The Iron Age 1932-05-19: Vol 129 Iss 20

..THE IRON AGE.. NEW YORK, MAY 19, 1932 ESTABLISHED 1855 Practice in the Last I en Years By HERBERT R. SIMONDS ‘41_ JAD the present standard of quality and uniformity of castings been achieved ten years ago much of the business which was deflected to other methods of fabrication would have been retained in the foundry industry.”’ That is a recent statement of one of the country’s most prom inent foundrymen. The accompanying article describes some of the more important changes which have taken place in foundry practice during the past ten eventful years. Physical prop erties almost undreamed of in 1922 are standard practice today. New alloys, better methods of testing, and more exacting demands in raw materials and equipment are some of the factors con # 5 tributing to this progress FENHE assurance of sound casting it t Li? ed vr utter? ; | which the purchaser has today i f pig al i ikes for the use of standa ; is the result of the gradual de du 1 pleasing irfact ! ng foundri ind the d opment of better foundry practic: ts casting Repeated te er than of any outstanding produce tl ndition inges or sudden improvements. T peara ror Here apparer \ idua active foundryman the progr L me t lependent of etallurevy — irse. one been undramatic and in some aracte! lhe xp itstandinge developments in uses unnoticed, and yet, when hs foundry caused other lucet ry industry. and the impr ks back at his own records cove nsider appearance in tl} achining operation snot] ng his 1922 practice, he may find t n of pig iro ' ated advan , h ha surprise that the ultimate streng ‘ 1 found nor er f his castings at that time was abo , tter use of jig n and use of casting T} ial to the yield point of his cast nesten rbide and rd cu today and that his rejections i: * tools has lowered the machini1 122 were perhaps twice his present nce due to the fact that th ection average. ‘ ale ' The biggest factor contributing t yreat a general improvement in quality o required astings has been month-to-month at t ral he f ntion to the multitude of small have appeared ls which constitute the full scier ne I X-r u f the manufacture of casting The seld | ete yundry, in a word, has become a ndividua : gs. I production unit. is experienced a marked 4d Sand problems have been solved and is a measure for cont quality of all raw materials ha ng practice, and the relative free een improved as a result of an in- oncealed defects in casting tent demand from foundrymen. A due in no small measure case in point, one large foundry d Ir the ase f hig pressure service there has been an ncrease in the actual 100 per cent X-ray testing of castings. Recently the gamma ray test has ne nt prominence aS a 1esS ex ensive method of detecting flaws in heavy sections. Gamma ray capsules re now available for commercial use ( Mpat itl ve ( ” A 10 l I in ! mere piace a Cap ile ( i a casting ind a s¢ 1 e on the other when he g home night and in the morn ny neg wi I Y inter! truc re ()ther ( no! ruc é te r i ( ( ‘ n recent veal elt nce magne ng al na wave trar I ve to?) ha hye re I extel ( Cnal dure. The « of clea é ! peratior } ( red Dy imp 1 he us¢ both the ele ni ne ga \ ding torc! difficu exagrel ence i weld n tl I l ! ! At f he elding I a regal ed 1 I I i ’ ) Y ] Y W pre + r y d tl he advanta é I ff s« i ] tio! , ‘ ng ‘ no Pen eI Y | TABLE | Production of Steel Castings in United States r Percentages of Total Output by Processes TABLE II Standard Specifications Covering Cast Steel ! Cc = Locomotive frames } ae r} spe ty the iSé I certalr 1 cti ! the casting ‘ r pee re ec n contact W tne aw and by this means rise > in Steel and Alloy Castings Improve ee enough while in non ferrous foundry practice ther I ee! i decided tre? i toward a a rease in the numbe f alloy t eel foundryman | turned to moi I more 1Oys to meet he deman 1098—The Iron Age, May 19, 1932 for a great variety of physical prop- erties. Perhaps the most notable de- velopment during the past ten years in this direction has been in the field corrosion and acid-resisting cast- ngs. Well standardized alloys of chromium or nickel-chromium steel have found vast new outlets in build- ng construction and in the chemical ndustry Similar introduction into many other fields is starting. Among these may be mentioned the automo- paper, food and textile indus- Some idea of the progress in us« loy steel castings may be gained from the fact that in 1922 the total put under this classification was 66,000 tons, whereas in 1929 it had reased to 216,000 tons. Of this rge total, according to a report of Electric Steel Founders’ Research Group, 48 per cent was produced by open-hearth method, 48.8 per cent the electric furnace and the small ainder by converter and crucible. ‘he electric furnace today assumes or importance in the production teel and its influence in the duction of standard steel castings gradually increasing. In 1922 the production of steel castings in open hearth furnaces totaled approximately 1,000,000 tons as against 200,000 tons he electric furnace. During the cceeding years up to 1929 the open 0.0 TABLE Ill Typical Properties of Malleable Iron 19 . 4) { { ‘i M to 0.30 { 0 4 ; ( under { inde } ' A | \ ea t 1650 deg. 1650 t TABLE IV Yis I Lt H 1¢ I hearth production showed no ap ciable upward trend whereas the « tric furnace production of steel ings increased rapidly up to app mately 460,000 tons in 1929. Tal illustrates the upward trend of tric steel castings. Tradition Often a Handicap As foundry metallurgy impr and the various alloys increas: such qualities as machineability, tility and yield point we may ex; wider and wider application in in try. Aside from quality, how: the influence of custom or tradit is to be considered. One foundry: asked: “Why cannot we design necting rods, straps, crankshafts cranks in cast steel? Without thought of insecurity we subj sq. in. of cast steel crosshead to 47, lb. alternately 18 times a minute, we must have 10 sq. in. of fors connecting rod coupled to that head subjected to the same loads vibrations.” One of the most interesting tures in the progress made in foundry industry is the fact that tain desired properties have been up and alloy castings or speci: processed