The Iron Age 1931-04-30: Vol 127 Iss 18

= Macon, Editor I. Bditor Emeritus L. LacHmr, Managing Editor ). BE. News Editor E. F. Cons 8. G. Koon MILLER G. 8S. HERRICK F. L. PReNtTIss Cleveland R. A. Fiske Chicago T. H. GeRrKEN Pittaburgh BURNHAM FINNEY Detroit L. W. Morrett Washington GERARD FRAZAR Boston R. G. Cincinnati ON AGE PUBLISHING Co 239 West 39th Street, New York, N. Y. Address: ‘‘Ironage, N. Y."’ Frank, President H. Grirritus, Secretary Baur, General Advertising Manager Division of TeD BUSINESS PUBLISHERS, INC New York, N. Y. Diatrict Offices: sco, Otis Building rSBURGH, 1319 Park Building YELAND, 1362 Hanna Building ADELPHIA, 1402 Widener Bidg 7338 Woodward Avenue (INGTON, 536 Investment Bldg NNATI, 402 Traction Building ALO, 616 Ellicott Square N, Room 230, 80 Federal St. FraNcISCO, 381 Bush Street 1 1045 Sansome St. Copyright, 1931, by IN AGE PUBLISHING CO er, Audit Bureau of Circulations er, Associated Business Papers shed every Thursday Sub ion Price: United States and sions, Mexico, Cuba, $6.00: ida, $8.50; foreign, $12.00 a Single Copy 25 Cents April 30, 1931 Old Industry Keeps Pace 1415 Large Cores Displace Foundry Flasks 1416 When Use Scrap Foundry 1422 Developments deLavaud Process 1426 Curing Defects Sand Control 1432 Steel Railroad Ties 1438 Repair Uses Resistance Welding 1440 Uniform Hot-Blast Temperatures 1444 Dr. Haney’s Page 1473 w New Equipment 1449 News 1463 Personals and Obituaries 1471 Editorials 1474 Markets 1477 Construction and Equipment Buying 1498 wv Ww USEFUL IDEAS ARE PREMIUM can recall time when the demands made the industrial executive have been more exacting than present. Not only methods but men, well, are being severely tested. these lean times requires con- siderably more ability than the palmy days the Coolidge era. Complacence has hit new low. terest improved methods and business condi- tions bumping the top the chart. All which contributes closer reading business papers for ideas that will serve weapons the battle against red ink. The production head railway equipment manufacturing company says: confident that trade has publication that equals The Age keeping its industry in- formed important AGE YEAR | || | i} | 1} | | $s (=| 117213) COS Aw il = if | | i} i] | | | | | | | | il | | | | | THE IRON AGE APRIL 30, Page Good bearings help produce good gears j Good gears are like New Departures one respect. They lot hard work and well that people are becoming more and more uncon- scious their presence machines and cars. Machines built the Cross Gear Engine Company, Detroit, are playing important part the production good gears. Their tooth-rounding machine shown here. The accurate work required this mechanism and the rapidity with which operates explain the use New Departures every vital shaft. The rigidity and accuracy these bearings are especially valuable cutter and gear holding head. And idler pulleys and counter- shaft they bring carefree dependability .... once-a-year lubrication. The New Departure Mfg. Co., Bristol, Conn.; Detroit, Chicago, San Francisco. a ‘ — NEXT WEEK ANDLING scrap and oil the S.K.F. plant will discussed the next issue. In- terest lies number details: Direct profit investment: ower handling costs; loading expense, and the pro- cleanliness ind safety. Molding Sand Can Too Frequently the sand ts strong thar necessary. Don’t make the mistake increasing the strength. should lowered Tempered clay bond not friendly with 1433 Cheats Scrap Pile Twist Drills with Broken Shank Simply turn small neck round piece ot steel, place its sistance welder with the drill body, TAA weld and then Page 1441 Don't Blame Brittleness the Weld Steel that will air-harden becomes brittle after welding because the | steel adjacent to the weld actS as a chill Virtually steels | 4 velded Page 1442 Weld High-Speed Mild Steel Anneal about in. steel nearest the joint heating lead pot Preheat the mild steel eta 49 4 Resistance Welder Handy Repair Tool Ie will saly ige be i S. t i ea s, dies 1 xtures, ea pa See-Sawing Tempera tures Eliminated pr il rurnacs I p é 1al 1ea 1 1444 Use Scrap Properly and Save Money Close sorting 1s the Key to ¢ rap rap | if ra m The 1 r 1 ran rope ip } j rk ( i ste i } 1 symo«¢ ite ip 1424 APRIL 30, 1931 Flasks for Massive Steel Castings Give Way Cores production and assembling now the main problem the roduction of such large castings as tive toundations Page 1416 Lime Transfers Manganese from the Slag Basic O.H. Metal Iron loss the slag reduced nimum by maintaining tne high silica content consistent with stee iality Page 1421 Trebles Life deLavaud Pipe Molds Forging of Kel-chromium is good for it ( pieces of O-1n pip sew molds of chrome-moly bdenum wil produce neariy three ) 1 ece I Molding Sand Moisture Should Evident the Touch iter than sa 1, if ed feel dr nis a ona tent h ira ) ind ves re a rning Poorly Baked Cores Frequent Cause Casting Defects Such cores do not have Which Shall Use Virgin Metal Scrap? T} i Cold-working Salvages Forged Molds. When moid used in making i race 5 pre vi ‘ P 430 = trength or rigidity to remain in plac p between the haplet pports Pag 5 n the rap yard, the enorn is t ore ealer and nsumert Page 142? THE IRON AGE APRIL 30, 1931 Page INGERSOLL-RAND Portable Air Compressors Billings Forgings uphold performance-record years the making Original Ingersoll-Rand units built 1910 are still seen daily operation: conclusive proof correct design and sound component parts. such complete depend ability, Billings contributes half-century craftsmanship and name betokening basic value mechanical equipment. product-acceptance the world THE BILLINGS SPENCER COMPANY, HARTFORD, CONN. New York: Warren St. Stocks) Chicago: 564 Randolph St. Wa OLD INDUSTRY KEEPS PACE casting ferrous and non-ferrous products one the world’s older industries. Tubal Cain was “worker metals” and the probabilities are that bore the scars molten metal. indications are apparent that this age-old industry danger being superseded. despite the remarkable developments forging, welding and stamping, which have rendered valuable service industrial applications, there diminution our need for castings. Progress fast enough this world absorb all good new ideas without handicapping the those old and tried. This