The Iron Age 1932-02-04: Vol 129 Iss 5

..THE IRON NEW YORK, FEBRUARY 1932 ESTABLISHED 1855 VOL. 129, No. MOBILIZ FOR RECONSTRUCTION INCE the dawn recorded history, man has continually pushed forward, regardless temporary setbacks. Particularly America, from the hazardous days the pioneers continental discovery, down the different but still difficult present days with their more intricate problems, the record has been one continual endeavor and progressive achievement. Whenever Americans, with characteristic ag- gressiveness, have widely organized accomplish given purpose, has usually been attained. time, since the war spirit 1917 mobil- ized and united American public sentiment, has there been widespread mobilization pur- pose among all classes, conditions and kinds our people, attain given end. That end reconstruction. Partisanship has been set aside, even pres- idential year, order that the road recovery may opened. Capital and labor are closer accord today than any time our history. Minds all kinds are thinking more clearly than before about our common problems and are meet- ing common ground. These are the signposts hope that are point- ing the way the road reconstruction. are not fairly upon yet, but least are not groping blindly the dark, have been, not knowing what direction take. The men the metal-working industry will put their shoulders wholeheartedly the wheel the common effort for reconstruction, knowing that the world will never cease need better men, materials, methods and machinery. q 323 q ACCURATE MACHINING, TYPIFIED SMALL ARMS MAN war time makers arms were faced with problems with the return peace 1919. Many went out ex- istence and those who have survived have turned other products either substitute for augment the manufacture small arms. One the most successful making the transition peace time basis was the Colt’s Patent Firearms Mfg. Co., Hartford, Conn. Immediately after the war this company with large plant and elaborate equipment its hands bought out existing companies other lines and developed new products keep its spare equipment busy. the same time consoli- dated and reorganized its small arms manufacturing and today regu- larly turning out many thousands pistols each year addition fair production machine guns and other ordnance. Recently the company has devel- oped new accurate pistol with many Iron Age, February 1932 pecial features. calls this pistol the 0.22 Ace and description some the manufacturing will serve illustrate many the prob- lems accurate machining required the successful production small arms. When new complicated forming and punching operations are developed the material used must studied well the design the die and this one reason that uni- form material important the production complicated precision instrument such automatic pis- tol. Even slight change steel analysis heat treatment may mean that crack will occur under dies which normally would work per- fectly. the development new small arms model, the designers may specify one grade steel but the production managers some depart- ment foreman may find that the work- ing this steel extremely difficult and, therefore, although may have the quality desired the finished product, the use other steels may necessary large scale commer- cial production. The final result often compromise between the de- signers and the production men. Oc- casionally happens that steel alloy found which the end- product has properties even better than those originally specified the designer. Nearly individual piece subjected three-cornered struggle between the price the ma- terial, the quality desired and the adaptability commercial fabrica- tion. Angle Cut-off Saves Many Tons The cut-off department equipped with steel cutting band saws, power shears, and high-speed circular saws. When the head this department receives work order calling for one hundred Ace pistols, makes out requisition for material present the man charge the inventory. — | \ HERBERT FACTUR producticn was given its initial impetus America the manufacturers small arms, among which the Colt’s Patent Fire- arms was prominent pioneer. Today, the methods precise machining employed the same company the production its pistols offer valuable sugges- tions makers similar precision products requiring the machining high grade steels. This article describes the working 1350, 1035 and 1085 steels into pistol barrels, receivers and hammers. The requisition forms important record part the perpetual inventory system. This system well organized that errors between the recorded inventory and the actual inventory are very small. Close co- operation between the stores depart- ment and other departments reduces possible bars are purchased lengths which are multiples the lengths pieces required manufacture. example cooperation between de- partments which has led economies seen the suggestion the head the cut-off department that cer- tain pieces sawed off angle instead square was customary. For certain work, corners two pieces were thus saved which totaled surprising saving material the end the year. Many the pieces coming from the cut-off department direct the forge shop and the irregular form some the forgings makes large amount trimmed scrap unavoidable with the regular square cut bar. This one case where slanting angu lar cut has proved economy. Other examples were found the case some pieces going direct the ma- chine shop. One interesting part new Ace pistol known the magazine and cut from flat strip in. wide 0.025 in. thick. Here also the re- . quired pieces are cut angle and first the press department they are formed and punched over mandrel intricate forming tool. This leaves the pieces box-like with overlapped joint. The join later oxy-acetylene welded. This welding semi-automatic opera- tion. The torch mounted feed- head and the piece welded clamped special jig built the side lathe frame. This jig constructed that may re- volved through 180 deg., thus mak- ing possible for the load one side while other side being welded. The in- side later broached give accu- rate dimensions and smooth surface and the outside polished. would seem first glance that such piece could made tubing, but that type construction was