The Iron Age 1933-12-21: Vol 132 Iss 25

CONTENTS INDEX PAGE PROCESSES NEWS ING MACHINES MILLING CUTTERS CUTTER -:- MANAGEMENT DECEMBER 21, 1933 THE 21, 1933 Page CAMS SANDPAPER Machine Cams STEEL Airplane Tail Skid For heavy machine cams all sizes where leading chrome Cobalt tool steel, cast toughness and hardness cre first essentials; shape, and hardened still air; Martin paper slitters—those small 5-inch and Castaloy, both economical air-hardening wheels that cut sand paper into commercial tool steels, cast shape, and Carbomang, sizes—wheels which must hold their fine cut- oil-hardened tool steel, cast shape. ting edge; for airplane tail skids upon whose toughness and hardness life itself may de- pend;—for all these and hundred more uses have the correct, efficient, and eco- nomical alloy tool steel, cast shape. Let our sales engineers cooperate with you working out your die designing machine tool problems. There tion for this service. Write also for book- lets describing the application, etc., Included our complete line are Krokoloy, our steels. DETROIT ALLOY STEEL COMPANY Foot Iron Street Detroit Eastern District Sales Manager: Andersen Central District Soles Manager: William Eakin 135 Post Ave., Lyndhurst, New Jersey 707 Berkshire Ave., Pittsburgh, Pennsyivania IRON AGE, published every Thursday the AGE PUBLISHING Office: Cor. Chestnut 56th Executive Offices: 239 39th St., New York, second class matter the Post Office Philadelphia March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 132, No. 25. : | = 4 - A ° — = | | | | 7 | | Wy | | | 4 | | | | i 4 ity | fe — THE IRON December 21, 1933 Editor Managing Editor Consulting Editor News Editor Machinery Editor ae ie, F. J. WINTERS G. EHRNSTROM, JR. BURNHAM FINNEY GERARD FRAzaR Pittsburgh Detroit Boston Cleveland Chicago Editor Emeritus Washington Cincinnati | / The NRA Life-Raft Alloys for Malleable Iron WE BO OUR PART Making Automotive Piston Rings Pressure Casting Non-Ferrous Metals Choosing the Right Finish Helps Metal Products Sales Creep Testing and High Creep Steels New Equipment News Personals and Obituaries Washington News Automotive Industry Markets Construction and Equipment Buying Products Advertised ening THE IRON AGE PUBLISHING COMPANY you FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager | and PUBLICATION OFFICE: Corner Chestnut and Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th St., New York, Y., each | Member, Audit Bureau of Cireulations 4DVERTISING 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 i] Published every Thursday. Subscription Price: Peirce Lewis, 7338 Woodward Ave., Detroit i} United States and Possessions, Mexico, Cuba, $6.00; Charles Lundberg, 45 Kent Rd., Upper Darby, } Canada, $8.50, including duty; Foreign, $12.00 Del. Co., year. 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. YEAR SERVICE THE METAL WORKING INDUSTRY | | | | | } der Act Page Alloy Steels Open-hearth electric-furnace alloy steels for all purposes, hot-rolled and cold drawn, rough-turned ground; MAYARI nickel-chromium steels; MAYARI engine bolt and staybolt steels; spring steel; for superior physical properties high temperatures. Bars, hands, billets and blooms. Auxiliary Locomotives Axles, Wrought Steel For passenger and freight cars, engine, tender and trailer trucks; for electric for mine locomotives and mine cars, cinder, ore and other industrial ears. Bars, Bands and Special Sections Carbon steel bars and bands, Bessemer and open-hearth; special and automotive sections every description; iron bars (double refined) staybolt, engine-bolt and chain-iron quality. Bars, Concrete Reinforcing Bethlehem deformed bars constant standard rounds and squares. Blanks Rolled steel blanks for gears, flywheels, crane wheels, tire moulds and mould rings, shaft couplings, brake wheels, brake drums, and other forgings. Bolts Plain and galvanized; machine, carriage and special; heat-treated, carbon and alloy; steel frog, track and fitting-up bolts; staybolts, hollow and solid. self-locking threaded bolts. Cars, Steel Mine Cars, Steel Freight Cars, Steel Passenger Castings Carbon and alloy steel (open hearth and electric), manganese steel, iron, brass and bronze, rough cast, machined. Centrifugal cast and liners. Abrasion-resisting castings. In- got moulds. Corrosion-Resisting Steels and BETHALON, covering prac- tically every requirement for corrosion and heat-resisting steels, including the free-machining grades. Fence, Woven Wire CAMBRIA woven wire field and poultry Flanged Products Tank heads, boiler heads, dome sheets, manheads, yokes, bolts and saddles; mis cellaneous flanged plate work. Forgings Carbon and alloy, hammered draulically pressed; drop seamless vessels for oil refineries; high- pressure seamless boiler drums and chemi- cal vessels. Nails, Wire Nuts Hot-pressed and cold-punched; all sizes, shapes and standards; self- locking threaded nuts. Oil Burning Equipment mechanical-atomizing oil burning system for stationary and ma- rine Pig Iron Basic, Bessemer, foundry, low phosphor- ous, malleable, malleable Bessemer; Ma- YARI pig iron for alloy- iron castings. Piling, Steel Sheet Bethlehem Steel Sheet Piling for bulk- heads, jetties, cofferdams, and similar ap- Pipe, Steel Butt-welded and lap-welded pipe, black and galvanized; copper-bearing pipe. Plates, Steel Universal and sheared plates, for all pur- poses; slabs. Pole Line Material Posts, Steel Fence Posts for farm fencing; snow fence posts; highway sign posts. Rails and Accessories Standard tee, girder, girder-guard and high-tee rails; light rails; splice bars, rail clips, tie plates. Rivets Semi-Finished Steel Carbon billets and slabs, rerolling and forging quality; sheet bars and skelp. Sheets, Steel rolled, heavy cold-rolled sheets; furni- ture, heavy-furniture, sheets; tack plate; galvanized, formed sheets; painted formed sheets; special-finish sheets. Sheets Loy (copper-bearing steel). Spikes Structural Steel Shapes Bethlehem wide-flange beams, girders, and joists and stanchions; stand- ard beams, channels and angles; car and shipbuilding shapes; standard and special and Z-bars. Tin Plate Coke tin plate; black plates; galvanizing, enameling and lithographing