The Iron Age 1934-01-25: Vol 133 Iss 4

rs, but crip- etal- the ile CONTENTS INDEX PAGE MANAGEMENT JANUARY 25, 1934 PROCESSES -:- you read this copy The Iron Age—reflect that before the week out 45,000 men the metal-working industry will have done the same thing. Because your sustained interest evi- denced subscription renewals, The Iron Age the most widely read journal the metal- working industry. Thats why you find more advertisements The Iron Age than any other publication this field. i ¢ 4 . lica- 4 and th - : the that e , isly Serr. THE IRON JANUARY 25, 1934 Page producers transmission gears, differential gears and similar parts, Improved Series 3100 Steels offers decided economic advantage. Made with developed metallurcical control, these improved 3100 steels are furnished closer specifications. freedom from distortion, they are markedly superior the standard 3100 analyses. many applications for which higher priced alloy compositions were heretofore employed, Improved 3100 Steels are now being used with better results and lower costs. Write for complete data. IRON AGE, published every Thursday the JRON PUBLISHING CO. Publication Office: Cor. Chestnut 56th Sts., Philadelphia, Pa. Executive Offices: 239 39th St.. New York, Y., second class matter the Post Office Philadelphia under Act March 1879. $6.00 year S., Canada $8.50, $12.00. Vol. 133, No. } : a 4 | a 4 r | | 1} | {| } | | | 7 1} | GENERAL OFFICES YOUNGSTOWN,OHIO THE IRON January 25, 1934 J. H. VAN DEVENTER G. L. LACHER Ww. W. MACON T. H. GERKEN R. E. MILLER Editor Managing Editor Consulting Editor News Editor Machinery Editor Detroit Boston Cleveland Chicago Editor Emeritus Washington Cincinnati Repatriated Dollars | Special Equipment Machines Large Water Gates WE DO OUR PART Refining Period Making Steel Molding Cast Iron Belt Pulleys Attractive Finish Helps Sales | Molding Unit for Mass Production Rolling Mill Reduction Gear Units Vacuum Die-Casting Aluminum Bronze Scrap Iron and Steel Institute Meets | Washington News Personals and Obituaries Markets Construction and Equipment Buying | oped | | THE IRON AGE PUBLISHING COMPANY FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager PUBLICATION OFFICE: Corner Chestnut and Sts., Philadelphia, Pa. oved EXECUTIVE OFFICES: 239 West 39th St., New York, Y., ADVERTISING STAFF Member, Audit Circulations Emerson Findley, 311 Union Bldg., Cleveland Member, Associated Business Papers Herman, 675 Delaware Ave., Buffalo, Hottenstein, 802 Otis Bldg., Chicago Published every Thursday. Subscription Price: Peirce Lewis, 7338 Woodward Ave., Detroit i United States and Possessions, Mexico, Cuba, Charles Lundberg, 45 Kent Rd., Upper Darby, $6.00; Canada, $8.50, including duty; Foreign Del. Co., Pa. $12.00 year. Single Copy Cents Ober, 239 West 39th St., New York | W. B. Robinson, 428 Park Blidg., Pittsburgh m | Cable Address, Sweetser, 239 West 39th St., New York Warren, Box 81, Hartford, Conn. a — A : x len f - AN THE IRON JANUARY Page Many 25, 1934 Hundred Years Are You Going Live? RYERSON STEEL SER- VICE carries complete stocks all steel and allied prod- ucts, for immediate shipment. Years experience the purchase and use just one class material maximum buying power rigid specifi- checking and testing large and complete stocks your assurance quality steel—delivered the very hour you need it. Interesting watch people live— some act though they had thou- sand years instead the short side hundred! Plenty time—no need conserve it—there always another day—and on. Others understand live serve appreciate the shortness their opportunity—they value and con- serve their time. have found real pleasure help- ing busy buyers capture and con- serve bit this world’s basic treasure—time: Time placing orders. Time interviewing salesmen. Time following orders. Time waiting for shipments. Time receiving, checking and paying for material. Commercially, time money. Ryerson Steel-Service saves money and adds years your life enjoy- ment and service your firm, your family and yourself. JOSEPH RYERSON SON, INC. Plants Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City RSO SERVICE | Ly why; & = | | | Pay JANUARY 25, 1934 ESTABLISHED 1855 Vol. 133. No. Repatriated Doll estimated that from one two billion dollars private American capital have been vacationing abroad during 1933. These dollars took the trip overseas avoid exposure the epidemic progressive anaemia that stay-at-home dollars experienced. Now that stabilization the dollar hand, many these fugitive dollars which became pounds, guilders, francs foreign securities will hurry get back home with their profits. For they know that the eventual devaluation currencies abroad will deprive them the fat that they have put on. This homeward flight the dollar will tend lower foreign currencies and raise American dollars, thus reducing our present export advantages. And this just what the Govern- ment does not wish happen. Hence the proposed two billion equalization fund which used buy foreign exchange. other words, public dollars will abroad offset the exchange effect private dollars coming home. these returning private dollars, with their profits taken from foreign capital, are simply added our present hoard uninvested private capital, they will good. they can put work, along with our other idle private dollars, the financing business and industry that now being done public funds, they will great deal good. They are not likely work, however, unless some practical way devised whereby these private dollars can into private enterprise with reasonable assurance safety and profit. When solve the problem idle dollars, will have solved the problem idle men. © Large Water Gates Machined the welding the water gates for the Boulder Can- yon project THE IRON AGE, Oct. 19, 1933, showed number the special facilities that had pro- vided for the fabrication this large work. even greater extent, special methods and adaptations machining and assembly equipment had devised and the shortest possible time and with the greatest possible utilization existing equip- ment. The equipment was adapted the new work the manufacturing division, with some necessary assist- ance from specialized departments the works, such the manufacturing