The Iron Age 1934-02-01: Vol 133 Iss 5

a | Engin YEAR SERVICE THE METAL WORKING INDUSTRY MANAGEMENT FEBRUARY 1934 PROCESSES -:- NEWS Ohio. yurgh. Readers Want...and Get This Weeks News ever have executives the great field used many question marks comment the future. Never have they needed know quickly and reliably what government, competitors, customers, labor and public have done intend that will compel change their business plans. ever have the news pages The Iron Age magnified their office been such demand every part the industry. That means that the paper gets speedy reading and does not once the shelf, often happens with newsless publication, awaiting the convenient time that may not come. means also that articles technique and practice The Iron Age come with like promptness under the eyes the men high and intermediate command. makers The Iron Age well know that much the prestige has due the genius and caliber the men its industry who have built themselves into through the record their achievements. hat The Iron Age the first choice readers shown the results independent reader interest investigations, totaling 10,500 opinions. The Iron Age was first with 7,537 polled votes —leading wide margin. : +. ats ‘SS 42 THE IRON 1934 Page makes muscles effective Likewise takes skillful engineering moke even good bearings perform their best. Just the coordination mental processes makes the muscles the athlete successful, the trained engineers alone can make the finest ball bearings deliver the performance that built into them New Departure. Remember, when you select New Departure Ball Bearings, you are building into your product performance. Such the inevitable result “application engineering” born the experience gained ceaseless research. Bring your problems bearing engineering The New Departure Mfg. Co., Bristol, Connecticut; Detroit, Chicago, San Francisco, London, Eng. THE IRON AGE, published every Thursday the AGE PUBLISHING CO. Publicatien Office: Cor. Chestnut 56th Philadelphia, Pa. Executive Offices: 239 39th York, Y.. second class matter the Post Office Philadelphia under March 1879. $6.00 year S., Canada $8.50, Foreign $12.00 Vol. 133, No. | | } | “is, ~ | re wt | ‘ _ a & February VAN DEVENTER LACHER Managing Editor MACON Consulting Editor GERKEN News Editor MILLER Machinery Contents Scuttling the N.R.A.? Speeding Orders Between Office and Plant Rail Fractures Low Temperatures Lubrication Rolling Mill Gear Units Aluminum for Reflectors Development Hard Metal Carbides Gas Furnaces Pipe Plant New Equipment News Washington News Personals and Obituaries Automotive Industry Construction and Equipment Buying Products Advertised 104 Index Advertisers 122 THE IRON AGE PUBLISHING COMPANY | F. J. FRANK, Prestdent G. H. GRIFFITHS, Secretary c. S. BAUR, General Advertising Manager PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th St., New York, Y., ADVERTISING STAFF Emerson Findley, 311 Union Bldg., Cleveland Herman, 675 Delaware Ave., Buffalo, Hottenstein, 802 Otis Bldg., Chicago Peirce Lewis, 7310 Woodward Ave., Detroit Charles Lundberg, Kent Rd., Upper Darby, Member, Audit Bureau of Circulations } Member, Associated Business Papers Published every Thursday. Subscription Price: United States and Possessions, Mexico, Cuba, $6.00; Canada, $8.50, including duty; Foreign Del. Co., Pa. $12.00 year. Single Copy Cents Ober, 239 West 39th St., New York Robinson, 428 Park Bldg., Pittsburgh Cable Address, Sweetser, 239 West 39th St., New York Warren, Box 81, Hartford, Conn. adel phia, ider Act SEVENTY-NINTH YEAR SERVICE THE METAL WORKING INDUSTRY |: | he a | | | | | | | | | igs, | | Te } < 4 4 | | | | | | “ | 4 | | THE IRON ACE FEBRUARY 1934 Page These superfine TOOL STEELS UALITY Tool Steels never The superfine quality Bethlehem Tool Steels built step, with infinite care and patience, throughout manufacture. Each process followed representative the most advanced steel-making practice. The result inevitable: Tool Steels uniformly fine bring marked economies wherever they are used. HIGH-FREQUENCY INDUCTION MELTING Bethlehem Tool Steels get the right start melting the high-frequency electric induction furnace, which makes steel laboratory standards accuracy. LIBERAL INGOT DISCARD Large discards, from both the top and bottom the ingot, mean that the buyer gets only the “cream” the tool steel. HAMMER-COGGING INGOTS It’s far costlier hammer-cog ingots than roll them. But the tremendous impact developed under the hammer insures complete working the entire ingot and the breaking all undesirable ingot structure. PROGRAM-CONTROLLED ANNEALING The exact heating, soaking and cooling curve desired obtained motor- driven cylinder which the edge plate guides the tempera- ture regulator. Possibilities human error are eliminated. RIGOROUS INSPECTION Thoroughly representative cross-sections for