stock. * Tool Steels Bethlehem special high-speed tool steel; carbon and alloy tool steels; cobalt mag net steel; hot-work tool steels; die steels; rivet set and pneumatie chisel steels; special tool steel billets, Rock and mine drill steels, hollow Tools Rivet sets, punches and dies; chisel blanks and chisels; hot and friction saws; slitting shears, shear blades; spe- cial high-speed tool-holder Trackwork for Steam, Electric, Mine and Indus- trial Railways Frogs, switches, hook flange guard rails; heat-treated and manganese crossings; Bethlehem and New stands; silico-manganese and manganese special trackwork; switch heaters, guard rail chairs, compromise steel ties; gage rods, rail braces, rail an- Tubes, Boiler Genuine old-fashioned knobbled charcoal iron tubes; double-pass steel pass copper-bearing steel tubes. Wheels, Wrought Steel Wrought steel wheels for freight and passenger cars, and engine, tender and trailer trucks; for cars; for mine locomotives and mine cars; for der, ore and other industrial cars. Wire and Wire Products Plain, bolt, chain, extra-soft rivet and hard bright nail wire; bright essed, annealed, normalized heading and telephone wire; galvanized wire; wire rods; (special zine-coated) wire; clothes-line wire; processed wire; stapling wire; border wire; APEX and INVINCIBLE spring wire; barbed wire; SILVER bale CAMBRIA wovel wire field and poultry fence, Nails. BETHLEHEM STEEL BETHLEHEM STEEL COMPANY, Gencral Offices: Bethlehem, Pa. Divtrict Office: Dall Detroit, Houston Indianapolis, Milwaukee, New York, Philadelphia, Pittsburgh St. Louis, St. Paul, Washington, Wilkes-Barre, York. Pacific Coast Dist: ibutor: Pacitie Coast Steel Corp., San Francisco, Seattle, Los Angeles, Portland, Honolulu. Export Distributor: Bethlehem Export Steel Corp,, New York, Atlanta, Baltimore, Boston, Buffalo, Chicago, Cincinnati, Cleveland, THE IRON AGE...DECEMBER 21, 1933 ers, and stand- ‘ar and special nizing, steel; mag mine chisel riction spe- rails; sings; switch guard ties; an- arcoal ouble- and and for cin- rivet proe- and wire ated) essed wire; THE IRON DECEMBER 21, 1933 ESTABLISHED 1855 Vol. 132, No. HILE this life-raft not the most com- fortable the safest seat that industry could wish for, one yet has produced suggested better one. Certainly would not industry’s advan- tage this emergency raft were scuttled. The octopus and the sharks are still hanging around. must not anything that will punch more holes NRA’s buoyancy tanks. And must make every effort patch those that poor judgment self-interest have already put there. Alloys for Malleable LLOYED steel and gray iron are common today, but the use alloying agents malleable cast iron comparatively new. The explanation lies the nature mal- leable iron. Its desirable qualities, ductility, strength, and machinability, are the result heat treatment which breaks down the massive ce- mentite and causes deposition tem- per carbon. Since nearly all alloys affect this annealing process, either ac- celerating retarding it, malleable foundrymen have naturally been slow trying alloys their material. However, there great deal interest present the use al- loys malleable iron produce cer- tain special characteristics. Foundry- men are being asked supply malle- able iron with exceptionally high strength, with resistance wear, resistance corrosion. Just the steel and gray iron founders have done the past, some the malle- able foundrymen are now turning the use alloys bring about these desired properties. More data the subject alloys and their effect malleable iron are available than would appear first glance and this paper attempts collect and sum- marize briefly some this informa- tion. Alloys with the following ele- ments have been investigated: alumi- num, antimony, bismuth, boron, cer- ium, chromium, cobalt, copper, lantha- num, molybdenum, nickel, selenium, Etched Tensile Strength Yield Point Brinell hardness 8—The Iron Age, December 21, Ordinary Malleable REBECCA HALL TABLE The following elements have been discarded by most investigators as having but slight effect and practical advantage for use with malleable iron: Bismuth Yes Decreases fluidity Lanthanum .... Counteracts inhibitors influence Yes Softening influence tellurium, tin, titanium, tungsten, uranium, vanadium, zine and zircon- ium. the case several, little information published, but enough known about most them give the malleable foundryman idea what each may improve his malleable castings, how much safe use, and what degree success others have had this line. Aluminum Combinations Aluminum can used malleable iron combination with other ele- Fig. Effect Chromium X100 Etched 54,500 37,500 18.5% 131 Malleable Containing 0.56% and 1.39% ments produce hard case for nitriding. 1.25 per cent aluminum and 0.90 per cent chromium give the hardest surface, although per cent aluminum and 1.00 per cent vanadium also good. iron with low carbon and low silicon, containing per cent aluminum and 1.00 per cent chromium, hard and tougher than high carbon, high silicon Aluminum itself has not found much use alloy malleable iron. Small amounts under 0.08 per cent are said strength and ductility. Above 0.08 per cent, reduces strength, ductility and fluidity. strong graphitizer and deoxidizer, but dan- gerous because promotes the sepa- ration coarse angular graphite. little 0.05 per cent aluminum said make hard white iron castings appear mottled. Under 0.08 per cent, aluminum apparently has effect upon the behavior the iron the mold, but above that percentage, brings about sluggish condition the iron, making hard pour, and causes larger amount slag. High- percentages this alloy change the nodular graphite malleable iron into the irregular flaky shapes found gray iron, with corresponding marked decrease strength, ductility and reduction area. The graphitizing effect aluminum reaches its maximum 1.5 per cent aluminum low carbon irons, and 0.5 per cent high carbon irons. Some investigators think aluminum should X100 80,500 52,500 6.00% 201 as I ce v i e 2 | for minum the cent with aining per iron. found lleable per both per ength, strong dan- sepa- stings effect the ge, and High- hange iron found nding cent 0.5 Some hould