The Iron Age 1932-03-03: Vol 129 Iss 9

IRON AGE.. ESTABLISHED 1855 NEW YORK, MARCH 1932 VOL. 129, No. PROGRESS ATOMIC HYDROGEN WELDING SAMUEL MARTIN, JR. Industrial Engineering Department, General Electric Co., Schenectady, atomic ing electric and maintained be- tween two tungsten electrodes. into this and surrounding the electrodes mo- TOMIC hydrogen welding affords temperature 4000 deg. compared with 3600 deg. for the electric and 3200 deg. for the oxyacetylene flame. Due this higher temperature and its producing reducing atmosphere, the use atomic hydrogen welding broadens the field welding include many alloys and light-gage materials. lecular hydrogen. The intense heat the electric arc breaks down the molecular hydrogen and atomic hydrogen which has absorbed large amount heat. Molecular hydrogen being blown into the are and dis- places the atomic hydrogen. This action removes the atomic hydrogen from the intense heat the arc and, becoming cooler, recombines form molecular hydrogen. recom- bining gives the heat absorbed its The temperature this reaction approximately 4000 deg. compared with the electric arc 3600 deg. and the oxyacetylene flame 3200 deg. There are several important func- tions the hydrogen this method welding. First, acts heat in- tensifier, explained above. Second, envelops the work reducing atmosphere, protecting the molten metal and preventing the formation oxides, which are harmful. Third, protects the tungsten electrodes and keeps them from being consumed rap- idly. The hydrogen comes from the its atomic state forms fan-shaped flame. with the fringe this flame that the welding accomplished. The atomic hydrogen method welding does not displace other meth- ods welding. broadens the field electric welding include many alloys, well light-gage als. can used for heavy work well light work. has been used weld successfully steels with carbon content high 1.25 per cent. evident that the use the atomic hydrogen flame step forward the art welding. Smooth and Strong Welds Are Produced The quality the resultant weld above the average. Oxides and other impurities are minimized the shield hydrogen which constant- molten This can have only one result: stronger, ductile welds free from porosity and slag inclusions. Another important feature weld which has_ been made with process that smooth and has finished appearance. order verify the above state- ments consider some the applica- tions this process industry. Boil- ers with working pressure 150 per sq. in. and test pressure 750 lb. per sq. have been manufactured with this process. These boilers were ft. long, ft. diameter and made from shells with %-in. The 41.2 ft. welding such boiler was accomplished the net rate ft. hour. heads. expansion joint manufactured the Croll-Reynolds Engineering Co. The sectional view illustrates clearly the location the weld the cor- rugated, nickel-steel expansion ele- ment. This weld subjected ex- tremely severe service because the ex- pansion and contraction the pipe line constantly flexes the welded joint. The tensile strength this weld 175,000 lb. per sq. in. the = G { i ‘ 537 | | — Figs. and 2.—This flexo-disk expansion joint, made the Croll Reynolds Engineering Co., has corrugated, nickel-steel expansion element. This welded the heads with atomic hydrogen, giving tensile strength weld 175,000 per sq. in. othness of the can clearly Many where quality the finished product important fea- ture the product can named. For example, consider the gas-fired fur- ce, the combustion chamber whic} example atomic hydrogen subject expansion and con- traction. Not only that, but the the completed joint tie The this furnace are also welded the atomic hydro- gas-tight. gen process. Welding Thin Sheet-Steel Stock Fig. illustrates the atomic hydro- gen welding equipment being used weld thin sheet-steel stock. The piece first formed the cylindrical shane shown and then clamped jig. The seam backed that the molten metal, which quite fluid under the ished weld. This enables the erator complete the seam without the use filler rod. particular job illustrated made 16-gage sheet steel and welded the rate in. per minute. An- other user this equipment obtains welding speed in. per min, 20-gage steel. These speeds which are obtained daily. alloy steels are coming into common use, imperative that welded joints are heat and atomic hydrogen flame, will not fall through, leaving hole the fin- under al] these conditions must welding them. The atomic hydrogen 4.—Thin sheet-steel stock for center drums cable reels be- ing welded jig Hayward Co., Chicago. The atomic hydrogen process employed for this purpose. Fig. The sheet-metal section joints this gas-fired furnace are quickly welded, the plant Emil Steinhorst Son, Utica, Y., means the atomic hydrogen process. at Ne a ig 538—The Iron Age, March 1932 = ‘ > into hat for rogen process has been successfully ap- plied most alloys. Chrome steels, including those having chromium content per cent, have been welded. The resultant welds are not particularly brittle the chromium content less than per cent. Heat treatment after welding relieves any tendency brittleness, giving strong ductile weld. The class steels in- cluded under the above contains As- which has chromium content between and per cent. Modifications the original chrome steels have resulted stainless steels, and many other special alloys such KA-2, Enduro, Allegheny metal and Super-ascoloy. Most the modifica- tions have been the addition nickel some percentage the chrome steel. This added nickel chrome steels aids the welding and makes possible strong ductile weld without heat treatment. example the welds made Super-ascoloy, per cent nickel, which are strong and ductile. Welding Non-Ferrous Alloys non-ferrous alloys can welded satisfactorily the hydrogen process. Calorite, per cent chromium per cent nickel alloy, can welded not only worked form, but also the form casting. This metal used for resistance units and heaters for furnaces, which the welds are subjected severe strains which they readily withstand. Some atomic more common non-ferrous alloy general rule alloys copper and zine are difficult weld because the lower melting point zinc. The result, therefore, welding this