The Iron Age 1933-06-15: Vol 131 Iss 24

are for being Al- JUNE 15, 1933 have ESTABLISHED 1855 Vol. 131, No. their In- Con- situa- but smelt- the Castings Thrive Competition accordance with long established custom, this particular issue THE which published just prior the convention the American Foundrymen’s Associa- per The Review the Industry, which appears the pages immediately following, shows conclusively that the ancient and honorable art casting has actually gained through the experiences depression times. ship has gained because has responded competition; the dhere competition other materials. And responding the spur this competition, the art casting has made faster progress the past few years than made many previous decades. few years ago, for example, one who had forecast. heat treatable cast iron alloy steel castings with ultimate strengths approaching 80,000 150,000 per sq. in. re- spectively would indeed have been considered impractical dreamer. Today, these accomplishments, thanks the spur and competition, are taken-for-granted realities. these Competition will never relegate castings minor posi- tons tion the field metal-working materials. They are here stay. Occasionally they may have give ground for specific uses where newer materials are proven superior. But they continue develop new qualities rapidly they have during the past few years, they are likely find two new applications for use for every one that they wisely 933 i 7%. special , be- . WR ject | 7 ANY new uses for castings have been developed during the past year. The casting in- dustry, fact, whole may position the broad field machine construction than was 1930 1931. Champlain, general works manager Westinghouse Electric Mfg. Co., for example, reports prog- ress the foundry industry despite adverse commercial conditions. many cases, says, castings have demonstrated new ability com- pete with stampings and fabricated parts. The heat treatment iron castings, particularly those containing alloys, has been widely extended. Practically all Diesel engine castings, including cylinders, liners, cylinder heads and pistons, are now artificially aged thermal treatment. This usually falls within the temperature range 800 deg. Fahr. 1100 deg. Fahr. contrast, some foundry metallurgists have taken steps avoid the necessity ther- mal treatment. least one manufac- turer automobile cylinder blocks, and several machine tool builders, have added 1.5 per cent nickel their castings, reduce stresses and thus avoid the necessity arti- ficial aging. Molybdenum also has been employed some extent for this same purpose, For extremely high physical prop- erties more elaborate heat treatment now used the most progressive foundries. This includes quenching and drawing after the methods famil- iar with forgings and drawn steel. Many the new alloy castings have been developed especially for their heat treatable properties. marked increase the use electric furnaces and permanent molds for gray iron castings perhaps the most significant feature the past year. The use permanent mold casting machine the mass produc- tion cream separator parts de- scribed elsewhere this issue. Fully automatic pressure casting steels and alloy steels has been accomplished Morris, consulting engineer, Spring- field, Mass., and much other important progress this same direction has been made research laboratories and some commercial applications are imminent. One the outstanding advances the foundry industry during the last 934—The Iron Age, June 15, 1933 two three years has been closer adaptation castings and materials the specific use intended. Prior 1929 the fact that casting was stronger than needed for certain purpose was often ignored, engi- neers felt that this was error the right direction and that any addi- tional expense thus incurred would negligible. The close scrutiny de- tail engendered the depression has corrected this laxness with the re- sult that the selection materials and fabricating operations have been brought into close line with spe- cific needs. One detail interest this connection concerns the finish castings. Heretofore, requirements for mold surfaces were generally uniform. molder paid much attention one surface his mold did another. During the past year the practice specifying the various grades finish castings has ex- tended the molder, with appre- ciable saving his time. Thus casting which form interior part mechanism may allowed considerable leeway the finish surfaces which are not machined. Advance metallurgical technique has made possible give one part casting special quali- ties without affecting the remainder the casting and saving over the previous requirement high phys- ical values for the entire casting. example this the surface aluminizing gray iron make nitridable. The lower costs some raw mate- rials, particularly non-ferrous met- als, have brought changes commer- cial applications alloys, and the need for reduced production costs has caused many developments auxiliary equipment and materials. One inter- esting example the development emulsified core oil the DeLaval Separator Co., Poughkeepsie, using about half core oil and half water, both which are run through its centrifugal emulsifier, this com- pany produces binder for which many advantages are claimed over the original core oil, addition marked saving cost. Engineers are increasing both pres- sure and temperature castings limits hardly dreamed few years nique have reduced costs and im- proved quality many cases. Thus one foundryman reports dried molds are replacing dry sand molds and that castings fully sound with dry sand molds are produced this manner. Heat Treatable Gray lron Castings UTSTANDING entire foundry field the commercial production high strength iron which may designated treatable cast iron. This material fills long-felt want that inter- mediate between cast iron and steel. According Carl Morken, found- engineer the Detroit Electric Furnace Co., there are three general groups heat treatable cast irons commercially available today. The first group has yield point ap- proximately 45,000 per sq. in., ultimate tensile strength about 70,- 000 per sq. in. and elongation per cent. The second and third groups sacrifice