regarded deoxidizing agent, not alloy. Antimony, Boron and Cerium Antimony has slight accelerating effect graphitization, but some think makes castings brittle. Boron amounts under 0.10 per cent favors graphitization, but above centage retards it. Results some tests boron contradictory. Cerium, although itself not ac- celerator, counteracts the inhibiting effect several other elements forming globular sulphides, and pre- venting the formation films which interfere with the migration carbon during graphitization. Yet cerium caused hardness and brittleness tests some investigators. Chromium Has Possibilities Chromium inhibitor graph- itization, due the formation stable carbides; but there differ- ence opinion how much can present without appreciable effect. Several give 0.03 per cent maximum amount possible cupola malleable without getting brittle and cracked castings. Others have found Tensile Strength Lb. per 0.5 1.0 Per Cent Aluminum ONSIDERABLE difference opinion exists among those who have investigated the effect chromium and other alloys malleable iron. Miss Hall stated paper some months ago that the tensile strength could increased chromium additions the silicon content was prop- erly adjusted. Dr. Enrique Touceda statement appearing The Age, November 30, 1933, took issue with Miss Hall and suggested maxi- mum 0.035 per cent chromium. the accompanying article Miss Hall gives the result the work many investigators the field alloy malleable iron, and while occasion- ally there difference opinion, both sides are presented that the malleable foundrymen now can get concise form the probable effects these different alloys. Miss Hall consulting metallurgist, Chicago. tion depends the composition the base iron. Chromium additions increase tensile strength and hardness and decrease ductility. One authority suggests rais- ing the silicon content adding nickel overcome the stabilization carbides, and another reports that fine structure results from the addition 0.34 per cent chromium and 1.37 per cent nickel. Balancing chromium ad- ditions with similar increases silicon retains some ductility and gives in- Per Cent Elongation Inches ow Fig. Effect aluminum tensile strength and elongation malleable castings. that iron containing 0.05 per cent chromium had fracture after annealing. least one case cited where 0.08 per cent produced hard sections, but most investigators feel that from 0.05 per cent.to 0.07 per cent would produce only ex- tremely slight retardation anneal- ing. They think that about 0.10 per cent chromium would serious, and some have stated that even under 0.10 per cent will cause steely fracture the annealing temperature higher than usual. generally agreed that chromium from 0.20 per 0.25 per cent practically stops the an- nealing operation, although the exact amount necessary for complete inhibi- creased strength and hardness, with fine grained structure. Cobalt and Copper Cobalt has tendency favor graphitization, and cause the temper carbon precipitate nodular form. Copper apparently has but little in- fluence malleable iron. Early in- vestigators thought retarded graph- itization, but now established that copper has small effect toward graphitization. The most interesting thing about copper malleable, and one reason for its use, that im- parts anti-corrosive properties when present amounts under 1.0 per cent. has been stated that this effect noticeable only cases atmospheric and smoke corrosion, where malleable containing 2.0 per cent copper per cent more resistant than unalloyed malleable. However, well known that several patented copper-bearing malleable irons give excellent resist- ance under acid conditions. Molybdenum and Nickel Molybdenum has tendency hold the carbon the combined form, but the extent this effect. Some con- sider its influence insignificant and others feel that should present fair amounts retard the anneal. Two authorities, however, state that molybdenum retards the decomposi- tion massive into temper carbon, with corresponding in- crease strength and hardness, and decrease ductility, although less active this respect than chromium. According others, molyb- denum does not stop graphitization until least over 5.0 per cent. One states that gives anti-corrosive properties when present amounts under 0.10 per cent. Nickel has long been known strong graphitizer, with the maximum effect between per cent and per cent, depending the carbon content the base iron. The higher the nickel, the lower the temperature re- quired for graphitization, and the lower the transformation point alpha iron into gamma iron. One in- vestigator has said that the graphite formed given heat treatment nearly proportional the nickel con- tent, but others find that there quantitative relation the amount nickel present and the amount carbide decomposition. small amounts, nickel raises the tensile strength and ductility, and favors fine grained, nodular graph- ite. Although itself graphitizer, nickel counteracts the effect silicon, even rather low concentrations. Titanium was known deoxidiz- ing and degasifying material for malleable iron long ago 1911. graphitizer, perhaps less ef- fective than silicon. Titanium also (Continued Page 60) The Iron Age, December 21, a's > wt 60,000 | 40,000 e e | A i | &%o - ote >: 3 5 Manufacture Automotive XPERIENCE has taught Chance tion sizes readjustments tools HIS the third, and the con- Co. lay particular stress the and machines. cluding, article the gag inspection division. Each piston obtain this tungsten carbide cut- series which describes the are spectors and gagers before the ring permits the manufacture over piston rings. this installment, pis the finishing operations are de- Previous articles the two pre- qui covered design, patternmaking, Pis molding and foundry inspection and control. Co. giv rin thousand pieces between grindings, hig without the slightest variation di- mensions. Piston Rings Also Made Metric Standard order meet the demands tio customers, necessary have tro hand and able manufacture the large quantities any the thousands ite different sizes piston rings thi the market today. addition sup- plying piston rings for American made cars, our supplies rings for foreign made cars and has quite large foreign business. Piston rings for foreign markets are gen- erally made the metric system, all which necessitates large amount special equipment the form the finally packed for shipment. This Fig. 15. The sides inspection covers: the rings are rough Swelled and dirty castings. head face grinder Thickness before machining. equipped with swing- Width before machining. ing work fixture. Thickness after machining. Width after machining. Quality grinding and finishing oper- ation. Gaging for outside diameters. Inspection for flaws. Inspection for tension. 