steel castings then ha been produced to closely meet specifications. An example of this the case of an alloy developed by General Electric Co.’s steel found at Everett, Mass. There was a ne for a casting with exceptionally | creep at high temperature. Aft much research a molybdenum all steel was produced to meet requ! ments. This has approximately t! following composition: carbon 0.32 0.35, manganese 1.35, silicon 0.35 0.40, molybdenum 0.30, phosph and sulphur, below 0.04 per cent. connection with this development foundry superintendent states: “Te indicate that this alloy has less crt than any other alloy we know ab but our study is still going on and may be we will find something « better.” Another superintendent of this sa company states: “We have increas the carbon content of our carbon ste castings by about 0.10 per cent ar we anneal all of them. This h raised the elastic limit and ultim: strength with no decrease in elong tion or reduction of area.” + Conforming to advances in otl fields steel castings have enjoyed remarkable increase in uniformity in tensile strength and a striking duction in the number of conce Per Ce¢ S ngtl Klong: I in 2 lr 132 192 » O00 5.000 18 t 0.00 27,000 } 65.000 R5 000 20 Z 12 000 50.000 1 ct and { tne efter I : l d f of different en it has been possible greatly To present economic condition has driven prices down to a com- ce the annealing time required petitive level that does not encourage the manufacturer to make ia aaa sie iameisiatiite aciele aan ion quality the first objective. The effect of this is serious in the foundry ’ ength and malleability. 01 industry, and the comment in this article on the gradual increase in quality , kor instance aoe suppues of castings should be somewhat tempered to more accurately describe gen aR "4 one ag ergot re eral practice at the moment. h elongation, an by changing ' A consistent and surprising betterment in physical properties and in a eee See ee ) castings with foundry practice continued throughout the industry up to the first part of ' ee th ft @aaen ee x] 1930. Since that time some foundries have felt forced by price competition gation of 14 p to produce castings of a quality somewhat inferior to that produced by : ove them in the past. ‘aia te a u rv wv I irKi ma A eans alone it ha rten the time e an t Che increas¢ in tensile h ar t ; reater u1 Ponce na . gth is illustrated by the ul ! n Ni research work h ri. ed specifications of most any st« i ! y eld nit? n f ry covering the years from 1922 r} eff ! e pa , es. and. wi ! 132. The Union Steel Casting C Mi e Iron R h In i to a ' uurgh, for instance, published A So he ation ' specifications covering cast st \ ne mun ne ine motive frames which showed a n a wi rea abot 1 malleabl e strength of 80,000 lb. per s raising the ultin reng r ed case whicl a vhereas the published specifi ng n only, and ’ yr this same type of locon ng a ( frame a ~~ f 000 Ib. pe Von-Ferrous Castings Are eth of 90,000 lb. per sq. in he ’ c scatheds Uaiiniiie tem aitine ahead ge : aa Standardized ties for this ame piece al WW to ving — eve nent le té : in table II. an perti For N hea reating alu n ha 510 le re tl I ‘ ope I | : Better Attention to Details noint 500 Ib.. al ne in ngs, a ! ms nands for better design and n for grad No. in ling develo} n en y | cmanship have kept pace with t : FeBER OUNNU ee dry work. A Af ands for improved physical pri ay a a me =e ne ee ee al In certain steam turbine wi WI ation rart w rs ee 11 necessary to have the inne? - G and al e% andthe 000 Ib a y surface entirely free from en anufac =: red after heat t 9 led sand. After a great deal eee <r eis 4 oe so : this problem was finally solved : " ae a h e attention to many details. A lt ! tix — = sand was needed and it w gl point r ting ire being u ’ \t ! important to use a high silica é me a tne litimate eng — , Ovor Te hed sand with uniform grains. A a r it ecificatior ir treads with embedd cr er face wash was developed by ig In t et 1 aero eee zace naw al g a mixture of bentonite and oil ir m int meip 1 7 we in p keep the ground silica quartz have taken place The tender I mSUl - ispension, Other details included been t educe tl rbor ! : \ im ting gyn of gates and accurate temper a } ! lin é ne-nall tin as mucl! re control at time of pouring. The Timken R r | ng it for equal engu oe case of attention to detail i Cantor Ohio, gi eight of the aluminum frequer ie ‘al of the work of many progres- son of malleal thar e-half the weig! ri y e steel foundries and because of 122 and at present, and th ! Ir é " etal castings thi na s some of the products former!y Table II]. The company I er arked tendency to standa! a ide with forgings are now products luces a product with a tens y and to reduce the number * the steel foundry. 50,000 lb. and elonga One large company turning Ul + sie . at < Che former casualness on the part 15 per cent. = = —_ ee eae : = ' steel foundrymen in regard to By closer attention to te ( | cu cown , reg ilar rnal defects has been blamed fo1 contr non-oxldlzing os at Pe re 3 ‘ "1 y ] . . > ‘ nan 4VU ] ome eal ago ‘ ; loss of much business of an im- th, a me and now ain : tant character. Now with bette: Re ‘ g ictice and better methods of test ae air eseree ai 5 : g, a freedom from defects in gen- awe ne Sean production should help some of In br nd bronze foundry Worse conscientious foundrymen to re- CEtamS Cevenspunem: Re _ n this lost business. © he progr which smelter a ade n producing eane! ng Malleable Iron Has High his has come about through ; — tion and a better educated demand Yield Point n the part of the foundry. It e] 1922 the average standard spec liom that an ingot containing dr ations for malleable on cas an get by a foundry in clo! called for an ultimate ensilé hereas ten years ago the preser ength of about 38,000 lb. per sq. Concluded on advertising MLge )) The Iron Age, May 19, 1932- 1099 THE FOUNDRY INDUSTRY NOW ANDI, By EDWIN F. CONE 1t treatmer a pment of r} rol now available, made pos irticularly ) | on of alloys and by nas mu v4 n the process of product or \ an intr ly A I a beg ul n the heat treatment of gra mond. the newly Ir Ul e cw found) heid the \merican non-ferrous, ‘h in store. Yinning nas been im. a contribution