equipment engineering department and the tool repair department. stated the previous article these gates will control the flow water into the penstocks from the lake formed the Boulder Dam. There will four towers out outstanding project the past year was the fabrication the large gates that are con- trol the flow water into the penstocks from the lake formed Boulder Dam. This work entailed not only many unique welding problems, shown previous article, but involved unusual dif- ficulties machining, due the large size and weight the gates and the accuracy required. Some the ingenious adaptations existing machine tool and assembly equipment devised for this work are described this article. the lake, rising well above the sur- face, each tower forming the entrance one the four penstocks. There are two gates each tower, one the base the tower and another slightly lighter construction, Nose Liner Cylinder Gate Fig. 1—Cross-section Boulder Canyon intake tower. Equipped with two gates each, four these towers will control the flow water into the penstocks. 12—The Iron Age, January 25, 1934 point about 150 ft. above the bottom gate. The towers are 338 ft. high, with clear inside diameter ft. and maximum outside diameter about ft. They are concrete fluted construction, shown Fig. and will have top circular building containing the gate-actuat- ing mechanism. these towers will had means bridges extending from the towers the crest the dam proper. The gates themselves have outside diameter about ft. and height overall 10% ft. The lower gate unit with appurtenances weighs about 261 tons and the upper gate, 212 tons. The assembly consists three major portions, the gate itself (see Fig. 7), the nose liner, and the throat liner (see Fig. 3). The throat liner and nose liner with upper guide brackets are bolted together and built into the concrete the tower, the gate being raised and lowered inside the nose liner. The nose liner con- tains the water openings, each ft., has inside diameter ft. and maximum outside diameter ft. in. The lower nose liner weighs tons and the upper one, tons. The large size and weight these parts together with the accuracy necessary made this job one un- usual difficulty, and some the ways and means devised this work are described briefly this article. Operations Throat Liner The throat liner was made castings bolted together form circle. Since there were these pieces the order seemed wise provide some sort set-up which would obviate much handling possible and the same time assure job machined the close tolerances required. The first step was plane the top flange within in. the finish line. The second op- eration was planing the excess stock from the edge the skirt, which theuppermost partion shown provided flat surface upon which i dril ind suc pro end ing 0.0 tha tog the po: pre po: tio EL. Throat Liner clamp the part for the milling and drilling the end flanges. The seg- ment was mounted the rotating indexing table boring machine, such position that milling marks upon the table segment proper chord length and with proper end angles was obtained. close were these castings made and machined that the circle formed bolting the segments together was within in. over under perfect circle with maximum open- ing partings not more than 0.002 in. The drill jig, which may also seen Fig. was designed that lining the longer straight edge the jig the inner surface the liner segment, the bolt holes were placed bring the joints together with offsets. the field these segments are welded together position and much the weld preparation was done the mill possible, the balance the prepara- tion around the curved portion being done means air chisel. Devise Special Facilities Face Top Flange and Turn Monel Seats When assembled the throat liner formed circle with maximum out- side diameter ft. in., which was beyond the capacity any bor- ing mill available. standard 28-ft. mill was rearranged the following manner provide the needed facili- ties for facing the top flange and turning the monel metal seat which was mounted this member the assembly. The housings and rail were lifted from their foundations unit and moved away. The table was then enlarged sufficient diameter means large fabricated beams clamped the table radially, ex- tending out point sufficient catch the lugs which were cast the inner surface the throat liner seg- ments for this purpose. Provisions for carrying the cutting tools were made using the housing openside planer, which was bolted the foundation pads the regular mill. Fig. the planer housing may seen place the center background, also portions the pecially Adapted Equipment CHARTERS Manufacturing Engineer, Generator Division Westinghouse Electric Mfg. Co. East Pittsburgh radial beams will noticed extend- ing below the skirt the throat liner. The center post was employed for centering and taking measurements and was also used during the drilling the monel metal seat which was mounted the throat liner. Operations this piece were such make possible the use star wheels and knockers mounted the table. The outside the skirt the lower throat liner had turned for the connection the steel pen- stock, but since the column the openside planer was too far away make use the planer side head, another tool post was mounted angle plate and fed means star wheel and knocker mounted the bottom one the radial beams. This tool post arrangement can just discerned the lower right hand corner Fig. The radial drill seen the left this illustration was used for drilling and spot facing the bolt holes for at- tachment the nose liner. The drill- ing these holes while the throat liner was the mill saved one dis- mantling and assembly operation and awkward set-ups under radial drill press. The throat liner remained as- sembled until dismantled for ship- ment. might well mention that the joints were held proper alinement means taper dowels, that trouble would Fig. 2—Milling the partings throat liner segments, which, bolted together, form the throat liner. The top flange was first planed provide flat surface clamp the segment for milling and drilling the end flanges. The Iron Age, January 25, 1934—13 ~ +9 ; i » ? “es ~ el Monel metal seat. The table 