The Iron Age 1932-02-11: Vol 129 Iss 6

IRON ESTABLISHED 1855 NEW YORK, FEBRUARY 11, 1932 VOL. 129, No. PHOTO-ELECTRIC TUBES USED MAKING AUTOMOBILE VALVES LECTRONIC control and the rearrangement equipment for straight-line progression work have effected new economies the production automobile valves the plant Thompson Products, Inc., Cleveland. The use photo-electric tubes for controlling operations outstand- ing feature the plant now ar- ranged. photo-electric tube pro- vided for controlling the temperature which tips valves are heat- treated electrically the hardening operation. Electronic control used also gathering machines the forge shop. With this control the machine does not perform its func- tion gathering the metal that forms the head, the first forging operation, until the end the piece that gathered the proper heat. Bar stock used making com- mon type valve received from the mills 12-ft. lengths, most the material being ground before shipped. Various grades alloy steel are used, the most common being nickel-chromium and chromium steel for intake valves and chromium- nickel-silicon steel having high heat- resisting qualities for the exhaust valves. The first operation cutting the bar length, 10% in. being the length piece required for making most the valves. The bars are cut hot automatic cut-off machines. Economies have been effected the use special furnaces for preheating bars ranging size from 21/64 29/64 in. diameter. furnace, ft. long, back each cutting-off machine. row gas jets one side extends the length the heating chamber. PRENTISS Cleveland Editor, The Age LECTRONIC control among the innovations in- troduced Thompson Prod- ucts, Inc., Cleveland, effect new economies the manufac- ture automobile valves. used the operation gath- ering machines, which gather the metal forming the valve head, and hardening the tip the valve stem. The entire bar heated the cham- ber one time. the stock monorail deposits bundles table, from which the bars are fed down slight incline into the through slot-type the furnace. heating chamber opening the side the chamber the bars rest side side inclined After being brought the proper temperature, the end the bar drawn from the furnace and rails. with into the The bar then moves along delivered machine. until all cut off. the between the machine and the only about ft., only small por- atmosphere, and the time between leaving the furnace and cutting off short that the bar retains the sary heat. When bar (the one that } has been the furnace the longest) removed, another fed into the furnace over the incline and takes side those that are already being heated. Usually pieces stock are the place the furnace cut-onr chamber one time and this give the proper time sequence for heating. However, the number what, depending the varies ome- size of stock. Bar stock previously was heated box-type furnaces. When that method heating was followed, the bar did not remain required temperature long enough cut its length and had taken the furnace for reheating. entire back The blanks are carried barrels from the cut-off machine the forge shop, where they are first ground roll grinder, about 0.002 in. metal being removed provide smooth, clean surface the stem. Forming the head, which follows, consists the case most types valves two hot-metal operation about one-half the metal the piece into ball and then ham- mering the ball into head with one blow header. gathering The gathering operation done Bartlett-process gathering machine developed the plant. This semi-automatic with pneu which the work The matic control placed pads forming the anodes and provid- ing sliding contact. One end the blank placed against carriage ith feed, which moves forward and backward pushes the piece forward against head effecting electrical contact. soon this contact made the eye cuts off momentarily the motor operating the feeding device. piece quickly attains red heat, the proper emperature for forging the motor feeding starts and the 3 & 1 e1ec t 381 machines which ends valve blanks are heated and the head valve. The use the electric eye means con trol The travel the piece the ma- minute, depending the grade steel. Each machine will gather about 400 pieces hour, the number length valve. Usually in. the furnishing the amount material re- quired for the finished valve head, designed furnaces are used for heating bar stock for automobile valves before although some types valves cutting off. The man the foreground feeding stock from the furnace into automatic much in. the material cut-off machine. (Below) Labor cost making keyways valves has been materially reduced transferring this operation from the machine shop the forge shop and hot punching the keyways. The thus gathered up. The remaining material becomes the valve stem. The picture shows special furnace for heating the stem and the adjoining punch press which gathering machines are arranged the operation performed. four groups six machines each. Five machines are operated time, vice pusher again functions, suf- treadle control and the operator can the sixth machine being provided ficient pressure being exerted the stop the machine instantly. spare. piece against the head gather the heated end the piece the form ball. Then the pressure, which controlled adjustable stops, relieved and the mechanism reverses automatically, the pusher re- turning its starting point. pro- viding automatic control through the electric eye, the danger having the piece too hot, which would cause to burn, or too cold, which would cause bend under pressure, avoided. The temperature range usually from 1900 2000 deg. The work the machine operator confined largely feeding the ma- chines. The operator places piece the groove the pad and closes the jaws the pad with lever, which holds the pads tightly together when the piece moving through. After the head gathered and the machine reverses, the operator raises the lever opening the pads, removes the piece and inserts new piece. The machines are provided with foot- 382—The Iron Age, February 11, 1932 7 4 4 Ad ated con and then gathered into ball, the first forging operation making trolling operations not applied the battery machines illustrated The valves are headed