past year has borne witness the continued progress the foun- dry industry. has held the pace. Through the aid such professional bodies the American Foundry- men’s Association, the Gray Iron Institute, the Steel Society America, the Institute of Metals and the Malleable Iron Research Institute, the industry has moved forward distinctly even during period severe recession business. Evidence this found the continued refinement the physical qualities gray iron, malleable iron, steel and non-ferrous castings and the improvement alloy iron and steel castings. addition product refinement, there has been similar progres- sion production methods and foundry management. Witness the marked progress heat treating; the extension and improvement mechanical handling; the refinement methods impact and wear testing: the develop- ments foundry apprenticeship and cost-keeping. This issue THE IRON AGE bears witness some phases the steady forward progress the foundry industry. 1415 STABLISHED 1855 127, No. | \ \ \ | & SS TYPICAL tion locomotive bed casting made the company, cores. MASSIVE CASTINGS MADE WITH ADICAL changes the methods produc- ing massive steel castings have developed the last few years. Less than years ago, among the largest steel castings made were stern posts and stems for battleships, with large frames for locomotives common product. Today such castings, which 1910 1920 even 1925 seemed large and difficult make successfully, are dwarfed the massive products cast the modern steel foundry. produce the stern post battleship few years ago, the writer was connected with foundry which made such castings specialty, large and cum- bersome flasks were required, often made sections. Complicated cores were necessary. The drying such molds and cores was problem itself, say noth- ing the handling them. Skill molding was NDERFRAMES for large tank cars are another type casting made the cor- poration. 1416—The Iron Age, April 30, 1931 CORES NEW paramount. Assembling the dried mold, with its cores, required great care and much time. Pouring the final casting was signal event, fraught with keen tension. Usually two three heats were simul- taneously poured into long mold pit. And the suspense was not over for some days, perhaps week, until was certain that the final prod- uct had defects, such shifted cores, cracks scabs. The same was true lesser degree the cast locomotive frames. Molds for these, ft. long, required careful drying, with the annealing and straightening the final product always problem. Large Cores Displacing Heavy Flasks Today, according the latest practice, and expensive flasks are disappearing. fact the locomotive frame gradually vanishing separate Associate Editor, The Age FEL FOU DRY flasks and molds for making massive steel castings has resulted radical modification former steel foundry prac- isting. now part what known founda- tice and the production larger and castings for locomotives—marvels workman- more complicated castings than ever be- integral steel castings and beautiful and im- fore. Leading features new essive appearance. 000 foundry designed make these cast- some the illustrations show, the foundation ings extensive scale are surveyed ft. long some cases—is made the this article. frames, the cylinders, the cross ties pieces, the riving boxes, the bumper body and even the platform the cab. short time ago would have been re- irded wild dream make, one casting, the rts which then were produced separately and after- the production such large castings, and the building ird assembled the finished locomotive. and equipment foundry for such products produce these large castings, steel foundry entirely different problem from what was fev practice has changed markedly. Flasks have years ago. With success assured such method irgely given place massive cores. The production making large pieces, the advantages are many and ind assembling cores now the main problem readily evident—a minimum handling The Age, April 30, 1931—1417 — t — “ie the plant the showing its location General Steel Cast- the ings Corpn. River. 4 less expense the preparation and assemb- The plant erected cost $13,000,000. The first heat ling, and product probably stronger. was poured last year. Just previous this, $13,000,000 Plant Built Swamp work this had been done Commonwealth Steel Co., Granite City, which meet these new conditions, group interests, now the Commonwealth Division the new company engaged the manufacture locomotives and large Details the organization and development Pa., under the name General Steel Castings Corpn. The new plant impressive testimonial The companies back are American Locomotive modern trend steel foundry practice. Only few Co., Baldwin Locomotive Works and American Steel its many features can touched this article Foundries. way introduction, few facts concerning 1418—The Iron Age, April 30, 1931 —— | > Tread = = = = Ls 7 7 — — = +—A — = | 4 == | + lac top cS pes of ya | SSS —~ . l t+ Collector — continuous core oven will dry 800 tons cores per day and claimed the largest ever built. ngineering problems its construction are marked sides. There also direct connection with the Pem nterest. sylvania Railroad and the Reading Co. location, site, which originally was nothing prepare the swamp for the erection buildings swamp the Delaware River, was selected approximately 900,000 eu. yd., about 20,000 adjacent the large plant the Baldwin Locomotive loads, filling material were deposited. Major cor Works, also Eddystone. The original area was struction required about one year, during which 35,000 res ground, the total acreage now being 113 acres cars material were received, 120 cars being unloaded the bulkhead line, with water navigation three per day some months. SHAKE-OUT house which movable and which will take care very large The Iron April 30, 1931—1419 } y 4 & - support all the structures, including sewers, water mains and on, over 24,000 wooden piles were driven, varying length from ft. ft. The total floor area covered the buildings 680,000 sq. ft. about acres. The main foundry building covers about acres with about acres the product machine shop, these two buildings being the principal producing portions the plant. About 26,000 tons structural steel was required. assure maximum lighting, there are 258,000 sy. ft. glass the roofs and 434,000 sq. ft. the side walls and monitors—692,000 sq. ft. put place the side-wall glass, tons putty was consumed. Foundry and Machine Shop Very Large the eight buildings the two largest and most striking are the foundry and the machine shop. These The foundry are connected transfer building. HIS core breaker large cores, sepa rate the dust and rods and return sand mined quality the foundry. 