The Iron Age 1932-05-12: Vol 129 Iss 19

IRON NEW YORK, MAY 12, 1932 ESTABLISHED 1855 Vol. 129, No. Engineers Plan Study Determine What's Wrong with the Industrial System MACON Consulting Editor, The Age that economic ills may largely eradicated uncovering basic faults the terplay commerce, finance and production, the engineering profession has undertaken searching investigation our whole industrial system. Such comprehensive study regarded necessary because year preliminary research vealed lack conclusive evidence for most the charges against our economic order. While necessarily reserving final judgment the issues under inquiry, the engineers, their initial re- port, oppose extension government control, favor retention competition and the profit mo- tive means promoting advances, and recommend furthering high living broadly distributed and freed from wide fluctuations. HAT promises move- nating conditions causing unemp! the committee that has been ment far-reaching impor- ment. idering the question for year tance has been initiated have reason expect much more highly stimulating. point the engineers. proposal in- from the plan. This opportunity for doing vestigate the industrial system, or, nothing will taken for granted. ervice such comes only rare specifically, Instead, the question mark will terva brought about the present unbalance put all existing practices manu production, consumption and distri- Genesis the Movement facturing, commerce and finance. bution. program presupposes committee was appointed The intention discover root study the whole gamut the American Engineering Coun evils. Therefore, the program one activities business, thereby Thi the national engineering preparedness for the new vide the groundwork for modifications body that was organized number that will prevail when the present our industrial practices. years ago represent the crisis has passed. Many the meas- Money will national affairs, largely render ires offered today the way cor- articulate matters broad socia rectives are palliatives, serve concern. The council has been build conditions. The engineers would in- ters involving technical question stitute searching inquiry ascer- suspicion special well source helpful informa tain the disease and then terest. Only then may there tion for legislators. Its membership ishing the best methods caring ceptance. January, 1931, took one for unemployment toward elimi- reading the preliminary report duties the study the relations A. a | | i i | q | | consumption, production and distribu- tion. The committee named for the work headed Ralph Flanders, Jones Lamson Machine Co., Springfield, Vt., outstanding student indus- trial economics. the committee proceeded with its studies, evidently became reluctant merely point out ral unproved charges laid rain } ; against the industr‘al the several ystem, but de- termined rather use the results its months work basis for deep delving into the whole complex business fabric. has the ambitious aim lay before all concerned such clear picture the interlacings modern society that such catastrophes lent business upheavals may reassuring that the engineer not presume that they alone can the job. They count other pro- fessions for cooperation, but reserve themselves the task doing much the steering for two reason these, barely intimated, that en- rineering, young profession, sin- gularly free from hampering tradi- ons, such the knowing too many things that cannot done. The other that industry now in- terwoven with science and technology terwoven witn science and tecnnok gy One that the engineer accepted adviser along with the and the financier. aware the claim widely current that responsible for much to- day’s woes, but refuses admit the charge without ing the fact engineers’ pre liminary fin that everything bearing practice needs sharp questioning and that out all should come clear picture, show- ing the paths taken prevent the collapse what term the capitalistic system. The report living that high, broadly distrib- uted and free from severe tions. Furthermore, the committee be- lieves there must mimimum government control, and strong for the retention the profit motive and the kind competition that ters advances Causes Depression Not Proved quate” the committee’s ion the popular ex- planations the present economic situation. Convincing are found lacking, and that why pene- trating investigation advocated. The report covers some length each the so-called causes present trou- bles, including technological unem- ployment, wasteful manufacture and distribution, general over-production, peculation, installment buying and the breakdown international trade and credit. There evidence, say the report, prove that improvement manufacturing, processes organ- ization responsible for the reces- ~ cnaracteriZé ION 1054—The Iron Age, May 12, 1932 Instead finding case against technological advances, the engineers point out that the census tures the Department Commerce indicates that there was the whole slow but perceptible increase the percentage the total population gainfully employed the business recession 1929. Technological de- velopments, the report have been going for centuries. “Also that the normal method adjusting the volume production general increase the efficiency production has been progressive shortening working hours.” the matter waste distribu- tion, there may plausible case, that distribution has absorbed some displaced improved methods manufacture. the inefficiency distribution has mitigated the severity the problem technological unemployment.” 