without be- ing reheated, this being made possible the arrangement the forging equipment for the rapid flow work from the gathering the heading operation. The gathering machines are located mezzanine floor and beneath battery these ma- chines the ground floor cial-type Manville valve-heading ma- chine. taking valve from the gathering machine, the operator drops into steel pipe, through which falls endless chain conveyor located above the heading machines. This conveyor discharges into chute, which delivers into screw- feeding mechanism. each a spe- From > Pieces pass from the gathering machine (on the floor above) through the pipes conveyor, which delivers them through chute from which they are fed into heading machine This performs the second and final valve head forging operation. Below) The electric eye automatically controls the operation machine for hardening elec- trically the tips automobile valves. This control assures proper and uniform hardness shutting off the current and releasing the piece when has reached the proper temperature, shown the color, and discharging into quenching tank passes into slot, down which slide perpendicular position. the the fingers the heading One blow the header flattens out the ball end the proper thickne for the valve head. From the head ing machine the pieces short which them into shop boxes for removal The the bottom conveyor, discharges the machine shop. rapidly from the heading machine that the heat the piece has duced only about 1800 deg. the equipment consi gathering chine been when header. The heading two 150-ton and three 250-ton headers. new method for making keyways reaches been adopted the stems popular mé { ulted perform thi machine sho and saving labor operation. done valves used automobiles, marked ing the work Formerly the drilling three holes and broaching out the keyway. This operation has been transferred the forge shop where the keyway made while the metal hot. The stem the valve inserted the was flame special The Iron Age, February 11, 1932—383 { a.) | | ~ : N > 2 — oil-fired furnace with automatic tem- perature Across the front the furnace series round holes, each which just large enough stick the stem through. When the stem heated 1800 deg., the fur- nace tender passes the valve the operator punch press the side the furnace and cuts out the keyway with broach. With this method, two men make keyways the rate 400 500 hour. The valves, after being headed, are annealed gas-fired furnace. Then they the machine shop where the various machine shop operations are performed, the work moving pro- less than days—from Oct. through not only with gratifying dis- for Nov 16, machine patch, but without damage loss Hardening the Tips Valve Stems shops and offices the Keller shipment and without single acci- Mechanical Engineering Corpn. were dent. base and coil which standard the Kell this moving the Keller shop it: electric rivet heater. This machine new home, some 120 miles distant. almost the same period, buildings trol. The valve placed ing plant, and execute the moving the jaws holder and the tip with the least possible delay ex- electric current. When the tip and with the least interference with the proper heat, shown operations and personnel the Hart- the color, the electric eye shuts off project involved the handling ford works. Then, considerations the current, causing the jaws open each end some freight minimum labor and other expense, and release the piece. the use load and automobile truck loads chronic habit the modern manu of the photo-electric tube, very close ol machine tools, small tools, gages, facturing executive, were not to be x “eS ‘ rns r rh ras > ‘vec ex. well automatic temperature con- and fixtures, patterns, rough and overlooked. these objectives trol provided finished stock and shop and office fur- erted strong pressure provide valve drops from the jaws the hardening machine into oil quenching tank. After quenching, the Limited yard clearance complicated the handling long columns and girders; head stenciled show the kind gasoline tractor cranes were used get them into the driveway and swing teel and the type valve. Follow- them into position for pulling into the erection square with the stem and finally the grinder. \ or tested. similar instrument used for testing the diameter the which held within 0.0005 in. The valves are weighed and counted after inspection, and then slushed hot oil dry out the water left the surface after the grinding opera- tion and give the pieces protec- coating. They carried through the slushing machine pans wheel-mounted racks. Surplus oil passes through perforations the the pan drip tank be- neath. Then the valves are wrapped paper and placed cartons for Iron Age, February 11, 1932 - > == = — ’ | F ? t NING RESULTS KELLER PLANT ~— MILLER gencies, such double handling, im- identification, shipment and the many others that could occur move this kind. proper Brooklyn Shop Production Die Sinkers Die-sinking and toolroom machinery were the main products the Keller shops, which, when operating peak, employed 300 men. These machines, widely known tool and die shops, reproduce dies, punches, molds, pat- terns, etc., automatically from mas- ter form template, cutter mill- ing tool working unison with tracer guide. Electrical control all motions the cutting tool feature the more recent de- several signs. The line comprises sizes automatic duplicating die sinker; two types reducing die sinker, rotary and straight line; electrically-controlled duplicating ma- chine with capacity 108 in.; and automatic duplicating and con- touring milling trical machines with elec- hand control. the company manufactured variety flexible-shaft sinking, grinding, addition, equipment for the polishing, and also small tools for use all machines. Hartford, the will operate self-contained unit; although, like other divisions, will use certain general depart- ments the plant, such the dry, toolroom, plant maintenance, etc. Kelle r division foun- housed two buildings, one which contains both light and heavy manufacturing departments, One end the erecting floor with the steel work place and the second floor the old three-story mill-type structure half ripped out. The foundation for