ductility secure greater tensile strength. yield point about 50,000 tensile strength about 70,000 lb., together with elongation per cent, characterize the second group. the third group yield point 70,000 lb. and ulti- mate tensile strength 100,000 are attained with elongation about per cent. These irons are produced electric furnaces and commercial success depends primarily upon accurate control the composi- tion and thorough mixing during superheating. The heat treatment varies with other characteristics but general short cycle completed less than hr. consists some cases simple anneal. other cases the anneal combined with quench either oil air, and other cases the quench followed draw. Some foundries used alloys this type iron. Com- paratively small additions molyb- denum increase the strength from per cent per cent above that 4 — = — = = —S >, — the Depression over phys- casting. surface nake mate- met- ommer- the sts has inter- nent Laval half hrough com- which ver the pres- ngs years tech- Thus skin sand oduced marily mposi- during but ipleted some other vith ved molyb- hat ERMANENT molds for steel and alloy castings, fully au- tomatic die casting operations for gray iron, new heat treatable ferrous and ings: these are some the im- portant developments year the foundry industry. The following review gives brief description some the new materials and presents pertinent comment from many authorities. the unalloyed iron. Such alloy iron has excellent engineering properties including high fatigue resistance, good stress dampening, rigidity and shock resistance. Mr. Morken gives some the present applications this material gear housings, cam shafts, crank shafts, manhole covers, suspen- sion brackets, golf club heads and dif- ferential carriers. Uses Electric Furnace Iron “For nearly year have been producing our gray iron castings Schenectady from electric furnace iron,” states Sampson, foundry superintendent, General Electric Co. Mr. Sampson finds that due the low cost raw materials, including cast iron turnings and silicon sheet steel scrap, the cost the spout has compared favorably with cupola oper- ation. states further: “The prod- uct, for equal machinability, shows greater strength, for equal strength shows greater machinability. Many castings that formerly showed certain losses when made from cupola iron are now made with fewer rejections from electric furnace iron. experience closer control chemical analyses and physical properties. The electric furnace iron, for the same Brinell hardness, readily machined.” Cast iron has taken new life re- cently, according Walter Saun- ders, consulting chemist, Providence, I., who gives some the more im- portant developments heat treat- ing, simple annealing increase machinability and wider application through better understanding its advantages. The dampening effect vibration, together with increased strength, has led the successful production automobile crank shafts out heat treated gray iron castings. Another new application found the range oil burner, product de- veloped during the depression and now enjoying heavy sales rural districts because converts stand- ard coal wood range into oil stove. The principal parts the burner are thin gray iron castings fine grain structure. Mr. Saunders states that his experience has found that where strong iron de- manded, the purchaser usually able pay the cost alloying and still find economy the use iron casting. cites several cases where nitridable cast iron containing alumi- num has come into successful produc- tion during the year. Centrifugal Casting Progress Notable progress has been made during the past year the centrifu- gal casting cast iron. This has been due better temperature con- trol all the way from the cupola the storage yard. The installation from 10-ton 15-ton capacity fore- hearths into which the cupola con- stantly discharges has meant better and more even distribution the chemical constituents cast iron. Foundry Co., states: “Further im- proved and more closely controlled an- nealing temperatures made possible refinements furnace construc- tion have added their contribution and today all our tests show that are turning out not only more uni- form structure the pipe wall but also that have increased the im- pact resistance without reducing ten- sile bursting strength.” Larger centrifugal castings have been made and new appliances de- signed include special mechanical joints pipe sections. turer now centrifugally casting pipe in. diameter and ft. long. combination centrifugal casting with nitridable surface has been developed. The principle involved first pour into the revolving mold thin layer aluminum alloy. After this the molten iron poured and heavier the aluminum tends work back toward the center and thus penetrates the iron, producing excellent nitridable surface with core unalloyed gray iron. Gray Iron Sympesium symposium gray iron which will part the annual meeting the American Foundrymen’s Asso- ciation this month Chicago, will in- clude detailed description the in- fiuences the various alloying ele- ments. Thus small amounts man- ganese per cent are said have little effect iron, the sili- con content ample. Above per cent, manganese tends combine with the sulphur present, forming manganese sulphide and general beneficial deoxidizer and scav- enger. Nickel machinability, texture, hardness, den- sity and heat corrosion resisting properties. They often are used with other alloying elements such chromium molybdenum. Some typi- cal examples nickel cast iron are given Table Chromium increases heat resistance, hardness, and strength certain limits. essentially carbide for- mer contradistinction graphite forming elements such silicon and nickel. few examples chromium cast iron are shown Table The usual ratio nickel chromium for Commercial applications chromium cast irons are found where greater hardness and wear resistance are needed machinable iron. The practice annealing iron castings has widened greatly the The Age, June 15, 1933—935 : at | ¥ : 3 ‘ TABLE Nickel Cast Chemical Analysis Per Cent Per Casting Si. Mn. Ni. Charge 3.25 1.8 0.65 1.25 High strength iron.......... 2.75 0.80 1.00 240 Locomotive cylinders........ 