The Iron Age 1931-09-17: Vol 128 Iss 12

THE IRON NEW YORK, SEPTEMBER 17, 1931 ESTABLISHED 1855 VOL. 128, No. MARKET ANALYSIS FIRST REQUISITE NEW ERA SELLING CHARLES ABBOTT Executive Director, American Institute Steel Construction, Inc. RESENT-DAY thought tends toward problems merchandising, marketing. The first requisite the new era selling, says the author, market analysis. Today, manufacturers must consult the whims the consuming public. Organized research necessary develop the trends future markets. Success will come chiefly those companies that keep touch with modern tempo. production increased and our production problem solved, manufacturers must meet the consumer and understand the new buying tendencies. OMMODITY prices have declined radically lem solved, must start once meet the eon- during the past year two. Today, some sumer and understand his buying tendencies, his countries, basic prices are below what they desires wishes. must assemble the facts were 1913, and the United States gen- are build safely. erally have gone back pre-war basis Market analysis will vigorously applied the values. This has disrupted all invested values and future. The location and listing all possible users, jeopardized the ability debtors repay full reasons why sales are not made, the attitude the money they borrowed when values were higher. prospects toward the product and the company, and This situation has been due small measure other selling influences should recorded and pre- the universal practice business executives re- pared for sales planning. far more important sort barter during the period the decline. But know what business not doing but might just because have been victims universal than know what being done. the business practice assurance that are going work that not being obtained that should receive seriou our way out the morass distress attention. the same methods. Market Analysis Substitutes Knowledge for The first requisite market analysis. Guesswork The immediate problem before sales or- today apply intensive Market analysis keeps the pertinen study their markets. consumption facts before the sale executive and increased and our production prob- ables him guide his 743 E 7 and effectively. substituting knowledge for guesswork and assumptions. records the activities competition and opens the way for program ex- tend the present existing market selling those who previously have not been buying. also opens the way for more sales present customers more Sales knowledge their possibilities obtained. promotion, advertising and sales direction, policies and plans are first based upon the facts produced market analysis. even greater service the possibility pre- dicting trends consumption, tabulating the chang- whims and fancies stabilizing the fluctuations business. more fickle public means and accurate knowledge consumption ind all the for accurate planning. forces that influence indispensable engineering age and age when change the accepted order the day. longer live the sluggish economic age which ex- isted more years ago, when consumers fought stubbornly against their own advancement. How many know that, when bathtubs were first the prejudice and opposition was great that laws were passed forbidding take baths them for reasons “public How many know that the newly-invented telephone, when exhibited the Centennial Exposition 1876, attracted very lit- large crowds hung around the booth where there was displayed statue man arved out butter? How many know that vears ifter the typewriter still being kicked out make the terrible suggestion that business firms tle attention, while invented salesmen were business offices for daring ~ typewrite their letters? Business men thought type- written letters would insult their customers! those days was the consumer who was back- ward, and the manufacturer was the dictator. But Millions people automobile shows, radio shows, and this condition has all been changed. stores, and then read magazines eagerly get acquainted with the latest goods. Influence Today Sways Consumer Demand Today the consuming public swayed the in- fluence the woman who alert and date. had fine demonstration this influence when the scientists discovered that calves’ liver contains large amount vitamins. Within one week after that announcement the women New York raided the meat shops, and you had reserve your liver almost far advance you now tickets big Broadway theatrical hit. Mrs. Consumer had in” the moment she discovered that there was new scientific advantage available her. Woman teaching that are have Iron Age, September 17, 1931 prosperity must inject beauty into mass produc- tion. must remake our tin-lizzy world into artistic world, world color and style and con- venience, comfort and even luxury. day ap- proaching when the things will turn out our factories will have the beauty those the days handicraft. Our buildings and bridges will longer eyesores, but combinations service economy and beauty. Most forget that approximately eleven mil- lion new families—new homes—have been started since the Great War. other words, not far from half the homes this country are operated today young women who have been married since 1920. They are the younger generation with new and more modern ideas; and with determined, intelligent, educated, independent outlook life, such did not know before the war. They are the most critical, the most sophisticated body consumers that American business has had face, and what they say goes. Modern consumers are longer docile, old-fash- ioned, uneducated, contented stupidly stubborn. often not they “beat you it.” the indepen- dent retailer does not, the alert chain store will, and one manufacturer does not, another will. The competition today for the consumer’s favor, for consumer acceptance and prestige. Industry Must Ready Meet Whims the Consumer Important changes happen twenty-four hours; big successes are sometimes made few months. Serious upsets come almost overnight—all because consumption-minded, not must ready meet business today must merely the consumer’s bidding. one time American business history thought was great thing manufacture some- thing and then push and fight for years put over against