10. General inspection before wrapping. order obtain low consumption gasoline and oil, necessary make rings with: Perfect contact against cylinder walls. Perfect contact the flat side against the groove. Perfect tension against the cylinder wall. Sufficient clearance for free expansion the piston ring the groove. Fig. 16. special Sufficient range dimensions fit the machine used for various cylinder requirements. inside grinding, the obtain perfect contact cylin- rings being rotated friction drive against the internal wheel. der walls and sides, was necessary for the company design, make purchase sturdy modern machines with tools that would large quan- tity pieces with minimum varia- 10—The Iron Age, December 21, 1933 7 7 \ i q be machines, tools, jigs, fixtures and gages. Highly specialized mechanics are required maintain this equip- ment for the manufacture quality piston rings. The illustrations which accompany this article show some the various quired, step step, their sequence the process making “Gas Tite” Piston Rings. The “Super” rings made Chance Co. are heat treated special fur- nace under pyrometer control which gives uniform heat treatment. These rings are gradually brought high heat but held under the critical point represented (25 deg. Mn) This process brings out imperfec- tions, any, caused unseen metal trouble. The rings are slightly softer, the tension about the same and ite matrix little more uniform through transforming combined car- bon into graphitic carbon. These fea- tures are considered most desirable many users piston rings. Inspection addition rings being inspected and gaged each operator during the process manufacture, the rings iston Rings— are reinspected trained group inspectors separate unit from the machine department. order function properly, and that stand- ipheries are ground against face wheel, the ring being rotated flexible drive. Fig. 18. Following the rough grinding oper- ations, the outsides are rough turned. JOSEPH CHEETHAM Factory Manager, Chance Co. ard quality the product insured our customers, set-rules the form standard practices are thoroughly learned each operator. Sample standard piston rings are mounted boards showing the finish required that any machining opera- tion foundry flaw not the standard shown must Each inspector examines rings for one classification only. That is, one gages the width the ring with gages that are checked with the master gages periodically, others gage the diame- ters, others gage the thickness, others gage the tension, and others inspect for various machining operations and foundry flaws. After passing through this inspection feel that control quality assured. Cleaning and Packaging Operations After passing the final inspection, The Iron Age, December 21, all “SF the piston rings are dipped alkali solution free the rings oil and dirt. After this they are dip- ped oil solution rust pre- ventive. further insure that cus- tomers receive rings free from rust, all piston rings are wrapped mois- ture proof wax paper. readily find any oversize that may desired these rings, the Chance Co. has adopted color scheme. Each oversize carries dis- Fig. 19. (Upper left), Next, the sides the rings are finished surface grinding rotating multi- station fixture. Fig. 20. (Center), After the joint tenoned (not shown) the outside per- iphery the ring finished Fig. 21. (At right), Oil grooves are cut this rugged lathe which equipped with quick acting chuck. tinct and different colored label. operate our own printing department consisting several automatic and hand-printing presses, which are ca- pable doing two, three and four tone color work. nets 12—The Iron Age, December 21, 1933 Solid Pressure Casting Non-Ferrous Metals sure plastic metals and, di- recting the flow into steel molds, forming accurate parts having advan- tageous physical properties, has been subjected extensive experimenta- tion during the past few years. commonly known that such theory has passed its early stages devel- opment Europe and every- day commercial proposition there. However, not quite commonly known that least one American manufacturer having just much success along these lines. Because the marked improve- ment the product this process, seems obvious that within few years not only the jobbing die casting concerns, but also the large users die castings will fabricate parts this method. This improvement, to- gether with broadening number metals adaptable die casting practice, will all probability lead revamping design and methods manufacturing practically all metal mechanical and ornamental parts. The advantages this new product can more clearly defined consider and compare the product various typical methods production manufacture; namely, sand casting, forging, machining forming from rolled stock, extrusion, die casting and solid pressure casting. theory applying solid pres- Sand casting usually least ex- pensive where the part intricate and production duplication the part small. large quantities, the extent which depends entirely upon the part question, usually S we SSS METAL INLET METAL POT WILLIAM LESTER Lester Die Machine Co., Cleveland becomes the more expensive method manufacture because machin- ing and finishing costs. Sand casting not suitable for parts having mini- mum size weight limitations and which are subject considerable stress and strain. Furthermore, sand casting should not used where ho- mogeneity important factor either from heat conductivity, elec- trical conductivity ultimate pol- ished surface standpoint. true that considerable success has been ob- tained