The Iron Age 1933-11-23: Vol 132 Iss 21

YEAR SERVICE THE METAL WORKING INDUSTRY NOV CONTENTS INDEX PAGE MANAGEMENT NOVEMBER 23, 1933 PROCESSES -:- NEWS The Consumers’ Verdict EADERS and advertisers form supreme court beyond which there appeal. This court alone can hand down decisive verdict publication leadership. What this verdict the metal-working field? two parts. One part has been written readers, the other part advertisers. The reader verdict this: During the past year, per cent more men the metal-working industry have bought and paid for The Age than have bought and paid for any other publication this field. The verdict this: During the present year, per cent more advertising space has been bought and paid for The Iron Age than has been bought and paid for any other pub- lication this field. Advertising executives who contemplate 1934 investments the metal-working field will wisely insist having the details this decisive consumer verdict. They will cheerfully sent any- one, any where, any time. 4 q ’ | 2 of way : _S | THE IRON 23, 1933 Page requir Liners for ceramic molds. Eastern District Sales Manager: Andersen Central District Sales Manager: William Eakin 135 Post Ave., Lyndhurst, New Jersey 707 Berkshire Ave., Pittsburgh, Pennsylvania IRON AGE, published every Thursday the AGE PUBLISHING CO. Publication Office: Cor. Chestnut 56th Sts., Executive Offices: 239 39th New York, Y., Entered second class matter the Post Office Philadelphia March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 132, No. 21. SKETS COOKING sales engineers are with the many widely varied die designing and machine tool Ask for booklets describing the DETROIT ALLOY STEEL Foot Iron Street Detroit THE IRON AGE November 23,1933 GERARD Boston Editor Managing Editor Consulting Hditor News Editor Machinery Editor Pittsburgh Detroit Cleveland Chicago Editor Emeritua Washington Cincinnati Contents Collective Bludgeoning Attractive Finish Helps Metal Products Sales OUR PART Conveyor Screws Various Natural Gas Furnace Steel Tube Making The Place Metallurgists Industry Personnel Work the Small Plant National Founders Association Reviews New Deal New Equipment News Personals and Obituaries Washington News Automotive Industry Markets Construction and Equipment Buying Products Advertised Index Advertisers THE IRON AGE PUBLISHING COMPANY GRIFFITHS, Secretary BAUR, General Advertising Manager PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th New York, Y., FRANK, President Member, Audit Bureau Circulations ADVERTISING STAFF Emerson Findley, 311 Union Bldg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo, N. Y. H. K. Hottenstein, 802 Otis Bidg., Chicago Peirce Lewis, 7338 Woodward Ave., Detroit Charles Lundberg, 45 Kent Rd., Upper Darby, Del Co., Pa. Cc. H. Ober, 239 West 39th St., New York W. B. Robinson, 428 Park Bidg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address, ‘‘Ironage, N. Y."’ D. C. Warren, P. O. Box 81, Hartford, Conn. Member, Associated Business Papers Published every Thursday. Subscription Price: United States and Possessions, Mexico, Cuba, $6.00: Canada, $8.50, including duty; Foreign, $12.00 a year. Single Copy Cents SEVENTY-NINTH YEAR SERVICE THE METAL WORKING INDUSTRY 23-B 100 | bite | | 2 | | | > J ladelol under THE IRON AGE...NOVEMBER 23, 1933 Page for ordinary, every-day applications, such gas holders, tanks, standpipes. Plates for unusual pressures temperatures. Plates resist severe abrasive corrosive Whatever you require plates, send your specifications Bethlehem. are unsurpassed facilities, highly skilled operating personnel and metallurgical staff that can apply the solution any problem the experience derived from making complete range steel products. Bethlehem Steel Company, Bethlehem, Pa. STEEL subj “ope mar inte han and “A the ing, NIR trati gene und diff THE IRON NOVEMBER 23, 1933 ESTABLISHED 1855 Vol. 132, No. Collective Bludgeoning which conveys different meanings different minds. Its interpretation subject much latitude the terms “open” “closed shop,” which were ban- ished from the NRA lexicon. the measure non-admission code phrases, this term, collective ing, would never have crashed the gate NIRA. For between the apparent adminis- trative conception its meaning and the great the distance between the poles. Collective bargaining, the general pub- lic and the majority employers have understood it, means the amicable meeting between management and men indus- trial company for the purpose adjusting differences and improving mutual relations. management well men profit this interchange opinion based hand knowledge the specific conditions and problems facing the individual com- pany. This sort collective bargaining brings men closer together, puts employee and employer the same side the fence. OLLECTIVE bargaining, “‘organized labor” sees it, and the Recovery Administration seems see it, means that management not talk things over with employees and thus settle differences, but must with outsiders who neither toil nor spin the trade and who have first- hand knowledge company conditions. This sort collective bargaining drives men apart; puts employer and employee opposite sides the fence and often with the fence gate shut. bludgeoning, not bargaining. mistaken notion that employers oppose collective bargaining the sense its true meaning. But equally mis- take believe that collective bludgeoning can ever upon American industry. not the cards, even the New Deal. sits ~<a eS. em. ical ica . ing How Finish Helps This illustrates the difference appearance between cleaned and uncleaned metal product. CUTLERY stalled simple agitator his cleaning tank and cut his cleaning time per batch from min. min. Thus did demonstrate the former “out-of-dateness” his cleaning equipment. Outside the clean- ing room this particular plan was mod- ern and highly efficient, but economies cleaning had been overlooked, condition typical great number plants all branches the metal working industry. Cleaning has been widely discussed and dozens arti- cles have appeared describing the technique and the required equipment, but very little has been said about the relation cleaning sales, the process. Why should manufacturer clean products? Even