discarded because the difficulty getting seamless high carbon tube the re- quired section. Specifications for the magazine call for steel with carbon above 0.40. After polishing the magazine cleaned preparatory bluing and heat treating. The cleaning with rasoline, after which the pieces are rubbed hand with flannel cloth and chalk mixture. The bluing op- eration performed partly for ap- pearance and partly give hard resistant surface. separate part the heat treating department which devoted bluing has forty gas- fired bluing furnaces. Pieces the blued are put racks and then placed the furnaces and left for two and one-half hours temper- ature approximately 700 deg. Fahr. Then the pieces are taken off the rack and reversed end for end and again placed the furnace for further two and one-half hours the same temperature. mixture bone and charcoal used the fur- naces and because summer there variation the pressure city gas, all gas used, not only for these furnaces but throughout the passes first through large reservoir tower the This keep the pressure uniform The receiver, which sense the backbone the pistol, forged from bar in. long in. wide and in. thick. The forging irregular and care taken the 4 (AAS The bars from which receiver forgings are made are cut save material. This shows one the two hammer operations which produces this forging (At top page). Each pistol here given final inspection after which goes the target room for actual shooting test. The Iron Age, February 1932—325 4 J A PECIALLY built cylindrical racks jigs are used hold pistol parts for blue finishing gas furnaces. Forty these gas fired bluing furnaces are operation the plant. grain the steel running parallel the sides the piece. The pieces the heat treating department for pack hardening and annealing before being sent the machine shop Many Pieces Treated The heat treating department has modern furnaces, all pyrometer con- trolled with the usual recording and indicating instruments. One two electrical furnaces are used for ex- perimental work. Pieces heat treated are taken the furnaces hand carts built with the floor the cart level with the Quenching oil water depend- ing upon the result desired, and afterward the pieces adjacent furnaces for the draw heat. Some parts are drawn cyanide bath. The receivers after heat treating are pickled and then the machine shop where the first operation rough grinding large Blanchard grinders. Groups twenty pieces are ground one time. Afterward the pieces are started one end the production row and when they reach the other end they are com- pletely machined. Some the principal operations are rough milling the top tom, drilling holes for the magazine opening, drilling for barrel opening and broaching the magazine opening square corners. This unusual broaching operation because the accurate dimensions and smooth fin- ish desired. The broaches used are in. long and have teeth which gives cut 0.0025 in. per tooth. The next few operations are milling for the main spring housing, milling for the hammer cut and cutting side openings Pratt Whitney pro- file machine. This machine special design for the work required. has dished cutters which follow master form generate the outline. The small hammer forged several time under drop hammers. The barrel machined out solid special shaped bar which has the cross-section circle with projecting rib one point. The full length the rib milled off except small piece which left for the locking mechanism. The next oper- ation turning the end, thus mak- ing possible locate center for drilling. The drilled hole allows 0.015 in. for reaming, which deli- and fussy job and frequently consists five separate operations. After reaming, the inside the bar- rel lapped with square tool hav- ing piece wood attached one its sides. This combination cov- ered with oil and held within the barrel fixture which gives free play while the barrel revolves. This until checking with plug gages with tolerance plus minus 0.0005 in. indicates that has reached the proper diameter. The rifling the barrel follows the lapping. The grooves this rifling This battery grinding machines used for finishing Ace and other small arms parts. 326—The Iron Age, February 1932 — = | > d 7 ad THe rifling the barrels important operation. This shows the machine (at right) developed engineers after many years’ experience. The close view the rifling Ace barrels shows one clamped central position. The cutting tool (D-G) drawn back and forth through the barrel the same time that revolving its axis. The disk (B) presses the tool clear the work the return stroke. are 0.0035 in. deep and the combined space occupied the grooves equals two-thirds the circumference the barrel opening. The rifling ma- chines are the same general de- sign those originally invented the engineer when rifle manufacture was first started. They consist es- sentially cutter long rod something like broach cutter, which moves back and forth within the bar- rel, cutting the forward stroke and held free spring the re- stroke. Coincident with the movement the cutter the barrel rotated slightly means cam and rack. The rotation the barrel carefully adjusted the time the work set and the movement the cam interlocked with the move- ment the cutter. Six grooves all are cut and the indexing from one groove another automatic. Naturally many the machining operations connection with the parts entering into Ace pistol have not even been hinted and some these are highly specialized. took many years, for instance, perfect the accurate drilling long rifle barrels and present, while the drilling done essentially rou- tine job, there are many ticklish points still considered. One these the sharpening the drill point. this point not accurate within 0.0005 in. the drill will have tendency move slightly out line operation. The drilling tool hollow, made heavy seamless tub- ing with small opening near the q cutting point. under high high 500 per square inch, During drilling, oil stantly away from the cutting point along the groove the shank carries with the fine steel drillings which pressure, sometimes forced through the tubing, out the not promptly removed from the point and back along the drill shank cutting end