The Iron Age 1933-11-16: Vol 132 Iss 20

MANAGEMENT NOVEMBER 16, 1933 PROCESSES -:- NEWS the Cards the Table.... Insti- than oteges culate des- quain- wire heck udget. ington press counts dustry our ent your The wise player insists that all the cards laid the table, not merely the aces and kings. For average strength and not the occasional lucky ace that determines the winning hand and the winning player the game. The wise buyer advertising should likewise insist complete dis- closure facts when accepting evi- dence reader preference. mixture strength and weakness more convincing independ- ent and square deal than the ex- clusive display survey aces. the separate and independ- ently conducted investigations industrial advertisers which The lron Age and other publications were rated sales influence through determination reader preference, The Age was beaten other publications times. won first place times. Putting another way, among the 9500 buyers industrial equipment, materials and machinery who thus expressed reading preferences, The lron Age polled 6566 reader votes. This far exceeded the polled vote any other publication. The Age will glad lay all these cards your table anywhere, any time. and ing who ahead aces metal- News led ditors he's THE IRON 16, 1933 Page The Wire Electrica! e THE IRON AGE, every Thursday the JRON AGE PUBLISHING CO. Publication Office: Cor. Chestnut 56th Pa. Executive Offices: 239 39th New York, Y., second class matter the Post Office Philadelphia March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 132, No. 20. — use Hoskins Electric This application ing Company: November 16,1933 THE IRON AGE VAN DEVENTER Editor WINTERS LACHER Managing Editor G. EHRNsTROM, Jr. MACON Consulting Editor BURNHAM FINNEY GERKEN News Editor MILLER Machinery GERARD FRAZAR Pittsburgh Detroit Boston Cleveland Chicago Editor Emeritus Washington Cincinnati Contents Real Hobgoblin OUR PART Applying Technological Gains Zinc for Steel Protection Accuracy Large Roll Finishing Lump Peat Blast Furnace Fuel Advances Electrical Applications Steel Featured New Railroad Station Choosing the Right Drive New Equipment News Personals and Obituaries Washington News Automotive Industry Markets Construction and Equipment Buying Products Advertised Index Advertisers THE IRON AGE PUBLISHING COMPANY FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th New York, Y., Member, Audit Bureau 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 Peirce Lewis, Woodward Ave., Detroit United States and Possessions, Mexico, Cuba, $6.00; Charles Lundberg, Kent Rd., Upper Darby, Del Co., Pa. Cc. H. Ober, 239 West 39th St., New York W. B. Robinson, 428 Park Bldg., Pittsburgh | W. C. Sweetser, 239 West 39th St., New York Address, ‘‘Ironage, Warren, Box 81, Hartford, Conn. | Canada, $8.50, year. including duty; Foreign, $12.00 a Single Copy 25 Cents YEAR SERVICE THE METAL WORKING INDUSTRY | | | | i ~ — | 4 | | | 7 | Cig THE IRON AGE...NOVEMBER 16, 1933 Page Highest Achievement the Polished Nickel Chrome Group Young Peter Seems Pleased Peter Van Dyke seems pleased with this sheet polished Allegheny Metal (18.8 stainless steel). But the sheet will have pass his old man before accepted for Ryerson stock— And Van Dyke, Manager the Special Steels Division, difficult please. matter how flat, how smooth, and highly polished, always wants them better—and usually gets what wants. with all other steel products. They must pass rigid Ryerson inspection before being accepted for Ryerson customers. ESTABL 2 od Ingot Capacity, Per Cent J 3 q Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City ‘ ‘ ‘ ‘ ‘ THE IRON NOVEMBER 16, 1933 ESTABLISHED 1855 Vol. 132, No. Real Hobgoblin for General Johnson 4 +20 Weekly Steel Operating Rate Since July forceful Recovery Administrator has expressed his opinion those who are setting “imaginary hobgoblins” which reflect ad- versely upon NRA. this page, present real hobgoblin. the curve weekly steel operations since July This factual hobgoblin gives food for thought. The underlying theory NRA that increased wages and shorter hours will offset greatly stimulated volume business. Steel volume has been more than cut half during the past four months. TEEL accurate reflector the capital goods industries, because steel the chief basic material these industries. steel goes, our capital goods. Capital goods are financed very largely private investments. They are not bought with income are food, wages, housing. The flow private capital into capital goods investment shrinks when public confidence falters. And confidence not fostered bureaucracy, threats union domination socialistic experimentation. steel hobgoblin real one. cannot dismissed ridicule abuse. Restoration confidence private capital the one way get rid it. ¥ | 5 + | | | | present standard living was only attained virtue widespread technical progress. know that must continue that progress. Yet, spite that, there now strong current opposition the introduc- tion further labor-saving devices any kind, whether they new ma- chines, new methods, merely the abolition useless practices. This opposition nothing new, but al- ways most pronounced time when remunerative jobs are scarce. then that the machine labelled and libelled devilish device for push- ing more men into the ranks the unemployed. essential that the social effect the machine clearly understood, and especially its effect employment. When management introduces new machinery, should fortify its posi- tion having definite policy gain the willing cooperation workers. Far too many concerns simply forced acceptance the machine neces- sary evil; these who are now shirking the whole for things quiet down”—rather than contributing solving our prob- lems. the face the present ag- gressive mood labor, such defensive generally recognized that our 10—The Iron Age, November 16, 1933 strategy delusion, for neither defensive nor strategy. The German philosopher Spengler may right regarding man the highest development the predatory species, but his logical prey the planet, not his fellow-man. The task for management see that the extract ever-increasing yield from nature the benefit all our work- ers, whether