7 vorKers Overproduction, the report finds, cannot admitted without question primary cause the depression, for “the real difficulty due the lack proper balance between pro- duction, purchasing power and con- umption, and not overproduction.” Installment buying, the committee undoubtedly prolonged the un- table balance the boom and has hindered the processes recovery, but believes there are “unrealized possibilities usefulness the ex- tension consumer credit, provided the proper time the business cycle.” agrees, Advocates Long-Time Budgeting MONG suggested lines action, particular attention paid long- time budgeting, for government well for industrial management. “Tt one the new mechanisms management which has resulted from union engineering and financial principles. not accordance with the principles good management for the government attempt bal- ance its income and expenditure each fiscal year. The government should recognize that the course business cycle there time tax and time relieve taxation. There time borrow and time re- pay borrowing. There l a time to expand money and time contra it. There time extend ations for public works and time contract them.” “The time for taxation,” goes the report, “is when business and profits are being made. ation then, taken from profits, the effect reducing the amount funds seeking investment and increasing taxes during one phase the business cycle, excess savings decreased, and floating ment bonds another phase portunity may provided for ing savings.” The committee stresses the that when the rate savings exceed the rate investment, decline business initiated. urges that the proper timing and distribution taxation, borrowing, expenditure repayment would have highly reme- dial effect business conditions, though the total amounts involved not materially greater than Centralized public works the balance international payment the stabilization money, the con- dition agriculture, the government reclamation policy and decentraliza- tion manufacture have been covered the committee subjects that should receive thorough consideration. Develop New Channels for Capital committee considers wise also search may made set guide for profitable investments. New out- lets for capital may required re- place the railroads, the automobile, war materials and Perhaps engineering staff should set each banking organization, committee suggests, staff should aggressive searching for opportunities for ment the sales departments been enlarging the list de- positers.” Trade associations, the committee gather the basic information relating their industries and make public.” Also, progressive shortening work-week should receive serious con- sideration industry and commerce. “It probable that the distribution wealth between consumers and in- vestors could much improved adopting new working hours and over- time policies.” concluding this necessarily con- densed review, the wish may ex- pressed that enough has been said arouse the hope that the complexities modern industrial life will clari- fied the manner outlined. need clarification give the charts for steering our courses. clarification too difficult achieve, should know it. The sponsors the inves- be, will publie benefactors first rank. — « - averted. a 5 4 | } | - j 5 Production River Rouge ERE are the first pictures showing the resumption activities the Rouge plant the Ford Motor Co., released exclusively They were taken during the past few days and should encourage those who may have thought that the average man had lost his purchasing power. impossible, any picture, show the vast expanse employees’ cars which extend for over mile along Miller Road, but this photograph, multiplied per- haps ten, will give idea the number that one may see parked during work- ing hours. Coming off the shift. Almost like the “good old days” the outpouring those whose day’s work has been completed and the incoming those whose night’s work begin. Employment, course, not yet normal, but production increasing daily and nearly million dollars day has already been added the purchasing power Detroit’s wage earners through these activities. The Iron Age, May 12, 1932—1055 l e- 4 | : + Cc nm. SO | | le | | le, an | in | 5 he aff Ve | ce. €s- j | STEEL BARRELS MANUFACTURED} PPROXIMATELY 6,000,000 steel barrels are manufactured year- the United States alone tanks, are considered, the num- ber will run much higher. this large number the majority the standard 55-gal. barrel made from No. gage steel and weighing about The barrel consists chimes heads and body that made from sheet measuring sneet is rolled int tubular shape and joined the edges, and the tube thus formed corrugated add strength and facilitate pleted barrel. handling Methods that have been used barrels the side seams these 2.—In welding the 36-in. long side steel barrels, ance welding machine produces the rate 100 more barrels hour. Except for loading and unloading and clamping the steel tubes, operation entirely automatic. Iron the con i ITH the development suitable cluding flash stripping ma- chine, important savings have been made joining the side seams steel barrels means electric resistance welding. The process and results are out- lined this article. clude riveting the seaming, and welding matic lap joint, lock the auto- other autogenous proc- ess. More recently electric resistance welding has been applied, and with the equipment developed the past Federal Machine are or months the 1.—Movement the platen the barrel resistance weld- ing machine great- est during the upset. The 36-in. long seam welded completely Welder Co., Warren, Ohio, importa savings have been made possible the joining these side seams. The machines not only operate high speed, with resulting lower cost, but they produce weld ver high quality. For the weld metal the sheet itself, instead filler rod electrod metal, utilized. The welding heat steel the passage low-voltag high-amperage and uniform over the entire length seam. The unusual formity this electrical heating due the fact that current normally follows the path least resistance; the resistance increases with increase heat, the current always flows across the coolest juncture the metal until the entire weld area reaches uniform heat, when the cur- rent density becomes uniform, duction heat plays part this and, all, heating metal along the seam very Notwithstanding that safety facto: always considered order ove: come any irregularity the edges the sheets, the heating and welding these seams accomplished fron process j Ae sec. Fig. shows the barrel welding graphically, including the celeration the feed flashing and May 12, 1932 = — | ‘ Yr) + } 5 4 | 6 - Inca? | Flashing auf ™ 7 ELECTRIC RESISTANCE WELDING a, ECKMAN Research Engineer, Federal Machine Welder the upset. Electrical energy one edge the sheet agair into heat the point the ating gage, moves air