1045 Sansome St Copyright, 1931, InON AGE PUBLISHING Member, Andit Bureau of Circulat ix flember, Associated Business Papers Published every Thursday Sul scription Price: United States Vossessions, Mexico, Cuba, $6.00 Canada, $8.50: foreign, $12.00 a vear Single Copy 25 Cents — April Trend Real Wages 1247 Slow Draw Press Motion 1251 Open-Hearth Ports 1254 Reducing Motions the Foundry 1258 Data for Sheet Buyers 1264 Metal Terrestrial Globes 127 Galvanizing Pot Life 1274 All-Welded Hopper Car 1279 Alloys Capt. Campbell’s 1280 Dr. Haney’s Page 1303 New Equipment 1283 News 1291 Personals and Obituaries 1300 Editorials 1304 Markets 1307 Construction and Equipment Buying 1328 OUR READERS SPEAK have before pile letters, several inches high, complimenting the improvements made The Age beginning with the first issue April. few specimens the comments are: pleased with the new dress. The cover very attractive—modern, striking—yet restrained and have made great improvement arrangement your news items. like very much the attractive head lines your lron Age improves with age and getting better and not for the enterprise your staff always developing some improvement, one would led feel you have now about reached perfection trade journalism.” not like use superlatives, but believe, with your book before me, could eliminate all the Age the most attractive paper.” examining cur- rent issue, find good magazine even better, that could about the only magazine trade paper really take time AGE YEAR | ™ = = = | | if | | | | } | | 7 | $s | BAR ine J | | | | 1} | 4 } | | THE IRON AGE 16, 1931 Page simpler nor more effective drill spindle mountings have ever been evolved than those employing the New Departure Dou- ble Row ball bearing. Such design used Master drilling machines built the Superior Machine Tool Company, Kokomo, Indiana. The Double Row New Departure compact and accurate, has high thrust capa- city. preloaded assembly for perma- nent rigidity, needs further adjustments This bearing eliminates lag and looseness the spindle drills start cutting soon pressure applied. will gladly tell you more about this long- lived bearing. may save money for you. The New Departure Mfg. Company, Bristol, Connecticut; Detroit, Chicago, San Francisco. NOTHING ROLLS LIKE BALL NEW DEPARTURE BALL BEARINGS ‘ | NEXT WEEK HAT industry dur- ing long term periods declining live subject, this, for economists believe that may experi- ence similar trend that which followed our Civil War. The leading article next week’s Iron Age will tell, detail, what happened costs, prices and its during this long term price trend. This much will tell you advance—declining prices not need mean declining prof- its. The stimulus competition urge necessity often impel more rapid progress than the easier going the long term upward swings. APRIL 16, 1931 Long-Time Wage Trend Steadily Price Declines Have Not Upward Affected Wages Study period from 1859 pe Crank Press Increases Output Preventing Pressed Metal broaching bushings Higher drawing press builder predicts. Velocity the starting resistance punch low when resistance start the crucia ing greatest initial contact moment Suddenness startin Page 1253 met moving is what breaks the Open-Hearth Fuel Economy Gained Greater Gas Velocity Ideal Open-Hearth Port The reaction combustion Flame should have creased, and better convective heat with the bath port should pro transfer from the flame the vide large contact surface bath gained. This calls for special ible, the place the ports and increased chimney draft has the highest temperature Page Page 1257 Tall Stacks Best for Open-Hearth Furnaces Ten Men Foundry Work Increase gas velocity increases } velocity of escaping gases of com carbureter plant foundry Page 58 Otherwise the gas chamber will remain cold Page 125 Sheet Maker Will Help Reduce Your Stamping Costs Melted Electric Arc ~ 1 Steel makers have store accu- Furnace mulated experience which will help é Cc expe ence vi n Iki if Carbureter castings in new found: solve v blem t fer vice . as to improving your product and electric arc furnace The charge con owering your cost.—Page 126 sists foundry scrap, cast * scrap in 1 Low phosphorus scrap steel Metal-Ware Galvanizing Pot Page 1258 Should Last Months ' Investigation reveais that extreme Eliminates Effect Deep Drawing . . | range of service is four months to 60 os ‘ P INormalizing produces such a fine months all fuels, coke gives the grain structure im cold-rolled sheets Pag longest pot ire age Specify How You Want Your Page 1267 Sheets Shipped Where crane facilities for unload Welded Freight Car Stands available, box car loading the are being superseded open gondola 95-ton all-welded hopper car car loading the ise since October, 1929, giving methods loading, you assume ervice. Ratio pay load 1768 ratio 1s 2.78 to 1 Page 1280 7 | | | | | | | | tha LOTTI wWithh OF AaACTOSS the makes little apparent THE IRON AGE APRIL 16, Page Tool Room Work Production Basis Bausch Lomb Optical Company Rochester, Parts Optical Machine Tool These parts were formerly made two machines—an old type turret lathe and engine lathe. Now, one Warner Swasey No. Universal, speed all geared head turret lathe does both chuckings half the time. Look the savings made these jobs. You, too, can duplicate such savings. engineer will gladly make careful study your problem and submit recommendations for lowering your costs. His services are yours without cost obligation. Write wire for him today. minutes min nutes minutes Warner Swasey Co. , 4 _ 4 REPLACEMENT OUR MANUFACTURING WORKER AND HIS WAGE SIDNEY KOON view the present-day discussions written late re- things and, with the com acts. The accompanying article presents tation among wage indisputable ones, drawn from 70- petition for the dollar, has resulted low earners, what has been year record American production and ering further the price euphemistically called tech- wages. the consumer. The most nological unemployment Since 1869, with but a few exceptions conspicuous example ot that may interesting which help prove the rule. the this. course, the compare the wages paid much oted