those who are doing the most cleaning are not aware just why they and just what should cost. One reason for cleaning render product salable. This, however, has reference particularly that phase cleaning known wash- ing and degreasing. Another large division the cleaning process has with removing scale, which proc- ess primarily prepare for fol- lowing operations rather than pro- vide immediate good appearance. Both types cleaning often are facilitate subsequent operations the manufacturing sequence. dirty wire, for instance, cold drawn, the dirt not only worked into the wire, creating poor surface, but also causes abrasion and excessive wear 12—The Iron Age, November 23, 1933 the drawing dies. The same thing true with most other products. Nearly always the sequence when nec- essary anneal, also necessary clean, because the annealing forms scale. Cleaning Screen Production example the importance cleaning production may found examining the detailed manufac- turing operations most any metal product. Take for instance the famil- iar window screen. Here the cleaning may start when chippers the hot mill clean the billets before they are rolled into wire bars. Some form descaling may take place when wire rods are drawn from the bars. the wire mill the usual procedure pickle the rods before starting any further operation. This remove mill and other surface dirt. steel the scale nearly always oxide. copper may sulphides combination sulphides and oxides. drawing the wire down the final size for making screen, will probably necessary anneal two three times, and this will call for many descaling operations. De- sealing after annealing the wire mill usually accomplished pick- ling. The wire then washed cold water, coated with lime, and then baked. The lime put neutral- ize any acid pickle which might re- main after the cold water rinse, and also aid carrying the drawing lubricant into the dies. The baking EMONSTRATE manufac- turer assured economy machining operation and will usually adopt it. assured clean- ing economy the other hand must far more spectacular receive the same considera- tion, yet cleaning metal now takes its place established production process, closely asso- ciated with fine finish and with greater sales value. Why should metal parts cleaned? Can cleaning avoided? What method cleaning should the manufacturer select? These are some the questions consid- ered the accompanying article which the third series de- voted some commercial aspects metal finishing. Subsequent ar- ticles will consider pickling, rust- proofing, galvanizing, buffing, pol- ishing, plating, and other branches the metal finishing art. give the lime adherence and also remove any trace hydrogen, ab- sorbed during the pickling, which otherwise might embrittle the wire. Customarily after the last anneal, the wire intended for the manufacture screens pickled, although here the practice differs, depending the type anneal used and the type grades wire frequently are not pickled after the final anneal. the plant the screen manufacturer the wire cleaned before weaving, move grease and dirt. This operation coils tank some alkali cleaning solution and following this thorough rinsing and the wire leaves the weaving machine, screen, thoroughly cleaned again order put condition receive the final finish which may enameling, plating, galvanizing, some other finish. 85,400 Tons Nails Cleaned Wire and screen are products hav- ing comparatively little cleaning their manufacture that the extent cleaning throughout the metal in- dustry should judged from the cleanir list the such the which oughly even used, furthe coated tomar soda them, and (100 Takin means the final nails result can will grow the the tude maki Roun then ens anne neali The gas thro thro vani for j Dy ‘ j a | i j Sales also ab- hich eal, nere not the the tion the fter ine, ned nay ent in- the HERBERT SIMONDS Cost and Value Cleaning cleaning history some other items. listing cleaning operations the production table silverware, for instance, would much more for- midable affair. Some wire products such nails are not cleaned during fabrication, but usually this calls for the use better grade wire which has therefore been more thor- oughly cleaned the wire plant. And even the case nails, finish used, there must cleaning. large tonnage nails galvanized and further large proportion cement coated. For such finishes cus- tomary wash them caustic soda similar solution, then rinse them, and then pickle them. 1931—584,000 kegs (100 lb. each) galvanized nails were produced, and the same year 1,123,000 kegs (100 lb. each) cement coated nails. Taking these two products together means that least per cent the total production nails received finish requiring cleaning. nails are galvanized without being thoroughly cleaned, poor job will result. rusty nail, for instance, can hot cold galvanized but will not long before the rust will grow and push the galvanizing off. Cleaning for Some the products which call for the greatest amount cleaning the metal working industry are auto- mobile bodies, tin cans, pipe, electrical conduit, and strip used for multi- tude purposes, among others, for making protective conduit the electrical industry. The production Round steel wire received the manu- facturing plant first cleaned and then flattened. This flattening hard- ens the metal, making necessary anneal. one large plant the an- The flattened wire fed into ma- chine which has its first stage gas annealing oven. After passing the wire continues through pickle bath, then through and subsequent operations continuous chain, electro-gal- vanized, rinsed, dried, and reeled. Terne plate and tin plate both call for extensive cleaning operations and because the large production both these industries, highly specialized equipment has been developed. Clean- ing preceding vitreous enameling important operation and this the large industries such stove, re- frigerator, and tile manufacturing, are big factors. Cleaning the manu- facture metal furniture neces- sary operation, also the pro- duction Pullman cars. Most metal elements such screw machine prod- ucts are cleaned remove the oils and greases the production proc- salvage cleaning may found any large