The Iron Age 1931-06-11: Vol 127 Iss 24

W. W. Macon, Aditor A. I. Frnpiey, Editor Emeritus L. Managing Rditor B. Wricut, News Edttor E F. Oone 8. G. Koon B. MILLER G. S. Hmrriok F. L. Cleveland R. A. Ohioago T. H. Pittaburgh BURNHAM FINNEY Detroit L. W. Morrerr Washington GwRARD FRAZAR Boston R. G. MoIntTosH Otnoinnati IRON AGE PUBLISHING Co. 289 West 39th Street, New York, N. Y. Cable Address: ‘‘Ironage, N. Y."’ F. J. President G. H. GrirrirHs, Secretary ©. §S. Baur, General Advertising Manager Division of Business PUBLISHERS, Ino New York, N. Y. District Offices: Otis Building PITTSBURGH, 1819 Park Building OLBYBLAND, 1862 Hanna Building PHILADELPHIA, 1402 Widener Bldg Derroit, 7838 Woodward Avenue WASHINGTON, 536 Investment Bldg OINOINNATI, 402 Traction Building BUFFALO: 847 Ellicott Square Boston, Room 280, 80 Federal St San FrRaANorsco, 381 Bush Street and 1045 Sansome 8t. Copyright, 1931, by IRON AGE PUBLISHING Oo, Member, Audit Bureau of Circulations Member, Associated Business Papers Published every Thursday. Sub- scription Price: United States and Possessions, Mexico, Cuba, $6.00; Canada, $8.50; foreign, $12.00 a year. Single Copy 25 Oents. June 1931 Financing the Recovery 1883 Let’s Back Arithmetic 1884 Large Ingots for Forging 1888 Industrial Cleaning 1892 Zirconium Alloys Steel 1895 Pulverized Coal Foundry 1896 Furnace Control Steel Making 1902 Piercing Bars for Seamless Tubes 1905 Working Rustless Steels 1908 May Steel Ingot Production 1925 New Equipment 1913 News 1923 Personals and Obituaries 1928 Editorials 1932 Markets 1935 Construction and Equipment Buying 1956 THE SUN SHINING” “Too busy see today. Come back two weeks,” says the plant running night and day.” New England lawn mower plant. Rain has been plen- tiful this spring. Grass has grown rapidly. The metal-working field diversified that profits practically any kind activity, even that the elements. Just run your eye over this list few the products made new subscribers who started taking The Age May: Permanent Hair Wave Popcorn Machinery Machines Rifle Cartridges Dry Cleaning Machines Bus Bodies Advertising Novelties Airplane Propellers Cotton Gins Saddle Hardware Funeral Cars Rubber Tires Bedsteads Greenhouse Equipment Inkwells industry that favorably affected wave even ripple prosperity such contrasting fields beauty cul- ture and undertaking, aviation and equitation, not men- tion motor bus and dry cleaning, you cannot expect find any time state uniform, deadly dullness, matter how black the business sky. —A. AGE | | | j BAEEEER | | | | 7 } | | 7 | 1} | | | 2 i | : | | 1] | | | THE IRON AGE.... JUNE 11, Page New Departure-equipped Westinghouse motor driving wire straightening machine equipped with New Departure Ball Bearings are doing more and more industry’s work. And for good reasons, too. They are economical keep up. Need lubrication but once year. Are cleaner, both inside and out, because they lend themselves better sealing. And bearing effectively resists and its consequences. Specify New Departures all your electrical machinery. one sure way save money. The New Departure Mfg. Company, Bristol, Connecticut; Detroit, Chicago, San Francisco, London, Eng. Why their tribe the increase | 7 A j 1746 NEXT WEEK APPLIED science ized industry and our modes living. And the end not yet. Technical achieve- ments the future will even more far-reaching effects than those the past. Technical research creating new and im- proved products and shifting the currents competition. Tech- nical knowledge, and not dollars, constitutes the real capital in- dustry. Advances technical research are best insured united effort and such uni- fication activities the iron and steel in- dustry now seems well the way realiza- tion. The views three leading metal- lurgists this impor- tant development will presented our next issue. How Stimulate Business Activity “Reduction cost goods and increase average consumer income are the two logical ways increase consumption,” says John Van Deventer, industrial The Iron Age (page 1885). Commodity price average declined during the years following the Civil War, while the annual output manufactured products increased four times dol- lar volume, eight times actual vol- ume. The prosperity formula that proved successful then will work today So, urges Mr. Van Deventer, instead cutting costs reducing wages and in that way diminishing purchasing power, get costs down by replacing inferior with today’s superior equip- mene. * * Invention, Not Age, Determines Obsolescence delusion and are the old accounting methods which arbi trarily gave production machinery rates depreciation, calculated with- out consideration have enticed many company into paying out dividends what should have been set aside for replacement reserve. Whether not piece equipment should replaced not determined its age, but the avail- 1887. * * How and Why Piercing Mill Pierces The mandrel not forced through the metal. The rolls cause the metal to flow over and about the mandrel. 11 he rouis Even without the mandrel v ould form a centr il cavity, for Ww hen piece steel round form pressed or hammered into oval form, several times succession, rupture occurs the center that extends longitudinally second piercing operation the already which consists essentially hollow billet, larger sizes tubes can made, the quantity metal displaced reduced.— Page 1907. * Fuel-Wasting Soot Removed Vacuum Cleaner coating soot, 1/16 in. thick, over the heating surface boiler, will cause fuel loss about per cent. Vacuum cleaner removes the dust rapidly. One plant saving $45 $50 month “vacuuming” its boilers daily. A central vacuum sys- tem permits quick, economical clean- ing floors and equipment, helps keep dust out of product and m achin- ery.—Page 1892 JUNE 11, 1931 One Pound Coal Melts 4.05 Lb. hen maltlieabie foundry usea a hand-fired furnace charge 70,000 lb., started 10:30 p.m. could not tapped until 3:30 the following after- noon. Now, with pulverized coal equipment, 90,000-lb. charge started a.m. ready pour 3:30 p.m the same day. Coal, labor and time are saved.