The Iron Age 1931-10-08: Vol 128 Iss 15

IRON NEW YORK, OCTOBER 1931 ESTABLISHED 1855 VOL. 128, No. evils mechanization form popular home. One has have “goat” for the pres- ent condition employment. Mahatma Gandhi takes goat and spinning wheel about with him wherever goes. not certain that the goat Gandhi typifies him, addition nourishment, the evils mechanization. known, thanks our own Mr. Charles Chaplin, that Gandhi’s spinning wheel does. For when these two distinguished world figures met recently London, their conversation hinged upon improved and unim- proved machinery. “‘Wouldn’t better,” suggested the professor pantomime, referring the spinning wheel, “if you used more up-to-date textile machin- ery?” And Gandhi replied: machinery would give our people too much leisure.” “DAT OLE DEBIL,” MACHINERY JOHN VAN DEVENTER Consultant, The Age Saints and sinners, they are all talking about mechanization. The term “machine age” becoming synonymous for less jobs for more people. Serious proposals are being made—and will made Con- gress probably, ban improved machinery some our public works projects. The good old dog rap- idly acquiring bad name. Just few weeks ago, the president promi- nent engineering society was quoted the press having said that inasmuch engineers and inventors had brought about this condition unemployment, was them find the way out for us. The first part that statement will probably stick lay minds longer than the last part it. The general public goat hunter. Multiply these instances thousands and tens thousands; pick almost any newspaper almost any q ; a4 | | 923 7 day and you will agree that the getting the spotlight nowadays. Out all this tight and loose talk crystalliz- ing, lay minds—and this includes political and leg- islative minds, too—a rather unflattering portrait mechanization and what call modern production. The chief attributes the subject appear be. hoofs, horns and barbed tail. “Dat Ole machinery seen action this picture, tormenting un- employed millions with the red hot fork technolog- ical displacement. Machinery Needs Voice Thus far, the machine has paid little attention the derogatory remarks and opinions hurled its di- rection. Knowing that most these were expressed those knowing the least first hand about the matter, continued quietly about its business, per- mitting adverse comment slide unnoticed from its iron back. But now that this thing has gone far saddle with chief responsibility for causing the present maladjustment world affairs, due time for the machine rise upon its hind legs and speak its piece. And also for the friends mechanization and modernization join the chorus. Otherwise, the gathering clouds adverse public opinion may cast enduring shadow over the machine, the men who build and the men who use it, well over our future prospects. Make mistake, the machine has convincing story present the public, story not based upon plausible theory but upon forthright facts. story 924—The Iron Age, October 1931 that undeniable record performance. The machine cannot tell you who what did cause this depression and neither can anyone else. But can and will prove beyond question that mechanization has built breadlines. The machine can look the public the eye and say it: “Here record, attested Uncle Sam. You can see that forty years active and increasing use, have not deprived one American worker employment. Whenever have closed one employment door have opened another and larger one.” “But,” you may ask, “what about technological dis- placement? know actual cases where scores men have been displaced from their jobs because machine improvements.” which the machine will reply asking another question. “Do you draw balance sheet from one side the ledger only? Then why consider displacement without taking replacement into account, also?” What Years Mechanization Have Done Employment have done most effective work,” says the machine, “in the manufacturing industries. have wrought with increasing vigor your shoe factories, steel works, automobile plants and hundreds other production plants. During the past forty years have fathered countless progeny improved mechanisms which are work turning out every variety prod- ucts from pins printing presses. Surely, were gobbler men’s jobs and creator unemploy- ment, would have been evident during the past years. “Let us, ‘Al’ would say, examine the record. 1889, years ago, there were human workers per thousand population employed these ‘manu- facturing’ industries that some have called the ‘hot bed mechanization.’ 1929, after mechanical offspring had been put work for forty years these industries countless increasing numbers, there were 72% flesh and blood workers employed therein also per 1000 population, more than the average number per thousand population for the entire 40- year period. And this despite the fact that this aver- age included the superintensive year 1929, when industry was still geared war proportions. “Does this look had caused unemployment, permanent displacement even those industries where have been work most intensively? VEN the “hot-bed” mechanization, the manu- facturing industries, improved machinery has caused displacement labor during the past years. For the number workers, 1929, this industry, was greater per 1000 population than the average num- ber for the entire year period. ‘4 ERE are the facts about technological ment, and replacement also, during the last ten years: Sixteen workers left the farm, field and forest. One left the mines. Four left the large group comprising manufacturing, construction, etc. Total shrinkage, workers, the basis each 1000 population. Seven these went into transportation; seven into professional service and seven into domestic service. addition absorbing the whole 21, three new workers were required clerical and miscellaneous work, and one new worker for public service. net gain workers per 1000 population during the last ten years. are the figures; you may wish show them those who have been saying hard things about me. DENSITY EMPLOYMENT OUR MANUFACTURING INDUSTRIES Wage Earners Census Wage per 1000 Year Earners Population Population 4,252,000 61,775,000 69.3 5,468,000 82,601,000 66.3 6,615,000 90,691,000 73.0 8,998,000 105,003,000 85.5 6,944,000 108,196,000 64.0 8,350,000 118,140,000 70.6 AVERAGE...... 