The Iron Age 1933-09-07: Vol 132 Iss 10

THE IRON AGE September 1933 J. H. VAN DEVENTER G. L. LACHER W. W. MACON T. H. GERKEN R. E. MILLER Editor Managing Editor Consulting Editor News Machinery Editor Pittsburgh Detroit Boston Cleveland Chicago Editor Washington Cincinnati CONTENTS Chromium Steel Improved Nitrogen Open-Hearth Furnace Design Application Beryllium-Copper Alloys Phosphorus Chromium Alloy Cast Iron Putting the Question Mark Work The Farmer Sees Way Out News Personals and Automotive Industry Washington News Pig Iron Production for August Markets Construction and Equipment Buying Products Advertised 104 Index Advertisers 122 THE IRON AGE PUBLISHING COMPANY F. J. FRANK, President G. H. GRIFFITHS, Secretary Cc. 8S. 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, Kent Rd., Upper Darby, Canada, $8.50, including duty; Foreign, $12.00 Del. Co., Pa. 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 year. Single Copy Cents SEVENTY-NINTH YEAR SERVICE THE METAL WORKING INDUSTRY | Baer | = = af r | | | + ae y | 4 | t 4 | SE | fittings stroyer Room. We: —— hia THE IRON AGE... SEPTEMBER 1933 Page HOT ROLLED ALLOYS 8.A.E. 2315, 2320, 2330, 2335, 2340, 2345, 2350, 3115, 3120, 3130, 3135, 3140, 3250, 6145, ete. Rycase (Hot Rolled, machine straightened) Rytense (Hot Rolled, machine straightened) COLD DRAWN ALLOYS 2315, 2320, 2330, 3115, 3120, 3135, ete. HEAT TREATED ALLOYS Ryco (Hot Rolled, machine straightened) Nikrome (Hot Rolled, machine straightened) Nikrome (Cold Drawn) STAINLESS AND HEAT RESISTING ALLOYS Allegheny Metai (Sheets, Bars, Welding Rod, etc.) COLD FINISHED STEELS Std. Shafting, Turned Ground and Polished, Special Accuracy Stock, Rycase High Manganese Screw Stock, S.A.E. 1020, 1035, 1112, 1120, ete. TOOL STEELS Ryerson V.D. Ryerson XXX, XX, X Ryerson B.F.D. (Best for Dies) “4-Point’’ Chisel Steel High Speed Mill Treated Bars Diamond B High Speed Tool Holder Bits Carbon Steel Drill Rod GENERAL STEEL PRODUCTS Bars, Structurals, Plates, Sheets, Re- fined tron, Shafting, Strip Steel, Welding Rod, Tubes, Babbitt Metal, bolts, nails, ete., are also carried in stock for immediate shipment. Ryerson Specializing the finer Steels Your competitors are burning the midnight oil economizing—improving their products. are you! And the newer, finer steels that are accomplishing miracles. The new stainless steels, high manganese alloys, new process tool steels, special accuracy bars, etc., etc.—these and many others are responsible. For this reason the Ryerson Special Steel Divisions are working overtime helping facturers whenever the problem steel arises. have experienced group special steel men awaiting your beck and call, and hope you will take full advantage this most impor- tant service. not let well enough alone. not too easily satisfied. Call Ryerson for sugges- tions that will economize and improve your product. will glad help you. Write for the Ryerson Steel Book, guide the most complete stocks ready for immediate shipment. Plants at: Chicago Milwaukee Louis Cincinnati Detroit Cleveland Philadelphia Jersey City that nless tool these Steel steel hope too your Cincinnati City ..THE IRON SEPTEMBER 1933 ESTABLISHED 1855 Vol. 132, No. Will Uncle Sam Move Out —Or Unionize would indeed helpful this time per- sons who are mentally unable accept the necessity and value having genuine and respon- sible labor organizations for the self-protection labor interests and the stabilization industry would emigrate some backward country where there are free schools and where the level common intelligence very low and would cease clutter progress the United States with the rubbish outworn ideas and dead philosophies.” Donald Richberg, radio address and Se- curity Under NRA,” Aug. 29. Mr. Richberg gen- eral counsel the Recov- ery Administration. Uncle Sam going permit the union- ization all Government willing arrange the pay rates and hours Government employees through collective bargaining Will deal these matters and with working conditions with any representative that the majority his workers may choose, even this person has connection with Government work and entertains antagonis- tic viewpoints Will Uncle Sam instruct the United States Treasurer deduct union dues from the pay checks all Government employees and divide these amounts among the professional labor leaders? Will tolerate strikes, picketing terruption Government service because impossible labor demands? Will abolish the civil service examina- tion medium choosing employees and substitute the union card for it? Mr. Richberg’s interpretation the Administration’s intent correct, Uncle Sam must these things once, move some backward country. For cannot force upon private employers policy that himself unwilling accept. ™ 4 Ae the Sac = any 2 | | | wer 3 uf Chromium Steels Improved FTER many investigations has been generally accepted that nitrogen, when present more than certain amounts, produces harmful effects iron and ordinary steel. For example, the work cated that nitrogen detrimental iron and steel, while claims that nitrogen increases the strength and hardness and decreases the ductil- ity and toughness open-hearth steels. Little has been published re- lating the effect nitrogen the characteristics the more highly al- loyed steels the high chromium type. 1926 published ducted investigation the influence nitrogen chromium and some chromium-iron alloys. chromium steels are known commer- cially corrosion-resisting and heat- resisting metals. They have many excellent properties but, the case all metals, there opportunity for certain improvements. the cast condition, steels contain- ing relatively high percentages chromium have structures consisting large crystals, sometimes arranged columnar form, but many in- stances arrangement less regular. Castings having such large grains frequently show porosity under hy- draulic testing. large grains give difficulty hot working, and even though the opera- tion may successful, their effect may persist the finished forging. One Part Nitrogen 100 Parts Chromium After considerable search for agent which small amount would RUSSELL FRANKS Union Carbide and Carbon Research