3.00 1.1 0.85 1.25 200 Heavy machine tool beds.... 3.20 1.00 0.80 1.00 200 3.30 1.5 0.60 1.25 200 3.00 1.0 0.75 2.00 220 Automobile pistons.......... 3.40 0.65 1.00 180 Heavy crusher frame........ 2.75 1.75 0.80 2.00 230 3.00 1.00 0.80 1.25 220 *These typical examples should not used specifications. **Hardness bore. TABLE 2—Typical Applications Chromium Cast Per Cent Casting Total Carbon Silicon Chromium Grinding balle and liners........... Upto 2.0 3.0 Heat resistance castings: (a) For temperatures 1300 deg. (such fire pots and stove grates). upto 3.5 2.25 1.25 (b) For temperatures 1800 deg. F.... 2.5 2.50 *These compositions should not used for specifications. last year two, according iron order obtain increased tensile strength and promote duc- Coyle, International Nickel Co., tility. paper which presented this month before the Institute British Foundrymen. classifies the present annealing practice under four head- ings: Annealing gray iron for softness fa- cilitate machining. This 1400 deg. above. Where maximum machinability the sole factor, the addition alloying elements usu- ally detrimental they increase hard- ness. Annealing martensitic white iron facilitate machining. This done be- tween 1100 deg. and 1200 deg. te Annealing white alloy cast iron impart toughness and resistance im- pact. This done between 1600 deg. and 1700 deg. Partial malleabilizing alloy white Concerning heat hardness, Mr. Coyle says: “It pos- sible consistently obtain Brinell hardness above 500 with nickel and nickel-chromium irons suitable to- tal carbon and silicon content quenching oil from above the criti- cal range.” The use small additions nickel the general run iron castings has been extended. One manufacturer recommends adding 0.75 per cent 1.00 per cent nickel for light castings and 1.00 per cent 2.00 per cent nickel for heavy castings. New Alloy Castings Appear ERHAPS per cent the recent developments the foundry in- dustry has been the field alloy castings. The term “alloy” broad and used some engineers in- clude almost any casting containing nickel, molybdenum, chromium, similar metals. Here re- stricted ferrous castings having sufficiently high proportion alloying metals take them out the strict carbon steel classification. The manu- facturers Z-Metal classify that met- under alloy castings, but identify temper carbon steel. This particular metal one the most recent developments and although classified alloy steel cast- ing, originated the malleable in- dustry and produced manner somewhat similar that used with ordinary malleable castings. The com- position the white iron and the nature the annealing cycles are varied. The Industrial Furnace Corpn., 936—The Iron Age, June 15, 1933 Buffalo, licensor Z-Metals, states that this product has been accepted for use elevated temperature where resistance wear and abrasion are important requirements. has been used for gears, chains and sprockets, road machinery and automotive parts, also for pressure castings. This cor- poration withholding descriptive de- tails for release sometime July August. The Cooper Alloy Foundry Co., Elizabeth, J., reports improved melting practice connection with stainless steels which results new properties. This company claims more uniform distribution carbides, with increased corrosion resistance. the case 18-8 alloy castings, claims more austenitic metal than has been heretofore possible, and structure which retards carbide pre- cipitation. The Lebanon Steel Foundry, Leba- non, Pa., has developed new castings for the oil industry and, particular, alloy containing 4.50 per cent 6.50 per cent chromium, with approx- imately 0.50 per cent molybdenum. Castings this alloy are said have unusually high physical properties and low creep values high temper- atures. Parts for heavy duty oil pumps, high pressure valves, and for oil still fittings are being successfully made this chrome-molybdenum alloy. The company engineers state that their opinion the trend the present time toward the use chromium nickel even higher chromium-nickel alloys, rather than toward the straight chromium anal- yses. This they state because the higher ductility values, particular- where high stresses shock loads are encountered. Makes Cast Die Blocks The Mfg. Boston, successfully casting die blocks Invar type iron. The dies operate elevated temperatures and requirements are for iron low coefficient expansion well resistance corrosion. The anal- ysis total carbon 2.40 per cent, silicon 1.50 per cent, manganese 0.30 per cent, nickel 38.00 per cent, chro- mium 4.00 per cent, with sulphur and phosphorus low. The castings have tensile strength 30,000 lb. per sq. in. and Brinell hardness 140. bar 12-in. supports and loaded the center with 4200 Ib. showed deflection 0.250 in. new Monel metal heat treatable casting has been developed during the year. This has slightly altered chemical analysis with higher silicon content and better machining proper- ties. The manufacturers claim that can annealed for machining and then heat treated Brinell hard- ness 350 more. The metal cast has hardness about 300 and the annealed state down 250. Some the less expensive alloys containing per cent chromium have found many applications for heat and corrosion resistance. These are the low carbon variety usually containing less than per cent car- bon. One foundry now producing substantial tonnage beer fixtures this material, according Mr. Morken the Detroit Electric Fur- nace Co. Other foundries are using pprox- have perties emper- oil for ssfully denum state the higher than anal- use icular- shock die ‘atures ron well anal- cent, 0.30 chro- and have 140. and the silicon roper- that and hard- tal and 250. alloys for These car- xtures Mr. Fur- using PROGRESS similar material for general food con- tainers. New Ductile Alloy One Mid-west foundry has developed manganese nickel steel casting which when water-quenched develops some remarkable This alloy contains approximately 0.30 car- bon, 1.07 manganese,.0.32 silicon, and 0.85 nickel, and the average heats after water quenching gives yield cent, reduction area per cent, and Charpy impact rating per cent. Steel Foundry Activity ALUABLE experience was gained during the last twelve months the production low alloy