72.3 Data from Statistical Abstract the United States, 1930, page 791. “During this same period forty years, not only have not diminished the number jobs the man- ufacturing industries per thousand population, but the wages the workers therein have been almost doubled, not merely dollars fluctuating value, but real buying power. Therefore you cannot charge with causing unemployment, and you must credit with nearly doubling the consuming power wages. What Years Mechanization Have Done Total Employment Some may say that the machine stating this case, has been telling only part the story em- ployment; that the manufacturing wage earners industry represent but one-fifth our total number breadwinners all occupations. What has hap- pened the other four-fifths, including the farmers, the miners, the lawyer, doctor, business man and clerk? Mechanization has not been confined facturing; have had the farm, business and the home. The machine has convincing answer this ques- tion. “In 1900,” says, “there were 383 breadwin- ners the United States for each thousand popu- lation. These included all ‘gainfully employed’ all lines industry, agriculture, business, professional service, domestic and public service, etc. The Iron Age, October 1931—925 gf “In 1930, depression continues the ma- chine, “we find the density employment greater in- stead less. There were then 398 breadwinners for each thousand our population; gain work- ers per thousand over 1900. Look any way you over the whole picture man’s work sec- tional part it, participation has multiplied jobs; not diminished them. Occupational Shifts During the Past Ten Years “Take even the past ten years,” mentions the ma- chine, “during which time technological displacement said have been accentuated. Let examine the record displacement and replacement, for can- not strike balance without putting the credits along- side the debits. “Here the occupational balance sheet, per thou- sand, occupational groups during the period be- tween 1920 and 1930: “Sixteen workers left the farm, field and forest. One left the Four left the large group combin- ing manufacturing, the mechanical industries and con- struction. This represents all the losses, total workers per thousand population. $23,912,000 $22,166,000 $20,784,000 $12,452,424 $13,687,424 $12,137,881 co 926—The Iron Age, October 1931 25,143,000 non-productive overhead has been going up. Perhaps this one the reasons for our present troubles. 1910, the number workers non-productive groups the type was per cent our wealth producing group workers. 1920, was per cent. 1930, was per cent. The machine has been carrying more and more passengers its back. “Seven these displaced workers went into the field transportation. Seven more them were ab- sorbed into professional service. Seven more entered domestic service, thus completing the entire aosorp- tion the displaced. But addition this com- plete replacement, three new workers were needed for trade, clerical and miscellaneous work, and one new worker for public service. net four workers per thousand side the employment balance sheet. And remember, 1920 was boom year; 1930 depression year. “No,” concludes the machine, “you cannot make the scapegoat depression. For years, and more, record has been one construction, not de- struction. and into the depression year 1930, have continued build employment. work has been the honest creation new values and new wealth. has not been the blowing specula- tive bubbles. not fault you built upon back structure inflated capital values too great for any machine carry, and which finally toppled under its own excessive weight. Put work again, honestly and intelligently, and will again rebuild wealth and employment.” $60,508,000 ERE the record cost the Department Agriculture; the “service the American farmer. has gone up, cost, 718 per cent since 1914. This service costs $28 per farm per year today. $36,822,000 31,526,000 87% expenditures form part our general Here the way which the cost the Department Commerce, which the “service industry and business, has gone up. 585 per cent increase since 1914. $23,676,000 $27,108,000 $30,942,000 $36,973,000 Instead ascribing our present troubles too rapid advance efficiency production, might find them increased “overhead.” Agriculture, mining, manufacturing and construc- tion are our basic wealth producers. These groups industries, with the aid machinery transform our natural resources into needed and pleasing things for mankind. Without them, there could creation distribution wealth. Transportation, trade, public, professional and do- mestic service are necessary adjuncts production, and living. They facilitate wealth production, but themselves they create new values. They may called our Here the way our “overhead” has been going up: 1910, the number workers comprising the “overhead” occupations was per cent the num- ber the “productive” groups. 1920 was per cent, 1930 was per cent. pretty rapid in- crease years’ time the number passengers riding upon the machine. Transportation, for example, jumped from 28.6 workers per 1000 population 1910, 36.1 1930. Professional service jumped from per 1000 1910 27.9 1930. Public service jumped from per 1000 1910 8.6 1930. When overhead increases faster than volume privately owned industrial plant, the management sees trouble ahead. And, wise, begins prune. More men, women and machines engaged our actual wealth production and fewer lawyers, politi- cians, public servants, financiers the may one way refinance consumption. What Goes Stays Certainly, slowing down our machines and declaring moratorium improvement will not give the $66,891,000 $196,175,000 $169,660,000 $74,637,000 $66,420,000 wherewithal pay either more doctors’ bills divi- dends. “What goes must come old proverb which seems apply quite aptly successive busi- ness cycles. Overhead creeps unawares dur- ing profitable times. Additional services, which cost money, are instituted for the benefit our customers. When the time prune overhead comes, sur- prising find that can dispense with great many the “services” which thought were indis- pensable. pare the