locomotive repair shop. The practice the Reedville shops the New York, New Haven and Hartford Railroad disassemble the incom- ing locomotives and put every part through thorough degreasing proc- ess before anything else done. Proper inspection thus possible. Some products are degreased order prevent injury complete assembly. Gears, for instance, which are used the assembling machine tools must cleaned because scale left assembled gears will flake off and become mixed with oil, forming exceptionally abrasive mixture, which circulates through the moving parts machine tools score the gear teeth and cause rapid pitchline wear. also cuts and destroys bear- ings. the production airplane operation preceding unit assemblies. Parts which are joined press fit must thoroughly cleaned order give correct alinement. The great scope general hand cleaning which not dealt with here illustrated the quantity wiping cloths, rags, and cotton waste sold the metal industry each year. Cleaning Stainless Steel Another example necessary clean- ing the degreasing stainless steel sheets and strips prior annealing. Unless all traces grease are re- moved from stainless steel sheets the Oshawa, Ontario, plant the General Motors Canada, automobile wheel assemblies are cleaned and dried belt type automatic cleaning machine. The Iron Age, November 23, 1933—13 ac- ina will an- ith uld id- cle > strip before annealed, the mate- rial becomes stained spotted and these spots cannot thereafter re- moved. Unless all traces scale oxide are removed steel, part the final finishing, the steel itself will not remain passive stainless but will rust rapidly and around the spots from which scale has not been removed. What Dirt? the shop piece metal either greasy, stained, scaley, rusty, may have its surface, combinations many forms dirt. Usually all dirt classified scale grease. The conventionalized diagram shows the relation grease, scale, and metal, typical dirty metal product. The metal itself, shown, surrounded closely adhering layer scale and the scale covered with grease and dirt. cleaning, the grease which forms the outer layer re- moved before employing descaling Grease can removed many dif- ferent ways. may removed simply wiping off with rags buffs, either hand mechanically. Tin sheets which are coated with palm oil they emerge from the hot tin dip are customarily cleaned passing them between revolving cotton disks onto which are fed Grease may removed tumbling with material such sawdust, immersion washing solutions, steam jets, and centrifuging. There are three general classes greases; (1) the non-saponifiable, mineral oils; (2) the saponifiable, the vegetable and so-called sulphonated oils; and (3) mixtures the above, which are usually known partially saponifiable oils. The principle de- greasing differs, depending upon the nature the grease removed. The first class greases usually removed vapor degreasers volatile solvents, sometimes called or- ganic solvents. Typical the vapor degreasers and typical the volatile solvents are benzine, gasoline, and carbon tetra- chloride. The method using the volatile sol- vents varies from merely rubbing the surface with the solvent, the use elaborate cleaning machines which jets the solvent impinge upon the moving articles cleaned. Per- haps the most usual method merely dip the work open tank con- taining solution the solvent. Theory Cleaning Non-saponifiable greases can re- moved emulsification alkaline solutions containing soap. They can also removed emulsification electric cleaners, but oils and greases which are completely non-saponifiable cannot removed readily cleaners _ This rotary machine cleans, rinses, and dries safety razor blades one operation. The machine was built the Metal Wash Machine Co. and special cleaning solution was developed the Magnus Chemical Co. 14—The Iron Age, November 23, 1933 this type. The principle the re. moval these greases rests upon the displacement the greases soly. tion which has greater capillary at. traction for the metal and consequently stronger tendency wet the than that the grease itself. The cleaning solution which properties and thus displaces the grease also must readily removable subsequent water rinse. Saponifiable greases cannot moved vapor degreasers. They can removed with volatile solvents and they are readily removed alkaline greases react with the free alkali form soaps and consequently pro- the agency required for emulsi- fication. obvious that mixtures grease oil containing saponifiable elements can removed the same methods are used for the removal the totally saponifiable greases. The difficulty removing such mixtures roughly de- pendent upon the proportions the two elements which form the mixture, Vapor Degreasing The diagram sketch tion through one form vapor de- greaser. Here the liquid trichlorethy- lene placed the trough the bottom and the vapor from this liquid when heated rises the tank until meets the cold air escaping from the cooling chambers shown each side near the top. soon the vapor strikes this air condenses and drops back the bottom the tank. The work cleaned merely lowered between the cool- ing chambers, and the condensing vapor washes off the grease. This excellent method degreasing, but for its success requires that the work free moisture because water contact with the trichlore- thylene will acid which soon causes trouble destroying the properties trichlorethylene. The theory vapor degreasing simply the reduction viscosity. the viscosity which holds the grease the material and can sufficiently reduced, the grease will run off. rather common way removing the partially saponifiable greases modified emulsification. The parts cleaned are immersed boiling solution which partly emul- sifies and partly reduces viscosity effect the cleaning. alone course will clean metal parts grease, but expensive and cult because subsequent operations. Also, tends increase the scale. Heating steel oxygen-free atmosphere does not produce scale and this feature sometimes ployed heat treatment avoid subsequent descaling. This possibil- ity reducing the extent clean- ing operations will discussed some length under the subject descaling. The three The simila type, non-s: and sively cle