inspection are obtained cutting slabs from the tool-steel billet stock before rolling, and cutting discs from the finished bars. These samples are subjected hot-acid etch, hardenability tests and microscopic examination. BETHLEHEM STEEL COMPANY GENERAL OFFICES: BETHLEHEM, PA. “ad THE IRON AGE ... FEBRUARY 1934 ESTABLISHED 1855 Vol. 133, No. Scuttling the NRA? NDUSTRY becoming reconciled its shot gun marriage NIRA. The young lady has her faults and have discussed them freely these columns. and large, however, General Johnson has succeeded remarkably well keeping NIRA’s feet the straight and narrow path. But now disturbing element intrudes upon this state comparative conjugal equilibrium. Senator Borah and others take their cudgels behalf the small business man, claiming, NIRA, that “she done him And the Federal Trade Commission, which appears “want job that might have done but didn’t, murmuring “come and see some time.” Political commentators point these doings the beginning attack upon the NRA. should develop, hope and believe that the metal-working industry will stand back General Johnson. administrator American industry, the Gen- eral, next the President, has been shouldering the heaviest load any man present day public life. And has progressed further and faster with than any the other lesser emergency load car- riers who started from scratch with him. The General has made mistakes, being human and not supernatural and being under tremendous pressure for quick results. has done some things that have not liked. number these has had under the terms law which did not write but which was given him administer. doubt there any other man who, under similar conditions, could have made better score One the reasons why industry should support General Johnson that has kept his organization free from brain trusters and constitution busters. the most practically minded set-up the entire alphabetical array. turn over the intricate cre- ative problems industry now facing NRA the legalistically and literally minded Federal Trade Commission would not merely set back the recovery clock but break off its hands well. QUALLY threatening the interests both employers and wage earners Senator Borah’s proposal disembowel the Recovery Act with the rusty “anti-trust” knife which President Roosevelt has placed, temporarily, the shelf. Such action would completely wipe out the gains made through code cooperation and leave only the wage, hour and unionization clauses Section operative. Thus employers would have nothing show for their pains but unionized plants and the privilege pay- ing high wages. Even these would not long remain, for let the hungry wolf price competition get his head back into industry’s door and the carefully built wage standards NRA will topple like house cards. Labor would then get its coveted 30-hour week might even 20-hour one. Certainly not want see the small in- dustrialist business man penalized through in- justices codes. far the steel code con- cerned, the small consumer better position than ever before, being able buy his small require- ments the same price paid the largest con- sumer. There are probably clauses many hastily constructed codes that need revision. But when our clothes need altering, take them tailor who knows how they were made, not plumber. would equally foolish intrust the job code alteration Congress the Federal Trade Commission. 5 { Mig \ : = 4 3% 3 tik, ie > 4 > plating have been developed, the decorative and the industrial wear resisting. The decorative far the most commonly encountered, being extensively used for automotive fittings and hardware, plumbing fix- tures, miscellaneous hardware and cutlery. Ordinarily this form plate consists soft steel base which are applied successive layers cop- per, nickel and finally three five minute flash chromium. The nickel usually buffed. The resulting chro- mium bluish cast compared the yellowish cast nickel. The chromium extremely thin, approx- imately 0.00002 in. 0.00004 in. depth. sometimes termed metal- lic This combination offers excellent corrosion resistance. The chromium protects the softer plates beneath and inherently remains pas- sive atmospheric conditions, while the nickel forms continuous film, protecting the steel part. The thin film chromium will form fairly continuous surface and less likely show cracks pinhead leaks than the heavier plates. distinct types chromium Industrial wear-resisting plate never will become well known the decorative. Nevertheless filling increasingly important in- dustrial role. Usually this type plate applied directly fully semi-hardened steel base. Successful applications also are being made 14—The Iron Age, February 1934 ~ a soft steel, cast iron and many non- ferrous alloys. The depth plate ranges from minute flash approximately 0.0001 in. any reasonable amount. depth 