overhead structure down close the machine that carrying possible, not through choice, but necessity. the machine had voice; were gifted with organized influence had the oratorical powers congressman, might say word two Uncle Sam the matter government overhead. For gov- ernment the old proverb does not work. What goes stays up. When government income falls, the first thought our legislators increase taxes. Pile more burden the back the machine, lame though may be. The last thought prune the overhead. the machine could speak with the eloquence and influence that its record entitles to, would say Uncle Sam: “Investigate and prune your overhead. Your government employee’s job and pay more sacred than the jobs and the pay the men and women who work with industry; the farm and the mine. “Look, for example, the record expenditures for the Department Commerce, the service depart- ment for business and industry. Its cost has 585 per cent since 1914, compared with our na- tional business increase little more than half that percentage. With its commercial attachés scat- tered broadcast over the civilized world, feeling the pulse business and industry every land; with its elaborate fact finding and statistic interpreting organ- (Concluded page 983) The Iron Age, October 1931—927 z CONVEYORS INSURE MAXIMUM LEXIBILITY the word which probably best describes the new gray iron foundry the American Foundry Co., Indianapolis. signed make cylinder blocks and other cast- ings for the automobile industry, arranged get maximum production minimum space largely means mechanical conveying equipment. The com- pany has abandoned straight-line manufacturing favor U-shaped formation with the maintenance department and material storage yard the center. Only moderate size, the plant has combined the best practice the large foundry with the favorable fea- tures the small. The result efficient plant operating surprisingly low cost. Four Independent Foundry Units Four separate units, each independent the other, make the foundry department. The two the west end the building are identical and are used for high production jobs. The third unit run fair-sized orders. likewise supplements the work the first two units whenever desirable. The fourth bench work unit for special castings the quantity which does not justify putting them through the mechanized monorail conveyor dips shakeout station pick castings taken cooling room. Foundry unit No. the background. . 928—The Iron Age, October 1931 process. This system enables the company segre- gate its orders according size and intricacy de- sign and, effect, have within building 100 160 ft. four complete molding, pouring and sand-condi- tioning units. Molds are made unit No. four molding ma- chines set 14-ft. turntable made 12-in. channel irons. the outside the channel irons are angle clips support gear rack. Reinforcing the table are 6-in. I-beams, which extend across the table right angles and are welded the channel irons, thus forming the support for the grate top the table. The table itself rests six 16-in. chilled cast iron wheels, being driven 5-hp., 1200-r.p.m. motor. The turntable rotates variable speed one revo- lution min. one min. and can set meet the ramming speed. Serving the molds the turntable sand slinger, which fills flask sec. The flask then lifted air hoist steel conveyor thence passing through the various operations cleaning, spraying, skin drying and core setting. When has reached the opposite side the sandslinger, the cope added and the mold travels the pouring station nearby. After TRAIGHT-LINE manufacture gray iron castings has been aban- doned the American Foundry Co. Indianapolis favor U-shaped formation, with the maintenance department and material storage yard the center. There are four independent molding, pour- ing and sand-conditioning units building 100 160 ft. Two units are identical and are used high-production jobs. The third unit run fair-sized orders and supplements the work the first two when necessary. The fourth bench work unit for special castings. Two 84-in. cupolas are connected with two centrifugal blowers, the smaller which used when the hourly melt tons less and the larger when more than tons. Thus the cupolas are operated alternate days steady run business, this practice being employed prefer- ence having different-sized cupolas for large small production. the iron has been poured the mold stays the con- veyor for min. until arrives the knock- out machine. Following the knockout, the casting lifted air overhead monorail carrier and taken the cooling room. Incidentally the knockout machines for units No. and No. are close proximity, only the steel storage table separating them. This makes possible for the monorail conveyor serve both units econom- ically and with minimum trackage. Sand from the passes through the shake- out grate apron conveyor over which mounted lump crusher consisting balanced pulley in. wide The crusher breaks the large lumps sand before they pass into the general foundry sand system. The apron conveyor, running speed 100 ft. min- ute, delivers the sand from the shakeout second apron conveyor which col- lects the spillage sand pass- ing through the grate the turntable. This con- veyor discharges the sand inclined apron belt conveyor, which carries riddle ma- chine. Near the upper end the inclined con- veyor and directly above magnetic pulley belt which draws from the sand any tramp iron and dis- charges into barrels. the top the inclined conveyor the sand goes through reciprocating screen in. equipped with 5-hp., 1200-r.p.m. mo- tor and having capacity for handling tons sand hour. Below the screen new design, consisting two rubber-tired mulling wheels rotating 42-in. conveyor. Each wheel operated 15- hp., 1200-r.p.m. motor. Sand falls the muller through chute 24-in. belt conveyor which clined belt conveyor run- belt near the ceiling, these last two conveyors forming The cross belt con- veyor equipped with re- versible drive, that The Iron Age, October 1931—929 ing conditioning unit for high preduc tion work. Molding machines are set turntable ground). Sand slinger fills flasks sec Various operatiens cleaning, spraying skin drying and core setting are performed conveyor