would introduce inaccu- the opening. This oil flowing con- racies. Steel, Twenty Years from Now FLOYD GRADY twenty years from now ent slow and expensive methods will still steel, but will painting the high-priced cars. better steel. Many new uses will The tinny, rumbling metal bodies found for steel during the next ten are rapidly giving way sturdy years. lumber grows scarcer and construction minus the objectionable more expensive, the harder the re- features mentioned. search boys will work dis The time not far away when places use steel instead wood. pig iron will longer made Fire hazard alone enough jus- the present type blast furnace. tify extra research investments. The Houses are now being built all about over, and during brick and basic iron teel, and the buckling brick and the next five years the scrapping the cracking concrete are even now blast furnaces that cost millions will turning the attention road en- seem like terrific waste money, gineers steel for paving. but the following five years will prove the wisdom that Shorter cuts the produc- Stainless steel will greatly im- eeming extrava- gance. proved. One st p forward is going king steel the discovery makin colors that will eliminate the pres- immense saving. The Iron Age. February 1932—327 4 af — 4 | a | | NEW IDEAS CREATE NEW OUTLETS ANUFACTURING facilities have had publicity, but comparatively little heard the new idea facilities industrial concerns, although new ideas are the life blood business. Prior the development modern business management, organized efforts develop new ways net profits were rare. Modern industry goes after new ideas aggressively and plans. Modern industry spends large sums pure scientific research where the ultimate results are unknown specific ideas, but known aggregate net profits. The research departments the big electrical manufacturers are the best known examples this method getting new ideas. Twenty-five per cent the General Co.’s production 1929 was items developed the previous Modern business management realizes that through scientific research. profitable search the world for new ideas; instead being confession weakness, this mindedness. “We have all the experience need,” sometimes urged reason why outside sources experience are not required. One man work for 328—The Iron Age, February 1932 years one company has years experience the comparatively narrow environment one company; 100 men work for years 100 different companies have 2000 years’ experience different environments. Consider the breadth ideas gathered from the 100 men com- parison with the ideas the one man! Yet the past, and, unfor- tunately many business concerns today, executives depend the ex- perience comparatively few men. HIPPING fire brick skids creates new use for steel strapping. screw type conveyor, new idea con- veyors that cuts han- dling costs. What organization can have “all the experience” needs modern world where life and business are sub- ject rapid changes? one man, one organization, has experience enough have the best ideas all times. New Ideas Available Any Business Opportunities for making money cultivating “idea exist every business. The maximum re- sults can obtained only well- designed plan developing ideas from the whole organization and the use all available outside sources. They cannot obtained depending entirely executives re- sponsible for certain work within the organization. Ideas may produced any member organization. The Newport News Shipbuilding Dry Dock Co. had campaign for ideas from all its employees. The total value the suggestions received was estimated $250,000 and included ideas from laborers the president. However, the most productive source ideas person who has cer- tain definite type mind; active imagination, vision, perspective and courage. analytical ability and training scientific methods collecting and using facts, coupled with wide experience and contacts more than one industry, are necessary the best results. man vision one who can free his mind present-day limita- tions and look into the future. what others see the unexpected today, sees the accepted truth tomorrow.” Ideas are stimulated vision the future, founded knowledge the trends the various arts and sciences. could see into the future would know that certain machines and practices now vogue will re- placed better machines tices. the modern idea not accept final any good idea, but aggressively work and search for the new ideas the future, shortening the time when these better machines and practices are ready serve industry. production methods that achieve such remarkable records reducing process time from two days two hours. equally profitable reduce the productive time new ideas. idea recommended that will cut costs, say, immediately, not wait year. probably would good business spend $2,000 $4,000 once make effective plan that would yield net profit year $4,000 $6,000. Many Ideas Had Cost New idea facilities should protect against spending time and money developing new idea which much time and money has been expended some one else. This requires wide sources information. Some ideas that reduce costs and improve servic: are available practically cost, the development work having been done another organization, which willing give others the benefit its experience. Other ideas cost more acquire, but money applied this purpose accordance with well defined plan has proved pro- ductive handsome profit. Some companies are hampering the revival their business restrict- ing the initiative their employees and this means preventing the birth many profitable ideas and FOR PRODUCTION ~— STOCKER EPRESSION forces the adoption new ideas—ideas that effect economies and ideas that create new demands. The develop- ment new ideas, necessary under present conditions, should permanent rather than temporary policy, since the best results accrue from sustained efforts. Twenty-five per cent the output the General Electric Co. 1929 was items developed the previous decade through scientific research. Other examples cited the author, in- dustrial engineer, indicate that small things well large undertakings the consistent pursuit new ideas pays. making the work interesting Organized effort stimulate, than