weld; having the proper heat, only valve clamp rigidly, and finally pressure needed make the weld. the usual et-up, and clamps the edge resistance welding like formed sheets that constitute the the sheet. The gage removed forge welding, except the barrel come the welding automatically and with the pressing the heat and pressure are sci- chine upon gravity push button the machine entifically applied. thi operator slides the formed tube into tarted its cycle operations. closed electrical circuit through the the machine rollers provided sec. the flashing has been com- back the barrel, considerable cur- the purpose (see Fig. and ther pleted and the welding finished rent travels this path, but this al- moves the front latches the upper forcing the edges the sheet to- lowed for the transformer design. clamping arms into gether, which welding nomenclature Barrel Bodies Welded Rate 100 Hour The machine developed the ral company for the welding contained unit and the principal ele- ments are the transformer for sup- plying the heating current and the motor-driven ism for applying the necessary pres- ure the proper time. The machine built low facilitate handling the barrel stock and out it; this feature importance because upon the handling time depends the speed production. This welder uses only about 150 kva., per cent its the moment upset uses its fuil rated capacity 250 kva. for about ding see. Production 100 barrels hour easily accomplished with this and machine, and under ideal handling onditions one operator and two help- ers have welded and flash stripped barrels the rate 140 hour. 4.—Flash stripping machine with 36-in. steel barrel body place for stripping. The roughing cut made the outward stroke and the finish cut the return stroke, both the inside and outside flash being stripped the same time position the handling rolls, dies, clamps platens, transformer and other units the machine _\\ pictured Fig. are shown this diagrammatic sketch Actvated | med u etting welded tnhe ing the machine ready for the next CTATIPA A LO} O “ T} ipset throw a ragged fin f metal cailed the flash for rea- L 4 . efficiency and apr arance, 7? 4 } near flash stripping hine hown Fig. his machine has reciprocating double ram which car- the ries roughing and finishing tools, former cutting the outward stroke the ram and the latter the re- ‘ (Concluded advertising page 20) The Iron Age, May 12, 1932—1057 | | i q = x > r J ccurate Rol formed head cap screw. wer headed two blows, The heads annealed bath and the round head then squeezed hexagon row electric furnaces supplies the metal tandem drawing dies. After the for casting billets and slabs heads were thus formed they were shaved both top and bottom and the stems were then pointed when they LARGE part the material table coiled container were ready for the threading. used the production extruded. the wire department, the method produced strong head chine and cap screws the rods are drawn down the desired ture with hardened facets and ab- sence cracks. 1927, however, plant Manufacturing Co., diameter the usual manner with Waterbury, Conn., brass and cop annealing frequent intervals and new type head was adopted the per which produced the com close inspection features. Sections American Society Mechanical En- own nearby mills. Raw mate- containing defects are cut out and dis- and the Society Automo- the form carded. tive Engineers and the manufactur- per, and scrap are melted down Wire ing procedure the Scovill plant was electric induction furnaces located pecified, enters the large screw de- head contains less material but the top floor the casting shop. partment which occupies entire pecially designed multiple the lower floor become raw ma- mold means which five six terial stock for the production strength. bars are cast one time. The dif thousands varieties screws. The threading the Scovill plant ferent mold sections, clamped together all done holding dies. This method during casting, are quickly opened Making Rolled Thread Screws has been use since some time soon the metal solidifies and the 1920 the company started prior 1900. first rolled threads bars are then removed and later are the manufacture what was called were not particularly accurate. How- rolled into strip. Other furnaces are apped directly into billet molds , 4 are extruded into rods which later are drawn down wire for the machine extrusion machines where crew department. The billets before entering the extrusion machines are sawed to length with cold saws. These saws are omewhat unusual design that they reverse the cutting action the fa- miliar disk saw. The cutting teeth the billet saws instead being the periphery circle are inner edge flat ring, thus pre- enting concave arc the billet stead convex with disk saw. This gives greater angle contact with resultant quicker cutting action. The pieces cut length are heated nearby furnace before the process extrusion, netal forced out through dies into long rod which runs out rollers chines fitted with automati coiling device means which the IRE from coils fed into automatic heading machines for the first cperation the hot od instead of running out on a manufacture of cap screws. Iron May 12, 1932 # s}Required for Threads HERBERT SIMONDS ever, When Scovill engineers began nanufacture rolled threads much experimental development work was more closely control thread method rolling was invented and adopted. this method one the dies firmly fixed the thread roll- ing machine and the other die held float relation the fixed die. With this method was found possible produce threads which were more ac- curate than those produced any practical method die cutting. Within the last few years, addi- tion the standard cap and machine business both steel and non- ferrous metals, the Scovill company has Scovill Manufacturing Co., Waterbury, Conn., first started the production machine screws the old upsetting, rolled thread One the first jobs was small brass screws used shade holders for electric fixtures hold the shade position. outside electrical manufacturer became interested this process that asked the Scovill engineers experiment the production all brass screws used electrical work. method 1903. placed particular emphasis velopmen and for + this special special and ingenious machines have screw line signed and built the company’ The company now turns gineers. routine procedure special cold headed considered casting and machining. method making mos usual types screws were follows: Wire from coils fed into matic header machine which desired pieces front of the dies where the upset one more blows. screws the moves each piece, one time, + which practical ne y cuts Inge This was done, the screws were satis- factory and with this encouragement full line sizes machine screws was developed. 