The Iron Age 1933-08-31: Vol 132 Iss 9

ngs hon tion iced er: le Pa. undef THE IRON August 31, 1933 Editor Consulting Editor Managing Editor News Editor Machinery Editor F. J. WInTERS G. EHRNSTROM BURNHAM FINNEY FRAZAR Pittsburgh Detroit Boston F. L. Prentiss R. A. Fiske A. I. FINDLEY L. W. Morretr R. G. McIntros# Cleveland Chicago Editor Emeritus Washington Cincinnati CONTENTS New Fields for Steel Open-Hearth Furnace Design Welded Steel Diesel Engines OUR PART Corrosion Effects Upon Bearing Surfaces Late Developments Germany Personals and Construction and Equipment Buying Products Advertised THE IRON AGE PUBLISHING COMPANY F. J. FRANK, President G. H. GRIFFITHS, Secretary Cc. 8. BAUR, General Advertising Manager PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th New York, Y., Member, Audit Bureau of Circulations ADVERTISING STAFF Member, Associated Business Papers Emerson Findley, 311 Union Bldg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo, N. Y. H. K. Hottenstein, 802 Otis Bldg., Chicago Published every Thursday. Subscription Price: Peirce Lewis, 7338 Woodward Ave., Detroit United States and Possessions, Mexico, Cuba, $6.00; Charles Lundberg, 45 Kent Rd., Upper Darby, Canada, $8.50, including Foreign, $12.00 Del. Co., Pa. year. Single Copy 25 Cents C. H. Ober, 239 West 39th St., New York W. B. Robinson, 428 Park Bldg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address, Warren, Box 81, Hartford, Conn. SEVENTY-NINTH YEAR SERVICE THE METAL WORKING INDUSTRY ‘ > 12 _ 2 : 7 | A till 7 ps oe 7 ‘ee | | = 7 AUGUST 31, 1933 the coupon and send for sample Bethanized Wire. See you can fracture the coating cause flake. Don’t waste time the usual test bending the wire around its diameter. This test all for Bethanized Wire. Bend the wire flat itself, examine under magnifying lass. The chances are strong that 5 y our ideas what can can- not done with zinc-coated wire will undergo complete revision. But even this doesn’t tell the whole story about Bethanized Wire. The Bethanized coating the purest zinc ever manufactured commercially and remarkably uniform Further, Bethanizing permits coatings two and even three times the maxi- mum thickness possible with older processes. These factors make for unusually high ance, opening the door many cases the use Bethanized Wire replace expensive alloys. you are now using wire, expensive alloy, re- sist corrosion, suggest that you WIRE review your requirements with eye the properties Bethanized Wire. Bethlehem Steel Company, General Offices: Bethlehem, Pa. STEEL Bethlehem, Pa. Send sample Bethanized Wire for testing. COMPANY ADDRESS | | | THE Page hay dist tion | | | | | } mak | worl NAME dues | | | am nized Pa. ..THE IRON AGE.. AUGUST 31, 1933 ESTABLISHED 1855 Vol. 132, No. Smoothing the Path NRA HEN the organized labor lobby tated the terms famous Section NIRA, they placed serious obstacle the path the recovery movement. successive industries have traveled the road codification they have bumped against this with damaging results. Section had not been dragged into the recovery act, industry would probably have been completely codified this time and should not have had the serious and disturbing labor discontent which this tion has fostered. But Section the act and must dealt with. being dealt with, the chagrin and discomfort the professional trouble makers, who hoped stampede American workmen into one hundred per cent union dues-paying body through misinterpretation Presidential intent. ENERAL JOHNSON has made clear that there are two sides Section although our labor-ridden legislators were careful express only one them the terms the act. one, now, need misled into the be- that must become “union card man” order gain higher wages and shorter hours under the recovery act, that the paying dues any group will aid him one iota toward these ends. ambitious and independent workman need now stampeded into hasty ad- herence any particular organized group sponsored professional agitators; longer need interpret representation synonymous with accepting leadership from outside his own ranks. ANY weeks ago predicted the troubles that the NRA would experi- ence because Section and its political use. Now that the Administration hew- ing path around this obstacle, predict smoother going for codes and rougher going for labor opportunists. SES 7 x | 4 gi ‘ : | — - a bonanza outlets today are likely the declining outlets tomorrow. Sales execu- tives the metal-working indus- try, elsewhere, cannot afford overlook the law diminishing returns which tends bend their customers’ volume curves into the well recognized shape that spells look and listen.” Steel executives, says Mr. Murphy, can steer clear the curve effect their own business they will recognize that their customers and diligently cul- tivate new fields for tomorrow’s sales harvest. “See The Age, Feb. 1933, 225—Industry Must Recognize Law Diminishing Returns. one the best ways develop steel business. fact the his- tory steel runs parallel with the rise new industries. The markets not only for steel but for any product are constant state flux. The bonanza outlets today are likely the declining outlets tomorrow. The manufacturer who does not always keep searching for new markets will find his sales limited proportion the recession his original markets. see just how this principle oper- ates let consider the history single company. The founder this concern was Connecticut farmer. His farm had little value for agri- cultural purposes. Its principal asset was stream which cut diagonally. The owner decided dam the stream, but did not know what with the power that thus harnessed. took trip New York City, hoping find something that could manu- facture. the big city saw that hoopskirts were all the rage. learned that these skirts were sup- ported wire framework. bought few sample frames and began experimenting with their pro- duction when got his farm. discovered that could make them and, what was more important, that could sell all could produce. This erstwhile farmer did pros- perous business for several years. Then the wheel fashion turned and all that was left the hoopskirt was 8—The Iron Age, August 31, 1933 its page history. The manufacturer had find