automobile, the products steadily increased, And yet, 1929. the price which today far lower than that that same industry. The the latest year for which information imilar car before world goes back more than year exceptional profits advanced their years, the period and large dividend payments—the percent- post-war elevation prior the American wages production values was less the War. than for any year 1909. shown the table iven product wages paid increased even during long-term periods vages for from per cent declining prices. consider have held uniform declining, their value product little fact before heed the counsel those practically so, and the more than per cent. who would attempt reverse 70-year ndividual wage has shown There has been only trend. distinct tendency reduction, through entirely independently the years, the changed value the which the wage earner has dollar). This fact, with received. fact, 1909 the attendant fact that percentage was its very lowest point, ower price for the product, has permitted the wage 1923 showed the highest ratio since 1889. earner buy more the products industry—has, This condition has reacted upon the wage earner word, raised his standard living. several ways. the first place, with the growing beside our present purpose indicate that, ise machinery and labor-saving devices gen- whereas the cost putting labor-saving equipment eral, fewer wage earners have been required turn has been borne wholly the manufacturer (capital, out given volume production. This turn has other words), the benefits have been passed resulted lowering costs below those prevailing the wage earner higher wages the one hand 1247 | — I TOTAL SALES VALUE oan How the dollar, received for goods manufactured, has been split—among wages, materials purchased, and other expenses and profits—over period three score years and ten. and, the other, the ultimate consumer lower price tor the product. This does not mean that the manutacturer has not had his benefit also. has able lower his unit overhead costs markedly, make much quicker turnover from raw material shipping platform, and cut costs number other ways. Thus the benefit has been three-fold apital, labor and public. Changes from Nineteenth Century the percentage relation between total wages and value production, set forth table page 1250, shows variations and down, over the whole period, may clarified grouping the figures nto decades. Thus, for 1859 1869, the average between 20.09 and 18.33 19.21 (per cent). Similarly, for 1869 1879 have per cent. And for 1919 1929 the average six figures gives 17.51 per cent. this basis possible set table which 1248—The Iron Age, April 16, 1931 shows some important things very clearly. Average Decade Wage Percentage for Decads Casual inspection tells once that sharp line occurred relationship, about the this 18.76, and they are fairly uniform The three last figures, averaging 17.19, are fairly consistent, also. And none either group would fit into the other without extending the limits that group This break coincided roughly with the ginning large employment electri power industry. similar calculation, taking the totals the orig inal census figures and then establishing the relation comparable results. Thus, for census dates the nineteenth century, the total valu products made was 31,421 (millions dollars), and wages aggregated 5847 (also millions). Their ratio 18.61 per cent. For the nine census years the twentieth century the corresponding figures are 167 and 72,765, giving 17.36 per cent. Hence, aside from the one recorded change between the nineteenth century and the twentieth, the wage earners’ stipend has maintained consistently uni- form proportion the total value industrial output. Since 1900 the trend the wage percentage has been upward, for the latest decade shows the highest ratio the twentieth century. Now what wages will buy. will have been noted that, with the sole exception 1899, each census year showed the average wage earner receipt higher yearly wage than ever before. But the purchasing power indergoing continual changes—some- times, violent ones. Use the relations commodity prices from year year, measure these changes buying power, may challenged the ground that these prices not completely represent liv- ing costs. But they are, nonetheless, fair gage living costs, though they are wholesale (not retail) prices. And the fact that there are adequate tail price figures, cost living fig ures, except for brief recent period, makes necessary use the wholesale power scale over period seven Average yearly wages manufacturing wage earners the United States, Hence, the last column the table 1859 1929, are shown light lines. The black bars show the changes nual wages American manufacturing plants, expressed buying power real wages. census years show average $845—in the same this column sharp rise noted after 1880 and “buying power” dollars. Here further other after 1920. These appear graphically the the American standard living—insofar wage chart. Each signalized new and turing wages are index thereof—in the order higher level real wages. After 1880 that level held, per cent. substantially, until after the Armistice, showing Comparing this recent decade with the years slightly rising, but not uniform, tendency. Since 1920 overed the three earliest census figures quoted, the same fact true, rising trend further advance the living has been less than 166 elevated level. Averaging the yearly averages 1859 1879 have $317 (in 1913 dollars, buying power). From 1889 1919 the six figures show average $552, the same buying power basis. This means ad- vance per cent the average scale living, during the years 1880-1920, compared with that prevailing prior 1880. Again, since 1920, ne nve at INCE 1869, the procession real wages the United States has continued its steady upward progress. Yet the real cost manufactured products has steadily decreased. Let think twice before reversing 60-year trend which has greatly increased consumption The April 16, 1931—1249 WAGE Value Total Per Cent, Wage Average Commodity Real Products Wages Wages Earners Wage, Price Index