the concrete floor being laid and tamped down. Automatic duplicating and milling machines with electrical control are among the tool room and die shop machines built the Keller division the other houses the erecting and heavy machining and the electrical parts manufacturing and assembly departments. Production shop offices are the floor above the erect- ing department. Moving the course, many steps Brooklyn shop involved, executed for the most part simultaneously. First all, quick selection and as- the space made vacant the trans- fer the Pratt Whitney Aircraft Co. its new plant East Hartford. allocating the various departments, certain changes the buildings se- lected, including the one building remodeling suitable machining and erecting floor, provide a heavy were seen desirable, and these initiated the production means template benche 3 tool cril furniture immediately. Floor were + layouts were made and stock racks, and other shop were or- Quick Handling and Erection Receiving End While deciding the order dis- mantling and shipping the various Brooklyn departments, arrangements were made for crating and packing, making platforms and skids and the hauling and shipping. system identification accounting raw and finished stock, out; and due consideration procedure em- markings, including department symbols for quickly worked was given ployed the receiving end, such the marking the freight depot department and floor locations, and the quick handling and each shipment received. erection that well was this planning done that machine tool equipment was belted previously ready for operation, soon after ar- The Iron Age, February 11, 1932—385 = wy wal way -ia al rival Hartford. Storeroom mate- rial, marked with Brooklyn shop, was quickly put the same places formerly occupied; and less than week orders were being filled from these shelves. Before dismantling shipping Brooklyn however, two production three partly finished large die sinkers any the equipment, were transported Hartford finished and Keller men, delivery dates. the load the third floor and roof and the same time provide the needed unobstructed space and head- Plans were prepared and the steel fabricating and erecting contract let. Excavation for the concrete floor, the column footings, piping tunnel, under the floor was begun Oct. 12. The first steel work was received Oct. 23, and Nov. the entire steel work—110 tons—was place. Mean- while concrete floor covered 3-in. creosoted wood reinforced View completed erecting floor, with work going forward regular production. The mezza- nine floor the far end all that remains the old second floor. Next spare machines, rough castings, bar stock and other raw material hand. Shipping machine tool equipment began with one entire manufacturing order was the shipment group, and was completed with the large planers and radial drills located one end the erecting floor for the machining bases and other heavy parts the larger Keller machines. The building selected house the erecting shop and the electrical parts three- story mill-type structure with brick walls, columns, girders and space, 157 ft., there were addition, the ft. ceiling the first floor was in- adequate, because the larger Keller machines are ft. more height; furthermore, sufficient 15-ton span assembly department was timber heavy wooden columns. headroom for bridge crane was necessary. Accordingly, was decided take out the second floor, and replace the construction steel columns that would adequately wood and girders 386—The Iron Age, February 11, 1932 block, giving depth floor, was laid 4-ft. deep trap rock fill. The steel work consists main columns and many crane columns, nine each side, spaced along the wall 15-ft. 4-in. centers. The main columns are 10-in., H-sections and the crane columns, riveted the main columns, are 10-in. H-sections. girders, one for each pair columns, nine all, measure ft. in. depth and ft. in. length and weigh tons each. The crane girders extending the length the building carry 60-lb. rails which the 15-ton Niles floor controlled overhead travel- ing crane runs. The cross The entire steel work was put place before the old wooden construc- tion was demolished. yard clearance complicated somewhat the handling the long steel columns and girders. With the footings place, each column (the main column with its crane column) through the first-story window means gasoline tractor cranes and placed position through holes pro- Then the main cross girders were put through the second-story windows, jacked the under part the their respective pairs columns. the same manner the crane girders were put place and the crane as- sembled. All this was done rapidly, and when completed, the former posts and all other wood construction, from the girders supporting the third floor down, were removed, leaving the un- obstructed, well-lighted erecting floor shown the accompanying illustra- tion. Although the original two stories windows provide for daylight illu- mination, remodeling the interior this building necessitated changes the artificial lighting system. Twelve reflectors have been installed two rows the ceiling, each reflector being fitted with 1000-watt lamp. Ten angle- type reflectors, each with 300-watt lamp, have been placed along the side walls just below the crane rail, about ft. above the floor. This lighting controlled through four inclosed panels, one each quarter the room. Heating System, Well Rearranged Rearrangement the heating sys- tem was also necessary. The seven Sturtevant unit heaters, size No. formerly used were rein- wall and design stalled, four one side three the other. They are now fitted with cold air intake boxes, hav ing cold air intake openings floor, the warm air being blown out height ft. The same sys tem circulates cool air the summer. Advantage was taken the modeling this building collect and place within accessible con crete tunnel all the steam and water pipes that previously were low the first floor the remodeled building. This tunnel, ft. in. high ft. wide, inside, extends under one side the ground floor building. equipped throughout its length with structural steel pipe rack, ft. wide, arranged that all pipe lines carried are accessible for