steel castings, according Bull, di- rector, Electric Steel Founders’ Re- search Group. This caused better- ment melting and heat-treating procedures and vital shop practices that are distinct from furnace opera- tions. the other hand, the keen interest many consumers high alloy steels rolled and wrought form has been followed encourag- ing attention similar metals the part those who require castings. This has increased substantially the number foundries producing such materials, even though satisfactory casting manufacture, the case many alloy steels, calls for special shop technique, due problems fluidity, shrinkage, and temperature- susceptibility. committee the American Foun- drymen’s Assn. evolving for pres- entation steel casting makers, classification scheme based chemi- cal composition and intended elim- inate confusion among buyers. This The rapid development lower priced alloys important feature the past year the alloy castings field. addition this, many new high strength and high alloy steels have been developed. The Penn Steel Casting Co., Chester, Pa., has devel- oped new nickel-chrome-molybdenum steel for Government dredges. This material, with composition approx- imately follows: manganese 0.60 0.80, nickel 3.00 3.50, chromium 1.00 1.50, molybdenum 0.25 0.35, silicon 0.20 0.40, air hardening steel which will show Brinell hard- ness about 350, together with tensile strength close 150,000 per sq. in. The Chapman Valve Mfg. Co., Indian Orchard, Mass., has pro- duced new chrome-tungsten steel for special applications. The Union Steel Casting Co., Pittsburgh, reports manganese-vanadium steel with tensile strength 90,000 per sq. in. and elongation per cent. This heat treatable alloy. certainly step the right direc- tion. sectional committee the American Society for Testing Mate- rials recently developed set pur- chase requirements for eight grades alloy steel castings for structural purposes. anticipated that the testing society will adopt these speci- fications tentative its forthcom- ing meeting. such action taken, the result will physical test re- quirements that will indicate what may expected under many severe service conditions. The committee agreement already reached evidence progress, because required con- siderable experience enable foun- drymen determine what they could guarantee, when manufacturing the variety steels represented (by physical properties only) the speci- fications. Despite discouraging conditions output, the industry has advanced along general lines foundry prac- tice. Much this improvement has been necessitated economic factors, but the most efficient steel foundries have not permitted cost considerations retard progress respect quality. Clean Steel for Strength “We find that the steel castings in- dustry has achieved appreciably higher physical properties during the year, independent the new alloys,” states McKee, production man- ager, Strong Steel Foundry Co., Buf- falo. “This means extremely clean steel, accurate analyses, close heat control, and better heat treatment.” Doerr, Scullin Steel Co., St. Louis, reviewing situation among steel foundries, says: “From quality standpoint, many steel foun- dries have benefited the depression because during the days high-speed production they could not give proper attention experimental work and study details leading improved quality. think that many the factors entering into the successful production steel castings have been more thoroughly investigated during the last year two than during any time the past.” The increase manganese and sili- con content steel castings has re- ceived wide consideration. Where large heats are poured, and many castings, imperative that the manganese and silicon high the beginning, otherwise the tendency the latter part the heat will for the castings have blow holes the manganese and silicon oxidize. Better Castings Produced Under Present-Day Conditions Ballard, the General Elec- tric Co., says: think safe state that the average steel foundry today position produce cast- ings both carbon and alloy steels with decidedly higher physical prop- erties than ever before.” This has been made possible the study various metals and their effect ad- ditions and more intensive appli- cation heat treatment castings. Today heat treating steel castings quite general any up-to-date foundry. Better application mold- ing sands different classes work progress. The fact that unique design for unusual product may escape the effect the depression shown the experience the Chicago Steel Foundry Co. its production cast steel screw for use both do- and industrial stokers. David Evans, president this company, states: “For the first four months 1933 the increase demand for this product was almost 100 per cent over the same period 1932, and during the first week May this year The Iron Age, June 15, 1933—937 qe ; produced more cast steel screws than produced during the entire month May 1932. have success- emerges from the depression with better reputation for uniformity and soundness castings than ever before, according Enrique Touceda, consulting engineer the Malleable Iron Research Institute, Cleveland. The substitution malleable for com- petitive products has increased dur- ing the past year, states, and adds that engineers have turned mal- leable some cases because such cast- ings complicated design stand under severe abuse service. other cases they seek the excellent machin- ing properties malleable iron. number technical societies have sponsored the classification and designation surface qualities malleable iron and recently some en- gineering society committees have suggested stepping standard speci- fications covering malleable castings and expected that this recom- mendation will approved the meeting the societies this month. The need for such action clearly shown from the fact that with mem- bership plants the Malleable Iron Research Institute, qualified under the higher specification and these plants could have qualified under still more severe specification, according Dr. Touceda. The trend the malleable industry toward the use electrically heated anneal- ovens and shorter annealing eycles. Many foundries are regularly operating two anneal heats