1170 ft. long and 270 ft. wide. 990 ft. long and 192 ft. wide. one end foundry the open-hearth department, equipped with three 50-ton oil-fired, basic open-hearth furnaces the Stevens type which are used the latest means The machine shop atmosphere and combustion control. The capacity the plant about 60,000 tons steel castings an- nually, running 150,000 lb. weight per cast- ing. the whole plant there are overhead cranes Besides the open-hearth furnaces, there one mold drying oven, large continuous core oven and All are fired with fuel oil, requiring about 1000 gal. hour when full opera tion. The feature this equipment the large con tinuous core oven which has capacity 800 tons cores per hr. and full automatic control tem perature and time cores the oven. This the oven which the main spring the plant for drying two annealing furnaces. ¢ 4 a ae HIS sand blast 1420—The Iron April 1931 f cannot included this survey. the very large cores for the foundation and similar arge castings. Sand Handling System Feature Two extensive sand handling systems have been nstalled. Each one has capacity tons hour. adequate description would require separate ar- ticle. Some the features include movable shake- house; breaker which breaks cores, separates lust, rods and other material, and returns sand pre- quality the system; special measuring ind proportioning equipment over the sand mills; and slingers. Pouring pits are among other features, all which Most the large astings are poured pits the main floor the foundry. these the cores are assembled from the oven. The numerous pits vary size, being ft. ft., some ft. square, with the depth ranging from ft. ft. There are about sq. ft. taken such pits. The machine shop equipped with some very large nachine tools for finish machining the locomotive bed, bottom and similar large castings. The equipment ncludes planer-type milling machines, planer combina- tion planers and slotters, drilling machines, hydraulic presses, double cylinder and valve chamber boring ma- hines. The tables all machines planer type are standard design, that all fixtures and set-ups are interchangeable. There also smaller equipment for the miscellaneous castings produced. All the Composition Basic regularities the composition basic open-hearth slags were ascertained Schlei- her (Stahl Eisen, Dec. 18, 1930) the analyses varied heats. While the MnO content these ranged from per cent, the average sum MnO CaO was 61.4 per cent, with maximum variation from the mean 1.87 per cent. finding agrees with results other work which mean heats gave the value 61.53 per cent while the MnO varied from per cent, and the average sum from six electric heats with MnO from per cent was 61.58. High acidity slags LOCOMOTIVE bed casting one the planers for machining. planer-type machines have bed 135 ft. long suitable for taking care the large locomotive foundation castings. One these position for machining reproduced above. Large Acetylene Plant Provided Another feature the oxy-acetylene plant. Both the oxygen and acetylene are manufactured ture outside the main buildings and then piped throughout the plant. The gas used for cutting heads and risers and for welding. The length the piping required for supplying the gases all parts the plant 36,000 ft. Provision for sand blasting has also been made One large unit has been installed, ft. ft., which complete locomotive bed may cleaned one time, arranged that eight sand blast men can erate Open-Hearth Slags contents between and 2.5 per cent, the sum SiO, P.O, ranged from per cent tively. The above figures apply low-carbon hea high-carbon heats, MnO CaO MgO was found about 65.5 per cent, and the iron content for given acidity was lower than the low-carbon mel The results show that ing slag causes transfer manganese the metal, and that iron loss the slag reduced minimun maintaining the highest silica content consistent with steel quality. The Iron Age, April 30, 1931—1421 | WHEN USE SCRAP THE FOUNDRY proper use scrap will materially contribute the profits nearly every brand industry.” This quotation (the italics being ours), from recent Government publication, states fact which being more and more clearly recognized. However, the use scrap has received great and deserved increase during recent years and, con- sidering this, well keep mind the con- verse the above quotation: use scrap will materially con- nearly every brand industry. One the outstanding lessons the World War was the enormous importance raw materials for to losses Many assortments where pieces all sizes collect. Iron Age, April 30, 1931 national welfare. particular, iron and steel indispensable peaceful developments—doubly time war. have become accustomed think our inexhaustible supplies iron ore, but the present rate the good ore being rapidly pleted, and national safety requires the this all-important material. hardly sary point out, the past, that old harvester outworn automobiles, rusting away the field are blot the landscape—such sight indicate needless waste precious raw material. indeed fortunate that iron practically destructible; only remains that old iron and steel collected and re-made. But first condition & All kinds miscellaneous scrap this pile from saws housings ma- chines. day used scrap.” MPROPER use scrap will materially contribute losses nearly every line industry. About 725,000,000 tons iron and steel use the United States, most which will some day used scrap. Proper sorting the prime consideration the use scrap. Alloy scrap should segregated the producer; the dealer help- less effect separation. Steel scrap now used improve the quality gray iron. malleable practice, metallurgical control scrap particularly nec- essary for the effect alloys drastic