The Iron Age 1933-06-01: Vol 131 Iss 22

pre- the gas ime ets gases nts gas actory give rating with per gas proper ige until about rti- ent de- the roduc- tools grind- and work sum up- the the rators find meth- econ- rough sed af- the idea crank piece- idred. pur- ion ..THE IRON AGE.. ESTABLISHED 1855 JUNE 1933 Vol. 131, No. Steel ndustry Hails Roosevelt Partnership Plan CHARLES SCHWAB steel industry welcomes President Roosevelt’s plan for gov- ernmental partnership, declared Chairman Schwab the Ameri- can Iron and Steel Institute its semi-annual meeting New York May 24. “The President will have strong support for his plan assist the nation’s business machine through the easing laws that are unduly restrictive and through substitution cooperation instead ruinous trade practices and price cutting,” declared. Chairman Schwab assured his audience that “revitalized” insti- tute ready function for its membership carrying out the aims the industrial control program recently formulated Washington. less unequivocal than Mr. Schwab’s stand this subject was his declaration favor voluntary unemployment insurance. recommended that institute members “give consideration the earli- est possible opportunity the formulation and adoption adequate unemployment reserve plans for the protection their employees future periods business recessions.” come about the past few weeks has given all new hope. cent are still far from what would like see; nevertheless, this more than double the per cent rate which existed few weeks ago, and the im- portant thing that the trend the right direction. March this nation was state chaos. This was followed program action more vigorous and more effective than any other The President had the courage take steps the direction balancing the budget and make certain other forceful moves which were necessary rehabilitate our economic structure. That restored faith throughout our entire nation, and faith turn has had its far-reaching influence our financial situation. This has led improvement the credit struc- ture, which the basis increases industrial and commercial activity. consider tribute our dem- ocratic form government that has been flexible enough meet the situation critical hour, and fully confident that President Roose- velt will use his vast powers sanely and constructively, probably never employing them the full, and relax- ing them rapidly the situation will permit. Business cannot shirk its responsi- bilities this situation. chair- able say that were never ina better position our part. Since our last meeting have had the good fortune have the Hon. Robert Lamont, former Secretary Com- merce, assume the presidency our 851 CHARLES SCHWAB institute. The institute’s organiza- tion and program have been greatly strengthened. Furthermore, under our new set-up, there executive committee comprised steel execu- tives who are lending continuous close counsel the conduct its various activities. This should most help- ful promoting and maintaining the stability our industry. ask the most earnest cooperation our members the work our association, because trade institutions today are being looked spokesmen their respective indus- tries. Industry must regulate itself wisely and for the public good, escape regulation from without. have said many times that the in- dividual success our the end proportionate our abil- ity cooperate for the general good. never before our business, this belief about put the test. President Roosevelt his splendid address the country May in- vited industry into partnership with the Government solve its problems. This open-minded pronouncement warrants the admiration the entire country. The President offers the business world the facilities and pres- tige our Government eliminating unfair competitive practices with all their effects upon prices, wages and profits. judgment would most unfortunate—indeed . AS ~ | | pe Tale, | | 7 would calamity—for business and employment this country, anything were done legislative fiat interfere with orderly and sound therefore, encouraging note the President’s rejection Governmental control and the substitution the more effective proposal Govern- mental partnership. have had quite enough restricted production, hours work and wages during the past three years. What need now greater production, more hours work and expanded income for our employees. Moreover, need price stability. The President will have strong sup- port for his plan assist the nation’s business machine through the easing laws that are unduly restrictive and through substitution coopera- tion instead ruinous trade practices and price cutting. Speaking for the steel industry, say that gladly accept this offer partnership, be- cause with this kind support and through our revitalized institute should speedily and effectively able see brought into line those selfish interests who persist unfair prac- tices that are contrary sound pub- lic policy and ruinous industry. Sound Profits Basis Prosperity for All make greater contribution the country’s total economic well-being than return our individual com- panies profit basis quickly possible. This will not only give courage proceed with needed re- habilitation and other deferred plans; but, more important still, will ar- rest the downward trend our em- ployees’ purchasing power. This progress toward profit-making already under way. Our steel pro- duction for the year 1932 less than 15,000,000 tons descended levels which even the worst pessimists would not have predicted two years ago. small wonder that the in- dustry sustained loss approxi- 852—The Iron Age, June 1933 mately $161,000,000 under such cir- cumstances. Now are steadily emerging from that deep water. view the short time which have had this improvement, feel too early forecast ingot produc- tion for this year. But safe say that will improvement over last year and there every indica- tion that shall look back 1932 record low. Would Scrap Obsolete Plants have had three years facing stern facts, and can profit con- tinuing realistic. Let see straight our manufacturing set-up. all the obsolete semi-obsolete plant equipment were eliminated, that would far toward strengthening our whole situation. dare say, were possible