per Alloy additions malleable cast- have been disappointing many cases. However, small addition molybdenum successfully used some plants increase both ultimate strength and yield point. Some experimenters have carried through tests mixtures abnor- mally high silicon and low carbon but the results are not available although stated general suc- cessful. The past year the malleable field has seen the development higher physical properties and lower costs. The lower costs have been achieved part shortening the annealing and this turn has been ac- complished using better control temperature and annealing higher temperatures. Some malleable 938—The Iron Age, June 15, 1933 fully adapted this same type cast- ing for use screw conveyors the cement industry.” Seek Higher Malleable Specifications foundrymen have altered the composi- tion the white iron with consider- able success. One metallurgist reports that composition with lower carbon and increased manganese makes possible anneal considerably higher temperatures. Experimental work with the so-called shock anneal has been carried several inves- tigators with The cycle this case consists essen- tially one more quenches high temperature during the anneal. Some the new castings are known semi-malleable and have high tensile strength elongation. These irons usually run lower total but higher silicon than malleable irons and are more amenable quick graphitiza- tion. New Aluminum Alloys LTHOUGH the fields applica- tion are far from explored, 1932 developments brought aluminum alloy castings place among engineer- ing materials, even more important than heretofore. particular inter- est the high purity aluminum-mag- nesium group. new per cent mag- nesium alloy, because its corrosion and tarnish resistance, machinability, and mechanical properties, proving satisfactory for dairy equipment and other food handling appliances. new per cent magnesium alloy the heat treated condition, possesses greater strength and impact resist- ance than any other cast aluminum alloy with which are familiar. The mechanical properties are such permit satisfactory substitution for cast steel with maximum weight saving. promising use for this alloy railroad car construction for truck frames, bolsters, and car body parts. Heat treated aluminum-silicon al- loys, although developed prior 1932, have come into considerably more commercial importance during the past year. They have general better corrosion resistance and cast- ing properties well lower specific gravity, than have the older alumi- num-copper alloys. per cent sili- con alloy with controlled amounts copper and magnesium, possesses satisfactory properties for water- cooled cylinder heads for aircraft and automotive engines, and new uses for this alloy are developing the in- dustrial internal combustion engine field, particularly for crank cases, water jackets, and manifolds. per cent silicon alloy the heat treated condition, addition possessing mechanical properties com- parable with those some heat treat- aluminum-copper alloys, also pos- sesses certain advantageous casting characteristics suitable for the pro- duction intricate pressure tight castings. Automotive and Diesel en- gine crank cases, pneumatic tool and air compressor parts, engine bases, valves, and fittings are few the uses this alloy. For automotive pistons the use per cent silicon alloy with con- trolled amounts magnesium and nickel, has grown steadily. Because the lower coefficient expansion and combination other physical and mechanical properties desired for pistons, this alloy during the past year has replaced some the older aluminum-copper alloys, the case several automotive engines. New Applications Cast Aluminum Certain the newer applications aluminum from intensive experimental develop- ment are worthy note. Diesel en- gine parts different aluminum al- loys are proving highly satisfactory. What believe the largest heat treated aluminum casting made date was completed during the past year. Diesel engine crank case and block weighing 7500 The advantages the T-slot design pis- ton have become more generally rec- ognized and this design cast alumi- num alloys has been adopted number automotive, truck, and marine engine builders. Aluminum cylinder heads for automotive engines, permitting compression ratio, lower fuel consumption, and greater horse-power per motor have also been adopted standard equip- ment number automobile builders. Recent large-scale examples the architectural use case aluminum al- loys various colors finishes will found the Empire State Building New York, finished early 1932, and the more recent Rock- efeller Center development, also New York. \ ly nh j ind car con al- rior derably during general cast- specific alumi- ent sili- unts water- aft and ises for engine cases, the ition com- treat- pos- casting pro- 2sel en- ool and bases, the use con- and Because pansion for past older case tions levelop- en- al- factory. heat date year. ase and The pis- lly and yression and have equip- omobile the num al- finishes State early Rock- also This Sales ANY changes have occurred industry during the de- pression, but none more far- reaching effect than the foundry trade. Long accepted methods producing iron have given way new processes because technological advances and shifting markets. The foundryman who was content sit back and watch his company things they were done years ago has discovered his business slowly vanishing. Unless elected something save the situation, his cause was lost. This precisely the situation which recently confronted the Ryan Foundry Co., Ecorse, Mich. Having turer automotive cylinder castings and other automotive parts, this com- pany found that the trend events the automobile industry was under- mining the foundation its business. Motor car makers were equipping their own foundries handle the class work which for years had been done outside suppliers. This develop- ment alone meant that the company was cut off from substantial share business which formerly had enjoyed. Here then was foundry with specialized equipment, but use for it. After making survey con- ditions, the management decided that two courses were open—to re-equip the foundry for the extremely eco- nomical