they wear white shirts black—and equally important, make these benefits plainly apparent all. shall see presently that there are circumstances under which antagonism the machine justified. Such causes need exposed and avoided. shall therefore here attempt sum- marize analysis the impact the machine and suggest formula which may used basis policy. axiomatic that labor-saving device, being one which saves more labor operation than consumed building it, releases human effort and adds the potential wealth all. But whether realize this potential wealth depends entirely what with the released labor. long human wants remain un- satisfied, cannot side-step the issue shortening working hours. Any industry achieve self- control, must act impar- tial arbitrator the conflict be- tween men and mechanization. And act intelligently this ca- pacity, must formulate sound policy regarding the treatment technological gains. this article, Mr. Losely pre- sents thoughtful and construc- tive study the five avenues open the distribution profits from mechanization. suggests per cent ownership for writing off cost new equipment, per cent the general wage fund and per cent reserve minimize impact rising prices pur- chases. also advocates use licensing plan enable indus- try control its obsolescence rate. attempt legislate unduly short fac- tory hours will simply stimulate home industry. What with Profits From the Machine? the whole problem centers around the dual question the profits from the machine. Who get them and what done with them? There are essentially five different courses which may taken: may pay the same wage rate for labor, but using less per unit output, sell the product lower price. may maintain the selling price, but increase wages, divi- dends and bonuses. may use the additional mar- gin further expand and im- prove the plant. Governmental authorities may impose greater taxes. may hoard the profits, either cash inventories. should able gain much light the workings the machine tracing through the consequences The first course, reducing prices, could rigidly adhered to, would result general rise real wages, Q and sion stin ran di: LOSELY logical Gains Reconcile Man Machine and with that, immediate disper- sion the benefits improved tech- nology. The increased purchasing power given the consumer would stimulate demand, not merely for those goods which are lowered price, but expansion the budget range, permit purchase goods hith- erto out reach. any unemploy- ment caused would quickly cured new work provided elsewhere. Unfortunately, this method dealing with profits has another effect the condition business, which frequent- comes into play before reemploy- ment relieves the stress. profits are directly passed the consumer, are confronted with the condition descending price level, notoriously discouraging enterprise. Damag- ing really closer description when the conflict competition directed into price wars. For soon price concessions are forcibly exacted from the plant owner, turn demands that his workers pass back him their savings from reduced living costs working for lower wages. thus engender warfare commercial attrition, which the less efficient producers not only cut wages, but also sacrifice their own resources. Selling prices less than true costs, their income from sales, even full capacity, does not provide enough replace the machinery. the stage set for the sheriff. the process involved nothing more than the sac- rifice obsolete machinery, the social consequences would not utterly disastrous. But just military warfare, the drawn and the shifting forces, there wholesale destruction intangible values and vast losses national wealth and income are in- curred. The moral for the individual with the continuous march progress and avoid being caught with obsolete equipment. But almost equally avoid precipitating war- fare passing processing gains the form disturbing price reduc- tions. {ncreasing Individual Income The second course, increasing wages, dividends and foremen and method disposing technological When spent rapidly enough— and they are often spent before they are earned, via the credit route—they not only avoid causing unemployment, but may even create labor shortages. The steel industry has not lacked lead- ers who used high remuneration build strong organizations and hold them top-notch performance. is, however, not commercially feasible use all the gains this way. Espe- cially competitive field, success- ful technique soon copied; even patents and secret processes not afford lasting security. retain leading position, some the profits must devoted experimentation and search for further improvements. the third course using released labor for making still more machinery and expanding plant capacity pur- sued the exclusion everything else, the gain Profits continuously ploughed back into plant improvement have further- more the unfortunate effect build- ing excessive employment the manufacture capital-goods the expense developing the more stable consumer-goods industries. The ef- thereby sterilized. Then period business contraction pay the na- tional penalty for having built too elaborate plant without providing for consumption. not that all the plant too elaborate; the most injurious result the fierce compe- tition for superior equipment that sive rate and consequently wealth rapidly destroyed. This factor ex- ceedingly important. There much evidence indicate that, during the eight years preceding the crash, the major portion our increment productive power was absorbed this barren effort build super-efficient plants. Then apparently had simultaneous realization that good thing had been overdone and new in- vestment ceased, throwing out work our most highly paid men. Not only that, but effort keep the best equipment fully occupied, the profits longer used for improvement were diverted price reductions and destroyed the commercial value much in- ferior but still serviceable equipment. This explains much the disorgani- zation our producing system. Much has been said about the in- equality distribution wealth and income cause national trou- bles. One our leading economists predicts that must expect