appraise fully the struggle justify obsolete plants, would find that much the uneco- nomic disturbance American manu- facturing today due attempts make “dead horses” pay. takes courage scrap huge investment. need not feel, however, that doing are admitting mistake the past. are fact recognizing that conditions have changed and that are reconstructing our set-up line with modern demands. Consumer Goods Revive Steel Our steel picture very materially changing. the year just prior and immediately following the war, the steel industry was manufacturing primarily for capital huge buildings and heavy-production equipment. This will always substantial backlog, but its dominance will less marked. increasingly important part our business the next few years will consumers’ goods. The public for three years has been doing without thousands items which enter into our normal standard living. There three-year lag automobile consumption made up. Progress home building has lagged for even longer period. The use steel many directions has been arrested its momentum the hard times. This emphasis consumers’ goods, with particular demand for quality tonnages, bears out prediction which made two years ago that may see the day when value comparisons may become more and more measure our business. seems quite possible that may return the profit-mak- ing days prosperous years without equaling them tonnage because the lighter, higher steels which are currently demand. Predicts More Advertising shall leave the subject market- ing the speakers that field, but must observe that the new emphasis consumers’ goods must bring about changes our methods selling. There will more intelligent and more extensive advertising, closer an- alysis markets, and more thoughtful study extended uses for steel. return now the advances which the steel industry has made the field human relationships. The old- fashioned policy every man for himself and the devil take the hind- most was abandoned the steel in- dustry many years ago. Our indus- try throughout this depression has done its utmost protect the finan- cial status its workers. believe that the splendid loyalty our em- ployees, and the absence labor troubles throughout these hard times, has been due recognition the employees that management has been doing its utmost dire situation. Long Record Employee Benefits maintained the rate wages long was feasible, maintained un- til there were very considerable de- clines the cost living. Our in- dustry was the forefront the distribution work, before the for- mal organization the Share-the- Work Movement, and cooperated the fullest extent with that move- ment when was put into effect na- tionally. the adoption dis- tributed work the steel industry has been able carry rolls ap- proximately 200,000 more employees than would needed had fol- lowed the policy working those whom retained full-time basis. The average working time the steel plants has been less than hr. per week per man, which in- dicates the extent which have adopted the work-sharing principle. The steel industry has done its part and believe that this will fully recognized when the history these times written. could cite score instances company-wide relief plans, employee garden projects, rent concessions, pensions, sickness bene- fits, all carried voluntarily and direct cooperation with representa- tives our employees and aggregat- ing many millions dollars. well aware that the unem- ployment situation continues grave this country, and that work- sharing not the Part-time incomes are not sufficient for meeting the high standard liv- ing which have achieved this country, and which our people will not and should not forego. revival has taken place and our production has increased, however, employees who have been working meager part-time schedules for many months have gotten more employ- ment and better income. Sees Wide Spread Prosperity Moreover, with pros- perity for the people whole, believe that shall see orderly and effective correction present un- employment. our own industry, given reasonable demand for our products, shall again absorb our > owl 5 | 4 a if A a“ LI a more ises for which the old- ian for hind- teel in- indus- has finan- believe em- labor times, the been ation. un- Our in- the the for- are-the- move- na- dis- try has olls ap- iployees fol- those ull-time time than hich in- have ciple. its part fully these score relief rent bene- and resenta- unem- work- ufficient liv- this and our king many employ- erity pros- orderly sent un- ndustry, for our orb our quota the nation’s wage earners, affording, heretofore, employment reasonable standards hours and good wages. The relations be- tween our employees and management are splendid shape. Our industry has had long record paying good wages, affording our employees their fair share our economic prosperity, well enhancing the purchasing power the public and the ultimate stability American business. The institute has responsibility see that conduct our businesses that may continue the fore- front whatever movements may necessary for social progress. must not neglect this duty. have cited the splendid work which the steel industry has done reliev- ing distress among its employees dur- ing this depression. Splendid this has been, however, only fair say that the industry the main was not prepared meet the situation adequately would have been the case reserve funds for unemploy- ment had been built times prosperity. emerge from the depths this depression, industry should profit the experience the last three years and voluntarily, both matter social justice and sound business, work out with its employees and put into effect plans unem- ployment reserves help meet any future depression. Legislation should not required this job any more than has been necessary assure the introduc- tion pension and other relief plans. legislation proves necessary spe- cific instances, should drawn not affect impair voluntary activity forward-looking industries. Otherwise, years progress and vol- untary action would endangered. can work out voluntarily this industry method providing re- serves commonly called “unemploy- ment insurance” that the end will greater benefit our employees and society