either promoting inhibiting graphitization. The average differential between pig iron and scrap about $4. the past. collection scrap metal that there tons iron and steel scrap having been remelted for price which makes its collection last year. the same time, the stigma sale profitable. This turn the regular associated with the collection and use scrap, has each separate kind scrap, insure been removed. The humble “junk” dealer rapid isonably continuous market. earning honorable place vitally important The magnitude the problem using all scrap cog the conservation national resources. And appreciated when stated that “there the plant metallurgist can improve his the United States about 725 millions and possibly his costs—by the iron and steel—and that most this will without casting suspicion his product, Realization the need for conservation has been the conservation iron and steel has become wing rapidly, the enormous total 50,000,000 important and complex, the conservation and use alligator shear and its food. cuts the scrap into small pieces. The Iron Age, April 30, 1931—1423 7 alloys has become more so. For, metallurgically “Age passing, worthy note that the development alloys constitutes one the greatest steps ever speaking, are just entering the ade the conservation national resources. This acted two ways. Heavy sections relative- weak metals are being replaced lighter sections ronger all rons and steels And metal hich rusted away nothing, are ade indestructible which should another, indefinitely. Collection and Preparation Scrap toundation for the use scrap lies its sorting. This simple where ducers, such railroads, automotive com- xtensive salvaging vards both ipment and personnel for the accurate division materials. The inevitable result that such terial more valuable than mixed scrap. the hand, some producers and dealers, both large ind small, have neither space nor inclination for sorting, with the result that their product essential that both producer and dealer hown more the metallurgical reasons for scrap lassification For instance, the dealer sometimes feels that metallurgist unreasonable, because objec Cast scrap being mixed with malleable scrap. argued, one case, that cast scrap was selling ton more than malleable, that was getting the better end the bargain. did not realize that the high phosphorus the ast scrap would very harmful the malleable The dealer should have working knowledge the more common principles mixtures. has been known criticize the metallurgist un- reasonable theorist, because the latter objects the presence chrome steel scrap bought for malle- able mixtures, while passes gladly the same ma- terial for the gray iron cupolas. would seem that the metallurgical fraternity could, advantage, sell the dealer his ideas word-of-mouth through the dealer’s trade papers organizations. Techni- data and specifications could covered. This closer contact would result better understanding ind fewer rejections, which some cases are ex- tremely costly. The present method sending Alloy Scrap Problem economic disposal alloy scrap getting major interest producer, dealer and con- being used ever-increasing cast iron well steel. And where 1424—The Age, April 1931 nickel and chromium were formerly the only comm: alloys, now find also molybdenum, manganese, copper, tungsten, cobalt and others. Owing the complexity the problem, has grown feeling that alloys scrap constit real liability the dealer. This will not case scrap can properly classified content. Then alloys will far from many cases they will the most valuable the scrap. Many consumers would use far alloy scrap, they could sure its classificati and would willing pay premium, they either not buy the material all reduced price. very timely sugyestion was recently made fore convention, that all alloy scrap the producer for, when once mixed, dealer helpless effect separation. The tice strict separation alloy scrap and its according its analysis would immense val all concerned. The widespread use the numbers, dicating composition for alloys and carbon, possible method for scrap segregation. now customary for many iron and steel product whether cast, rolled, forged, labeled the manufacturer’s trademark woul equally simple for such iron and steel products marked with some numerical symbol, that the E., indicating type and approximate composition. Such system would advantage the producer scrap, would obtain full value fo: whatever alloy scrap might have for sure just what alloys was buying and, mixed material, could sort accurately and tain far better price for the sorted alloy scrap could for the mixed product. would great value the metallurgist using tage the increasing volume complex particularly the case metals requiring control composition. Scrap Used Improve Quality Gray Iron Years ago foundrymen learned that the steel scrap their mixtures gave gray iron creased strength. Since that time this use has been elaborated that present there numbers processes for the production high strength irons, depending wholly partly the melting steel scrap the cupola. The iron and semi-steels are examples. newer development, the melting steel the cupola, with additions alloys, has resulted cast irons with strengths well over 60,000 per sq. in. The often-expressed fear that 4 17 not desirable. mixtures. +a)] l int . } ‘ metallurgical information the dealer, via the pur- chasing department, wasteful time and often il 4 dental amounts alloys scrap would gray iron not well founded. bility such alloys act cleansers Close Control Necessary extremely inadvisable use any large rtion outside scrap mixtures, technical supervision materials res. Buying specification ie pection scrap received, and frequent This load represents mixed scrap gathered the country. z far cry from this horseless carriage the modern type, which are t essent ial. some the very modern plant spectroscope and spark tests are used. for the equally for the dealer. scrap con close control desirable mer, Any improve ‘nts the technical control scrap sorting dealers’ yards will welcomed the consumers. new method scrapping automobiles, vhich all materials are used fullest advantage, excellent example efficient scrap control. means malleable