Labora- tories, Inc., Long Island City, refine the grain these steels, nitro- gen proved the most desirable from several points view. Approxi- mately one part nitrogen one hundred parts chromium suf- ficient for this purpose. When present this extent the nitrogen uniform- alloyed the steel nitride, and solid metal readily obtainable. much more nitrogen into high-chro- mium steels, the nitrides tend de- compose and the metal likely contain blowholes. The nitrogen can conveniently added the form high-nitrogen ferrochromium having ratio chromium nitrogen. fer- rochromium this kind used, sound steel can secured furn- ace manufacture according the usual processes. One word precau- tion: The high-nitrogen ferrochro- mium should not added exces- sively hot steel, this tends cause decomposition the nitrides, result- ing liberation gaseous nitrogen. When properly added, practically all the nitrogen will remain the fin- ished steel, and the metal may remelted without appreciable loss this element. Nitrogen Effective High-Chromium Steels Nitrogen has proved particularly effective reducing the grain size and improving the physical properties cast steels containing per cent more chromium. While nitrogen effective improving the strength and toughness steels containing even per cent chromium more, advantageous have the chro- mium approximate per cent or- der obtain comparatively strong and tough castings with good resist- ance heat and corrosion. Castings such steels have the properties shown Table The analyses given the table show — steel containing 18.25 per cent chromium, 8.71 per cent nickel, 0.18 per cent carbon, and 0.20 per cent nitrogen the hot rolled condition—100 diameters. that some the steels contain rela- tively small amounts nickel, which were included for two reasons. First, considerable proportion high- chromium steel scrap constantly used, nickel will time accumulate TABLE I—TESTS HIGH-NITROGEN CHROMIUM STEEL CASTINGS Per Cent Yield Max. Point Stress Heat Treatment Lb. per Sq. In. 24.21 0.32 0.20 0.15 63,000 82,000 24.21 0.32 0.20 0.1 Heated 850 deg. furnace cooled to 600 deg. C. 24.43 0.35 0.26 Heated 850 deg. hr., furnace cooled 600 deg. and water quenched........ 61,000 103,000 25.97 0.32 0.30 1.13 Heated 850 deg. C. 2 hr., furnace cooled 600 deg. and water quenched........ 62,700 106,400 in. diam. tapered bar loaded the middle, in. between centers. Transverse Test* Elong. in2In., Breaking Brinell Per Cent Lb. Hardness 3 7,800 0.30 202 &,700 0.53 223 9,700 0.60 223 207 6,800 0.23 196 10—The Iron Age, September 1933 7 | y = ] q § byNitrogen cent rogen ining more, chro- or- trong stings erties 8.25 per kel, 0.18 nitrogen jameters. rela- which First, high- ulate Brinell 202 the castings; secondly, small quan- tity nickel the presence nitro- gen gives some added strength. The tensile tests show that the high- nitrogen cast steels are strong and comparatively ductile. similar state- ment can made with respect the transverse strength, and apparent that the steels are fairly tough, shown the extent which bend- ing occurs before fracture. These properties are accompanied slight increase hardness, but this does not impair the machinability. Successful commercial heats have proved the desirability high nitro- gen content these steels, particular- the production castings highly susceptible cracking, such pump impeller parts having great differ- ences cross-section. have been encountered the produc- tion such castings from steels con- \e . c \< j j € \ \\ j ; \ é J . — TRUCTURE the same steel after heat- ing 1150 deg. min. and water quenching—100 diameters. taining more than per cent chro- mium and normally low nitrogen. Reduces Grain Size The high-nitrogen cast steels are resistant oxidizing media the low-nitrogen steels. Increasing the nitrogen content does not affect the the steels oxidation elevated temperatures, and there experimental evidence that the fine- castings resist the grain growth that occurs the higher temperatures. The addition nitrogen cast steels containing about per cent chromium produces some refinement grain structure, but the improve- ment not marked because the steels lower chromium have grain when uniformly alloyed the chromium and the chromium- nickel steels, and amounts the order 0.20 0.30 per cent, has been found impart such beneficial effects that broadening the use these steels regarded the natural The researches bear- ing the subject have now become available through the accompanying article. Castings and also the wrought steels, including those the stainless class, respond the beneficiation the nitrogen. the case the high- chromium alloy castings, product obtained that withstands abuse with- out cracking, suggesting its application pump impeller parts having great the case the chromium-nickel steels, the introduction the nitrogen improves machinability and provides non- magnetic castings relatively high strength. all the low carbon classes these alloys, considerable ductility and toughness added and non- magnetic wrought material high yield point, machinability and resistance staining obtained. The nitrogen added the form high-nitrogen ferrochromium, explained the early passages the article. differences cross-section. initially smaller than metal contain- ing per cent chromium more. The accompanying photographs show fractures commercially pro- duced high and low nitrogen chro- mium steels. They illustrate the effect nitrogen reducing the grain size castings such steels. Improves High-Chromium Wrought Steels Nitrogen has been added steels even lower carbon content containing chromium below and above per cent, and sound ingots have been ob- tained without difficulty. They are readily forged and rolled tempera- tures the neighborhood 1100 1200 deg. Table gives the re- sults tests conducted wrought chromium steels high These show that the steels are strong \ 4 4 rk) < & LA <> > { 4 A far ) = > = ~ ix ¢ a anid 4 j steel containing 18.13 per cent chromium, 8.67 per 0.075 per cent carbon and 0.21 per cent nitro- gen the hot rolled condition—100 diameters. and ductile. The high-nitrogen per cent chromium steel especial- strong, although slightly harder than those