general than any in- flexible compulsory plan which might forced upon us. therefore, rec- ommend that the membership this institute give consideration the earliest possible opportunity the formulation and adoption adequate unemployment reserve plans for the protection their employees fu- ture periods business recessions. Now for final word. vet- eran this business cannot close these remarks without word con- gratulation you who are carrying the industry through these difficult times. The steel industry its very na- ture peculiarly difficult business for swift adjustments. steel com- pany cannot get its supplies the spur the moment, build tear down its equipment within few weeks. must have large supplies raw materials and enormous in- plants covering wide areas. Such institution must built such proportions during active times, involving overhead fixed charges and taxes, which prove ex- tremely burdensome periods low operations. The managements the companies the steel business have made short-cuts, taken enormous de- creases income, bought shrewdly and have plants with maximum consideration for the welfare the stockholders, the employees and the public. our fixed charges have made impossible earn profit, have nevertheless kept our financial structure reason- ably sound condition. Our eyes are now lifted the fu- ture. The present upturn has done wonders instilling hope the heart everyone. chairman this institute, say that the men this great industry will tackle the problems ahead with characteristic vigor and enthusiasm. are ready onward and forward with faith the future our industry and our country. Barrel Rack Oil Storage Floor Space floor space, lower in- ventory and saving labor have resulted from the construction oil barrel rack the supply room the machine shop the In- gersoll Milling Machine Co., Rock- ford, When the subject the oil barrel rack first came there was the ques- tion how many barrels should support. survey the needs the shop found barrels scattered and that more than were needed were use. study actual needs resulted the use only seven barrels, all located single rack and their contents all coming from one source supply. The rack was made from scrap pieces angles and plates. consists essen- tially two A-frames made angles. These are spaced about ft. apart and are held welded cross members. a Extending across each A-frame three levels are steel angles that ex- tend beyond the legs the frames. These angles are turned upward their outer cantilever ends that they form supports cradles for oil barrels. the top the frames are saddles for support barrel. The capacity the rack therefore seven barrels. Welded the cross members are horizontal steel plates that form three shelves for the storage grease buck- ets and cans. Each barrel piped within easy reach the attendant. Stenciled the front legs are the des- ignations the various oils. With barrels place this rack occupies floor space ft. wide ft. long. The total height about ft. for- mer practice floor area ft. ft. was required for the storage oil. This oil barrel rack has conserved much floor space and has greatly facilitated dispensing oil the shop. The Iron Age, June 1933—853 Bat | vA ; x } e BLAKE trial gas fuels presented THE IRON AGE May 25, empha- sis placed the present com- mon practice attaining either “perfect combustion” some constant, predetermined degree oxygen carbon monoxide concentration furnace atmos- pheres. Taken whole, the two articles stress the importance net heat values, rather than gross heat values, for son, and outline rational meth- comparing two seemingly very dissimilar gases. has been shown that the com- engineer has reduced the selection and application indus- trial fuel gases founded upon physical and chemical data, and that apparently great dif- ferences quality may have mean- ing. There remain few considera- tions, however, due the chemistry combustion, and the combustion products. Table shows the composition flue products quantitative combus- tion volume before condensation moisture, well the value moisture-free basis. Examples combustion products from oil, coke have been included, the same quantitative basis. These results would need revision practical assuming the usual percentage ex- tion practice for these fuels. The data presented phere which may expected when substitution fuels made, and per- such changes. The condition theo- retically quantitative and homogene- ously mixed air the only one as- deg 0% sumed for these tables, for the sake too much ignored fact that gases can burned with the use several di- vergent types firing equipment, | | Efficiency ,per cent ized, and capable producing fur- nace atmospheres zero oxygen and Fig. 2.—Thermal efficiency curves for some the chief components industrial gases. For the data reference made “Combustion,” third edition, the American Gas Association, When for any reason, the appara- Gas 1932. tus adjusted for providing some 854—The Iron Age, June 1933 \ \ \ \ 4 \ | | = | 790 4 + 4 4 4 | | article, part indus- THE empha- com- either some legree atmos- the ortance than ympari- mingly com- uced the indus- chemical reat dif- Mean- nsidera- nbustion combus- ation coal and same sults fuels, yen and ex- table atmos- when fects theo- nogene- one as- sake size the ses can eral di- ipment, fur- and some Fuels constant excess air, gas, there will corresponding change the furnace atmosphere, including addi- tion free oxygen, desired much the ceramic work today, the addition carbon monoxide. point for emphasis is, that what- ever the adjustment, the atmosphere produced will constant degree depending upon the constant composi- tion and temperature the gas used, and assuming absence draft, there will positive pressure the fur- nace which will prevent entry cold air cause heat loss and introduce undesirable free oxygen. The results excess air gas upon flue products may calculated without undue trouble. Excess air commonly required the successful burning oil and solid fuels, contrib- uting lowered efficiency heat- ing. After the requirements for any particular minimum free oxygen, carbon monoxide, are satisfied, any further departure from combustion (0.0 and 0.0 CO) should prevented. may create some surprise note