—Page 1901. Catch the Carbon the Heat Comes Down? Recarburized heats have lower chip- ping costs, but rejections are not less The recarburized steel gives re- sults the analysis made Dr. the other hand, there are better regularity to be obtained from ths steel In which the carbon is ¢ iught coming down Page 1904 1 results and greater physical Revolving Molds, Poured Off-Cen- ter, Produce Superior Ingots Heavy ingots for hollow forging should be poured toward the outside the mold and not the center, has been normal practice. The sonims, which rise toward the liquid surface, are forced the center and eventually into the sink-head. This prevents them from sticking the mold wall being entrapped liquid steel, ultimately causing defects during forging Rotating the mold promotes the centering the sonims The risk corner cracks minimized Page 1888 Away With Confusing Rustless Steel Terminology! plead for standardized terms. Why call steel “iron?” Holland Nelson fears that weld- ing chrome-nickel alloys the formation chromium carbide, with the chro- mium content per cent the material immediately adjacent the grain boundaries impoverished of chromium, reducing the chromium content below the point necessary maintain chromium resistance. May not the alloy contents be rearranged produce the desired metallurgical conditions? Says Dr. Becket, “Our experimental evidence does not yet permit accep- tance the view that changes down the chromium-nickel ratio overcome intercrystalline corrosion.” Magnetic susceptibility indica- tion that the steels are always subject intergranular attack, says Johnson. Some the most resistant steels are definitely magnetic Page 1908 THE IRON AGE.... Page the Greatest Variety Work the lowest tool cost the No. 4-A Turret Lathe with Compound Cross Slide and Cross Sliding Hexagon Turret This ideal machine for all classes turning work including bevel gear blanks and similar work having steep tapers, and long taper boring jobs. With the Cross Sliding Hexagon Turret the same cutters may used for repeated cuts different diameters and lengths. Swing The compound swivels through 360° and will feed “avelo Turret the cutter power any position. Write wire for further information. Warner Swasey Co. Cleveland, Ohio, | | | 22” Chuck | 3 | | ESTABLISHED 1855 New York, June 11, 1931 FINANCING THE ONEY may said the lifeblood industry and business. Under normal conditions its free circulation through the arteries commerce and the veins industry keeps business healthy condition. Today industry and business are anaemic. not from lack the vital fluid, but from impeded circulation. Our bankers have more savings their care than they know what with. Some way must found restore the circulation funds, give ment these idle dollars and thus renew the vitality our industrial and business body. recovery must financed, either from the top the bottom consumers will not through the resumption buying, our men must through judicious lending. The banker must learn the distinction between capital investments for plant expansion and expenditures for cost reduction. Pending business recovery, all thought economies from volume must dismissed. The present problem industry cut costs the current reduced rates operation. The only effec- tive way doing through introducing better methods and better equipment. Our whole industrial history chronicle steadily declining unit costs manufacture and steadily increasing per capita production and consumption Wage reduction, particularly when means lowering living standards, safe way cutting costs, since nullifies the effect the manufacturing economies achieved. Greater, rather than less, purchasing power per capita essential permit further growth American enterprise. And real gain buying power can come only through adopting more modern methods production. Modernization places heavy responsibility the banker. Without port, run the risk further deflation business profits and workers’ income, with concomitant industrial failures and home foreclosures. there- fore, well industrialists, recommend the thoughtful reading the article which follows. the last analysis, profitable industry and busine form the one sound security back bank deposits « wealth. 9 ~ ~_ j aA 1883 FEW years ago work was being carried Washington for the purpose banishing the fluctuations the business cycle and industry. that time—it eems long ago now—you will recollect that im- pressive group economists, statisticians, labor leaders and business men leisure afford the and demand the hope finding the way secure time was exploring the antics supply a balance. From what has happened since then, quite vident that the question economic stabilization too big settled committee conference, un- business. course there this difference between and the time previously referred to; today everyone thinking about the future, while then most the captains industry were too busy mak- ing products and selling them profitably worry about there probably great deal more thought than there “what’s hand.” time our history have being given many high-powered mental telescopes been trained economic horizon. Bankers, industrialists, business men and thoughtful members the rank and file the statesmen, economists, emploved unemployed are seriously pondering whys and wherefores economic cause ind effect. national and international, The mechanism business and indus- receiving its most ritical from great diversity view- being studied from all sides, well from the top and bottom. Something bound eventuate from this unexampled concentration ble mind result this movement, American finance, dustry and business are unconsciously forming themselves into committee the whole. yet the minds its members “have not met,” nor have definite paths progress been defined and accepted. too soon expect find marked differ ences opinion, for example whether thrift are the more prosperity uilders; whether increasing prices better than lowering costs; whether wages should maintained lowered; whether increased mech- anization aids harmsemployment. Unanimity these things will come natural course more light thrown upon them constant examination and discussion. Already find overwhelming 1884—The Iron June 1931 preponderance belief that industry and business must shoulder the responsibility for adequate em- ployment. How long step forward this will recognized those familiar with