something else make back farming. Fortunately about that time the all-metal clock was being developed Connecticut. The developer asked the former frame- maker try his hand fabricating clock springs. did, thus launched himself spring manu- facturer. From that day this, the record the growth the company started nothing more than re- cital the organization’s entry into one spring-using industry after an- other. Since scores industries use springs, the company’s rise has kept pace with the expansion the spring- buying industries. During this period, the concern has sold springs hundreds industries. Many these industries have entirely disappeared. Others have declined until their importance market only fraction what once was. Still others are comparatively new in- dustries, whose value markets for springs, still the ascendancy. Success From Selling New Industries This manufacturer owes his success, then, his skill selling new in- dustries. had been content let well enough alone and confine his selling the industries from which had receiving business, the chances are would have been out the running long ago. His current markets would eventually have drop- ped out from under him. was only keeping his fences constantly re- paired that was able maintain his business prosperous condition. Thus did preserve his own company from market-obsolescence, but what just important, from our viewpoint least, provided ever-widening outlet for steel. Every new industry that added his list customers increased steel consumption just that much. That, course, the scientific way build business. The successful manufacturer always striking out for new markets. The producer that makes industrial product does this cultivating new industries. knows that will need these new out- lets before long for some the old ones are likely dry up. has learned from experience that the new markets today will the bread- and-butter markets tomorrow. realizes that the profitable markets the moment are likely the de- clining markets the future. The biggest markets for steel re- cent years were the construction field, automobiles, cans, railroads, and the oil, gas and water industries. Most these are comparatively new indus- tries. One the largest them, the automotive, did not exist all the turn the present century. The amazing rise the canning business has taken place largely since The long-distance piping oil and gas another development the last decade two. these industries had not come into existence steel peo- ple had not been quick adapt their products the needs these flourish- ing infants, how different would have been the recent history the steel business. Every market that steel mills are today selling was one time new industry. hundred years ago, the beginning the century being cele- brated Chicago this summer, the railroad business was brand new. that time there were few who were imaginative enough predict that one day would larger user iron than all the uses combined that existed late 1873, railroading was still new industry, may per- mitted call “industry,” for the sake present argument. The mileage that had been laid that time was insignificant. The country was the midst the worst sion that had harassed our life that time. number 7 «% > 7 ( = \ ; / < d re- field, the ost indus- the the The siness 1900. and last had their urish- have steel are new the cele- the were one f iron was per- ‘or the The that lepres- ynomic ber capitalists got together and decided that needed more railroads and longer railroads. great rail boom started. broke the depression the 70’s and gave the steel business the largest outlet had yet known. Business Since 1742 From its inception this country more than two hundred years ago, the iron business has progressed con- stantly finding new places sell. Fortunately there one company the steel trades whose own history comprehends almost the entire history the steel industry. This the Taylor-Wharton Iron and Steel Com- pany, High Bridge, con- cern was founded 1742, which makes not only the oldest organiza- tion the steel line but also the second oldest business enterprise the North American Continent. antedated only the Hudson Bay Company. taking bird’s-eye view Taylor-Wharton’s history can get graphic idea the part played new industries the rise steel. High Bridge was selected for the location this business for two rea- sons. the first place ore deposits were available locally, timber for char- coal was abundant and there was plenty water power. The second reason, however, more significant. that time the manufacture iron the Colonies was forbidden the English Government. High Bridge was isolated spot those days. Iron could made there compara- JOHN ALLEN MURPHY Basford Co. tive safety. The ban iron making was lifted 1753, but that time the Taylor organization was really operating bootleg business. During the first couple decades, this pioneer concern made wagon tires, nails, crude farming implements, oxen yoke, and shoes for oxen, horses and mules. fact until 1840, during the first century its existence, there was very little industrial development this country. The iron made this period consisted mostly what was used farming, logging, hunting, trapping, the home and warfare. When the Revolutionary war broke out, cannons and cannon balls were manufactured for the Colonists High Bridge. That was probably the first industry” market the young company founded. one market that has maintained itself, though ir- regularly, ever since, for Taylor- Wharton has made cannon balls shells for every war the United States has been in. The Revolutionary war contributed the success the concern an- other respect. After the battle Trenton, quite number the Hes- sian soldiers the British army de- serted. Many them found work the High Bridge iron works. These men were skilled iron workers, having been trained the iron foundries Hesse Cassel. Their thoroughness, ex- perience and high craftsmanship did much exalt the position their em- ployer the industry. The introduction the steam rail- road gave Taylor-Wharton another “new industry” market—the largest had yet founded. The company’s first railroad products were chiefly for the rolling stock, such coupling links and pins, axles and wheels. started with the chilled-iron wheel and later took also the steel-tired wheel, specializing what was known the fused welded wheel. This was wheel with steel tire and cast iron center, welded together that the wheel was really solid and one piece with bolts rings. Later this principle one-piece construction was carried out the development the rolled steel wheel, which throughout and which superseded the wheel two materials. Harvest Impressed with its success the railroad field, the concern began ac- tively look for new industries for which could make steel products. this way discovered that mines were promising outlet. 