metal that the zinc has ten- vaporize before the copper has reached its melting point. When the brass contains more than per cent zine practically impossible weld it. For brass with con- tent less than per cent the aid the hydrogen process. There one very interesting application brass. hydrogen welding brass which worth noting. the manufacture thin brass strips necessary draw the metal down from say in. thick 0.01 in. doing this the strips are passed back and forth between several times. The metal can readily wound spools the end each piece brass and continually reverse and set the machinery motion. Therefore, one manufacturer joins to- gether several pieces brass welding, using the atomic hydrogen Fig. Liberty Coppersmithing Philadelphia, uses process welding Monel metal gasoline storage tanks process. The weld but inches wide the feet wide the operation. The successful result only obtained welding the sheets with the atomic hydrogen process, cause the weld sound and free from start and several end the rolling n porosity. Welding Monel Metal Monel gasoline tank shown being fabricated Fig. torave meta! ft. diameter and ft. long, and made from 3/16 in. stock. The complete fabrication the tank was accomplished the == hydrogen welding process. Thi illustration also shows the adding filler the seam. This necessary when there opening complete the joint. Other Uses for the Process The atomic hydrogen welding ess not limited fabrication new products. has proved itself invaluable the repair saws, and other odd jobs. welding piece the saw blade, illustrated Fig. the hydrogen equip- Fig. new section was inserted this 108-in. inserted-tooth cut-off saw the atomic welding process the shop Vance Scales Co., Tacoma, Wash. The Age, March 1932—539 1a ¥ A ‘ \ : q it. An- alns a in, on ictical be- = — — ‘ 3 ' ad “d > 2 ment more than paid for the initial When counted for job, :n- dicates that the welding process has established itself such savings can ac- atomic hydrogen leader the field quality welding. Fig. shows some drills being repaired. The hard surface cutter bits has been successfully built this process. Automobile used the process pair their dies. Sometimes necessary preheat the work before surfacing, this not only aids welding, but also prevents cracking the die being surfaced. Die metals the following analyses have been welded successfully several com- panies: chromiun a 7.—The atomic welding process applicable building hard surfaces tool bits and repairing dies. This shows hard surface cutter being built plant the Hughes Tool Co., Houston, Tex. 4.1.5 per cent carbon, chromium, 1.1 per cent molybdenum, 0.15 per cent boron, 0.5 per cent nickel the repair die the filler surfacing material should the same analysis the die itself. Many hard surfacing materials, in- cluding Stellite, Stoodite, Cristite, Bo- rod, Blackor and tungsten carbide, drills, dies and other equipment re- quiring high wear-resisting surfaces the hydrogen process. New Welding Material for Manganese Steel NTIL quite recently autogenous steel has not been satisfactory, be- cause the unreliability the welds secured, said John Howe Hall, tech- nical assistant the president, Tay- lor-Wharton Iron Steel Co., High Bridge, J., recent address before the New York Chapter the American for Steel Treating. This due the fact that the heat welding damages the manganese steel close the weld, and when welding rods are used, which deposit metal analysis similar the cast- ings, failure the welds service oft close to the weld. occurs the damaged metal About four years ago the Taylor- Wharton Iron Steel Co. special manganese steel, known developed which contains from 0.60 0.80 per cent carbon, from per cent manganese and approximately This steel does not require water retain the austenitic condition with its accom- panying strength and toughness, and ordinarily “Timang” steel parts are per cent nickel. 540—The Iron Age, March 1932 1 heat treated simply normalizing. With “Timang” welding rod the con- tact zone between the weld and the underlying manganese steel far stronger than when welds are made with normal said Mr. Hall. This thought due the dilution the carbon content the contact zone, and its impregnation with nickel the metal derived from the welding rod. any event has been found many laboratory tests that man- ganese steel parts welded with this new material are far stronger than rods, types similar parts welded with normal manganese steel. railroad welded with this new rod and re- stored service. Frogs, switches, and crossings for steam and electric railroad which have worn down the intersections, like- service, been wise have been successfully restored their original elevation large saving over the purchase and instal- lation new castings. addition wide range manganese steel crush- ing and wearing parts being re- stored service this kind weld- ing. wear secured from the welded part the majority in- stances satisfactory, and sometime even good that the original casting. for welding manganese steel, “Timang” sold the form cast- ings and also rods, plate and sheet. castings the principal applications are parts subjected heavy wear and the same time temperatures 600 deg. Long exposure temperatures between 300 and 600 deg. destroys the strength and toughness normal manganese but the new material found not damaged these temperatures. result has been used for num- erous applications steel works and other industries requiring materia! capable resisting heavy wear as- sociated with exposure hot mate- rials. rods the chief applications far have been woven screens. plate used for chute liners, vator buckets, car bearing liners, etc. = | WIDE FLANGE BEAM MILL SOUTH CHICAGO WORKS ring the making roll changes, the entire stand lifted out the way and replaced shes another that has meanwhile been assembled the setting-up stand. For this purpose ton, 300-ton crane 100 ft. span has been provided. The large scale operations, which include the making wide-flange beams in. depth, may indicated the size the motor equipment. Two motors, each 5000 hp., drive the blooming mill; one 7000 hp. and one 2000 hp. take care the roughing mill; 6000-hp. and 2000-hp. motor are the main sources energy for the intermediate