the thinking decade two ago. Flood Forecasts The multiplying forecasts and prognostications which have accompanied this intensive and wide- spread probing the future natural by-product. Everyone seems anxious give his opinion what forthcoming and each day adds fresh material the growing pile contradictory predictions. They vary from the promise shortly forthcoming aa if it — THMET period unexampled prosperity the belief that there will years extremely painful plodding your money and take your choice” predictions, for there are all sorts choose from. should before business once more tops its 1929 level. quite evident now that the soothsayer who gazes upon charts for the purpose foretelling the future reliable, and more so, his prototype who peers into the crystal ball. forecaster can sketch for the future Its building will the work too many hands and minds line American business. minds that are even now changing over from fixed beliefs many forecaster can sketch for the Imerican industry and business. Its will the future skyline work too many hands and minds minds that are now discarding fixed beliefs and grasping new concepts. an & JOHN VAN DEVENTER Industrial Consultant—The Age and grasping new concepts and prin > ciples of action. Problem Division the present time are more less inclined grasp straws order keep our heads above water, regardless the fact that they will not bear our weight. Witness the current discussion the advisability raising railroad rates and other prices. Making things more expensive not assurance that people will buy them. fter all, the resolves itself into problem simple division. question supply and demand Average annual income, divided average cost things bought, equals number things that can bought. One cannot sidestep arithmetic. If, then, make things cost more, without first increasing average income, not obvious that less things bought? can the other hand, when reduce the divisor average cost, increase the quotient number units purchasable. other words, diminished cost the consumer the logical step toward turn ing out more goods and employing more people. Reduction cost goods and increase aver age consumer income are the two logical ways increase consumption and hence stimulate busi ness activity. there are any others, they not fall into the category mathematical reasonability During period years following our Civil War, the average commodity declined riod receding prices increased our annual output product times dollar volume, eight times actual volume, paid laid the succes and multiplied the annual industrial almost four. was this performance that foundations for prosperity which could fully stand the later terrific punishment overcapi- talization, inflation, speculation, graft, Government interference and excessive taxation and which failed the ultimate debacle 1929. accomplished? Merely giving heed the formula income divided J net wale miracle progress Consciously unconsciously, our ancestors hat period chose the one effective way ply thi formula build prosperity. They put improved ma- chinery work American industry such not merely compensate for the declining The Iron Age, June 11, 1931—1885 = prices but make increasing profits out them and pay increased wages spite them. For wages—measured power doubled during this period shrinking prices. Thus the prosperity formula was worked two ways, de- creasing the divisor cost and increasing the divi- What else could result except the ensuing multiplication business dend average purchasing power. volume and the diversification industry? Arithmetic Has Not Changed great deal water has gone over the dam ince the termination the long 30-year period price declines and prosperity building, but the laws rithmetic remain unchanged. The formula that Water seeks the low level. Busi- ness flows the low cost level times of depression as well as dur- ing prosperity. Cost reduction the plant more effective than high pressure selling outside it. predecessors used effectively pull them- elves out great depression good today Why are not putting work One reason, perhaps, that industry, business ind life general have been made appear com- plicated constant dissection, classification, psy- choanalyzing, forecasting and the magnification minute details that the whole lost sight the elaboration its parts. are not thinking simply nd le irly nowadays Perhaps that what President Hoover meant recently cautioned American business ery Panaceas there are choose from, they won’t get anywhere. need stick arithmetic. Some one has said that the way get the best depression “outsit” it. The thought that 1886—The Iron June 11, 1931 you nothing for time depression will be- come discouraged and away its own accord. Plenty people are trying outsit this depression. But getting them nowhere. Sitting seldom does. cannot outsit this depression, but can out- wit it. The way this use the same method that put the panic 1873 flight, and built pros- perity the face declining price trend. When prices fall, make costs down even faster. Get the formula busy, through industrial modernization. After all, machinery our one great cost re- would tremendous job cut the cost hand worker’s output per cent, preserving his wage rate and the quality the goods. But give him the proper machine and will produce ten ducer. parts for the former cost one, earn better wage rate and turn out better product. That’s working the prosperity formula two ways once! cuts will not increase industrial business volumes because they reduce the dividend (purchas- ing power) the same measure that they reduce The quotient (volume) remains the same before, unless perhaps the worker re- the divisor (cost). taliates for wage cuts through diminished output strikes, which case less. Nothing gained here. Prices are too low many industries. Low prices are only beneficial the public and non-ruinous the maker the goods when they permit profit margin. This condition profitless pricing par- ticularly apparent today such commodities steel and copper. such industries, where efficiency levels are already high, price adjustment upward seems essential. All the more reason then, for cost reduction other branches industry not well mechanized for production. With