greater taxation the future means wider social dispersion the gains from mass production. That may perfectly sound proposition dis- tribution economies, but raises many questions human manage- ment. release labor private production only have comman- deered government, have as- surance that will put bene- ficial use. may even used for ex- tremely destructive purposes. Military warfare not any means the only one; government may embark all kinds undertakings which indi- rectly compete with private enterprise and reducing the volume available the latter, destroy capital values. Canals, housing, free departmental services and many other instances are now being brought into the limelight. private industry still continue will presently need code fair competition from our various govern- mental authorities. different class are the expenses self-government industry, the self-imposed charges through trade associations for their own policing and promotion collec- tive research and development work. Being under control those who best understand the needs, they are more likely restrained before they reach the point vanishing returns. Certainly, the leaders who are trying develop better self-government The Iron Age, November 16, ¥ — ye J e- C- we 10 i ° 5 ‘ their own industries need the thoughtful help all their members are avoid further political encroachment. The fifth course dealing with profits, piling liquid resources, the most dangerous all. its consequences are less commonly under- stood and have critical bearing our economy, need examine some detail. There course need for certain amount stored wealth. The cotton tween crops, pig iron the yard the merchant furnace, finished stock ready ship from warehouses are all necessary shock-absorbers. The danger comes when such stocks are piled excess normal needs and ultimately come into competition with current production sarily slow down the latter till balance restored. other words, delay- ing effective distribution the profits, set the stage for later contraction business. then that especial care necessary the application labor-saving devices, for they are used pile liquid resources, the men displaced will forced into fields diminishing re- turn. Forced Into Gold Mining Under these conditions see re- sort subsistence farming, and un- with ever less return. The ultimate effect this procedure most clearly evident when the exaggerated demand for liquidity and cash diverts more than the normal quota producers the mining our exchange me- dium, gold. The established mines readily increase output, the men who seek produce wealth mining gold have work areas which are commercially unprofitable. And the more men are pushed into such occupation, the poorer the field they will find, and the less wealth per day they will able produce. when the machine thus used push men into fields diminishing return, without opening new fields increasing return the same time, that arouses-antagonism. should now clear that the ma- chine not any means neutral factor the business cycle. may agent destruction. the need for definite constructive policy should equally evident. Can devise basic formula which, followed, will ensure beneficent results? must immediately rule out any use the machine for accumulating liquid resources “hoarding” profits. Tax rates are generally beyond indi- vidual control, but have recently seen New York some interesting re- sults concerted action against mulcting impositions. One may also recall the frequent use bonuses distributed after the war avoid pay- ing excess profits taxes. Even today, the alert manager not totally help- 12—The Iron Age, November 16, 1933 bargain with his local assessor, and judicious disposal surplus equip- ment, can write off sufficient compensate for inadequate govern- ment depreciation allowances. Our principal choice, however, lies between the three major courses: Are pass cost reductions the form price reductions, shall increase wages, should spend the profits grand effort build ultra- modern show-place? Formula for Distributing Gains The objection price reduction has already been stated. Yet there one obstacle total abstinence from using it: may the only way new machine process can prove its superiority and displace the old one, unless quality instead price can used the leverage. The use rains increase wages desirable far may practically possible. Sinking profits entirely into machin- practical balancing forces, the fol- lowing division the gross profits from new machine basically sound practice under present conditions: Allot per cent ownership for writing off the cost, for further de- velopment work and for incentives management. Allot per cent the general labor fund the concern increase wages for all. Out the remaining per cent, absorb much possible any increased cost supplies, minimize the impact rising prices, but any part this use not necessary, divide between dividends and wages. This scale course approximate one, subject judgment. The reasoning which based may briefly indicated: Examination the manufactures census figures indicates that industry whole tried for several years distribute the technological increment the suggested 40:30:30, and the result was profitless the “plough-back” rate per cent and the first per cent set aside for purposes management and absorbing losses equipment, will leave per cent the gross for obsolescence; that would demand active use equip- ment for years, and about more year reserve, and that should practically fast enough change over major machinery. the theory (admittedly debat- able) that the reward labor should increased the same rate tech- nological efficiency and the further assumption that per cent con- version.costs are for labor (since that usually yields the best net economy) per cent the profit profit should the labor account. Hence the per cent (50 per cent per cent) the gross. This also accord with experience with wage in- Although Taylor years ago used very high rates stimulate sus- tained efforts, the general tendency was use not more than per cent bonus normal recompense for first-class performance. One ob- jection really high bonuses was that the worker accumulated more than could