the slight variation nitrogen con- centration the flue gases these typical fuels, well the fact that the value for anthracite gas lower than that for butane. The ratio CO, furnace atmospheres varies considerably and much importance, owing the effect these gases upon metals high temperatures. The producer gases and solid fuels show low and high This reversed for high duty gases, especially oven gas. This.may explain oxidizing (scaling) effects metals, when the reaction metals upon steam high tempera- ture recalled. Selection gas for producing large volumes inert gas for solvent recovery, for source would hardly fall upon the hydrocarbon gases, oven gas, with- out unusual inducement price. Coke and bituminous producer gases are somewhat sluggish due partly very low hydrogen con- tent. Anthracite gas, with consider- ably more hydrogen, burns very much natural gas, and flames “ribbon” burners, even atmos- phere wet steam, bakery ovens, are very tenacious. Producer gases not backfire violently when burners are turned off, some the high duty gases do. This another point resemblance natural gas. dicting the effect change the composition gas supply. shows the theoretical thermal efficiency TABLE II—COMPARISON THEORETICAL COMBUSTION PRODUCTS FUELS 17.30 11.90 11.54 7.83 11.34 H,O 17.67 16.45 14.88 16.05 22.50 18.01 Neo+SO, 65.03 69.19 73.22 72.41 69.67 170.6 (dry basis) 21.01 17.20 13.98 13.75 10.10 13.83 17.44 16.17 19.08 22.00 16.50 18.90 15.60 9.69 8.23 5.80 8.35 5.60 3.24 13.20 72.87 75.60 75.12 69.65 77.90 77.86 71.2 19.31 17.62 20.25 24.00 17.50 19.53 17.97 “Steam Power Plant Gebhart, 5th Ed., 50. 55. Medium Oil; per cent per cent 0.8 per cent 0.2 per cent 0.1 per cent 0.1 per cent (Only and taken account same reference Note 9). Note: This table has been prepared in answer to doubts sometimes expressed as to the effect of a change of fuel upon stock being heated in industrial furnaces, such as, oxidation of metals and “burning” of steel forgings. It will also assist in selection of fuel for carbon dioxide, nitrogen or inert gas manufacture. The CO. the dry basis will assist judging the results combustion denoted flue gas analysis, continuous or intermittent. Excess air, necessarily used in burning oil and solid fuels, will add oxygen and more nitrogen to the results shown. As to the gaseous fuels, quantitative combustion, with zero O2 and zero CO has been commercial practice for over years and now very generally recognized. Attention called the low moisture values (denoting low “hydrogen loss” combustion, and lessened oxidation activity toward steels) for the three examples producer gas. the common combustible components. The influence increase ethane natural gas can judged fairly close- ly. The effect “stripping” natural gas the small amounts ete., often carried, can seen. Steel Panel Construction For Silos and ILOS made steel panels offer another outlet for the steel pro- ducer. Co., waukee, has perfected design that eliminates framework and hoops and which, being bolted construction, can readily salvaged. The panels are made from copper- bearing steel and are such size and « Smoke Stacks weight that but two men are required the erection job. They are formed from sheets varying from gage 5/16 in. thickness depending upon the size the structure. The four edges each sheet are turned form flanges which are punched for field connections made the outside means bolts. This type con- struction gives smooth surface the inside the silo. All horizontal joints between panels are broken and all panels one size are interchangeable. The roof sheets are galvanized. The side shects are ready for painting the outside and for special coating inside for protec- tion from acids silage fermentation. Advantages claimed for these steel silos are that they are permanent and with reasonable care will last life- time. Special equipment not neces- sary for their erection. Further, they are fireproof and lightning proof. Tests show that freezing weather has little effect silage steel silo, and claimed trouble en- countered with frozen silage. The construction such that increased height can had removing roof and the top half-panels. The doors are made steel and are hinged swing inside flat against the wall. The doors fit tightly against steel frame, assuring positive seal. Construction very similar these silos also being applied smoke stacks. Advantages are rigid con- struction and replacement only such panels need removal. not necessary take entire stack when making repairs. The Iron Age, June +. | j $ 4 q 3 4 oy q utting the Question Mark Wor Seasoning Steel Castings One our products rather com- plicated steel casting which rough machining. have had some complaints warping. Can you tell whether any change dimension apt take place when green cast- ings are machined and shipped shortly after leaving the foundry floor? Would the difficulty corrected season- ing, thus allowing time for reorien- tation crystals? Would annealing normalizing advisable after our rough machining? experience shows that any castings whose dimensions should remain reasonably fixed should annealed prior rough machining and, the casting has varying sec- tions and not thoroughly tied to- gether, should further strain- annealed after rough machining. This will relieve any strains due ma- chining, which may have caused slight dimensional changes, and the subsequent finished casting should then stable. Specifically, should say that all cases where accurate dimensions are required, annealing normalizing after rough machining decidedly indicated. our own experience with steel castings have found two ways overcome this warping difficulty. One rough machine within in. perhaps 1/16 in. and then anneal be- fore finish machining. Our other method normalize and anneal be- fore machining. Union Steel Casting Co. Salt Water Alloy desire use aluminum castings below the water line salt water ves- understand ordinary alumi- num will corrode. Can you tell any simple way preventing this cor- rosion? New England Steel Rack Co. suggest the use castings 95/5 per cent aluminum-sili- con alloy protected anodic oxida- tion, the oxide coating being finally impregnated with lanoline bi- tuminous paint. This sure would