such exceptions, however, the increase prices, whether freight rates other forms are not the way out. The formula tells that. one who advocating price increases suggesting that wages raised too. Thus, prices raised, find the divisor increased, the dividend unchanged and the quotient (volume) decreased. Improvement industrial mechanization through the replacement inferior with superior equipment one way reduce the divisor cost, increase maintain the dividend purchasing power and hence increase the quotient volume. It’s not panacea, but time-tested method restoring and building prosperity. Superior Equipment Available? today’s production equipment sufficiently perior cost performance warrant the cost modernization? Decidedly yes, the average plant and the average industry. course, but, and large, American industry could cut its costs one-third replacing its obsolete ma- There are exceptions, chinery with up-to-date equipment. Ideas concerning obsolescence are changing rap- idly and will change still more the years come. are learning that more profitable discard hale and hearty machines than wait for them wear out, provided that sufficiently better ones are } | ir — had. Our conceptions fixed and standardized rates depreciation equipment have been sadly jolted, with the realization that age has little with obsolescence and invention nearly everything with it. The old accounting methods which arbitrarily gave production machinery life from years have turned out delusion and snare. They have enticed many company into paying out dividends what should have been set aside for replacement reserve. insurance act- uary who estimates the probable life his prospect twice what should making more costly dangerous error than the factory accountant who does the same with industrial equipment. Modernization Creates Employment Some executives who are thoroughly convinced that the replacement existing equipment would profitable their companies hesitate take action this time because they think that further mechani- zation might increase unemployment. must look this problem the large way, not the small way, because depressions, like booms, affect all and not few individual con- cerns. Looking the large way, unemployment can only diminished creating condition which will result greater volume business. Unem- ployment will only diminish when people buy more things. But how can they buy more with unaug- mented diminished income unless costs re- duced? The formula tells the story. Unless can raise average income, the only possible way create more volume reduce average cost. That why mech- anization, instead making jobs scarce, makes them plentiful when apply honestly the formula. “But,” some one asks, “Did not American industry Improved machinery the best re- juvenator sick and sleepy dollars. America’s indus- trial equipment, through intelligent replacement, will put our idle dol- lars work and multiply jobs for our idle men. Beware of false de preciation rates mates the probable life his pros pect twice what should en- dangers the security his com pany. does the accountant who sticks precedent writing off depreciation. apply mechanization more intensely than ever the lecade following the war? Why then the depres ion? Something the matter with the The formula not blame; was not applied honestly during the past decade. was applied honestly during the post Civil War price decline. Machinery multiplied wealth during decade measure greater than ever before. But speculation, inflation, Government overhead, graft, overcapitalization and other voracious prosperity-destroying vermin multiplied even faster. Cost reductions were not passed along consumers the measure they should have been reduce the divisor. Average income was depleted the nib bling the non-productive vermin, and wages not increased the same proportion output during the 30-year price decline. Improved machin ery was doing its part, but were not doing ours Steps the Banker Modernization American industrial equipment and the consequent stepping production ciency and stepping down unit costs will large part determining the future skyline will the banker, who, throug! the control cash and credit, position how far this modernization will extend and where The banker heavy load responsibilit upon his shoulders today, not merely the safe the twenty-eight billions American ings that are now entrusted his care, but vesting them that they will properly multiply. There reward here hereafter for the custodian The Iron June 11, », A | | (Continued page 1934) LARGE STEEL INGOTS OME years ago the writer first experimented with 2000-lb. ingots applying lateral pres- sure the walls split ingot molds during solidification, with view liquidating the segregate and closing the pipe. this same period ingots similar weight were cast molds placed slowly rotating table, mainly with the same ulti- mate object. With view elucidating some the problems heavy ingots, number small experi- mental ingot molds were made direct proportion the 268,800-lb. mold. From the same ladle from which these heavy ingots were cast, steel was cast into the experimental molds and efforts were made cool these the same relative rates the full ingots. These experimental ingots tioned and examined and was found that the ten- dency segregation was the same the full- size ingots. Taper Wall Show Chill Effect study the chill effect the mold walls the metal, mold normally proportioned inside was cast with taper wall, shown. Zinc ingots were cast, with the thick section the base, while for ingot the mold was reversed, the thick section being top. The quicker cooling the lower portion ingot due the thickened wall, illustrates its advantage the production sound ingot, and also shows how the formation the base cone depressed which, steel, would removed small percentage bottom discard. Conversely, ingot with slow cooling base and quickly solidifying head, extensive pipe formed addition long base cone, portion which would remain the finished forging. stated Brearley 1916, his paper steel ingots, this base cone anything but desirable, line considerable weakness developed, due the junction the chill crystals, and also the in- closed segregates. This weakness may sometimes