readily spend without playing truant. Under present con- ditions, with shorter work-hours and generally low base rates, may need revise our figuring; the question what bonus over common going rates will produce optimum results again fertile field for research. The suggested disposition any balance should self-explanatory. Under present conditions, new ma- chinery should not used reduce prices; any extra consumer induce- ment necessary, any margin would better used product improve- certainly should not used cumulate cash even liquid resources beyond prudent needs. Advocates Use Licensing Now able practically oper- ate any such budget plan evidently necessary that industry ob- tain control over the obsolescence rate its machinery. now, compe- titive manufacturing has not had any such control, but has all too fre- quently been compelled take huge losses when the sudden introduction new machine has made existing ones obsolete. Hence neither its sta- bility nor its planning have ap- proached the standards reached monopolistic business, such telepone companies. Therein lies major obstacle the expansion credit. Those who are lending millions short term would only too pleased loan for longer period higher rates they had assurance security. (Concluded Page 56) \ materi secu coatins search center task. many are cating other recent these the su tween answ the other chem oper: may whic hot- elec best Bet som exp Ger ling tro fac the the tio els 4 on ETALLURGISTS agree that pure zinc one the best corrosion protective materials for steel. The problem secure thin, impervious, uniform coating pure metal and much re- search work and discussion have centered around this seemingly simple task. regard zine coatings many steel products, investigators are divided into two schools, one advo- cating. electro-galvanizing the other hot-dip galvanizing. England recently the relative advantages these two methods galvanizing was the subject important debate be- tween leading manufacturers, but nothing was definitely solved, for the problem, although sounding simple, in- volves many variables that the answer does not depend alone upon the method selected but upon many other factors such mechanical and chemical details. the wire, mechanical operations subsequent galvanizing may cause non-uniform coating which will throw criticism back the method galvanizing. The consensus opinion among English metallurgi- cal engineers seems that the hot-dip process may lend itself better the galvanizing sheets, and the electro-galvanizing method best for wire. this country electro- galvanizing steel wire still pretty much the experimental stage. The Bethlehem Steel Co. some electro-galvanized wire and experimenting with new methods. The General Electric Co., John Roeb- ling Sons Co., and others are elec- tro-galvanizing flat wire the manu- facture protective wires for the electrical industry. But other than these examples there seems one regularly steel wire. contrast this, the produc- tion electro-galvanized wire Europe well standardized basis with more than plants operation. Some the European manufacturers claim that thin coating zine put the electro-galvanizing process will withstand corrosion better than the much thicker coating put the hot-dip process. the recent questions received The Age question and answer department have been concerned with galvan- izing one form another. electro-galvanized steel wire avail- able the United States? hot- dip better than electro-galvanizing for sheets? How thick coating zinc should used for the best protection guy cables? What paint best for use galvanized structural shapes? These are typi- cal the questions received. Some questions are answered the ac- companying article, and others will articles. Hereafter, the policy question and answer department will group questions far possible and answer them sort symposium, which this article the first. answer question about electro-galvanizing mitted the Langbein-Pfanhauser- Werke Leipzig, the following com- ment was received: “We have placed operation many plants for electro-galvanizing wire, some them for the simultaneous gal- vanizing many wires and with this experience back firmly be- lieve that the electro-galvanizing process the only one which will yield pure zinc coat. hot galvanizing, even bath electrically refined zinc used, the bath will soon become contaminated with iron which readily dissolved the molten zinc. has always been prob- lem hot galvanizing keep the forma- tion zinc iron alloy Electro-galvanized wire can guished from hot galvanized wire im- acid solution. The former will outlast the other three four times. “If the electro-galvanizing process properly carried out, homogeneous and uniformily thick deposit pure produced, intimately bonded with the base and having smooth and shiny sur- face which will neither peel nor crack. HERBERT SIMONDS fact would justified claim that electro-galvanized wire need not have thick coating hot galvanized wire give the equivalent service. “In addition, the electrolytic method does not affect the physical properties the steel base and therefore recommends itself for the higher carbon grades wire subjected special heat treatments. “Because the smoothness its sur- face, electro-galvanized wire worked more easily into barbed wire, cloth, braids, cables, etc. The uniform thickness the deposit and great resist- ance corrosion make suitable for outdoor uses such telephone wires and guy “As the cost producing electro- galvanized wire, compares favorably with that hot galvanized. general, for thin coats lower and only for very thick coats will higher than for hot galvanized wire the same thick- ness deposit. For outdoor service, ex- perience indicates that coat from 2.4 oz. per sq. yd. will give satisfac- tory corrosive protection for many years, indicated the Swedish Telephone service. some the plants fur- nished, electro-galvanized wire pro- duced with zinc coatings weighing 7.2 per sq. yd. meet certain specifications. Such wires have much longer life than double dip hot galvanized wire.” Problem Safeguarding Interior Strands The difficulty safeguarding in- terior strands steel cables against corrosion has been