satisfactorily withstand the ac- tion sea water. will, however, result dark colored surface. alternative would use un- protected castings the German Seewasser alloy which claimed stand well under the corrosive action salt water. The composi- tion this alloy, understand, is: Manganese 2.5 —3.0 per cent Magnesium 2.25—2.5 per cent Antimony 0.2 —0.5 per cent The British Aluminium Co., Ltd. 856—The Iron Age, June 1933 COST NITRIDING can determine the cost nitrid- ing? What the cost electrodes What should fuel cost annealing? These questions recently received will answered early issues. you have questions answers please address Forum Editor, Age Publishing Co., 239 West 39th New York. 124 Vibration Tests understand some extensive ex- perimental work being carried the field vibration tests steel Can you tell who doing this? far have not made sufficient progress our vibration tests rails warrant publication re- sults. When these results are avail- able they will released through the University Illinois, Engineering Experiment Station, and the joint Advisory Committee the rail manu- facturers and the American Railway Engineering Association. Prof. Moore. 125 Forging Furnace Trouble had trouble tempering small tools forging furnace until one day used this furnace burn insu- lation from copper wire. Now, appar- ently, some chemical reaction takes place prevent proper tempering. BELIEVE this trouble caused copper vapor which has col- lected the work form in- sulating film and prevent proper tempering. common practice copperplate certain surfaces steel parts order keep these surfaces soft during heat treatment which tempers the uncoated surfaces. sug- gest using quantity common salt the forging furnace combine with the copper high temperature and thus remove the difficulty. 126 Asbestos-Coated Sheets you know concern making asbestos coated sheets? are manufacturing product consisting steel core coated with special asphaltic compound, hot, over which bonded asbestos felt with the edges turned protect the side edge the sheet. After this the sheet corrugated and addi- tional protective weathering coat applied. American Steel Band Co. 127 Painting Steel Barrels would like some information the experience manufacturers painting welded steel barrels. Bartlett Snow Co. paint our steel barrels and drums revolving them the paint station while two operators spray them with spray guns. While rotating, the barrels are supported the outer edge that practically complete coverage secured. The barrels are automatically fed from the drying ovens the spraying sta- tion predetermined intervals. The two operators, each holding two guns, often cover with two even three colors with clear separation. Atlas Steel Barrel Co. Intensity Illumination illumination? want check the intensity illumination our plant. Spencer’s Sons, Inc. urement for describing the intens- factor based upon the candle power the source light and the dis- tance the surface plane from such source, and varies inversely with the square the distance. surface ft. away from source light candle power would have intensity illumination ft- candle power lamp ft. away from the surface. 129 Making Hollow Steel Balls hollow steel have noticed Iron Ace that someone makes such ball flash welding the joint between two hemispheres. Can you the company making the machinery that does the job? Doheny Stone Drill Co., Torrance, Cal. believe the manufacture hollow steel balls, mentioned the Doheny Stone Drill Co., can- not due the present patent situation. However, made the welding equipment for this par- ticular job. Federal Machine Welder Co. 7 ' 4 { 22 Co. els and the erators While rted ctically The from sta- The guns, three Co. dles ion Inc. meas- intens- power dis- from rersely source have from Titanium Gray Cast methods this work have been somewhat different from those apparently employed others who have published reports alloy cast iron. not claim experts the production high- test cast iron, even iron foundry practice. Not having foundry facili- ties our own, have been depend- ent various friends the industry for the actual production the speci- mens which have tested. most instances therefore have been obliged take kind iron which was actual use, and compare its properties with those the same iron treated with titanium with other alloys. While may have missed this policy the highest possible strength values obtainable with titan- ium, feel that something has been gained keeping the tests strict- practical basis, and drawing con- clusions only from comparative re- sults with titanium and other the same iron base. The titanium alloy used this work was made the following specifica- tion: Titanium per cent, sili- con per cent, aluminum less than per cent, carbon less than 0.5 per cent. typical analysis fol- lows: 17.7 per cent titanium, 20.3 per cent silicon, 60.6 per cent iron, 0.3 per cent aluminum, 0.2 per cent carbon, 0.1 per cent chromium, 0.1 per cent phosphorus, 0.07 per cent manganese. For use cast iron the titanium was generally crushed through screen. Possibly finer crushing might have been better. Preliminary Tests Our first report the effect this alloy gray cast iron came from large foundry wide reputation where lumps the alloy were placed the top small pot molten iron about 0.75 per cent silicon content, and stirred in. The solubility the alloy was reported satis- factory, and the addition was said make the iron hotter and more fluid. Test bars were cast dry sand. Iron with per cent the alloy was per cent stronger than untreated iron; the hardness was increased, the deflec- tion decreased, and the microstructure was greatly refined the titanium ad- dition. addition per cent fer- rotitanium iron containing per GEORGE COMSTOCK Metallurgist, Titanium Alloy Mfg. Co. cent silicon gave per cent increase strength. test was then made small local foundry see how the effect per cent ferrosilicon would compare with that the ferrotitanium. The alloys were crushed through screen, and placed the bottoms hot 50-lb. pots, before iron was poured in. The pots were stirred, and poured green sand molds make two test- bars in. round and in. long, which were tested transversely sup- ports apart. The breaking loads were determined with Olsen Uni- versal three-screw testing machine former years considerable taining per cent titanium and per cent carbon) was used cast iron, but comparative tests the treated and untreated iron seldom showed any difference strength. Eventually was rea- lized that this alloy was difficult- soluble cast iron ordinary foundry temperatures, most the alloy used these tests did not really enter the mol- ten iron. The work Piwowar- sky Germany seemed show that titanium, really incorpor- ated gray iron, would have certain definite beneficial effects, and when alloy lower fusion point and good solubility ten cast iron was developed, fur- ther experiments were with its use iron foundries. this and succeeding article, the author presents the results these tests. 