restrict, the creation new ideas modern way profit. one has monopoly idea they may originate with the office boy with the president, or, happens, witl yme one outside organization. Manufacturers hous hold product are realizing that housewives are excellent ing their products. Some manu facturers have women their organ ization whose duties are ideas from housewive Examples Savings from Ideas salesman steel strapping company was cooperating with author developing skid shipping * > — r — 3 4 — — | steamship company’s dock. ship was discharging lumber piece. Piece piece the lumber was made into slingload the hold the ship and then hoisted the car the wharf, where was again handled. The salesman, being ma- terials-handling conscious and famil- iar with the fundamental materials handling that are ap- plicable all industries, saw thi method wasteful and obsolete. result his idea, experiments were tarted shipping lumber pack- ages held together with steel strap- ping, which method now bids fair produce large economies and advantages for lumber steamship companies and dealers. Upon taking over the management company, one executive elimi- steel salesman conceived the idea bundling lumber with steel strapping, thereby greatly facilitating the loading and unloading vessels. The Iron Age, February 1932—329 new ideas the design and = | — nated entirely useless operation the office that had been going for years. Certain documents were issued and sent shippers, who, turn handed them back the dock force the transportation company. The executive could not find sufficient reason for their existence and elimi- nated them. The result? saving stationery the steamship com- pany, better service and less expense the shippers. The reason for this waste money, material, time and effort? have always done that way.” The from that “idea” paid the executive’s salary for the year. direct savings another time, while searching for new ideas, this executive thought the unused capacity freight ship for carrying cargo oil bulk, and increased his company’s profits $25,000 year. employee steamship com- pany Los Angeles conceived the idea new type rope sling which saves rope replacement handling bags coffee and other bagged cargo. The idea was developed the cargo-handling gear shop and new type sling evolved that has Age influence natural and arti- toughness and dimensions cylindri- specimens 2.36 in. length 0.275 in. diameter steel analyz- ing 0.98 0.19 Si, 0.43 Mn, 0.026 and 0.01 has been investigated Steinberg and Subow (Stahl und July 16, 1931). The test were hardened quenching water from 1380 deg. Rockwell hardness was measured, and the tough- Conti | racti Ver ¢ Per Cent Hardenir 10.0 | 15.0 04 15.4 I 10 min 2.4 0.03 | ) 14 | 0 O58 17 18.6 0.124 eg. 0.020 10 0.090 resulted large savings each year. forms idea that has cut handling costs and prevented damage brick, and, because avoidance damage, has increased sales for the brick man- ufacturers and has increased traffic for the transportation company that conceived the idea. engineer sugar refinery had idea about applying the twin type conveyor the han- dling bags. From his idea grew the successful screw-type conveyor today which handles modities packed bags. railroad the use this con- veyor conserved its warehouse space and cut the cost piling bags refined sugar. Organized efforts find new prod- ucts are often the way increase the use productive capacity plant. New Processes Applied Old Products products, there profit the application Besides developing new ness was determined static bend tests under Brinell press. Results are shown the table. Natural aging water-quenched steel proceeds slowly with gradual increase hardness and toughness. The hardness passes through maxima after days aging 167 deg., hr. 212 deg., and hr. 257 deg. Toughness increased every instance, and also the length the test pieces decreased, approach- Hardnes Toughness, After Lb. per Sq. In. Initial Aging (Bend Test) ho 66.3 65 66.3 220,000 67.0 227,000 t 65.5 206,009 65 66.0 203,000 t 66.6 209,000 66.0 241,000 67.0 248,000 t 67.4 258,000 67.3 258,000 67 270,000 66.5 301,000 t 63.5 310,000 65 66.5 234,000 6o 66.5 258,000 66.0 278,000 64.5 361,000 454,000 old products new processes. The photoelectric tube finding wider application, reducing costs and im- proving quality. The photoelectric cell has been applied handling mail recently postal railroad terminal. The bags are dropped from elec- tric tramrail the proper car shaft light from the car acting photoelectric cell attached the tramrail. Undoubtedly there are many other applications this re- markable development pure science that will produce profits for depressed industries reduction costs and will increase the market for photo- electric cells. these days depression, com- petition and unemployment, the idea- providing machinery business greater importance than any other time. Business men should sure that the minute and capable producing the best results possible. Any reasonable expense justified for well-planned new idea facility. Today, with inadequate non-existent profits, vital know that new idea facilities are adequate and functioning their best. Hardening Carbon Steel ing limit per cent the elongation which occurred harden- ing. The microstructure was ap- preciably affected hr. treatment 257 deg. F., etching with nitric picric acid producing dark colors more rapidly than the quenched specimens. Since the increase hardness ob- served aging each temperature length, the change cannot ex- plained the basis the austenite- martensite transformation. The de- composition the residual austenite still very slow 300 deg. Hence the increased hardness must due aging phenomenon marten- site. The fact that the contraction length tends toward limit ap- pears indicate that this change connected with the relief internal strain. According these views, the tetragonal form martensite ob- served Kurdjumow disappear 212 257 deg. not new type but represents strained cubic martensite. For practical pur- poses, half-hour treatment 250 deg. recommended for water- quenched carbon steel, in- crease its hardness and toughness and reduce the internal stresses. — = 0.116 g 2 } 0.116 Iren Age, February 1932 ( OME new