recognized for long time. Tests have shown that cor- rosion the interior cables such elevator cables and power trans- mission cables may the three years. one case the reduction was per cent seven years. The problem serious because the diffi- culty determining the extent corrosion the inside the cable, from the outside. Several investiga- tors are now engaged exhaustive study this phase means the X-Ray. Cable manufacturers order prevent internal corrosion often use lubricated core, but this lubricant naturally dissipates time and almost impossible replace out- side application. Also, this emphasizes the importance using corrosion- (Concluded Page 56) The Iron Age, November 16, 1933—13 r re LE i special type roll caliper used for checking dimensions during grinding. the rubber and the cellulose in- dustries have placed with the manufacturers large chilled iron rolls startling demands for extreme accuracy finish. The need for precision finish unusual nature may understood from the fact that certain types paper are now being covered with ultra-thin colored coat- ings alternative the former method printing. The coatings are rolled the paper part the production process and must pass be- tween close-set coating rolls before the actual contact with the paper made. the rubber industry ultra-thin silk, and the cellulose field almost microscopically thin water-proof coat- The roll the background thought the largest paper machine calender roll ever made. 14—The Iron Age, November 16, 1933 > ings are being rolled many thin sheet products. These are just few many examples show the trend the manufacture thin materials and illustrate the challenge put roll manufacturers produce adequate precision product. The rolls for producing the ultra- thin coatings are frequently ft. long and ft. diameter, and the accuracy roundness some the smaller rolls used for coating paper 0.0001 in. The accuracy parallel- ism demanded such that two rolls running contact with strong light behind them will not show the slight- est crack under close observation. The great need for accuracy the finish the rolls not determined solely the need for uniform thickness increased demand from sey- eral industries for extremely accurate rolls has taxed the in- genuity chilled iron roll manu- facturers. often happens, the solving this problem has opened the way for extension the use large accurate rolls many new fields. The accompany- ing article explains some the methods used the Farrel-Birm- ingham Co., Inc., produce ex- tremely accurate rolls. One recent product this company, calen- der roll 405 in. long, thought the largest its kind ever produced. stock, for some the coating pro- cesses high speed work the whole drying operation carefully reg- ulated that spot with even slightly greater thickness will fail dry and thus will cause wrinkles. Such extreme accuracy that de- scribed can obtained large units only when there meticulous control operations from the raw material through the shipping department. One the large companies which has been leader helping solve the problem securing thin coatings the rubber and paper industries the Farrel-Birmingham Company, Inc., Ansonia, Conn. the large roli manufacturing plant this company, precision rolls are produced part the regular day-to-day operations. 405 in. long overall and weighed Incon compan chemica the con furnace furnish peratur ing for the position foundry poured prof vices terial tween ings control eter. The mas upon terior pound, ing joints tions. the carefu connec custon not surfac Aft off, roll thi aroun Large Rol = Incoming material checked the company’s own laboratories for both chemical and physical properties. the company’s foundry, cupolas, air furnaces and electric furnace furnish molten iron the proper tem- perature and composition for the cast- ing the large rolls. The molds for the rolls are built vertical position deep pits set into the foundry floor and these are bottom poured through long, sandlined gates. profusion cranes and other de- vices facilitates the handling ma- terial and makes possible accurately regulate the interval time be- tween the filling the ladle the furnace and the pouring the cast- ings the floor. Such regulation necessary for precision temperature control. Temperatures are checked before pouring, with optical pyrom- eter. Making the Roll Castings The molds are built with series massive cylindrical chills piled one upon the other and coated the in- terior with specially prepared com- pound, which serves parting coat- ing and which also smooths over the joints between the different chill sec- tions. The neck ends journals the rolls are molded sand and are baked closely specified temperature, and the procedure connection with these parts follows customary gray iron practice, not desired have chill these After casting has set and cooled sufficiently, the runners are broken off, the chills are removed and the roll lifted out the pit and placed the foundry Later the sand around the journals broken away BERGES Manager, Roll Department, Farrel-Birmingham Co., Inc., Ansonia, Conn. and the gates are chipped off means chisels and pneumatic ham- mers. this point the rolls are ready transferred the machine shop which spacious well-lighted building equipped with much special machinery. Finishing the Rolls The rough roll castings which enter this shop one end are first centered preparation for the turning the necks, fillets and collars. The center- ing done while the casting re- volved idler wheels, that the center points are located from the out- side surface. The necking opera- tion performed lathe, with the roll revolving its centers and the same time the contour the shoulders completed. Where special fillets collars are called for, special- shaped tools are necessary, but this all work softer metal and fol- lows usual machine shop practice. The roll then goes the facing lathe have the chilled body surface turned down. The facing operation accomplished long, flat tools held parallel and moved against the roll surface means screws. For this work the roll revolves very slowly, not more than six revolutions per minute. The cutting tools are normally high speed steel