can alternately fill with sand the 50-ton hoppers which are part both the first and second units connection with the hoppers are two sand which aerate the sand and deliver the hoppers. The hopper for each unit located that discharges sand into the sand slinger beneath Third Unit Handles Tons Sand Hour The third foundry unit consists mold conveyor and sand-conditioning machinery. The 30-in. gravity mold conveyor comprised straight section ft. long. 180-dey. bend section with radius the center, and another straight section ft. long. From the knockout station back the posi convenient positions opposite the sand hoppers two jolt roll-over machines for the drag and cope. After the various molding operations are completed, the iron poured with the mold resting the conveyor. The mold then pushed air operated device along the gravity until arrives the shakeout There the casting lifted out the mold and placed the same conveyor which serves units slowly for min station. No. and No. the cooling room. One out every four carriers the conveyor passes units No. and No. and picks casting from unit No. the vibrating screen the shakeout the sand freed from lumps, core rods and gaggers, passing through hopper 18-in. magnetic separator 930—The Iron Age. October 1931 steel conveyor which carries ft. chute and thence into measuring hopper, deflector plate taking the tramp iron down passag way into metal containers the floor. The sand through the gate the bottom the measuring hopper into 8-ft. Simpson mixer operated 900-r.p.m. motor. From the mixer the sand taken 20-in vator nearby, which carries ft. and discharges into conditioner. Here the sand aerated seasoned, being delivered distributing belt veyor which takes four hoppers with gates operated from the molding stations. No. has capacity handle tons molding hour. Only Bench Work Fourth Unit Unit No. adapted solely bench work consists several portable jolt squeeze machines which the molds are made. There are two small hoppers below which the molds are prepared. molds are then picked hand and placed roller conveyor, which transports them the cupolas where the iron poured. Remaining the conveyor, they pass the opposite side unit and are shaken out hand directly over sant throwing machine, which throws the sand into hoppers. Each the two cupolas has melting unit No igh preduc centrifugal blowers the smaller which used the hourly melt tons less and the larger more than tons. This practice makes ble operate the cupolas alternate days run business and employed preference ving different-sized cupolas for large ‘tion. There actual saving operating this method and the investment less, thereby ing overhead expenses. foundry department equipped with Louden ead monorail conveyor system, spreading out from upolas all four the pouring stations and hing into other parts the department. Hot from the cupolas tapped into 2-ton ladles, are hung the monorail conveyor and moved men the pouring station. Slag from the (fore taken large buckets the Louden con- slinger into the yard where dumped. sec material storage yard, under roof, 180 ft. Spraying and core eyor and divided into bins for coke, limestone, vari- pig iron and cast scrap. served 3-ton overhead electric cranes. Cars can alongside the yard, which siding main line the Indianapolis Union Belt Railroad. per cent the material goes direct from railroad freight cars down chute into cupola ing bucket, which rests scale. After 2200 made up, the bucket picked Shepard 3-ton charger, taken the cupola and tied through the bottom the bucket. Five men required get the material from the railroad rht cars into the cupola: One man (crane oper- inloads the cars, three men make the charges PaSsag AS 4 -in ket : charg RECIPROCATING ted handling elt hour and continuous quipp ler new design unit No. sal ines all m n nto Ing and one man operates the charger. This crew handles 125 tons day. Cooling Room Feature Castings which have been knocked from the molds are transported the overhead monorail conveyor from the foundry department the cooling room adjoining building. This equipped with sepa- rate somewhat heavier monorail conveying system. operated independent unit that will not tie either the foundry conveyor the one serving the finishing departments. Castings are transferred from the foundry conveyor light crane. Arranged the form loops running the length the cooling room, which under roof but has side walls except one separating from the finishing departments, the conveyor timed that casting route hr. from the foundry department until arrives the knockout machine the end journey through the cooling room. The casting removed from the conveyor and placed the knockout machine second light crane. material drops inclined belt con veyor, which takes through magnetic separator and thence into refuse tank outside the building. From the knockout machine, castings are lifted carried to the tu nbling barrels where they are cleaned They then pass overhead conveyor through sandblast room and are delivered one four roller conveyors for the finishing operations grinding buffing and inspection. casting has defect which can remedied without its being totally rejected, hung The Iron Age, October 1931—931 — 4 4 When sand needed core room, flows from storage bin through door wall into measuring hopper wheels, which pushed hand sand-mixing machine where dumped. machines are installed pit ft. deep with their tops about half foot below floor level. overhead monorail conveyor the end the roller conveyor lines and taken special repair department nearby. When this department has completed its task, the casting returns the head the finishing department travel again through the final oper- Core Sand Stored Building Sand for the core room unloaded from railroad hopper cars into Link-Belt track hopper, which feeds apron conveyor leading bucket elevator. This elevator discharges the sand distributing belt run- ning the length the sand storage bins. inter- vals ft. along the belt are plows which divert the These sand various parts the storage space. per cent goes over the end the belt and put into production immediately. All the sand the production line forms reserve supply, which drawn upon principally during the winter months. having all sand stored inside the building, the com- pany has eliminated troubles arising from frozen and sand which has mixture deleterious matter acquired outside exposed stock piles. When sand needed, door the wall storage bin opened and through the sand flows into measuring hopper wheels, which then pushed hand sand mixing machine where dumped. These machines are installed pit Cooling room has separate monorail conveyor arranged loops running length room (right). After cooling, castings are knocked out machine foreground and extraneous material passes belt and into refuse tank outside the building. 