elected president Foundrymen’s The Foundry Industry as a Whole By T. S. HAMMOND President, Whiting Corpn., Harvey, lil %, Tal i tr tounary I Ist! i ] art > ? erned about the prig té t rted that the or example, it is 1 Ford car has n the general situation tk more malleable castings than al >» ‘ tha n of the sub imounts I I I LT il \ h ror I , na I l amy pM ASTIN} that the foundry industry is far fro y é l ady , \ ) ! ind é r) W ice i 1 i cnal npete VIt!I i I ] ture en } i! automo ndust1 ' ethods 1a] 1 Ta { I re ) i n¢ ind arked progr en ; the increase: n favor of castings 1 and experimental T. S$. HAMMOND N. K. B. PATCH e! I Asting have revious Model A, besides increast : castings. isefulness an standards, W. BOLTON ‘DIAFTER THE DEPRESSION—A Symposium f al Da a ‘ * +) ; ; On-f errous astings : f their — . By N. K. B. PATCH Secretary. Lumen Bearing L Butta er ra ( 7 A ised ? anutactured pl ] the nor rrous ca fe a , ta I al iff I I ] a S t i? try. rh \ | s 4 nstituent meta D ! I in +} 1 Zl n these non-ferrou : I i ’ : have influenced buyers to b as : I ‘ se casting mmediately need . it h the hought it the mat : a ' ne further a nu : } ‘ at : Tore T S probabl« hat . j : may prevail at any mon ' \ 1a , ur : hat attitude 1 ne ] { run \ “ tings in anticipatior i I ! na ir onfin no h¢ Y 7 ate ; ict y l y ‘ ' : : ’ nor el ! r ] mis . rgently needed. ° , ires and demanding prices fot i ; Fcier how ffect of this attitude wieiiaaals We ; P ‘ ' i r he foundry the prod , t. and vet the var eT n nimum imbe1 ple A $ 5 4 er I pa ern resu ng n r ? ‘ | y r , ? V the undrie f y ’ A i nk I £ y } ; ra astir +} r ng i ? re nit iT ier ed b l I I 1 netter quallt } ny y iuct rt I il ow Try T t ire y nv I I ] i reason ell i a thus the n ha od | pul i i ne r ‘ I ound! ari I tnelr f nee tnat 1 ast p i j ‘ worth ar r Ihe : ’ f the ‘ no advantage in tne I insist upon castings that are the highest quality, even hirst t ligner tnan wv r iT é r grade W.D MOORE H. BORNSTEIN A. W. LORENZ \y nteresting fact ir ‘onnectior } ' th the use of non-ferrous casting { _— i the «a ineness on the part of The Iron Age, May 19, 1932—1101 1102 than a new brand Compared with lower — strey nt in } ! ethir that has been irons, high-strength gray irons ind foun wantin n the past. increased tensility, somewhat } Fre ! t ( ( rand a rigidity, some improvement I re-a for all bear sistance to shock, greater hard: greater wear resistance and bett havior in heat treating. They u iy cost more to produce, some are more susceptible to shrinkags fects, and the machineability is ered, All factors should be caret High Test and Allloy lron analyzed in each case to make The Iron ige, May By |. W urs LUNKE 19, 1932 that higher strength irons ar vest material” before such iro: BOLTON ‘t nheimer Co. Cincinnati adopted. It must never be forg that the “garden varieties” of g iron will continue to be the best iOV teria iS In Many cases. The high-alloy austenitic cast (such as Ni-Resist and Causul Me poss rather unique properties, field experience demonstrates iltimate economy in many corr ervice In a number of cas¢ ? { n I e proved superior t ror DU ilso Nave supplantet expensive materials of constru C . ast lron Pressure Pipe By W. D. MOORE President, American Cast Iron Pipe Co., Birmingham | )' RING the ten years prior to lished our right to enter fields pr« 1930 the production end of the ously closed to the cast iron pipe try had been rev dustry. By way of illustration: W nize that we entered thi compete for high-pressure oil and ga on wit 1iodernized transmission lines, form rly consid ! fficiet roducing unl red completely outside « he scoy ng the depré of a cast iron pipe, and we do inufacturing hesitate to supply material for tl ou he a ( el with the pre nomle ot n ranging from 500 to 1000 li I WI ner Likewise in the oil refiner reau n tne ¢ 1emical industries wv ire now a ! t vere not ol ipply materials of supe1 r nad alrear ul d-resisting qualit whi I tne if ! tnar economical vnen co! anu e1 n the ght of any i materia ! } Ci, ner cen f our a I nances Nn? ig} ting i tf ft Y erla l stocl most naturally we anti an improveme! in volume with a the result that the weight mprovement in the bond market en reduced approx with an improvement in the bond ma t d th vorkir et there v come an im} em et ner ad ior a n the stor arket and this will a] 10 prove the nancial tuatio1 publ sé ee corporations oO! ( houl ring about a definite bett } sf n tl ime ot Dusll ! re re beir e! a The desirability and nec ba ( parisor rovid iblic work i! euofad r f ern pro } ( nou re In Dringing ou cle I r ot i imatel nu ne I I cast iron pressu l nerea I i ndustry e from 86 to 100 The ever-increasing demand ’ - _ = initary conditions dictates an factors of satety. crease in the number of water filtra I} idition to the above we are now tion and sewage disposal plant to produce super-strength ca throughout the country. This + rr’ of fundamental branch of the cast ucts, aS Well @aS All orms i ‘ ed products, and have thus estab pipe business, and naturally with a Ae sae haa a cs ray ol : om t ¢ ; : iy a e: : ‘ = ; oe oe ee from this field. a ; "ST ea ; aan es ares oa 7 Poe Hf : cast 1ron pipe business always L re tL 1tselt ti ! | ‘ it “é W é ist atche t f . ry ¢ field ‘ eat treatn Developments In Gray lron n. Just as in steel, wi By H. BORNSTEIN Ste hak teen, | Chief Metallurgist, Deere & C Moline. III nt l ~ ire beings ne i iv +S i I? APID progr ve nade it \ the field of ra a ron duri r . nit : nve a And we ma ( i i ich during the next ! many years t e! : i n was just i ro! i I A I i } n } cal py ertic il elting ! i * come a rea ation tnat I ] ne name fa wi grou [ als and a definite cast iron ( ed to serve a particular \ specificatior now D ed the American § oe g Materials which will \ n into classe accoralng t ter trengths. Higher strength it A . to 60,000 Ib. per 1 in. are I ‘ ng regularly produced. The e1 I will De able tu specify tne ] By A W LORENZ rm ils he requires and be reasor Metallurgist, Bucyrus-Erie C South Milwaukee, Wis A. E. GROVER F. D. CHASE mangan as an alloying materia! ha ¢ ‘ mar tec ne deve opment The Iron Age, May 19, 1932—1103 Effect of the Depression on the Electric Steel Casting Industry By R. A. BULL + ' j Development