overwhelming odds. held ex- amples final success such efforts wonderful achievements. But never checked find out how many thousands other businesses failed try- ing put over goods which consumers did not want. every success there were probably five thousand failures. This because most these corporations are not fitted their market either merchandise, y | \ | + a the consumer supreme. trying drive the consumer. They are trying sell unwanted merchandise; sell uneconomic prices. selling price policies. They not acknowledge Instead, many are still Possibly one-half the merchandise sold today re- juires too much wasteful effort sell, costs too much money distribute, too high price; ompeting price alone, which most ruinous policy. Why too much effort sell? Simply be- ause the merchandise was not tailor-made, the onsumer’s preferences, because the consumer’s ideas were not previously prepared for its accept- unwanted merchandise; goods unfitted consumption. The Government discovered its Louisville sur- retail trades that stores were still offering for sale cans food from factories that had been Ve business for six years! Many these store were merchandise cemeteries. Row upon row lead merchandise the shelves, like many tomb- tones. There are thousands like them everywhere, and there are many more thousands offices and actories that are nothing more than equipment attempt run counter the consumer’s wants invite disaster. That accounts for the proportion the distribution wastes that have been hampering business. estimated that per cent the bankruptcies result from lack intelligence. And the last analysis intelligence msists mainly knowing what the public wants buy, and applying that knowledge. Buying Power Will Increase With Greater Consumption must prepare ourselves for great consump- era. are going increase the per capita vealth and buying power this nation far beyond record figures today. The big tool will loser adaptation manufacture and distribution the consumer. far cry indeed from the old principle “the public damned.” Just have overthrown the old emperors and autocratic rulers the people let the people rule, business the consumer has arisen and the old order dead and gone. industry actually knew the opportunities for greater use its product, the waste that occurs failing develop new uses and new mar- kets, and the loss profits that could readily realized, would immediately insist upon organized research. Courageous spending, true, but why should much courage needed when the results are obviously profitable? know for certainty that our structural steel consumption might have been increased tre- mendously. matter fact, has been in- creased nearly three times volume since the World War. possible today increase per cent more properly promoting the markets which know are possible. This, however, would require greater concert selling methods and more scien tific approach the market problems. Similarly, relief could undoubtedly be found for the other branches the steel industry proper attention were devoted study present mark- ets, combined with the application research promote new uses. The chromium and other alloy steels, but recently perfected, are line with the development mar kets. From automobiles, airplanes, mechanical vices, buildings, kitchen utensils and host other uses, these new steels have found acceptance. battledeck steel floor, armor steel highway ruard, steel dams, and other new uses have also been developed result research. These new markets, once developed, would bring the steel in- ustry millions tons new demand that would long way toward absorbing any excess ities what plans to analyze these new markets and arrange for efficient distribu tion. Advertising, sales promotion and salesman ship are the tools necessary fully realize tnese vast possibilities. Keep Step with Modern Tempo Rule for Success Inability business executives fully ciate the problems distribution, have any known yardstick whereby measure market possi- bilities, lacking any scientific approach the con- trol marketing costs, constitutes the basis this problem. Opportunities for profitable business will escape those who fail take full advantage the possi- bilities that are offered. the man who refuses keep time with this modern tempo. Nothing detrimental grow- ing business the failure spend amount equal the tasks set for the spender. Success will never come The industry which grasps the full meaning (Concluded page 799) The Iron Age, September 17, 4 uc- an on- ap- yur ym re it, rs that may exist. are being formulated sales managers 7 double-deck electric hardening and draw furnace for steering spindles Hardening chamber above. Furnace hearth ft. long. q Iron Age. September 17, 1931 J 13.—Most carbur- ized parts are drawn air furnaces instead oil salt baths. The conveyor mechanism feature. 14.—Rear axle drive shafts for passenger cars and trucks are hardened double-deck furnaces. The hardening chamber above 2434 ft. long; the draw chamber below. — a — > ELECTRICITY USED LARGE SCALE FOR HEAT TREATING GLENN COLEY Detroit Edison Co., Detroit zation was described. OST carburized parts are drawn air furnaces instead oil salt baths. One these furnaces with the conveyor mech- anism shown Fig. 13. ft. long and has four rows work passing through it. The rows alternate opposite directions obtain savings from the counterflow effect. Ring gears and similar parts are loaded directly the hooks, while maller parts are loaded wire baskets. Rear axle drive shafts for both passenger cars trucks are hardened double-deck furnaces Two furnaces are used model and one truck shafts. They have the lening chamber above and the draw chamber The upper chamber ft. long, ft. high ft. in. wide, and has three control zones with kw. connected. takes two rows hich are pushed through shoes riding grooved rr 7 + rails. The shoes are auto- the first portion this article, THE IRON AGE Sept. 10, the use electricity for forging and for heat treating the Ford organi- this, the concluding section, besides con- tinuation the description the heat-treating furnaces, there brief discussion how pig iron from the blast furnaces and cupolas duplexed with electric furnaces for making iron castings. cept the draw