Wages, Products (Thousands) Year Buying Power (Millions Dollars) 1859 1,885.9 378.9 20.09 288.96 324.67 1869 3,385.9 620.4 8.33 2,054.0 302.04 130 232.34 1879 948.0 17.66 2,732.6 346.95 394.26 1889 9,372.4 1,891.2 20.18 444.88 536.00 1899 11,407 2,008.4 17.61 4,712.8 426.14 546.33 1904 14,794 2,610.4 17.65 5,468.4 477.39 542.50 1909 20,672 16.58 6,615.0 518.10 528.67 1914 24,246 4,078.3 16.82 579.66 591.50 1919 61,739 10,453 16.93 8,990.0 1,162.90 205 567.27 43,619 8,200 18.80 6,944.0 1,180.85 147 803.30 1923 60,258 10,999 18.25 8,768.0 1,254.40 154 814.55 1925 62,668 10,727 17.12 8,382.0 159 804.88 1927 62,718 10,849 17:30 8,349.8 1,299.15 145 895.97 1929 68,453 11,421 16.68 8,550.3 147 908.67 RNINGS AMERICAN MANUFACTURING per cent. That has accounted for the prevalence the homes automobiles, luxuries. And has brought commissions and individual economists from the today’s wage earners radios and other erstwhile four quarters the earth learn how was done. Trend Steadily pward HESE changes have not been without setbacks. But each time there was setback the next period showed spurt new high level. Thus the 1869 ugh higher than that 1859, had nothing wage, tho like great buying power. Post-war inflation prices rible crimp the employee’s pocket would buy less than thre analogous that years ago put ter book; his -fourths much the smaller pay ten years earlier. But 1879 mbined effect higher ind lower for what had buy put him the highest ] ] living had ever attained has been since the World War. Wages did keep inting prices, between 1914 and Test the Drawing ESTING sheet metal deformation under loaded ills gives variable results because frictional effects the surface contact. Some times rupture occurs the surface the cup pro duced, affording measure the strength all direc tions, but more frequently the break occurs the edge the cup and merely indicates failure under radial tension. applying liquid pressure directly the face sheet clamped between circular jaws, Ch. Jovignot Revue Metallurgie, August, 1930) obtained very consistent results, provided that the sheet itself was uniform. sure chamber, rupture was detected means gage connected the pres- instantly, even 1250—The Iron Age, April 16, 1931 They doubled, but prices more than doubled. Hence the week’s envelope would buy less than five earlier. But here the deficiency buying power was the order only per cent, against drop per cent 1869. And the rebound, after 1919, through average wages continually and uninterruptedly advancing, while prices have fallen sharply, has kept the real wage far above anything before known. Such temporary decline (in wage buying that 1925, and those 1904 and 1909, are mere incidents the progress events. similar reces- sion perhaps will shown for 1931, when the manu- facturing census for this year compiled. But the main story all these figures wages not only tend, through the decades, rise, but that they tend rise faster than prices. They when prices are falling—witness, 1921 and 1927, well 1879 and 1889. And they everlastingly hold their gains and consolidate them into bigger ones. The American standard living has consistently forged ahead. Qualities Sheet Metal when the failure was almost invisible the cup. the cups were about twice the size ordinarily pro duced the ball method, the deformations could Absence frictional effects the working surface insured comparable results. spherical outline the cups formed permitted ready graphical solution for the coefficient extension all directions and the load rupture, whatever the thickness the sheet. homogeneous material rup- ture usually occurred the summit the sphere, extension being greatest that point. Steel ball instruments may converted into the liquid pressure type with little difficulty. The results obtained the method are considerable industrial importance. read more exactly. a a “SLOW DRAW” MOTION INCREASES CRANK PRESS OPERATING SPEEDS WILLIAM BLAKE ECENT developments the power press field include modified Whitworth motion which, applied crank presses, produces uni- form velocity the punch the downstroke and quick return the upstroke. The practical outcome this development relates both marked increase speed and greater accuracy, explained Mr. Blake, this article. Furthermore, adapts the crank-type press, with its simpler construc- tion and more rapid operation, for redrawing, broaching and burnishing operations usually done other types equipment. redraw long shells maximum and, that now being done more slowly rack and the same time, uniform speed; and pinion presses and other types and burnish bushings more accurately, paradoxical that, addition, this uniform-velocity uniform rate and faster speeds than “slow mechanism may also used speed present attainable, new crank motion has bee many drawing now being done patented and introduced Bliss Co., Brook- simple harmonic motion regular crank lyn. This mechanism replaces the simple The displacement curves reproduced her motion the regular crank with modified Whit illustrate the differences motions and worth motion which brings the press slide down wit} of two slide tuated by the two different cra approximately uniform velocity over the mechanisn vhile operating the same number part the down stroke and imparts quick trokes per minute and over the same the upstroke. The length this stroke can troke. Curve the motion imparted the accurately and easily set and controlled mechat For the the regular crank presses. the above well below mid This new slide motion makes possible the troke, the speed the slide very nearly con crank presses—with their inherent advantage stant, indicated the uniform slope the simplicity construction and greater speeds quick return the upstroke brings the sli much redrawing, broaching and burnishing top position the end the same time-inter TOP STROKE TOP STROKE BOTTOM Displacement curves two slides having the same length stroke. Curve the simple harmonic motion imparte@ the regular crank. Curve shows the approximately constant velocity motion the downstroke and the quick return the slide the upstroke obtained with the drive mechanism. The Iron Age, April 