1892 the company began the manufacture alloy steels. this connection soon learned valuable lesson about marketing new indus- tries. figured that could greatly improve its railroad car wheels making them manganese steel. This plan proved disappointment, how- ever, manganese was not satis- factory material for this purpose. The same idea, with the thought constantly mind reaching out for new mar- kets, was tried street car wheels and mine car wheels. Again failure was met, except where the cars were given severe service, anthracite mining. The concern was soon awarded, however, for its persistency seeking new places sell. The very material that would not car wheels, turned out more than suitable for the track work which those wheels ran, particularly the frogs, switches and crossovers both steam and electric railways. Thus did Tay- lor-Wharton enter the next stage its development. And this way, one one, the company tackled industry after industry until reached the wide diversity its production which exists today. All Big Buyers Were Once Little Ones course, for long time this meth- winning markets cultivating new industries has been practiced the steel dusiness, and recent years quite extensively. Strange say, however, this philosophy market de- velopment not generally accepted one would suppose. Too often all the selling emphasis placed get- ting tonnage business, with the result that new industries are frequently neglected. forgotten that the large tonnage buyers the present = ay / =~ —— : 4 is The Age, August 31, 1933—9 were once new industries, and their orders were comparatively small. The heavy purchasers few years hence are likely today’s unim- portant small industries. But even after the value new in- dustries outlet for steel ac- cepted, there still much done before such business can obtained. mistake steel men make going after new industry orders ap- proaching these new prospects they would approach old customers. The old customer knows the function the fabrication his produc- tion. The new buyer, the other hand, may not possess any such knowl- edge. does not necessarily have any expert information about steel. fact may convinced that other materials are better for his purpose. may have used other materials the experimental work the creation the product. may have but little experience actual production and not familiar with the difficulties will encounter regular run-of-fac- tory work. sell this man steel, therefore, essential not only show him how use steel, but also convince him why better for his needs than any other material. get business from new industry much educational work has undertaken the outset. For year two the selling campaign may con- sist entirely educational effort. Dur- ing this period ordinary salesmen should not call the prospect. The missionary work this stage the drive should the hands metal- lurgists, production specialists, engineers who are trained help new businesses with their peculiar prob- lems “scientists overalls,” one steel company calls them. All elements the prospect’s market should recognized this campaign. Architects, designers, consulting engi- neers, technical advisers and any one else that has anything with the making the product should cov- ered the educational Above all the owners the new busi- ness should not overlooked. the last analysis they who will decide which material they can “afford” use. Other things being nearly equal, the material that the most thor- oughly sold all buying factors the new industry, the material that most likely used. One the steel companies, three four years ago, cultivating new industry, learned the importance these various buying factors. was trying sell rustless steel one the large food industries. This in- dustry was using big quantities various metals and other materials its packing plants, but very little rustless steel was being used. The superintendents and mechanical technicians, who did the actual buy- ing, were sold this special steel. They requisitioned frequently, but for some reason their orders were not approved the higher-up-executives. 10—The Iron August 31, 1933 Age, Just what the objection was not even the plant superintendents could find out. inquiry was conducted un- earth the source the trouble. was soon discovered that the Big Boys felt that the price stainless had not yet stabilized and that any substantial investment equipment made it, would have written down drast- ically short time. course was easy convince these executives that their fears were groundless. The ‘point is, however, that that time the steel company had contact with these executives. was figured that they were too far removed from the actual buying equipment have any voice deter- mining what material should pur- chased. When contact was established with them, and selling message de- livered them systematically, the steel company began get business. Competition With Other Materials selling new industries, will usually found that the competition other materials the chief obstacle that has overcome. For ex- ample, the building business, far new market. took the structural steel fabricators several years find out how get their just proportion the building market. lot orders that belonged the steel trade were going the cement folks. one time was figured that this out- side competition was displacing close million tons structural steel annually—that business that properly should have gone steel. Cement has its place building and important place, too, but was getting more than its share. The rea- son was the intelligent activity the Portland