observed when forging the bottom end large Iron Age, June 11, 1931 FOR FORGING HERBERT Consulting Metallurgist, Irvine, Pa. ingots; the body the ingot will open out slightly, forming small annular space with the base the cone, Artificial Cooling and Heating Proceeding with normal ingot mold, ingot was cast hot and extreme cooling conditions were effected. The bottom plate stool was water-cooled while the major portion the mold was kept hot gas rings and gas flame kept impinging the surface the molten metal the mold. The influence the development the bottom cone outstanding interest, while the growth the entire crystalline structure shows upward sweep. the case steel, the segregates may well conceived lie between these marked crystalline boundaries. Ingot was cast normal temperature and ring, water spray, was applied from the middle-half downward, while the top half was kept hot with gas ring and the metal kept liquid the top, ingot will appreciated that, due the rapid rate Special test ingot mold, observe the effect thickness mold wall. " cox & Yj, 4, “jf J Yj 4 “jj jj fy Mii Yy Vj Yj; " > _ OTATING molds for forging ingots during the process casting acceler- ates solidification, thereby arresting segre- gation, insuring more uniform analysis, preventing structural weakness and shorten- ing pipe. Other ways improving the quality steel ingots, including the water- cooling molds, are also described the accompanying article, which based paper delivered Chicago before the American Society for Steel Treating. closing the discussion his paper the author outlined method double-pouring large, round ingots. solidification steel very small ingots, more difficult retard its progress with view promoting segregation. Sulphur prints ingots cast from metal remaining the ladle after cast- ing 44,000-lb. ingot, however, conform what might anticipated, and correspond closely with results obtained from the zinc ingots. was thought that, the addition aluminum the still liquid discard portion large ingot, the solidifying point would depressed and re- tarded, and thus stimulate the flow segregates from the main body the ingot this area and lead them the still more fluid sink-head. Five pounds aluminum was therefore added the liquid metal when within in. the top the mold, and casting continued usual into the sink-head. was however found that, this addition, the freezing point the serviceable metal well below the portion treated was depressed also, and that segregation was developed rather than lessened. Practical Cases Forging Work the manufacture large hollow forgings, the usual procedure remove the top and bottom dis- card and trepan the core. The latter may much in. diameter. Providing little ghost marking has been detected superficial examina- tion, has been considered safe proceed with the forging. Considerable anxiety has sometimes arisen, when machining the bore such forgings, find well developed ghost marks distributed over large area. Another cause annoyance manufacturers large ingots ingot corner segregation and corner cracking. These two defects are first cousins and, not perceptible the unaided eye, can usually detected sulphur printing the ingot corners the discard face. These defects, how- ever, often not run the full length the ingot, and the worst location generally about ft. from the base. When the ingots are allowed cold, the corners should ploughed into and examined, these defects usually are deeply seated and are not disclosed until the corners are removed down diameter equivalent the octagon face the Ingots Big-End-Up Much has been said and written concerning the advantages and disadvantages casting ingots big- end-up. This method unquestionably the best where careful casting conditions are not observed. But equally good and sometimes better ingots are cast, big-end-down, where the casting temperature and rate teeming are carefully controlled and cient sink-head provided. One advantage this latter method that mold can stripped earlier stage, the ingot partially cooled air, and then, through the critical periods, allowed cool more slowly dropping over the ingot refractory lined casing. Further, where ingots are trepanned for hollow forg ing, the question pipe little moment. this same purpose and remove the risk refrac tory materials falling from the sink-head into the mold steel during casting, not uncommon use unlined sink-heads. Experience has shown that, casting these heavy ingots toward the outside the mold and not the center, has been normal practice, markedly superior results have been obtained. This method greatly facilitated revolving the ingot mold comparatively slow speed during casting. the case octagon ingots the sonims, which always accumulate the rising liquid surface, are forced the center and eventually brought into the sink-head. This prevents patches the sonims sticking the mold wall and being entrapped the rising liquid steel, ultimately causing deep sur- face defects during forging. Further, the hot metal the mold more equally distributed, giving less steep gradient from outside center. This minimizes the risk corner segregation and corner cracks, reduces the pro- A air water cool- ing, for observing | LAA tn 1D LA« = The Iron Age, June 11, a ingot. 3 | \ a inced dendritic ingot structure and has a marked effect the distribution the Cylindrical Ingots Have Advantages further development during the past twelve ears has been the manufacture heavy ingots have been made without loss, 179,000 weight, and larger ones will follow tagon molds become worn minate defects the sonims more read into nter the mold | \ | } Double pouring for large ingot, using two ladles. the hollow forgings removes the risk the ends bursting. Some years ago the writer introduced air vater-cooled mold. series steel pipe coils was encased the walls the mold, which also trengthen the mold, and through which the cooling “drawn” and circulated. Some hesitance has been expressed relative the use water, but this “drawn through” the same principle applied the water-cooled tuyeres the blast fur- need for reluctance as, the event leakage, water would cease flow and air follow. will noted, the cooling coils are stages, that the level the fluid steel the mold