28-ft. boring mill, enlarged Fig. 3—Set-up for turning and drilling the throat liner and fabricated beams, was used and the housing openside planer utilized for mounting the cutting tools. Other machining units included tool post carried angle plate the lower right, and radial drill. Fig. 5—Finishing the Monel metal seat position the throat liner. The seat was turned means special radius turning attachment fastened the clapper boxes the open- side planer. ~~ Fig. 6—Device used for forming the radius the seat the lower gate. 14—The Iron Age, January 25, 1934 i § Fig. 4—Drilling and mounting Monel metal seat. com- bination clamping and drilling fixture was used hold the seat place. The special drill head was attached arm pivoted the cen- ter column and sup- ported frame equipped with wheels that run track. encountered during assembly the field. Set-Up for Drilling Monel Seats After the machine work out- lined above had been completed the monel metal seat was mounted place. Fig. shows clearly the set-up used for this purpose. The seat, sections, came the job finished except for drilling. combination clamping and drilling fixture was used for holding the seat place. The drill press used was special head taken from machine for milling and Fig. round device built take the place the large boring mill for many the gate operations. con- sists framework pivoted the center and ro- tated circular lass. The device eliminated many separate set-ups and saved great deal time. drilling railway rocker rings. was attached arm pivoted the center column mentioned previously. The arm was supported frame equipped with two wheels that ran upon the track shown under the operator’s right foot. This frame had device for locking the rail that could neither shift nor lift when drilling. The tap size drill was run through both the seat and throat liner the proper depth, the hole was then opened means combination drill and countersink, after which the hole cleaned out and the monel metal screw inserted and pulled tight before drill- ing was started the next hole. Seats Turned Special Attachment After the seat was mounted the drill press arrangement was removed, and the seat was turned means special attachment fastened the two clapper boxes the open-side planer, shown Fig. The radius piece was mounted proper relation the seat means vertical and horizontal lines scribed upon it. Measurements were taken The Iron Age, January 25, Fig. employed for checking the shape the nose liner. (at right). from the finished back the seat and the large flange surface. attempt was made provide power feed since the operator had con- stant attendance and the surface turned was short the direction the feed. There was between and 3/16 in. material left for finish the curved surface. Two roughing and one finishing cut were taken, the first two with round- nosed tools and the last with wide tool having considerable lip and mini- mum clearance. Although very tough, the Monel metal finished very nicely. The tool was mounted the rear the tool post that there would tendency pull into the work. assure steady, smooth cut for finishing, was necessary run hardwood block against the bot- tom the skirt the throat liner. This removed the tendency chatter which would naturally result from much overhang the work. After the finish cut was taken motor- driven buffing wheel was employed give high finish the surface. might mentioned passing that the final assembly the gate unit water was poured into the space above the line contact between the gate seat and that the throat liner with signs leakage. Fig. shows similar radius turn- ing device used for forming the radius the bottom gate seat. Operations Speeded “Merry- Go-Round” Device Because the need for speed the original plan all the machin- ing the gate while mounted the boring mill had altered, piece apparatus known the “merry-go-round” was built take the place the mill for many the operations. This consisted com- paratively light circular frame work pivoted the center and rotating circular track six roller-bearing wheels. Fig. shows this device with 16—The Iron Age, January 25, 1934 Fig. 9—Press for correcting distortion liner segments due welding. several machines place. The two machines the left are milling machine and slotter, used for making the vertical slots which carried the stainless steel guide shoes. the right may seen the combined drill jig and clamping fixture, which was used for attaching the lower monel metal seat the gate, together with the drill press and its section circu- lar track. This device was rotated means power-driven windlass, the snatch block and cable showing the foreground. This device was great time saver because the elimi- nation great many separate set- ups, since all the drilling and slot- ting could done here, many the operations simultaneously. The welded structures were large and heavy, the machining tolerances close and the amount finish rather limited that was necessary work very close dimensions. Fig. shows the checking fixture for the nose liner use. The partings and other finish lines plainly that any variations from the proper size were once noticed and could corrected the press shown Fig. The press was made from two crane lifting beam, and cylinder and pump taken from hydraulic press. > oO o Registrations per 1,000 Units 1933 -------------->| Domestic passenger car registrations the three leading automobile manufacturers during 1932 and the first months 1933 are charted above. The narrow spread between Ford and Plymouth sales 1933 especially noticeable. | tior hea the + + + + > + | | | | | | |_| es _| 4 =! of | | Le + . 