work metallurgical control par ‘ularly necessary for the effect alloys drastic, ther promoting inhibiting graphitization. tools Alloys are becoming most interesting ai produce the Chis W two Vavs also rious alloys the st oO xture ‘ economit View re; Cost met l! nabied ft } Strengtn tert is me ‘ can use grea + iseaq ilns enable hin neape her is } Differentials national sources. After all, the whole matter using supplies comes down »a question ot service to the public, which means maximum performance minimum cost. subjec 0 pl ¢ and sect ip And is the k na a ( The old price could he made often rusted as lifferentials between new meta rap. mis metnod as 1 iit until t! that apparent saving substitution for pig iron. result was the purchase Was There tendency swing too far used material high proportior metal that its use attended financial order that the great tonnage scrap iron steel may used profi all concerned, must delicate balance between the price “primary” and metal, and balance scrap metals times the old story “Killing the Goose that Laid the Golden Eggs.” typical case erve illustration. certain kind scrap was tically drug the market method was worked out for the economic use this hich selling differential under pig iron. pite market along other the price this scrap rose equivalent over the price pig iron. made its use uneconom 7 he Tron price dropped to d on page 1431) April 30, 1931—1425 strength- ners. unless there = & & 4 7 ical, was discontinued and the LATE ) \ J EVELOPMENTS THE deLAVAUD PROCESS CLARK Research Engineer United States Pipe Foundry Burlington, making deLavaud pipe, molten iron, taken direct from the cupola, introduced into cylindrical metal mold which slightly inclined the hori- ntal. The mold enveloped hot vater and rotated comparatively high velocity. iron fed into the mold through trough having irved spout its lower end. The trough turn supplied with iron small ladle sufficient ca- pacity make one pipe. This ladle designed that, when moved about its point pivot, constant, delivery iron the trough maintained. When the mold position ready for casting, ugh extends down the barrel for nearly its full The bell end the pipe first cast and the then moved uniformly down the bed away from the spout The stream iron, discharging surface the mold, where held place centrifugal forms homogeneous pipe. After the pipe extracted from the mold. oper- ation facilitated the expansion the mold the shrinkage the pipe, taken, while still the annealing furnace. perature Here annealed ter approximating 1700 deg. treatment serves eliminate the slight surface transformation the carbon from combined graphitic form and insures the complete removal casting strains. Early History The application centrifugal force produciny cast iron pipe not new, dating back 1850 fore. The majority these early attempts embodied the use sand-lined mold, although there evidence the trial steel cast iron molds, some cases, split two halves form cope and drag section None these earlier experiments proved commercially successful. 1914 Dimitri Sensaud deLavaud, Brazilian and graduate L’Ecole Nationale des Ponts modern deLavaud machine for casting 18-ft. lengths. 1426—The Iron Age, April 30, 1931 = 4 ATE developments the production centrifu- gal cast iron pipe the de- Lavaud process are given this article based paper delivered before the Ameri- can Society Mechanical Engineers Birmingham. Alloy steel molds which have served their purpose are now being reclaimed special cold-working process. Their life after recovery has been found equal some- times higher than the original. Today 24-in. diameter pipe being successfully diameter and ft. long soon made. From the time the hot metal leaves the cupola until the finished pipe ready for shipment only three hours elapses. started experiments Santos, State Sao Paulo, Brazil, using permanent cast iron mold many discouraging results machine was eloped. this machine the mold was water led and the iron was first led into refractory lined trough which, when filled with the proper amount iron, was dumped sideways through 180 deg The first machine this type was completed December, 1915, and was reported successful. this machine was claimed that pipes in. diameter, and ft. long could produced hourly. 1916 deLavaud came the United States with view introducing his process here, and, rder demonstrate his ideas, built Buffalo small exhibition machine. THE IRON AGE, its Sept. issue that year, published article describ- ing deLavaud’s experiments and claims. Gordon Perry, president the National Iron Corpn., Toronto, Canada, seeing this article, took option the Canadian rights and soon thereafter built machine Toronto. The early experiments Toronto were most dis- Continued trouble was experienced en- deavoring make pipe with the side dumping trough, and further difficulties were encountered due the binding the revolving mold its bearings. More than two years were spent Toronto ironing out these troubles before the process was thought ready placed commercial operation. During this period the major developments the machine itself were made. The trough was replaced water-cooled runner and, moving the mold relation the trough, the iron was deposited pro- MICARTA INTERMEDIATE GEA MOTOR BED PLATE Details gear drive for the alloy steel mold. was completely immersed water, and the present method mold support and water seal was adopted. These changes and others resulted the development patented machine which the fundamental prin ciples design and operation are the same most installat The Stant Iron Nottinghar the next adopt this process. commenced production the early part 1921 and the four-machine unit full operati 1921 the United States Pipe Foundry Co., rights for the United States building small unit Burlington, J., during the latter part that year, started September, 1922, four-machine installation Birmingham. Soon thereafter the National Cast Iron Pipe Co. Birmingham, operating under sub-license, laid down installation four machines Growth the Process Until the latter part 1922, deLavaud pipe had been produced relatively small commercial scale Previous this time, the process was state rapid change. The casting machine originally brought the United States deLavaud 1916 had been modified scarcely recognizable. 