Cement Association. The cement men were doing better selling job than the steel men. That was all there was it. Once the American Institute Steel Construction got busy, this sit- uation began change. The splendid selling campaign that the Institute waged for ten years furnishes with almost ideal program for market- ing new industries. Essentially the plan operations that followed get the story structural steel the 101 factors that influence are likely influence the selection ma- terials any building job. get orders from new industries, necessary keep continuously advertising message some sort. This should gen- eral coverage appeal, reaching all in- dustries that should using this way, interest will aroused new industry that could not reached economically any other way. Once the prospect has thus been isolated, simple mat- ter concentrate the entire selling barrage the prospect. steel mill digs one worth-while new in- dustry every two three years, will justify all the effort that may have been used discover it. Discusses Failures Engine Exhaust Valves AILURES exhaust valves in- ternal combustion engines were the subject paper contributed the recent meeting the (British) Iron and Steel Institute Hodgson, Preston, England. Breakages are con- sidered the result corrosion- fatigue, the hot gases taking the place the usual corroding media. There are also failures that are classed burning and cracking, the edges the valves; these are be- lieved caused initially small leakages hot gases. The author’s observations apply all types steel used for the purpose, including nickel- chromium sten steels. the matter burning, the author the opinion that trouble for which the steel has often been held responsible due mainly other causes. The best steels far devel- oped, says, are incapable meet- ing the demands, which are difficult satisfy. meet the requirements ideal valve, combining resistance the seat burning, high strength and scale resistance the neck and the best wearing conditions from the stem and tip, would require, sug- gests, three-piece construction two-piece construction surface heardening. that these methods would considerably in- crease the cost part already high priced, assuming that the manufact- uring difficulties were overcome. For rail ingots, where soaking pits are not available, bottom pouring sets five six ingots preferable top pouring, according article Spetzler, Stahl und Eisen June steel making and rolling the Krupp- Rheinhausen works. The steel should teemed about 1390 deg. and the initial rolling tempera- ture should not less than 1160 deg. ss 0 a St a 4 —— 0 q the the Iron rson, con- sion- the edia. are be- hor’s steel uthor . for held other level- meet- nents tance ength and the ective that ly in- high ufact- pits ing erable article sen ing The 1390 npera- deg. HARRY WILLIAMS natural gas industry has devel- oped many new gas fields which have greatly increased the available supply natural gas. the same time, the expansion distribution facilities making natural gas avail- able ever increasing number steel plants for industrial purposes. fact, natural gas now available such quantities that can used fuel the open-hearth furnace with the assurance that sufficient supply available. the past few years, the Natural gas has been used open-hearth fuel the Pittsburgh district for many years. Consequently, its application not uncertain ex- periment, for experience has shown that ideal open-hearth fuel. fact, natural gas has many desir- able features that cannot secured with any other open-hearth fuel. The advantages cover all phases open- hearth work, for example: Construction costs can reduced. Maintenance costs can reduced. Combustion can improved. Quality steel can improved. Each these above advantages will this article, while sub- articles will take the fea- ture open-hearth construction and design that must given attention all the advantages natural gas fir- Reduced Construction Costs the construction open- hearth plant, there are many parts that can eliminated and other parts that can simplified, the plant designed for the use natural gas the fuel. This simplified construction results reducing the cost the installation. pen-Hearth Furnaces with Natural Gas Firing WILLIAMS Industrial Gas Engineer Equitable Gas Co., Pittsburgh First, consider the furnace alone. The port construction when the furnace designed for na- tural gas. The best design port for natural gas firing consists single port and single uptake, with the gas entrained through the sides the port. While, the other hand, the usual design for producer gas mixed blast furnace and coke oven gas firing, three-uptake design with water cooled gas port set inside the that natural gas has been made available many steel- making centers, thanks the great systems pipe lines that have been built distribute from the oil fields, special study natural gas fired open-hearth prac- tice timely. The present article makes strong case for the natural gas application and will followed four others, particularizing design and operating matters, such the gas ports, regenerators, combustion control and furnace insulation. The author, Harry Williams, has been with the Equitable Gas Co., Pittsburgh, industrial gas engineer since 1931, specializing steel mill applications natu- ral gas. After graduating from the Carnegie Institute Technology, and prior his present connection, served the open-hearth de- partment and later assistant plant engineer with the American Steel Foundries. air port. The usual arrangement for oil tar also three uptakes. furnace designed for natural gas re- quires only one regenerator each end the furnace, while all regen- erated fuels require two regenerators each end the furnace, and much more intricate reversing valve arrangement. All these items tend reduce the construction costs when natural gas used the fuel. Now, consider the auxiliary equip- ment. the elimination the auxiliary equipment required handle other fuels that the greatest saving the fuel, only necessary lay gas line from the furnaces the meter house. But other fuels are used, the auxiliary equipment required handle the fuel often costs much the furnaces. For example, oil tar used the fuel, neces- sary