may controlled, mold may also followed up, the rate cooling any desired portion the mold. The retained any desired temperature liquid steel has been cast. From number charges, two 21,000- lb. ingots were cast from the same ladle exactly the Same type mold, one being water-cooled while the other was allowed cool normally. each ast the ingots were run alternately, No. the water-cooled mold, No. the vice versa. normal mold, and 1890—The Iron Age, June 1931 every case, during the whole the casting period and throughout their cooling, was possible for one place his hand any portion the walls the water-cooled mold. With the normal mold, very short time the walls became red hot and, owing one could not get within several feet without considerable discomfort. From analyses taken the outside in. diam- eter cores, intervals in. from the base up- ward, the following are the average four, each With the water-cooled ingot not only was the carbon uniformly distributed, but also the sulphur, phosphorus and nickel. the case the normally- cooled ingot, these elements were migratory with carbon. Discussion Steel Ingot Practice ingots came for considerable discus- sion, With regard both the size the ingot and the quality that could obtained. Dornin expressed the opinion that George round ingots are not commercially successful, cause they are too slow production. in. diameter thereabouts round ingots seem large, all right; above that his experience seems indi- cate epidemic slag inclusions. 100-ton heat, each 3-ton ingot must poured from sec. The speaker does not think that the skin under those conditions forms fast enough withstand the ferrostatic pressure. expressed the view that the chipping costs the average well managed plant eat about per cent the earn- ings the plant. face duplicate this loss. Rejections because poor sur- Another speaker reported having introduced cop- per into the material his molds for the purpose using its high conductivity take the heat away quickly from the surface the ingot, and thus form heavy enough skin withstand subsequent pressures. From this went copper ingot mold, cooled with water. closing the discussion, the author brought notice interesting manner producing large, round 100 tons. This cast with the big end down and with sinkhead top taking about per cent the steel. Two ladles are used, one which set carriage got great size that the other may brought above it, somewhat the manner the sketch. When the lower ladle about half empty the upper ladle opened and the steel from this source, which somewhat hotter than the other, runs into the lower ladle such speed that the level the lower ladle kept about uniform until the upper ladle empty. This maintains over long period virtually uniform ferrostatic head, and consequently keeps the rate flow about the same during the greater portion the period. q | case: CARBON ONLY (A at Bottom End) ‘ ad 0.29 io 4 0.33 0.34 0.34 0.34 The Iron June 11, ¥ 7 3 3 t i 4 Phoatoarat Colorado } Fa ra | ‘ +} + ‘th hackneyed expression, fre- paraphrase quently heard these days popularized psychology, the industrial world becoming Manufacturers are realize more and more the importance pleasant Statistics comfortable and attrac- surroundings for the workmen. have proved that shop can turn out more work than those having perform their tasks amid disorderly and unpleas conditions. For this reason the cleaning, well the lighting, heating and ventilating fac- given far more consideration today than ‘e, and mechanical equipment has been de- velored and applied meet the needs modern ndustry this respect. The purpose this article describe some the services that the vacuum leaning system, especially the central tionary type rendering industry. usually installed, the central vacuum cleanin vstem comprises vacuum producer and dust eparator located convenient point the build- ing. From the separator carefully designed piping svstem extends all parts the plant. Numerou inlet valves are located each floor permit the attachment the cleaning implements. Each oper- tor supplied with 50-ft. length vacuum hose, leaning tools especially designed for the work done. floor handle and For instance, the floors are made concrete one type brush required; entirely different cleaning tool used hardwood floors. Dust and litter, drawn into the cleaning tool, pass through the piping 1892—The Iron Age, June 1931 PLANT VACU LESTER SMITH Engineer, Spencer Turbine Hartford, Conn. which periodically emptied and the refuse burned though customary install central vacuum cleaning system the time building erected, into the the equipment may readily installed older plants. Central System Adapted for General and Special Services The central vacuum cleaning system rendering least five distinct services industry. These are: 1.—Rapid and thorough general cleaning. return boiler flues and the boiler room. Cleaning electrical and power plant sectional equipment. 1.—Removal dust its source when nec- essary prevent explosions and safeguard the health 5.—Removal excess material manufac- turing processes. The following brief descriptions actual instal- lations illustrate some these types service. Sweeping and similar methods cleaning hand have been entirely replaced the vacuum factory cleaning watch-making plant Illinois. There, the daily use stationary vacuum cleaning system has been found effective the removal dust which, scat- tered, would work havoc with the fine mechanism addition, the vacuum machine production process for general large the watches employed connection with certain =a 4 4 = ‘ 3 q 4 q 3 } ¢ CLEANING MEN AND MACHINES processes, thereby serving dual purpose. this tention and study that they deserve. many mod plant considerable amount valuable material, ern power plants, however, there daily routine including watch jewels and scraps precious metal, vacuum cleaning, starting the breaker house, recovered from the separating tank the vacuum then through the pulverizing other fuel han cleaner. dling plant, boiler room and into the turbine and Other establishments which have found the use room. vacuum equipment profitable for general clean- commutators and other dirty electrical machinery are realized that dirty windings, connections ing