inspection and repair. Ample ac- commodations for future piping stallations have been provided. The above details will serve in- dicate something the extent work involved moving the Kelle: plant its new home Hartford; obviously, success was due thor ough planning and clean-cut execu tion. q & handling systems using conveyors, the method transferring from one conveyor another often very important. The individual belts shown travel alternate opposite the transfer from one the other being effected means revolving disks which automatically pick and deliver the next belt the smallest jars and vials. This same method could used for larger objects and packages. (Standard Con- veyor Co.) CU — Manual Switching Conveyor Loads Automatic Control conveyors, switches can controlled manually, with cables levers and they can also controlled electrically. With electricity the operation can made fully semi-automatic The shown full automatic. Note the motor underneath equipped with solenoid brake quickly stop the travel either direction. (Logan Co.) illustrates switch. Note the special section gravity the left. This con- struction gives flexible curve the switch section. The use this type curve permits the switch swing wide arc with minimum horizontal length. this installation each switch serv- ing five storage lines gravity conveyor. (Logan Co.) A } 4 a & we »\\ > ¥ i G d le = n | “ in- ail The Iron Age, February 11, 1932—387 ‘ ELECTRIC HIGH-SPEED WIRT SCOTT Westinghouse Electric Mfg. Co., Ohio 44 . electric pit-type furnace, with the cover and insulating plug removed. Sam- ples the preceding charge are shown around the base the furnace. the insulated plug are shown bars super- high-speed steel, and several lumps coke the size used the crucible the breakage such tools. The in- IGH-SPEED speed steels, after forging, are full of terrific strains these are not thor- moved before the hardening empering operation, additional In f ifficient stre es be up aust the t ] lite? The annealing opera important eels lish the annealing acking mica dust around the exclude all air and there- revent oxidation. The mica dust ipposed give uniformly ling for the proper anneal. manufacturing plant where rable quantity such steels was worked into tools used the production equipment, in- vestigation was made locate the cause trouble being experienced 388—The Iron Age, February 11, 1932 showed that was prob- vestigation ably due the annealing. Tempera- ture exploration tests the charge steel under heating and cooling onfirmed this. The stock, before being annealed, was forged either into bar stock di- rectly into tools, which consequently left some scale the surface. The bar stock tools were anywhere from in. in. long. Pit-Type Electric Furnace for Annealing designing crucible-type elec- tric furnace for this application, the time abandoning the use the mica dust, that was considered the heat treaters part the thought was essential process. With the pit-type electric furnace supplied, having vertical cruci- ble made cast nickel-chromium al- loy 17% diameter 35% in. deep and sand sealed door, the op- portunity was presented for experi- menting with gas agent rather than using the mic: dust. Charcoal was first used, but was found burn too Coke, free sulphur, was then tried and found 100 per cent succes ful. One-quarter peck, placed the furnace, would last about week. remarkable thing brought out that there appears even scale the work after comes out than when goes into the Whatever scale the steel ver) flaky and can brushed off with hand. With gas furnace, hr. required get out heat—12 hr. heating and hr. for cooling. Wit the electric furnace heat being obtained exactly hr.—7 hr. heat ing and hr. cooling. Four test samples were taken out the charge, selected random, given Brinell test. These tests wer From these tests, evident the high-speed steel was dead so! and thoroughly annealed. = » : t et ae I ‘ odat While the furnace has not been use long enough obtain accurate data its effect the life the tools, which undoubtedly will show time, there are positive indications that the steel better condition for hardening. considerable amount the super-high-speed steel cut into tips various sizes for form- ing the tips cutting tools. This steel must cut into the required sizes hack saw cutting machine. Since using the electric furnace, the hack times much cutting they would LECTRICALLY heated pit-type furnace for an- nealing high-speed and super-high-speed steel. Ap- proximately one-third the furnace below the level the floor. The white rim the furnace the sand seal trough, leveled off, and the cover being lowered into position. The insulated plug-type inner covering for the crucible shown position. The protected-type thermocouple centered for lowering with the cover, directly into the heart the charge. CHART MO, oan WO-POINT tempera- ture control recording chart. Heavy line indi- cates temperature the charge. Light line indi- cates the temperature the heating element. De- grees are centigrade The current was cut off the furnace only once the temperature the heating element. After that, the cutting and off was due en- tirely the temperature the charge 3 formerly stand before having The temperature resharpened. addition, the clearly indicates the functioning much more easily and quickly cut these couples and the pyrometer. The The electric furnace supplied for charge heat treated 900 deg. this application equipped with (1652 deg. F.). thermocouples and ment set control the charge rat tam re nra Tha imiting tem- and controlling ter. that temperature. The limiting tem One thermocouple, the protected perature the heating element tube type, extends through the top fixed the pyrometer setting 980 the furnace, and sufficient deg. (1796 deg. F.). heating reach down into the center up, the temperature the heating charge. The other thermocouple ex- element reaches 980 deg. before the tends through the side the furnace, work reaches 900 deg.; hence, the where influenced directly pyrometer causes the control cut temperature the heating element off the current. The charge continues 4 — $ ; N ~ co 32 | * P ‘ si | q — The Age, February 11, 1932—389 heat for short after the current off, and when the current comes