although tungsten carbide used some cases. long rolls several cutting tools may -be operation one time. Each Finishing tool about in. long and its positiom controlled two screws, one each end and each provided with head which fits special wrench. The lathes are set pairs facing each other with operator between control the work both lathes. The feeding the tools inward toward slowly revolving roll important. operation and one the delicate parts the roll manufacturing se- quence. The amount feed the tools governed the feel the operator’s wrench the regulating screws, and this calls for long experi- ence and knowledge behavior different irons under the cutting action. Because the accurate con- tour the rough casting, minimum machining called for, and, course, the less metal removed the greater will the depth chill the finished roll. Usually the casting about in. greater diameter than the finished roll, which leaves about 7/32 in. for turning and in. for grinding. During the various stages the facing operation the roll carefully examined for pin holes. pin holes they are marked with chalk the operator. the number pin holes seems excessive inspec- tor who has the authority accept reject the casting. cast- ing with some pin holes accepted the facing completed bring the roll the required diameter before grinding. The roll then goes an- other section the shop where each pin hole drilled and plugged with special material. These plugs are carefully fitted that nearly impossible find them after roll finished. After all pin holes have This shows the method turning journals, collars, and fillets 42-in. diameter linoleum roll. The Iron Age, November 16, 1933—15 | Xs. i] ) i late | 4 re + 7 elaborate system handling equipment required the roll foundry. been plugged, the roll then returns the regular production sequence and now ready for grinding. Special Machines for Grinding The extreme accuracy required the finishing some large rolls has taxed the ingenuity the company’s engineers and only after much research that the demands the rub- ber, paper, and metal industries have been met. The Farrel-Birmingham Company, Inc., for many years has built and operated precision grinding machines using two grinding wheels, one each side the work and both wheels mounted swing rest supported knife edges the carriage. Special gaging and caliper- ing instruments have also been built enable the operators determine the accuracy the finishing advances. The general scheme accurate roll grinding the plant its essential features follows customary practice accurate grinding. The rolls are rough ground within 0.002 in. finished dimension and then ground with finer cut and with wheels finer grain about 0.0005 in. After this the roll allowed age relieve any slight residual strains and permit stabilizing the surface grain structure. The final precision grinding merely ex- tremely delicate cut taken rugged machine using the principle two suspended wheels, the end that the action gravity tends minimize any tendency error. Some special features design are involved grinding stack rolls where 16—The Iron Age, November 16, 1933 necessary compensate the weight and the spring the lower roll. The new Farrel Ni-Hard rolls test- ing from the Shore sclere- scope present some unique problems production. These rolls are hard the face and journals that practically impossible cut them grind the entire roll, even the journals and fillets. This done heavy duty one-wheel grinder the pany’s own design and manufacture, This capable both heavy ing and the finest mirror finish and has been developed meet the growing demands for speed and curacy the finishing metal work- ing rolls. These new rolls are now being used for the finishing ex- tremely fine metals and are considered well adapted for this type work. Giant Calender Roll What thought the largest paper calender roll ever made was re- cently produced the Farrel plant and its unusual size created several manufacturing problems which were successfully overcome. The tion, in. diameter and has face 298 in. length. the bot- tom roll 8-roll stack and 405 in. total length. the rough had weight tons. was neces- sary build entirely new roll pit the foundry, the previous one had insufficient capacity handle this length. The old pit was ft. deep and the pit built for the large roll ft. deep. The construction the pit itself involved some culty, extends below high water adjacent river and yet must absolutely water-tight trouble might develop. addition the usual type waterproofing, necessary supply interior finish which would not damaged accidental run-out molten metal. Briefly, the completed pit consisted outer steel caisson inside which was concrete wall. Inside the concrete was layer waterproofing (Concluded Page 51) This shows complete paper machine with large roll stacks installed plant South Carolina. has cording per cen peat The peat not been The the years the Gorky machir high for tained Soviet coal south coal Owing tra 23! iron, sary lines. Suc org the ing impos for ing iron prod cont: peat The ash phos equa am hy — Soviet Union country which has large supplies peat. Ac- cording the statistic data about per cent the world’s area occupied The possible area occupied these peat bogs this country estimated not less than 130 million hectares. the present time peat had been only used for firing steam boilers. The peat problem became actual the Soviet metallurgy during the last years owing the development the machine-building industry. The central districts the Soviet Union such as: Moscow and Gorky form the main centers the machine-building industry, where the high quality pig iron, which needed for the building machines, ob- tained from distant places the Soviet Union as: Ural district, Donetz coal mining district, located the south Soviet Union and Kusnetz coal mining district located Siberia. Owing this reason pig iron has 2350 kilometers, which not only greatly increases the cost the pig iron, but also brings about unneces- sary overburdening the railway lines, Such condition makes necessary organize the production pig iron the above mentioned machine build- ing centers. the present time this had been impossible