0.050 in. not uncommon, and these heavier plates are used chiefly for salvage purposes. ¥ 3 a - 4 ‘ . Industrial a HIS the first two articles which Mr. Nemser, authority the subject, reviews progress and practice the comparatively new art industrial chromium plating. this first installment, the properties chromium plate are succinctly set forth, applied for decorative and for wear-resist- ing purposes. the concluding article, which will follow our succeeding issue, practical appli- cation tools, dies, etc., discussed. This part our general series metal finishing. This “hard” plate possesses unusual wear-resisting properties. Incidentally commonly thought that the deco- rative chromium soft while the in- dustrial type hard. Actually they are both hard when considered from the wear-resisting standpoint. The depth plate very thin the aa ABOVE Buffing chromium plated concave break down roll made for using flexible shaft machine designed for this purpose. LEFT Typical set-up for light plating flat railroad gages. These pieces have been carburized, hardened, ground and then 0.0003 in. the ele we ge Ww . Chromium decorative scheme and deposited extremely soft underlayers that any testing action indicates soft mate- rial. The heavier industrial plates the harder bases can tested proper- and truer result obtained. Schneidewind reports deposited chromium plate has the fol- lowing hardness values: Vickers- Brinell 625, Mohs and scratch width with Bierbaum microcharacter test microns. While the impression hardness not very high, the scratch tests indicate outstanding wear resis- tance. The hardness figures will un- doubtedly vary with changes plating conditions such concentration electrolyte, composition electrolyte, temperature and Willink outstanding wear resistance parts plated under unusual conditions. reports that when using high temperature to- gether with high current density with consequent increase voltage, the wear resistance raised over three one compared that chromium plate deposited under the so-called standard conditions. ABOVE Generating unit which supplies electrical the installation shown RIGHT Pratt Whitney chromium plating department showing the preliminary clean- ing tanks the foreground and the two plating tanks beyond. ating—9 Piersol also has investigated the variations plate hardness and result, has designed testing machine measure the relative abrasive resis- tance chromium plates, deposited under variant physical and chemical conditions. Briefly this equipment consists special grinding wheel operated under uniform conditions, and mounted that definite and constant wheel pressure exerted NEMSER Chief Metallurgist, Pratt Whitney Co. against the plated test piece. The wear resistance usually expressed terms depth cut unit time. general, can said that chro- mium plate possesses much greater abrasive resistance than any type fully hardened tool die steel. steels this respect. The diamond and the cemented carbides tungsten (Concluded Page 76) ay ‘ 1a] lly he The Iron A Feb 1. 1934 (Above): Battery machines the order department the company Youngstown. (Below): group order forms, simultaneously written teletype transmission. CORPORATION _ copy OF ORDER CORPORATION ome ACKNOWLEDS INVOICING DEPT.—COPY OF ORDER REPUBLIC STEEL CORPORATION GENERAL ORDER DEPT. som MANUFACTURING COMPA SA CUSTOMER ‘ORTS SEPARATELY "-2267 PAINT ONE EXD RED = SAE 1080 OPEN HEARTH 6 - — HOT ROLLED — STEEL spec O40 MEAT i - ANDARD ALL PLus - an 7 18 000 25 000 | 63 mix spect 16—The Iron Age, February 1934 well known fact those en- gaged the production basic commodities that processors and manufacturers finished products, due the intermittent demand for their goods the public, are carry- ing practically inventories ma- terials today. The steel industry times like these finds itself linked closer then ever with the ultimate consumer and its activities governed more exactly the fluctuations consumer demand. The delay between the time the consumer makes known his demand and the time that the basic industry aware this demand longer exists, least exists only minor degree. The buffer the form large manufacturers’ inven- tories has been removed. This “hand-to-mouth” buying manufacturers finished products demands close attention the part the supplying manufacturer the speed with which orders are handled after they are received from the cus- tomer. large percentage orders received the steel company today are either telephoned telegraphed the customer, and the customer, pressed the exigencies “hand-to- mouth” buying, has come expect the same speed the transmission his orders from the office where they are received the point where produc- tion started. The many plants the Republic Steel Corpn., scattered several di- rections from Youngstown, where gen- eral office and sales forces are located, permit