higher chromium. The structure the wrought high-nitro- gen steels consists small grains, showing that nitrogen effective also reducing grain size the low-car- bon high-chromium steels. This takes place without producing marked in- crease hardness, which rec- ognized advantage. The high nitrogen content these wrought steels does not diminish their resistance stain- ing. Another interesting effect nitro- gen its tendency retard the devel- opment brittleness the low-car- bon steels containing over per cent chromium. Wrought steels containing more than about per cent chro- mium and high nitrogen will be- come brittle between 400 and 500 deg. C., but longer time required develop brittleness than with the low-nitrogen steels. The explana- tion may that the nitrogen combination with chromium. so, the solid solution thus depleted chromium would more slowly af- fected these temperatures. chromium steels containing substan- tial amounts nickel have yielded interesting results. with the plain chromium steels, nitrogen can in- TRUCTURE the same steel after heating 1150 deg. min. and water quench- ing—100 diameters. The Iron Age, September 5 by v te 4 AS > x TABLE WROUGHT HIGH-NITROGEN PLAIN CHROMIUM STEELS Per Cent Yield Max. Elong. Red. Heat Treatment Lb. per Sq. In. PerCent 19.37 0.10 0.28 Held hr. 760 deg. and air cooled..... 56,000 100,000 163 22.67 0.11 0.27 Held hr. 875 deg. and water quenched 51,400 90,250 149 26.08 0.12 0.28 Held hr. 875 deg. and water quenched 60,000 87,200 153 troduced the form high-nitrogen ferrochromium. For both steels the same melting practice would gen- eral employed. The results physical tests chromium-nickel steels are given Table III. Considering that these steels are austenitic their strength exceptionally high. They are ductile and tough, and the machinability difference the grain the steel having the higher nitrogen content shown these two pictures the fractures cast steel. That nickel type are shown Table IV. Attention drawn the extremely high yield points which these wrought high-nitrogen chromium-nickel steels possess the hot-rolled condition, ac- companied considerable ductility and toughness. Water quenching from 1150 deg. increases the ductility, toughness and softness, with lower- ing yield point but less ultimate strength. These steels are easier for about hr., followed air cool- ing, renders them even more adapt- able machining operations. seems almost unnecessary state that some important requirements may met such high yield point, non-mag- netic steel the stainless type which can wrought and machined. Photomicrographs low and medi- carbon per cent chromium and per cent nickel steels having high ae the left cast steel containing 27.35 per cent chromium, 0.56 per cent carbon, 0.34 per cent nickel and 0.32 per cent nitrogen. The fracture the right cast steel containing 27.85 per cent chromium, 0.50 per cent carbon, 0.75 per cent nickel and 0.06 per cent nitrogen. somewhat improved result the nitrogen addition. High-Nitrogen and Steels The physical properties high- nitrogen steels the well-known per cent chromium and per cent machine both the hot-rolled condi- tion and after annealing 1150 deg. than the per cent chromium and per cent nickel steels the usual type. This includes threading, drill- ing and turning. Heating the high- nitrogen steels 700 800 deg. nitrogerr content are here reproduced. Examination reveals that practically all nitrogen solid solution. The steels consist relatively small grains which not greatly increase size heat treatment temperatures high 1150 deg. TABLE HIGH-NITROGEN CHROMIUM-NICKEL STEEL CASTINGS Per Cent Yield Max. Heat Treatment Lb. per Sq. In. 17.94 9.04 0.27 0.19 44,500 88,000 17.94 9.04 0.27 0.19 Heated min. 1050 deg. 22.58 11.47 0.23 0.25 45,000 83,500 22.58 11.47 0.23 0.25 Heated min. 1050 deg. 45,500 90,000 17.33 34.42 0.2 0.12 Heated min. 1050 deg. 39,500 85,000 *1% in. tapered bar loaded the middle. in. between centers. Elong. Izod in2In., Impact Per Cent Ft.-Lb. Load, Lb. tion, In. Hardness Transverse Tests* Brinell 8,000 3.00 163 179 8,350 2.40 170 170 7,500 1.00 163 170 — OHA 12—The Iron Age, September 1933 That The ically The rrains size res rinell rdness 163 179 170 170 163 TABLE IV—TESTS HIGH-NITROGEN CHROMIUM-NICKEL STEELS Per Cent Heat Treatment hot rolled Quenched from 1150 deg. C.... Yield Max. Point Stress Lb. per Sq. In. 89,000 121,000 48,000 107,000 Held hr. 750 deg. and air cooled Quenched from 1150 deg. C.... 80,000 82,000 48,500 124,000 113,000 99,500 Held hr. 750 deg. air cooled 117,000 Elong. Red. Izod In., Area, Impact, Brinell Hardness 235 100 159 207 217 120 149 207 The fact that practically all the nitrogen solid solution partly ex- plains why stainlessness the steels not noticeably diminished its presence. Samples have remained unaffected the salt spray atmos- phere for comparatively long periods. This equally true samples ex- posed the normal atmosphere, clearly showing that under these con- ditions the metal has excellent re- sistance. Nitrogen has one important det- rimental effect the properties the wrought chromium-nickel steels. Decreased stability exhibited elevated temperatures. the high- nitrogen steels are held for relatively long periods temperatures between about 600 and 900 deg. C., they suffer greater decrease toughness than metal having the same percentage carbon with normal nitrogen. The high-nitrogen steels are subject in- tergranular attack, and this respect they offer improvement over the usual types this material. Advantages High-Nitrogen Content Summarized has been shown that castings high-nitrogen steels containing over per cent chromium are relatively strong and tough. These castings con- sist small grains, which apparently account for their improved properties. This pertinent because castings these steels are sufficiently strong withstand abuse without cracking, fact not always true for castings the plain chromium steels. Nitrogen imparts high strength castings the chromium-nickel steels appreciably lowering ductil- ity toughness, but the decrease grain size not marked that resulting from the addition nitro- gen the plain chromium steels. The introduction