100,000 Ib. capacity, but using 10,- 000-lb. poise. The beam was auto- matically balanced during the test. The deflections were read from stress-strain diagram plotted autographic mechanism the ma- chine, showing the movement the lower cross-head between the first ap- plication and the release the load the bar. The diameter the broken test-bar was measured the fracture, both upright (in the position tested) and crosswise horizon- tally, and the breaking load was then corrected, means these measure- ments, strength value for simi- lar bar exactly 1.25 in. diameter, using the known relation that the strength beam proportional, other things being equal, the width times the square the height. this way correct strength comparisons were obtained spite variations the sizes the bars. These meth- ods are explained detail because they were used for all the tests re- corded this paper with few ex- ceptions when bars were tested else- where. The results the tests described above were follows: Corrected Transverse Strength, tion, Lb. per cent Ferrosilicon 3080 0.12 per cent Ferrotitani- 590 0.12 per cent Ferrosilicon 700 0.10 per cent The pot which the last addition was made came from different cu- pola-tap from the others, that al- though the increase strength was per cent, the result not strictly comparable. The other values show quite definitely that the average strength was decreased ferrosili- con, but increased slightly the fer- rotitanium. Other tests made about the same way, treating the iron small ladles, gave similar results but were not en- tirely conclusive account some uncertainty regard the uniform distribution the alloy when added the small pots, the use too small number specimens rep- resent each kind iron. These re- sults are therefore reported only condensed form, Table All these test bars, and those discussed later this paper, were poured green sand. noticeable that the results shown Table are consistent that the titanium-treated iron was The Iron Age, June 1933—857 x 3 { ure you hinery > f can- j resent made oO. 4 a "eS Vv FIG. 4 FIG. 2 Fig. Untreated Showing Coarse Graphite. Fig. Same after Treatment with Per Cent Ferrotitanium. (Both show cross-sections square bars, about midway be- tween center and edge, from Foundry (see Table Unetched and magnified diameters.) stronger every instance than the untreated, although the case the 0.5 per cent addition and some the tests where per cent was used the improvement was gible. The maximum increase strength from the titanium treatment was from per cent, but this was not always with the per cent addition. Titanium Treated Specimens Show Finer Graphite Particles The structures most these specimens were examined with the microscope, and the graphite particles were found invariably finer the titanium-treated iron than the untreated. Figs. and illustrate this comparison, which was very defi- nite and consistent all through the work. Another feature the struc- tural comparisons that was nearly al- ways noticeable was greater propor- tion ferrite the titanium-treated iron, illustrated Figs. and This might expected known graphitizing tendency titan- ium, since increase graphite iron not definitely hyper- eutectoid structure must necessarily result the formation more fer- rite; but rather surprising that the microscopic study these speci- mens this effect titanium was shown increased prominence ferrite, and not graphite, the treated iron. The fineness the graphite the titanium-treated samples evidently made less conspicuous polished surface, even though there may have FIG. tively. Probably the effect these fine crystals the physical properties negligible, though there may connection between their abundance the iron and the refinement the size the graphite flakes. More Decisive Tests Using Large Ladles Advice from our foundry friends, based their practical experience with alloys cast iron, indicated that better results would obtained the ferrotitanium were added the iron large ladles, holding 500 more, instead 50-lb. ladles. Sev- eral trials were made therefore this way, and the results are given Table II. Test the iron was treated spreading the alloy over its surface when the ladle was partly full; the other tests the alloy was dropped gradually into the stream iron ~ > FIG. Fig. Untreated Iron, Showing Few Titanium Cyanonitride Crystals. Fig. Same after Treatment with Per Cent Ferrotitanium. (Both show cross-sections 1.2-in. round bars, about midway between center and edge, from Foundry (see Table 1). Unetched and magni- fied 500 diameters. The titanium cyanonitride crystals are bright angular spots darkly outlined.) been actually more the metal. While discussing the microstructure titanium-treated cast iron the pres- ence titanium cyano-nitride crystals should mentioned. These are very fine hard bright specks, usually angu- lar and darkly outlined polished section, and varying color from pale bluish gray red orange. They can found almost all cast iron, but are especially numerous when the titanium content the iron intentionally increased. Figs. and illustrate their appearance ordinary and titanium-treated TABLE TRANSVERSE STRENGTH GRAY IRON TREATED SMALL LADLES WITH FERROTITANIUM Average Transverse Strengths Pounds With Content Iron, Cent Cent Per Cent FeTi. FeTi. Foundry 2.5 2890 3330 Foundry 3270 3290 Foundry 2.4 2200 2300 Foundry 3940 4040 Foundry 2.0 3695 3900 Distance Per Test Between Cent Cent Bar Supports, FeTi. FeTi. Shape In. 3140 in. sq. 