the production fairly sound parts specific instances but this depends entirely upon the skill and ingenuity the producer. Forging is, unquestionably, means securing product having the most suitable physical properties. Its limi- tations, however, are manifold. First, the process expensive, requiring costly molds and entailing high unit labor charges. Second, although fair- accurate, does not eliminate ma- chining for most practical purposes. Third, the metals adaptable this procedure are limited number and most cases cannot used their crude ingot state but must the more expensive rolled form. Fourth, the shape the part serious limitation and only compara- tively simple designs are possible. parts which lend themselves few simple machining forming forms can successfully employed Fig. base alloy die-casting ma- chine (left). Fig. 2—Principle alumin- die-casting machine. with low cost. This method, however, becomes increasingly expensive with increases complication design. Only few the more common metals are suitable for this means manufacture. reached any extensive proportions applicable but few metals and extremely simple parts. The product this method, however, has very desirable and advantageous physical properties. production many the limita- tions the previously mentioned processes have been eliminated die casting. Extremely accurate parts great complication can produced this method with little ma- chining after casting. Industry, its sorrow, however, found that even this process had its limitations and defects. First, only few metals which had either strength limitations unstable physical and metallurgical characteristics could worked this method. Second, the finished product was found very porous and, therefore, with seriously affected physical properties. Third, many im- purities, the most common which was iron, were found contaminate the part and made corrosively un- stable and hence undesirable many cases. Fourth, long exposures the molten metals, high temperatures, the atmosphere, caused oxidation these unstable metals which re- sulted decrease worth the finished part due strength and machining characteris- (Concluded Page 60) The Iron Age. December 21, 1933—13 4 W nent and Ca- our Fic r. U6 © x fy a Ne 4 ~ one TO VALVES serve METAL POT <> Choosing the Right Drive—6 The Horizontal Worm Gear Reduction Unit HIS method applicable the horizontal slow speed driving the process manufac- turing industry, because its ef- ficiency, low maintenance, and power and ratio capacity. The single reduc- tion unit right angle drive and the double compound reduction unit parallel drive suitable for ratios the single and 10,000 the compound units can obtained, but such reductions their efficiencies are comparatively low. With the ex- ception conveyor and foundry equipment driving there little need for this type transmission the produetion shop field, based the absence slow speed apparatus. The modern single reduction unit pro- portioned for proper heat radiation, speed driving, particularly important the process in- dustries, finds the worm gear re- duction unit especially applicable. Efficiency, low maintenance cost and high ratios are characteristic these units. this, the sixth installment Mr. Staniar’s comprehensive series mechanical transmission meth- ods, the subject horizontal worm gear reduction units discussed. worm reduction gears mounted and inclosed single housing and necessity the power input and output shafts are arranged parallel. Fig. 39. (Above), Power may applied either top bottom the unit and both radial and thrust loads are provided for. the bearings are the anti-friction type properly placed accommodate both radial and thrust loads and power input can applied either top bottom the reducer, shown Fig. 39. This unit can obtained standard power capacities from 300 hp. Higher power capacity can secured, but beyond 300 hp., special design required. The compound unit shown Fig. composed two sets i4—The Iron Age, December 21, 1933 Fig. 40. (Below), Input and output shafts lie one plane the compound worm reduction unit. some instances this preferable the right angle feature the single reduction unit. The compound unit limited power capacity for the aver- age industrial driving, because com- mercial sizes worm gearing not permit the transmission large powers when the ratio requirements are the thousands the torque for given amount power delivered the gear shaft varies with the speed the shaft. Such reduction units are usually rated torque basis and therefore necessary ana- lyze the load conditions carefully when dealing with abnormal ratios. The “Tandem” Method For powers beyond hp. where abnormal ratios are required, resort can made combination one single reduction worm gear unit and one herringbone bination this character known the “tandem” worm and herringbone tandem installation such this cheaper than the compound worm reduction unit and will perform better the field high powers with high ratios. The housings the mod- ern horizontal worm gear reduction units are usually the square box design because increased oil and heat radiating capacity, greater rigid- ity and the possibility larger span & | « A WILLIAM STANIAR Mechanical Transmission Engineer ingle nit aver- between the gear shaft bearings. Such izontal type can employed lustration such adaptation em- features economy, because great advantage the driving pro- ploying vertical unit shown lowered maintenance and length- gressive assembly conveyors. il- Fig. 43. Modern foundries which are ened life the reducers. the right 2 . . reduction unit necessary and the ratio demand higher than Production Shop and Process Manufacturing Plant Driving pinion gear can mounted directly asis > » > ana- the slow speed shaft the reducer. METHOD Horizontal worm gear reduction unit. and the bearings must suitable for SERVICE progressive assembly conveyor Where high ratios are necessary overhung load. illustration For foundry equipment driving. Where driving reducer designed for this service advantage here show n by k 1g. 42. Lubrication of hor- For all types of horizontal slow speed | Where space is limited e angie 8 t ace. | 1e smoo ss 0 ower appli oO and tems, the former for light and medium where A 1ess Of power application is requirec bone and the latter for heavy duty. com- emphasized that correct lubrication speed direct connection . essential. bone the efficient performance the worm 100 4000 r.p.m 100 4000 r.p.m. such reduction gear, otherwise short WORM SHAFT All standard turbine and motor speeds. All standard turbine and motor speeds. When first installing worm reduc- CAPACITIES 100 special. 