furnace divided into two separate chambers about ft. wide. The chambers are di- vided into six control zones with 198 kw. connected for each chamber. Shafts are carried through chains. The draw chambers are unique that they operate three different temperatures across their width give three hardnesses the shafts. The gear end the shaft drawn give hardness about 512 Brinell, the center has hardness 477, while the taper end has Brinell 340. These fur- naces have capacity 400 shafts per hr. Steering spindles are hardened and drawn double-deck furnace with the hardening chamber above and the draw chamber below. This furnace has hearth ft. long, ft. wide and ft. high and total connected load 855 sketch shown Fig. 15. The work loaded The extension the front the furnace below the matically returned the charging end means Shafts are re- moved hand and placed element level makes cer- clear- ing the front will clear the heating shown which are above and the spinning type. After below the hearth both this the spinning machine chambers. quenching the shaft. with flat cross members After removal from that form smooth, con the quenching bath, hearth upon which bers below. These are ers can placed. This approximately the same size the ones above, ex- Fig. 16.—Sketch rotary hearth furnace for hardening camshafts. ehain pulled inter vals lever shown The Iron Age, September 17, in in | fe rs e near the discharge end, which engages pauls the side the chain carrier. the work drops from the belt the upper chamber falls down the chute into the quench tank. enters the tank strikes the baffle which helps keep the parts from piling and directs them the con- veyor This conveyor takes the work out the quench tank, carrying over pulley, where dropped the belt the lower draw chamber. This belt operated similarly the upper one ex- cept that pulled from underneath. After pass- ing through the draw chamber, the work dumped into wagons for transmission the next operation. One man operates this furnace. temperature The quenching approximately 1500 deg. The heating cycle about hr., while the heating cycle for drawing about 2/3 hr. Being double-decked, this furnace occupies half the space formerly taken two furnaces this operation. Camshafts are hardened rotary hearth fur- nace, shown Fig. 16. The hearth, rotated central shaft, motor driven from above with thrust bearing the bottom and roller bearing near the top. Supporting racks for the camshafts are carried the hearth, where camshaft shown position. The shafts are loaded and un- loaded through the same door, the operator remov- ing heated piece and replacing with cold one. The heating elements are above and below the The furnace has three zones control, with connected load 178 kw., and will handle 320 camshafts hour. The shafts are quenched vertical spinning Iron Age, September 17, 1931 18.—A machine developed Ford engineers harden water-pump shafts. machine the right the furnace. they are rotated and sprayed the solution, the end where the timing gear works shielded from the quench- ing solution. Thus, while the body the shaft has hardness about Rockwell the scale, this portion the shaft can easily threaded. The pinion the center the shaft cut before hardening. wire brushing the pinion the only cleaning done the shafts. Crankshafts are hardened and drawn the double-deck furnace shown Fig. 17. The dis- charge end the lower deck hardening furnace and the charging and discharging end the draw chamber are discernible the picture. Crankshafts are placed alloy shoes which slide grooved alloy rails (seen the opening the lower deck). This chamber ft. long and ft. in. wide. When crankshaft reaches the discharge end the fur- nace, the operator raises the door depressing the foot lever and removes with tongs. The alloy shoes then drop into baskets. crankshaft removed from the furnace, placed spinning machine, shown the right the picture, which rotates fairly tight bearing jaws immersed caustic quench- ing solution. This combination rotation and clamping prevents distortion quenching. the shafts are taken from the quenching solution they are placed grooves the upper side chain conveyor. These grooves may seen the pic- ture. This chain carries the shafts through the upper part the draw chamber; they reach the opposite end the furnace, they strike guide rail which fits over the top the grooves. The chain continues over the pulley, the shafts dropping rails the lower part the drawing chamber and being pushed the grooves, which are now top, back the entering end the furnace. When they reach the end the furnace they are dis- charged curved chute and removed hand. The draw chamber the furnace ft. in. long and ft. in. wide, and with the double pas- age the work has travel over ft. The quenching chamber divided into three zones. The two chambers have connected load 800 kw. and handle 150 crankshafts weighing lb. each, with production lb. per kwhr, for the quenching furnace and lb. per kwhr. for the drawing cham- ber. Fig. shows machine developed Ford engi- neers harden water-pump shafts. modified welder with the welder grips replaced upper and lower copper grips containing round grooves which make close contact the shafts about in. from each end. One pair grips stationary, while the other pair free move horizontally away from the stationary grips. The pump shaft placed the lower grooves and contact made pressure ap- plied through foot pedal bring the upper grooves down upon it. the circuit completed, current flows through the shaft, the resistance the steel the passage the current causing the pump shaft heated. the shaft becomes hot, expands and care- ful calibration has been possible set release that, the steel reaches correct hardening tem- perature, the expansion will cut off the current and the same time flash light indicate that the piece ready quench. Since the current takes the path least resistance, passes through the copper grips where they make contact with the A > q q » P - A | Fig. hardening crankshafts done this double-deck furnace, whose chamber ft. long. spinning machine the right the camshaft immersed caustic quenching solution. steel, thus leaving the ends cool and likewise soft for further machining. This operation completed sec. The heating rapid that, even shaft with finished surface, only slight discolora- tion occurs. One the shafts ready quench shown the white bar the center the picture. and control the mech The Iron Age, September 17, 1931—749 le, 1e ie WwW Ss n > 4 4 Fig. 20.