nitrogen the chromium-nickel steels improves the machinability and provides non-mag- netic castings having relatively high strength. The low-carbon, high nitrogen chromium and chromium-nickel steels offer difficulty hot working. They can worked under substanti- ally the conditions employed for steels normal nitrogen content. These wrought steels have high strength and considerable ductility and toughness; particularly this true the high nitrogen per cent chromium and per cent nickel steel. Thus advan- tages may accrue from the addition ama ECTION centrifu- gally cast tubing steel containing 24.43 per cent chromium, cent carbon, 1.20 per cent nickel and 0.28 per cent nitrogen. the upper right same steel, while the up- per left shown the frac- ture steel containing 25.08 per cent chromium, 0.35 per cent carbon, 1.18 per cent nickel and 0.04 per cent nitrogen. nitrogen, especially when non-mag- netic wrought product high yield point desired, combining machina- bility with resistance staining. Briefly expressed, the beneficial broaden the applications the high- chromium and the chromium-nickel steels. The aid and interest shown Dr. Becket, president, Union Car- bide and Carbon Research Labora- tories, have been invaluable con- ducting this investigation. Much credit must given Bacon and James Thompson for the skill they contributed the making and test- ing the steels. Harbrecht, Niagara Falls, also contributed greatly making some the larger heats these steels. Vilella should complimented for his metal- lographic work, should Ham- ner for his assistance analyzing the steels. Occurrence and Influence Nitro- gen Iron and Steel, Tschischew- ski, Journal Iron Steel Institute, 1915, No. II, 47. Phenomena Iron and Dispersion Hard- ening the System Iron—Nitrogen, Transactions Am. Int. Min. Engrs., Iron and Steel Division, 1929. Effect Nitrogen Steel, Frank Chemistry, Vol. 23, No. 1931. Effect Nitrogen Chromium Frank Adcock, Journal Iron and Steel Institute, No. II, 1926. The Iron Age, September 1933—13 te 18.25 8.71 0.18 0.20 some met nag- high burt ted natural gas-fired open-hearth furnace that requires special at- tention, the ports. first feature the design The ports open-hearth fur- nace serve alternately inlet for the fuel and air, and outlet for the products combustion. When used inlet, the port controls the mixing the fuel and air and direc- tion the flame. Proper port design very important natural gas- fired furnace because the weight fuel small comparison with the weight air that the direction the air stream controls large extent the direction the flame. the other hand, when heavier fuels are used, the direction the gas (or oil) stream controls the direction the flame. The following table gives this re- lationship between the weight fuel and the weight air. the col- umns for coal tar and fuel oil the weight steam required for atomiza- tion the fuel included because the atomizing agent helps the direction the flame. When used outlet, the port must permit the flow waste gases from the hearth under the draft con- ditions existing the furnace. must also withstand the high tem- perature and slagging action the waste gases. the past, has been generally Area sq. Fig. construction natural gas fired 25-ton open-hearth furnace. 14—The Iron Age, September 1933 aa ETAILS construction the open-hearth furnace designed for firing with natural gas are of- fered the author series six articles, which this the second. The first, enumerating advantages natural gas firing, appeared Aug. 31. The third article will devote itself regen- erators. accepted that the limiting factor that controls the area the ports the minimum cross sectional will remove the waste gases from the hearth. However, natural gas- fired furnaces the most important function the port the direction and position the flame. This can best accomplished with comparatively small port area. This small port area should sufficient relieve the furnace the waste gases because the volume the products natural gas-fired furnace than furnace fired other fuels. Type Port: The port design that generally recommended for natural gas firing the simplest design port that could constructed open-hearth fur- nace. consists single uptake for the preheated air and single port for the gas-air mixture. Ex- perience has shown generally successful for natural gas firing. plain port this type also reduces the construction and rebuilding costs the furnace, and the lines the port will maintained longer than the lines ports furnaces using other fuels. Fig. illustrates the port design 25-ton basic furnace that gave very satisfactory results. was fast-working furnace, producing four 28-ton heats per day, using 1130 B.t.u. natural gas. The fuel con- sumption from tap tap was under 4,000,000 B.t.u. per ton. Fig. illustrates the port design acid furnace that also gave very satisfactory results. The heats produced this furnace aver- aged tons each, with few heats going large tons. When this furnace was operated capacity the fuel consumption was low 3,000,000 per ton, using 980 B.t.u. natural gas. Area Port: The proper area for the nose the port can determined from the amount and velocity the gas-air mixture that one desires pass through the port. The amount this mixture can easily determined. simply the sum the gas and air flows corrected for temperature. For example: Consider the 25-ton furnace, Fig. The maximum rate gas consumption 18,000 cu. ft./hr., cu. ft./sec. 10.7 cu. ft. air are required per cu. ft. deg. Since combustion has when the gas-air passes through the nose the port, the aver- age temperature this mixture probably about 2900 deg. However, the temperature the flame the furnace may high 3300 deg. for temperature. 