developments alloy steels for high-temperature, high-pressure service were out- lined recent meeting the Hart- ford chapter the American So- ciety for Steel Treating Malcolm, metallurgical engineer, Chapman Valve Indian Or- chard, Mass. particularly recom- mended chrome-tungsten steel for such service. Mr. Malcolm said that the ideal alloy steel for high-temperature ser- vice would show complete resistance abrasion, corrosion and oxidation. minimum requirement steel for such use the ability carry loads continuously without appreci- able distortion. Short-time tests temperatures over 700 deg. are not true test this ability, they measure principally elastic de- formation and not plastic yield, which large factor the higher tem- peratures. Creep strength, expressed terms the load which can without distorting over per cent 10,000 100,000 hr., the measure used determine the ability the alloy withstand high-temperature service. expansion, thermal conductivity, oxidation, and erosion are also properties which must known. Toughness, well hard- ness, required for wear resistance. Limitations Some Steels Carbon steels are not suitable for temperatures over 700 deg. Nickel-chrome steels can used 900 deg.; per cent chrome steels show grain growth above 900 deg.; and rustless steels develop in- tercrystalline brittleness between 900 and 1200 deg. and, they fail, without warning; per cent chrome steels with molybdenum show banding, segregation carbides, scal- ing and decarburization, giving re- duced wear resistance. Chromium and tungsten strengthen steel below the equi-cohesive tempera- ture, assist the work the carbon and reduce amount occluded gas, giving finer and denser struc- ture. Chromium gives very stable CHROME-TUNGSTEN STEEL FOR HIGH TEMPER carbide which does not agglomerate, lowers the carbon the eutectoid, dissolves iron all proportions, restrains plastic flow, and produces carbides prevent intercrystalline slippage. Tungsten strength even the cast rolled condition, inhibits grain growth, re- quires high draw-back temperatures which allow higher operating tem- peratures, and adds the impact values. The importance accurate exten- someters and tests simulating operat- ing conditions was stressed Mr. Malcolm. Curves plotted two ex- tensometers attached the same test piece revealed that the one reading two millionths inch had re- corded the proportional limit the test piece before the other, reading one thousandth inch, had plotted single point 1200 deg. Mr. Malcolm showed slides parts which had failed high-temperature service. rustless steel part 360 Brinell failed seizing. and rustless superheater let without warning after 18,000 hr. service. test piece this showed per cent elongation, ft.-lb. Charpy impact and 285 Brinell, again test taken before service showing high elongation, high impact and 165 Brinell. per cent chrome steel forging failed without warning and test piece showed per cent elonga- cent determined before the forging was put into service. Chrome-Tungsten Steel Favored Mr. Malcolm described steel with analysis carbon 0.15 0.25 per cent, manganese silicon 0.50, ulphur and phosphorus 0.05 maxi- mum, chromium 4.5 6.5, tungst tensile strength 120,000 per sq. in., yield point 100,000 per sq. in., Be TURE USE and reduction area per cent. Quenched from 1400 deg. show 386 Brinell and quenched from 1600 deg. F., 428 Brinell. 27¢ nickel-chrome steel does will Brinell. Its coefficient expansion close that carbon steel. resists corrosion West Texas crude oil and the same this respect rustless steel. scale resistance, strength, shows advantage about 400 deg. F., over carbon steel. carbon steel, 1000 deg. F., showed creep strength per cent 10,000 hr. under 800 per sq. in. loading against value 80,000 per sq. in. for the chrome- tungsten steel. cast chrome-tung- sten steel showed per cent better creep strength than the rolled forged condition. This alloy can used temperatures 1400 deg. shows slight intercrystalline brittleness 1600 deg. Discussion brought out the infor- mation that the carbon kept low the chrome-tungsten steel increase corrosion resistance, prevent tender- ness, and facilitate removal risers. Chrome-tungsten steel finds economical use temperatures over 800 deg. The Germans have tried adding per cent tungsten 0.7 per cent titanium and rustless brittleness. Failure and rustless prob- ably due incomplete austenitic tructure and incomplete diffusion carbides. 280 320 Brinell, chrome-tungsten forgings bar stock thread satisfactorily. This steel ni- trides exceptionally well. per cent nickel, per cent chrome steel used for high-temperature service has very high coefficient expan- sion. Monel metal, used for valve seat rings 800 deg. dropped out due the different coefficient ex- pansion from the valve material. The Age, February 1932—331 — —— = = = - <a MONEY SAVING Nickel Wire Screens for Nitriding generally considered ad- visable separate steel prod- ucts when packing them con- tainers for nitriding. One manu- facturer suggests the use nickel wire screens accom- plish this separation. says his plant gives the packers ample supply such screens various sizes, and this way has been able cut down the time packing one his standard nitriding about minutes. uses standard “V” blocks made nickel steel for supporting long shafts and other cylindrical parts prevent sagging warping during nitriding. Jigs Reduce Heat Warp tendency warp the case thin steel parts under heat treatment constant dif- ficulty plant producing ac- curately machined products such ball bearing races. One manufacturer such races has largely overcome warping dur- ing heat treatment the use jigs. jigs are slightly conical shape and are pro- vided with long handles. Their use simple and effective. The bearing races are spread out single layer over the furnace hearth. The operator extends his long-handled jig into the fur- nace, drops place into one the races, and this means lifts the race, removes from the furnace and lets down 332—The Iron Age, February 1932 —— adjacent oil quenching tank. This tank deep enough take the full length the jig handle, which means hooked end hung over the edge the tank. After quenching, the pieces are removed from the jigs merely tapping the jigs