install storage tanks, pumps, insulated pipe lines for oil and steam, heating coils, strainers, steam boiler plant, and atomizing burners utilizing steam compressed air for atomiza- tion. producer gas used the fuel, necessary install com- plete gas producer plant including coal storage bins, coal handling equip- ment, gas producers, steam boiler plant, ash removal equipment, pipe lines, etc. Consequently, the cost building open-hearth plant for nat- ural gas much less than for other fuels. Reduced Maintenance Costs The large item the maintenance open-hearth furnace is, course, the brickwork. The number heats per campaign, when repairs were made, and other information re- garding maintenance brickwork The Iron Age, August 31, are isly age { j nat- steel j r . q several natural gas-fired furnaces, follows: 10-ton acid furnace, 10-to-12-ton heats heats the furnace campaign, usually repairs roof, back wall, ports during entire cam- paign. Front wall repaired about every 250 heats. Checkers are not touched throughout the entire cam- paign. 30-ton basic furnace About 300 heats the campaign using natural gas the fuel, and 260 heats the campaign the same furnace using fuel oil. Usual- natural gas, while the ports required repairing every heats, when the furnace was oil. 35-ton acid furnace, 40-to-60-ton heats 700 heats the campaign with only minor repairs the ports, front wall, and roof. 75-ton basic furnace 300 heats the campaign. Repair front wall and port ends after about 150 heats. repairs are required the other parts the furnace during the entire campaign. The long furnace campaigns and low maintenance costs the above furnaces prove that the cost main- taining the brickwork natural gas-fired furnace lower than furnaces fired other fuels. Another feature natural gas that reduces maintenance costs its free- dom from dust and dirt. The regener- ators none the above furnaces were cleaned out blown down throughout the entire furnace cam- paigns, while the checkers furnaces using other fuels, such producer gas, are cleaned out blowing down the dust every week-end. The fact that natural gas requires auxiliary equipment for storage handling the fuel also greatly reduces the maintenance costs, because the maintenance complete fuel oil in- stallations, gas producers, and steam plants, quite extensive. Improved Combustion Experience has shown that very satisfactory open-hearth flame can produced from natural gas and pre- heated air alone. The proper port design for natural gas firing produces slow mixing the gas and air, which results long, highly lumin- ous flame. The luminosity the flame produced the free carbon heated incandescence the flame, out contact with the air. The free carbon results from cracking part the gas. The principal constituents natural gas are methane and ethane The cracking re- actions are follows: Thus, highly luminous open-hearth flame produced burning natural gas alone, and with this type flame heats fast any other fuel. 12—The Iron Age, August 31, 1933 The speed which furnace will turn out heats, using certain fuel, very important factor regarding the choice fuel. fact, cutting down the time heats one the ways effecting the greatest reduc- tion the cost producing steel. idea the average time heats for few natural gas-fired furnaces, follows: Charge Tap. Hr. 15-ton heats, acid... (45 per cent pig iron in charge) All the above furnaces were charged with scrap and cold pig iron. The above figures are not suggested the ultimate that can accom- plished with natural gas firing, but merely every-day results group furnaces. Most open-hearth men will agree that the above figures represent good time for turning out heats and this material submitted refute the erroneous impression held many open-hearth men that natural gas not fast fuel. Another desirable feature nat- ural gas open-hearth fuel its constant composition and high calo- rific value. This constant composition insures uniformity operation and quality. tpical analysis Pitts- burgh natural gas follows: Analysis Pittsburgh Natural Gas Methane, per 80.7 Nitrogen, per 0.5 Carbon None Gross heating value per cu. ft. deg. and 29.92 in. Net heating value per cu. ft. deg. and 29.92 in. 1047 Finally, one the most desirable features natural gas fuel for the open-hearth its adaptability combustion control. There dis- tinct trend the present time toward the installation combustion control the open-hearth furnace. Combus- tion control, along with other improve- ments, involves proportioning the fuel and air flow measurements. The flow natural gas can accurately and easily measured installing orifice meter the line. However, this not true with other open-hearth fuels. Producer gas cannot meas- ured directly because the tar, soot and dust that accompany the gas. Fuel oil and tar cannot accurately measured because the pressure drop across orifice varies with the fuel well with the rate flow. mixed fuels are used, such blast furnace gas tar, coke oven gas and oil, the proportioning fuel and air still more difficult and Consequently, natural gas the only open-hearth fuel that adaptable accurate combustion control. Improved Quality Steel very important feature natural gas open-hearth fuel its abso- lute freedom from sulphur. The re- moval sulphur from the bath steel the basic furnace very un- certain, and the acid furnace, im- possible. follows, that the only way keep the sulphur content steel within the specified limit have the sulphur content the charge below that limit, and use fuel free that fuels carrying compounds sul- phur may responsible for portion the sulphur content steel. The sulphur content fuel oil varies from 0.4 1.2 per cent while coal tar con- tains 0.75 per cent sulphur. Producer gas and coke oven gas contain sulphur varying amounts. fact, these fuels may add much 0.015 per cent the sulphur content steel. Blast furnace gas also contains.a trace sulphur. The amount sulphur present these fuels depends the sulphur content the coal. Thus, natural gas the only open-hearth fuel that does not increase the sulphur content the steel, since stated above, the only open-hearth fuel free sulphur. Another advantage natural gas open-hearth fuel the reduced amount final additions that are