production all classes gray iron work install system for making superior product sold premium. Adoption the first course meant severe competition price basis for the relatively small volume existing business. The latter course, embracing new conception selling castings and new manufacturing processes, was given the preference. “Custom Made” Iron Two electric rocking furnaces, one capacity and the other capacity, were installed, and chemical and metallographic labora- tory set up. The problem selling castings was approached from new angle, that making the best product obtainable for those willing pay for it. This involved manufacture custom-made iron fit the particu- lar job. Instead turning out one grade and kind iron, perhaps two, became necessary make many grades and employ many types alloys. Special consideration had given each order that the castings delivered customers would nearly possible ideal for the purpose intended. Today the company has number grades iron, each which can modified suit special require- ment, take care the needs its customers. These grades are approxi- mately follows: cupola cylinder HEN the market for auto- motive cylinder castings be- gan disappear, the Ryan Foundry Co., Ecorse, Mich., in- stalled electric furnaces, set chemical and_ laboratory and started sell castings meet specified pur- pose rather than ring door bells soliciting gray iron orders. Among its many products today electric furnace iron with tensile strength 100,000 and elon- gation per cent. Through use the electric furnace and development practices, has reduced the an- nealing time for malleable cast- ings hr. iron, per cent steel addition for medium heavy work, per cent steel addition for heavy work and heavy round stock, soft iron for light work, pot iron for tool and die pots, mal- leable white iron heat-treated, hard iron resist wear and abrasion, and high chrome iron for rustless appli- cations. Particular attention has been given heat and corrosion resisting cast- ings, especially equipment for handling molten metal. For instance melting pots for aluminum are being made showing over twice the life pots cast from ordinary cupola iron. These pots are high-carbon, low- silicon gray iron with dense grain structure. For the production cor- rosion-resisting castings metal per cent alloys. thoroughly homogeneous casting secured result melting the alloys with the charge instead adding them the ladle. Tensile Strengths From 55,000 100,000 high-strength, heat-treated iron with tensile strength about 100,000 and elongation per cent being made the electric fur- naces. Low carbon, this iron heat treated secure structure. The tensile strength most malleable castings about 55,000 lb. with elongation per cent. Somewhere between these two limits 55,000 100,000 Ib. tensile strength and per cent elongation analysis which will fit most malleable jobs. this analysis, varying with the individual order, which the Ryan foundry meeting. The long-accepted annealing cycle for malleable castings seven days. Through the use the electric fur- nace and the development new melting practices this has been re- duced hr. other words, there are several factors which affect the length and effectiveness the an- nealing process. One the melting temperature, which around 2950 deg. the electric furnace; another the control the carbon and sili- con within 0.05 per cent; third the absence impurities due the electric melting process, the sulphur and phosphorus being held unusually low. With the annealing cycle cut about one-eighth its former time, now possible deliver malleable castings the third morning after order received. far the range annealing temperatures concerned, the cycle approximately the same before. The chief differ- ence that the cycle has been short- ened, although each part the cycle the same proportion the others was previously. the anneal- ing time shortened, greater strength secured the casting. Apart from the technical accom- plishments the Ryan foundry, its expanding its business recent months due large measure (Concluded Advertising Page 14) The Iron Age, June 15, 1933—939 ° 4 var | | i j + 4 Permanent Molds Manufacturing principal parts the con- struction modern DeLaval cream separator grained gray iron castings which are made electrically melted iron cast permanent molds. This done foundry which perhaps unique that was originally designed for permanent mold casting. large ro- tating Holley casting machine used shops than can used for production the regular castings and addition the contract for electric power calls for minimum kilowatt consumption above that required for present found- operation. Therefore advantage taken slack periods produce pig iron for storage for future use. The pigs are the exact analysis required that they may melted without Fig. Continuous and near-automatic production cream separator castings accomplished this rotary casting machine. for most the parts and the chief production unit. Several stationary types permanent mold machines take care large castings and spe- cial work and one small section the foundry equipped with sand mold- ing machines but that the nature auxiliary. feature the design the plant its flexibility which, combined with high unit capacity, permits low inven- tories. Under stress the production speed high that even with active demand almost complete cream separators need kept stock. present, with somewhat re- duced demand, the company unusual job. using its Detroit electric furnace make its own pig out the scrap which develops other departments the plant. This done for two reasons. More produced the machine Iron Age, June 15, 1933 additions when they are used. The analysis the cost the pig iron thus made (not including power charge) gives value about $17 per ton. This includes charge for elec- trodes and about $4.50 for ferro-alloys, principally ferro-silicon, ferro-man- ganese and ferro-phosphorus. Under normal conditions the electric furnace operated continuously throughout the day, receiving charge about 500 every min. When part the work produced sand molds the general scheme pour permanent molds the morning and sand molds the afternoon thus giving the molders time build supply sand molds. Large bull