1922, however, the experimental stage was end and the infant process entered new era, that mass production. The capacity the machines ually enlarged and the rate cast trebled. 1921 machine, casting 6-in. pipes ft. + long per hour was considered operating sati The Iron Age, April 30, 1931—1427 7 -_ -_ — FORGED STEEL PINION » | A 4 J / ~ wr \ ] PACKING HIGH PRESSURE INLET MOLD MANOREL \ y / 4 = CONTAINER 1926 the same 6-in. machine was ne LOW pipe per 10-hr. day, a tonnaye equivalent £0 nin ny a pacit 14-in. 1) I nd 1928 new battery f machine ne same } int I ike mete ths 1] e In opel ! Burl Within the next vear a new { I ted \ J B ("| & son ating undel ci sub-license, al oshocton, Ohi tonnage deLavaud pipe produced annually me and abroad has increased at a rate exceeding xpectations This rapid growth has been made mat mprovements the design build machines, annealing furnaces, and other rrangement buildings and equipment pro- ides all cases for perfect “straight-line” operation. the time charge pig iron picked ‘ MODERN furnace for deLa- vaud pipe. 1428—The Iron Age, April 30, 1931 ETAILS method the Langenberg reclaiming alloy ~ steel molds for deLavaud machines the cupola iron yard the time the finished pipe loaded for shipment, period less than far the longest operation the elapses. the manufacturing time could radically reduced The Casting Machines the first commercial type deLavaud machin lower extremity. Aside relatively high cost hydraulic power, this type After various types rope, belt, and chain drives, direct the mold was rotated drive was deficient speed gear drive was adopted. The motor pinion and driver are made forged steel, whereas the intermedi ate gear These gears operate pitch-line speeds high 3500 ft. despite the fact that vapor and steam, the per min. are continually surrounded average life high. planer type, direct-current, variable-speed motor with special ball-bearing mounting, coupled tive drive, provides excellent speed control. the earlier machines the iron ladle, which sup- plied iron the trough, was tilted means 4 A Ww Side elevation car hearth partially withdrawn from annealing furnace hydraulic cylinder. The speed tipping was therefore being made with steel containing variou ilve controlling the input this cylinder. This Failure the mold int pening was small that frequently became clogged the breaking down the bore. Fire checl ind vith grit, rust, and several instances even small cracks eventually develop sufficient depth impede fish, which had apparently come through proper withdrawal the pipe. vater-intake screen, were found lodged the valve eat. Wearing the cylinder and piston rings and after they have been used destruction their mall variations water pressure also contributed inal bores, has been developed Dr. Langen speed control. The substitution small, com- berg, director research, United States Pipe Four motor drive for this hydraulic cylinder eliminated ill these difficulties and insured proper speed con was developed Dr. Langenberg the main hydraulic cylinder that centrifugallv-cast steel alves, the speed variation this cylinder small hardness and embled nandrel, far type drive has been developed which pos- subsequent reduction diameter the mold sufl esses sufficient power and ruggedness meet cient eliminate the internal scores and checks. The mold and mandrel are next inserted very heavy Other unusual features design are the mold- ipporting rollers made tool steel, mounted oller bearings and running completely submerged vater, and the piston-ring method water seal which embodied these rollers, and also the end- lange assembly the water box. Molds Are Hollow Chrome-Molybdenum Forgings The molds are made from hollow steel forgings hich are carefully heat treated and machined ery close tolerances. The earlier molds were made rom nickel-chromium composition. After exhaustive xperiments was discovered that much improved could obtained with chrome-molybdenum teel. 1923, for example, the life 6-in. mold nerally averaged about 1000 pieces, while molds recent manufacture the average life has been trebled. believed that still further improvement Annual sales pipe all countries, made the life and continued experiments are excluding Canada. The Iron Age, April 1931—1429 j — Photomicrographs showing typical structures 100. Middle the wall pit-cast pipe middle the wall deLavaud centrifugal pipe (right ? + } ret end + + ++ anc ) no with he rt a al il DaACK i It i velTail ana Wil aii i + + } tun » +) + } ; + } ty ne ? aa VUL- Wil iS ill ALILCU All Wilt } + T } + } } t WI! » ana are arivel it a WO! il il t , + + 4} » } ne cel in¢ irna l ie! = let 4 +} +} t ire aqava ed m S¢ rou al ! 1 wid Varla a rt ihe) Se) hic ton nNojete ¢ & S a 1 al? Val\ a | i POY I aha macn [urna fla LW pata 4 i al iT! Ss eacn s1a ne ent?lra end Ol ia I r than rigina lit Iurnace are operated DV One set ntrol Valve + ] T + . VY all a sim 4 i ier. at nr Irnace > nmer Furnace Deve opments ™ +} nonrt f +h, ‘ are ea i ve 6- nod air alw + rding hy $+ nor } } rest n tw sets t hneat-resistant v Wheels. the tamnaratir Th Snmatallatinn af ¢+hi »+ 4 wtae + 4 + ‘ ) + ) ] } } ins t nin nr + siminated = pipe Was practically ellminated. pe I Turbace, VaSUV Supe! I ] y + + ‘ ae 4 <a ‘ larg] ix D tT T? tT < ré Two iines lal Ul pi} LIN? no ) ‘ 4 » he + 4 +} 5 ’ niy, tnere 1s some enaency n tne o-ln. a t ind o XCeSSI1V Sts {jy +) + how + the T R til + f +} rhayr no na F rthey WN T f — <4 1344] +} hen nnerating at maximum rated Wad Lilis » wus il =a VW sci vice Lilt LAULIUALC, al in ] rar Superseaqead DV ml } nftinwous 1430—The Iron Age, April 30, 1931 q 7 7 _ r red alo’ s hearing s aring l inger oO Dow Yr Aiud T re = spots opera als cu TY) TY) } i t e! ra ¢ ean ‘ ont +} he Nerat tammy } + +} Nrevi nr ii id i Ul A il iu i | i, NaS deen NILNI\ ry iW y | ry ++ y GOSikT, WI 1h Are iv il ver —2 l ra ea®riyv } i +) tinge Ww + + y + y 4 ‘ 7 i IN i n rT d + ne orat thar es il i> é I 18 ives ea + +h, ‘ ‘ i i ic I y the Standards Yearbook, 1931 } +} + } + +} nrir fey y tandaara neo rene +} rOV I a A at = terd +h +} a? a r aeai i i a a I + y no + ny +} fF +} } 4 UL 4 y na +, + tar y et, ay + er } ne y y Stas + +} rr ; y r tan ‘ rer the exter y — tine + +h, + +) +) lor r+ ernr "+ at me +} aust a . The Age, April 30, 1931—1431 q +i nn I rh 109 T furnace ft. long and wide enough accommo- late all Or-ll. pipe. lla a illd Uili Lal A iit apacCilty O «#79 LtlONS Dl il if) Gialh ~ £ a0 + A in 19 in trom 4 1n. to lz 1n. ne are 1 +¢hy +} upward incilne mea! iraliel 1S al norial deaic en} 2} y nar riace \ n minim1zZ no try ; +} ny I I n. la i and noe finoere | +} ¢ the ni +hon 6 the + } inte + na ee linea lal economic difierent ? 