and Use of Foundry Cost Systems By A. E. GROVER t Du t r nst ite Cleveland Ww er Phe Wepreasion af 1990-40 an f yst } rought the productior I ist I I ear 1 dual foundry grad he very | levi it 1s ex d it ndustr\ lay An ecli n ume of busine ha ' een uniform among the variou ial companies of the industry 1 hing a prt f \ this industr\ recovel alo? a ( et vith other allied industries from thi I [ \ ma e case of “depressionitis,” it wi ndries were running overtim e necessary for the individual com 1104—The Iron Age, May 19, 1932 1 i l il mor ire il ina al tne ive é e) aone ( ner ( i irtv to he¢ nd no} he isine ‘ ( I ! a recel ni i yra ron ? ] | a re Ov ica I i Nn £ y he y rely il ) i ! L} l} ! cl e} ‘ » ce oul mn } y ! heir ( ar i i i Oo esta I hi ll retur? he ‘ eff el | ll be mort ! iSll executive } oO i ee] lif t y y ( y ) eve ‘ ’ y he , ‘ y ’ ) ’ it VW not pe iTé to ise pa T recoras on any Ol nese eieme! a Soe ete : tablisning cost of individua \ 2 < , + ng Neither can inven alue be established safely if e calculated on past purchase r¢ d All of these elements must ‘ } ] + culated upon the market price p1 ne when the product I expect made and under no? il ne conditio1 t present in the 1 I i ry 1 remenaous Val i OT lanent i eT ised a 1 ba tab n¢ ea cCnarpe for l ! { of ndividua Ur f new order of busine \ be important that the pres« la utility value of tl e asst iretull tabl hed oO that narymen W 1] nelude depret iat Ke insurance, and possibly inte n nvestment, in the estimated et f jobs on a uniform basis with tl mn pet tor If they do not do hey are liable to either turn p1 ible busine to their competito wece} ord that will not re N ( any eal ag stir \ ‘ alm entirely old on : nage basis, but at the present there is an increasing demand quotations based upon a separate s« ng price for each individual castir produced; and this will be one of t important factors in good costing business gets back to normal. T far-sighted foundryman will ace: these conditions and make such nec sary changes in his methods of costi1 before he is ready to use them, so t] he will be ready to analyze the prot possibilities of each job submitted him for quotation and take his | Trend in Foundry Construction By FRANK D. CHASE President F nk D Cc (a Steel Foundries Gird Themselves for Future plants to handle thei By GRANVILLE P. ROGERS The Iron Age. May 19, 1932 1105 EFFECT OF SECTION ON TENSILE}S N investigation of the sections of some large gray iron cylinders which A failed in service led the authors to the conclusion that the strength of castings of different thicknesses follows a fairly definite law and that the effect of composition is greatly minimized as the section increases Test bars do not afford a reliable basis for judgment. A probable strength range for all compositions in heavy sections is offered and a chart has been formulated for sections from 2 in. to 10'2 in. thick ee 1 rustwortl I I f al I i¢ na ne nane t l ry apt Ximate l ‘ ther nly e te inythins re nan a rie r . oT ren noe \ tw ad I corre I I naness, W I l St N ime na een ! e to < engtt a Ings Dal irea fi TY 4 ntly pu r lifference il I \ I é I rt ra rengtu! I t T t References in the Literature 7 ding to Rother Fig. 2 cast iron in heavy <s tions a and Bolton Strength of 1 he Iron ige, May 19, 1932 ] 106 ast iron in heavy sections. The: omplete sources of information articles by Rother, THE IRON A Aug. 7 1924, and Bolton, Foun Nov. 15, 1925, and THE IRON A Dec. 9, 1926 Rother determined the strengt] specially prepa Various portions of tepped castings, in which the sect ncreased by ‘2-in. steps from 1 t *2 square at one end to 5 In. He found that an iron, of 34,000 lb. square tne other. biting a strength q. in. when cast in ection, suffered a decrease in streng a 18,000 | to about b. per sq. in. in In. square section, representing of nearly 50 per cent as a ilt of the increase in section fr | l in. to 3 In Bolton published curves showings | the strength of various cast iron mix tures in various siz some as large as 9 in, in diameter. A in strength was not ror all mixtures, was progres ive up to 4 in., at least, and then bi for further in creases in size The values given by) castings of mat ked decrease which marked Rother and Bolton are shown grap! ally together in Fig. 1. Some Cylinders Which Failed . ‘ eal iL ne writer nad ) nit ) examine everal la i ron castit vhich had fa inder con I el Ce vhich w i accu t nown., De 1 ff ences oO I eX ed i l ! a ngs, t r soul . . s a . e -Average tensile results of failed gray iron cylinders. -EISTRENGTH OF GRAY IRON By F. P. GILLIGAN AND JAMES J. CURRAN Secretary-treasurer and Metallurgist, respectively trength and suitabilty for tl Henry Souther Engineering Co., Hartford, Conn n which they had failed. These castings were hydraulic cy we weighing about 30,000 lb. ea cast, with wall thicknesses 10%2 in. The internal pressure t test ndicated a strengt f a tr i t eng l lt appr x i t hich they were subjected in ser- K<imat 11,650 e) ’ No factor of ‘ e reached as high as 6000 lb. per th ateria f ea nde hence it is not surprising that th The compositions of the ma- sii ee f nders fail n service It is more a ‘ ‘ ‘ 1 ’ I PUA I . - _ 7 ' F al of the two cylinders were: he Lamé formula for hea itter of rise that they withst Manga- § Phos Ss indicated a maximun hy ' inywhere near the maximum pressure ; 0 r : de 1e walls of 13.000 lb. per s y} applied, for the reason that invis 18 0.71 > | 682 tne internal pressut Ww t insound areas might easily nave \A , it } , nelgnborhood f 6000 Ib. pe ered the average trength of the w While these analyses indicat : ee a ; : Ou sts indicate (¢ page | ) vely hign silicon iron for p rpose, careful examination of the ictures at the point of failure dis- ! ' } ' } ‘ . a tn tr ! sed excellent soundness considering great size and weight of the cast vil : mx ‘o determine the actual strength ot Fig. 4—Structure of a . 105 izes. ese cylinders, exploratory tensik in. wall of cyl r. A ts were made on specimens cut inder. 