16, 4 . + ~ 00, ™ » ~ | a that which the regular crank mechanism makes complete cycle with simple harmonic motion. Curve B.) The maximum downstroke velocity each slide the mid-position, indicated the greater slope the two curves that point. will noted that though each curve completes the cycle the same interval time, the regular crank press, be- sides having non-uniform motion, causes the slide travel faster mid-stroke than does the slide actuated the “uniform-velocity” mechanism. mid-stroke, the speed the slide with simple harmonic motion—with 16-in. stroke and operating strokes minute—would 62.8 ft. minute. would beyond the limit the maximum speed which most steels can drawn without the shell up” the dies. Under identical con- ditions, evidenced the curves, the velocity the slide moving down with the approximately con- stant speed the “slow draw” mechanism would ibout ft. minute. Besides being uniform this speed would conservative for drawing steel shells and would maintained over greater portion the downstroke. With this special crank motion, therefore, and, under the conditions shown the displacement chart, the operating speed the press ute without increasing the maximum drawing speed above 62.8 ft. minute, which the drawing speed mid-stroke the regular crank motion when oper- ating strokes minute. a crank mechanism applied Bliss No. 306 straight-sided press. Iron Age, April 16, 1931 From the comparative velocities, indicated the slopes the two curves, can predict, there- fore, that the redrawing long shells and the broaching and burnishing bushings presses equipped with the “slow draw” mechanism can safely speeded about per cent above the number strokes per minute possible regular crank presses. This increase would be, the case cited, about the maximum speed which the shells can fed hand. Where production re- juirements warrant high-speed automatic operation, this same mechanism may used speed work this press, used for broaching bronze bushings, the mechanism provides constant- velocity downstroke. The length stroke in. 12-station ratchet dial feed automatically places the bushings position under the broach- ing tool. point where mechanical feeding can very profitably employed. The best available figures (data the subject are admittedly incomplete) show that under favor- able conditions steel shells have been drawn speeds high ft. minute. This was the speed regular crank and the slide mid-stroke position. Here the downward component the peri- pheral speed the crankpin equal this tan- gential speed and is, course, its maximum value. Somewhat beyond this point speed only slight- less than this maximum the punch enters the shell hits the blank and starts the redrawing (or 5 7 ‘ ‘ > { @ 5 q q 3 3 aif \ The uniform velocity downstroke ob- tained with the drive used with marked success redrawing long, thin-walled copper shells for thermo- stats. This press has 24-in. stroke and operates strokes minute. drawing) operation. more conservative value for the maximum drawing speed steel, commonly used for estimating purposes, strokes minute. large concern Connecticut, drawing brass shells, has been able get speeds high 200 ft. minute, with some reports great 260 ft. minute that metal, with exceptionally close con trol over the operation due long familiarity with that class work. When considered that the speed which steel wire drawn the order 2500 ft. minute, and that testing steel (cold) the percen- tage elongation increases with the speed the test, would seem that the present limit drawing speeds more matter the sudden start punch hits the blank shell. this point the stroke the velocity the punch maximum for the period the draw. Tests indicate that “the comparative resistance drawing, set the flange (partially drawn) shell not any greater due higher drawing speed. But with given starting resistance, made up, say, severe draw, too sharp corners punch and draw die, and too *E. V. Crane “Press Working nd Formi: of Met Metal Stampings, January, 1930 high an initial blankholding pressure, an Increase in the sud lenn wit} which tha mat ] ig tartead mony tne Suadenness itn wnich the metal is started movy ing should increase the tensile strain the metal around the nose the punch. This phenomenor would increase the tenden the metal that point. practice has demonstrated that cation smooth, even pressure will increase the quality and cut down the breakage drawn shells For broaching and burnishing operations such constant-velocity motion has long been recognized increasing the speed and accuracy the work f‘olou lroaw’’ lal ih] +h such even pressure the greater speed required more economical production Copper Steel for Dynamo and Transformer Sheets steel containing about per cent silicon has little resistance atmospheric cor rosion. additions copper improve the weather resistance structural steels, Kussmann, Scharnow, and Messkin (Stahl und Aug 21, 1930) have studied the influence copper the nagnetic properties silicon steels. Melts 1.5 and per cent silicon steel were made high-fre- quency furnace and 0.2 per cent copper added. These melts were cast iron molds and forged cylindrical rods 1800 deg. drawbacks due copper were apparent the hot working. The 7-in. diameter rods for measurements were slowly cooled after hr. anneal ing 1600 deg. the field solid solution, about 0.8 per cent copper 1.5 per cent silicon 0.6 per cent copper per cent silicon steel, the coercive force, measured magnetometer, practically the same the copper-free material, but above the solubility limit the coercive force in- creases sharply with increasing copper content, and the hysteresis loss becomes greater. The magnetic induction and the electrical resistance were unaffected the copper additions. Corrosion resistance was tested treatment the polished specimens, with and without annealing per cent and per cent sulphuric acid ordi nary temperature. the per dynamo steel, 0.2 per cent copper produced re- markable improvement corrosion resistance which remained constant for further additions; the per cent silicon transformer iron about 0.4 per cent copper was necessary for maximum