26,000 different styles and sizes screws with total production reach- ing hundreds millions screws yearly. ] and a fed automatic slotting machines cut the slots the heads round and head screws. Today the Scovill screw department produces the first blow drives the short wire snugly home into the dies and partially upsets the head; the second blow completes the heading. this ejector pin pushes the upset piece out the die and causes drop into container below. Blanks from the header clip ping machines which trim the head hexagon shape. Then follow auto- shaving machines which bring the heads exact dimensions having the top and pensive screws, such brass binding posts for dry batteries, go from the and from there the threading chines. heads slotted small which operate automatically head slotting machines. one type chine the screws are fed revolv- ing disk which passes beneath the aw. For large headed screws with wide slots two saws are used, the crews passing first one saw which cuts one-half the slot and then another saw which cuts the other half. Sometimes the slotting crew done the header time upsetting, but this does not give sharp edge and seldom used for screws intended for after original assembly made. Screw with Dies Must Accurate The success rolled thread termined the dies. These are care- fully designed and constructed. the dies are cut with mill- ing hobs which have the same tooth contours those desired for the screws. The process rolling thread looks very simple. blank fed the rigidly held lower die and the upper floating die quickly moved across the face the die, rolling the blank between the two dies much pencil might rolled (Concluded advertising page page 20) threads The Iron Age, May 12, 1932—1059 After | ic "€ ISiT lany new been ae en- out 1S yreviously ony DY e preseni - the more 1d hy eth rd = P ] > | > Carbide Milling Profitable Research NGSTEN CARBIDE milling na ed experimental I u ed icces uli\ Face milling with rte itter practical tion, for example, one or two tools la ao il] the work, mut wv th i lling operation the metal removal divided among much greater num ber of tes th, so that no great load i ever imposed upon any one cuttin per revolution not uncommon, yet milling, half this amount per tooth FRANK CURTIS Kearney Trecker Corpn., Milwaukee to rely ] ical, W reas doubt to the combined rigidity needed fi ica tungsten-carbide millin chine, the fixture and the cutter. milling. One longer life between would offset the effectiveness rrinds; the other is more output. other two. Where the set-up time changing Considering the fixture, the question rreat, tungsten carbide can used profitably the now possible with other cutting ma- terials because its long-life advan- tage. However, same feed combined with longer cutter life be- tween grinds the most usual gain. Best results are obtained from milling machines basically designed for tung- operation, yet there are many existing machines that will per- rarely reached. From this evi form favorably with tungsten-carbide dent that cutting edge cutters. Old, dilapidated machines feed, and therefore less duty per- are never considered practical. form, will stand much longer than The foe tungsten- one cutting heavier feed. Thi vibration; put another comparison made merely because ay, the most essential requirement tungsten-carbide turning conceded rigidit Three factors contribute tungsten-carbide milling these aluminum spirit levels furnishes ample savings due the elimination subsequent operations. Formerly these castings were disk ground, and the sur faces were somewhat scratched. Inasmuch these surfaces had unusually smooth, was necessary add two rough polishing operations and finish stoning operation Finishing these levels tungsten-car bide milling has eliminated the two polish ing operations; likewise the heat usually caused polishing has been eliminated that the surfaces not warp they did formerly, and this, turn, has elimi- nated straightening operation. The pres ent milling feed 100 in. per min. The milled surface unusually smooth, that only very slight stoning operation nec essary produce unusual polished-like surface 1060—The Iron Age. May 1932 once asked what the best rul would be to follow in the design of a fixture, and the reply was: fixture strong and husky your better judgment directs; then add about per cent more strength margin safety.” This about all that can said. Clamps should unusually strong, the locating points should positive nature, and the work should given much support possible. There de- cided advantage making fixture such that the work can located and clamped quickly. was The same rule rigidity applies cutters. Above all, the cutting should receive adequate sup- port, and the cutter the in- serted blade type, the blades should positively locked the body that there chance having them push away from the cut becoming loose the body. edges Cost Per Piece Should Not Determining Factor Tool Tool cost per piece any product should not the determining factor whether tungsten-carbide mill- — 4 { 1S¢€ nc t} VC! th. ld ra a } } | = = 4 q - output combined with longer cutter life be- tween grinds the most usual gain milling. But there are others— shown Mr. Curtis this abstract his paper presented recent meeting the metropolitan and Plainfield, sections the American Society Mechanical Engi- neers. Other data contained Mr. Curtis’ interesting paper were included the report the meeting THE IRON AGE March 24, page 746. should used. There are cases where expensive cutter could ised for two weeks considerable tool cost per piece, but ther savings resulting the two- veek period operation have more than paid for