—Loaded cars await their turn into the furnace. The Ford Motor Co. makes large part the grinding wheels used its plants. The various abrasive materials are bought granular form and mixed give the abrasive mixtures desired. The proper bonding material then added and mixed This gives mate- rial resembling moistened sand, which formed with the abrasive ball mill. pressing into molds the various sizes and shapes wheels desired. These wheels are dried electric furnace and loaded cars for trip through vitrifying furnace. This furnace, views which are shown Figs. 19, and 21, unique its design and operation. ft. wide and ft. high, and divided into three zones, Its chamber 250 ft. long, namely, tne whi h 1 preheating zone has heat applied and about ft. long; the heating vitrifying zone which ft. long, and the cooling 150 ft. long and without ating zone has istors in. diameter and in. long, and connected load 620 operates about 2000 deg. and divided into four tem- Since the side walls the furnace not extend the floor, there open space about in. beneath the cars which facili- tates locating any conveyor trouble that might occur. With the exception loading and unloading grinding wheels perature central zones. from the cars, the operation the furnace automatic. The cars, which are ft. long and ft. wide, are loaded track paralleling one side the fur- 750—The Iron Age, September 17, 1931 nace. They have cast frame with angle iron sides which engages the san seal the furnace side wal! The top the car made refractory material and extend about in. above the work. each end the lug for engaging the chain link the These lugs are tapered the op- posite direction only the the end the car, which the front when the car tion, will engage the chain. car loaded with grinding wheels pulled down the outside track until about even with the end the furnace, where left the chain which returns underneath the floor pushed the transfer car the next car brought down. The transfer car, shown Fig. with the front wheels the furnace car just rolling it, moves rails pit which right angles the length the furnace. car loaded with grinding wheels pushed the transfer car, makes contact with switch which starts the trans- fer car motion. When the transfer car comes line with the rails the furnace, makes further contact with switches that open both end doors the furnace and through delayed switch operates hydraulic ram push the filled car into the fur- nace and discharge vitrified car from the opposite end. This hydraulic ram can plainly seen the lower foreground Fig. 19. Fig. furnace holds carloads one time. 7 4 = # i 4 4 A ~ § 4 a ‘ q 4 san wal] tend With the car place the furnace, the ram withdrawn and the doors closed. When the ram withdrawn, another switch operated return the now empty transfer car the loading end the furnace its original position. the discharge end the furnace another transfer car operating through the same cycle and the same time the just described, except that the loading cycle reversed. empty when comes the furnace door and loaded when leaves. All these switches are interconnected so, one fails work, they are all automatically shut off. operate and control the mechanism this furnace requires electrical limit switches. The furnace holds cars one time with car discharged every min., making furnace cycle per car about hr. The cars are discharged ap- proximately room temperature. The duplexing process the iron foundry un- isual and could probably used other com- pany, because other foundry operates under con- ditions similar those the Ford plant. this process the iron from the blast furnaces mixed with cupola iron, and this mixture finished di- rect are electric furnace. This mixing takes place large cylindrical steel drum lined with refrac- tory brick and well insulated. The mixer heated oil. The blast furnace iron transferred into the ladles locomotives and emptied into the mixer overhead crane. Here the blast furnace metal mixed with scrap metal. From the mixer the metal ladles hauled electric trucks the are furnaces. The iron that goes into the electric furnace weighed three stages: The scrap before charg- the cupola, each ladle molten iron either rom the cupola blast furnace, and each ladle April several cars freight train the Pennsylvania Railroad were derailed, with disas- trous results. Investigation showed the responsibil- lie broken axle under one the cars. The train carried 123 cars, which 108 were loaded. The causing the trouble was carrying more than net tons bituminous coal. Examination showed that this axle had had worn area built electric welding the point the journal fillet. Such practice was said never have been used the Pennsylvania Railroad, the axle hav- ing been built and installed under the car while operating another road, which later discon- tinued that practice. Building fillets worn axles the welding process has been prohibited 1924 the American Railway Association. circular that organi- zation refers this action bad prac- taken from the mixer. Since the analyses the scrap and blast furnace iron are known, this assures good control the iron entering the electric fur- naces. The time for heating about min. for tons. Occasionally some slight adjustment iron made the electric furnaces. The iron tapped from the furnaces into monorail ladles for various parts the foundry. This installation has recently been increased another mixer and two electric furnaces. the brass foundry are several ing, indirect are furnaces used mostly for melting brass and bronze. Each furnace covered hood with exhaust carry out any escaping fumes, especially while the door open during charging. These furnaces are arranged for rapid and convenient charging. the floor above and directly over each furnace sheet iron stack with hinged door the side. The charges, properly weighed and proportioned, are placed barrels near this door. When the furnace has been emptied metal and rotated that the open door the top, man