again there only small temperature differential be- tween the charge and the heating ele- men After one more cutting off temperature heating element tne ter ratut Oo tne charge na 900 ind from that ontro cutting and off the heating element nes 960 other words, I perature the tempel tur heating element only \ ( ea JUU hou and current cut off When the charge has cooled to 400 deg. (752 deg. F.) may re- from the Three hun- ind fifty pounds high-speed ind iper-high-speed steel tre time This steel costs anywhere from $1.50 $2.50 type, lends itself the best possible unloading ut wi may not word a r to pla tne couple In tne + Ixy artlw in position than only partly larg heated. The center the charge the reach the final temperature. Soaking the annealing for hr. after the uple reaches the correct temperature 1s guarantee ol thorough saturation heat through- out the entire charge. The elimination the mica dust tion and also permits the charge heat more quickly and cool anneals are one-half the time. down faster. Perfect being obtained Repeated tests the electric fur- nace showed maximum differences the time the graphic chart temperature shown there was annealed 400 lb. steel, with power consumption 135 kwhr. This gave production lb. steel per kilowatt-hour con- sumed, negligible cost comparison with the value the steel and the results being 390—The Iron Age, February 11, 1932 period time built ison, Wis., pecial Fixture Facilitates Checking Ball Bearings for Dynamic Balancer ALL bearings used the roll- ers and headstocks the pre- cision balancing machines the Gisholt Machine Co., Mad- must meet very exacting equirements. The bore the largest used, for instance, has tol- rance 0.0003 in., and the radial any bearing must not ex- eed 0.0002 in. The necessity for such extreme iracy lies the fact that the ma- hines which the bearings are used are designed measure very accu- ately the ample, tolerance more than the unit unbalance, equal the inbalance ) in. radius, ete. Any radial runout + the bearing will cause the part being balanced rotate eccentrically and thus create false reading unbal- ance. runout 0.001 in. bear- ing may cause the part being balanced run eccentric the same amount and create error 1.6 over five times the permissible error, the test the 100-lb. crankshaft. avoid any possible inaccuracy from this source, all ball bearings for use the balancers are carefully in- spected, and place this inspection definite mechanical basis the com- pany has devised the fixture shown the accompanying illustrations. This fixture consists spindle driven fractional horsepower mo- mounted journal the outside which are suitable attachments locate and support dial indicator The ends the spindle projecting from the jour- the necessary positions. Previous checking for eccentricity and other inaccuracies, the bearings are inspected for outside diameter and width. Extreme care taken prevent exposure bearings dirt and dust. = most conveniently placed the center the charge, and one can q ix nal constitute very slightly tapered gages for the the bearings inspected. bores various Outside Diameter and Width Checked First After checking the outside diameter 0.0001 in. and checking the width means micrometer caliper, the bearing slipped the tapered portion the spindle where two lines indicate the permissible smaller and larger limits the bore. which will not pass over the first line which the line rejected having small passes beyond second large bore respectively. With the bearing firmly seated the spindle the radial runout eccen- tricity observed means the dial indicator placed against the out- side diameter while the inner race rotated r.p.m. and the outer race held stationary. The slow speed rotation and the use indicator reading 0.0001 in. curate inspection. Longitudinal run- out observed the same with the dial indicator reading from the face the outer race. permit very ac- Inspecting the ball bearing for fric- tion and the presence foreign mat- ter too great importance left the feel the spector’s hands his individual judgment. each different size bearing certain maximum and mini- mum weights are specified for this phase the inspection. With bearing mounted upon the spindle, the smaller weight attached the outer race spring clip and the spindle then slowly rotated the motor. pass inspection the outer race must rotate with the inner race, carrying the weight around with it; this show that the bearing closely fitted and has radial play. sense in- 1 tne Inspected for Presence Foreign Matter Passing this requirement, the larger weight substituted for the smaller and the spindle again ro- tated slowly. indicate that the friction not excessive, this weight must prevent the outer race from ro- tating with the inner. This test continued for about min., during which the presence foreign matter will detected sporadic rotation the outer race with the inner race spite the restraining influence the weight. This inspection made immediately after receipt shipment bear- ings. Extreme care used pre- vent exposure the bearings dust and dirt, and room temperature close deg. required. Bearings this clean mixture Nys delicate passing inspection are dipped chine oil and rose oil proportior two. They are then wrapped NSPECTION vised facilitate check ing eccentricity, etc., ball bearings for use Gisholt balancing machines oreroom In the original How Casting Temperature and Additions Affect Bearing Bronze effect casting tempera- tures and additions iron the properties bearing terial consisting per cent cop- per, per cent tin and per cent lead, has been investigated the reau Standards, Washingtor addition determination hard and microstructure leaded bronze, several method employed hich mulat phases actual servi litior These test included defor I der pounding, resistance impact notch toughness, and resistance wear both dry and the presence coolant. bearings are above room temperature while op- above tests were conducted ted temperatures. the founding bronzes sel dom possible pour all casting the same temperature tal drawn from the furnace various temperatures and cools the ladle during pouring operatior The study the effect different casting temperatures thus aids the manufa turer producing