that particular cutter. Here actual example: op- rator being paid $5.60 per 10-hr. day vas able double his output using tungsten-carbide cutter. The was facing small casting which rmerly paid him $1.04 per 100, but vhich now pays him per 100 ecause the increased feed and ‘ re tha hop in ng | ip 1j | was in. per min ] qaait\ | wer sp te } if te r nd tl re i ing surface craping operation formerly mat lled with exacting every that the pump bodies are machined day year the one pass, instead the usual rough- ILLING cast-iron motorcycle cylin- der Milwaukee Simplex milling machine fitted with 7-in. full-back tung sten-carbide cutter. The index type fix- ture permits loading one piece while other being milled. Approximately 3/32 305 ft. per min. The table feed per min. The life the cutter proximately 1500 pieces per grind, though times this has been exceeded Formerly the operation was done lathe with single-point tool, the operator run ning two machines. per cent increase hourly production now obtained from the one tungsten-carbide milling machine The Iron Age, May 12, 1932—1061 é - & i ig 4 4 per day. The rather conservative, | ’ } extra aay S WOrkK Woul J $10. That means a t ] ing $15.60. The would pay for itself day a large return fe investment. cent increase had been cutter would pay for days. Based 300 I \ 3 y 4 = q 4 q ome finishing cuts, approxi- mately min. for both sides, against min. for both merly machined milling the carburetor face cast-iron manifolds with 4-in. tung large auto- plant in Detroit, the feed wa increased from in. minute 6 1inute, and the cutter was 300 ft. per min. ten-carbide cutter motive iful finish was obtained, something that had never been done before, and 900 pieces were milled between compared with approximately 200 pieces formerly. Subsequent Operations Eliminated case where scraping was elim inated because the smooth finish tained from tungsten-carbide milling has been mentioned. There are many savings this nature which are in- dependent the actual savings from the machine itself. tungsten-carbide which that milling intake mani two very careful washing operations have been eliminated. With the grinding, abrasive intake ports and extra precaution had taken remove it, and even after two washing operations, there where the abrasive dust get into the cylinder after the ‘old had been Tungsten- not only eliminated this dif milling was formerly disk dust lodged in has been found face much that milled with other cutters. way scraped, the scraping time has been reduced almost half. This be- cause tungsten-carbide milling done high speed and that less heat our own smoother surfaces generated the work. Then, again, tungsten-carbide cutter produces clean smooth finish, high speed steel has tendency “com- press” the surfaces the metal ing more difficult. that Iron May 12, 1932 There are bide milling operations which have enabled roughing and finishing cuts combined into one. many cases has been possible attain better finish the one cut than heretofore two cuts with other cutters. addition the advantages men tioned, others. standing gain the fact that less ma- terial allowed for machining there are ILLING the top and three pads cast-iron frame unit. Milwaukee Simplex Miller with three-spindle used; two 5-in. cutters are mounted each spindle, which, operate 260 ft. per min, The table feed in. per min. and sec. The work was pre viously done single spindle machine and indexing fixture. y given surface. Tungsten-carbide mill- ing not affected seriously scale, and where allowances from in. depth have been made, these can now 3/16 in. halved, reduced 1/16 When such change pos- sible there decided gain pro- duction because the increased feeds can used without straining over- loading the machine. Another gain, course, the fact that less power per square foot surface machined made some work chipping breaking away of edges is a serious objection, and with the average cutter essary reduce feeds proportionat avoid such condition. With tungsten-carbide milling cutter rare that the edges casting chipped broken away. Profit Carbide Milling Sing! Piece The question has been frequen which would milling profitable. For our own use tungsten-carbide cutter have only one piece machine, find this profitable from mar standpoints. the first place, operator knows can turn out better job and produce much bett finish with tungsten-carbide Then, often reduce the time subsequent operations, which amour easy for operator get tung sten-carbide cutter from the crib get any other cutter. Ther difference the set-up time, but there gain the work can done more accurately and the finish will better. Naturally the most outstanding gain from tungsten-carbide milling will made high-production jobs, but must remembered that even where the runs are small there gain that makes tungsten-car- bide milling profitable. Tungsten car- bide not cure-all any means, but where this material can used should applied without hesita- The development tantalum car- i€ rab ise asi a4 4 I en ing I } here tions. — for machining steel rapid and today quite pos- mill great many steel parts amazing speeds and feeds com- rable tungsten carbide. From experiments conducted te, seems that tantalum carbide not have the same high strength tungsten carbide, and for this rea- the greatest limitation the cut. Undoubtedly this will overcome the near future, be- the strength and resistance tantalum carbide being in- ased very rapidly. milling, for example, seems the maximum depth cut for -milling cutters fitted with tan- im-carbide blades is, this time, roximately in. the depth exceeds this amount, and the ter itself operated speeds and that would ordinarily ex- ted then there likely dif- ilty. light cuts, 3/32 in. th, the results are amazing. ent tests, S.A.E. 1020 steel was lled speeds ft. per with table feeds exceeding per min., and depth cut vary- from 1/12 3/32 in. These cuts far greater than would ordinarily recommended; they are mentioned here merely show the possibilities tantalum carbide for milling steel. Generally speaking, what has been said about tungsten carbide applies jually the use tantalum Wear Service Testing Car Parts Taking his subject, “Relation Service Testing Metallurgy