owing the lack fuel for blast furnaces these districts; raw ore being present the form calcined pyrites such waste pro- while preparing acid. present the problem utilizing peat fuel for the blast furnaces combines with the problem using pyrites raw material for producing pig iron. The advantage obtained from utiliz- ing peat fuel for the blast furnaces order produce high quality pig becomes obvious, take into consideration that blast furnace coke produced the Donetz coal district contains from 2.5 per cent sul- phur; while the sulphur content the peat does not exceed 0.3 per cent. The phosphorous content the peat ash equal 0.5—1.0 per cent. The Phosphorus content the peat 0.04-0.05 per cent. Lump Peat Fuel for SUSLOV Metallurgical Engineer Research Institute, Grosneft Trust, U.S.S.R. Thus, using peat possible produce high quality pig iron. order find out whether possible use peat the blast- furnace smelting performed under the supervision committee well-known Soviet metallurgists the Kosogorsky iron works situated the south Moscow distance about 200 (near town Tula). This test lasted one month—Octo- ber, 1932. Machine-moulded peat, which was obtained from the Lenin- grad and Moscow districts, was found quite suitable for the coking per cent moisture and per cent ash. The size the peat brick used dur- ing the smelting test was standard in., which was found too long and inconvenient for charging the furnace, The product obtained from agglom- eration calcined pyrites was used essential ore. Its average Fe. con- tent was equal per cent; Si0.—14 per cent; Sulphur—0.15-0.40 per cent; Phosphorus—from traces 0.11 per cent; per cent; Copper furnaces interesting Soviet development. The U.S.S.R. con- tains more than two-thirds the world’s peat bog area. Heretofore, this peat has been used for firing steam boilers. Mr. Suslov tells recent engineering accomplish- ments the use peat blast furnaces combination with cal- cined pyrites. result these tests, furnaces particularly adapt- this fuel will designed and constructed the central Soviet districts. Blast Furnaces —0.31 1.35 per cent. The ag- glomeration product appeared quite suitable raw stock used the blast furnace even when its content the ore charge was equal 100 per cent. The purpose carrying out this experimental smelting test was prove the possibility producing pig iron means using peat coke blast-furnaces; with effective (use- ful) height and capacity equalling 20.8 and about 348 cub. respec- tively. Diameter hearth was 3.4 1923-1924 the possibility pro- ducing pig iron commercial scale proved means using peat mixture peat and wood fuel charcoal blast-furnaces with small daily output from tons and means using metallic turnings instead iron ore. Whereas the moisture content peat has been usually from per cent and even more per cent. 1925 the possibility producing pig iron commercial scale was proved means using peat alone fuel with moisture content from per cent and iron ore (calcined siderite—Fe—38 per cent) charcoal blast-furnaces with daily output from 27.8 tons. 1932 above mentioned tests using peat fuel for coke blast-fur- naces gave favorable results. The conclusion made the com- mittee metallurgists under whose supervision the experimental smelting operation was carried out fol- lows: Peat with mean degree decom- position suitable for blast-furnace smelting. should contain not more than per cent moisture and per cent ash. necessary maintain the intensivity the smelting means properly supplying the blast, assuming that the peat consumption equal 1.1 ton per cubic meter effective capacity furnace. Notwithstanding the peat and peat- coke, which obtained out blast-furnace, burns easily the temp- erature the blast should near the possible maximum 750 deg.-800 deg. Pressure corresponding 35-40 cm. with the effective height the furnace equalling 20.8 was (Concluded Page 47) The Iron Age, November 16, 1933—17 Sap 8 \ | - 300 200 100 Thousands Hp. Installed Per Year 1915 1920 300 1925 1930 Amount Hp. Installed Each Year Electric Drivesfor All Types Rolling Mills Year =) =) Instatited Per oO Drives COMPREHENSIVE survey manufacturing equipment the current year, encompassing largely the advances made electrical apparatus, was pre- sented the recent meeting Pitts- burgh the Association Iron and Steel Electrical Engineers Burr, chairman the association's committee electrical developments and electrical and mechanical super- intendent the Lukens Steel Co., Coatesville, Pa. From have been taken the following items covering major features new equip- ment, the complete report touching also machine braking, circuit break- ers, new wire insulation, lightning protection and meters: Rotary Process for Making Steel particular interest this year the new rotary process making steel. One hundred per cent steel scrap charged into electric fur- nace; the melt poured into mold revolving high speed; the resultant 2-ton circular bloom, in. sec- tion and ft. diameter, sheared into arcuated sections; flash heat brings these sections rolling temperature and they are ready for billet conversion breakdown mill. plant for making steel the rotary process nearing completion De- troit. Combustion Open-Hearth Furnaces doubt the two most interesting developments combustion field are: Luminous flame combustion and one- way fired open-hearth furnaces. existing furnaces there has been intensive effort cut fuel cost and shorten time heats. This has led new methods burning fuel the open-hearth furnaces. large East- 18—The Iron Age, November 16, 1933 ern company has been trying top- fired furnace and Mid West concern advocating firing from all four corners. Real progress has been made the control open-hearth furnaces. Con- stant analyses existing gases are now possible and furnace combustion regulated automatically from these analyses. Turbine-Generator Set Out Doors For the first time erator set was designed for outdoor operation. non-condensing unit and produces 6,000 kw. reducing the pressure the 400 lb. steam mercury-condenser boiler 250 for use the shops. The principal outdoor feature special lagging that covers the tur- bine casing and bearing brackets well the collector rings and exciter. The bearings are equipped with sight-flow indicators located under windows this lagging. The valve gear parts are all non-corrodible material withstand the effects the weather. 