corrosion resist- ance the annealed condition, and susceptibility acid attack increased again further addition. corrosion resistance satisfactory 0.5 per cent copper both steels, which content the and magnetic are not impaired. The Rockwell hardness increased about per cent the copper content increased from per cent, and the tensile strength lay within the usual limits for the dynamo steel. The Iron Age, April 16, 1931—1253 — : ap y — | | 4 DESIGN OPEN-HEARTH PORTS ROPER design open-hearth ports has fre- quently been considered late, owing the number new patents this field and the growing use gases other and richer than producer gas. may interest summarize what has been done along this line re- cently, and thus prevent the repetition mistakes The most essential part furnace its combus ion chamber, the case solid fuel, and its burner, the case liquid gaseous fuel. The burners the open-hearth furnace are their port ends. The portance the proper design the ports evident rom the that the time furnace campaign long their condition good indamental principles for such define the ditions the from the hotter flame the a Methods Heat Transfer now hat heat transferred main a I st] vin carbon particl the luminous flan the radiation the then hly investigated Schack pr redominal the transfer from the flan here all the history the discussion liat The theoretical sed chiefly Stefan Bolzmann’s vhich runs thu According this erred by law, the amount heat trans radiation directly proportional the dif- ference the fourth powers the absolute temper- atures the bodies question, and will therefore 254—The Age, April 16, 1931 the flame, thus the same time must fitted the shape the bath. narrow furnaces the predominate high temperatures. But any case ertain experiences not correspond with this point view. know, for instance, that the metal bath begins boil first the point where comes into contact with the stream furnace flame. Besides this, the melting down the parts brickwork which are washed the flame also known fact. Such ex- periences are evidence favor the convective heat transmission and are taken into consideration The influence flame luminosity was clearly esti mated Lent and Aye follows: flame filled with particles soot, and consequently luminous, has lower temperature but greater radiation than non-luminous flame, assuming that all other condi- tions are the same.” Fundamentals Port Design Basing upon this statement can assume making the flame luminous, would promote radiation but eliminate the convective heat transmis tion, due the lowering the flame temperature. Without going into details can state the following: Apart from the relative value convective heat transter, the design the ports must such as: cause intimate contact the flame with the bath provide large contact surface ible; this contact must the right pla where the flame has the highest temperature. must endeavor get higher velocity effecting convective heat transfer her flame temperature, due more intensive burning process. The slope (inclination) the For long and smaller than for angle will wide and short ones. 1. The most important direction is the direction that element (gas air) which has the highest Ports Common Type his valuable articles, “Dimensions Open-Hearth Furnaces Estimated Empirical Data,” Prof. Pavlov gives the average inclination the gas ports Deutscher Some German authors recommend Bansen-Abmessungen und Leistun- Siemens-Martin Ofen). The differ- ence not great, considering that the exact slope ~ +] Pay = I 4 ai at 1 q 4 inclination) further estimated after the nace. The shape the flame then will has made campaign, because depends the shape the furnace hearth than the case process question and the shape the hearth parallel ports, and thu onvective heat transfer fact, when looking from above the flame will instance the flame welding burner) must bear mind that the gas stream bliquely on a horizontal plane, Wwe can se that the from the ports t the melting chamber of the fur hottest part the surface would nace has because the vas heated Fig. The greater the angle the broader and the tors nly 1100 deg. and there shorter that oval will be. being fore heavier than the furnace atmosphere, which val converted into circle. Approximately the temperatu 1700 deg. Exceptions same occurrence takes place the open-hearth this can happen when the nace. Suppose have established deg. mparat for during the charg during the operation the furnace noticed that peri too short. Then evident that ngle minou trean cannot change Both the gas and the air ports usu mpare this bag comparativel irrower (conical) toward hav hot acceleration and the specific weight the But actually this conical very Tian and the angle between the arch and the bottom ort does not exceed deg. Conditions With Steady Burning This can be explained by the bu Suy definite nditioy +} flues. the conical shape were larger, the area the {) ne LOMOWI neiu ns rect direction the flame would disturbed. Using Two Ports for Entering Gas gas each onstant Large open-hearth furnaces then that, for given tion two gas ports each side. this case the prope! the ports, the flame will shorter the velocity direction the flame may attained inclining the gas stream being diminished. The opposite hoth ports slightly toward the center line the fur- conclusion will right only limited sense, for The Iron Age, April 16, 1931—1255 4 = 7 q ry 4 j i | 4 the intensity combustion will rapidly increased when the whirlwind region reached (turbulence). evident that every increase combustion intensity will cause shortening the flame, what- ever the cause may be. This can sometimes ob- served large furnaces with high regenerators and narrow ports, when the furnace running very hot. The flame this case getting shorter and ransparent and begins hum, Le., makes = Fig. assumed flame from burner, impinging acute angle upon bath steel. peculiar noise typical the whirlwind region (tur- Modern theory attributes the luminosity the ame great influence upon the heat transfer, and oken the increase flame transparency + mentioned should have unfavorable effect. But ] fact, all such