mill, and 3000-hp. motor provides for the finishing mill. Correspond- ingly large motor-generator sets were required. cent jum, } MONG recent improvements and per foot can produced the new mill located the northwest additions made mill. end South Works adjacent the Steel Co. are new beam mill The new beam mill, put oper- ting 28-in. and 22-in. structura 40,000 tons month capacity and ation December, designed mills, thereby forming group seven 150-ton stationary open-hearth produce wide-flange mills with capacity for the production furnaces the Gary Works, and shapes ranging from in. in. full line structural shapes fourteen 150-ton stationary furnaces depth with flanges in. in. izes in. depth. the South Chicago Works. Wide width and weighing from 425 This mill consists 54-in. re- re- flange structural shapes 425 per ft. versing blooming mill, re- re- reld- the in- Saw MACHINE io ii al d } | SAN | CRANE RYNWAY CONNECTING tions wide-flange beam mill the Illinois Steel Co. South Chicago adj pany tion mills. connection with the general plan, the following center center distances between stands may given ooming roughing mill, 271 ft.; roughing mill intermediate mill, 210 ft.; intermediate mill finishing mill, 241 The Iron Age, March 18-ton ingot about enter the rolls the new wide flange beam mill. Looking toward the west the 52-in. roughing stand. 542—The Iron Age, March 1932 versing roughing mill stand, intermediate reversing stand, and 52-in. one-pass finishing stand, all motor driven. Soaking pit equipment, located line with existing soaking pits serv- ing the and 22-in. mills, con- sists seven furnaces two holes each, with capacity for heating ingots required for the production beams within the capacity the mill. the finishing end ample hot bed, cut- ting, straightening, handling and shipping facilities are provided area 720 690 ft., fully commanded overhead traveling cranes. The soaking pit building contains seven two-hole soaking pits, fuel for which provided gas producers. number sizes ingots are used, the maximum weight being ap- proximately 32,800 lb. Tunnels are installed below the soaking pits for handling slag and provide easy ac- cess valves, Slag run into pots and removed through series openings east the pit building means 10-ton overhead traveling Ingots are transferred the mill tilting car operating the full length the soaking pit building. Special electrical control equipment installed which the pit crane- men can control operation the soaking pit covers and the ingot car. electrically operated transfer car used move ingots from the tilt- ing car the blooming mill entering table. Adjoining the soaking pit structure the west the 54-in. blooming mill building, containing the 54-in. revers- ing blooming mill stand, entering and delivery tables and manipulators. Buildings and Crane and Motor Milf, Illinois Steel Co. Size, Ft. Cranes Blooming mill 125x207 100 115 ft. mill 110.5x756 300 tons, 100 ft. tons, 100 ft. Motor room 72x328 ft. Motor room (63x 72x1023 10 tons, 65 ft. | 244x100 720x690 Spare storage Hot bed Storage runways Eight tons 4 | = } { | Motor eel Co. ‘anes ‘ons, 76 ft. ns, 1 15 ft. ms, 65 ft. ns, 100 ft. ns, 100 ft. ns, 65 ft. This mill equipped with electric roll changing device which greatly reduces the time for changing rolls. Racks are provided the building for storage rolls. Next the 54-in. blooming building the west the 52-in. building, containing bloom shear, the reversing roughing mill stand, the intermediate reversing stand, and the one-pass finishing stand. Racks are also provided for roll storage this building. mill mill the three mills, setting-up stands are provided where roll stand includ- ing housings and rolls may as- sembled complete. When roll changes have made the entire mill stand lifted out the way the 300-ton crane and provided with roll stand already assembled the setting-up stand, Between the roughing mediate roll stands there off-set ft. in., which the steel transferred sideways before entering the intermediate stand. this ar- rangement steel may rolled each stand simultaneously without inter- ference and has the advantage bringing the roll stands gether. The spacing the four stands indicated connection with the ac- companying plan the works. The roughing intermediate mills each have two separate roll stands, one being the main roll stand and the other the edging roll stand, provided with separate motor drives with pinions, couplings, etc., for each stand. The edging stand zontal rolls, but works only the toe edge the flanges, while the main rolls work the entire face Wide Flange Beam South Chicago Works Motors, etc. 5000-Hp. reversing 9000-Kw. motor-generator 1000-Kw. motor-generator 7000-Hp. reversing for roughing 2000-Hp. reversing for roughing edgers reversing for intermediate 2000-Hp. reversing for intermediate edgers 7000-Kw. motor-generator 6000-Kw. motor-generator 1000-Kw. motor-generators for auxiliaries synchronous for finishing 2 = 3 End view the 52-in. reversing roughing mill stand. — view the 52-in. finishing mill stand. The Age, March 1932—543 n iS t. or ull he 65 ft. | tons { General view the motor room for the 54-in. reversing blooming mill. Iron Age, March 1932 the web and the inside the flanges. Between the necks the main rolls set rolls with vertical axes oper- which work the outside the flanges over the entire width. These rolls are not driven, their rotation being imparted the steel passing through the main rolls. Roughing and intermediate mills have automatic screw down devices which stop predetermined settings means specially designed limit switchboard. Through automatic control, proper speed relations are maintained between the motors driv- ing the main and edging stands for any condition drafting. Suitable operators’ pulpits are provided each stand for the housing these automatic controls and switchboards. Beyond the bloom shear, adjoining the 52-in. mill building the north, furnace building, containing re- heating furnace for heating blooms ft. length. The function this furnace maintain roll- ing temperatures second and third cuts long blooms, while the first cut being rolled. The furnace served transfer car used for transferring the bloom the furnace and back the roller table leading the rough- ing mill. Adjoining the blooming mill build- ing the north motor room, containing two 5000-hp. direct-cur- rent reversing motors, one driving the bottom roll and one the top roll the 54-in. mill, separately. 