metallurgist, Ford Motor Co., paper before recent joint district meeting three local Detroit sections large technical societies, said that, hen design completed and mes while still the formative tage, becomes paramount prob- answer the question—How will wear? metallurgical point view ere are two ways “wear” occurs. first one the more common one how the parts will resist the rasive action encountered service. other—will the structure wear ense having sufficient strength all its component parts and, whole, withstand the stress imposed perform? this latter type that test for service when design complicated and stress imposed service diffi- analyze. Such service tests often short cuts means wledge that the parts are ade- Many Automobiles Now Have Tin Plated Cast lron Pistons tin very small, the general practice, thus far developed, being limit the thickness the tin plate not more than 0.001 in. Usually the coat- about 0.0005 in. The pistons are placed electrolytic plating bath which the tin coating applied ac- cording standard electroplating methods, The cost claimed small and more than justified th« results One the major annoyances purchaser new automobile the the last year new fact that, for the first 1000 miles use for tin has been developed so, the speed must kept down the automobile industry. The appli- moderate pace not harm cation both novel and interesting. engine. pointed out that the tin About year ago the General Mo- plating cast iron pistons largely tors Corpn. made some experiment eliminate this drawback—it not the coating cast iron pistons necessary with such pistons “rur with tin. These were promising in” the engine long and new car that the idea was further developed. can run faster from the start. authoritatively stated that While some the tin plate worn large majority the cast iron piston off points high pressure used General Motors all its car models are now given coating tin and that one two other auto- mobile producers have also adopted the first 1000 miles, the benefit coating tin still remaining cidedly noticeable. The automobile industry rated the practice. the second largest consumer tin. The idea back this development Should the practice tin plating reduction the coefficient fri iron pistons increase, will mean, tion between the piston and the wal course, still larger consumption his industry, easily made gines. The tin plate produces the present low market price Effect Nickel Graphitization Cast lron ILATOMETRIC studies the alloy raising both the graphitiza influence nickel tion point and the transition tem graphitization white cast iron con- perature. This addition chromium taining 2.7 3.0 per cent carbon, produced exceedingly fine struc 0.04 0.10 per cent graphitic car- ture. bon, 0.4 per cent silicon, 0.12 0.19 per cent manganese, 0.02 0.08 per cent sulphur, and 0.07 0.09 per cent phosphorus, have been re- ported Thiery (Revue Metal- lurgie, January, 1931). the ab- sence nickel, graphitization thi iron was slow, owing the free phur and low silicon content. graphitization temperature sively from 1100 875 accord- ing curve the same concen- tration nickel lowers the trar show the influence 0.34 per cer chromium the 1.37 per cent cke!, The Iron Age, May 12, 1932—1063 —= = e ter running surface. The amount the metal. - lg r- | A- - Hot metal charged into furnace from 100-ton hot metal ladle suspended from 150-ton overhead crane the Gary, Ind., Works the open-hearth furnaces four existing open-hearth units. new units are the stationary type, each 150 tons capacity. There provision the present building installing one additional the plant designed future ter 14-furnace plant The charging floor placed high level ft. in. above the yard level, thereby avoiding the essity pits for steel ladles and providing ample height for regener- ative chambers and space for installa- tion air preheaters later date found advantageou Full equipment ludes one 600-ton hot metal with provision for the installation second mixer, modern equipment for the operation furnace port cooling devices, etc. waste neat iler of the horizontal fire tube type installed each furnace. In- got stripping requirements are ided 60-ft. extension to-each two tripper buildings. ory material handled through the present refractory plant added The seven 150-ton open-hearth fur- naces have ft. hearths, which measure ft. outside brick- work and are spaced ft., center center. The furnaces are the pan bottom type, that is, the brickwork the furnace bottom supported structural steel beams and columns instead solid masonry. This form construction provides air cooling, thus make breakouts molten metal less likely than when 1064—The Iron Age, May 12, 1932 the furnace bottom directly sup- ported concrete foundations. The main building the plant 154.5 816 ft.; ft. the width comprises the charging side the building and ft. in. the pouring ide. The charging side the build- ing served two traveling cranes ft. in. span, each having 150- ton main hoist and 40-ton auxiliary. Hot metal from the mixer conveyed the furnaces 100-ton capacity ladles mounted cars running the 4, Capacity 800,000 Tons Ingots Added Gary Open-Hearth Plant full length the building. charg ing furnace the ladle lifted the car and carried across the charg- ing floor the 150-ton overhead crane, the hot metal being charged into the furnace through suitable runner. Raw materials are charged into the furnaces charging machines. the pouring side the build- ing are two traveling cranes ft. in. span, each having 200-ton main hoist and 40-ton auxiliary. Pit side open-hearth plant showing 150-ton steel ladles and cinder ladles position. The crane 200 tons capacity. 7 = s > - ee Steel Co., seven mix furnace, and ai The teel tapped into ladles 150-ton Along the side the are arranged three pouring and tracks for pouring the eel into ingot molds. 