against the side tote box. Lubricators Replace Oily Rags soaked rags and other similar means lubricat- ing strip steel which being fed into stamping forming machine may eliminated usu- ally with considerable advantage installing automatic lubri- cator. Several types such lubricators are available. They are often mounted the frame the press above the work and are actuated each press op- eration. The lubricant ap- plied spray the strip just ahead the dies. Those who use such lubricators, claim that the lubricant and strip are cleaner and that the life the die correspondingly greater than when open oil soaked waste and rags are used. Scrap Re-Working Cuts Freight Bills paid both ways good deal material which leaves producing centers finished steel and returns these same centers This double freight has been particularly evident the case New England metal stamp- ing works, where often hap- pens that skeleton scrap repre- senting sizable proportions the weight the outward shipment must returned Pittsburgh for its best market. eliminate this double trans- portation heavy material, man- ufacturers who make nothing but sheet steel blanks have lo- cated close steel works, and they are finding success sup- plying blanks any shape character stamping com- panies various parts the country. This not only elimi- nates the double freight scrap, but reduces handling and cuts out the first operation the stamping plant. Saws Saved Him Dollars often happens that small steel products are best pro- duced from disks which previ- ously have been cut from bars. Such disks may successfully cut motor driven reciprocat- ing saws. One manufacturer uses such saws preference band saws because finds the initial equipment less expensive and more compact. has cut-off department with re- ciprocating saws operation cutting disks from bars ranging from in. in. diameter. These saws are all provided with automatic shut-off switches and one operator looks after some tenance crew replaces the saws and makes any necessary adjust- ments. this particular case the first machining operation the disks requires that the sides the disk parallel and right angles the axis the original bar. secure such accuracy the bars must per- fectly straight and the proper lubrication must used. DEAS = SSS | Manganese Steel Rivets OILER manufacturers may well try manganese steel rivets where high joint strength desired. Such rivets were used for the lower chord the Kill van Kull bridge, re- cently completed between New Jersey and Staten Island, New York. Under test, both single and double tier rivet connections gave strength for joints using rivets more than per cent higher than similar joints using carbon steel rivets. Thin Forgings Stay Straight manufacturer small thin forgings has corrected warping during heat treatment the simple process leaving the flash and trimming with cold trimming dies afterward. Trimming the hardened forgings little severe the trimming dies but the advantage the method overbalances this diffi- culty. One Hammer: Two Furnaces large cutlery plant the manager has increased pro- duction supplying each ham- mer operator with two heating furnaces and then providing furnace man assist several these operators. Under the new plan while group bars one furnace being forged, the furnace man places group second furnace and brings forging tempera- ture. this way when the first group has been finished the sec- ond group ready used without any loss time. Several Ways Save Scrap Blanking HEN rectangular sheets are used for large irregular stampings, the scrap resulting from the first blanking operation often disproportion- ately high. some cases this excessive scrap may reduced using very large sheets and cutting several irregular blanks from these operation pre- ceding the usual first blanking operation. method which being used successfully one manufacturer flash weld, edge edge, two more small rectangular sheets form large sheet irregular out- line approximating the form the stamping. The sheets thus welded are held accu- rately butt position slightly little wider one end than the other. low voltage, high amperage current, then switched and flash starting the narrow end quickly spreads throughout After just the right time inter- val, the current turned off and the sheets are forced together with quick positive motion which spreads the metal ini- tial contact form beads either side. This brings to- gether under the beads, the soft unembrittled metal just back the high heat zone. The beads are later removed drawing the sheets between shear dies. FOR WORKS MANAGER New Insulating Brick Saves Space plant wishes save space the construction new furnace may profit investigating the new insulating bricks which have recently appeared the market. One such brick has four times the insulating value common fire brick. That is, the heat flow in. wall in- in. wall fire brick. some types furnace this means weight ratio for the insulating brick 16, and addition means floor space saving from per cent. addi- tion, there the question fuel economy, which very impor- tant intermittent work. Reducing Atmosphere Reduced Cost SIMPLE means main- taining reducing atmos- phere hardening furnace has been devised manufac- turer universal joints. has simply installed metal chute extending from the discharge end continuous heat treat- ing belt type furnace that the lower end the chute below the surface quenching tank. The pieces leave the belt about 1600 deg. Fahr., and drop into 14-ft. deep quenching tank into pockets conveyor ex- tending from the bottom the tank discharge table. The depth the tank and the speed the conveyor are ar- ranged give definite time in- terval the quenching tank. The Iron Age, February 1932—333 — 4, | ELECTRICALLY HEATED GALVAN ONSISTING steel tank essentially brick fur- placed setting, the galvanizing has certain extent considered necessary evil. Along with many this galvanizing beginning receive careful consideration, the ultimate idea being modernize. been others, process Any manufacturer galvanized products interested producing article high quality and low over- all cost, and produce under the best possible working conditions. Many variables, course, must controlled obtain high quality, some