9000- kw. motor-generator set for furnish- ing current the two mill mo- tors and 1000-kw. motor-generator set for furnishing current auxiliary motors, together with other electrical equipment, also located here. the north the 52-in. mill hp. reversing motor drives the roughing mill main roll stand and 2000-hp. reversing motor drives the 40-in. edging roll stand which forms part this mill. The motor room also contains tabulated 6000-hp. reversing motor for the main > The size the blooming mill shear in. straightening machine located the finishing end the beam mill. é of ish- mo- ator to ther ated mill 000- the ‘ives hich )-hp. nain rolls the intermediate mill and 2000-hp. motor for the 40-in. edging roll stand that mill and also the necessary motor generators. motor for driving the 52-in. one-pass finishing mill. Adjoining the 52-in, mill building the south spare storage build- ing for keeping spare machinery. This building served 10-ton traveling crane, used partly for handling scrap and scale from sev- eral scale pits located the building. the west the finishing mill hot saw and hot bed, divided into three independent sections for flexi- bility handling the product. Ad- ditional equipment provided, such gag presses straightening beams, cold saws and end-facing ma- chines, welding and cutting oxyacety- lene torches and grinders for prop- erly finishing the product. Extending north right angles the mill are eight covered runways, enclosing space, for storing mate- rials while the finishing process. Each runway served 20-ton, double-trolley crane for handling and shipping. from one bay the other transfer table, 690 ft. length, Also, facilitate handling orders consisting shapes and product the new mill one crane runway from the finishing end the existing structural mills overlaps one crane runway the finishing end the new beam mill. Suitable skid rails supported foundations are installed the stor- age yards, necessary because the fact that very large tonnages are all times and the loads per square foot are much greater than heretofore encountered. Depressed standard gage tracks run right angles through these shipping run- ways the extreme north end, per- mitting the loading cars for ship- ment each bay. Miscellaneous buildings include of- fices, store rooms, laborers’ quarters, sanitary buildings, also machine shop, electric shop, riggers, repair shop, etc. — 3 Showing motor room for 52-in. reversing roughing and intermediate mill. The Iron Age, March is ese ‘ds. The hot saw the beam mill finishing end. ing rth, re- j the ont The gag press. 4 4 a Fig. intermediate man- ganese steel 100 diameters. Fig. same steel Fig. after commercial normalizing (100 diameters). Fig. structure manganese seg- regation (100 diameters). 546—The Iron Age, March 1932 DDITION PROPERTIES MEDIUM HAMILTON Research Director, American Steel Foundries, Chicago ARBON, manganese and silicon are all common constituents any cast steel. When used without additional alloying agents, possible obtain attractive phys- ical properties from proper com- Manganese and silicon are useful obtaining the proper solidity, but, addition, they both exert decided in- fluence physical properties. These two elements, addition carbon, must therefore given due consider- ation steels with without the addition other elements. generally conceded that intermediate manganese steel has at- tractive characteristics, but that er- ratic results are common. Manganese good deoxidizer and also aids the removal sulphur basic prac- tice. manganese welcome constituent pig iron scrap used most steel furnace charges. Our knowledge the iron-carbon- manganese system incomplete, and there still much learned about the behavior manganese steel, both with and without the influence other elements. Manganese known exist steel double manganese and iron, and also solid solution. Under the microscope, intermediate manganese steel often shows decided segregation Fig. steel Fig. 1000 diameters. rich areas when the steel cooled rapidly air. This segregation formed during solidification, and its effect can changed only heat treatment. have reality two types steel represented when this manganese segregation occurs. The normal structure while the areas rich manganese are really air-hardening martensitic steel. Whether not this non-uniformity occurs depends largely the ratio between the carbon and manganese the steel. is, therefore, extreme- important maintain the proper ratio between carbon and manganese and, the manganese excessive, order obtain uniformity this segregation results the forma- microstructures and tion martensite the manganese- formity physical results. TABLE I—PHYSICAL PROPERTIES INTERMEDIATE MANGANESE STEEL AFTER DOUBLE NORMALIZING Elongation, Reduction, Yield Point, Tensile Strength, Bar No. Per Cent Per Cent Lb. per Sq. In. Lb. per Sq. Izod 26.5 55.2 70,100 107,550 20.0 26.0 58.1 65,700 107,400 25.0 31.0 59.6 59,750 90,900 28.0 26.0 51.9 68,700 111,850 17.0 25.0 52.8 65,450 107,250 16.0 Bar No. contains somewhat lower carbon than the others, manganese steels (containing 1.25 per cent manganese) frequently show segregation and excessive grain growth under conditions prevailing commercial pro- duction. The addition about 0.10 per cent vanadium makes possible proper carbon- manganese ratio, retards grain growth and eliminates mangan- ese segregation. The resulting steel, according the author, shows decided improvement yield point and impact value. Another undesirable factor this intermediate manganese steel due the tendency for excessive grain growth. large grain structure plain intermediate results low impact values. possible produce this type steel without manganese segregation and also without excessive grain growth, but commercial steels generally are subject both these undesirable Fig. shows the structure in- termediate manganese steel mag- nification 100 diameters. This structure quite uniform and has very little grain growth. Fig. shows structure the same steel after