10,000 special. with tion unit, should borne mind HORSEPOWER nod- that the manufacturer the unit has CAPACITIES .002 300 standard standard. ‘tion not filled the housing with oil. Over 300 special. Over special. LUBRICATION Fluid lubricant either splash cir- Fluid lubricant either splash cir- motive industry the worm gear reduc- igid- tion unit either the vertical hor- span Fig. 42. Special bearing design provides for overhung Fig. 41. The “tandem” employs worm reduction and herringbone reduction load the case directly mounted pinion. combined single unit. The Iron Age, December 21, ——— — = = Sts hes P| , Fig. 44. base plate almost essential for permanent alinement and the use flexible coupling between motor and reducer advisable. Fig. 46. example the installation heavy type worm gear reduc- tion unit. Fig. 43. Worm gear reducers are particu- larly adapted progressive production conveyor drives. generally component part large production shop plants employ va- riety slow speed apparatus, which, based gritty and dusty atmospheric conditions, should driven closed methods high maintenance costs are avoided. This the particular field production plant driving, where the horizontal worm reduction gear should employed, because entirely inclosed and can easily adapted the powers and ratios required. process plant slow speed driving, practically all horizontal driving prob- lems where comparatively high ratios exist can solved the single double reduction worm Where right angle driving impera- Fig. 45. typical ex- this unit should considered, ample since possesses greater power duty worm reduction range and less costly than the right gear driving. angle spur gear reducer, its only com- petitor for this class service. the light duty field standard types power capacity from 0.02 135 hp. and permissible worm speeds from 100 1200 r.p.m. the medium duty field standard types have ratio range 16—The Iron Age, December 21, 1933 3 educ- hp. rom luty nge city from 0.13 260 hp. and permissible worm speeds from 100 3600 r.p.m. the heavy duty field standard types power capacity from 0.13 200 hp. and permissible worm speeds from 100 3600 r.p.m. Worm speeds 4000 r.p.m. are possible and higher power capacities than mentioned can obtained, but such requirements are not furnished standard units. The horizontal unit can coupled di- rect steam turbines and all standard speed motors. Whenever possible base plate should em- ployed for the integral mounting motor and reducer shown Fig. 44, because permanent alinement essential for successful operation. Re- gardless the use base plate, the medium connection between motor and reducer should cou- pling the flexible type. start- ing torque high torsional resilien- type flexible coupling should employed; low, this feature un- necessary. typical installation medium duty worm reduction gear driving shown Fig. 45. outboard bear- ing used here connection with the open spur gear reduction because the gear shaft the reducer not designed support the overhung load. application employing heavy duty type reducer shown Fig. 46. This 100 hp. installation Finish Tubing Improved Using Inexpensive Bright Annealing Furnace straight lengths, now being bright annealed controlled at- mosphere the Cleveland plant the Chase Brass Copper Co. specially designed, continuous electric furnace, and recently developed in- tubing, both coils and ment eliminates the usual pickling, washing and drying operations, well all labor connected with those operations. The like finish the furnace product also much superior the etched pickled surface. The material discharged 180-kw. electric furnace specially designed for the continuous bright annealing copper tubing coils in. diameter in. high and straight lengths ft. long. expensive hydrogen-nitrogen bearing gas are used the process. The drawing copper tubing re- duces the ductility such extent soften the metal annealing between drawing operations. Ordinary an- nealing without atmospheric control satisfactory, but the dull finish the metal unde- sirable for most purposes. The tub- ing must pickled and washed restore bright finish. The new bright annealing equip- from the furnace properly an- nealed, absolutely bright and dry, without water acid stains, and can packed within two hours the last drawing operation. The furnace shown the accom- panying view has input 180 and ft. long, ft. high, and ft. The view shows coils tubing the discharge end ready for ship- ment. The long 30-ft. cooling cham- ber shown clearly, and the 18-ft. heating chamber and charging end driving rotary dryer with worm speed 700 r.p.m. and ratio 2/3 The flexible coupling con- nection can seen between motor and reducer. The double reduction compound unit should considered for ratios from 500 10,000 when the power requirements are below hp. Between the practicable limit for single reduction worm units and 500 possible with the spur gear reduction unit, more economical employ the spur type. The choice between the compound worm unit and the tandem method described must based power and ments. can seen the distance. There are hoods both the loading and dis- charge ends prevent the escape atmosphere and heat. When straight stock annealing the hoods are re- moved. The electric elements are mounted the side walls the heating cham- ber, and two temperature zones 1000 deg. 1200 deg. are used. The cooling chamber has double walls within which water circulates rate suitable reduce the tempera- ture the tubing below the oxidiz- ing point. heat-resisting alloy helt conveyor carries the work through the furnace, and its speed may regulated for various tube sizes and degrees anneal. The automatic equipment for pro- ducing the artificial atmosphere located the side the furnace. The atmosphere