shoul the clean mach alone Clear chine mant more off ical ing. dirt, type, solut way ing chan tank the then gets use effec Whe tank and one the men Mit Gar this pur sett the and spe era the anc twe f a v con cos The saponifiable greases are three kinds; the hard, stearic acid type; the medium, vegetable wax type; and the soft, tallow type. The non-saponifiable greases may similarly classified hard paraffin type, medium soft paraffin type, and soft petrolatum type. The non-saponifiable greases are cheaper and therefore the tendency manu- facturing use them more exten- sively than the saponifiable. Cost Cleaning cleaning problem his first thought should not the cleaning itself but the plant operations which make cleaning necessary. may that can change the cutting oil the machine tools and this means alone effect big saving cleaning. Cleaning expense nearly always re- duced increasing the proportion saponifiable oils the preceding ma- chine metal working operations. manufacturer can often afford pay more for cutting oil that will wash off easily. Sometimes econom- ical actually immerse the work saponifiable oil preceding the clean- ing. other terms, add more dirt, but character-changing type, already dirty part, aid removing all the dirt. Cleaning solutions are relatively expensive and usually pays take some steps increase the life the bath. One way using preliminary clean- ing operation such centrifuging. Another way use 2-tank inter- changeable system. both tanks contain the same solution and the work immersed first one and then the second. The first tank gets dirty quicker because the bulk the grease removed it, but its use keeps the second tank clean and effective for much longer period. When the first tank becomes too slow service, due dirt, the second tank becomes the first the sequence and new solution replaces the dis- carded dirty solution the other tank. Another 2-tank scheme which one tank allowed settle while the other working, being recom- mended with much success Mitchell the Magnus Chemical Co., Garwood, Mr. Mitchell calls this the regenerative method. Im- purities and sediment the idle tank settle the bottom and oils float the top. When the tank put use again, the oils are floated off and the sediment removed special trap device. this method alone the life cleaning solutions said have been increased much times their normal when regen- eration not practiced. one case the previous normal was two weeks and with the new system became twelve thirteen weeks. Because the great variety conditions, general statement cleaning can made, but few examples will serve give the These show two types metal cleaners use the Citroen automobile plant France. what his cleaning costs should be. manufacturer twist drills uses continuous washing machine good design, but not elaborate. about five years old. The tank holds 100 gal. and uses oz. clean- ing compound per gal. water about lb. cleaner tankful. The capacity the equipment small work tons for 8-hour day. The solution lasts five days with daily make-up additions compound which totals 13% Ib. This for five days ten tons, mak- ing cleaner cost about cents ton. The labor cost this case $1.00 ton and the overhead about cents, giving over-all cleaning cost $1.71 ton. manufacturer pressed steel open boxes, size in. in. in., uses cleaning solution oz. compound per gal. open tank with electric acceleration. The current flows from the work the anode density 35-40 amp. —— sq. ft. work surface. The solu- tion kept boiling and the total cleaning cost cents for 1000 pieces. Electric Cleaners Electric cleaning for the removal grease and dirt and also for the removal scale and oxides, particu- larly from iron and steel articles, increasing popularity. consists immersing the work tank con- taining suitable solution, the work forming one electrode and the side the tank, insoluble plates, are connected form the opposite pole the electric circuit. When electric cleaners are used remove grease and dirt, alkaline solution always used. The base this alkaline solution caustic soda soda ash, which there usually added such chemicals water glass tri-sodium phosphate. The current which flows through such breaks down the water the solution into its constituent gases, (Concluded Page 52) The Iron Age, November 23, 1933—15 the ore- oric the ring ale. ale Conveyor Screws Various itches and Diameters Single Steel from solid patterns and made any combination pitches, di- ameters and flights are being pro- duced the Chicago Steel Foundry Co., Chicago, patented method. cast one operation may made with variable diameters, vari- able pitches, right and left hand flights, flights that are continuous offset, and with any type coupling either both ends. This one piece casting may also have blank shaft spaces any point points along its length. may have variable flight thickness and section, tapering flight diameters, double lead flights and either solid hollow shafts. These may cast carbon steel any analysis, “Evansteel” for resistance abrasion and for high strength, “Pyrasteel” for high temperature work. also interest note that the process used this foundry VEYOR screws cast integrally diameters coupling 16—The Age, November 23, 1933 Variable pitches the form one-piece casting, the screws can made with variable diameters and pitches, with right and left hand flights, flights continuous offset, with blank spaces the shaft where desired, variable flight thickness and section, double lead flights and with the shafts hollow solid and with couplings desired design either both ends. astings found practicable cast screws with heavy edged concave flights, straight flights, with standard tapered flights, such cannot met methods employing split patterns and flask consisting cope and drag, means one piece pat- terns necessary lengths screwed from the sand. This new method has been employed cast screws within 20-in. diameter. Larger diameters of- fer serious problems. Molding equipment consists single piece flask, open top and bot- tom. constructed wood with rigid bracing the tom plates are pieces steel plate. one end the flask metal tail-shaft guide the pattern centrally while being screwed out the sand. the op- posite front end the flask