1}<- + + + - + S varies greatiy, Wing SUPDPIV al qemana il many ia rs. Willi aliWwa stricets A tahle whieh mich? e e for i al A lap a i al is il nd entere u ind ta rigures aKken I m an ensive survey n and Scray sts, Snow tnat tn averay I T T sc } } ++ rio y } 4 il etween plg ana Scrap 18 a De, CA iG ‘ t + + iat ind where 1LS1Q¢ n all 4 iting scrap mixtures, typical table hich j an attemn? + lacar i-K 1h iS all ALLE a nt! i | y y 1 gnalitv wnaiderations 7 JUAaLILY ine abie represé! ij ne Kind ] 1 tne ngures are, I course, arvoicrary al ‘ y conaltions, etc., and art subject Ireque! we 18S Simply a gulae toward the iowes ’ na +h e with ¢ho four nai the par ind plg iron, togetner witn the figure 1naica liynest proportion USadDie, WILNOUL U 4ilics. ~ In qimerent rtounaries tne! al I yolu Minimum Economic Differential Between Pig Ir and at AY , resear I the burs A — te much me mntrol ot sand i ntrol metal, realizing that more r-hour involved sand than any the foundry For example, take with daily production 100 tons. About seven men labor-hours are required delive ten metal the floor. the other hand, r-hours the molding floor, HARRY luding the core other 99 +3 imes that knowledge of work- noun 1235 hr., 154 men. labor cost sand working S rule € po ed out the metal determines the nes suitability the molten metal entering the sand mold produce the casting: the prob ina good, casting molten metal reaches the nowledge working the sand determi bility that the molten metal will result ible casting. The climax producing ttained the time the irface the mold, not only the ibilitv and medium sand the correct field low consisting itv the adding to amount sand control. Where the sand controlled consistent, high perme- strength, the moisture Fig. casting defect caused excessive moisture the Fig. 2—Casting defect caused low green permeability (right sand above 1432—The Iron Age, April 30, 1931 DIETERT content should sufficient make the presence moisture evident the touch the hand. Thi should 0.5 per cent more water than sand, tem pered feel dry. This practice desirable, allows lower bond content, hard rammed molds and gives sand plasticity and resistance cutting and burning on. Ample moisture content cannot achieved strong bonded sands. Fig. shows appearance casting caused wet sand. Not the surface blow section and the sharp edges around the contour the blow. There are two pieces apparatus for testing the moisture sand: One sand rammer with moisture indicator attached the rammer de- termine the moisture production sand system, and the other the Grubb moisture tester, which electrically dries the sand and computes its weight betore and after the drying process. Permeability, venting mold, must pres- ent both the green sand and dry sand portions the mold. Green sand must vent gases metal, combustible material, the air the mold and water vapor, which far the largest volume. Fig. example defect caused insufficient green permeability. The defect does not appear the core side. The metal thickness the casting in. Proper permeability for the jolted mold 120 instead 60. many cases defects this nature may eliminated increasing the ferro- static pressure the mold. q Sand Tempering Promising Field for Control ind mixing the q IMPORTANT CONTROL METAL THE FOUNDRY Fig. shows stove plate casting with “rat tail” due low green permeability, which was was remedied using sand with permeability aused low permeability the green sand core between the ribs. This condition can eliminated augmenting the permeability reducing the trength the green sand. defect developed the failure venting baked portion mold illustrated Fig. shows cold shut section surrounded normal ron. The probable cause this condition dry permeability. ner smooth portion where the iron also failed the lower right hand cor lie against the core. Uniformity core mixing reliable remedy. Fig. core blow caused insufficient enting. The dry permeability the core not rreat enough take care all the gases. The cor must freely vented with vents which will not take iron. This blow with the smooth round hole the blows created iron getting into vents the core. Fig. reveals defect which much study has been given. The blow does penetrate the thin wall the casting; the iron aid perfectly the green sand. Losses ture have been traced oxidized iron and there fore eliminated. Loss Due Strength Sand The strength molding sand often causes iss. Too frequently the sand stronger than 4 3 ERE are given some examples de- fects castings caused improper molding sand and core practice. The au- thor, who has perfected many types ap- paratus for testing sand, offers remedies. The article based address recently delivered before the Detroit Foundrymen’s Association. essary One may feel that the thing increase the strength, whereas should lowered Tempered clay bond molding sand not with which the clay (with practically zero iron, due the large amount holds within itself and its excessively high the mold has peel urface off has been kicked off gas pre sure, appears Figs. and 10. The casting wall in. thick and the jolt rammed shear strength 1.1 not 1.7 lb. The remedy applied this case the addition silica sand reduce the rreen strength, the reduction clay bond, the addition new sand. early 1356 A.D. foundrymen were troubled with high strength and low permeability complex, 1 “ — Fig. 3—A defect stove plate casting caused low green permeability (at left). Fig. blow fin casting caused low perme ability the green sand core between the fins The Iron Age, April 30, 1931—1433 | Fig. 5—Core side casting showing failure iron lie > firmly the dry sand core, due low dry permeability _ y = Fig. 6—A blow caused iron getting into the vent the core. 4 ” 7—A blow that does not penetrate the casting. Metal has lain firmly the green sand surface. Defect caused oxidized metal and not sand. “4 4 Fig. 8—A scab green sand side casting caused exces- sive green sand strength. 