better castings and the same time helps the consumer predicting what variations prop- erties may expected bronzes various temperatures. the 80-10-10 bronze cast tem- cast study peratures varying from 1850 2120 deg. was found that, the cast- ing temperature, the grain size, and the resistance to wear were increa ! the hardness decreased slightly, and a light tendency was noted for mor even lead distribution. Casti bronze about 2000 deg. caused lowered the toughness hown the notch test. The deformation der pounding was minimum 1900 and be Lween leaded bronzes, sma cumulate during through the iron stirring ounts often manufactur crapped bearings, rods, ete. While the quite small most iron this element generally consid ered harmful, and the reported estigation the content ried from 1.0 per cent was studied to a it effect nm be bronze was found tha additions over 0.3 per cent were detrimental the bronze gated Small addition iron (up 0.5 per nt) decreased the resi wear and increased the hard When the iron content exceeded 0.3 per cent, segregation the lead occurred, the grain size decrease noted toughness. Additions 1.0 resistance pounding. reduced, was iron per cent increased the The Iron Age, February 11, al q 4 = >> aT clean waxed paper and sent the paper boxes, the seal which indicated their deg. Although iron not usually added intentionally ntent the effect particles the notcl well-painted plant usu ally cheerful place which work and congenial sur round ngs are conauclve » good work. Labor turnover reduced. Clean ness encouraged and the psycho- logical well the physiological benef workers are not over- looked Even mportant some respects the effect vision. Properly painted ceilings particular have marked effect upon visibility, especially light depended upon areas what removed fram windows wna removed from Windows or SKy- lignes. n é Ul arvulncls rit lights. The quantity artificial required can also be reduced There therefore, ample reason for the con- properly-painted interiors. tention that money intelligently spent interior painting pays good divi- dends, and for inquiring what tutes good painting. most important factor proper 392—The Iron Age, February 11, 1932 HERBERT CHASE Consulting Engineer, New York interior painting the selection colors employed. For upper walls and ceilings color with high light- ection value most important, for light except that which re- fiected can reach that side work away from the light source except reflection from some surface, and the largest surfaces available for such reflection that the ceiling and walls, including the vertical sur- faces beams and columns. Much the light that enters through win- dows and skylights lost unless #} reflected from such surface. & NTERIOR the Ford steel mill, example well-painted and well- kept plant. Walls, ceiling and steel work are painted cream color, ap- proximating white. The dado gray and the machines black. Photographs, courtesy the New Jersey Although all modern artificial lights are fitted with their own reflectors, some light always reaches walls and flected them just that much light subtracted from the illumination the work itself and from other objects which the worker see clearly work efficiently. Colors Vary Reflecting Ability Colors vary greatly their light reflection ability, the figures given Table indicate. These figures, resulting from tests made the Munsell Color Company for the New Jersey Zinc Company, show the per- centage light what termed diffused reflection, distinguished from the direct reflection from polished surface. measured angle deg. the surface with the light striking the surface normally; that is, right angles, A = = Zit ( Png. | . if and the type reflection which depended upon bring the eye all light which does not come direct from the source direct reflec- tion from polished surface. will seen, white, which without color, much the most effi- cient, gives the highest light re- flection value. is, therefore, the best use upper walls and ceilings for nearly all factory conditions which good lighting important consideration. rare cases, where there excess light some times the day, pure white some surfaces may result glare which trying vision. very light tint light color then desirable for upper walls and still lighter near-white for the ceil- ing. Even light tint, however, re- duces the light reflection value from per cent more, hence the least departure from white that will PROPER selection colors affects lighting, seeing ability, cleanliness, appearance and working conditions. also important. The psychological effects are Well managed plants are nearly always well painted. One might say that there close relation between paint and profit. Mr. Chase brings the plant manager some sound ideas and sugges- tions this important phase maintenance. meet other requirements is desirable for the surfaces mentioned. For the same reason, white which allowed become dirty which, because inferior materials the paint, colors quickly, likely have marked effect upon illumination. Not infrequently such deficiency made pensate for increasing the wat- tage electric illumination. The in- creased consumption current may } \ « then easily cost more than would new coat paint washing sur- faces that not need repaint HITE paint the walls and structural members this Kear ney Trecker plant, Milwaukee, not only adds the fine appearance, but its high light-reflecting value aids both natural and artificial illumination ‘ Mills which excessive smoke and other factors tend dirty white surface quickly, present another prob- lem, the solution which get rid the smoke fumes through adequate nodernized equipment means ventilation. Where this not feasible, some color may sub- tituted for white, but course with considerable loss light reflection value. often argued that color which does not show soil quickly advantageous and this un- doubtedly true some instances. But should not forgotten that surface which does not show l may less dirty than light ored one and that extent encour- the accumulation dirt. light green sometimes recommended for exposed trusses and other over- head steel work, “to give feeling support” and there are — | of these surfaces aluminum paint may The Iron