the furnace floor pushes button which lights red light the furnace floor and green light the charging floor. Inside the steel stack inverted steel cone with the end removed. When the door the stack opened, barrel con- taining material for charging pushed two- wheeled buggy and dumped into this inverted cone. This cone serves the double purpose holding the inverted barrel upright and directing the charging material into the furnace door. When the charging completed, man the charging floor pushes the button turning out the red light the furnace floor and replacing the green light the charging floor with red light. charge handled this man- ner min. tice and calls upon all the railroads take out service all axles which this treatment has been applied. The circular states that the transformation the structure, with corresponding internal stress« points axle where bending stresses magnitude occur, will readily permit the developmen detail fractures. the case question this detail fracture had progressed over per cent the cro section area before the final break occurred. Tests the metal the journal showed good quality material, with elongation limit (average two samples) 37,400 the sq. in.; ultimate strength, 72,150 elongation in., 25.5 per cent; and reduction area, 41.6 per cent. The carbon worked out 0.43 per cent, manganese 0.37 per cent, phosphorus and silicon under 0.010 per cent and sulphur 0.036 per cent. While slightly low manganese, this analysis verifies the good qualities found physical test. The Iron Age, September 17, Cal ere’ link lism. Op- One mo- 4 rack the Irns be by ‘ont it, ns- her tes ur- ite Derailment Caused Axle Broken Built-up Fillet 1 ale Fig. prove that standardized details construction not necessarily involve deadly WALLS, FLOORS AND PARTITIONS THOMAS FOSTER Chairman, National Bridge Works, Long Island City, SURVEY the use steel residences the United States shows that nearly all them steel substituted for wood without any offset for the use the more expensive material, reduction the per cent waste mentioned the Department Commerce. Nor has there been attempt profit the criti- cisms and suggestions Wells, Dr. Keppel, and others who have called attention our antiquated methods building. Those who built steel residences 1930 con- tented themselves with variations the method used Naugle 1907. large organization with plenty money and experience carry experimental work was unable use this method would seem, therefore, that must make some other approach the problem steel houses. New materials require new methods. With the use steel for the frame house change becomes evident the relationships the structural parts, and the functions walls, partitions and floors must studied the light new conditions. Many suc- cessful attempts will made bring together these functions and the materials that suit them. would unwise find fault with previous attempts solve these problems unless possible solution were 1G. 40.—Interior house. The floor exposed beams) only in. thick, including the finish surface. 752—The Iron Age, September 17, 1931 tal HAVE SEPARATE offered. The following attempt show the relationships the materials one another and the functions which they fulfill. The Wall ERETOFORE the function house wall has been support the floor loads, furnish rigidity, offer protection from the elements, and provide archi- tectural treatment for the exterior and interior. Such wall was necessarily heavy and built slow hand process. But the functions strength and rigidity are transferred steel frame the type used office buildings, that the columns are the corners the rooms, with girders between columns and filling floor beams, the frame becomes simple, made the cheapest shapes obtainable, has the vest pieces handle and takes but little space. allows the wall become merely clothing the outside the framework, and, having fewer functions perform than the old-fashioned bearing wall, offers great flexibility treatment and wide choice materials. Weight ceases essential. Small, heavy pieces laboriously piled one top another are not necessary for beauty. Fig. shows window slab making one unit from floor ceiling the window frame, sash and spandrel under the window. Insulation and heating unit can placed back this spandrel and fastened it. The Partition wood has been abundant this country, and wood studs, wood lath and plaster made cheap partition. But the expansion and con- traction the wood caused the plaster gradually loosen and drop off, made good housing for vermin and supplied fuel for any fire that might develop, and Was noisy. With steel frame carry all the loads floors FUNCTIONS ALLS, floors and partitions are three types ele- ments house construction lending themselves peculiarly the use steel members. Analysis their several functions helps determine what way they may best framed and built. the wall made merely garment, clothing the house, its construction will once greatly lightened. Partitions become merely curtains between rooms, the steel frame made carry all the load. And floors made slabs, with the beams exposed covered, can both fire- proof and inexpensive. This the concluding install- ment six this article telling what has been done, and what may done, the use steel for private dwellings. and partitions, the partitions are merely curtains between rooms. Sufficient strength carry their weight from floor ceiling can obtained without the thickness required the load-bearing partition. Good insulating materials are available. Partitions not have large, bare surfaces requiring special treatment break their monotony. The side room may made easily-handled units that themselves break the monotony, and re- quire artificial treatment make them attractive. Shop-made units may extend from floor ceiling and require labor after installation except decoration. The Floor difficult solve the floor problem until cease imitate the traditional wood joists with wood flooring fastened the top and ceiling plas tered the bottom. This was the only floor possible its day, but the entire construction had all the bad qualities wood construction. The flat ceiling was difficult and expensive decorate. With the use steel not necessary have the joists close together. Slabs ft. wide need not over in. thick cementitious materials are used. Such slabs are economical make, easily installed, can insulated for sound. The bottom the slab when installed ready for paint other finished decoration. Fig. shows exterior proposed construc- The Age, September 17, 1931—753 al ny the r ; sameness the finished product, here are twelve houses all having the same floor plans and framing oe oe ise es ts, ic- re >- n. e tion more clearly than possible verbal descrip- tions. The shop-made slabs are clearly defined, water- proof, economical make, easily handled and are toy and the bottom the Many materials, colors and textures can quickly fastened the steel frame. used for the face this slab, which allows greater flexibility treatment than has ever been known building construction. gives the artist free hand excellent work, unhampered tradition, and Steel enamel sheets resorting tne bizarre. 