5 + } + + + mot : — | | 1a | } | | | | bili | | | | — . | | ° < | | | — * * = + + - + mac the | | + + + + 5 + + + + + — + + + + + | erg. has Standardizing the Refining Period Making Steel the three distinctly different phases working open- hearth heat, namely, charging, melting and refining, the last men- tioned has been the least affected progress. This resistance change probably due the fact that the methods employed “working the heat” have been entirely governed the individual judgment the fur- nace operator. Men found their advantage guard religiously from enterprising engineer the secrets their trade, especially the art reading steel tests. This was com- mon practice until quite recently and, obviously, did not any good pro- moting progress. The building the modern so- called tonnage mill, however, opened new era with great possibilities making strides toward more sta- bilized and standardized refining pe- riod the heat. Already some im- portant changes this end have been made. The bigger the furnace, the more pronounced has the change be- come. Experience has shown that the larger bath has enough heat en- ergy stored absorb great quanti- ties iron ore way the charg- ing box without any material slowing- down the lime boils. The result has been that “working the heat” has become matter timing the carbon reducing effects the lime boils with those the ore. perfectly timed heat would thus one where the lime and ore boils FOLKE SUNDBLAD cease somewhat above the desired car- bon point, depending upon the tem- perature the bath and the condi- tion the slag. this connection interesting note the vast dif- ference between this practice and the one used extremely small Swedish open-hearth furnaces making super high-grade steel. this case “work- ing the heat” means nothing else but letting the heat “ride” all the way down without the addition any oxidizing agents whatsoever. the tonnage hour record the furnace, well as, certain ex- tent, the uniformity the product, dependent upon the uniformity methods employed the refining pe- riod the heat, evident that much would gained these meth- ods could standardized much possible. add known weight iron ore single operation has given strong impetus this move- ment, principally because the furnace operator according this practice can divide the said period well de- fined stages, the length which, course, depends upon the weight the ore charged and the temperature the bath. Consequently the result can estimated with reasonable ac- curacy. the other hand standardizing large open-hearth heat evidently out the question, mainly due the impossibility getting uniform charge. The scrap naturally contains more less oxides iron the form rust. Besides, the enormously increased use fast melting scrap from the automotive and can industries without corre- sponding increase charging speed tends produce vast amount iron oxides. These, together with the added the bath the hot metal, will somewhat influence the speed and degree the carbon reducing process. For these reasons, when seeking yard stick that will apply all large heats, the first step will sep- arate the constant factors involved the above mentioned timing process from those variable nature. the first class find: The charging the limestone and the scrap such manner clear the furnace bottom the “middle far ahead the other “doors.” the second class: estimate the temperature and car- bon the bath the time ore addition. estimate the weight the ore charged order oxidize the carbon certain number points. estimate how many points car- bon will reduced the residue lime- stone. this timing process depends large extent upon the operator’s ability read the test piece ac- (Concluded Page 70) The Iron Age, January 25, 1934—17 4 ~ = | ~ the major problems con- fronting the foundryman spe- cializing and transmission work the economical molding belt pulleys, particularly those ranging size from ft. diameter and face depth from in. Where pulley molding ma- chines have been installed, heavy outlay patterns and flask equip- ment unavoidable, and, unfortu- nately, the net results frequently not warrant the initial investment. There exists, however, way producing these particular castings Fig. (Above), Heavy duty semi- steel belt pulley ap- proximately ft. diameter. the “open sand” system, which de- serves more publicity than has at- tained, and concise description which follows. Fig. shows pulley casting about ft. in. diameter, with finished belt face depth in., usual straight six-armed type, for heavy duty, which will serve general example. loose iron rim pattern the diameter required, plus contraction and machining allowances, cast ordinary mold, either from wooden master pattern, swept spindle and segment equipment, and machined the proper dimen- sions, the inside and outside faces being made parallel give even thickness all over, taper neither necessary nor desirable. The depth the rim pattern should that the maximum sized casting ever expected under ordinary condi- tions for pulley having one set arms only, castings from minimum maximum depth are easily made from single pattern. The pattern used form the arms consists 18—The Iron Age, January 25, 1934 independent six-armed spider cast- ing with upper and lower half wooden hubs, fitted loose, and provided with coreprints the desired size, hubs and prints being made interchange- able permit wider range cast- ings from single pattern. Drag cheek part flasks only are needed, and may lumber metal, the only stipulation their size being that they, whether stacked the form shallow frames made single sections, shall approxi- mate the depth the pulley about molded, plus about in. extra depth the pulley rim for ing allowance, this additional ring / Fig. 2—(Above), Pulley drag mold rammed showing arms bedded correct depth template. are holes allow insertion hooks when drawing pattern. Fig. 4—(At right), Cross- section view mold with lifting plate rammed ready for with- drawal. metal being easily cut off the lathe with parting tool. When molding the pulley, the rim pattern first set dead level the foundry floor, the flask part being then laid the floor outside the pat- tern, and the space between rim and flask lined next the pattern with suitable facing sand, rammed full with heap sand and struck off flush with the edge the flask the usual way. Following this operation, the arm spider and lower half the hub pat- tern are bedded correct depth, the use wooden template the proper size, the mold this stage being shown Fig. Lifting Plate Feature Before completely making the part- ing round the arms, lifting plate ar- rangement consisting six castings bracketed together six wrought iron clamps which are cast in, thus forming integral unit, bedded into the joint, the upper faces the plates being stamped down level with the