65,000-sq. ft. condenser, con- structed electric welding, the latest mile post the progress the art joining metals. Designing the condenser for welding involved re- arrangement ening members, view which ex- haustive tests were made upon one-sixth-scale model, which showed strength greater than calculated. second 160,000-kw., 1800-r.p.m. was placed service the Hudson Avenue Station the Brooklyn Edi- son Co. Among the instruments are interference recorder for rotating parts that will indicate and record squeak other sound, vibration am- plifying with detectors each bearing, and Selsyn power ampli- fiers for the remote operation and indication valves. Transformer Developments Numerous interest steel companies op- erating electric arc furnaces the development motor-operated, tap changing switch mounted inside the transformer casing. The switch pro- vides for connecting the high voltage windings the transformer, cither delta and may also provide for two taps each connection. This switch course greatly decreases the number oil circuit quired control multi-voltage necessary place furnace and other high-capacity transformers with low- voltage high-current secondaries in- doors. Now, however, low-voltage weatherproof bushing for secondary bus bar terminals available which permits mounting furnace and similar transformers out-of-doors. Transformers filled with non-in- flammable insulating liquid, called Pyranol, are now available sizes 500 kva. Pyranol new non- inflammable insulating and cooling medium, which heavier than water, non-sludging, non-oxidizing, and non- acid forming. Pyranol-filled trans- formers eliminate the fire hazard inflammable liquids. distribution transformers there has been introduced detachable stud well cable bushing which has its advantage that can attached from the exterior the case without the necessity removing the cover. This feature eliminates the necessity handling tools inside the trans- former case whenever bushing mensic were provid cars details tion sign result: and values tectivi For type arrest therel tice ton the form melti vario provi prim with prac betw the This high whic cons A cc mar bala com | mor und 200 100 Year 300 200 Instatied Per 100 Drives 1905 1910 1915 1920 300 1925 1930 Number Electric Drives 300 Hp. and Over Installed Each Year for All Types Rolling Mills Manufacturing Equipment li- number power transformers exceptional ratings and physical di- mensions were built, some which were large that was necessary provide specially constructed freight cars for their shipment. Many the details power transformer construc- tion underwent modification de- sign utilize practical way the results lightning investigations and secure higher factor safety the coordination the insulating values transformers and the pro- tective elements power systems. For the protection distribution- type transformers, was found feasible locate intershunt Thyrite arresters inside the transformer tank, thereby simplifying installation prac- and providing distinct advance the over-all protection distribu- ton improvement has been made the coil construction large trans- formers used connection with steel melting and other furnaces, also for various chemical processes. The im- provement consists arranging the primary winding such manner with respect the secondary that practically uniform reactance exists between the two windings throughout the full range secondary voltages. This gives low reactance which highly desirable transformers which carry heavy amperes. This gives another advantage. coil constructed has additional advantage the fact that the pri- mary and secondary are practically balanced with respect one another against mechanical stresses caused heavy overloads short The new surge-proof transformer combines better-built transformers, more effective arresters, and better understanding lightning. The pro- tective elements are built inside the walls the transformer itself; and though the intention that ground wire shall used, the protection effective even without it. When incoming surge raises the potential the high-voltage winding, pair sparkgaps flash over the case, and third gap flashes over, connecting the case the ground and discharg- ing the over-voltage and the gaps are self-extinguishing. They invariably interrupt the current half cycle less—so rapidly, fact, that the primary fuse will not blow, nor overload relay operate. Even case the ground connection missing, the surge dissipated the grounds the secondary. Electric Furnaces with Controlled Atmospheres The trend modern electric fur- nace development toward the use protective atmosphere the heat- ing and cooling chambers, oxidation material being heated, some cases reduce the oxide already the material. Development and installation two types atmosphere producing equip- ment were made. One these ammonia dissociator which tanked anhydrous ammonia connected the coiled alloy tube, which contains suitable catalyst. The coil placed electrically heated chamber where the temperature automatical- controlled the proper value. The ammonia gas dissociated, giving mixed gas containing per cent hy- drogen and per cent nitrogen. This gas produced cost approxi- mately per cu. ft., which includes the cost ammonia and electric energy. This figure based the price ammonia cylinders. purchased tank car lots, this cost may reduced per cent more. Such gas suitable protective atmosphere for practically all appli- cations where hydrogen suitable, and much less costly than tanked hydrogen gas. equipment was developed provide atmosphere low cost. con- sists device for controlled mixing air and gas (either gas natural gas), combustion chamber which the gas reformed, and cooling coil where excess moisture removed. The analysis the gas can varied from one that practically neutral one that highly reducing char- acter, adjusting the ratio air gas. The cost the atmosphere produced this equipment approxi- mately 30c per cu. ft. (when using city gas approximately 500 B.t.u. co