38.—Window slab one unit from floor ceiling includes win- dow frame, sash and the spandrel below. Erection this unit construction. The finished surface various colors are available. the slab made the shop. The amount insulation needed will determine whether the wall has thickness one slab, two slabs with air space between. double-slab wall should cost more than the brick veneer portion the typical wall now use. The interior such slab-formed room shown Fig. 40. Three inches thickness will give enough strength and sound insulation for non-bearing par- Iron Age, September 17, 1931 good architecture show the slab struction the artist does his work satisfactorily. blank wall characterless, paper, wood titions. and other expedients have been used present pleasing surface. can add character the interior decorati building into the wall instead applying the surface. Fig. shows also ceiling character cor a & 39.—House ished with shop-made waterproof ened top and bottom the steel skeleton the structure. here served texture and color well arrangement. nection with the wall. The distance from the ceiling between the beams the finished floor above need only in., and retain the necessary strength, stability and soundproofness, greater cost than the ordi- nary wood floor with its 12-in. depth, its combusti- bility and housing for vermin. Thin, strong slabs for walls, partitions and floors are made possible the use steel reinforcement and the strength the steel connections the steel frame. Such buildings could through the con- earthquake without loosening the slabs the frame. Steel used for strength, and insu- iting materials are used for insulation, and the rrect combination materials according their hope reach the goal good But the ability produce economical steel ame and slab construction will not solve the housing iestion. How create attractive house and then rchandise are problems equal importance. There are only few practical arrangements seven-room house. Give one floor plan hundred architects and they will produce hundred fferent expressions the exterior and interior. In- viduality attained the use texture and color the visible portions the house, and the fur- hings within and landscaping without. The struc- ral part the house may therefore standard oduct, without the sacrifice individuality. Fig. illustration the exteriors twelve houses ilt from one plan. have good materials that are cheap and that fer wide range expression. But have not assembling them economical satisfactory anner. possible that only one thing lacking solve the housing problem—the use these ma- rials cerrect relationship. corporation un- Developments High-Frequency Furnaces for Steel ROGRESS made the development and appli- ation high-frequency induction furnaces capacity, resulting from experience the pro- tion several thousand heats steel, has been viewed Broglio (Stahl und May and Electrical improvements included reduc- the stray field loss bringing the furnace closer together, and improvement the power reducing the frequency 500 cycles per + change frequency apparently increased the condensers. Air-cooled condensers were water-cooled, and instead tin-foil sus- between oiled paper, rolls aluminum ar- ved horizontally and cooled copper coils were Economy demands abundance capacity the battery condensers, for the walls the rucible become thinner the improved coupling re- more capacity correct the power factor, the condensers are too small, point will ‘hed where the power supplied the charge be- insufficient and crucibles still good shap ‘om ceramic standpoint must discarded. considerable saving time and expense was omplished the substitution lutting sand for ind was tamped between the furnace coil and pat- tern. After removing the pattern, the crucible was arefully charged and heated redness about hr. dry the crucible. After two melts the sand well sintered that there little danger The time for the first heat was reduced prejudiced building traditions should able employ these materials economically and efficiently. Art Must Not Forgotten Each type has evolved architec- tural expression suit the materials hand, the requirements comfort and the spirit the time. stupid insist adapting new materials old forms. The use modern products convenient shapes designed for proportion, color and suitability will result the sanest architectural composition. But the architect must more than craftsman must artist. His work only half done when the highest expression has been given the material structure the house. must also the dignity and beauty that are the spiritual structure the home. Many architects have experimented widely new architectural forms, with unsatis- factory results house, but have neglected the soul the home. They have expressed the body of the This article has attempted review the trials and failures the building industry and give some hope its efforts solve the problem the small house. The building industry whole must face the matter squarely. must not fail its share country where much has been accomplished for the betterment humanity. Here challenge that cannot ignored + about hour with saving power. metallurgical trouble occurred and the damp lining caused trical irregularity. One the chief advantages induction heating that the heat developed within the charge itself contrast