parting line along both sides every arm. The half inch clearance Fig. 3—Plan view lifting plate set inside arms pulley pattern. space between plates and arms next slicked down, and little sharp silica sand strewn over the area just slicked secure perfect separation when lifting the plate prior remov- ing the arm and hub sections the pattern. will noted the plan and cross-section views the lifting plate, shown Figs. and that sharp taper allowance provided, feather edge being essential obtain good results, and that three tapered foot guides, one each alternate section, are put tion the men tern low clan spec for men drag mad A plat the and ner avoi the has the insic the 4% \ — | } | \ ‘ \ a t used f ae Vor lron are cast on, insure the plate being put back absolutely correct posi- tion when finally closing the mold. Incidentally, the best way mold the plates when making the equip- ment, sink the six separate pat- terns into specially constructed fol- low board, reverse side up, the binder clamps and lifting loops placed into special holes gaged the patterns for their reception, the whole arrange- ment being then rammed deep drag part, rolled over, the parting made, and the cope rammed the usual way. After the cope removed and the plate patterns drawn out, any loose sand around the projecting ends the binder clamps and lifting loops cleared away, and the mold closed and poured through spray gates from central sprue. Plates carefully made this man- ner will last, given good treatment avoid distortion, formany years. When the parting around the pulley arms has been made, the upper half the hub pattern set place, the inside the pulley rammed up, tough facing sand mixture being used and backed with heap sand, the inside being struck off level with fraction higher than the level the outside diameter the mold. a & author describes open sand method molding pulleys both large and small size. recommended for its flexibility and for the savings effects avoid- ing heavy outlays for patterns and flask equipment. cases where the hub exceptionally large, ringed wood screw used, usual when carrying loose pat- tern parts ordinary cope mold. When about ram the last inside course the gate pin set into the hub pattern accordance with regu- lar pulley practice. Removing Lifting Plate After ramming completed, and the off level, the joint around the rim pattern slicked and lightly swabbed with clear water, the rim pattern being then rapped and drawn out hand crane size dictates, the holes Fig. being used for this purpose. The plate now ready for removal. three-point lift with turnbuckles carefully drawn tight, just enough start the lift little before hoisting, usually gives clean lift. soon the plate hoisted clear Fig. left), Plan and sec- tional views finished pulley mold. Fig. (Below), Adjustable follow board with pulley pattern and flask placed plain jolt machine table ready for produc- tion. Interchangeable lagging EASTHAM the drag mold and swung away, the hub pattern drawn downward, any slightly broken edges repaired, and plumbago brushed over the face the mold, rim, arms, and hub. The plate has been set down board other flat surface, the three pro- jecting guide feet functioning sup- porting columns, and preventing any contact between the face the mold and the foundry floor. The spider pattern forming the arms next swabbed and drawn from the sand, then the lower half the hub pattern; the mold finished and dusted with plumbago from fine bag, this partly avoid waste, and also prevent undue accumulation lead the bottom the rim. The mold then slicked, the hub core set position, and the three inverted conical prints left the guide feet deepened half inch the insertion pointed round bar less diameter than the diameter the guide feet their junction with the plates. This precaution obviously insures little clearance under the guide feet, and removes the risk crush any the three points, particularly when molding pulleys small diameter, when the guide pins are necessity fairly close the rim mold. Another precaution worth noting allow plenty taper the upper hub coreprint, this also with the in- tention avoiding crushes when low- ering the plate back place, op- eration easily accomplished single craftsman when making the smaller sizes, two men when the greater diameters are being handled. Thick- ness gage sticks may used three (Concluded Page 68) The Iron Age, January 25, 1934—19 if A / 4 © the How Finish Helps Meta further process removed from the in- itial raw material, the more spe- cialized does tend be. Thus, finishing operations are frequently non-standard character, and the equipment often custom made for the job. Pickling, however, associated not only with the finished product but with the raw material well, and the range equipment varies from highly stand- ardized apparatus elaborate ma- chines designed for the pickling and handling mass production one particular product. previous articles was pointed out that full economies could effected only through full coordination processes before and after descaling. for instance, plant which manufactures bicycles. Here many small parts are machined, heat treated, pickled, and Other parts are forged, pickled, ma- chined, heat treated, pickled again, and then ground. Certain frame parts such the front fork tube may heated and formed and then pickled and enameled. Some the factors pertaining pickling, which the manufacturer such plant should consider and which already have been discussed more less length, are: relation good pickling good finish, se- lection cutting and quenching oils 20—The Iron Age, January 25, 1934 a several years the design specialized pickling equipment ran far ahead available materi- als, but now materials have caught and the manufacturer metal parts offered automatic and in- dividualized pickling machinery suit his needs. Some the mod- ern equipment features are de- scribed this third article pick- ling, series devoted metal finishing. facilitate scale removal, use re- ducing atmosphere heat treatment avoid one more pickling oper- ations, importance proper pickling technique, and economy correct lo- cation pickling equipment. Assuming that the manufacturer has studied all these features, then