which are: pickling, and temperature. Probably the most im- portant these variables the tem- perature. the variability this can eliminated, materially re- duced, then great step has been made toward raising the quality and lowering the cost. a 334—The Iron Age, February 1932 Cherry, Industrial Engineering Department, General Electric Co., Schenectady, Electric heat eliminates the trol temperature from the list variables, since the heating units the electric furnace can placed and distributed the heating chamber desired. Also, the temperature the heat source, (i.e., the ribbon re- sistor) only few degrees above the heating The desirability electric heat un- questioned today except standpoint cost. con- When considering the cost the fuel-fired furnace, the effect the heat source the overall cost the product must taken into considera- tion. strictly B.t.u. basis, there question that electric heat higher-priced heat source than most the available fuels. the B.t.u. basis alone, certainly the decision would use soft coal the majority cases, since soft coal has lower cost per B.t.u. than i practically any other available fuel. But the use soft coal source heat for hot-dip galvanizing has practically been eliminated, for other factors than strictly B.t.u. cost enter into the overall cost galvanizing. Some the major items affecting the cost the hot galvanized product are: Temperature control. consumption and dross formation. Labor. Maintenance. Production, downs. Inspection. Temperature control affects the other items cost. For each product, there proper temperature se- cure the best results and, the closer the ideal temperature conditions can maintained, the higher the quality the product. LECTRIC miscellaneous parts. Rated: 100 kw., 220 volts, phase. Installed the Wrought Iron Co. America, Leb- anon, Pa. 4 4 IZING FURNACE EMPERATURE control emphasized prime importance electrically heated furnaces for galvanizing baths. The efficiency galvanizing depends decidedly upon keeping the temperature within certain rather limited range. goes too high the pot burns out greatly accelerated rate. goes too low the zinc not sufficiently fluid for proper work. Zine consumption will vary from Its rating kw., 220 volts, } is ‘ Concrete ky ao ‘ Concrete Molds electric galvanizing furnace. One illustration end-view show- 300 for each ton steel phase. This furnace has been op- ing the inclined charging platform galvanized, depending upon the type work being galvanized. few de- the user now grees change temperature affects electric furnace the thickness and quality coating. The amount dross formed, also, largely dependent upon the accuracy temperature control and the elimination hot spots that usually occur fuel-fired furnaces. installation The item maintenance includes not only the replacement repair tank, but also the expense involved rebuilding the brick setting and cleaning out the after tank failure. eration approximately months and installing second which measures in- side in. wide, ft. long, and has rating 220 kw., 460 volts, 3-phase. That this user has found the first satisfactory, the standpoints both quality and op- the discharge side, and out one erating cost, indicated the in- stallation the installation larger electric galvanizing furnace for miscellaneous parts appears second picture. second equipment. and discharge end. The furnace has inside tank dimensions in. wide, in. deep, ft. long, and total rating 630 kw., 220 volts, 3-phase. in. deep and Pipes galvanized enter one side and are pushed down means air-operated plungers. They pass across the tank near the bottom, end the discharge side. this gives effect continuous operation, the heat required greater the incoming side. For this reason, the 630 kw. input divided into three separately controlled circuits around One illustration shows installa- tion small electric galvanizing furnace, the tank which, inside, in. wide, in. deep, in. long. Galvanizing Pipes Another interesting installation that for galvanizing puddled iron pipe the Reading Iron Co., Reading, Pa. the tank, with the highest rating cir- cuit the top the entrance side. This layout provides for maximum production with the given rating. wire gal- vanizing furnace. Rated: 204 kw., 220 Electric Co. for Frost Steel Wire Co., Hamilton, Ont. 7 ne q wd q q 9 - The Iron Age, February 1932—335 3 This equipment was maximum additional accurately. average production 4.67 4 > de signed for a hour, and has galvanized un. The table gives re- fiv consecutive his furnace. noted that the Was 182.5 hr. month ‘urnace were run hr. day, week, giving total month, the energy con- kwhr. per ton would wer. Since the zinc emperature slightly below temperature during all eriods, the only the additional operating that heat absorbed by the work, heat required melt zinc, and the difference and items can calculated ur, operating 520 hr. ons month), the con- estimated 114 kwhr pipe galvanized. T Operati 168.2 116.0 S4.4 239.0 1,032.5 119 08.9 268.7 1,340.2 182 850.4 this average production should increased, say, tons hour, operating time 520 hr. month (3120 tons month), the consumption estimated 104 kwhr. ton. These figures, also, include the heat losses Wire Galvanizing heated wire-galvanizing Canada shown. This furnace ha: tank in. wide, in. deep and ft. long, rated 204 kw., 220 volts, phase. The vided into two separately controlled heating units are di- circuits the length the heating chamber. The surface the zinc, except course where the wire enters and leaves the bath, covered with insulating material, thereby reducing the heat approximately in. losses minimum. Operating results this installa- tion have been remarkable, partic- ularly regard power consump- tion, saving dross and the quality galvanized wire produced. The operating results four table gives il Operation Pipe-Galvanizing Furnace Total Power! Productio nsumed, To Hourly | Kwhr. Pipe in Tor 1} 137,¢ 174 1.67 i} 1G O00 164 0 152 101.800 200 136.300 160 1.67 | | ‘ for galvanizing Reading, Pa. Rated: 630 kw., 220 volts, 3-phase. 