100 diameters ot various points, near the frac- pres tured surfaces. Most of the tests were “oe 1 be en at predetermined locations, n ely, near the inside and outside Fig. 5—Structure of n by faces, and half-way between them, 1.0-in. sq. bar from apl the top, middle and bottom of th Heat E of Table Ill ngs. Other were taken at ran 100 diameters and at points which appear : ° finitely unsound ° 1 [he tensile strengths observed in arg e 24 specimens taken from the tw Fig. 6—Structure of 10.5 by 30 by 48-in block from Heat E of Table tll. 100 diam eters ai nders showed extreme uniformit} W \ll except one fell between 10,000 and $50 lb. per sq. in., the one excep taken from a visibly unsound i tion, showing a strength « per sq. in. f 5000 The average of all of 5 Fig. 3—Probable strength for cast iron in heavy sections a ‘ ig The Iron Age, May 19, 1932—1107 Adaptable Ideas From Pattern and Foundry Practice EST gages (Above) being used for setting cores. Each of the jigs is equipped with spring actuated feeling pieces. The setting is accurate when the top of each feeling piece is flush with the top of the jig. Th one-half green core (at Right) is made on the Grimes machine in the center. The dry sand core is located on top of it by means of a location frame. Then the cope hanging in the rear is closed over the dry sand core. The mold is then rolled over, bringing the green sand core on top, as at the right and in the foreground HIS is the outfit (Below) for making the casting for a six cylinder motor. The cope and drag patterns are mounted on the two machines in the center. Twenty seven core boxes were required for making the neces sary dry sand cores ter ee 1108—The lron Age. May 19, 1932 Pew eee. tt accompanying pictures repre sent current practice in the pat tern shop and foundry of the Pontiac Pattern & Engineering Co. Each illustration contains an adaptable idea and is almost self-explanatory. These pages bear out the old Chinese axiom that one good picture is worth a thousand words of text. By H. M. LANE Note the heavy surface plates for pattern checking the drawings suspended for convenient examination checking instruments and the double rod parallel surface gages The Iron the convenient ige. ACKET cores Above being reamed in a spindle boring machine Abrasive reamers grind the proper diameter and at the same time jacket Six secure accurate spacing HE grinder at the right adapted from a drill press grinds the faces of cylinder cores. The grinder at the left is especially designed for grinding core joints arrangement of May 19, 1932—1109 {G 1.—Apparatus for determining green strength of sand in tension. At the left is Grubb tension cylinder connected by receptacle at center which receives shot from hopper at right, the hopper being controlled elec trically by a breaker mechanism giving direct readings n the scale. The breaker mechanism provides an aut matic shut-off, eliminating the human element a a & ( il pen ! ‘ ( ind pa \ ! Ni } ! he 2 [ ! l bef I I I \ ( ng ini ) l i « eral ! ly 2650 deg. | Wt ‘ n ( ng rel Ll} ne I I I ind pul l . 7 VV sand r Cla ll t l ma ’ ’ ' ‘ : T t I | ‘ wrwvwr wv I a AND control in the steel foun dry calls, first, for regulation ning th en! of incoming raw materials and, ay, Be Bs SOOT secondly, for the proper mixing bent 2 d ee and use of these materials on the in elect en, weighins molding floor and in the core room. Measures employed by the Beth- . = lehem Steel Co. are described in rial tested this article, abstracted from a The t ne of tl paper before the American Foun ne teat a Py aos drymen’s Association. 1110—The Iron Age. May 19, 1932 ge el SAND CONTROL IN THE STEEL FOUNDRY By A. V. Leun, Combustion Engineering Department, Bethlehem Plant Bethlehem Steel Co. ermeability after each burn Specifications Enforced on Incoming Materials (he materials that go into the ma ng of molds, cores, ete., may be list Sand, both strong and_ sharp; inders, such as clay, corn, flour, oil itrines, etc., and silica flour. lt tands to reason that, by maintaining a reasonable and yet enforceabl cification on the various material ted above, we will be assured of nstant quality in the various mat when used in the foundry. In making our dry sand castings a naturally-bonded, semi-strong sand is ed. This material comes from New Jersey and possesses much greater dry strength than does a_ synthetic ‘ and with an equivalent amount of ay. To keep this product uniform, pecifications are placed on it in re- gard to the percentage of coars« ‘ grains. A minimum permeability of i5 is held, and a dry strength of 8 Ib. per sq. in. is required when rammed ip while containing 7 per cent mols- ture and dried at 750 deg. F. for 1 hr. This latter specification is the most mportant, as it assures firm molds vhen dried and a minimum of cutting when they are poured, For green sand casting a _ sharp the Binders resting Ting é y rit el Ve! mite ‘ A ‘ xt Ve i lraté met? \ in nae I i ne f } { i t , 4 I -» 4 1 Washed sand A) l : } } + t 1 1 t i Sand WIil Ssumece i wher being r ! ' . . Ma iT I bo y tan , ‘ , : : : 1 | ’ way ‘ ed a i ’ ‘ : ! il nade | ) \ ten ! ir la , i ay ndor il ind ) eT | } ’ ! } f n.,a float i fi I ! ‘ 1 } ry | 1 | rracde I can vorked ] : y i T y i ‘ ; min, It hen ramn ( aun ! her 1u¢ ( he pt £ y i t } Lining ’ re, depending n Ise a i eat ere ¢ t ‘ ‘ rit i y y ‘ f i iry rengtl . i! ' . ] ne di trengtt y \ oly r ¥ ¢ 1 ! y : ‘ ‘ la : a é tT) iT y 4 1 f per pound eng ‘ in nde ‘ { I How I 1 ma ley en pl \ P re vA a i A listinguishing Between Good and . fi 1 \ Bad Clays rah 4 , e suff , ' iff I I a i? Y certain é l if rength a } ore ' ; - - B : | va : r) ’ m i r) i : er ne li¢ 7 t ing f : ; ' ¢ \\ ims Tuy y 7 ( a I y I $ t 9 sufficis etw | if i n in va l¢ t a y ‘ ’ her ; , y ¢ eing : Fic 2 Apparatu a 7 tor determining é strength of sand in tension with same uN } type of breaker = mechanism as in Fig 1. Note that a spring here is used to take n care of the deflec sit tion of the beam In case tf weak sand the bucket is hooked _ ‘ on the middle of the beam and fed by hand. The normal ratio from the tip of _ the beam to the test | } ing point is | ft J I The standard briquet : mold is employed oe giving | sq. in. at the smallest cross-section : of the briquet The Iron Age, May 19, 1932—JI1I111 Sand Control on the Foundry © cause a Not Nec 1112 prepared for dry sand molding and & cent 1 generally averages between 7 per cent. To go below 7 pel reduction in dry strength