932—The Iron October 1931 Castings then are hung monorail conveyor (extreme left) — ig 4 — hs. nN Sal ore the flows hen with their tops about half foot below the through the finishing assembly operations, setting evel. After the sand mixed the operator pulls them the conveyor which delivers them dipping control from the floor above the machine, pen- tank. Here they are placed hand dipping door the side the mixer and allowing sand frame which holds cores. The frame then through electric riddle. lowered air hoist into the dipping tank. rom the riddle the sand drops into steel hopper, When the cores come out the tank, the drippage divided into four equal sections and which blown off air and the cores are put steel racks the same capacity the mixing machine (110 again and transported second time electric truck 14.7 cu. ft.). While the hopper being filled, the core ovens, where they are dried for sts dolly track the basement the min. After removal from the ovens, the cores which carries down aisle between two spection and storage. They are delivered needed core benches. opening separately the direct the molding floor the next building divisions the hopper, the operator can deliver previously stated, the U-shaped buildings sized cupolas for large small volume serves the cupolas. sand four core benches, two each side the regarded superior straight-line arrangement for handling material and for service demands. The \fter the hopper has been emptied its con- maintenance department occupies small building returned the monorail position di- the center the where all production department above open pit adjoining the sand mixing are readily accessible. The material storage building machine. Here lowered the dolly, which moves are the middle, with the silica sand rravity underneath the electric riddle. The core structure close the cleaning department. One the room equipped with two mixing machines, one for storage buildings used for fireclay and molding sand wi rs » } » tu mi for run work and another for special sand, with space between the two materizls for mixing the dry jocket grade. For certain types for ladle and cupola linings. addition the manu sand dried Pangborn sand dryer. acturing buildings there whicl not only houses the executive staff, but also lipped 18 There are six rows core benches with 1 vith snowel atns and lor empiovee hes each row. Steel core racks, ft. ft. high, are stationed behind the core makers. Equipment for the new plant was supplied racks are picked electric trucks and taken following firms: Foundry units No. and No. core ovens, which there are arranged the Beardsley Piper Co., Chicago; foundry unit rows, seven the row. Holding two core racks No. III the Bartlett Snow Co., the ovens are oil-fired and the brick, station- and conveyor serving the core department ype, Link-Belt Chicago: overhead monorail \fter period hr. the ovens, the cores foundry department and finishing department emoved truck and taken steel shelves nearby the Louden Co.; overhead monorail conveyors from mporary storage. Paralleling these shelves foundry department cooling room and cooling roller conveyor ft. long beside which men room, Palmer-Bee Co., Detroit; and core ovens, Foun- portable benches. These men put the cores dry Equipment Co., Cleveland. The Iron Age, October P- « a - | — 1: behind hich = . | 4 ~ A a _ the May meeting the American Iron and Steel Institute, the author presented paper entitled “Corrosion Resistant Alloys the Stainless Type Use and Fabrication,” abstract which appeared THE IRON AGE, June 11, 1931. The discussion this paper led the sugges- tion that was pessimistic regarding welding these alloys. view these remarks and fairness both myself and the industry, the author feels justified writing this article clear the air, feeling that this there has been spirit, some extent, between the manufacturers welded and sign. However, today most fabricators an) ing are position build such equipment manufacture chemical equipment eith welded design riveted design, becomes obvious that any doubts that remain are those tained either the manufacturer the mate: the ultimate user. The fabricator usually concerns himself wit (left) representing the various metallographic conditions which can pro low-carbon chromium material with welding rod the rustless steels after welding. may advantage alike the manufacturer the materials, the fabricator and the user chemical Chrome Iron for Chemicals the time the first chemical installation for the manufacture nitric acid was the subject discus- sion, was decided fabricate this from chromium iron. Riveted design was decided upon because the air-hardening tendencies the lower chromium al- loys, and further because the higher chromium alloys, while non-hardening, were subject grain growth and subsequent embrittlement. should understood that that time (1925) comparatively little was understood the chromium- iron alloys containing upward per cent chro- mium, far the fabrication this type in- stallation was concerned. The first installation, how- ever, established something precedent not only for the use upward per cent chrome iron, but also riveted design. this and successive installa- tions can traced the popularity chrome iron and riveted design the United States contrast with much the welded work the chrome-nickel type found use abroad. The author realizes that for considerable time 934—The Iron Age, October 1931 physical condition the material, this insta! with its malleability, the facility with which ca! hot and cold worked, and, course, whether the material can welded such way least closely