2390 257 1.2in.round 4290 1.25 in. round 3905 1.25 in. round 858—The Iron Age, June 1933 the spout, just left the cupola. The latter practice seemed preferable. Six seven bars each kind iron were made these tests, and the re- sults were averaged. The bars were made in. long, about 1.25 in, diameter, poured upright green sand, and tested supports in. apart, and this applies also all bars discussed later this paper. The method used determine the cor- rected transverse results was the same described above, but values ad- versely affected serious surface flaws were omitted from the aver- ages. Tensile tests were made bars machined 0.8 in. diameter, and threaded the ends fit spherical- seated grips that the stress would truly axial possible. re- sults were omitted from tensile test averages. Hardness tests were made cross-sections, about midway be- tween center and edge the bar cast, using mm. ball applied with 3000 kg. load for sec. These results indicate that, when the alloy was added large ladles, Ci n n F ~ | | | these erties nee size iends, that the iron Sev- was its full; after bars, agni- ned.) pola. able. iron re- were bars The cor- same ad- ‘face ‘ical- rould re- test nade be- with vhen dles, per cent addition was better than per cent. The smaller requirement the larger ladles was probably be- cause more thorough melting and mixing than the small ladles. The microstructures these samples were interesting connection with the re- sults obtained. Structures the pair irons Test are illustrated Figs. and where the differences form graphite and ferrite are well shown. the irons treated with per cent ferrotitanium there was even more ferrite than shown Fig. and especially the one Test the ferrite was excessive. This explains the failure show any improvement strength for the treated iron that test; the high-silicon iron from that foundry (Tests and having been made the same plant) per cent ferrotitanium was too much 2 FIG. TABLE TESTS CUPOLA-MELTED GRAY IRON TREATED LARGE LADLES WITH FERROTITANIUM Test Test Test Ferrotitanium added, per cent. none none none Titanium content, per cent.... 0.042 0.198 0.060 0.132 0.060 0.087 0.126 Silicon content, per cent....... 2.64 2.54 2.19 2.00 2.20 Graphite content, per cent..... 2.84 2.99 2.91 2.77 3.05 Transverse strength, 3,700 3,710 3,492 3,774 3,456 4,291 3,973 Tensile strength, per sq. in.. 27,200 34,200 30,500 166 163 170 192 179 cupola practice was such give higher total carbon and silicon con- tents the iron than were desired. An- other test was then made with better results, and the latter set bars treated with molybdenum was included since this alloying element has recent- attracted much attention cast iron. Results from both these tests are included Table III matter Fig. Untreated Fig. with Per Cent Ferrotitanium. (Typical structures near centers bars 1.25 in. diameter from Test (see Table Etched with picric acid and magnified 100 showing finer graphite and more ferrite the treated iron.) add, causing weakness from excessive ferrite formation which counteracted the strengthening from finer graphite. Figs. and are submitted show how the same differences micro- structure, finer graphite and more fer- rite, persisted even sections the iron used Test Counteracting Formation Ferrite The titanium treatment evidently had better effect the lower-silicon iron Test than the iron Tests and where ferrite was too much evidence. Since titanium had such definite tendency promote the formation ferrite, the idea arose combining with carbide-forming element, that they would assist each other strengthening the iron, but neutralize each other’s effects car- bide ferrite formation. Since chro- mium commonly used carbide- forming element iron, with nickel the graphitizing element correct the hardening chromium, was de- cided try titanium and chromium, comparison with nickel and chro- mium. The first test made with these al- loys was disappointing because the record, spite the inferior prop- erties the high-carbon and high- silicon irons. Transverse test values Table III are averages from about six determinations, the results from | - FIG. bars showing flaws being rejected. Tensile test values are averages five determinations, with rejections. The test procedure was the same has been described, except for the ma- chining tests which have not been mentioned before. The machinability, cutting-re- sistance, tests were made for Prof. Boston the University Michigan, using his new Tool Dynamometer. Determinations were made with shaper, lathe, and drill press broken halves trans- verse test bars, about in. diam- eter and in. long. The results were obtained dial readings, indi- cating the resistance the metal cutting under conditions that were kept uniform for all these tests. The values reported are therefore com- parative only. The shaper tests were made iron about 1/16 in. below the surfaces the bars strokes in. long per minute, with feed 0.013 in. per stroke; the lathe tests were made the bars, after their diameter had been reduced in., speed 28.5 ft. per min., with 0.01 in. depth cut; and the drilling tests were made with %-in. drill length- wise the centers the bars, speed 153 r.p.m. and 0.012-in. feed, both torque and thrust being deter- mined. The check lathe tests were made 0.1 in. nearer the centers the bars than the first tests. Tool-life tests were not attempted, the sam- ples available were too small. Samples from Test reported above, were the first used for machin- (Concluded Advertising Page 12) Fig. Untreated Fig. with Per Cent Ferrotitanium. (Typical structures castings in. thick, 9/16 in. from chilled edge, from Test (see Table Etched with picric acid and magnified 100 diameters, showing finer graphite and little more ferrite the treated iron.) The Iron Age, June 1933—859 FIG. FIG. Use Rolled Steel Machine Construction MARSH Carnegie Steel Company, Pittsburgh STRIKING change has come the modern machine shop. Seattered throughout are nu- merous lights; some are bluish, sput- tering ones great intensity with hooded, ghoulish figures attending them; others are bright yellow, throw- ing off times showers sparks. These lights mark new era machine construction, for two new fabricating processes have been