2900 460 58.7= 380 cu. ft. mixture/sec. 460 2900 deg. Referring Fig. note that the area the nose the port 7.3 sq. ft. mixture. This furnace operated stack draft. Also: Consider the 35-ton furnace, Fig. The maximum rate gas consumption 25,000 cu. ft./hr. Slope sq.ft N Gas Fig. construction natural gas fired 35-ton open-hearth furnace. | a Vv n Vv Si 30 29 pipe ; - VS re gas , ‘ WILLIAMS Industrial Gas Engineer, Equitable Gas Co. 10.7 cu. ft. air are required per cu. ft. gas. above, find that the total amount gas-air mixture the nose the port 494 cu. ft. per sec. 2900 deg. The area 6.1 ft. 6.1 80.8 ft./sec. velocity mix- ture. This furnace was equipped with pusher fan for forcing air into the regen- erative chamber, which enabled them secure this high velocity the port. The velocity the port largely dependent the pressure and draft available; for most natural gas-fired furnaces operating stack draft, velocity cu. ft./sec. will give satisfactory results. the fur- nace equipped with pusher fan, satisfactory. The area the nose the port taken the unit area from which the other parts the port are pro- portioned, follows (see Fig. 3): Area nose port Area back port Area uptake port 1.3A For example, suppose want deter- mine the port area 50-ton furnace, maximum gas consumption 30,000 cu. ft./hr.; velocity gas-air mixture port ft./sec. The port design 30,000 3600 8.3 cu. ft./sec. -.10.7 8.3 8.3 cu. ft. mixture/sec. deg. 2900 460 §26 cu. ft. 460 2900 deg. nose port. port. uptake. After determining the area the rectangular nose the port, necessary determine the ratio width height. the nose the port too wide will difficult mixture/sec. area Pittsburgh control the position and direction the flame, while the port too high and narrow, the bottom the flame will smoky and combustion will not completed the hearth. This dependent upon the size the furnace and particularly upon the width the hearth. Large furnaces and furnaces with short, wide hearths require wider ports. general rule, the height the nose the gas Area “4” Slope = 4” per!’ Fig. 3—Port design for natural gas firing rec- ommended the author port should little greater than the width. Slope Port: The slope the port must suffi- cient drop the flame low enough sinter the bottom the furnace. The path the flame also partially con- trolled the port velocity. Refer- ring page 259 “Design Open- Hearth Furnaces” Williams, find that order drop the flame in. ft., which one- . AIR REQUIREMENTS FOR DIFFERENT FUELS—5 PER CENT EXCESS AIR Mixed Blast Fur- Gi half the length the furnace, the slope the port for different veloci- ties follows: in./ft. in./ft. in./ft. Short furnaces with deep hearths will require little greater slope. slope slope slope Referring the 25-ton furnace, Fig. Slope roof port in./ft. Slope floor port in./ft. Referring the 35-ton furnace, Fig. Slope roof port in./ft. Slope floor port in./ft. The 35-ton furnace has much shorter, and deeper hearth than the 25-ton furnace, and this fact justifies the difference slopes. The port design recommended the author shown Fig. The slope the port roof in. per ft. and the slope the port floor in. per ft. These slopes will prob- ably found satisfactory for most furnaces; however, case the port velocity very low, the hearth short and deep, slightly greater slope should used. Method Entraining Gas: The same general method en- training gas into the air stream used all three furnaces, Figs. and there are some slight differences the locations the gas pipe. the 25-ton furnace, Fig. the gas entrained front heel wall. The gas pressure the burn- very low, being only few inches water. The pressure the line this furnace was oz. This figure depends upon the pipe size, but the usual range oz. This very common method in- troducing gas into the air stream; however, has the disadvantage that dirt and cinders carried the port the outgoing products combus- tion tend clog the gas burner tunnels. Coke Pro- Natural Oven ducer Gas Gas Gas 15.5 0.065 nace Gas and Coke Coal Fuel 1.5 2.9 5.6 0.667 0.345 0.179 the 35-ton furnace, Fig. the gas introduced into the air stream down the uptake. The gas burn- ers are set in. below the floor the port and in. from the inside wall the uptake. The edge the 17.0 0.059 The Iron Age, September 1933—15 980 ass and /sec. be ‘ Includes steam for atomization basis steam per pound oil. | burner just in. from the wall. The purpose setting the gas burners this position secure more intimate gas-air mixture, and especially get small amount air underneath the gas order clear any tendency for the flame smoky the bottom when high, narrow port used. This set- ting the gas burners very criti- cal, and they are set too low too far out the uptake, the port roof will badly burned. The prop- location for the burners must found moving them around little until the desired flame secured. our recommended port design, Fig. the gas flows into the air stream the intersection the port cross section, shown the sketch, constructed order introduce the gas the under side the air stream, provide slow mixing gas and air, give luminosity the flame, and prevent burning the knuckle the roof. This arrange- ment improvement over that shown Fig. because the cinders cannot collect front the burner tunnels. Several bricks are placed the center this shelf deflect the gas upward into the center the air stream. Four-Uptake Design: Fig. shows the port construction 75-ton basic furnace that has given very satisfactory results op- eration. The furnace equipped with two regenerators and four uptakes each side. This port design can used vary the characteristics the flame. The two inside uptakes, are connected the inside regen- erative chamber, while the two out- side uptakes, are connected the outside regenerator. When large volume the total air required passed through the inside uptakes, the air and gas are premixed, thus resulting sharp cutting flame. When most the air passed Section A-A Section B-B Iron Age, September 1933 through the outside uptakes, com- bustion slower and highly lumi- nous flame produced. the furnace, Fig. the ratio air passing through the inside and outside uptakes determined the setting of.air hoods which are lo- cated the flues between the regen- erative chamber and the reversing valve. The furnace operated stack draft. the furnace were equipped with forced draft blower, dampers the flues would have replace the air hoods. The over the inside uptakes should water- cooled because the hot furnace gases pass both sides the brick work. This can done placing several 1%-in. water pipes across the fur- nace inside the brick work. Gas