corresponding those the adja metal. Beyond this point, rule, the fabri does not go. The manufacture the material his hands and seldom does know much metallurgy the case details the corrosive ditions the equipment must meet. Therefore, eliminating the fabricator the two parties who are really the deciding factor riveted welded design become the steel manulat- turer himself, because his knowledge the and the chemical engineer who going equipment contain some corrosive solution. The early optimism alloy manufacturers allowed unqualified statements forth that ++ welded joint can produced with physical prope! llav } the aly, ~= Wl equipment. ¢ Wii could readily welded either oxyacetylene tric are led considerable difficulty when manufacturing equipment. was this opti- the manufacturer materials and welding that led considerable trouble; but op- not without its advantages, and failures, the causes are known, while unpleasant, are the necessary stepping stones the attainment lesired result. With this foreword let pass and study the rials themselves, following the history develop- and the progress made the art welding. welding means more than sticking two pieces together with third piece the same vsis, one might say that most our difficulties een overcome, but welding when comes corrosive solutions, gases vapors becomes tion involving mechanical, metallurgical and problems, assuming for the purpose the =>: 2—Section through spot weld gage low-carbon per cent chromium material. (Monypenny, “Stain- less and TEEL STRUCTURES nro ighout the Unite ik HOLLAND NELSON Consulting that the material various lecture tration that the chen find id, { while have stainless an distin ‘tly erritic type. Let take two this material, which would the only ricator would interested in, and them with the same type welding rod elding whatever method deavor introduce liquid metal the tion into area between two pieces metallurs lly and ally different nditior Fig. illustrate the writer’s haps thi seen fre hav introducing the liquid metal F., quite number complications whi ing the behavior such surf ntact with any type corrosive T the first place, with the lower sufficien steel the Brearley type. materials, irre tive carbo air harden pes ferred Philadelphia ana welded and have given d Stat list can ANY problems arise when either the riveting welding the vari- ous rustless steels under consideration. Air-hardening tendencies have made satisfactory welding the lower chromium alloys difficult. While the higher chromium alloys are non-hardening, they are subject grain growth and embrittlement. Welding apparently can done most successfully with chromium-nickel steels the and type. The author, recognized authority this field, states that many weld failures are due reliance small test pieces examples welding results and deprecates this. concluding article will discuss carbide precipitation and other important problems. have produce serious attack 14 per ce nt \ used them constant this subject the illus- many things, but and correspond more phy sive ce im Duce Practical content, or eT! tne the al mi ight n mbinat erie tter that 2700 ould 1 wnen n or er miurr extremely difficult upset fundamental laws many things the same chemically, difference within n- re The Iron Age, October 1931—935 Vet z ther se Tel ite rious cent rod is in ther ditions Original Stainless Steels Are Air Let nal l it Can | r or n f ‘tors Ol ICLO! nanulac- h ve he all h 4 < use | h whit Fig. riveted digester (Cr 18% 8%) for use the nitrocellulose industry. terials, have the air-hardening type. introduc- ing the molten weld metal obviously create heat gradient away from the weld metal itself and this produces hardening and tempering effects various legrees. The weld metal itself chilled quite rapidly and would either martensitic, martensitic with some austenite. present, whereas the material the heat gradient adjacent the weld would vary structure according the temperature attained. Now physically, what have the weld metal itself have partially martensitic cast structure. The plates themselves represent the annealed struc- ture the wrought metal. the area adjacent the weld have variety structures explained } above. Welds from the Standpoint Let now consider the weld from the fabricator’s standpoint. Such welds rule are comparatively hard and brittle. many cases, hardening cracks will develop the welding proceeds, usually not only the weld metal itself but alongside and parallel the weld. Knowing that with the per cent chromium alloys have material that will harden and temper, would appear that heat treatment annealing) all that necessary remove this con- fully anneal the whole structure. However, when have accomplished this, from our knowledge cor- rosion resistance relation these lower chromium alloys, have the material its least satisfactory condition withstand corrosive attack. Moreover, are still without homogeneous structure between the weld metal introduced and wrought material the plates that have been welded together, and this very often quite sufficient generate electrolytic action between the two areas producing failure this point. Rustless Steel Types Not Air Harden Passing the higher chromium alloys, and this mean the material containing carbon under 0.10 per cent with chromium per cent high per cent—these materials not air harden, 936—The Iron Age. October 1931 they belong the type and therefore one might ably assume that the chromium alloys with bon content could without this hardening brittling tendency. mean embrittling produ tially this true, and repeat that, the art ing was pieces together, these could welded entirely satisfact However, chrome alloys, when subr elevated temperatures, subject rapid grain growth and whereas sible weld them the sense making complete unit, again have physical together with physical properties which are far those desired. Fig. illustrates fairly well the author’s viey this subject. Here again are confronted with terial with extremely large grain size the weld metal and various degrees grain size the heat gradient away from the welded metal. The physical weakness the chrome alloys wit! large grain size well known; their resistance shock practically negligible, however, pointed