the elimination expensive crosshauling finished products through systematized production and distribution, but their distance from Youngstown precludes speedy trans- mission orders from office plant ordinary means. The obstacles pre- we j q _ — 48 Ww | ANY SPRCIAL INFORMATION FOR MILL | en- ASIC and cts, for na- ked ate sic no nly Orders Office Plant MORGAN Manager Orders, Republic Steel Corpn. sented geographical remoteness were overcome the installation teletypewriter system which com- bines the speed the telephone with the accuracy the written word, and the same time provides written ords used working and file papers and check accuracy. What the Teletypewriter The teletypewriter machine which makes possible the transmission written messages just the tele- phone transmits speech. The tele- typewriter has keyboard similar that ordinary typwriter, and messages typed the sender appear simultaneously the receiving ma- chine exactly they are written the sender. The two are connected Bell System private wires. The send- ing machines are also equipped re- ceive messages, that operators using two these combination ma- chines may “talk back and forth writing,” just two persons may carry conversation telephone. The various models print tape in. wide, page paper in. wide, forms especially developed for particular uses. The Republic Corpn. first set teletypewriter system which the machines printed page paper rolls. The essential details orders coming into the Youngstown office were transmitted teletypewriter the plant. Later this order was re- typed regular form and the copies distributed the proper de- partments. The copy for the mill was CHICAGO, ILL. MASSILLON,O. — sent mail the plant where was checked with the memo sent previously teletypewriter. After had given the teletype- writer system thorough tryout and found that enabled give our customers the service which they were accustomed even though they indulged “hand-to-mouth” buying, converted the system into form writing one, substituting form writing machines for the message writing tele- service has always been important. But today, and industries where price com- petition has been more less re- moved through codification, more important than ever. One the most necessary com- ponents good customer service prompt delivery. And prompt de- livery means taking out lost min- utes all along the line, from initial order final delivery. This article tells how the Repub- lic Steel Corpn., means tele- typewriter connection various plants, takes the lost minutes out the transmission orders. typewriters after had redesigned our formal mill order form fit the teletypewriter machines. The form writing teletypewriters have “positive drive” arrangement, which keeps the forms alignment. The positive drive feature, however, does not prevent the machine being used for general message use. After the paper has been changed the machines both ends the cir- YOUNGSTOWN ,O. HEADQUARTERS Diagram showing Republic Steel system teletypewriter communication. cuit, messages can sent back and forth. The teletypewriter system the Republic Steel Corpn. consists machines. Circuits connecting form writing machines radiate from the general office Youngstown the mill offices Buffalo, Canton, Chi- cago, Massillon, Warren, and Youngs- town. Separate from this general system, there are circuits connecting Canton and Massillon, the sales office and mill Buffalo, the sales office and mill South Chicago, the mill South Chicago and the mill Grand Crossing. addition, there are “teletypewriter exchange machines the general office Youngstown, the sales offices Cleve- land, Massillon, Philadelphia, Indian- apolis, and Cincinnati, used chiefly for messages having with sales and servicing activities. Teletypewriter exchange service similar ex- change telephone service, except that teletypewriters instead telephones are connected through local long distance central offices, permitting the interchange typed messages instead spoken words. How the System Functions Although receive the largest number orders Youngstown, orders for the alloy steel division are received its headquarters Mas- sillon and transmitted over the tele- typewriter circuit between Massillon and Canton, while orders for wire are received South Chicago, going teletypewriter the wire plant Grand Crossing. Since the procedure essentially the same all three points, shall describe only the tele- typewriter routine Youngstown. Orders received the Youngstown (Concluded Page 66) The Iron Age, February 1934—17 C) = 2 cts rs ts er, ct of \ ey J lic d ve A m e- the Siberian railroad lines breakages tires, car axles and locomotive frames have long been noted winter phenom- enon. Rails especially have been known fracture suddenly during times appreciable fall the atmospheric temperature. Brittleness rail steel was