Proper ependent on the deficiency of water. The wetter the sand, up to about 9 ntrol ove) ent water content, the greater i \ atte r ( ry strength. This high water e1 ! ntent, however, namely, above 8 per teria I eparing t ent, makes the sand less workable, ng and core sand ausing increased difficulties in drying foundry making casting and adding to the drying cost. ind the most portant pro; The green strength maintained on I witn reierence tf tne ich sand is dependent on the dry | er Tl rength aimed at. When the dry depends to a great extent trength is 15 to 20 lb. per sq. in., int and the type of binde1 the briquets being baked at 750 deg. r in the I It i yer I the green strength will average or al ses of rk t) etween 1.75 and 2.5 lb. per sq. in. in 1 strengtl uld not be les tensio1 It is generally not neces casting burning n’ effect of a clay used idely in steel foundries te) a Fu n temperature et ‘ 304 des F Dry Fic Test sh the wing = ‘ strength, 20 Ib per sq Dye adsorption, 145( vrTvwryvT sary to Test All Batches of Sand Mulled eT j ! erreen ength, as the sand to have a high . rel will always have suf pla t make t workable. ! Perme while paramount tance n green sand molding ! ( : ay minor part in dry sand Cast- et It true that the more open ickit nd facing sands, the ind faster will the molds dry In the ste 1} the ve but it is also true that Ste ( at Bethl e | er the met ction the more pact and dense must the facing ! ste I This is brought about by ! th ntrol « e addition of silica flour in amounts ngir from 10 t 10 per cent. In I cases, tne permeability de- es 1 lo maintain an op21 ng I an advantage. ng per AMIS J requir pecial equipment for ng the “fines.” This apparat nore mportal when green nd an ( nd lding is in the majority. In } ! average sho} pecializing in dry I \ nd bbing ! he permeability ( not ( {f the sand will usually run from 10 eX rative n heavy work to 55 to 100 on light kee] lium casting When the sand is rea able ns¢ dried, however, this permeability in- g reases in all cases, often as high as The Iron ige. May 19, 1932 100 per cent over the permeability the sand when in the green stat % Permeability Important in Gree Sand Casting For green sand watch must be kept meability, moisture content and g¢g ind dry strengths of the sand. higher the permeability, provided green and dry strengths are n tained satisfactorily, the sounder be the castings produced. The n mum permeability obtained is pendent on the sand employed and binder added to it. The maximum px meability maintained in practice is pendent on the degree of cleaning old sand receives and on the surfa of the castings produced. Where f casting Cal over the IG. 3—Specia three-gangue mol for ramming briquet for dry strength test permeabilit of tne ing sand is employed, its is limited by the openness backing sand, as it is useless to mal! tain an open facing if the backing u material is of much lower permeabil ity. For the individual shop the be permeability is arrived at by keeping high as possible, yet getting clean and moderately smooth cast ings. Provided the refractoriness « the sand is right, rough castings meal too open facing sand, which must corrected by either adopting a diffe ent base sand or blending a finer san i+ ¢ 1L as with the one in use, For green sand casting a_ shar} sand is generally employed to whi is added sufficient corn flour, ber clay, etc., to produce the n¢ essary green and dry strengths, |! is necessary that the water added | controlled very closely. The bes moisture content for a particular sh¢ making green sand castings depend on the base sand employed as well a on the binders added. It is best di termined by test and observation. Ir most cases, however, the water co! tained in the prepared sand will aver- If the moi tonite, age close to 5 per cent. en nter oes mu elow 1 | ’ es the re tar I “ } bra , ind hen i} erosiol! great I If, on tl her I nte Yr) . ' ’ \ an i i Va ani y : I I welg! i ‘ r g ter y ne the : ( eig vy taken r ) i ; 1) ] eo 4 iD] \ 2 en trer al noth These t take ‘ ur? he time tak c l riguets for the drv Core-Room Sand Control l} time I i ire S¢ 1 ] ) ’ ’ Y ecting the Moisture Content a al 1l/S < I I é ul sand m : l cted efor ng used qu : te ne nd and binders a ! riv 1 x they na +} : t f empe¢ a i I e l ( CE Xx i ( r el } : Lesting 1 ( ore Viix +7 : irs, i lt I I tC met ne pecii t t : ] I be 1 pa ed n i ; f the sand ‘ We 7 y to rem«e the ni y ‘ i £ oO tne } idl? ‘ ae l ed al Le f a i ¢ pevinning I ‘ . I ) atu I . | { i selecting Binders for Green Sand e dry ren ‘ { i ‘ t t t i} | Facing A ee : g l . I I al i t I | t! t 100 é } é ) r nN? l t I f the ’ 1 nea { ‘ . f I é ¥ . : ' lucing res . ' y iY writ i ‘ noth th DiI l l I Li? I I 7 > as at bon t time eftore eing “finished , . 7 ; ll } + a rn flour will have dried and the , ( ected in cracked casting : will not take water appreciabl; test nly meant for nakes the “finishing” very dif : shi-cection wot : Inder aa Core Sand Used for Light Castings . + } naer sucn circun ances, Io? g ID t Fé ind control, the ce fa C y ¢ i} ‘ . rir » replace the er type I ne ‘ t ' f the « floul $s necessal | reta ' ture much longer than will the ne (du f . nders for obtaining 21 ’ ind : . , ri f , j ' y I Tt eretore befor T xing reng t r ne f y roe é ind the operator should fit i fer¢ et n I ’ } " r wher t} san ‘ r : ' he Ir na ; : ' 1dding’ tne proper bind il ir é ‘ I ‘ Hur ngtor W \ ; ai ; : ; y he , y sl propert 3] y Strength of Sand in Green Sand : ' Tel Y ne ict , he ympar ler Casting = ‘ : y t ecurt reel and casting, as in dary ly tte e the dr exce } work, the drv strength , f the £ +h, are and hen haked . ee : 4} ar ‘ +, toy very important. If w leg. F. v average between | trengtl 10,000 lb. per Zs ifficient green strength in tl per sq. 11 In the n forg i ves » make it workable we will ger ts dr neth bake i I ngatior é ’ have the proper dry reng er ) r é e! ; es ‘ The Iron Age, May 19, 1932 1113 R uick Machines Its Crankshaft a tm tm By BURNHAM FINNEY Detroit Editor, THE IRON AGE l ‘ [ININ( ne ! r N DPD, =. enter-darlvt l pped on these dril presses. Ural ! the, thence issing t traighter shafts then are washed and blown ¢ - M ( vhe the three cent na tank, the shafts being held in I