Age, February 11, 1932—393 satisfactory. Contrary general belief, however, the light reflecting value aluminum paint not high, less than half that white and lower even than light gray. Best Colors for Lower Walk There much diversity opinion concerning the best color for dados wall portions areas and the cor- responding columns. great deal depends upon the general effect desired, the exposure and probable light available, amount frequency cleaning and other fac- tors. colors produce de- different psychological effect Thus, red “hot” exciting color and seldom recommended for large areas. ith danger, fire and fire-fighting equip- ment. Orange and yellow are colors are also the browns that contain them. T apt make room feel warm buffs and They help make cheerful interior but are ren hot and are not recommended for that are normally Conversely rooms warm sunny. they are exc or el- lent for rooms that are normally cool cold. contrast green cool and restful and blues are cold Light tints blue help dainty. make to room that normally hot feel cooler, just the shades red, orange and yellow help make feel warmer. cream buff color much “warmer” than white, green blue, and often employed for this reason, even upper walls when warm effect desired. Rooms tinted blue have often brought complaints feeling cold, though mometer showed otherwise. When recolored tints yellow buff, but with actual change tem- perature, all complaints being cold ceased. Facts such these properly have bearing especially upon the color Table Applied Painting Jobs ition Painting eT ) ( VALUES PER IN. BRUSH 039 Gloss 037 (ilo 041 (; O39 Flo Pri Gloss VALUES PER FT. Wall Prime .034 Prim 036 | Gloss O35 Gloss coat Gloss ‘coat 031 04 052) 069! *Values are terms time-units work, and are expressed tenths hours. the points should moved one place the left Iron Age, February 11, 1932 ~ | 067 055) O66 IN. Never Painted Before Smooth | | | | | METAL | | | tom | ~ | 3 3 — joa A WHITE PAINT 053) | | ( 5 5 | .05 | PAINT | | | .045 045) convert regular decimal values hour q | = | = | | | | = j | | | | Ta | | | | } | | | | | } } selected for both upper and lower wall areas. good general rule paint the ceiling white, the upper walls either white very light tint either the warm the cool color desired, and the dado darker shade the same color, but light the degree cleanliness that feas- ible maintain will permit. are seldom recommended they are inclined depressing. About their only advantage that they not show soil readily some col- ors. Dr. Luckeish, the General Elec- tric authority light and color, associates gray with the penitentiary and, pleasing contrast, suggests the following representative “cool” color scheme for the factory: Grays Near-white for ceiling, either mere suggestion yellowish green even cream; medium tint pea green for upper walls and other large ver- tical areas; gray-green for dado and lower portion columns and possibly for machinery. Many concerns have experimented with orange, yellow, green and blue machines and there are indications that these some other colors may yet take the place the standard machine tool gray. one shop, that the Armstrong Machine Works Three Rivers, Mich., where the management takes considerable pride the appearance its plant, flat white paint used for the ceiling. This paint covers about 500 sq. ft. per gallon, one coat, about one cent square foot. Data the time required for painting wood, brick, cement, plaster, and metal surfaces with three-inch brush are given Table II, taken from Report No. 520 the Alexander Hamilton Institute prepared recently Stewart Lowry and entitled “Financial Incentives for Factory HIS all white interior the Hamil ton Watch plant great aid good seeing, especially the center rows benches where operators work with their backs the windows Mr. Lowry’s long experience work for the Westinghouse Electric Mfg. Co. and other industrial tions Wage Incentives Applied Plant Painting this report Mr. Lowry makes clear that wage incentive plans can tenance work painting instance however! it nece Table Values Colors Whi Crean Light Yell 60.5 Light Pir Flesh Dark Red 14.4 Buff Light Light Gre Sage Gre 11 0 Dark Light Gray Aluminum Gra 11.9 Light Dark Blue Dark Gray, approximating machine-tool gra 15.0 Data determined Mur ell Color Co. values pend course, upon the particular shad elected. col establish certain standards ult careful analytical and com plete time studies. Such standards must take account many uch the character and location the surface to be painted, method of applying the paint, mixing the paint, and moving scaffolding and the like. Table II how one of tandards established After using the wage incentive plan painting many sets for painting operations. work for nearly three years the aver age production rate was found have increased per cent, the cost have been reduced per cent and average wag lave increased 13.8 per cent. Only per cent the ivings paper presented before the National Industrial Congre early New Jersey Zinc Co., hat the painter never stands the wage incentive plan discharged, for receives his reg- ular hourly rate even though his work falls below the standard set. part the increased output the result better planning and scheduling work. some instances per cent the premium paid goes the workmen and the remainder men and supervisors. get the most out the plan the foreman must plan ahead and anticipate abor requirements well ise incentive plans painting ically, but plants where the olume such worl ifficient varrant the time and other studi that are necessary establish accept- tandards and operate tive system, appears merit seri- The Iron Age, February 11, 1932—395 { | : | waterwheel generator rotor (25 ft. diameter) can made more economically cast steel even only one constructed. the con- machinery parts increased very rapidly HE use of welding struction has the last few years. Welding can now considered fundamental proc- ess riveting and casting for mak- The Westing- welded structures, castings and struc- ing products metal. house company large user tures formed combinations cast- and welded steel. Over 1000 tons structures ings welded are manufac- tured month spite the fact that the company operates five iron } foundries and one steel foundry. Cost Considerations experience the last few years has established quite definitely the economical dividing lines between the different methods construc tion The relative cost riveted to a we lded structure 1s q lite easy to largely compari actual cost the riveting - & Because the walls these castings had very thin was found more economical make a | & operation with that welding. Riv- eting has been practically eliminated, even departments which had elabo- riveting equipment. The parison the cost welded struc- vith more complicated, especially when the general the most important factor in- volved the number pieces which are made. there are only few pieces the saving the cost pattern usually insures cheaper con- truction welded steel. One the illustrations shows bearing pedestal construction which can more economically made casting rate ture becomes much manufacturer operates foundry. welded than four one design are needed. When the activity high the pat- tern does not affect the cost compari- son very much. The pattern cost usually about the same that the jigs and special tools required for the the lower piece, bed plate, welded construction. Iron Age, February 11, 1932 THE USE STEEL CASTINGS WELDED RITTER, Welding and Foundry Engineer, Westinghouse Electric Mfg. East Pittsburgh, Pa. high production welded structures. illustration shows synchronous motor which made quite large numbers. The frame, rotor and bed- plate welded construction and the bearing pedestal made cast iron. has been established that bedplates welded construction are the most economical regardless the quantity involved. This due the fact that this type structure has relatively small amount welding and fitting for the weight involved. They are constructed standard rolled shapes, cut length and fitted with very little labor and waste material. This contrast with the motor frame which constructed burning annular rings from plate with quite high labor cost and scrap ratio. Quick Delivery Factor There another factor besides cost which often involved when deciding used. This factor the question quick delivery and the welded con- struction has the advantage here. The 7000-hp. motor shown one the illustrations was completed very short time through the use welding. This motor used for steel mill drive. The main frame composed bars 9-in. 30-in. steel rolled into shape and welded together. general, the welded structure | = > ‘ © ¥ 7 and castings requires careful study each cations steel castings are more economical than welded structures. Some the considerations that determine how parts electrical equip- ment are made were outlined the author recent address, here abstracted, before the Steel Founders’ Society America. The main frame this 7000-hp. motor made bars 9-in. 30-in. steel rolled into shape and welded gether. the fabrication this motor the necessity for quick delivery gave welded construction the vantage. does not have great advantage The design consisted mostly flat them place. Cast steel with over steel castings does over thin walls which made their carbon content 0.30 per cent and iron castings. This due the fact that cast steel equally strong the rolled steel used welded con- struction. When replacing iron casting the welded construction can made much lighter and the welds not have very large order give structure strength. comparable steel, however, the design has followed almost exactly and the welds have large enough de- velop the full strength the steel sections. The waterwheel generator rotor shown can more economically made cast steel, even there only one constructed. The ro- tor ft. diameter. The shapes required involved much labor that the casting proved cheaper. Rotors large this but more simple welded designs. The direct current motor rotor shown another illus tration subjected very high stresses, being used steel mill re- versing mill motors. Welded struction the most economical for this type design except the smaller sizes, which are made cast steel. con- Another photograph castings which are used 350-hp high-speed railroad diesel engine. The walls these castings had very thin, 5/16 in., order save weight. was found more economical make the lower piece, bedplate, welded construction. with ment plate construction fairly under can welded successfully simple. There are many intricate the rolled steel. Higher carbon shapes the upper casting that and alloy steels can used the was not found feasible weld proper welding procedure used. ve if ti oft tings even combination One the illustrations shows forgings and rolled plates were circuit breaker tank with cast steel Combining Steel Castings with ring being welded Fabricated Structures Various pockets and brackets are Very often the cost welded combined into the single casting. Lil SU UL « tructure increased very machined and drilled complete and > < ‘ bile because some parts are quit then welded the tank. The tank complicated and require rotated the turntable shown and large amount labor. The logica the weld deposited the automati thing here construct welding head. This form construc- parts steel castings and then weld tion insured good gasket fit for This direct-current rotor, used steel mill reversing mill motor, can made most economically welded steel except the smaller sizes, which are made cast steel. The Iron Age, February 11, 1932—397 ; wo’ ™ 4 ~ > ~ Sea | 7 4 af | HIS synchronous motor made quantity. The bearing pedestal iron casting. has been found that bedplates welded construction are most economical regardless the quantity involved top well used lower foundry costs. The costs. welded designs are inherently simple welded steam turbin with straight sides, small radii there are several points wher corners, few holes and other features which would lower pattern and mold- the parts with cored passages are costs. cast and then welded the rest The recent increase the use the welded structures due the data improved welding methods and welding the cross tie brake hanger lugs and other small casting frames. The to the two side “a supports are steel castings welded the main fabricated structures. Pattern Designs Simplified were also welded place. main frames ov tern) gyroscope used t