cases, rapid heating the bath noticed. Basing similar facts, observed also other kinds furnaces, the author, who acknowledges wholly the importance radiation, nevertheless the opinion that the influence convective heat transfer often neglected. But the same time evident that, use non-luminous gas fur- nace built for luminous fuel, the result will diminishing the heat transfer. can increased only designing special burner with greater con- transfer. From all that has been said above, can draw the that every port should have such shape and inclination increase the convective heat transfer much possible Velocity Gases Passing Through the Ports are now going estimate the velocity the ports. First all must point that, increasing this velocity, not the time during which the gases remain the furnace chamber. illustrate this example anneal- ing furnace shown (Fig. 2). The gas and air ports this furnace enter the chamber from below; the air ports are placed between the gas ports and the velocity the entering air the gas not too high, not see any perceptible motion the furnace atmosphere. raising this velocity— 1256—The Iron Age, April 16, 1931 circulation this atmosphere can noticed, shown the arrows. This phenomenon explains the influence increas- ing the velocity the entering gases. The time during which the gases remain the furnace depends only the amount the gas and air per second and not their velocity. The circulation the furnace atmosphere increases the convective heat transfer and distributes the heat the furnace more uniformly. The same rule true also open-hearth furnaces, for the tongues flame which can see represent the near ends the turbulence rings. cannot see the whole picture the gas movement, because invisible; only the moment during which the carbon the gases burning can noticed. have suggested that the flame can com pared bag comparatively cold gas with thin, burning envelope. increasing the veiocity the gas stream, may simultaneously give such shape the flame (for instance, decreasing its height) that the surface the convective heat transfer re- mains undiminished. Therefore not need fear bad effect this respect. Considering all these circumstances evident that increasing the gas velocity will give the fol- lowing advantages: increased reaction combustion. better convective heat transfer from the flame the metal bath. Velocity Open-Hearth Furnace Gases Now shall estimate the velocities gases used open-hearth furnaces standard design. Fig. furnace atmosphere when the velocity entering gases raised. Prof. Pavlov his book recommends for furnace cross-section gas ports about 3500 sq. (540 sq. in.). Such furnace has producer gas consumption 1000 cubic meters 35,000 cu. ft.) per ton charge. Taking the gas temperature question 1100 deg. (1373 deg. absolute), and the time required for one heat hr., the volume gas per second (185 cu. ft.) and the corresponding velocity the gas: — | MO \ | 4 SSS 4 — ONSIDERATIONS the velocity and volume gases used fuels open-hearth furnace, and the velocity and volume the waste products combustion going the stack, influence materially the design the ports for directing the fuel above the bath and for removing the products combustion. The angle which these ports shall take and the cross-sectional area which they shall have depend upon nice balancing, and the factors arising from the incoming and the outgoing flow. this article the author ties theoretical considerations with practical observations operating furnaces, and shows how number the calculations are made. 524 0.3500 meters (49 ft. Such velocities were really adopted within years, but practice has shown the advantages increase these values and the latest reports Union German Metallurgists (Verein estimates the velocity gas deg. and 760 mm. (atmospheric) pressure meters (19.5 ft.) second, which will be, for the real velocity (at 1100 deg. C.), This value corresponds with the new velocity Prot. Pavlov published 1927 (see sions the 100-Ton und 1927, No. 23). this investigation Professor Pavlov defines the velocity smoke the ports (at 1600 deg. C.) meters (105 ft.) second. shall see later that the difference between this velocity and the velocity gas combustion very small. Most Ports Have Dual Function ports ordinary design, the velocity the gas very difficult increase, for the gas port acts the same time the flue for the products com- bustion leading the gas regenerator chamber. increase the gas velocity will therefore lead increase the velocity escaping gases com- bustion the gas port, which turn would require very tall chimney the use forced draft; other- wise the gas chamber would remain cold. must also not forget that both sides open-hearth furnace must well balanced, the hearth itself, having many openings, connected with the atmosphere. Consequently the pressure draft one side the furnace actually does not in- fluence the pressure draft the other side. (See Dichmann, basische Herdofenprocess” Having increased the draft the chimney, must also increase the draft the air chamber, for instance deepening the use air blast. For reasons which will considered later, may adopt for the air smaller velocity than for the gas. That allows make the air ports larger, and make correct distribution the gases combustion separate flues for air and gas, equipped with dampers. stream ‘ lit absolute water. According the measured draft never measured draft all resistan measurement. nave: ports 1600 deg. Sé na The locity furnace the 1130 kg. average 300 deg. C. f waste the the bottom will any investigati water. nothing else than the sum hearth the point head, therefore, in.) water temperature escaping and the corresponding velocity is: meters hows whether with practice: gases for the producer each 1000 calories corresponding amount Bansen, “Bau und Berechnung und Eisen, port the relation correspond corresponding sing through the for each cubic temperature gas oro 273) The Iron Age, April 16. 