include representatives such widely differing industries food packing and heavy machinery building. the former, cleanliness, course, cleaning switchboards. Moreover, dust, picked from the floor and machinery the suction the cleaning TY) likely give trouble, there systematic vacuum this equipment, including even the paramount importance; the latter industry also has definite value. tool, entirely removed, not merely scattered into Special Applications Vacuum Cleaning the air only settle again other parts the addition the use vacuum equipment for general cleaning, there are many specialized appli- cations which have resulted savings operating costs. Such applications include the cleaning boilers and flues, equipment for service usually installed addition the regular vacuum cleaning system serving the entire plant. When realized that coating soot, 1/16 in. thick, over the heating surface boiler will cause fuel loss approximately per cent, the need for thorough cleaning apparent. The vacuum cleaner permits rapid removal this dust, whether the boiler the fire tube the sectional heating Another advantage that soot may re- moved while the fires are banked; not neces- sary generate high pressure steam must done when the tubes are blown out. This alone ef- fects appreciable saving fuel and helps make the fire room more comfortable. Actual tests boiler installations that are vacuum cleaned daily have shown interesting re- sults. one plant fuel savings amounting $45 $50 month were found; another test 150-hp. fire-tube boiler showed saving 250 lb. coal day the result daily vacuum spection the tubes sections boiler which regularly vacuum cleaned usually shows the metal clean and bright. the maintenance electric power plant equip- ment, the vacuum cleaner has also been found ad- vantageous. Although most power plants are kept scrupulously clean condition, only recently that efficient cleaning methods have received the at- The Iron Age, June 11, 1931—1893 | E 7 7 { < * 7 a 4 7 re n plant. Consequently, frequent renovation walls Another application vacuum cleaning the maintenance electrical equipment telephone exchanges where has been found that even the slightest traces dust interfere with the operation boards. Insulated vacuum been developed which permit thorough the automatic panels without shorting Reducing the Dust Explosion Hazard serious fire and explosion hazard has been vir ally eliminated the plant well-known soap ufacturer the East the vacuum cleaning system which was installed some Those familiar with the soap industry know that powder and dust arising from the man- time ago. processes literally cover the machinery, floors, walls and overhead structure the plant. Spontaneous combustion and dust explosions may ad- ion, accidents are likely caused the slip- this dust allowed accumulate. pery the floor. Men from each the three shifts, which keep the machinery this soap ant 24-hr. basis, are assigned the vacuum cleaning work. They spend their entire time oper- pecially designed vacuum cleaning tools which remove the soap powder before has chance accumulate any extent. Another instance the use vacuum cleaning equipment lessen the danger dust explosions found the grain elevators large industrial alcohol plant the Middle West. are vacuum cleaned daily remove accumulations loors, frame work and other parts These elevators dust from the structure. Even more necessary the vacuum Iron Age. June 11, 1931 cleaning system nearby plant where corn syrup refined because corn produces more dust than most other grains. Vacuum Cleaning Safeguards Health Not only the improvement working condi- tions but also safeguarding the health em- the operation vacuum cleaning sys- tem frequently value, the plant manu- facturer white lead and other lead Formerly the health the workmen was seriously products. endangered the quantities lead dust which were produced during the grinding pig lead. practically impossible remove lead dust with broom, those familiar with the properties this Although certain amount the dust can collected sweeping, gray smear material will realize. will remain. the use central vacuum system with cleaning implements specially designed pick the heavy lead dust, possible thor- ough cleaning job. this particular plant are painted red, are made bright and clean simply passing vacuum tool the proper design over the surface. Virtually every trace the lead powder removed, and this with- out scattering any into the air. For instance, the girders, which Another important service rendered vacuum systems the removal excess material pro- duced during various manufacturing processes. though, strictly speaking, these installations might not considered vacuum cleaners, having part the removal incidental dirt yet, they remove unwanted material suction and might properly mentioned this article. machine tool builder the East experienced difficulty the cutting internal cams. Chips thrown off the cutter accumulated the cam groove, causing the tool jam run out. This trouble was eliminated the installation small flexible suction nozzle which could inserted the cam groove behind the cutting tool. This nozzle draws away the chips fast they are produced. similar suction nozzle removes wax shavings pro- duced the stylus which cuts the sound tracks the records used the production talking pictures one process. Aid Enameling Operations Removal excess enamel from metal parts prior baking valuable service performed the vacuum system the finishing industry. Here, en- amel sprayed metal part and allowed dry. Then templet applied and the required design outlined. Before placing the part the glazing oven, however, necessary remove the enamel coating extending beyond the stencil. This easily accomplished loosening the dried coating with small brush, resembling clothes brush but equipped All the enamel powder passes through the flexible handle the brush separator connected the central vacuum producer. Individual separating tanks may installed for each color enamel used, thus per- mitting the material reclaimed. with vacuum slot surrounded bristles. addition preventing waste enamel, the and ceiling unnecessary. ag =f rup han vacuum system eliminates serious danger the health the employees. Enamel