ready consider the selection pickling equipment. Today, 1934, fortunate having ade- quate materials and great variety ingenious designs choose from. research engineer the Bake- lite Corpn., commenting development equipment, said: itially, design provides the important advance; eventually, any type mechanism, material becomes the de- termining factor.” The first advance carried the de- sign pickling equipment far beyond the ability materials cooperate and only now that the fabricator pickling machinery has materials suitable for all parts and for all types pickling solutions. The recent rapid increase the development and use corrosion re- sisting alloys has brought close as- sociation and interdependence between these materials and the pickling proc- ess. Some the nickel alloys seem particularly resistant the acids commonly used pickling steel, and their life even under severe ser- vice pickling may exceed six seven years. Wire Baskets Despite rapid advance belt type continuous pickling equipment, the wire basket one form an- other still remains the usual contain- for small parts which are pickled. Wire baskets are usually made aluminum, Monel metal, cop- per, brass, nickel chromium, and steel. However, addition these, many new alloys are appearing. The na- ture the pickling process course determines large extent the ma- terial best suited for equipment. Aluminum attacked but slowly both nitric and sulphuric acids, but more rapidly attacked alkalis and nearly all concentrations hydrofluoric acid. Monel metal, which alloy nickel and copper, re- Small stampings are pickled and polished previous plating, relatively inexpensive ro- tating drums. | sis pic lif as sor phi tac aci nit fre att Is tior Products Sales Selecting the Pickling Equipment sistant nearly all acids used pickling except nitric, and has long life alkalis. Brass used good many the alkali solutions, but not suitable cyanide and not strong its usual form some the other alloys. not attacked hydrofluoric acid and used some extent dilute solutions sul- and muriatic acids. at- tacked hot concentrated sulphuric acid and nitric acid. When the cycle embodies both alkali and nitric acid dip, nickel chromium frequently used. This material not attacked alkalis and resistant the common acids used pickling. strength value and not affected any temperatures normally encoun- tered pickling. Suitable wire for making baskets obtainable all the above-men- tioned materials, and these wires lend the small shop one operator efficiently through pickling and rinsing operations. The tanks should con- veniently located and should provided with hoods and ample ex- haust system. themselves welding and other usual forms fabrication. Tanks The bugbear the pickling busi- ness for many years was the tank container, and shortcomings this line were responsible for the early separation the pickling depart- ment from the rest the plant. Now greatly improved tanks and lining materials have been big factor bringing the pickling operation back into the main production room. The more common types tanks are wood, either lined unlined, steel, masonry, and concrete. Each material may used with variety linings. The wood tank still commonly used be- cause its low first cost. recent study wood pickling cated that the expected life will range from one five years, depending upon the way the tank made and upon HERBERT SIMONDS the nature and temperature acids used. Usually wood pickling tanks require much repair and maintenance and, addition this, they leak acid. leaky tank not only causes di- rect loss acid, but source much indirect loss. First, causes damage floors and surroundings, and second, and more important, creates operating inefficiencies and, mentioned, necessitates isolated location. Wood tanks with lead lin- ings have proved successful many installations where the operations are jobbing intermittent character. Lead linings steel tanks have the disadvantage that seam opens the lead punctured, the acid may fill the space between the lead and the steel and may practically ruin the tank before the leak dis- covered. often The Iron Age, January 25, Fi y \ highly satisfactory, but hard install and when cracks develop they are difficult repair. One the good designs consists two 4-in. courses brick with layer as- phaltic material between them. This expensive, but when properly in- stalled, satisfactory most any temperature concentration acid. The usual rubber linings have short life high temperature, but where the maximum temperature 150 deg. they offer many advan- tages. punctured, they are repaired, and they may vulcanized intimately steel metal surface. This means that case punc- ture, the acid limited one spot and therefore eats hole through the metal container and discovered much damage done. New Materials for Tanks Recently some designers pickling equipment have turned the sim- plest all types construction, metal tank made some resistant alloy such Monel metal without any lining backing. The first cost such tank high, but for certain processes has offsetting advantages. One the disadvantages heat dis- sipation when high temperatures are used. New materials for pickling tanks are constantly appearing, that the best construction one year may not the best the next year. im- portant for the manufacturer who contemplates buying pickling equip- ment keep mind that the first cost the least his troubles. poorly located machine 22—The Iron Age, January 25, 1934 tank will offset the initial economy surprisingly short time. quotation from Percy Kingsbury, chief engineer, General Ceramics Co., may illustrate what may expected the line new materials for pick- ling operations. “Chemical stoneware offers many ad- vantages for the modern pickling plant. unaffected corrosive agents other than hydrofluoric acid, and com- plete tanks may made one piece with joints seams. Tanks this material usually have rounded corners and smooth, bright acid-proof glazed surface, making them easy keep clean. important that this type tank carefully installed that its weight evenly distributed over the entire bearing surface. The tank should protected from mechanical abuse, from sudden changes in temperature, and from local overheating.” Special