most other types heating where the must somewhat higher temperature than the charge order that heat may pass through the container the slag layer the metal. The demands upon the refractories used are therefore less severe than the case steel production the crucible The churning action the high-frequency fiel homogenizes the charge and promotes reaction. difficulty with slag inclusions results the steel deoxidized the proper manner and properly poured. the charge allowed stand short time, the gases and inclusions have time escape; the drop temperature with the power off for 600-lb. charge 2950 deg. min. about 150 deg. The power required for test heat was 537, 150, and 687 kwhr. per ton respectively for melting, fining, and total. Ib. metal from the previous heat, charge 150-kva. furnace, while cold furnace the time may hr. The rapidity with which melts made high-frequency induction furnaces sug- yests replacement older steel-making processes rge units this type, exact prediction The Iron Age, September 17, 1931—755 CO Cor ade the is ure in “ + ; lg l- rs la BRONZE CASTINGS NOW MADE HENRI MARIUS Lenoir Car Works, Lenoir City, Tenn word “permanent” may not perfect technical designation iron molds now com- monly used casting bronzes, brasses, gray irons and aluminum alloys, but considering performance compared with sand molds—having frequently life close 4000 cast- the case aluminum alloys exceeding this several thousands—we cannot far wrong calling such molds permanent. Their chilling effect the chief metallurgical laim permanent molds. Thi produces castings free from metallic fine homogeneous microstructure, burned-in sand, and hence castings all-around strength and easier machineability. Results physical tests contained Tables and are representative actual foundry practice over period four They have been gathered to- ether order express figures (at least insofar strength concerned) the betterment quality ronze through permanent molding compared with All test bars were cut from actual castings and nent-mold casting, with the corresponding mold asting fr m which test bars were ¢ it, were j Permanent mold for locomotive floating bushing, showing gating arrangement and base plate which mold proper rests. 756—The Iron Age, September 17, 1931 identical pattern, poured from the same heat from the same ladle. Test bars were cut from the position each casting order have physical test the castings rather than the test bars, which are not always true representatives the phys- ical properties the castings themselves. Large Quantity Scrap Used Test heats were picked random. each case the furnace charge was composed per cent scrap and per cent new metal. The value the hardness figures Table must read conjunction with data Table appreciated, for part the small increase hardness the natural result finer, denser microstructure and corollary expression greater all-around strength evidenced higher elastic limits, ultimate tensile strengths and elonga- tion, shown Table the field simple leaded bronzes, now un- reasonably high vogue among wearing alloy manufac turers and users, permanent molds, addition im- provements caused the chilling effect fracture, increase the power the copper-tin alloys hold more lead. This due the tin combining with greater portion copper, thus promoting the forma- tion larger amount finer network copper tin alloy, which solidifying first retains the lead evenly distributed throughout the mass form fine globules until the lead turn solidifies. this manner per cent tin can hold much per cent lead copper-base alloy without segre- gation. Railroads Use Leaded Bronzes for Molds Unfortunately bronzes with such low percentages tin and such high percentages lead can have only limited industrial application, because their lack sufficient hardness, resilience, tensile strength and compressed strength. recent leaded bronzes cast iron molds have found favor with railroads, which use them extensively wearing al- loys for locomotive bearings. our opinion that highly leaded bronzes, will find more useful application the manufacture car-journal bearings, for possible produce from them harder, stronger and more rigid bearing than present, capable taking highly polished surface such anti-frictional qual- ity eliminate the the present lining alloy babbitting. al sand n lding | 4 4 j 4 : | ; from urate bars, Case crap with mall iner, PERMANENT MOLDS space 100 ft. and with total working force six unskilled mechanics, the Lenoir Car Works, using permanent molding practice, sets up, pours and shakes out (including transportation castings the cleaning room) 130 150 molds, representing different pattern bronze castings with total weight over 20,000 8-hr. shift. The life some molds close 4000 castings. This article deals with the company’s experience using permanent molds and discusses pouring temperatures, melting conditions, gating, risers, wall thickness molds, clamping molds and type iron molds. based paper presented the author before the American Foundrymen’s Association. red brass, permanent molds correct porosity and formation dendrites commonly found sand- red brass unbalanced composition which the hite metals such tin, lead zine are abnormally high. for the newer but rapidly expanding aluminum, they are among the easiest cast permanent molds. fact, any kind composition alloys can cast iron molds, pro- the design castings compatible with this molding process. bronzes the average foundryman may feel that effect iron molds liable produce hard brittle castings, gray iron and steel. Such not the case. Hardness simple bronze prima- rily function tin, which forms with copper several alloys, some hard, some soft. When consider the hemical valences these two metals, find that the two extremes these binary copper-tin alloys corres- formulas Cu,Sn and respectively. The itter called the because its lower melt- point and softer than the one richer copper, fact, the eutectic little harder than pure pper, that the end simple bronze hard proportion the amount Cu,Sn contains. The chilling effect the iron mold causes nearly all, not all, the tin remain the bronze the form Cu,Sn, whereas the sand-cast alloy the slow solidification has almost the opposite