Mi is ad é ns traightened witt ink on racks. After being checke Machining ar crankshafts are sent to special di ! ft nte earil ro 8A} where 3/16-in. oil holes are dri art he ' 10 ir 18 in. hvdrau They then pass to a battery of d erinder. the diamete the front cen press to have 11/382-in. ol | the oe: eld within limits of drilled in all pins and bearings. The nN a ene ee a nd 2.29 n. and the rea presses have special fixtures for hr oa . ‘ es ' , { tc of 2513 it noving the chips from the oil hol ehtens mT 15 All front and rear bea: Another straightening operation ' } ‘ 4 hy +} f d na hvdrautli ows on the three center bearings or Tey “ the diamete f the fron special straightening machine. ne ca neat rance of 0.002 : eo , : Sl . - chines MDe te kcnicie Bearings and Pins Finish Ground I ng led on a tra The thrust bearing, rear cent no hing nd a nil bearing, front center bearing and th fi} turne na Ne fron and rear bearings are fini ! ! \f roing ground on a battery of 10 in. x 48-i1 I I nother straightenir per vrinders, Again the three center beat e ce] hearings. t nes are straightened, this time to lm rourh milled on ah ts of 0.004 in. All pins are finis ng machine ha sp ground on a ttery of automatic h . | z worl lop ‘ araull grinders. After the cent ! e milled on a ve bearings are straightened, the wid ; . Y lled of the balancer seat is finish turned ( if multi-cut lathe and the balance: f ’ ‘ na eat finish 1 le hvdron s e} ( The clutch pilot hole drille¢ ¢ I i ba 4-12 ox-tvpe drill ar four i ! ! ‘ ‘ ire d ed, reame ne i amfered ne 21-1n lril ress naving The ends of the crankshaft are centered on a special centering machine. ige, May 19, 1932 1114—The Iron iL holes are drilled in the crankshaft on a bat tery of drills equipped with hydraulic auto matic control oO! lle drill heads. The flange face chine; the kerosene is distributed t the headstock. which is bolted to tl pilot are finish ground on 12 in, x Ul ipping arms by i direct } achin¢ ist There is an adjustab n. grinders, while the pilot hol nected, motor-driven, centrifug ciprocation which moves the crank } 1 gh and finish bored and reamed pump, with anti-friction spindlk haft end from zero t , in nt | the flange chamfered on an aut machine is driven Dy a 5-h} | th tic screw machine. The rear bearing mounted in tl! base direct Studs Welded to Counterweight ini the pulley bearing are finish ground the headstock re: } ftey + ‘ in } } ' S-ir a 12 in. x 36-in. grinder. Flangs During the rough and fi \ cig , } } 4 = mn nner nut thy or} final ea ire drilled and reamed on 24-11 pine overatior —_ ey ped } ip A , } t ie + enter operation and : lim presses, aiter wnicn an opera Y toc} re) ed | ‘ . GAUINEE GIN he ' ; Bie 1+ } ’ : 7 ed At , inl ng a hand miller cuts tne f Va tw . i 4 i h the gear and pulley bearing I 1 n sser ' g nt rroove is finish ground on a 12 it chit n tur? it 2% 7 ring it blocks are asset idt 6-in. grinder and the threads are wnped crankshaf » hour. All lew th ift and the st d ed on a thread milling machine. tartine. stopping and rulatir nto place Asseml! ft the count n les are burred and blown 1t, +} need of the work are er . (Cone dvert a7 »¢) ) ng tools and scrapers being em d for this purpose All pins and nes are then burred on a speed Pins and Bearings Lapped Rapidly; and bearings are lapped rankshaft lapping machin s work tl crankshaft is places orting b t 1 the Labi ( achine 28 in. from the floor ans ed mechanically into proper alin¢ 2 { with the clute} sieeve, drive } footstock center. After the lay i fr arms are clamped and the lox ; ever released, the ipping ne Ss Started The reverse of tl dure follows n removing nal r} lap} i@ arms fo! earing i suspended fro1 a : ft directly above the work center : e stational tl apping arms : : e crankpins at inted on a : ib ‘ anda t tne real rie enters The ! counter- inced and ving n anti-friction ; n¢es 7 \ bonded abrasive paper 1s used as lapping medium. The tank for ubricant (kerosene) is held in the : + tstock end of the base of the ma Pins and bearings are lapped on a crankshaft lapping machine ; The Iron Age, May 19, 1932—1115 Steel Foundries Gird Themselves for Future y nt ip eture l prevail tl ‘ vie rofit above act i nve ( ip ul wil } le nterest provide na } ag ) Lint il? Cooperat he ! try . 1K future ( fu is based on the If € pment f ust i i é ss les eodii Mi t ( elling ethods I] ther improved hn | prov f the r the . . . Electric Furnaces in the Foundry By G. L. SIMPSON h Elect Furn Corpn., Pittsburgh Y : ar 1 WW ; eY 1 n furnacs ind ! \\ i W V\ iT ( na ntro n< product n t e time y ’ ave ! lled electric irnat ment lo so. Automotive bi) n exan () } ani re pa I ri i r , r n to increasing the efficien f eil rna eration. They az ices, ] itt ( ng t prove the power factor ( illations and ] t ne de ind contr levi ; ‘ , vel Developments in the Gray lron Industry By ARTHUR Jj. TUSCANY M ‘ ( ry u in Cleveland ind te are following this p vy with I rnt \ spiendid resuits The physical side y ‘ in ? f he set 1} I Hee}! y proved vise render ! hrougt he installatior modern 1116—The Iron Age, Mav 19, 1932 machinery and equipment This ‘an always be done more effectiv: vhen the plant is not crowded to p duce the product. More time can taken and the finished job results ir much more complete and thorou et-up than if the task is undertal when high production is deman rom the manufacturing organizati The Gray Iron Institute is comp ng, during the present period, a pi of work in which the casting user v profit in many ways. The institut developing through means of test b: furnished by members, a wealth outstanding information on the qu: ity of the product being produced member plants. All of these available to a special committee the American Society for Testing M terials which committee, in conjun tion with the technical director of t) institute, have set up a _ tentati pecification data have been ma for gray cast iron of d ferent types where strength is a fa r. The value of these specificatio The d ener, engineer and the casting us¢ vill be immediately obvious. ll have available for their use con et nformation of the most d rable nature. The proper grade of gra iron will be employed for each service, with augmented re- iit in every