essary finish heat steel. This fact has been proved the experience open-hearth men the operation furnaces converted from fuel oil natural gas. few the materials referred above final additions are ferromanganese, ferrosilicon, chromium, and ferrovanadium. fo: pr ter the the su £0 0 gi ar ferromanganese added the fur- nace there about per cent loss due the oxidizing action the slag. When this material added the ladle, the loss per cent. Ferrosilicon always added the ladle making basic steel, with acid steel, ferrosilicon may added the furnace well the ladle. Ferrochromium always added the furnace; the loss about per cent. Ferrovanadium always added the ladle; the loss about per cent. The above losses, due the oxidiz- ing action the slag, are less furnaces fired natural gas than they are furnaces fired other fuels, provided the initial slag produc- ing materials are the same. The re- duction loss final additions that can effected changing natural gas firing, depends present operat- ing conditions, but should range from sharp oxidizing flame, character- istic oil, tar and mixed fuels, will cause the slag more oxidizing, while soft, luminous natural gas flame will tend have reducing ef- fect the slag. The less oxidizing the slag the time tapping, the less will the loss the final addi- tions. Natural gas has several other fea- tures that help maintain high qual- ity product. They are the tendency natural gas flame prevent the over-heating and over-oxidation steel. These features are very im- portant the manufacture all grades steel, whether they alloy, high carbon, low However, these advantages natural gas are particularly important the production low carbon “rimmed” heats. There has been decided trend plants during recent years, toward the production rim- med instead killed heats. This due the following advantages rimmed steel: Produces better finish all types hot cold rolled materials. Requires less deoxidizers. Contains minimum non-metallic inclusions the outer case the ingot. There are two factors responsible for most the defective rimmed produced that must receive careful at- tention. They are: Too high pouring temperature. Over-oxidized steel. the pouring temperature too high, the rimming action will slow, the ingot will “grow” the mould and the gas holes will too close the surface, producing thin-skinned in- got. Therefore, important that rimmed steel poured the right temperature. The danger over- 75-ton basic natural-gas fired open-hearth furnace the time the tapping the heat heating steel minimized when nat- ural gas used the fuel, because the temperature much more ac- curately controlled than with other fuels. Over-oxidized steel caused too much iron oxide, FeO, solution the steel. course, all rimmed steel must have certain amount FeO solution order produce the rimming action. The FeO content the teemed steel depends the resid- ual FeO content the steel the furnace and the amount deoxidizer added the ladle. The ladle addi- tions can controlled but the residual FeO content the steel the bath varies from heat heat. However, when natural gas used the fuel, the FeO content the bath can controlled more closely than when other fuels are used, because the best natural gas-fired open-hearth flame not sharp oxidizing flame but rather highly luminous neutral flame. For this reason steel produceed nat- ural gas-fired furnace not likely become over-oxidized steel pro- duced other fuels. Since natural gas flame helps prevent over-heating and over-oxidiza- tion, which are the two troublesome factors the production rimmed steel, follows that natural gas should ideal fuel for the open- hearth producing rimmed tual practice has shown this the for large steel plant the Pittsburgh district, using natural gas its open-hearth fuel, has been very successful the production rim- med steel and seemingly has had less difficulty than plants using other fuels. summary the advantages natural gas, fuel for the open- hearth furnace, follows: Reduced construction costs Simplified furnace construction. Elimination auxiliary fuel han- dling and fuel storage equipment. Reduced maintenance costs Longer furnace campaign. Longer life brickwork. from dust fuel. auxiliary equipment. Improved combustion Luminous flame. Fast working furnace. Constant composition. High calorific value. Adaptable accurate combustion control. Low fuel consumption. Improved quality steel Absolute freedom from sulphur fuel. Reduced weight final additions. Reduced tendency over-heat steel. Reduced tendency over-oxidize steel. changed from other fuels natural gas very easily and slight expense. However, there are some features open-hearth design that are peculiar natural gas firing, and order secure the best furnace results, such lowest fuel consumption and short- est time heats, essential that these features given careful con- sideration. They are follows: Ports; Regenerative chambers; Combustion control equipment; Insulation. The first these features will discussed the following article this series. The Iron Age, August 31, 1933—13 ural bso- re- im- way steel have free sul- rtion The from con- phur these per steel. trace Thus, earth stated fuel This rience oil terials When a ONSTRUCTION the crankcase and other parts 1000-hp. twin-six engine outlined this section Mr. Chapman’s paper, continued from page THE IRON AGE Aug. 24. This welded crankcase, built alloy steel, has weight about 2.6 per hp., and the entire engine weighs less than per hp., running the test block. Calculated from the indica- tor card, each weld this structure said subjected impact load 38,000 occurring times each second. Another application welded-steel construction the crankcase cylinder, 600-hp. radial aircraft engine, this crankcase weighing less than have crankcase the same gen- eral type those shown Figs. and [page the Aug. is- sue], except that the engine two cycle and slight modifications were made the case take care this feature. These engines form part the exhibit the Winton Engine Corpn., Cleveland, the Century Progress Exposition Chicago, and have been continuous operation since the opening the fair, supply- ing power and light the entire Gen- eral Motors Building there. This in- stallation, including generator and sub-base, has specific weight ratio lb. per hp. The specific weight ratio the engine itself lb. per hp. two Diesels pictured Fig. Fig. 8—Main frame section cut out for model test engine. 