effect. There- fore, the same bronze composition, when cast iron molds, will harder than the sand cast only pro- the excess Cu,Sn plus the smaller portion ardness derived from the greater the chill cast alloy. ( Correct Pouring Temperature Important With iron molds the ranges pouring tempera tures are 100 deg. higher than when sand molds are used. For example, the pouring tempera $ ™ “= nag Duplex permanent mold for phosphor-bronze bushings, showing cores position. The Iron Age, September 17, 1931—757 un- fac im- ure, na- pad yn ture range sand-cast locomotive bearings 80-10- When iron molds composition 1700 1800 deg. are employed, the corresponding range 1775 1850 Since the molten alloy loses heat and fluidity incomparably faster iron mold, must possess these two physical conditions order for the metal deg. reach all parts the mold before becomes cold and and give sound casting sharp, well de- surface the mold those areas where erosion overheating have been greatest. Porosity and Oxidation Avoided Defects porosity and oxidation resulting fron faulty melting will made less apparent and less harmful the castings reason finer and homogeneous microstructure. Before poured, ive fined contours free from red spots, cold shuts, wrinkles melt should stirred with iron rod shaped like and draws under the riser and charac- paddle, thus imparting the liquid alloy the ladle ristic cold Likewise, the rapid solidifica- somewhat centrifugal motion which facilities the re- the iron-mold cast alloy hindrance the leasing absorbed neutral gases. The light and reiease of entra] pea alr or vases formed in the mold oe Ne oxides of aoe and tin and impurities suc h a absorbed the charge during melting, this alumina and sulphides will come the surface being especially pronounced iron molds skimmed away with the rest the slag. stings having thin sections. Since the molecular weights copper and lead ther hand, should the alloy poured too oxides are almost great those brass bronze, hot, erosion the mold face and the heating they are easily diffused and held throughout the mass will unnecessarily great and will hasten the metal, becoming more difficult extract stir- mold. Castings will come out with ring only. such cases small amount phosphor- here and there, caused volatili- copper magnesium will help effectively the purpose rbon particles peeled from the stirring reducing good part these oxides. a tr I—COMPARISON PHYSICAL TEST DATA SAND-MOLD AND PERMANENT-MOLD CASTINGS GROUPED ACCORDING CHEMICAL ANALYSES Composition Heats Grouped Together Sand Cast Permanent-Mold Cast Test I ee I t Tensil Per Cent Elast. Limit Tensile Per Cent Sq. Strength Elon Lb. per Sq. In. Strength Elong 17,440 28,210 20,050 32,000 17.5 17,930 30,300 20,000 35,000 20.0 16,410 28,100 20,500 33,650 19.0 15,900 27,480 14.5 20,750 15.5 18,750 29,450 20,000 34,750 20.5 14,150 19,000 18,700 29,420 14.0 13,070 16,130 20,100 26,730 permanent set fraction inch under 65,000 load one-inch cubes Sand-cast 0.184 Permanent-mold cast 0.162 7.50 11.50 13.50 per 0.50 per cent; 0.10 0.35 per cent GROUP Composition Heats Grouped Together 200 15,000 23,040 18,500 25,150 70-26 120 15,350 24,000 18,000 27,150 76-27 175 16,670 23,250 17,600 26,750 8.4 +-28 240 14,400 18,600 18,700 27,800 6-28 150 12,000 22,450 14,200 23,700 14-28 15,900 26,650 17,350 28,000 14,170 18,850 19,250 27,740 10.5 Average permanent set fraction inch under 65,000 Ib. load one-inch cubes Sand-cast 0.240 Permanent-mold cast 0.204 22.5 per cent; per cent; 0.70 1.30 per cent; 0.35 0.60 per cent; GROUP Composition Heats Grouped Together M77-27 120 18,300 35,500 20,000 40,150 M90-28 100 17,940 19,380 34,000 17,700 30,200 18,150 34,600 M104-28 17,650 31,500 18,500 35,000 M19-29 15,080 16,930 21,860 31,660 16,000 18,600 5.5 21,500 26,300 ent; per cent; ind 0.0 0.2 per cent three grou 0.505 from which test bars wer ht rave Age, September 17, 1931 However, watch diligently the whole elting process prevent the expensive and ineffec- doping the melt with fluxes doubtful value, method which the average foundryman tries from trieve carelessly melted heat. Ideal melting condi- less can obtained only when melting done utral atmosphere which the amount heat trans- the tted the charge melted remains constant time unit throughout the melting period. this impossible, the essence good melting practice then ike a ladle re- ymes strictly matter learning how control and intelligently regulate this atmosphere between asonable limits suit the needs the charge melted. Bottom Gating Necessary lead Use bottom gating almost necessary for mass duction sound castings permanent molds, danger undue erosion and overheating small stir- reas the mold surface, caused rapid and direct the hot molten metal, avoided. Bottom gat- also affords better upward draft for occluded generated gases from volatile matter the mold Moreover, the metal coming from the ite the bottom rises the mold evenly and gently lays the walls the mold; there splash- vith its subsequent formation cold shuts and hor- ating. pockets. To he conclude II—BRINELL HARDNESS CASTINGS TABLE GROUP 1*Chemical Composition Heats Grouped Together os Thickness,*+ Weight,? Depth,** Brinell No in In. in Lb in In Sand-Cast Permanent Mold Cast Avg Avg. 65.5 Avg. 61 6 61 Avg 67 120-28 1 40 4 65 69 64.5 Avg. 69.5 \ 28 3 240 1 4 62 64 1! 2 50 4 Avg. nt; Zn 0.50 to 1 per cent; Sb 0.10 to 0.35 per cent; ed 0.10 to 0.30 per cent : See Table I for analyses of metal of the three grouy and weight castings from test il r f istings te GROUP Composition Heats Grouped Together Heat Nos. Thickness, Weight,t Depth.** Brinell in In in Lt in In Sand-Cast anent Last 57 35 Avs 58.5 7 0-2¢ l 20 57 Avs 7 2 58 60 54 Avs } ) ) 1 ) ? ) 26-29 l 60 ] Ta I GROUP Composition Heats Grouped Together Heat Nos Thickness Weight Depth,** Brinell N in In in Lb in In Sand-Cast Pet : nt M M 4 6 ) 6 ( 5 Ay é M48-26 l 15 61 0 + 6) 6 ¢ Aves 68.5 61 Avg 61 l 57 60 Ave. 61 Avg 63 1 55 56 Avs 66.5 1 62 59 A 6? l 53 fh) 51 »4 M21-29 Ni 1 I I of nm *T } The Iron Age, September 17, 7 Avg. 4 Avg. *Cu 13.50 per indetern NOTE **Dey KAUERMANN Consulting Engineer the United States for Schiess-Defries A.G., Diisseidorf, Germany DVANCES the sound, close-grained technique producing castings,