produced chamber containing illuminating gas controlled supply air, where- cracking operation, breaking down the gas, produced com- bustion. The gas then dried cooling, and circulated the fur- nace electric agitators mounted top the furnace. Since the charg- ing and discharging openings are lower than the furnace proper, little the lighter-than-air gas mixture escapes into the room. total 4360 families and more than 600 permanently disabled em- ployees General Electric Co. have been the recipients over $9,000,000 death and disability payments since the institution group life in- surance 1920. Each beneficiary received average $2,000, made available time distress and need. present about 47,000 workers are protected employee and company policies, and the total insurance amounts $140,000,000, which premiums covering $60,000,000 paid for the company, and $80,000,000 additional insurance paid for employees. The Iron Age, December 21, 1933—17 4 3 ¢ rob- tios Poe: init. era- red, wer om- How INISH and pickling are closely related the metal working in- dustry, for, general, the better the appearance finish metal part the more prominent has pickling been its production. Today there insistent demand for better and better finish, which means that the trend pickling manufacturing process definitely upward. How long the trend will remain up- ward hard say, for there are forces opposing pickling just there are other and stronger forces favoring it. the long run—looking perhaps years ahead—metallurgical inge- tion (above) brick- and copperlined steel tanks service pick- ing wire per cent sulphuric acid solution 200 deg. Courtesy Good- rich Rubber Co. The process pick- ling steel calls for large auxiliary use the very metal which pickled, for use acid These tanks are lined with rubber the system known Vulcalock. 18—The Iron Age, December 21, 1933 ttractive Finish Helps nuity may perhaps largely eliminate pickling, insofar descaling, from metal fabricating Putting scale metal one op- eration and removing another manifestly inefficient, but the cumbersome process converting grass into milk, and yet the cow seems destined with for many years come. Scope Pickling Increases Not long ago most the pickling the metal working industry was done semi-finished material such sheets and rods, but demand for better finish nearly all metal prod- ucts started with the unusual flare for fine finish the automobile manufac- turing business, and today the great- est market for pickling equipment not the steel production field, but rather with the secondary fabricat- ing interests and particularly with the large group metal enameling and finishing plants. The most extensive with the manufacture refrigerators, radios, steel furniture, typewriters, cash registers and similar products. lac j iF ple mc all ‘es we sa eq /aa i done for ifac- but icat- the and tors, ters, ts. etal Products Sales Pickling one form another usual operation before annealing, lacquering, japanning, tinning, plating, and common practice most other types metal finishes. One authority has said that the manu- facturer who must galvanize tin the regular course production cannot afford slight any way the proper preparation metal surfaces, and pickling appropriate acid alkali bath the approved method securing such surface preparation. any method descaling where the work oily greasy, first neces- sary remove the oil grease, but the problem grease removal has been discussed previous issues. The extension pickling processes into many high production multiple unit fields has had much bringing the art from the position necessary evil its present promi- nent place nearly all manufactur- ing sequences. The manufacturer who years ago seldom spoke his pickling department, and who was inclined somewhat ashamed it, now points with pride continuous pickling equipment used more and more extensively the pickling department. This shows Mesta handling castings through sev- eral successive dips. 6—Pickling for Better Finish last three articles this series metal finishing were devoted cleaning degreasing metal parts. This the first similar group three articles pickling descaling. machine which takes its place his regular production line. Nature Scale One the reasons that the descal- ing process has been slow become established science that the scale coatings are not uniform thickness nor the tenacity with which they adhere the base metal. The bond between the scale and the base metal somewhat the nature capil- lary bond, differing from the character the bond formed the fusion adjacent metal crystals such pro- duced welding, hot galvanizing and electro-plating. Seales are much harder than the HERBERT SIMONDS metal from which they are formed. They are exceedingly abrasive, break- ing under impact into sharp-edged fragments which rapidly score cut the metal itself when scale rubbed against its surface. Scale hard that will dull and glaze the surface polishing wheels and will turn the edges cutting will score and damage drawing dies. Seales usually are oxides, chemi- compounds the metal itself and oxygen. They are formed when metal surface exposed air oxygen. Heat accelerates the forma- tion these oxides and herein lies the reason for much the descaling the metal industry. The heating required for many fabricating proc- esses—rolling, drawing, forging and others—causes scale form rapidly. Even the relatively low heats an- nealing are scale-forming operations unless air kept away. There are three general methods First, frictional abrasion; second, chemical reaction with the base metal; and third, elec- The Iron Age, December 21, 1933—19 inate ling, the Pox, Was: 4 tro-chemical scale separation. Such methods scale removal sand and shot blasting, scratch brushing, hand rubbing with abrasive cloth, and tum- bling, fall under the first method. Pickling, which simplest terms may described immersion metal dilute acid, the second method. Actually this method usually far from simple and involves such factors time, concentration solu- tion, temperature, use inhibitors, use electric current, and all the production features material han- dling and continuous processes, The third method represented the