in- troduced into this cutting and welding. These proc- esses have turn introduced new type construction and new mate- rial, rolled steel. Flame Cutting Basic Factor Flame cutting the oxy-acetylene some equivalent process far- reaching development the field machine construction and particu- larly responsible for the entrance rolled steel into this market. Before this process was perfected, the only method cutting steel was shearing machining. Shearing was limited thicknesses about in. where reasonably good edges were required and machining was very expensive. the contour was irregular, the cost machining was almost prohibitive. flame cutting practically all thicknesses metal can cut and with reasonable accuracy. For 2-in. plates the cutting tolerance can held plus minus 1/32 1/16 in. and for plates slabs 24-in. thick, plus minus 3/16 in. Practically all steels used ma- chine construction can flame cut without injury the physical quali- ties the metal, but the higher carbon steels they are preheated be- fore cutting and normalized after cut- ting. Automatic machines are available for straight and circular cutting and pantographs for irregular shapes. Almost all metals can welded. Low-carbon steel welded with lit- tle trouble, but approach the higher carbon ranges the difficul- ties increase. Alloy steels must considered from viewpoint the alloys involved, and while they can successfully welded, each presents problem its own. Cast steel 860—The Iron Age, June culty. ceding paragraph new material for machine construction was made with full knowledge that has been used some extent for this purpose for number years; but its use has been restricted the fact could not readily cut into irregu- lar shapes and the only methods fabricating were riveting and bolting. During this period its use was con- fined largely frames for conveyors and roller tables, cover plates and small parts rather minor impor- tance. Irregular shapes and parts complex construction required that the part cast. Development flame-cutting and welding now en- ables produce rolled steel practically any machine part regard- less its size and shape com- plexity. Knowledge Available Materials Necessary mechanical artist now has new medium and order obtain the best results must study thor- oughly, just any other artist must study new medium. means thor- ough grounding fundamentals and much practice simple problems be- fore the more complicated ones can mastered. Consultation with expert this line advised. The first difficulty encounters the lack limitations, rather the greater amount freedom and bility this new medium permits. The tendency weld, weld, weld! This costly and unnecessary and the de- signer will soon learn choose his material that will require mini- mum welding. many cases the best welded design the one with the least amount welding. Choice material utmost im- portance. There are available great number rolled sections and thor- ough knowledge them indispens- able. They include billets, slabs, plates, structural shapes various forms, bars all descriptions, pipe, forg- ings, steel castings specially rolled sections, which can all incor- porated into the design. There great difference the price per pound these products and many them can had various grades steel, with the wide choice ma- terials and their varying costs, be- sides the actual welding, not simple problem work out the most efficient and economical design for given job. Generally speaking, rolled sections are the most economical. Formed sec- tions come next, followed welded ones. Forgings are usually much higher cost than rolled steel per pound basis, but many cases they can used advantage. Special shapes are also high cost, but the job warrants, they are available, and sufficient tonnage involved, the roll cost can absorbed the steel manufacturer spe- cial arrangement. submitting inquiries the steel manufacturers for material for weld- construction important that sufficient information given. Sur- face requirements, flatness, size tol- erances and quality all enter into the question price, and the more that known about these things the more intelligently the inquiry can han- dled. Otherwise the manufacturer might quote highly finished plate rolled closely size and carefully flattened for part that ma- chined all over and could very well made from billet slab, which would naturally take very much lower price. Where the material important that full information given. complete, detailed drawing the part showing the proposed ma- chining desirable. While there great variety material available, the designer will well confine himself the few- est number shapes and sizes, some the published shapes are not always quickly available. The fewest number shapes and sizes should serve the greatest number uses. Designing for Welded Construction most important thing for the designer when first taking construction clear his mind the restrictions imposed upon design cast construction, such patterns, shrinkage, flow metal, etc., desirable the best results are 7 7 3 / , % 4 r ose his mini- ses the ith the im- great thor- ispens- plates, forms, forg- ecially incor- per any ma- be- not most for sec- velded much cases are age sorbed spe- steel weld- that Sur- tol- the that more han- plate efully ma- well which much ial also ma- will few- not hould tion the elded erns, obtained take full advantage the superior qualities rolled steel. Replacing cast iron cast steel with rolled steel, part for part, sec- tion for section, results nothing gainful. true something might saved weight but would prob- ably the expense stiffness. also likely such structure would cost more than the casting, due the excessive amount welding re- quired. The greatest objection, how- ever, that the design which may have been excellent one for cast construction carried out ma- terial which not suited, and all the advantages gained from the use the better material are lost. The best way start anew with careful analysis the function the machine and its component parts. The direction and magnitude the stresses involved should calculated closely possible, their relation each other studied, and then the best adapted sections should selected and combined the simplest possible wa