1931—1257 gas chamber second the maximum velocity the flue above mentioned German report, the averag the specific weight gases 1.35 kg. the cubic meter (0.084 foot) find that the static draf ane 273 1.35 52.4 mm. (2.06 the bottom chimneys almost yresents from For the 52.4 22.4 mm. 19.6 22.4 1873 act orda ount and 2490 der Siemens-Marti page (Vo). According the German the volumes the chamber is: 1:1.25 loadings the amount waste gases pas is: 0.8 cubic mete meter OF 6.40 gas burned. ANY specifications for carbureters now for bodies made cast iron instead non- ferrous metals. most designs there are complications, such heavy flanges and bosses, well wall thicknesses that often not exceed in. new foundry designed specifically for this class work, well for the pouring non-fer- rous metals, has been constructed the Bendix South Bend, Ind. well unusual feature the plant Stromberg Carburetor outstanding the fact that the iron melted electric furnace. Doubling Back Work The layout the foundry such that there doubling back work process. Raw materials are brought special department railroad cars. The switch track, which enters the side the foundry building near one end, extends +} | 1] ] + rit LULL the storage and furnace depart Overhead is a 5-ton electric crane, furnished the Shepard-Niles Crane Hoist Corpn., Mon tour Falls, Y., means which material moved from cars storage. The electric furnace ‘harged with the aid this crane. the entering end the materials department are three scrap storage pits, then platform which mounted the electric melting furnace. The transformer room next line, followed the sand storage bins and sand preparation space. The remainder this section the building occupied brass and aluminum melting furnaces. This plan provides for iron pouring floor rectly front the electric melting furnace, core-making department front the sand stor age and preparation sections, and casting floor opposite the brass and aluminum fur- naces. Therefore hot metal and sand are moved minimum distance, and the core-making floor, be- 1258—The Iron Age, April 16, 1931 WASTE MOTION ROGERS FISKE materials, molten metal, molds and castings are handled mechanical- the new foundry the Bendix Strom- berg Carburetor Co., South Bend, Ind. Crane runway, monorail, conveyors and aisles have all been placed that work takes the shortest and most direct route, with back-tracking. Both iron and non-ferrous metals are cast, all the iron used being melted electric furnace. located between the ferrous and non-terrous molding stations, feeds conveniently either side Molding sand unloaded from railroad cars the crane bucket overhead storage bins. Core sand, after having been prepared, loaded conveyor from which plowed overhead bins core makers’ stations. the end each two continuous mold con- which are installed only the ferrous side the foundry, there vibrating screen where the sand shaken from drags and copes through plate sand-reclaiming conveyor which located beneath the fcundry floor. This conveyor discharges the reclaimed sand belt conveyor which runs lengthwise the continuous mold con- veyor unit. This sand delivered the reclama- tion room, where screened, tempered and pre- pared Simpson mill, manufactured the Na- tional Engineering Chicago. then elevated revivifier, where put through heating and aerating process, following which finally raised — | <} Bar San Ca | at LIMINATED CONVEYORIZED FOUNDRY conveyor which delivers the prepared sand overhead bins located above the molding machines. These machines, which are located along the mold ing side each continuous mold conveyor, are the jolt-squeeze type, made William Nicholls Co., Inc., Brooklyn, and mold Bench Drills Air Hammer Bench, r?, RL Blasi Chute. Barre - ly Barre/ Sand Blast Cutfer [LW Roller Conveyor = SWITCH track, melting furnaces and sand preparation equipment are all under one roof. Molten iron and metals, well core and molding sand, move points use with minimum distance travel. The Age, April 16, 1931—1259 | Slower Mata! Pourtna Manora AS olading Mac es a il Core Machine: . | | J J | || ~ore Fack Molaina Mi and Conveyor Simp S a Malting } w/e Man f ora | | Storage q | Pr#ts ; | conveyor equipment was furnished the Link-Belt molding machines that are regular use each Co., Chicago. line are now producing total from 1500 1700 molds 9-hr. day, this being equivalent 750 850 molds day per pair machines. Plans are Molding Machines Feed Mold Conveyor Seven molding machines have been placed along already under way increase this output. side each continuous mold conveyor. Four Roller Mold Conveyors Non-Ferrous Department machines are required keep the conveyor loaded apacity and three machines are held reserve The molding sand for the brass side the either spares the event breakdown for dry prepared adding water paddle mixer, ise When pattern changes are being made. Cores passing the sand through aerator from which delivered coresetters who are located the conveyed overhead hoppers above the molding iter the mold convevor. These men set the stations. Metal the non-ferrous department the drag half the mold while being melted three oil-fired Rockwell Co., New toward the cope machines. York, reverberatory furnaces and four Alfred non-ferrous section the foundry the molds are first three machines are used for making drag molds and the remainder the machines are ised for producing copes. This arrangement allows time for core setting before the drag half mold reaches the cope machines. The usual arrangement pair machines, for instance, No. and BELT con- No. No. and No. dis- veyor After cope placed drag, man also tributes sand working the center the mold conveyor applies the wedge clamps. The remaining stretch mold this side designated the ‘ing head bins molding stations. Molds then take the turn the conveyor and cool while passing down the return line the shakeout station, which the opposite end the conveyor from the pouring station. The two mold conveyors are placed back,” that is, the molding stations are the outside runs. Each molder receives flasks the continuous conveyor, sets them his machine and pulls hand lever above him for sand, which discharged from overhead storage bin. makes his half the mold which then places the conveyor. The four t iron cast- ings are an- tric furnace. 