metal guide, stripper, the inside di- ameter which closely machined Pattern showing and tail shaft. hen the mold completed the pattern screw out the sand. the sand For than flask. durin disloc when mold. beyor Each tern plate Print The whic in: mold prov then with the diameter the pattern that the pattern removed from the sand cannot moved from the axis which the mold was made. The length pattern depends the diameter the screw made. For example, the pattern for 5-in. screw need not over ft. long. All patterns are made metal and are accurately ground tions within limits 0.002 in. Ex- tending from one end the pattern steel bar which somewhat longer than the pattern. This bar extends through the tail-end guide the flask. holds the pattern place during sand ramming and prevents dislocation the axis the pattern when being screwed out the mold. short shaft extends from the front the pattern. extends beyond the outer limit the front stripper and its end machined take wrench should one necessary turn the pattern out the sand. End pieces and core prints slip over the guide shafts and are screwed the pattern assure exact alinement. Each print cut with slot match the flight the pattern and quar- ter turn screws the print the pat- tern which has previously been placed the flask. End prints are neces- sary for drive couplings the ends stoker and conveyor screws. Operations molding section screw consist placing bottom plate the bench. The flask laid the bottom plate and the pattern, with end prints placed loosely the shafts, put position the flask through the front stripper opening. Prints are screwed place and the mold hand-rammed with oil core sand. Vent holes are pierced every in. and the flask rapped hand. The molder then screws the pattern out the sand, removes the flask and places the finished mold rack, which when filled taken lift truck oil-fired baking oven. avoid distortion the print plug inserted which remains the mold throughout the baking operation. The point has been brought out that the screw may be, say, ft. long, all cast one piece, and the pattern and the mold only fractional length the screw. The fact that the mold which poured consists series short molds made above. These are placed end end sloping pouring table, the angle which about deg. screw the same pitch and diameter throughout its length then necessary make one end mold for the riser and the end print for the desired drive coupling, then several molds without end prints and finally the mold for the opposite end the screw which will probably call for end print and core. the screw total length other than multiple the length the pattern necessary only stop one mold give the required length when all the mold (Concluded Page 51) (Above.) Molds ready baked. filled flask fore- ground. Molds are split the pitch line. complete screw mold (below) placed end end. Metal poured the lower end the inclined table. This process (at right) makes possible cast heavy edged con- cave flights, standard tapered flights, variable pitches the same thickness, all patterns being screwed from the sand. Heavy edged concave tapered ot- VJ hi bf f fp Vi hhh bf, ss } ret 4 NEALEY American Gas Association OCATED miles from Pittsburgh, the Ellwood plant the Na- tional Tube Co. covers 127 acres, employs 3000 men and has annual capacity 300,000 tons. The steel working division has 22-in. bar mill with range in. in. rounds while the tube division includes six seamless tube mills and cold draw benches with size ranges in. 10% in. fact this latter un- doubtedly the best equipped cold drawing mill extant. There are more than furnaces this plant, all fired with natural gas, including pointing furnaces, annealers, etc. Pro- ducer gas was formerly used some extent here but natural gas now the only fuel. Most the big heating and reheating furnaces are the same type and design and all have been recently equipped with luminous flame burners various makes. What known No. hot mill has four identical furnaces which rounds are heated 2150 2250 deg. and are discharged into the piercing mills. These furnaces are continuous, the hearth sloping that the rounds roll through the closed end and here they are pushed out through opening the side mechanical pusher. brick and steel construction, each furnace ft. long and ft. wide. supplied through gas burners lo- cated the end wall the dis- charge end and the luminous flames travel the entire length the furnace. 18—The Iron Age, November 23, 1933 Tubes are annealed between pesses the cold drawing process. Annealing Natural Gas Furnace One air manifold from blower and one gas manifold supply all burners. Air furnished in. water column pressure and gas the same pressure. This burner con- sists circular cast iron box foot diameter and in. long con- taining gas tube and air defusing vanes. This box affixed hollow refractory block, 14% in. square and in. long, which built into the furnace wall. The air and gas are introduced into the refractory block parallel streams with circular motion. Thus produced long cir- cular stream air inclosing gas core, the two intermingling diffus- ing support combustion. The back the burner opened and closed with shutter allowing some the air enter for primary combustion while all the rest the air sup- combustion With this shutter control all types flame are possible, ranging from the short and sharp type very heavy, the reheating fur- naces, the pierced and partially drawn tubes lie lengthwise the furnace and the hearth slopes each side. shows the burners employed ing. soft, With amoun change lumino Side Afte and heated The rou where 7 i soft, luminous flame great length. With this shutter also possible control the flame length, density, amount fixed carbon, etc. The pro- portion gas and air may changed will without affecting the luminous characteristics the flame. Side Slope Hearth Reheating Furnace After the rounds have been pierced and drawn out lengths they are re- heated another type furnace for AAA The rounds are fed gravity the pierc- ing mill furnace where they are heated 2150 2250 deg. manufacture steel pipe tubing roughly divided be- tween metallurgical processes and mechanical operations, the former requiring heat and the latter power. The