Burners Through End Wall: all the furnaces just described, very low pressure gas has been intro- duced into the sides the air stream. However, there are many oil and producer gas-fired furnaces with ports the full width the fur- nace, which would not prac- tical entrain gas through the sides without rebuilding the ports the furnace. jobs this kind gas can injected into the furnace through burner placed the end wall shown Fig. This three- uptake furnace the type that commonly used for oil, tar, pro- ducer gas. converting furnace this type, that formerly used producer gas, natural gas, first neces- sary arrange the old gas regen- erator that will preheat air, then the center uptake which was former- gas uptake, now air up- take. producer gas port then removed and trough constructed from the center uptake the hearth. The outlets the side uptakes are built until they are about in. higher than the outlets the center uptake. water-cooled gas burner the type shown Fig. then 4—Port design successfully operating 75-ton open-hearth furnace fired with natural gas. placed through the end wall and fires down the trough. The water-cooled gas burner shown jacket protecting gas pipe. This burner gave very satisfactory results 30-ton basic Cir- culation water the tip the burner secured means baffle strips. These strips are welded the 2%-in. pipe and the assembly then placed inside the 4-in. water jacket. The baffle strips were used instead placing water pipe the burner because they reduced the size water jacket required. de- signing water cooled burners good idea make the water jacket small possible order keep the heat loss minimum. The Water cooled gas burner Fig. 5—Where ports are practically wide the furnace, burner may placed the end wall. heat content the gas used was 1130 B.t.u. per cu. ft. and the gas pres- sure the line the furnace was Water-cooled gas burners this type should extend about half-way across the center uptake. the nose the burner too far forward com- bustion will not complete the hearth and part the gas will burning the downtakes, slag pocket, and regenerator the outgoing side. this condition exists will cult get the steel hot and the cam- paign the furnace will short- ened burning out the checkerbrick. the nose the burner too far back there will too much premix- ing gas and air and hot spot will developed the incoming side. The center the port through which the gas passes troughed that the secondary air that comes the two outside uptakes will tend cover the gas stream. This type burner givés sharp, hot flame, melts down quick- and turns out heats fast. This method firing natural gas has been tried several plants, and the fue consumption runs slightly a Si 0 is AAA A > ( pg 4,7, py 4 A, or a 1s cu ~~ Yj Y/ a pipes ‘ OLY A* V4 res ter pe. ory the sed the de- ‘ket eep The Water inlet jacket, pipe, Fig. 6—The burner for the end-wall firing application water cooled. higher than furnaces entraining gas through the sides the ports. End-fired furnaces not require much stack draft for their opera- tion furnaces entraining gas through the sides the ports. Con- sequently, difficulties such the burn- ing gas the downtakes, etc., may often overcome lowering the stack damper. should borne mind that the recommended method burning nat- ural gas the open-hearth furnace that shown Fig. namely, in- troducing gas into the air stream means pipes the sides the ports. However, this method firing installing burner the end wall has the advantage that can used furnace with straight roof Growth the Use Alloy Steels pictured the accompanying chart. the form rolled and forged products—that is, alloy steel originating ingots—there has been fairly steady increase since alloying has been factor. The expansion fact has been such that four and half times much such steel has been latterly going into use was the case years earlier. the form castings, distinguished from in- got alloy steels, more rapid increase indicated over the years, but actual steep decline oc- curred from early peak just before the war low point around the end the second decade the century. This recession the end was nearly per cent off from that peak and nearly per cent under the 1911 rate. Five-Year Averages Used The curves areebased upon the statistics production the Amer- ican Iron and Steel Institute, going back 1909. Five-year averages the per capita production, centered for each five-year group, were used get smooth curve show the con- sumption. will noted that the curve for the castings steeper from 1920 than the part Consumption steels the form rolled and forged prod- ucts—that is, alloy steel originating shown steady in- Castings, there has been mere rapid increase recent years Pounds Per Capita 1910 1912 1916 «1918-1920 1922 1994 1926 1928 1950 1952 wide ports without making extensive changes the brickwork. The construction suitable port the first step toward the successful operation natural gas-fired open- hearth furnace. The other features that require special attention, are regenerators, combustion control, and insulation. They will discussed subsequent articles. the curve for the ingots. This means that demand has been growing faster for castings than for alloy steels other forms. the seven years ended with 1927, alloy steel castings appear have reached rate use two and half times that 1920, while with alloy steel ingots, consumption 1927 was one and three-quarter times that 1920. Expansion Demand for Rolled and Forged Alloy Steels Steady The accompanying table the per capita five-year averages produc- tion shows that whereas 1911 the volume ingots was substantially eight times that the castings, the last years the war the ratio be- for the rolled and forged alloy steels practically never stopped, shown the curves, while seven-year slump (1913-1920) characterized the use the castings. CONSUMPTION ALLOY STEELS Pounds per Capita Population Ingots Castings 11.7 1.44 15.1 1.94 19.0 1.91 22.7 1.72 27.3 1.60 30.4 1.18 31.0 1.27 32.5 1.42 40.6 1.97 43.0 2.26 46.3 2.55 52.6 2.92 51.9 2.93 The Iron Age, September 1933—17 Section A-A wide 1130 } Special Properties and EAT treatment and cold work- ing bestow some striking effects