1434—The Iron Age, April 30, 1931 present-day foundries, but its end approaching with the acceptance sand control and the result ing increase knowledge sand. weak sand, whether caused brittleness from Fig. scab surface showing “rat tail” running -hori- zontal. This clearly demonstrates low permeability due the use too much new sand and poor mixing—a combination loss low permeability and high green strength. 4 4 a Fig. cross-section Fig. showing the sectional appear ance scab. Note the cavity caused sand dropping into molten metal and how the molten metal took the place the sand beyond the surface the mold. Fig. 11—A Spanish bell 1356, with seams caused mold cracks. The sand contained excessive clay bond. _ 5 x ir 3 ri rit 4 a sufficient moisture lack clay bond, limits strength figure narrow path between low and high strength values. Low moisture results low, dry the nature sand strength, which sometimes caused the bond. The appearance Fig. 12—A casting surface defect caused strength. low dry sand Fig. 13—Drop caused sand not being capable taking the crush the core print. Remedy—increase the asticity the sand. Fig. 14—Gas explosions mold loosen sand surface the mold which dropped into the drag the mold causing surface casting pitted. Fig. dry sand core side casting showing gas seam defect caused having the core sand too coarse, allow ing gas escape too suddenly into the mold cavity ax 2 the ~ Fig. green sand side the casting shown Fig. Molten metal has eroded the green sand surface the mold, due agitation caused the dry sand core Fig. 17—A combination core rising between chaplet supports and core washing, caused weak core due frozen sand lumps and poor mixing Fig. 18—Green sand side casting showing depressions cast ing surface, due core sand washed from the dry sand core which was improperly baked Fig. 19—The effect hard ramming and excessive moisture sand which had low permeability. Note needles blow sec- tion showing wet sand and the surface where metal could not lie firmly the sand surface. The Iron Age, April 30, 1931—1435 | #2, 5 eer 4 defective casting brought about low, dry sand strength illustrated Fig. 12. drop defect, easily distinguishable, shown Fig. The sand was not plastic enough take crush the core print. Fig. illustrates the effect the explosion collection gases the olten metal metal entered the mold. The shock loosened = Fig. defect showing molding sand inclusions dark cen ters definite shape around which metal flows. Defect caused soft ramming around bottom sprue and space between flask and sprue. The sand broke away from the sprue and was washed the swift current iron from the sprue and gate. When the current metal was reduced, the sand was deposited the mold. Note that the gate not washed articles of sand. The damage would have been less the sand been little more plastic, measured the deformation the sand, property closely related this point interesting note that the ength sand being measured equipment the market. One universal sand strength machine used test the green and strengths molding sand and cores. Another called the bond meter, which measures the properties clays and bentonites. Fineness sand plays influential part permeability the green sand dry sand portion mold. the case green sand, the clay con tent acts conjunction with the fineness deter mine permeability. silica core sand, however, fineness the controlling factor. Fig. shows core side gas seam and Fig. the green mold side thin casting. Defects this nature remedied using finer core sand. Open sand vents too freely into the mold space when the not baked properly. For castings with metal thickness, the gas content the core should g-in not greater than cc. per gram core burned Strength Baked Cores The strength test baked cores offers means deciding the causes core breakage, washing cores, ease shaking out and core raises. Fig. illustration core raise due weak core which turn resulted from poor mixing frozen sand. Casting defects caused poorly baked cores are high. Such cores not have sufficient strength rigidity remain place between the chaplet supports. core wash, traced poorly baked core, seen Fig. 18. The holes the face this casting are due core sand. The hardness ramming molds demands daily attention order maintain desirable standard. Fig. reveals defect caused combination hard ramming and excessive moisture sand which possessed low permeability for this partic- ular casting. The other extreme evident Fig. 20. Here the mold was rammed soft back the sprue and the side the flask, causing bottom end the sprue break and wash into the mold near the gate. Fatigue Stresses Rolling Mill Rolls PAPER Prof. Frederic Bacon the Univer- sity College Swansea, read last November before the South Wales Institute Engineers, and reprinted pamphlet 112 pages with number illustrations, deals with the breakage rolls, based particularly upon fatigue stresses. followed paper read Caswell, which the stress and strain which sheet mill and tin mill rolls are sub- jected received extended attention. Professor Bacon’s paper concludes that havior rolls inextricably interwoven with the term employed the strength ma- terials. believes that, when freshly fractured faces broken roll show hair-crack markings, the fracture one fatigue. The factor safety against fatigue, brought about loading stresses 1436—The Iron Age, April 30, 1931 only, small when one considers the numerous ad- verse contingencies involved. Most roll fractures showing hair-crack markings are believed have had the hair-cracks initiated from causes other than, additional to, the repeated normal working stresses. new roll outer surface the chill called upon carry the stress and about 18,000 lb. the square inch suggested the provisional estimate for fatigue limits. Available experimental evidence suggests that the temperature which the rolls work not high enough impair seriously the tensile and fatigue strength the roll core. Nothing definite appears known, however, about the mechanical properties the chill and