6-ton jib ane for handling the tapping spouts installed each furnace. lean-to, 816 ft., contains for raw materials, also the flues, stacks and reversing ives. Seven waste-heat lers the horizontal fire-tube type installed this lean-to, each ler having 7820 sq. ft. heating rface and equipped with super- iter 450 sq. ft. heating surface. mixer structure consists building ft. in. wide, and an-to, ft. in. wide, with length 150 ft. The main lding contains one 600-ton mixer served traveling crane ft. in. span, having 125-ton hoist and 40-ton auxiliary. The n-to, which contains lining pits drying stands, served one pouring cranes (200-ton main and 40-ton auxiliary), the run- which extends north into the xer building. gas producer building, 686 contains fourteen 10-ft. diameter ‘hanical gas producers, two each rnace. Each producer will gasify lb. gas coal per hour. mold yard, 100 336 ft., ft. in. span, having 25-ton stock yard, 70% 1344 ft., 9 rved two cranes ft. in. equipped with 10-ton hoists. skull cracker, 76% 240 ft., ikes use two cranes ft. span, each being combination ket and magnet handling crane tons capacity. The refractory plant extension, mprising three dolomite cupolas grinding capacity, equipped with crane ft. having 10-ton hoist. Normal capacity the seven fur- ice plant estimated 800,000 tons ingots per annum, for which pig requirements will available existing blast furnaces Gary } NS, ; ill - Scrap loaded into charging boxes magnet hung from 10-ton crane The ingot mold yard served 25-ton crane. The skull cracker shown the background. The Age, May 12, 1932—1065 aA — a ; re | ead ged ible ge d ild- Steel and e eel and cinder ladles position open-hearth furnace ary. } HOLLAND NELSON Consulting Metallurgist Philadelphia hollow electrode furnace the average person merely an- l ther type electric furnace, lligent steel manufac- and metallurgist, capable dis- ting this process and analyzing carefully, with due regard the va- the various possibili- apparent that possible accomplish this fur- nace many things embodying all the experience past art well in- troducing many entirely new features. The far-reaching possibilities and ac- tual results obtainable will probably not completely understood for some considerable time come. Is Stages an ties involved, Value Intimate Contact Stressed this article wish stress par ticularly the value intimate con tact—that say, the importance having materials finely divided form reacting and melting such in- timate contact that something ap- proaching ideal conditions tained, which are reflected high re- and more complete chemical reaction than otherwise possible. what known the hollow furnace, the author hopes that will able make clear many the ad- ntages this particular process gives cross-section diagram the furnace. will seen that ome respects resembles the old- type Rennerfelt furnace except for the vertical electrode. For the sake comparison glance the diagram the Rennerfelt furnace reproduced Fig. more careful inspection the Wiles hollow electrode furnace shows that place two solid side elec- trodes and one vertical electrode, there are two hollow side electrodes placed substantially horizontal position. the ordinary electric furnace prac- tice the are produced the source heat, which radiation capable melting either cold charge being used for the refining the du- plex process liquid charge. The electric furnaces with which are dealing today are usually the arc type the induction type and both heat radiation really the basic principle the method melt- ing. The hollow electrode furnace, how- ever, behaves quite differently and, al- though true that the heat pro- duced from the are available for exactly the same purpose, there are much wider possibilities and the proc- ess actually operated uses the arc and the actual heat the arc itself produce distinctly unique features and results. not necessary explain that { ] 4 | | ~ lil! | 1066—The Iron Age, May 12, 1932 when using opposed electrodes producing definite arc, the itself and, although carbonaceous acter and somewhat poor conduct the electrode heated over considerable portion its length gradually declin heat gradient away from the Therefore have the hollow term furnace the ordinary and which the same time will heat dient outlined above. While illustrations and referen this point have dealt only wit! single phase, this has been used mer for the purpose simple illustra tion. Furnaces will, all probabi ity, embrace six more electrodes, multiple phase. The adaptability the furnace itself and the flexibility operation one its outstanding features. Hollow Electrode Carbonaceous Retort From this point would suggest that the reader cease consider electrode, but visualize the fact that this hollow electrode automati cally becomes carbonaceous what one may consider chemical action chamber. make this process perhaps little more clear, let fer Fig. which represents larged view one electrode. IG. 1.—Cross-sec furnace Ores Reduced Steels b tn tr ) a a Ci li re Qa & i \ Hi} q 7 — DUS ectrode Furnace Let realize that regard the electrode retort which vary- degrees heat are available— end being cold and the other end having available the heat the elf—then not difficult real- that the chemist and steel maker cooperation may capable pro- icing many things that have previ- isly been considered extremely dif- ult impractical any other type furnace. probably not claiming too much say that, for complete under- tanding this furnace, can regarded single unit which apable taking the metalliferous from the earth and producing lefinitely refined and finished prod- ict; other words embodying furnace the practice and art the blast furnace combined with the nelting, refining and alloying even the highest type electric furnace. the first place, assuming were possible move oxide iron controlled rate feed through this retort, where there substantial amount carbon contact avail- able the side walls the retort itself, reducing atmosphere, one can readily imagine that within this chamber the oxide iron can read- ily reduced metallic iron with the release oxygen the form Such procedure, carried outlined, would probably cause onsiderable erosion within the wall the retort electrode. Therefore, proceed one step further and nagine that, instead withdrawing electric furnace } --- finely divided ores intimately mixed with reducing materials through hollow electrodes the principle the operation the Wiles hollow-electrode furnace, invented Sydney Wiles, metallurgical engi- neer, Buffalo, Y., and described this article. High-grade plain-carbon and alloy steels are produced the