ladles carried overhead trolley system are transported desired any part the foundry. Actual pouring most cases from small ladles filled from the bull ladles. Permanent Molds Used interesting example mass pro- duction methods applied the foundry provided the rotary machine like large horizontal wheel carrying near its rim per- manent molds each arranged for auto- matic closing, ejecting and cleaning. The sequence something follows: the first stage one man does all the pouring, being supplied with iron small ladles assistant. The motion the wheel series 1/12 turns which bring each mold succes- sively into each the stages. After pouring, the molds remain closed for short interval permit freezing the metal. has been found important Fig. Two parts cast iron permanent mold, together with the two sides the casting which produces. — { i j ring The iron power per elec- -alloys, charge When sand pour and supply carried are part most from pro- the rotary this per- auto- ollows: it. The 1/12 succes- sed for zing the first foundries designed and built permanent mold foundry now operation producing gray iron castings for cream separators for The DeLaval Separator Co., Poughkeepsie, The ac- companying some its features, with par- ticular reference the use permanent molds. open the molds the earliest pos- sible point and this point varies with different types castings the opening mechanism each mold separately controlled cams. most cases the molds are opened after trav- eling quarter the distance around the circle. Immediately after opening, ejector pins the castings out the molds and steel chute which carries them through opening the floor the annealing and clean- ing departments below. Soon after the castings have been ejected, the molds which remain open position en- counter series air blasts. These impinge upon all surfaces and are sufficient strength thoroughly clean the molds. After cleaning, the molds pass so-called smoke stage. Here series carbonizing acetylene jets coats all surfaces with layer lampblack. After leaving the smoke stage the molds remain open for short space permit the placing cores, case cores are required, and also facilitate inspection. Just be- fore they return the pouring stage ream Separator Parts the molds are closed air pressure and are kept closed against the pres- sure the hot metal toggle joint device. Eliminate Strains Naturally with such semi-auto- matic operation many difficulties were first encountered and these was problem more for me- chanic than foundryman although both arts must hand hand HERBERT SIMONDS permanent mold work. One the chief difficulties was the sticking hot castings the gates, preventing ejection. This was overcome re- designing the gates. Another difficulty was found with the air cooling sys- tem. The molds the time pouring are cooled strong air blast which passes through series cooling pins the back the molds. Such blast impinging equally all parts tends chill the thin sections the Fig. stationary type permanent mold casting machine. Many the features such opening the mold and ejection the casting are automatic. Fig. the cleaning department the permanent mold foundry. casting first, causing serious strains. This difficulty was overcome intro- ducing baffle plates designed for each casting, modify the blast and thus equalize the cooling effect the heavy and thin sections. this way not only were strains eliminated castings but also the molds and was found that the use proper baffle plates frequently would double the life the permanent mold. Molds Are Cast Iron These molds are made special analysis cast iron and are machined machine. Considerable care exer- cised the design the mold itself. Patterns are first made the usual way and, from these, castings sand are made and examined before the The Iron Age, June Comparison graphite permanent mold castings and sand cast iron. Magnification all cases 100. PERMANENT MOLD CASTINGS SAND CAST IRON y ~ “ . in. section annealed 1400 deg. 942—The Iron Age, June 15, 1933 final permanent molds are made. Im- mediately back the surface each mold forest cooling fingers pro- vided. These are about in. high, 5/8 in. diameter, and are spaced with centers about 3/4 in. apart. most castings ejection possible with one ejection pin which extends through the mold about the center. The life mold averages 10,000 impressions and complicated work this means that the cost the mold ap- preciable item the molds cost from $250 $400 each. Sometimes in- tricate castings even the most care- ful designing does not produce suc- cessful mold and after trial production certain changes have made such increasing clearances, altering gates changing the location ejection pins. direct comparison the cost sand molding and permanent molding has been made because the many difficulties involved. necessary course have conditions otherwise approximately equal for strict com- parison. Thus continuous rotating sand molding and casting machine would required for comparison with the present permanent mold machine. The company uses permanent molds both for economy and quality. With conditions otherwise the the grain structure finer when metal cast iron molds. The same analysis iron produces different structure electric furnace from that pro- duced cupola and also the same electrically melted iron structure depending upon whether poured into sand mold into iron mold. These differences are micrographs. Annealing After dropping from the casting machine the castings slide down inclined steel chute point con- venient for loading continuous pusher type annealing furnace. Under normal conditions the castings enter this furnace still red hot thus utiliz- ing the initial melting heat help the annealing operation. The anneal- ing cycle about follows: Trays with castings enter the furnace 10- min. intervals and remain the pre- liminary heating section hr., then hr. high heat 1500 deg. Fahr. and finally hr. slow cooling. The trays are nichrome alloy castings ft. long in. wide and hold from castings. After annealing, the castings follow through the usual cluding the use electric and oxy- acetylene welding for repair. Usually the gates are broken off while the castings are still hot. New Core Binder The operation the