certain beryllium-copper al- loys, considerably augmenting their range usefulness. the purpose this article outline some the properties resulting and describe some the applications these alloys. IRON AGE Aug. appeared the introductory article the subject. High Resistance Wear the cast condition certain lium-copper alloys have sistance wear. wear tests such alloys Amsler machine quenched from 1600 deg and tem- pered 1100 deg. F., was used the standard for comparison. This produced hardness C22 Rock- well. Six disks 2.35 2.46 per cent alloy were used. The aim was ascertain the effects age precipitation hardening the wear resistance. cast, the disks had hardness solution treatment 1479 deg. for hr., followed the precipita- tion hardening treatment 600 deg. for hr., resulted hardnesses Rockwell C41.3 and C43.3. The ef- fect the prolonged heating 575 deg. for hr. resulted softer product, Rockwell C31.4 and C30.1. The Amsler tests showed that the disks with Rockwell hardness lost per B85 Per Cent Conductivity Standard Annealed Copper 18—The Iron Age, September 1933 1.2 1.6 2.0 Per Cent Beryllium Weight EDWIN CONE 10,000 revolutions compared loss 0.0168 for the steel speci- men. The precipitation hardened (or C43.3) specimen lost only 0.0003 while the steel lost 0.0001 The 24-hr. precipitation men (C31.4 C30.1) suffered much heavier loss. Hardness the Alloys Demonstrated Hardness tests cast rods two beryllium-copper alloys—1.85 per cent and 2.35 per cent Be—have been made laboratory Brook- lyn, Heating the specimens molten salts 525 deg. and 575 deg. showed that 525 deg. the maximum hardness for both compositions was reached about the 3-hr. heating period. Some the effects heat-treat- ment and cold-rolling per cent beryllium-copper sheets are described the American Brass Co. the soft annealed solid solution condi- tion, the Rockwell hardness (1/16 in. strength 54,400 lb. per sq. in. After precipitation hardening the hardness B106 and the tensile strength 145,- 300 per sq. in. After rolling (be- hard, the hardness B99, with tensile strength 107,800 lb. per sq. in. this then precipitation hard- Electricai conductivity loys cast” con- dition, showing change conductiv- increased time precipitation hardening treatment. Hardening furnace temperature 575 (Beryllium Develop- ment Corpn.) ened, the Rockwell value B112, with 176,630 lb. per sq. in. the tensile strength. Good Electrical and Thermal Conductivity The electrical conductivity these alloys reported high, especially compared with steel, phosphor bronze and other high-strength ma- terials, according the results in- vestigations two American com- panies. again the heat treat- ment which brings this about. the precipitation hardening period ex- tended hr., the highest con- ductivity reached around per cent beryllium. This fact and other relations are shown the chart, Fig. Some preliminary data regarding the thermal conduc- tivity these alloys have been as- certained reliable laboratory. alloy copper and beryllium con- taining 2.45 per cent was used and tests were made the “as cast,” the quenched and hardened, and the quenched and annealed conditions. For quenching the specimens were heated 1450 deg. F., held for hr. and quenched cold water. ening was accomplished heating 575 deg. F., followed air cooling. The effect temperature the thermal conductivity the 2.50 per cent alloy quite unusual and in- teresting, says the report, means for studying structural changes age-hardening alloys. There sharp increase conductivity, re- lated some way, probably, precipitation taking place within the alloy. Insufficient data are available fully interpret the results, and more research necessary. Considerable resistance corrosion the beryllium-copper alloys in- dicated meager information now available. discussing applications products, this property will further elaborated. The American Brass Co. authority for the state- ment that these alloys are sion resistant any the wrought copper-tin alloys. Marked Resistance Fatigue Unusual resistance fatigue loys, according researches made Europe well this country- This varies, course, with the type heat treatment and with the de- 7 ( « be | | | | | | + +-—+- 4 —-- + | | | | | | | | 3 + Ox, | th | | | x | | | | | | ar | | | | | | | | | | | Fw, | | | | he: vith sile gree cold working. Some the highest properties this field have been brought out the wrought rolled springs. thus evident that the introduc- tion small amounts beryllium into copper results unusually high fatigue limits, greatly improved values electrical conductivity, high corrosion resistance, equal that copper-tin alloys, markable ductility. The fact that these alloys are heat greatly value. For example, intricate parts made the soft semi-hard (solid solution) condition and then heat treated after fabrication. This may increase the tensile strength, fatigue life, abrasion and corrosion resistance, hardness and other prop- erties. The Riverside Metal Co. cites the following: test was made piece hard-drawn beryllium-cop- per wire containing about 2.50 per cent Be. The original tensile strength 108,000 lb. per sq. in. was in- creased heat treatment 190,000 per sq. inch. Hardness Increased Rolling The extent which rolling in- creases the hardness per cent beryllium-copper alloy reported follows the American Brass Co.: Brinell Tensile Hard- Strength, Lb. Sq. In. Annealed soft............ 54,400 and Nos. hard (20 per cent reduction)..... 130 85,000 and Nos. hard (50 cent reduction)..... 212 108,600 Machinability one the out- standing properties these alloys. compares favorably with that other high-strength metals. Though they cannot classified free cut- ting alloys, they are not difficult machine. From the foregoing brief recital certain facts, evident that there are many possible practical applica- tions these alloys. Some Major Commercial Applications the main practical applica- tions thus far the wrought and particularly for electrical purposes and instruments. the heat-treated condition these alloys have tensile strength 175,000 180,000 per sq. in. with elastic a & 4 x Alloys 4 we 2.