14—The Iron Age, August 31, 1933 Ib. per hp. eliminate still more weight steel crankcases, the construction case which the gas and inertia loads were carried entirely the welded structure was initiated. With the tie-rod type construction, much material not working effectively, especially the-tie rods are not set properly. completely welded unit, better distribution the stresses can achieved because the monolithic construction. experimental gle-cylinder frame was built, embody- ing main frame flame-cut from plate steel 2-in. thick. This model was subjected strain gage tests determine the efficacy the con- ception. Fig. shows the main frame cut out for the model test engine, and Fig. shows the built-up single Fig. 9—Built-up single-cylinder unit model test engine. Welded Steel Used for cylinder unit. The main frame was joined welding the top deck, into which the cylinder head studs were tapped. This frame showed satis- factory deflection and acteristics. effective method determining points maximum stress three dimensional structure paint with varnish having low modulus elasticity and low yield point. When static load applied the structure, the varnish cracks the point maximum stress while the structure only lightly loaded. The varnish method shows points max- imum stress with single application load, and the load which the varnish cracks correlates wealth information about stress factors and fatigue performance. needless say that the varnish will first crack those points where experience dic- tates large radius. will crack the contours improper weld. will crack the root undercut. Construct 1000-Hp. Twin-Six Engine Based upon this experiment, con- struction was undertaken 1000- hp. twin-six engine, which the en- tire gas load was carried the welds. Fig. shows the type flame-cut main frame which was used. This frame transmits the gas load one bank cylinders past the gas load the other bank cylinders, and into the main bearings. The minimum weight design one which the material loaded straight tension. The flexibility flame-cut steel plate meeting this ideal condition well illustrated the frame member Fig. 10. The stub ends the frame could not run through the top deck because the stagger the con- necting rods produced 3-in. offset each cylinder with respect the cylinder the other bank, which ne- cessitated the use transition Since the transition joint had peculiar shape, more experimental work was done determine ef- ficient design for the joint before proceeding with the engine. Fig. shows the result tensile test the experimental joint. were inserted the notched plate and welded strictly accordance with the photoelastic studies. The experimental joint simulated the condition the engine where the joint carries im- pact load 19,000 lb. The joint shown fractured outside the weld, through the plate, load ‘ Vice-president, Lukenweld, Inc., Division Lukens Steel Co., Coatesville, Pa. the engine each side. The gas load each cylinder then carried through the butt weld the top deck, and through the two transition joints the main bearings. the condi- tion shown Fig. 12, each weld, in- cluding the transition joints, was discover any imperfections, unfused joints porosity that might have existed. The crankcase thoroughly inspected for undercuts and surface discontinuities. the construction two these crank- cases, was not necessary chip and reweld any the joints. Fig. shows further stage the progress the crankcase. The inner Fig. 7—These Diesels, welded steel construction, have supplied power and the light for the entire General Motors Buildings since the opening the Century Progress Exposition. They form part the exhibit the Winton Engine Corpn. side plates and stiffening ribs have 000 lb. Tensile tests such joints varnish are very instructive. ne Welded Joints Radiographed n- Fig. shows the crankcase partly finished. The top deck was welded the transition plate with single butt weld running the entire length Fig. 11—Result tensile test experimental joint made simulate the condition the engine where the joint carries impact load 19,000 The joint fractured outside the Fig. 12—Diesel crankcase partly finished. this condition each 12,- Fig. flame-cut main frame used con- weld, including the transition joints were radiographed discover struction 1000-hp. twin-six engine. unfused joints, porosity other imperfections. The Iron Age, August 31, x Fig. 13—Further stage progress the crankcase. The inner deck place and the side plates and stiffening ribs have been added. been added. The hand holes provid- ing access the connecting rod caps and the hand holes for inspecting the piston rings have been flanged the side plate itself. welded steel con- struction, there tendency use thin sections because the strength guard against unsupported areas any magnitude thin material when the mechanism one which may set such areas resonant vibration. The flued hand holes stiffen the thin plates admirably against this phenomenon. Fig. shows the main bearing caps and oil pan. The main bearing gird- ers are flame-cut from 4-in. steel plate. The oil pan was constructed shown provide tie for the bot- tom legs the main frame members. Fig. shows the completed crank- case left the weld shop; this Fig. 15—Completed Diesel crankcase left the weld shop. mounted the oi! pan show the manner which the pan forms the bottom tie for the complete case. 16—The Iron Age, August 31, 1933 view the crankcase mounted the oil pan illustrate the manner which the oil pan forms the bottom tie for the complete case. Built the high strength, welding quality alloy steel, this crankcase has weight about 2.6 lb. per hp. The entire engine weighs less than lb. per hp. running the test block. from the indicator card, each weld this structure jected impact load 38,000 times each second. Refer- ring Fig. [page the Aug. issue] the recently completed 300- hr. full-load run indicates that the frame has been subjected num- ber cycles stress far beyond that necessary establish the fact that the stress concentrations which