1260—The Iron Age, April 16, 1931 ¥ ay A SHAKEOUT screen lo- cated the end each mold con- veyor (above). Co., Syracuse, Other conveyor units this department were made and installed the Link-Belt Co. the iron side the sand preparation depart- ment thoroughly equipped laboratory. Frequent tests the sand prepared are made there. Conveyors Move Cores Filer Stations Core-baking equipment consists two vertical conveyor ovens and drawer type oven, all which were made the Foundry Equipment Co., Cleveland. Opposite each continuous core oven William Demmler Brothers, Kewanee, core machine and convenient points around the three core ovens are core benches. one side the core stations and the core pasting benches. From there the cores are moved only short distance storage racks, which are conveniently located with oven conveyor which delivers cores filer respect the core setters’ racks stations along the lines the continuous mold conveyors and the non-ferrous floor. Metal Tapped Each Hour from Electric Furnace The mixture used the electric furnace, which was furnished the Pittsburgh Electric Furnace Co., Pittsburgh, consists pig iron, foundry scrap, cast scrap, and low phosphorus scrap steel. Gates and risers, after having been knocked off the shakeout station, are transported truck one the scrap storage pits, which are constructed concrete and extend below the floor the room. These pits are under the 5-ton crane which, has been pointed out, also serves the material switch track. Cast scrap and gates and risers from the foundry are stored one bin. Pig iron and low phosphorus steel are stored second bin, and the third pit used for purchased cast stock. The furnace charge made from these bins and unloaded into the furnace means the over- head crane. The furnace operated that there 9-ton bath throughout the working day. Should necessary the future, the bottom the furnace can lowered provide bath. Furnace operation continuous, with tons iron tapped per hour. The temperature the metal 4 —— 4 q ye of 4 a The Iron Age, April 16, ty are OLDS poured they pass (at left). veyor ORE-MAKING machines and benches are placed around the core ovens, two which are the vertical conveyor type. Age. April 1931 1262—The Iron | _ the spout 2650 deg. Fahr. Every three-quarters hour sample the iron taken the fur- nace spout and careful chemical analyses and phys- cal tests are made. Hot Metal Handled Monorail Extending from the furnace spout and branching two ways each the continuous mold conveyors overhead monorail system, made the Modern unit supplied the Electric Furnace Co., Salem, Ohio. This furnace equipped with hydraulic pusher. The trays castings down one side and after being pushed across the furnace return the opposite side the loading end the furnace. The complete cycle requires approximately hr., the castings remaining the heating zone for min The temperature that zone 1500 deg. Fahr.. control being means Leeds Northrup Philadelphia, pyrometer equipment. The castings, after having passed through the annealing furnace, are dumped into barrels tumbling and sand blasting operations Sand blast equipment consists direct pressure units made the Mott Sand Blast Mfg. Co., Chicago. After the cleaned they are thoroughly inspected castings been for cracks and other defects and then given hydraulic pressure test which they are again inspected. After = HIS electric furnace, which the iron out the 9-hr. working day (above). OLTEN pig iron conveyed from the = — Wis. The ladle filled the furnace ft. one the other the pour- ing zones the continuous conveyors. The metal poured into several the molds and while others are moving into place the ladle returned the furnace, refilled and back pouring station. The poured mold moves along the conveyor the shakeout, where pulled off the conveyor vibrating screen where the sand shaken from the castings through screen plate. The castings are taken from the screen and placed trucks for removal gates and risers and rough cleaning. Annealing Done Electric Furnace Castings are then moved across the aisle and stored barrels preparatory being annealed machining and grinding operations they are again given hydraulic test and then Parkerized and finally given coat black lacquer. interesting note that, with this sand and mold handling equipment, ten men the work formerly performed men. They produce 800 complete molds 9-hr. day, producing 3200 cast- each. The Iron Age, April 16, 1931—1263 q q | 4 = - . re: > \ 4 1264—The Iron Age, April 16, 1931 WHAT BUYERS SHOULD KNOW ABOUT SHEET STEEL HAROLD ECAUSE the many uses which sheet steel now being put and the various finishes which being produced, the buyer should most circumstances explain the steel mill the purpose for which the material required. Whether the sheets are for specific operation for multiplicity operations many differ- ent parts, the more information that given the sheet mill the greater will the customer’s satisfaction quality and cost. might happen, for example, that the mill would able suggest quality sheet that would answer the purchaser’s requirements lower cost than the grade sheet originally con- sidered. some instances when buyer orders /sheets without fully acquainting the mill the purpose for which the material used, found that another grade would have better met the requirements. Specific information each grade sheet steel might many instances misleading, but for purposes general information, particularly view the technical and mechanical develop- ments the past few years, the author has en- deavored treat the various methods sheet production and the general results the finished products. =) (cel SCHROEDER this day and age countless articles are made and used which employ sheet steel either wholly part their construction. Many indeed are the factors which must met suitable types steel, and, likewise, varied finishes require appro- priate surface the sheet steel itself order permit ever more attractive appearance the fin- ished product. Years ago, when sheets were produced only stock sizes and gages the steel mills and carried jobbers’ warehouses throughout the country, black and galvanized sheet iro