commercial normalizing, and this structure considered representative TABLE II—PHYSICAL RESULTS AFTER DOUBLE Reduction, Bar No Per Cent Per Cent l 26.0 54.7 2 28.5 57.5 31.0 28.0 58.8 : 27.0 56.2 h 28.0 62.3 The lower tensile strengths, particularly ADIUM IMPROVES MANGANESE STEELS this type steel when made with- out manganese segregation. Fig. shows typical example manganese segregation. Even this low fication, the needle-like structures are readily seen. 1000 diameters shown Fig. where the needle-like This same structure brought out more clearly. Steel this nature, containing approximately carbon 0.35 per cent and manganese 1.40 per cent, while double normaliz- ing will noted Table The addition 0.10 per cent vanadium this inter- approximately mediate manganese steel produces marked improvement microstruc- tures and physical properties. Grain growth decidedly retarded, and the vanadium addition makes possible different ratio between the carbon and manganese, which results steel with superior physical properties and without manganese segregation. therefore, intermediate manganese steel without the man obtain, ganese segregation and without cessive grain growth, resulting steel uniform structure and with therefore uniform physical propertie Erratic formerly obtained from the plain intermediate man- results, ganese steels, have not been encoun tered this steel with the vanadium addition and with the proper carbon- manganese ratio. With the same normalizing treat- ment, the structure this man- ganese-vanadium steel one desig- sorbitic rather than e nated NORMALIZING i] St I Sq. I Lb. per Sq. I I 80.200 ) 100,350 69,409 93,450 72,700 71,700 750 N and 7 re due t cal ~~ Fig. manganese-vana- dium steel (100 diameters). Fig. 6.—Same steel Fig. 1000 diameters. [= ~ < a’ Fig. structure intermediate manganese steel with vanadium addition (1000 The Iron Age, March 1932—547 — a VO ile el. 1e- ni- } tA Yi pearlitic structure common the plain intermediate manganese steels. Fig. shows the structure the man- ganese-vanadium steel. Fig. gives the structure this steel 1000 diameters show the sorbitic struc- ture. This should compared with Fig. which illustrates the pearlitic structure the intermediate man- ganese steel without the vanadium ad- dition. Table are given physical results representing this manganese- vanadium steel after double normal- izing treatment. gether with the proper carbon-man- ganese ratio, results steel with decided improvements yield points and impact values; the same yield points are sufficient, the im- provement ductility and impact values would even nounced. made the American Steel Foundries, this intermediate man- ganese steel containing vanadium designated vanadium steel. Modern Pickling—Results Achieved with Acids and Inhibitors Reviewed ODERN pickling practice, with special reference the advan- tages the various pickling acids and inhibitors, was the subject director the Grasselli Chemical Co., Grasselli, J., recent meet ing the Hartford, Conn., the American Society for Treating. Four Acids Commonly Used The acids commonly used pick ling are: sulphuric, for its cheapness and ease handling; muriatic, for its faster pickling and reduced pit- ting action; hydrofluoric, remove sand; and nitric, for alloy steels and non-ferrous metals and alloys, and for the passivation chrome steels. Metal construction the pickling room should coated with pitch acid-resistant paint, Mr. Thomas said. Good wooden tubs can constructed with 6-in. 6-in., 6-in. 8-in., 8-in. timbers painted with thick white lead, rabbeted and held together with bronze, monel copper bolts, and lined with replaceable walls and bottom 1-in. cypress white pine locked place with copper nails. Steam hammering resulting from the use open and steam pipes for heating the pickling bath will cause vibration and leakage. can pre- vented, Mr. Thomas stated, using Duriron inductor, running the line the bottom, using forated pipe, increasing the number and decreasing size steam inlets. Traps should used re- move condensation prevent exces- sive dilution. For cleaning castings one part hydrofluoric acid, one part 20-deg. Be. muriatic acid, and six parts water are used cypress tanks 125 133 deg. The muriatic removes the rust and scale and saves hydrofluoric 548—The Iron Age, March 1932 acid. Pickling time about min. hr. For general scale removal baths from per cent, tem- peratures from 120 deg. min., are used. The tendency today employ larger equipment, which permits use low acid strength, low temperature, and longer pickling time, thus insuring uniform pickling with less danger burning, pitting, and wasting metal. Where ideal con- ditions capacity are present, per cent acid 150 deg. and min. time give the best results. Acid and iron content may and should carefully controlled. When operating with per cent acid solution, the iron content allowed grow about per cent. Standard capsules tablets are available for checking acid and iron content. acid per cent solu- tion generally used pitch-treated wooden tanks 100 130 deg. for pickling time min. Acid consumption varies with the area pickled and the thickness essential obtain thoroughly and uniformly pickled articles. Pickling High-Chrome Steels Representative pickling solutions for high-chrome steels are: parts deg. Be. acid. 10 parts of water or parts of 20 deg. Be. muriatic acid. parts deg. Be. nitric acid. parts deg. Be. sulphuric acid. parts water. The nitric acid passivates the metal large extent against action sulphuric and muriatic acids. Tem- peratures generally used are 150 160 deg. After rinsing, the work should passivated per cent actual HNO, for min. 150 deg. the work not passivated, much will not stainless. Inhibitors Recent Development Only within the last five six years have efficient inhibitors been developed. These are organic com- pounds and usually have nitrogen base. They are colloidally dispersed compounds carrying electric charges which form some sort film over the bare cathodic metal and prevent at- tack the acid the metal but not affect the attack scale. Some inhibitors now the market reduce the action acid bare metal less than per cent that obtained when inhibitor used, Mr. Thomas said. Tests efficient inhibitors showed 