direction. If the de- accomplished nothing user, it has important, else for the casting brought about this very ich desired de velopment. The Gray Iron Institute, through it upplying it nformation product be controlled and stud ry « e] lr} work insu? mprove niform quality, if th ng buyer rtunate enough to is hi ures f supply a gray it I ! workir oY nde! nst tandal Many member companie Gray Iron Institute have employed ime available, due to the lower leve fo ~ which business is operating, to uses f th The desig! er af velop new products and new gray cast iron. other buyers of have to their atte t and the qua castings many savings brough tion through this wor of the finished product has bes throug! + C L- K, improved use of gray iron parts which are m efficiently serving industry. nmeasurably manufacturer ‘+ The progressive realizes that modern gray iron pportunities not previously availa profiting in many directions, amor which are reduced cost and impr was 698,316 net tons, valued at $ 260.585. A de crease of 32 l pel cent and 34.5 per cent in va tonnage from the preceding year. Imports 1931 were 60,950 tons, a drop of al 17 per cent from imports in 1930. A Pictorial Interpretation of The Spirit of the Foundry HE remarkable pictures reproduced upon this and the following pages present a dramatic interpretation of the spirit of American 1 the foundry practice: the romance of sand and hot metal Starting with these two tense melters, intent upon the service of their molten charge, we follow, with John P. Mudd, of The Midvale Co., who made these striking photographs, the major steps in the birth t a sound casting y 19, 1932—1117 ODERN mechanization has not banished the element of human skill from foundry practice. The foundry is still a stronghold of craftsmanship and self expression Even this young apprentice is exhibiting the pride of personal service that is inherent in all true foundrymen 1118 The lron Age, Mav 19, 1932 oo ND this master molder, whose delicate and trained a touch is engaged in ‘‘slicking up” this drag, does not exhibit the look of one bored by the monotony of repeti tion. For there is infinite variety in the behavior of sand as well as of iron and steel, and skill must cope with the unexpected oem = The lron Age. May 19, 1932 1119 HOOTING stars of oxidizing particles, miniature meteors in fact, stage a pyrotechnic display to ac company the metamorphosis of swift running iron from quiescent pig ND then, guided by careful movements of craneman and ladleman, the eager, molten metal seeks out the far and near interstices of the mold, reproducing, first in liquid, then in solid metal, the form of the pattern The lron Age. Mav 19. 1932 Ii2] “"THE Parade of the Iron Soldiers.” Or perhaps we could entitle it “After the Ball ls Over.”” For the dance of hot metal has been completed, the shake out gang has completed its nocturnal duty and the empty iron flasks come back to the foundry floor for the next performance 1122 The Iron 4ge May 19. 1932 wr” RIMMING His Whiskers.’ That is what the pho tographer entitles this picture. It’s a stiff beard that must be cut, consisting of fins, sprues, risers and gaggers. But the barber is equipped with appropriate tools and his air driven chippers and grinders will give ii dle ai this huge casting a clean shave The Iron Age. May 19. 1932—1123 Vay 19, 1932 =" HE Man Made Sand Storm.” Bombarded by millions of tiny grains of sand per minute, the hard crust of the casting yields to superior numbers and is swept away be- fore the furious tornado of the sand blast. But the work is not all done by the hard flying particles. For it ts obvious that the man is taking strenuous part also in the battle. While the number of distinct cast- Effect of Section on Tensile Strength of ines made is not as large as: migh be desired for scientific accuracy, it Gray lron 7 nevertheless evident that the trength of 1 of castings of different thick nesses follows a fairly definite law, (Concluded from page 110 and that the effect of composition is greatly minimized as the section nsiderably below the figure obtained n some of the intermediaté ze reases. The close grouping of all th | } re its yn the as noes of yrena ts yur exploratory tests. vhere appreciable temperature gradi oe oe le casting f grea : thickness 10 ‘n.. i? hich the grea _ a ents may exist, this is not so easily thickn , 10%2 In., In which the gre Six Heats Made and Tested ' hle even When vumplne of est number of tensile tests were VOSSIVIC, vel wile VUITN DIN ) : S . is eo — ia ni of ‘ j ; eraged, indicates that in larg In order to obtain specific informa- churning is resorted to. "S = a ‘ tions, of this order at least, compo n as to the strength which might [The complete range of sizes of test » ay aisles t . . e eee ; tion plays a decidedly minor part. It sonably be expected in castings of istings is shown in Table I and the t that t vlind i’ © ’ , sit} ‘ , . = : a » evident tLnat the cylinders is size and composition, and I compositions of the six heats in Tabls hic} 1 th} nv .w . : ‘ a which inspired the investigation wert ler compositions advanced as more I] The average tensile results h. <n , ; . é ri nsi su no? 1] strength for the section and itable for the service, castings of tained are tabulated in Table III and rious compositions and sizes were hown graphically in Fig. 2. de and tested. Six heats were ie eels elidel, tae tack . With the dat a available, t | elted in the cupola, according to reg- a = nmi me Si He: : ‘A. ; ad - a9 a sible to establish a probabi« strengt ir practice, using charges of foreign saan an Nag aa #s — eee range for castings of all compositior ind domestic pig, foundry returns and nce = nig ngnaatnng ete ea n heavy sections, and such a range ight scrap, with additions of 5 to ae ae ae Sat eee hown in Fig. 3, for sections of 2 i : : different. Accordingly, the tensile re to 10% in. thick ) per cent steel, to obtain the de- , : : In. UMICK, red range of compositions. Test : eae St eee B = . I plotting the wer curve n Fig. 2. Effect of Alloy Additions Heats { na D were AISt ip pie- Th irs and blocks of various sizes from n. to 10% in. thick, weighing up to = : : . : is range approximates ¢ ely t arly 4000 Ib., were cast on end fr