Bullard-Dunn process metal protection. combination the principles pickling and plating. The Importance Pickling lengthens the life cut- ting tool edges, eliminates frequent tool regrinding, the consequent loss time and, certain instances, the loss precision caused tool resetting. Savings can made nearly all the finishing operations after heat treatment the heat-treat scale removed completely before such ishing operations are begun. For ex- ample, the cost lapping will less the lapping done scale-free surface because less time will re- quired for the lapping when scale has removed, and, addition, rapid wear and tear expensive laps can reduced materially. Grinding costs also can materi- ally reduced complete descaling be- fore grinding. The time required for grinding less because fewer cuts are needed when the metal surface scale-free and there less danger distortion the development surface cracks caused overheating during grinding. Grinding wheels are less apt become loaded glazed. Consequently, the life grinding wheels materially lengthened wheel dressings are less frequently required. smaller variety grits and grades grinding wheels will cover the needs the grinding de- partment, thus reducing the grinding wheel inventory. scale-free parts can located more accurately jigs and fixtures, complete descaling aids the practice gang grinding with its obvious economies. Inasmuch pickling part the manufacturing process sheets, the extent pickling may partially gaged the production sheets. One company producing metal alloy intended primarily for pickling equip- ment has assumed the life pick- ling plant 2000 days, which basis, for its particular design equipment, the company estimates the consumption one ton its alloy the pickling plant each 2000 tons sheets produced. 1930 there 20—The Iron Age, December 21, 1933 were 2,643,721 tons steel sheets produced this country. Technique Pickling pickling meant the treating metals with acid solutions re- move scale and rust. Scales are usu- ally iron oxides, which are classified Paul Blackburn under three headings: Hydrated ferric oxide ordinary brown rust. This soluble dilute pickling acid. Anhydrous ferric oxide—the familiar blue scale which heat-treated parts. This somewhat soluble pickling acids. Magnetic oxide—the black scale formed hot working operations. This slightly soluble acids. The scales chiefly encountered pickling are the last two, and therefore apparent that their removal not much dissolving the scale itself the mechanical action set between the scale and the base metal the acid solution. very thin layer metal enters into the solution when the acid penetrates the scale, and the accompanying evolution hydrogen forces the scale off me- chanically, after which falls the bottom the tank. Dilute acid forms the so- lution for major portion all pick- ling, but whatever the acid used, the solution tends dissolve both the base metal and the scale. The action more rapid the base metal than the and here the reason for much the complexity pickling technique. Everything possible must done reduce the attack acids base metal without interfering with the prime object, scale removal. High- steel attacked more rapidly the usual pickling acids than ordinary low-carbon steel. For this reason high-carbon steel requires sharp, quick pickle. The quicker the scale removed the less steel will dissolved. Alloy steels are attacked rapidly, due the presence large number minute electrolytic couples which are set between the steel and the alloying elements. This attack re- sults roughened blackened sur- face unless great care used. normal pickling practice the ac- tivity sulphuric acid pickling bath gradually slows down, due the presence dissolved iron. This effect not particularly noticeable until the concentration reaches about per cent iron, which equivalent per cent iron sulphate copperas. Pick- ling, though slowed down, can car- ried until iron sulphate starts out and attach itself the bottom and sides the tank and the work. has been found that crystallization starts ordinary pickling temperatures, when the dis- solved iron content reaches about per cent. During the past year electrolytic has been brought high- state development the intro- duction silicon alloy anode which has stabilized this method scale removal. This new anode said eliminate the necessity dumping the electrolyte preventing changes which normally occur elec- tro pickling. result the problem the disposal spent pickle liquors has been greatly lessened. The new anode was developed The Bullard Co., Bridgeport. Acids and Acid Containers the case iron castings, order dissolve the silica sand which may present. The extensive use sulphuric acid due chiefly its low cost. centrations pickling solutions vary from per cent per cent acid, the bath being heated order in- sure the maintenance fairly rapid rate pickling. unfortunate dis- advantage such hot baths that the fumes caused are disagreeable for the workman, but modern plants ventilation systems have eliminated much this trouble. Muriatic acid used strengths per cent per cent commer- cial acid. While the pickling action this acid more rapid and lower temperature can maintained the baths, the use muriatic acid gen- erally prohibited account high cost compared with sulphuric acid. should considered together, for both these factors affect the rate speed pickling increasing the sulphuric acid content about per cent actual acid. Beyond this point increase acid slows down pickling. actual practice the acid strength between per cent and per cent. Acid does not attack steel uniform- ly, owing the crystalline structure the metal and non-metallic inclu- sions, and hence the surface the pickled metal generally roughened. This effect increases the acid ac- tion proceeds, that prolonged at- tack results badly pitted surface. Changes temperature have greater influence rate pickling than variations acid strength. For some ranges increase deg. will double the rate pickling. The range temperature for most pickling operations between 140 deg. and 180 deg. Individual plant conditions and tank capacities frequently will determine the acid content and temperature. acid strength per cent and t