91.48 per cent in- hibition with 0.01 per cent inhib- itor (but decreasing rapidly with time) and 99.1 per cent inhibition with 0.025 per cent inhibitor. Advantages using inhibitors were reported Mr. Thomas follows: Acid spray practically eliminated, thus improving working conditions and decreas- ing building and equipment deterioration. Waste metal eliminated. Pitting prevented. Life bath prolonged because less metal dissolved. Absorption hydrogen the metal, the cause acid embrittlement, largely eliminated. Over-pickling burning prevented. High-quality work without skilled work- men During the discussion the point was brought out that, the grease re- movers, metasilicate soda was probably the most efficient, due the fact that gave emulsion oil particles surrounded water films and prevented the formation oil scum the top the bath con- taminate the work. | — SMALL PLANT OUTWITS DEPRESSION SIMONDS HAT the old-fashioned ficient and slow working kitchen range still exists hundreds thousands American homes few people would question, yet remained for the Silent Glow Oil Burner Corpn., Hartford, Conn., sce this fact the means developing new product and thus paving the way ‘or successful industry. The prob- lem which presented itself the com- pany management got better picture the typical rural struggling through the summer months with room-heating and yet low-cooking coal wood range, was how salvage these ranges. People become accustomed, after long usage, such important piece furni- ture kitchen range and with some reluctance even the summer months that householder would part with this well established household god. Basing their argument this fact and the additional fact that many features the average range are val- uable, the Silent Glow engineers set about design oil burner which would convert kitchen range into stove. The company, fact, came into existence the result such This shows aisle the RODUCTION has doubled each year, since 1928, the plant the Silent Glow Oil Burner Corpn., Hartford. The idea which has proved depression proof oil burner which converts kit- chen coal range into oil stove. Mass production has been adopted and the process manufacture involves some interesting operations. burner. started manufacturing and selling range burners 1924. tart was modest one ire, the idea “caught on” and larger qua ters were soon needed. The burner was the blue flame ing type, which had been the ket that time for about year. met with fair but required considerable servicing and the com- pany turned their whole at- tention making improvements. New models appeared almost every until the company’s model “W” was heating principle, which burner start quickly and give in- tense heat. Since 1928, when thi new type burner was placed market, the growth the has been remarkable more than doubled each year and factory has been moved larger and larger quarters. now occupies one unit consisting three buildings pre- viously occupied the Hartford Rub- Works Hartford and employ ore than one hundred men its tory. During the last few years the company has added many items its first line and now successfully pro- ducing and selling several types oil burners for heating large buildings and power plants besides smal! heat- ing burner for households. The manufacture the range burner larger and larger scale has meant the adoption mass pro duction methods with modern equip- ment. Raw material for the various products brought the receiving room truck, where checked, tested and put into bins await the demands the production depart ment. One the principal parts ™%, power burner department the Silent Glow plant. The Age, March 1932—549 ie l- 4 hr developed 1928. This new type in- en ‘en res at- ket are nat ed, ent in- rith was films con- The full equipment supplied for converting range into oil stove consists burner, oil container and its standard and suitable piping, valves and fixtures. burner the burner shell, the range perforated cylinder high chrome steel. There thes are several shells each standard range burner. After experimenting with many al- loys, chrome steel with abo give The mate- difficult fabri took good fur- was found service operation. however, was cate, and experimental work develop method perforating comme: basis. Material for the shell widths and thicknesses suited the different types One the most popular types burner uses strip wide and 0.029 in. thick. This comes coils and fed through Henry Wright high-speed punch which operates the rate 140 minute, with each stroke 152 These holes are grouped space in. the length the strip, which means production burners. strokes punching holes. more than minute This strip cut int and the cylinders for burner shells are made formin these lengths between rolls and spot welding the lap joints. ft. perforated strip one machine. desired shears The general construction typ cal burner shown left. base into which the shells fit iron casting which made under foundry, the Taylor Fenn Hartford. This casting fine grained smooth finish that used without machining. The variou other parts are nearly all made the stamping department the Silent Glow company. Each burn: assembled hand, the shells bein held the base snug fit. variations the casting are sated for the shell diameter ning one end the shell when sary through set squeezing slightly expand its diameter. company’s production about 600 complete burners day, almost every part, including aux iaries, made the company’ plant. Bright steel wire used make type bottle carrier designed part the burner equipment, The bottle serves the fuel reservoir. Handles for the bottle are made wire forming machine which one opera- cuts off length wire and forms the complete handle with semi-circular loops. tion Nitrogen Assures Success Etching for Strains METHOD determining the teel in which strain patterns wer heretofore visible has been de- Hensel and MacGregor, research Westinghouse Electric Co.. veloped East Pittsburgh. memb which has been stressed slightly ond the limit its elasticity will eturn its original shape after the load removed. Such teel miniature flow lines outer surface. this steel into sections, additional flow lines n the cross-sections will be exposed, was discovered years ago