Dr. Becket his discussion the paper previously referred to. possible certain hea treatments toughen this structure somewhat, again are confronted with the varying phy conditions producing electrolysis certain electr lytes. However, should clearly understood author realizes that, with the higher chromium electrolysis many chemical solutions can substan- tially disregarded. The physical weakness, however, must given due consideration and limits the such welded structures considerably. Repeated reference has been made heat ment, but when understood that temperatures + ward 1700 deg. are necessary and where installa tions the magnitude Figs. and are once apparent that simple matter and that anything that could done render suc! step unnecessary would decided advance. Small Sample Tests Unsatisfactory and Misleading Perhaps the cause more failures than prepared admit due the willingness facturers submit small sample test pieces we! material for the purpose tests. Usually such pieces can welded without cessation the welding operation any point and such small pieces can readily heat treated. has been the regular custom submit such pieces for the purpose demonstrating the mec! cal strength, the soundness the weld and its Ay ~ — Xe | | 4 0 nted out heat all iowever, attack. are make cannot too much for piece pocket size when dering installations involv- hundreds tons mate- They cannot consider weld that stopping, etylene ss, indicative equip- involving welding where stopping starting But the fabri- and chemical engineer, and use the granted from can made the electric evidence two three feet. cannot consider test pocket size which can heat treated pro- ideal conditions indicative huge installa- for which ‘at treating. here would only limited means Therefore have passed through era Wherein the manufacturer’s desire propa- sales has led claims being made, not with deliberate intention mislead, but with the that, from test pieces submitted, the fabricator able the manufac niniature. duplicate the larger structures turer had been able demonstrate this direction not unmindful the fact several large fabricators have installed furnaces the treatment completely fabricated equipment. However, the best knowledge, little this can deg. And, whereas this treatment decidedly vantageous and would render such equipment per- tly satisfactory for many purposes, could ans considered the metallurgical ideal, being nerally agreed that produce complete homogene- with all carbides solution the and type ome-nickel alloy temperature approximately deg. would necessary. the difficulty such tempera- supporting complete structure mediately becomes apparent and one the seri- drawbacks obtaining the ideal conditions led structures the chrome-nickel series. Special Atmospheres and Coated Welding Rods if ‘rom time time claims are made for different pes welding equipment. variety claims are these various improvements and ability surmount obstacles experienced elding these straight chromium and chrome-nickel vs. Sometimes the use special at- that will insure certain condition; other the use special coating the welding produce the desired result, but ask the reader this problem practical one. Atmospheres and welding rod coatings, while sting considerably producing welds free from des and flowing very nicely far the art ding have been advances rather art producing better weld the sense lity weld, elimination the porosity, elimina- slag inclusions, But have attained Fig. typical welded structure anything all the physical side other than the general improvement that one would expect from cleaner and more solid weld metal, have any these processes done anything prevent the natural tendency the material for grain growth, air harden ing, tempering, Far from belittle the efforts that being constantly made. need improvement; need welded structures these alloys. But the provements shall make will more the alloys than the equipment designed for their fabrication and this already have decided indi- cation. The entrée the chrome-nickel types material, commonly referred and has perhaps of- fered the widest step the advancement the art welding that has been made since the discovery hese corrosion resistant alloys. not the introdu tion nickel responsible for this? The addition nickel has produced substantial physical and metal lurgical changes the material. have, instead martensitic ferritic type chrome stantially austenitic material, material which grain growth not quite marked, that one stroke have eliminated many the problems the straight chromium alloys. have material that non-hardening; the introduction the weld metal theoretically does not produce different lurgical condition. other words the weld metal would austenitic and the material either side would austenitic that have similarity not only chemically but metallurgically do, however, have difference between cast structure and wrought structure, heat treatment will not entirely eliminate thi Earlier this article mentioned that slight difference physical condition, when the wa ovel 16 pel cent, ild in Case aisre arded and this true man vith the and serie would seem, therefore, from logical direction and from this point could vithout hesitation proceed manufacture welded tructures from the alloy However, are not entirely free from (Concluded on page The Iron fee. October 8. 