chemical reactions the electrodes, according the author, who metallurgical consultant the process. Particular attention called the unusual character the metal pro- duced and the effect the intimate contact the raw materials during the reduction high temperatures. The patents and the furnace are owned and controlled the Buffalo Electric Furnace Corpn., Buffalo, all the reducing agent carbon from the walls the retort-electrode, would quite feasible add least substantial proportion the re- ducing agent required the form carbonaceous material, such graph- ite, coke dust, etc., which would much easier the retort itself and still attain the desired ob; When have accomplished this and grasp its possibilities, taken blast furnace and put upon its side? not fact lave sim} Thus our miniature blast furnace becomes carbonaceous retort of, from in. diameter up, capable being used electrode, and place mass additions lump ore, coke and limestone, are able use intimately mixed particles ma- terials for chemical reaction and timate melting. Regarding, say, refore, Below this electrode chemical chamber, miniature blast furnace, easy see how, dealing with the principle reduction minia- ture, possible control the chem ical reactions much more complete and efficiently than when dealing with larger masses. The net result more perfect reactions, higher ery and, possibly, due higher avail able temperatures, new fields for met allurgical research. Immediately many questions the behavior the gangue, etc.; how these materials can carried through this retort, how they can controlled and what their reactions are. give the necessary details this would beyond the scope any one article. may sufficient ay, however, that, with the knowledge available today, the hollow elec- trode furnace iron ore can readily Front elevation standard Enlarged cross-section one the hollow half the chamber the Wiles furnace The Iron Age, May 12, 1932—1067 | i ai »} I cl m ol ning j t Wit! ners stra yabil odes, bilit \ iding mati rt, ocess 4 is ré n en | 7 — introduced into such manner and such careful hemical calculation thrust into material almost any sired chemical composition. the ar¢ Some the Heats Produced Analyses few heats material what can attained. the mold without any tendency rise, the contrary sinking the hot top like thoroughly deoxidized killed high-carbon steel. Further, metals their oxides the form fines, which have hitherto been obsession the manufacturer and have necessitated sintering briquetting make them any com- Fig. 4.—Tilting type Wiles hollow-electrode furnace 4 nly ore and chromium carbon substantially the + gent, are follow Per Car 072 14 nron l vith regard these heats that, when the material was finally ready tor tapping, was found taking spoon tests that there was necessity use deoxidiz- ers kill the metal. The material ank the test box perfectly and the ingots pouring settled down nicely Iron Age, May 12, 1932 mercial value, are ideal form for use this particular type fur- One the most vital points that understood those who have not had the opportunity watching rating this furnace the fact that the material prepared properly for introduction into the hollow electrode urnace intimately mixed that the highest possible chemical reaction obtained and so, where exo- reactions are an pe thermic involved, the maximum values are obtainable, or, vhere endothermic reactions are in- olved, minimum loss. More- over these finely distributed and inti particles, either com- ibstantially reduced, final- the area the are and are nelted and raised temperatures in- conceivable the manufacturer mixed ent processes. other words, one must visualize very minute particles raw materials produce definite chemical reactions ultimately passing into the area the are and attaining new and, this still extremely fine diversified condition, being melted and falling down into what would ordinarily call the bath the fur- nace. This bath maintained tem- perature the same and, ad- lition, combustible gases when the products the chemical reactions are productive such gases. designed other manner than reducing iron ore any type product from cast iron mild steel practically carbor interesting proposition; but when begins realize the possibilities reducing almost oxide under ideal conditions such hollow electrode furnace offers, plu the extremely available these minute particles, which factors result directly highest efficiency for chemical rea tion, the ultimate possibilities adaptations such furnace are tremely wide. The writer has had the opportunity watching this furnace and operating for number heat and has seen some striking results, instance, mild steel with content almost negligible duced from iron ore using carbon reducing agent: Per Cent Silicon ee 0.11 Manganest 0.2 Sulphur 0.02 Phosphoru 0.019 Full value this will ciated those skilled the art and, while carbon referred the ducing agent, there reason why other reducing agents cannot used Stainless rustless steels with car bons down low 0.025 per cent and with chromium from per cent using chrome ore with carbon reducing agent, and alloy steels various types, all from their metallif- erous oxides, have been produced. When the full import these state- ments appreciated think many would agree with that, further development this proces shows the the situatior what experimental work for shadows, within short time shall consider the development this process revolutionary char acter any those which have gon before. believe, therefore, that there process the steel industry which capable handling material finely divided state, actually melt- ing such infinitesimal particles, yet rapidly produce the desired liquid metal charges commensurate with ordinary electric furnace prac- tice, this particular operation of- fers. Moreover, the extremely high temperature the molten metal such that even highly refractory slag have such fluidity that some them which have previously been almost impossible handling furnace, are capable being run into slag pit ladle quite readily. therefore conceivable that reduce any metalliferous oxid passing them through the retort and accumulating desired bath molten metal, and thereupon can cea this phase operation, remove cumulated