rotary casting machine developed need for core which could easily removed from the finished casting, would not stick driers and the same time would in. section cast in. section cast Lo Al 44° 4 Zp. in. section annealed 1400 deg. le. Im- each pro- 5/8 with most one the life means ap- from in- care- suc- easing ‘ost olding many ary com- tating achine with chine. molds With the etal alysis icture pro- same her into are con- nuous enter utiliz- elp ineal- Trays 10- pre- then Fahr. oling. stings from aling, usual in- the sting from stick vould use. After considerable investigation new core binder was found which not only met these conditions but also lowered core costs. Strangely enough, this binder emulsion core oil and water, produced centrifugal Recovers UST from sand blasts being ex- hausted the cleaning room the Cleveland foundry the Alumi- num Co. America dust collec- tion system new type designed the Dust Recovering Conveying Co., Cleveland. The system used for exhausting the dust from one double and two single sand blast units. While the method collection dust, which with the use fabric filter bags, similar that employed dust collecting equipment previously built this company and including large dust recovery system used the Ford Motor Co. connection with its tumbling barrels, the system pro- vided for the Aluminum plant designed and simplified that the cost the equipment has been brought down figure where claimed economical installation for use cleaning room moderate sized foundry. addition takes much less floor space than would required with the use cleaning equipment the design heretofore made this company. The volume air drawn through this system 20,000 cu. ft. per min., which sufficient not only carry away the dust from the sand blast but the circulation provided assures the cleanliness the air the cleaning room. The system arranged that adding additional piping, clean air that now discharged into the at- mosphere after the dust removed may returned the cleaning room, emulsifier which one the com- pany’s regular products. This binder, owing the smaller amount oil used, generates less gas both the baking the core and its use later the casting. also makes pos- sible bake the cores lower temperature and shorter time than when regular core binders are used. Cores made from this emulsion are said have hard outer surface with interior which soft and easily knocked out the finished casting. Core Sand From Sand Blast thus cold weather restoring warm air and reducing the heating expense. the dust recovery systems this general type previously installed sev- eral dust filters were cylindrical metal compartments housings, each compartment provided with pneumatically operated mechan- ism for cleaning the bags vibra- tion. Several these compartments made unit, the number depending the cleaning capacity required. All the filter bags are inclosed one sheet metal housing with overall dimensions ft. ft. the in- stallation the Aluminum company’s foundry. There are 360 filter bags ft. long, in. diameter the bottom and in. the top. Each bag hung around cover the top and clamped place. The bottom clamped around collar the bottom plate. Forty bags are hung frame and there are nine these frames. Each frame supported eccentric mounted shaft. Air drawn through the system through 34-in. line Number Clarage fan driven 50-hp. motor located the roof adjoining building. This intake line connects the bottom the filter housing. Air drawn over the top three hop- pers into which the coarse particles dust are precipitated and the fine dust carried the current into the filter bags. the air drawn through these bags the dust deposited the interior the bags. The clean air passes into manifold the side the housing and from that through 34-in. pipe connected the exhaust fan. The filter bags are cleaned all once the end 8-hr. period vertical vibration which effected actuating the eccentrics from which the frames are suspended. This done motor with manually operated switch which drives the ec- centric shaft. The fine dust which shaken from the inside the filter bags passes down the hoppers be- neath. takes only seconds clean the filter bags. Three aisles are provided the compartment that the bags may reached for repairs replacement. Access the aisles from three doors the side the compartment. Tests the system measured the water gage show that, the ac- cumulation dust the filters per cent reduction the draft from the beginning the end the 8-hr. operation. other words, 19,000 cu. ft. air per min. are being drawn through the system the end the 8-hours’ use. Much all the sand reclaimed for use the core room. The coarse sand, comprising about per cent the total, usually re- moved before the fine dust shaken from the filters. However, times when great deal work being done the core room and the ing department not very busy, both the coarse and fine material are re- claimed for core room use. Cement-Coated Sheets CEMENT-COATED for building purposes that has evolved for the Robertson Co., “Protected Metals Fellowship,” estab- lished with the Mellon Institute, Pitts- burgh. According the annual re- port the director the institute, Dr. Weidlein, the material, Robertson Protected Metal,” consists core asphalt and asbestos pro- tected steel that enveloped with cement possessing novel properties. three colors—red, green and buff. The Iron Age, June 15, 1933—943 j 2 Cupola Charging Made asy Nash Motors Foundry IVE men have replaced work- the job charging cu- polas the Nash Motors Co’s. foundry, Kenosha, Wis. From car un- loading the discharge drop-bot- tom buckets the cupolas there practically manual labor except puiling materials from sloping bins into the charging buckets. The general layout consists two No. cupolas and two No. cupo- las. These stand parallel the north wall, about midway the length the foundry and about ft. from the wall. ft. ft. scuttle open the charging floor which extends from the cupolas the north wall the building. Operating above the charging floor electric crane ROGERS FISKE which especially equipped handle the charging buckets. Each bucket consists cylin- drical steel shell fitted with trunnions. The bottom cone shaped casting from which extends upward rod with e