Machinery Automatic machinery has been de- veloped for pickling nearly all prod- ucts which have sufficient mass pro- duction warrant the expense. Some idea the diversity this equip- ment may had from recent state- the Galvanizing Plating Equipment Corpn. rotary drum type pickling and cleaning apparatus has been developed for medium-sized stampings such as conduit boxes. This consists series six more tanks, each which a drum is partially immersed. The drums are all mounted large cen- tral, hollow shaft which provides the means of conveying the parts progres- sively forward from one drum the next. semi-automatic pickling, cleaning, and acid-dipping machine the hopper type has been developed for knife, fork, and spoon blanks and other similar articles. This machine usually operates conjunction with continuous hop- per chain attachment which carries the parts through drying oven. “Elaborate automatic cylinder type machines have been built for descaling brass and other stampings after an- nealing. one particular case the apparatus includes chain device which carries series wire screen cylinders, containing the parts, through the re- quired pickling and cleaning solutions. The equipment provided with auto- electric control that the travel the cylinders periodically stopped permit loading and unloading opposite ends the machine. “Large work calling for mass pro- duction, such fire extinguisher shells, handled through the pickling opera- tion tray type machine which the principle similar the cylinder type except course that the feature the revolving cylinder the solution omitted the case the trays. desired the tray machine, agita- tion may secured submerged pumps. “Small electric fan and motor parts are pickled before enameling full automatic pickling, cleaning and drying unit. “Electrical conduit requires elab- orate special construction when the op- eration is continuous through several processes. One machine has been built for automatic continuous sequence through different operations” When production less spe- cialized character, that is, when many different parts are put through one time, more simple equipment available. Typical such equip- ment the batch process rotary pick- ling machine manufactured Ransohoff, Inc. One these units described Mr. Ransohoff follows: “It includes rubber lined, star return barrel with rubber lined tank and acid-proof pump for circulating the solution over the work larger installations conveyors and special handling duce the labor cost the pickling department. fast resi cont viev cont feat equi seril tank men natic prob omie ling the taine the d lined Stanc Co. for sulphi Produ crates Albior Monel tated Monel Som tions The great ciples should against each operatic ing inhibito but t > b r bt while the tumbling taking place. reversing the direction rotation the barrel the work discharged and carried through draining screen, after basic cleaning compound. This washes off the tumbling sludge, neutralizes any remaining acids, and the same time brings the work sufficiently high temperature dry its own heat. The addition stars the tumbling process enables weaker acid used, since the acid loosens the scale which then removed the action the stars, leaving the work with bright and silvery Fastenings and Crates When wood tanks are used, important have the bolts and fastenings made material which resists acids, and fact all miscel- laneous equipment which comes contact with the pickling operation should studied from the point view corrosion either from direct contact from fumes. Some the features tank hoods and continuous equipment have already been de- scribed. the use general open tanks much special handling equip- ment often required. The Inter- national Nickel Co., which has made special study this phase the problem, says that surprising econ- omies handling through the pick- ling operation may made using the proper type crates and con- tainers. The company reports that the American Rolling Mill Co. suc- uses crib type lead- lined wood tank built the Hauser Stander Tank Co., that Williams Co. uses chains made Monel metal for handling bars and out boiling acid, that the Union Steel Products Co. uses metal built angles and flats its Albion, Mich., plant, and that large Monel metal cage used firm Great Britain for holding hollow metalware revolved and agi- tated pickling bath. One feature this cage the use expanded Monel sheet lining. Pickling Solutions Some the standard pickling solu- tions have been described and the value inhibitors has been suggested. The subject extensive and the number variables each case great that only certain broad prin- ciples can indicated here. most pickling there are losses should carefully balanced one against another the analysis each case. There may loss base metal, but the speed the operation may cause overall sav- ing compensate. The use inhibitor most always advisable, but some cases and with some in- This shows few typical conveyors used cleaning and pickling processes. Courtesy Magnus Chemical Co. hibitors the saving acid and base metal offset the attendant pro- duction delay. Some electro-chemical processes are said avoid loss base metal without introducing disadvantages balance. addition the large number commercial inhibitors available, some humble products such flour and yeast are often used advantage. Another common product, salt, sometimes added, not inhibitor, but improve the quality the work. Sulphuric acid reacts with the salt form hydrochloric acid and the presence both acids the bath helps particular cases. The Amer- ican Chemical Paint Co. gives 0.2 lb. salt gal. water the average proportion. The strength pickle bath sands Units Thou highly important factor the over- all economy. Picklers often taste solution determine its strength, but best this method does not indicate the amount ferrous sulphate the bath. The rate evolution gas an- other makeshift strength indication. Simple strength testing outfits for pickle baths are inexpensive and pro- vide adequate means for intelligent operation. Many ingenious devices have been built automatically regulate the supply acids and the temperatures pickling. this connection, Pro- portioneers, Inc., Providence, L., states that standard water meters can “feel” the rate flow and thus can made dictate the stroking rates reagent pumps. 