Fry, German physicist, that etching these flow lines with solu- + tion containing acid, the pattern the strains the metal brought black the metallic white background the While this into sharp relief distinct pattern, easily visible against unstrained portion. dis- 550—The Iron Age, March 1932 — covery was important designers steel structures and machinery, usefulness was limited because only Bessemer steel could successfully seeking extend the etching process open-hearth steels, the Westinghouse engineers found that Koester, another German physicist, had traced the success the etching the presence nitrogen steel. Experiments indicated that nitrogen was the controlling ele- ment, and, that was beneficial only when amounted between 0.01 and 0.05 per cent. Tests weld metal and Bessemer steel, whose nitrogen content within these limits, verified these conclusions. process the furthermore, Further evolved method nitriding these open-hearth steels that, when they were etched, the and the investigation flow patterns strains within the steel would become this process the test speci- visible. men first stressed and then cut sections nitrided and etch This etching reveals all the flow lines all surfaces the specimen. stressing, cutting, nitriding and etch- ing routine permits examination flow lines and strain patterns members practically every tion, including the important appli tion shafts torsion, and the amination certain processed stee! flow lines cannot obtain any other method. whose found that the requirements for cessfully etching the strain patter: steel members include sharply fined yield point and that the must stressed slightly beyond yield point. must have content between certain fixed limits contains less than this amount nitrogen, the deficiency must the material must correctly etc! q a I ake a part bottle indles wire PAPER read New York be- fore the American Society Naval Architects and Marine Engineers William Bennett, senior surveyor, Lloyd’s Register Ship- ping, New York, directed attention recent developments steel manufac- ture for the purpose assisting the shipbuilding art. discussion related the use alloy steels general and high-tension steels particular, number represen- tative ships. the Lusitania and Mauretania, built about years ago, high-tensile silicon steel was used for the strength deck and upper portion the side plating over about two- thirds the length each ship. This steel had about 1.25 per cent ilicon, giving tensile strength gross tons square inch, with yield point tons. Some the 2 thinner plates, below in. thick- ess, were high-carbon steel. Be- cause the strength this material, reduction about per cent weight scantlings was allowed | where this was fitted. Mild Steel with High Elastic Limit Another ship, built Scotland 1925, the Prometheus, was high- elastic-limit mild steel throughout the structure. this case the elas- properties the material were mphasized, and again reduction about per cent weight scant- was allowed. This saved about 250 tons the weight the struc- ire and made corresponding gain capacity. This steel was reported have nch, compared with tons for ordi- nary mild steel. Its tensile strength tons was not greatly higher than the tons mild steel. Elongation was reported per cent in. and the modulus elasticity was per cent higher than for mild steel. cost exceeded mild steel per cent. How these high elastic propertie may obtained are stated as: through increase nickel, silicon, manganese carbon; hardening and tempering treatment; normaliz- ing; temperature during rolling, and particularly the end that operation. this case care has taken that rolling com- pleted above certain critical range temperature, whereby normaliz- ing effect produced without need recourse special normalizing treatment. Admiralty Steel Steel which has been used British warship construction since 1922 reported containing 0.33 per cent carbon, 1.1 1.4 per cent manganese, 0.12 per cent silicon, with sulphur and phosphorus between 0.03 and 0.04 per cent. steel (Admiralty ing temperature, giving normalizing effect without the expense special heat treatment. For steel this quality finishing temperature 830 deg. (1525 1580 deg. F.) aimed at, this being slightly above the critical range. This steel has ultima strength between and tons square inch and proportional limi between and tons. pecified elongation per cent in. and must bend through 180 deg. around bar with radius one and half times the thickness the test piece. Stainless Steel Used for Fittings chrome-nickel teel known KA2, which under the Krupp-Nirosta patents several steel works this country pecial Quality Steels for Shipbuilding basic electric furnaces, has been used some extent. This high-grade alloy, about per cent heavier than ordinary Physical tests plates from in. thick showed for tests average 84,000 lb. square inch tensile strength, yield point 37,000 lb. and the high elongation 55.7 per cent in. This steel said have high proportional limit. Its chemical analysis carbon, under 0.15 per cent; manganese, under 0.50 per cent; phosphorus and sulphur, under 0.025 per cent; silicon, under 0.75 per cent; chromium tween 16.5 and 19.5 per cent and nickel between and per cent. This material has been used mainly for marine hardware and yacht trim- mings, rather than for structural pur- ings, forgings and rolled sections and resists atmospheric corrosion. Structural silicon steel open-hearth furnaces has tion about 0.44 per cent carbon, 0.18 per cent silicon, 0.063 per cen ulphur, and phosphorus 0.075 per cent when made acid furnace and 0.05 per cent basic furnace. Average figures for tests plate from in. thick, taken both longitudinally and transversely, gave ultimate strength 82,000 Ib., yield point 46,000 modulus elas ticity 29,300,000 elongation 25.1 per cent in. and reduction area 13.4 per cent. Nickel Steel High Tensile Properties High-tensile nickel steel, not heat treated normalized, depends for physical characteristics its position and the special control rolling. This steel contains not less than 2.75 per cent nickel, with 0.60 0.90 per cent manganese, not over (Concluded advertising page 28) The Age, March on nt in he} fo } py, } ) 4 4 | aay ra ( at ta = ~) \ re al