—Beryllium-copper bearing sleeve castings for adjustable pitch propellers for airplanes. limit (Johnson) 130,000 lb. The electrical conductivity high com- pared with other metals for springs. The modulus elasticity (Young’s) 18,000,000 with torsion modulus 8,000,000. The alloys possess resistance the softening effects operating temperatures 450 deg. These properties, including absence set and very high re- sistance fatigue, are largely ob- tained heat treatment. That these claims for properties are justified being borne out actual field experience. outstand- ing use clips for cord sets and the pins and plugs ap- pliances. The use beryllium-copper has cut down the burning arcing and the consequent wear, decidedly extending the life the cord sets. commercial laundries the life cord sets with beryllium-copper sets have been times the average life sets with standard spring elements. formance has resulted wall switches, relay parts, circuit break- parts, brush holder springs and electrical and recording instrument springs. Trials standard spring bronzes showed accelerated tests life 500,000 1,200,000 operations maximum. Beryllium-copper exact- the same size and gage ran 11,000,000 operations with fail- ures. ing 10-amp. current, which high current density, maintained its spring effect 2,000,000 operations when the tungsten contacts began fail. Without current, the spring has now been run 5,000,000 without in- dication fatigue. Duplicate bronze springs failed before the 2,000,000 mark, due the softening the spring temper because the heat in- volved. For Firing Pins Fire Arms Recent tests beryllium-copper al- loys firing pins fire arms have revealed remarkably increased life over older materials. Every time the trigger released with the piece un- loaded means that the shoulder the firing pin comes with heavy im- pact against the retaining ring. The result shock the unsupported shank end, which sooner later re- sults its snapping, with consequent time and trouble for replacement. Ac- celerated tests beryllium-copper pins have shown that the new alloy ran hr. before failing. The best per- formance with high-grade steel alloys had been min. life. For Tools Which Will Not Emit Sparks Elimination sparking the use tools working places where there fire and explosion hazard has been desideratum for long time. Such tools include wrenches, chisels, hammers, scrapers, screw drivers and ordinary hand tools. Such tools made the beryllium-copper alloys not spark all and meet the new re- (Concluded page 66) The Iron Age, September om- the con- per as- con- and ” in vere hr. ard- the in- the able sion ican ught al- 7 Phosphorus Chromium Alloy cast irons containing varying amounts phosphorus were investigated the as-cast, stabilized, annealed and hardened and tempered conditions Hurst, technical director the Sheepbridge Stokes Centrifugal Castings Co., Ltd., Ches- terfield, Sheffield, England, and the results were contributed the (Brit- ish) Iron and Steel Institute pa- per presented recent meeting the institute London. The specimens used were prepared from centrifugally cast drums. The test pieces which were machined were 4.4 in. outside diameter, 3.85 in. inside diameter in. long, and equipped with chucking flange one end. The ring-form test pieces were machined from the central por- tion. The castings were prepared from chromium alloy mixture made melting Barrow hematite, Sheep- bridge phosphoric foundry pig iron, and ferrochromium. and ferrochromium were melted one crucible and the phosphoric iron another. Varying quantities the two melts, mixed and cast, provided series castings varying phosphorus contents. The castings were made under the regu- lar and uniform conditions cast- ing temperature and die temperature normally adopted the centrifugal casting process. Seven different cast- ings were prepared; the full analysis each are given the accompanying table. Scope the Tests Twelve ring specimens were pre- pared from each casting and Brinell Cast lrons addition attempting es- tablish the effects single phosphorous,— the accompanying paper serves another contribu- tion foundry technology the field alloy irons and the field their heat treatment. The author, Mr. Hurst, discussed these columns recently May 18, may recalled, the nitrogen hardening aluminum-chromium iron castings. one that increasing number who are lifting the casting iron into the realm science and engineering. readings were taken from the com- plete set all rings. One group rings was retained for the determina- tion the properties the as-cast condition. Other groups were ar- ranged enable the properties measured after hardening and tempering various temperatures; after stabilizing; sta- bilizing, hardening annealing; annealing, hardening and tempering. every case hardening was car- ried out raising the specimens electrical resistance furnace, fol- lowed quenching oil. Subse- quent tempering was performed maintaining the specimens the de- sired temperature bath molten The stabilizing treatment used con- sisted maintaining the rings period min. followed slow ANALYSES SPECIMENS Spec. Graphite, No. Per Cent Per Cent Per Cent 1 3.39 0.52 2.87 3.49 0.49 3.00 3.44 0.30 3.14 3.55 0.46 3.09 3.58 0.39 3.19 3.60 0.54 3.06 3.81 0.59 3.22 20—The Iron Age, September 1933 Silicon, Manganese, Phosphorus, Chromium, Per Cent Per Cent Per Cent Per Cent 2.21 1.07 1.56 0.52 2.16 1.08 1.30 0.71 2.44 1.01 1.06 0.59 2.35 1.00 0.63 0.61 2.44 0.93 0.58 0.62 2.44 1.09 0.43 0.55 2.49 1.02 0.035 0.61 cooling still air. For the anneal- ing treatment the specimens were packed the cast iron borings and held temperature 900 deg. for period min. followed slow cooling the furnace. Hardness Cast and When Hardened The hardness the as-cast tion shows steady increase with in- creasing phosphorus content. This would expected, and clearly shown the lower curve Fig. the quenched condition the hard- ness values are raised within the range 500 580. this condition the effect increasing phosphorus appears cause higher hardness values, with the exception the curious behavior the two samples with intermediate tents 0.63 and 1.06 per cent, which not attain the high level hard- ness and consequently produce the curve, Fig. hardness lo