7 A consecutive weeks. The wire sizes were Nos. and 13, and operating temperature, 865 deg. Attention called the average consumption 106.5 kwhr. each ton wire galvanized and the average zinc consumption 67.7 lb. each ton wire. These results are the overall figures, including the standby periods and for varying production. dross was removed during this four weeks’ operating period. fact, the tank was not drossed until the furnace had been operation about four months, and then only 1000 lb. dross was removed. Dur- ing this four months’ period, over 2000 tons wire was galvanized. The seemingly low dross the electric furnace due primarily two things; first, accurate tempera- ture control; second, well insulated bath. Zine temperatures this elec- furnace vary between 855 and 865 deg. F., deg. range. the event production suddenly dropping from 100 per cent the over-shoot temperature elec- tric galvanizing furnace appre- ciably less than will found gal- vanizing furnaces fired other fuels. the case the electric galvanizing furnace plant, the maximum over-shoot re- corded under the above conditions did not exceed deg. Any galvanizing tank will ultimate- fail. the fuel-fired furnace, the tank failure largely due exces- A 4 { = high continuous sults from operation during all standby periods. operating this 51 2 days ¢ 520 hour sumption course held the the quired nours 1s additional These thre With tons month, (243 for i} | 336—The Iron Age, February 1932 LECTRIC furnace miscellaneous Rated: 200 kw., 220 volts, 3-phase. Tank deep. Installed the Joslyn Co. Cali- fornia, Los Angeles. sive temperature, usually localized spots. The fuel-fired furnace has high-temperature heat source (flame temperature) and while baffles, are commonly used even out these hot spots (burner location), they are not uniformly eliminated. Heating units the fur- nace are mounted the walls and distributed desired, both the length the heating chamber and the height the walls, thus definitely eliminating hot spots. The value accurate temperature affects the life the tank shown diagram. These curves show the rate solubility iron various temperatures, and for three steels different (but known) chemical analyses. For the usual temperature for galvanizing (825 875 deg. F.) the rate solubility practically constant and the analysis the has little effect. the temperature permitted reach, say, 950 deg. any part the tank, the rate that 850 deg. These curves indicate the advantage the accurate control temperature and even heat distribution obtained the electric furnace. They were taken from tests made Diegel, Julius Pintsch Corpn., and reported Zeitschrift des Vereines deutscher Ingenieure. un- range times Although the rate solubility the steel tank the zinc very low the electric furnace, the tank will fail time. the electric furnace, chamber there practically oxidation the outside the tank, which posed the heating chamber. which have been operation year have been examined ove! original chalk paint marks the outside the tanks the make were still clearly visible. repairing tank, the items building brickwork, clearing out the the loss great deal more than the and production may new tank. Electric Furnace for Galvanizing General construction the tric galvanizing furnace show drawing. The heating unit mounted on the two side wall are divided into one depending upon the size tank, and the production flow through the tank. The bottom ing units are kept abov through the dross, which good heat conductor. brickwork more C1! ex- Tank Hot-Dip Operation Wire-Galvanizing Furnace Operatin sta everal low points pockets number depending upon the size the furnace). these pockets are located alarm signal devices and elec- trically-heated drain tubes. The alarm device consists two heat-resisting alloy wires mounted alundum com- pound insulators. The ends the two wires are separated, that circuit normally open. Usually, when leak occurs, relatively small and the zine will conducted the sloping bottom the nearest pocket, where the zinc, coming into contact with the end the device, completes the alarm circuit. signal light alarm bell may used notify the operator that leak has occurred. the same time that the signal bell, light, operated, the alarm also closes separate circuit through proper panels, throwing power the electrically-heated drain typical electrically-heated drain ibe shown. These drain tubes built into the furnace wall and inclined readily drain out the from the furnace chamber into molds provided pit tal Z il per T r 10 618 11 104 11,947 The Iron Age, February 1932—337 ~ ’ ee ate } OES Zin + P n in are anc ana Ll heat dre drive + no | l 129.5 38.5 14 { 1] é 129.5 38.5 170.68 3 127.0 41.0 129.5 38.5 2 2 Average 128.9 39.1 176.2 ° z= 4 = Construction electrically heated drain tube, showing three stages the assembly. side the furnace. the molten nears the outside the drain tube, will gradually solidify and the drain, unless the drain heated. For this reason standard — 900 920 940 960 9801000 Temperature Relative solubility iron zinc three different steels, showing low losses below 900 deg. sheath-wire heating unit around each drain tube and the entire device, including tube heating unit, properly insulated. The rating this heating unit such that will maintain the drain tube tempera- ture above the melting point zinc. These protective devices provide for lower maintenance and lower loss Steel Garage Simulates Frame Exterior SING steel section, which when applied steel framework, ap- pears clapboard siding, the Metal Forming Corpn., Elkhart, Ind., has put two-car garage, illus- trated herewith. The picture was taken before the large doors were in- stalled. the interior view the construc- tion readily apparent, consisting steel studs and rafters with diagonal bracing, and with the rolled siding ap- plied directly both the vertical walls and the roof. the case the roof this obviates the need for pur- There combustible material any sort this building. The con- Exterior and interior garage built entirely steel. 338—The Iron Age, February 1932 struction lends itself any the usual forms roof—straight gable, side gable hip. can provided readily any one number standard sizes. Erection this building took two men about five hours. The material was supplied the job prime coated. portable spray outfit said painting for finish. This type construction has been developed for dwellings two sto