source the heat employed usually gas, and this fully ex- emplified the Ellwood Works the National Tube Co., where na- tural gas exclusively used. greater variety sizes, shapes and wall thicknesses tubing made here than any other single plant the world devoted exclusively the making seamless tubes. still further drawing. This furnace ft. long and ft. wide and the hearth slope from side side in- stead end end the stock used here nearly long the furnace itself. The lower tube line with mechanical pusher which pushed out the furnace. Heat supplied high pressure in- spirator type gas burners, arranged along the high side the furnace and overfiring the work, consisting two rows rounds. al ‘ the cold drawing division the tubes are doped (lubricated) and dried novel gas fired dryer which located below the floor level. This consists battery hot air ducts galvanized sheet iron pipe, each in. diameter and ft. long. motor driven conveyor com- posed loop chains, with the up- per strands just above and the lower strands just below these ducts, car- ries the doped tubes over them where the dope dried the ascending heat. Drying accomplished sys- tem heat recirculation. Heat supplied three separate air heat- ers, discharging into single mani- fold which supplies all ducts from one end. The other ends these ducts are open and part the spent hot products combustion, rising from these open ends, are col- lected another header manifold and returned the heater for re- circulation. induced draft from motor driven fan draws the spent products combustion into collec- tor and then returns them the heater. The heaters, barrel type, steel and refractory lined are each ft. long and ft. diameter. Heat supplied each through single valve automatic porportioning gas burner located one end. for sure with gas atmospheric pressure. automatic temperature control maintains the heat 300 deg. Annealing Between Cold Draws The tubes are annealed between the many passes the cold drawing divi- sion and this accomplished furnaces the car bottom type. brick and steel construction they are ft. square and range from (Concluded Page 51) machine and tube racks are shown. Sie lar ir- a The Iron Age, November 23, 1933—19 £ 3 Every phase industry, construction, transportation has responded the magic touch the metallurgist’s wand. lurgist and his laboratory, adjunct works operations, was chemical analysis and physical tests, information regarding raw materials received, routine control prod- ucts check upon practice, and certify specification requirements. so-called practical operators took pride their ability produce quality metal through experience and fracture determination. They were appreciative the laboratory the degree that its analyses checked their judgment, although deserved tribute the operating man ac- knowledge the high standard which reached rule thumb methods. initial function the metal- Routine testing today vital function the metallurgical division the works. has grown the importance primary rather than secondary control Specific information through test data the rule industrial direction, reason the ability thus afforded trace troubles, check practices with- out being constantly the scene, and meet changing requirements specifications for products char- acteristics raw materials furnished. difficult say whether specifica- tions for metallurgical materials have become more specific chemical and physical aspects because accumula- tion data the plants, whether the plants were forced such specific control through the growing rigidity specifications. The fact remains, however, that today metallurgical op- erations are hardly conceivable with- out the aid the chemical and physi- cal laboratories the control pro- duction. Routine and Research Divorced Proper organization important factor furthering effective service the metallurgist and the laboratory. While there blanket rule cover the needs any concern any industry, experience has set certain principles organization and 20—The Iron Age, November 23, 1933 personnel which should applied. Routine control and research must divorced. The former may properly come under the jurisdiction the direct operating superintendence, the latter, however, must independent such dictation otherwise the day day demands operating prob- lems will relegate research the background, and will cause interruptions which are detriment successful development new projects. Often this changed complexion organization noticed the complete removal the labora- tory, except branch for routine con- trol, from the proximity the works. Today the metallurgical work industry may assumed in- clude all that relates process material, and embrace the various phases analysis testing, such chemical, physical, metallographic, may logically divided into group concerned with routine analy- sis and control under the general di- rection the works manager, al- though close advisory and cooperat- ing relationship should exist with the metallurgical division proper. This last named group should have authority independent and equivalent that the production management order that points issue may properly presented All matters concerning service cus- tomers, claims, work troubles, new developments, and the various prob- lems research, whether applied fundamental, should controlled this group. Ramifications internal set-up will naturally depend upon size and scope work, and the personnel will vary accordingly. The customary divisions are those dealing with chemical analy- sis, physical testing graphic examinations. The highest scientific attainments are required for the more abstract and fundamental problems, whereas works minded and works trained assistance may de- sired for much the activity related processes and production. The Place JAMES ASTON Professor Mining and Metallurgy Carnegie Institute Technology, Pittsburgh would appear unnecessary state that activities should held within the scope the personnel and facilities available. Often investiga- tions had better conducted in- dependent organizations the type the Battelle and Mellon Institutes, There now praiseworthy trend toward group cooperative investi- gations common import within for some time the future, this co- projects non-competitive type. Jealousies among competing concerns any industry, and particularly the selling arguments which around secretive details process and product, will serve block extensive cooperation. addition group sup- port cannot logically applied individual problems. Cooperative Research 1923 tripartite arrangement was effected between the Carnegie In- stitute Technology, the United States Bureau Mines Pittsburgh, and Advisory Board consisting about more men from metal- lurgical industries. Each the three parties contributed funds, equivalent facilities, the work. For time selected individual prob- lems considerable importance were undertaken. 