and its etchn- st pplica the btair was ‘or suc- yatterns rply tha nount mad all, round steel bar. These disks are sawed cular metal saw. The bars must problem, however, has been put the steel mills and rejections are and the small disks thus salvaged from ° (AT RIGHT) disk rings are rough ground, turned and bored with allowance left for subsequent grinding. They are then heat treated after which the race way the outer ring ground the manner shown. The ring mounted quick operating air chuck the revolving head special radius grinder. The entire head rotates horizontal plane about the small grind- ing wheel produce the desired con- tour the raceway (AT RIGHT) raceways the inner rings are ground another special radius ma- chine which operates fashion simi- lar that the outer ring raceway grinder. Each inner ring mounted shown revolving head and the whole head then rotated hori zontal plane about large, thin, round- faced grinding wheel. After grinding, both the inner and outer raceways are checked contour and are then polished with formed dipped oil and coated with finely powdered abrasive. 552—The Age, March 1932 » | 7 q | toward the tionless bearing, which meant principally the ball bear- ing and the roller bearing. 1910 the annual production ball bearings was valued ap- proximately $5,000,000. 1930 had increased about $100,000,000. might expected such heavy increase has been accompanied ex- tensive developments the method manufacture. The accompanying illustrations give the high lights one typical modern method radial ball bearings. Vow ‘ A J — > = (BELOW) hardened rings are returned the large grinders for final surfacing The sequence throughout this opera tion is; rough grind one side then turn pieces over and rough and finish grind the opposite side then return the pieces the first position and finish grind the first side. After grinding the sur- faces, the bore the inner ring ground automatic irternal grind ing machine. The outside diameter the outer ring ground center less grinder (ABOVE) avoid the possibility strains set the thin, outer rings, these parts after finish grinding centerless grinders are put away shelves for extended period seasoning During this seasoning slight changes shape are apt take place and such changes are corrected taking further slight finishing cut cen- terless grinder. highly important avoid any possibility vibration this final delicate grinding. The result mirror like finish which requires further polishing. & (CENTER) ECAUSE the accuracy tne between balls and races and the damages which might result from even small particles dirt, much import ance attached thorough cleaning While the inner race being revolved speed, oil forced high pres sure through the bearing remove all particles dust and foreign matter After washing and while still coated with oil each bearing wrapped wax paper and then ready for shipping > a | 4q 5 y 4 a 4 a _ = 4 4 J a : > 4 CATTERED United plants the Ford Motor Co. where cars are built from parts made The last word progressive straight-line pro- duction, the Ford plant New Or- States are the Dearborn factories. leans typical these modern as- sembling units. Enameling lines and drying ovens, features special in- terest that plant, are illustrated with this article. Straight-line production begins the railroad spur which divides into “Y” one end the plant, the two branches running along opposite sides the building. concrete platform one side, and loaded directly into freight cars Parts are unloaded the other side. Minor assembly lines start the unloading dock and ter- minate points the main assembly line where the various sub-assemblies are incorporated, Motors are completed the first sub-assembly line. There the gea shift lever applied, the timer lated, the spark plugs, fan, fan belt and distributer installed and the lubri system and general perform- ance the motor checked. Other sub- assembly lines are: steering post sembly, including wheel, horn and tube; radiator assembly, including paint spraying, drying and testing; and the wheel and tire assembly and inflation. Parts Are Assembled Minor Assembly Lines number minor assembly lines are devoted enameling and finish ing operations. The equipment com- Iron Age, March 1932 throughout the assembly METHODS prises dip tanks and gas-fired ovens with traveling conveyors. The eling process continuous and auto- matic; parts are hung the con- veyor one end and removed the discharge end with the enamel baked and ready for service. There are, all, one washing unit, burn-off oven and sander, well two dip tanks and bake ovens for two-coat work. The parts enameled include fenders, shields, aprons, hoods, running boards, brackets, ete. The washer made plate steel cross-section and ft. long. pro- vided with conveyor traveling slat type and tanks soda solution and rinsing water heated steam from gas-fired boiler. The liquids are forced pumps through spray jets the work passes through. The conveyor extends ft. beyond one end the washer fa- cilitate loading the work. Six Gas Burners Heat Burn-Off Oven After washing, the parts are dried the burn-off oven. This almost identical shape and size with washer; place the tanks, ever, there series six gas ers under the conveyor. the air proportioning type, these burr employ pressure firing system are provided with recording troller which automatically mainta temperature 750 deg. the The combustible mixture turned and off intermittently and the temperature varies from degree set the controller. products combustion are removed veyors both washer and oven motor-operated, the speed the ter being regulated that the work remains the oven hr. The parts then pass along open mechanical conveyor the slat type, ft. long. Operators each side sand the surfaces preparation for the enamel. There are two enamel ovens, side side; each 110 ft. long, ft. wide, ft. high, and equipped with overhead chain loop veyor, driven motor through LEFT PERATOR receiving stock from delivery end washer and pass- ing into burn-off oven, where prepared for ee RIGHT AS-FIRED oven heat- with duct through which air drawn from the delivery end the enameling oven and forced back after heating. | P - Pe SSEMBLY PLANT on an slat nm eacn aration ns, long,