un- doubtedly exist the frame are not large enough raise the average stress above the endurance limit for the alloy steel from which the frame made, The performance this welded steel crankcase offers conclusive proof Fig. bearing caps and oil pan. The main bearing girders are flame-cut from 4-in. steel plate. that welded joints can designed and constructed commercially handle, high stress, the most se- vere type load encountered mod- ern mechanical practice—that re- peated impact. Welded for 600-hp. Radial Engine Another application welded steel construction Diesel crankcases shown Fig. 16. crankcase for 10-cylinder 600-hp. radial en- gine, and constructed welded steel, using the base metal the same high-strength alloy steel em- ployed the twin-six engine. All- weld metal specimens deposited with the alloy electrode used fabricate this case and the twin-six case have yield point 65,000 lb. per sq. ultimate strength 95,000 lb. per pe J su 4 4 \ 7 Wwe 7 welded-steel con- struction have been opera- tion marine service for two years, and stationary service since the opening the Century Progress Exposition Chicago. the railroad field, the 110-mile hour streamlined passenger train the Union Pacific will powered welded steel engine, and also the high-speed train be- ing built for the Chicago, Burling- ton and Quincy. in. Here again the main loads are carried weld and only necessary pay strict attention all the design details insure that such case will exhibit satisfactory performance. Steel castings were used form the periphery the cam pocket. The contours around the push-rod guide bushing and the bolts tying the two halves the engine together were sufficiently intricate dictate the use steel casting. The parts were cast units one per cylinder and the entire casting assembly welded into one ring, which and machined before welding into the rest the assembly. ap- plication such this, essential that the carbon content steel cast- ings maintained below 0.20 per cent and that the castings the finest grade obtainable. For use welded steel assemblies, electric fur- nace castings are highly desirable be- cause the close control over both pouring temperature and analysis. The small amount dissolved gases present offers favorable welding char- acteristics. The weight the radial engine less than per hp. Welded steel crankcases the types discussed enable the engine builder offer the user mobile prime movers light-weight, highly efficient and powerful unit, embodying all the ad- vantages the Diesel principle. The Winton Engine Corpn., Cleveland, with which has been privilege work this development, can offer today engine-generator unit sup- plying 750 kw. electrical energy which, including all auxiliaries, will weigh lb. per hp. Railroad vision has enabled immediate application this notable prime mover main line service. Under construction to- day welded steel engine structure which will used the power unit the Union Pacific System’s 110- mile per hour high-speed passenger train. The Chicago, Burlington Westinghouse Laboratories Study Gas Absorption During Welding sorption during welding has vital effect upon the finished weld, the Research Laboratories the Westinghouse Electric Mfg. Co., East Pittsburgh, has constructed the special welding hood illustrated, which the atmosphere may con- trolled for the study gas absorp- tion. this hood weld pads can under any atmosphere. The the amount gas ab- chemical and gas analysis the de- posited metal gives indication the interaction between gases and metals. welding temperatures the solu- bility metals for gases generally increased. After the metal cools, some the previously dissolved gases are given off and cause blow-holes. Other gases are not liberated, but remain solution; these affect con- tn tr RRANGEMENT the special weld- ing hood for studying gas absorp- tion during welding shown view below, preparation weld specimen pictured view left. — P Fig. 16—Welded stee! crankcase for 10-cylinder 600-hp. radial engine. Steel castings were used form the periphery the cam pocket. Quincy’s high-speed passenger train will have, its motive power, 600- hp. Diesel engine welded steel. Some progressive railroad undoubt- edly will take the next step and em- ploy two three these units single chassis for main line freight movement economy never before approached. siderably the properties the weld material. stated that with high-grade coated electrodes the oxygen content near the very low but the nitro- gen content over per cent. How- ever, the nitrogen absorption the deposited metal smaller with the higher nitrogen contents the atmos- phere. With the use the welding hood this strange phenomenon lower nitrogen absorption at- mosphere per cent nitrogen compared with the nitrogen absorp- tion air said have been con- firmed. This result emphasized important the welding industry because discloses some the mechanism absorption weld metal. shows, stated, that molecular nitrogen hardly dissoci- ated iron-arc temperatures. must assumed, therefore, that ni- trogen absorbed the weld metal the form active nitrogen- oxygen compound. Single gases mixtures gases can admitted the hood. gases are employed which might give explosive mixture, spark-plug test made the gas mixture before starting weld. the pressure in- side the hood increased too much result the heat developed the the flow gas can in- creased. The hood connected vacuum pump retain pressure. The Iron Age, August 31, 1933—17 . 2 | é | a ned re- machines are used process powdered raw material into pills. The powder poured operator into hopper, which feeds into oscillating shoe. The shoe passes over the opening the lower die, filling the cavity with powder. The shoe then moves out place and the top punch compresses the powder the necessary hardness. its adolescent period, the molded plastics industry has suf- fered relatively little from the depression. that stage its growth where new applications are being discovered almost daily and where its markets are expanding rapid rate. The reason for this sturdy growth the uncommon attributes which plastic molded products possess. They have smooth, lustrous and perma- nent finish not affected organic They are shatter-proof and chip- proof, li