1926, however, was decided enlarge the program, and concentrate upon study the physical chemistry steel making with particular attention nonmetal- lic inclusions steel, their effect certain properties, and their elimina- tion problem solubilities and and slag the open hearth furnace. Much the preliminary research was fundamental enough satisfy rabid such the termination the solubility molten steel, the identification inclusions, the rate coalescence and liquidation and the equilibrium constant consid when ciples makin, eral gested and share clas practi solubi relate and equ veloci The live ally with ings the toa heart probl work: All aids Chen tensi porta trol struc dyna tensi inter sults vices the little fabr mari our betw prop The lurg stric chie the = 4 ove : d metal and slag. There was, course, considerable skepticism the part the open-hearth superintendent when was sought apply the prin- ciples control iron oxide steel making practice. One luctantly offered its assistance. Sev- eral plants have now adopted the sug- gested methods operating practice and additional plants have asked share the works division the experiments. During the past year class was conducted and about practical steel makers struggled with solubilities, equilibrium diagrams related the open-hearth furnace, and even the mathematical phases equilibrium constants and reaction velocities. The moral developed was that live coordinated problem, scientific- ally competent direction, together with ability translate the find- ings into works practice, and per- sonality which could not only keep the interest the scientific worker toa high pitch but also win the whole- hearted cooperation the plant men. result, the initial laboratory problem has been translated into works practice. Test Methods Discussed All test methods are, course, Chemical analysis and the customary tensile tests are still the most im- portant ones the selection and con- trol materials for engineering con- struction. Even application where dynamic stresses are dominant, the tensile test, even though its data are indirect value, has not been super- seded the seemingly more logical interpretations made from re- sults shock fatigue testing de- The metallographic microscope has become indispensable adjunct the metallurgical laboratory. has little place the selection control except diagnosing troubles re- fabrication. The microscope pri- marily research tool; without our knowledge the structure metals and alloys, and the inter-link between heat treatment and ‘physical properties would sorry state. The application X-rays metal- strides during recent years. The chief value X-rays, however, will research order delve into the inner anatomy metals and al- industrial plants support theoretical investigations should their metallurgical departments confined routine control? Would better for small foundry mill avoid expensive research partially subsidize cooperative project? Professor Aston attempts solve these dilemmas reviewing the growth industrial metallurgy and concurrent expansion and improvement manufacturing processes. The author well-known industrial and theoretical metallurgist, and 1918 submitted original patents the slagging process whereby wrought iron could rolled directly into bars without the expensive practical opera- tions puddling and reheating. The accompanying paper was presented before the Society for the Promotion Engineering Education, and published permission the Society. loys manner far beyond the pos- sibilities thermal analysis and the microscope. The necessity subjecting metals continued high stress and high temperatures, the oil refining industry, and the unfortunate experi- ences resulting from the now well recognized ageing characteristics, has led large amount so-called creep testing. For the time being must considered exploratory test; one which systematic and long continued trials will disclose the characteristics various metals, and eventually result alloying combin- ations which will have maximum stability under working conditions. present much data being accumu- lated, but there strong underly- ing feeling uncertainty and sen- timent that the effort chiefly test test. Non-Destructive Tests Desired unfortunate that our best con- trol tests are destructive type, and many cases only indirectly valuable interpretation service merit. They are based upon the law averages, and are vitally dependent upon careful selection test samples and rational interpretation test re- sults. The metallurgical profession will acclaim that test method, magnetic, X-ray, unknown device, which will non-destructive, and which can applied the full mem- ber fabricated structure, and will reasonably interpret the merit value for specific requirements service. The corrosion field, for example, woefully lacking any test which will reliably predict values for given condition service time materially less than that actual service, comparison with the over- night basis which would the ideal for selection. Having considered general principles the relations the metallurgist and the plant, some ap- plications industry could ‘noted. The laboratory phases the study the physical chemistry steel making have been translated into works practice with two conspicuous developments. The control iron oxide between metal and slag, has been put rational basis function slag composition, thick- ness and viscosity, furnace agitation and agitation bath. This could hardly have been accomplished with- out the large amount data obtained the preliminary laboratory work where detailed