1932 Automobile production the United States and Canada during the past two years shown the above chart. Note the absence the usual seasonal decline June, July, August and September 1933. The Age, January 25, 1934—23 “ Molding operation. Flasks are the molding machine and the patterns are being lowered into the flasks, after which the sand run and the mold jolted. This view shows primarily the setting the cores into the com- pleted mold. the left the core setting operation, pouring taking place. Iron Age, January 25, 1934 Molding NEALEY American Gas Association foundrymen strive for the ideal mass production set-up, but few ever attain it. This grouping all operations such core making, baking, flask molding, pouring, shake-out, etc., about looped traveling conveyor these different operations standardized, synchronized and speeded up. Therefore the descrip- tion such unit which perfected the Springfield, plant the American Radiator Co. will interest. was made possible gas-fired conveyorized core oven. Cast iron pipe from in. in. diameter and ft. length made here, and there are two these combination core- making, molding and sand-casting units. One unit will produce 1800 lengths pipe and the other will make 800 lengths 6-in. pipe 8-hr. day. This pipe will average ft. length. The molds flasks are cast iron and three molds are cast single unit. other words, the three are single solid piece and are not divided into cope and drag. The conveyor the roller type, consisting two parallel rows rollers, ft. long and ft. apart, with roller cross-overs transfers each end. This sunk pit below the floor level facilitate the han- dling the tall molds. These molds stand bottom plates which ride the rollers and the lines molds are pushed along pneumatic pushers placed each the four corners the conveyor. the right and left respectively the starting end the conveyor unit are the molding and core-making operations with the charging end the core oven adjacent the latter. This oven runs parallel one side the conveyor. empty flask transferred crane jolting ma- chine, clamped into position, and three field Radi: syncl conv reser mass lowere then patter sand pulled clampe ready Core three form three arbor, into it. fed forms and gre chain gas-fire two two oven, process core the mor chain The construc ft. fire each sid are loca Gas this plan are bake hr., depe the molds are roller 4 ~ AST iron pipe, from in. in. diameter and 6-ft. lengths, cast permanent molds the highly mechanized Spring- field plant units the American Radiator Co. All operations are synchronized means loop conveyor and the installation rep- resents the present ultimate mass production simple castings. patterns, connected yoke, are lowered into the three openings. Sand then poured between the mold and pattern walls and jolted form the sand linings. The patterns are then pulled the hoist and the mold un- clamped and placed the conveyor, ready pushed the next station. Cores are made cast iron forms, three core openings form. form placed jolt machine and three cast iron rods, joined arbor, handled hoist, are lowered into it. Sand from hopper then fed and the core jolted. The forms are then opened and the arbor and green cores hung traveling chain conveyor operating through gas-fired core-baking oven. There are two these core-making units and two loop chain conveyors through the oven, which double. During the process core making the arbor and core rods are handled hoist the moment the core hung the chain conveyor. The oven, which sheet steel construction and refractory lined, ft. long, ft. high and ft. wide. each side, using gas lb. inspirate air for combustion. They are located just above the floor line. Gas the fuel standardized upon this plant because its efficiency, con- trollability and economy. The cores are baked 450 deg. for hr., depending upon the size. the meantime the prepared flasks molds which have been gas baked are pushed along that side the roller conveyor closest the oven and (Concluded Page 68) The entire set-up with pouring foreground. Note core-making and molding units background together with automatic and continuous gas-fired furnace for core baking. mold dryers are located under the molds. Core making—shows the operators ready set the arbors the core box prior jolting. The Iron Age, January 25, 1934—25 Fig. unit employs fine pitch gears, and the low-speed gears are two sections and the first gears one piece. rolling mill speed-reducing units, contributed Thomas Holloway, gear consultant, United Engineering Foundry Co., Pittsburgh, the an- nual meeting the Association Iron and Steel Electrical Engineers, the following has been taken the design and material gears for the purpose: The most common cause trouble with gears inaccuracy manu- facture, due the use obsolete machinery and methods. ary cause faulty design and, occa- sionally, there incorrect lubrication. only during the past years, and particularly the last decade, that gears have been placed which closely comply theoretical requirements. Broadly, there are ods used for manufacturing gears, namely, forming and generating. The generating methods may still fur- ther divided into hobbing and shaping, both which methods produce ac- curate and silently operating gear provided reasonable care exercised the machine shop. With the forming method, which in- cludes the use end mills, rotary milling cutters, and template planers, there are many difficulties encoun- tered that they should never em- ployed for high-speed gearing. obvious that any forming tool must designed represent the true tooth form when the correct relation the gear blank and the many dif- ficulties maintaining this relation around the periphery gear are apparent. The cutting edges become dull long before gear finished, necessitating resharpening and pro- 26—The Iron Age, January 25, 1934 viding opportunities for error both grinding the contour and resetting. Shaper Method Generation discriminate between the hob- bing and shaping methods not easy because both processes have been de- veloped intensively the last few years, and probable that the crit