dust similar ground glass and scattered about likely in- jure the lungs the operators. The vacuum brush collects the enamel powder rather than scattering into the air. use zirconium alloys for deoxidation and purification making and the effect physical properties were discussed Ph. Guy Aciers Spéciaux, Métaux Alliages, November, 1930, part follows: Experience has shown that the full benefit secured only the presence silicon. The analyses two types zirconium-silicon alloy The tendency zirconium combine with oxygen form ZrO, great that permits more thor- igh deoxidation steel than possible with man- silicon. Work the United States Bureau Standards has shown that residual oxygen, after treatment with zirconium-silicon alloys, only one- half one-sixth great after treatment with ordinary ferrosilicon. evident that the greater the percentage recovery the deoxidizer the slag, the greater has been its action the impurities and especially the oxygen the bath. series tests basic electric furnaces has shown 85.8 per cent recovery 0.219 per cent addition ferrosilicon, while the form alloy, 0.206 gave per cent recovery ind 0.15 gave 59.7 per cent recovery. This elimi- nation impurities insures fewer rejections and better fabricating qualities. Zirconium combines with one-tenth its weight nitrogen form cubic crystals lemon vellow nitride which tend pass from the metal the slag. Numerous experiments have shown that these crystals not appear steels containing less than 0.25 per cent carbon, and that their number the zirconium addition increased from 0.15 per cent, remaining practically constant after that. This upper limit ascribed limited nitrogen content 0.008 0.009 per cent ordi- nary steel, while below the lower limit appears that all the zirconium unites with oxygen. The the following comparison melts made with and without addition: } Ack Zr Per Per With seven-tenths its weight sulphur zir- nium forms the sulphide which resembles MnS appearance, but insoluble 1:1 acid. Addition zirconium was observed lower Many other central vacuum cleaning systems, serving many industries but differing only slight- the work accomplished, might described. Those outlined above are typical, however, and will, hoped, serve show the use the vacuum cleaner modern industry. Zirconium Alloys Steel Manufacture the ratio manganese sulphur required for sat- isfactory hot rolling sheets from about 0.5. steel containing 0.318 per cent addition manganese and zirconium together equivalent 0.67 this amount was found permit rolling; another steel amount equivalent 0.92 the sulphur produced like result. Zirconium has not been shown combine with phosphorus. However, when added phorus steel, the cold brittleness lowered. Such fragility may caused part the oxygen and nitrogen content the steel. The influence zirconium physical hown comparison the effects various els the following additions: Cent Zi low phosphorus (0.01 0.03 per cent P), 0.17 0.78 per cent carbon steel the chief result zir- conium addition was reduce the elastic limit about per cent. Addition No. gave ultimate strength superior additions Nos. and which were about equal this respect. high-phosphorus steels (0.12 0.17 per cent the adverse influence phos- phorus the Izod numbers was counteracted dition No. sulted ductility little inferior that low sulphur steels like composition. Comparison longitudinal and transverse tests showed improve ment Izod numbers, but little influence tensil trength elastic limit. improving the propertie high-sulphur steels, 0.15 per cent usually sufficient eliminate the influence the small amount sulphur remaining after the action ganese; further addition zirconium merely places manganese from its sulphide. Zirconium msiderable amount confers carbon steel trength comparable that special reason their freedom from gas teels treated with zirconium are especially suitabl producing difficult casting High sulphur steel improved machinability and rolling made with zirconium; exceptionally rew m a wit] i 0.15 0.20 I ent teels defects produced forging mum zirconium, owing the homogeneity its deoxidizing action. Chrome teels are improved machinability lit Fe-Zr-Si allo The Iron Age, June 11, 1931—1895 em- nu- cts. ere 1S la his ear em ick ich th- rht no rht ips his all on or he ad of wy) eget e 13 q 3 the bottom each two 15-ton pulverized coal storage bins ton so-called shooting tank mounted weighing scale. has been quite customary write descrip- tion pulverized coal plant installation short- after being placed operation and invari- ably closing the description with these words, plant has not been operation sufficient length time give accurate The present ase will different. covers pulverized coal Erie Malleable Iron Co. Erie, installation for the ontinuous operation since No- Pa., that has been in « ile iit vember, 1924. The installation unique also, because the first installation complete pulverized coal plant which the equipment was designed meet the All the the exception the pulverizers and varied conditions found this foundry. material, with motors, was fabricated one shop; the erection including the placing operation, Hev!] & Patter- tne equ pment, Was performed by one oryvan zation on, Pittsburgh, Pa. know the foregoing facts will appeal those vho have purchased equipment works and have had erect the equipment with their own labor, assisted set blue prints and supervising engineer. arrangement, rule, proves costly for the purchaser, because 896—The Iron June 1931 f.o.b. PULVERIZED Consulting Engineer, New York case, the writer’s knowledge, has the cost been within the estimate made the time signing the contract. The actual cost has always exceeded the estimate, sometimes high 100 per cent. The first installation pulverized coal for mal- leable annealing ovens this country was made the Erie Malleable Iron Co. 1890. The credit for this installation belongs Walker (the father the present president), who designed the combus- tion chamber and invented the burner known the Walker burner. the time the contract was signed for the new installation, the Walker system was use annealing ovens, divided into two groups one and the other ovens. Each oven had its individual pulverized coal storage bin wit