analysis each the factors was made and the under- lying principles determined. The de- velopment the double deoxidizer, and alloy approximately Si, was direct result the laboratory studies the influence the various deoxidizers and the speed liquida- tion the several oxides, singly and combination. Wrought Iron Production Simplified Prior 1918, attempts eliminate variably been mechanical devices agitate the metal simulation the manual efforts the puddler. Very little success rewarded the many attempts mechanize wrought iron manufacture. The microscope showed (Concluded Page 51) The Iron Age, November 23, held tiga- type utes, rend haps built and nent rgh, with hree rob- was and rch nce Personnel Work Has Paid the might think offhand that personnel work has place the small factory because the small number workmen and the high cost involved. Yet the National Industrial Conference Board discovered survey several years ago that small plants are being brought the realization that per- sonnel activities are not fad supported fat years and dropped lean ones. Although much their value intangible indirect and therefore cannot measured, never- theless their benefits are far excess their cost. Certain phases industrial rela- tions work are prevalent among small plants among large establish- ments, said the conference board. These include the giving bonuses for special accomplishments, such regularity attendance, punctuality, long service high quality output; profit-sharing plans; group life insur- ance; vacations with pay for wage earners; first aid and safety commit- tees; informal recreational activities, such picnics, outings and dances; informal employee education and training; and various plant conven- iences. Activities not readily adaptable the small plant are lunch rooms cafeterias, company housing home purchase plans, hospitals and clinics, expensive recreational facilities such club rooms, formal pension plans, incentive wage payment plans and works councils. How far the small plant can with industrial relations program dependent many factors, not the least which cost. Naturally the larger the number employees, the less the expense per worker. The National Industrial Conference Board, 22—The Iron Age, November 23, 1933 BURNHAM FINNEY Detroit Editor, The Age its study 4409 companies em- ploying 419,391 men, found that the total cost industrial relations work was per cent the annual factory payroll. The average cost per em- ployee was $26.65. the group plants having less than workers, the average expense was $49.17; the group with 100 workers, $26.16; the group with 101 250 workers, $25.31. While this shows disproportionately high cost the very small factory, the results justify the expenditure. One way for small plant carry many personnel activities which otherwise would prohibitive cost cooperate with other plants near- ~ & close relationship between management and men Amer- ica’s smaller plants has been recog- nized distinct public asset. would unfortunate the pres- ent pressure toward estrangement through enforced should erect barrier between employer and employee these plants. With this not all imag- inary danger view, will well for small plant employers and managers give thought the intensification personnel work preventive measure. Small Plant by. This method can used success- fully maintaining safety programs, foreman training classes, lunch rooms, dispensaries, health clinics and ath- activities. Particularly Phila- delphia during the past six years has the fact been demonstrated through cooperative effort small plants can have practical medical and health program cost commensu- rate with that larger plants. Discussing the training foremen, Vertrees, head the extension department Rutgers University, said recently that “the foreman the small plant well the large organization needs understanding the complexity the modern manu- facturing organization, the increas- ing specialization staff and other activities designed aid him, and the importance the human element production. Few foremen fail through lack mechanical ability, but many fail through lack train- ing the broader aspects the job. Employers are responsible for and until they give the foreman such training needs his executive capacity, they cannot expect him real executive.” Mr. Vertrees goes say that among the specific which the foreman should familiar are those pertaining the qualifica- tions for successful personal leader- ship, good working knowledge lighting, plant housekeeping and other problems having with physical working conditions, and the organization and administration successful job training. However, foremen are interested many sub- jects outside the province immediate jobs, such psychology, public speaking and economics. Because the limited size many ried side coll the or poss from men the are done benefit The forem knowl subjec men. throw and train comp all the hand item pose calls effec lack tion. its One dec. pla the fac onl jus ter joy companies, training work can car- ried best through outside agen- cy. Sometimes sessions are held in- side the factory under the supervision college instructors; other cases the men are encouraged join night possibly day classes conducted away from the factory where they will meet men like position. Courses under the auspices local branches the National Metal Trades Association are specific examples what can done along this line with maximum benefits minimum cost. The main point that not only the foremen, but also all employees should encouraged acquire further knowledge about their jobs and about subjects which will assistance broadening their ability handle men. training program will ineffectual unless the management throws its entire influence behind and takes the initiative pushing forward. One way for company indicate its wholehearted cooperation allow liberal use its time for training purposes. Another for the company bear least part the expenses for any training course course, for the management bear all the cost, because the willingness the employee contribute his share the expense often measure his genuine interest. the other hand, profitable investment for item for educational training pur- poses. Along this l