1931—937 — e + j Wor ar- ij | wel ing uld actor res, hem onditir } from weld the neat witl hat, but physical treat- up- nstalla- ter and we al ‘ vy) - welded test test resist- Gas firing system with automatic tem- perature controls for heat-treating nace. The parts are thoroughly pro- tected from damage, heavy VER since crankshafts, connect- ing rods, have been used, hot forging has been the process which they were manufactured. departure from this time-hon- ored method has been made, however, least one manufacturer these items, and material betterment product said have resulted. The new method employed that cast- ing special-analysis alloy steel. complicated and most precise, triple-heat treatment imparts the casting better physical properties than can obtained with forging and heat treating, asserted. has also been made possible, using castings, redesign the parts increase the strength the cus- tomary weak points and lighten the structure whole. Furthermore, with the new designs, the castings were found better adapted the uses which they were put, but this redesign not possible attainment the forging die process. This pioneering has been done the Industrial Steel Casting Co., To- ledo, Ohio. This company success- fully making cast crankshafts and connecting rods for two the world’s largest manufacturers pumps. The 938—The Iron Age, October 1931 company has enjoyed marked success also the manufacture alloy cast steel heads for Diesel Diesel engines. nickel-manganese steel with the following chemical ranges analysis used: X-18 X-19 ( rb 344 0.340 1.61 1.67 Sili n 0.69 0.61 Phosphor 037 Sulphur 039 0.040 Nicke 0.7 O.70 The heat treatment these cast- ings special one developed the company’s research laboratory, was the alloy steel. quite involved and divided into three distinct treat- ments. All temperature and heating periods must held within extremely narrow limits. This particular alloy steel readily lends itself different heat treatments and few the re- sultant physical properties are noted: X-18 X-19 Yield point 67,500 51,000 Ultimate strength 101,750 10,000 Elongation in 2 in., per cent ‘ 28.5 Reduction of area, per cent ‘ 3.0 $1.5 Brinell hardness 192 187 CRANKSHAFT HAVE HIGH QUALITIES Assistant Sales Manager, Surface Combustion Corpn STEEL HEYN Toledo, Ohio Carefully kept records the tory every casting enable ers trace each piece the from which was produced. This ord starts with the details heats, the chemical and physical prop- erties, and the micro-photographs the grain structure. All these Photomicrographs showing the cast | 3 2 Corpn cast unusual method making crank- hafts for pumps means castings special alloy steel. Use complicated heat reported give these members all the strength they need. addition, they have enough ductility take care the in- evitable shock. made before the castings are ped, Accompanying each shipment the castings card bear- analysis, heat number and photo- rographs the grain structure. are guaranteed come ithin very small variable tolerance their physical properties. the heat treatment the cast- ngs three furnaces are use. Each irnace heated with different fuel: oil and electricity. All the rnaces are the car-bottom type, the same brick and steel con- truction. They differ their ca- ities, the gas furnace holding and after treatment (at right), both car parts into heat-treating oven. Sand seal protects the run & charge tons, the oil tons and the electric tons. The gas-fired furnace was designed and built the Surface Combustion Co., Toledo. Outside ft. long, ft. wide and ft. high, and has single counter- weighted door front. The tracks which the car operates are led into the furnace through this door. The car pulled and out means overhead crane and cable. The car forms the hearth, provided with sand seal, that the heat the fur- cannot penetrate below the trucks. the same time the com- partment which contains the trucks open front for the free circulation cold air from the outside, elim- inate any heat from radiation. The Surface Combustion system firing employed, two-stage, high- pressure velocity-type gas burners be- ing located along each which side, making all. Half these are placed well down, close the hearth, and the others the upper portion the walls, which assures uniformity heat distribution. Atmosphere Regulated One Valve All burners are turi-type inspirators, gas bei inspirates air for combustion. This setup permits any ratio gas and air, that the furnace atmosphere can regulated suit the circum- stances single valve. this ratio automatically regardless the volume ning gear the car from the heat. ble mixture burner ports. this case slightly reducing atmosphere required and provided. through This furnace has two automatic temperature controls, connected with motor-operated valves the gas ply lines, and two thermo-couples the heating chamber, one extending into the charge from the roof the furnace, the other into the center the load from the side. The valves are the on-and-off type, e., when the temperature runs above the gree set the instrument they automatically shut off the upply; conversely, when the heat drops below this point, they open again. These temperature contro] truments also record and they op- erate between temperatures and minus deg. Waste products combustion vented through series flues built into the walls the furnace and which terminate the two main flues. These have motor-o; erated dampers, which close matically when the burners are off, so aS to prevent entrar of cold air upset the heat mos I he re teel barrel 590 from 580, August declined 565 July and represented 31.6 per cent capacity compared 10.7 per cent, according reports ceived the Bureau the Censu from establishment The Iron Age, October 1931—939 ve the his- custom- he heat This rec- prop- aphs CAST IRON PAVEMENT LAID LONDON LONDON, ENGLAND, Sept. 16.—A sec- tion iron paved highway has been ETER driving the laid the Romford Road Strat- motor car ford, a suburb of east London, by a over a new section of company recently formed under cast iron highway name Iron Roads, Ltd. The paving Roads, Ltd., stated foundation concrete, which pro- Age that tected bituminous float providing every cushion minimize vibration be- but with ing carried the foundation. out success. cast lattice design and laid The cast iron segments are bonded together with ferromastic, in- sulate the foundation from abrasive action. The traffic load said other disadvantages metal, hith- than the upper and lower surfa efficiently distributed, the applied. The iron blocks weigh lb. ficial area each iron section The ordinary wood paving blocks are rounded and serrated surfa greater than the usual road surfac- beveled machinery the foothold, and perforated for ing. Each section self-setting lower edges, and between each material, and are imbedded laid, rocking the blocks being elim- laid row cast iron blocks sand the ordinary concrete inated providing three-point sus double wedged section, thicker the The designer and patentee, Mr. upper and lower surfaces, than London architect), states that claimed that the blocks may fi