par- ticularly noticeable during the winter 1929-1930, when the temperature dropped minus deg. C., minus deg. This brought about in- tensive study the part Prof. Koosnetsov and Engineer Federov Tomsk, Siberia. The Tomsk rail- road management published table breakages for the period October, 1928, April 1930, which here reproduced American units. The temperatures are given the Fahren- heit scale. The striking relationship between low temperatures and rail SUSLOV Engineer, Research Institute, cause was not important and the figures for these were not included the table. Yet may assumed that prevalence the factors minor importance increased under the influence low temperatures. Fig. shows the relationship be- tween temperature and rail removals better than Fig. The temperature curve has been reversed and the num- ber rails removed covers those taken out for all four reasons men- tioned. Referring the table will noted that 826 rails had taken from track the five winter months 1928 and 1929 (December April, +90 +80 +70 +60 +50 +30 +20 Fig. 1—Breakages both heavy and medium weight from railroad rec- beria, showed sud- perature. 740 rails ON J FM A 1928 1929 1930 brittleness brought out Fig. which shows the monthly tempera- tures, and the number rails put out fracture. The Tomsk line management claims the rails have removed for the following reasons: Cross-section fracture . Chipping Cracks and pinholes Other defects The number rails removed for reasons other than the first mentioned 18—The Iron Age, February 1934 Siberian Rail Fractures Numerous inclusive), owing cross-section fracture, and 1929 rails for the same months the following winter. This average 1377 rails put out service periods extremely low temperature. The Tomsk railroad line has about 585,000 rails. Accord- ingly about 0.23 per cent the total number are rendered unfit the winter season. further study the question, investigation was made the im- pact resistance rail steel low temperatures. Charpy machine was used with notched bars different temperatures from plus 150 deg. (302 deg. F.), minus 189 deg. deg. F.), liquid air. The work was carried Mr. Federov the Physical Technical In- stitute Tomsk. specimens were 100 mm. (about 0.4 mm. diameter. Each specimen was held few minutes the liquid cooling medium definite tempera- ture, after which was quickly transferred the testing machine and broken. The entire operation from the time taking specimen out the cooling medium breaking the testing machine was about min. Therefore may accepted that the temperature the specimen was equal the temperature the deg. The results the impact tests are shown Fig. There shown reduction impact resistance from 4.5 kgm. per sq. 150 deg. (302 deg. F.), kgm. per sq. cm. —40 deg. (—40 deg. F.), and Fig. 2—The par- allelism between number rail re- movals and tem- perature indi- cated plotting figures upside down, and this graph total rail failures all de- scriptions were taken into account. 1929 1930 the pre pel cri ste ter e a . 2 400 |_| 15 t + 1928 ction same This low road total the tion, im- low bars plus inus quid Mr. 1ens ches men era- hine tion out men the Low then the strength appears ap- proximately constant with the tem- perature reduced low —185 deg. C., deg. F.) critical temperature —40 deg. —40 deg. shown for the rail steel studied. The temperature proved .to have effect the appearance the surface the fractures. low temperatures the surface flat and crystalline and shines the rays reflected light without any signs permanent deformation. The broken parts may easily put together again. Fibrous fractures, which are observed chiefly high temperatures, possess dull dark color with obvious signs deformation. The crystals not have smooth, glassy plane and ruptures may observed the Impact Resistance, Kgm. per Sq.Cm Temperature, Deg.C Fig. 3—Impact tests the rail steel showed reduced strength temperature dropped until deg. below zero the strength appeared hold substantially constant minimum the temperature was further reduced. fibers the specimen. the low temperatures, from —185 zero C., great difference noticed the form the fractures, whereas temperatures the range zero 125 deg. C., the fracture acquires more less fibrous state. The physical nature the brittle- ness steels low temperatures re- mains undiscovered yet, but ac- cording the information the tests obvious that low tempera- tures and not local defects are re- sponsible for the breakage the large number rails, tires, axles, etc., re- ported. Good quality steel free from defects become brittle and break the temperature low. The supposition that the brittleness rail steel low temperatures owing the presence phosphorus remains doubtful, the phosphorus content rail steel under the Russian specifications generally varies within restricted limits. For Bessemer rail steel not more than 0.07 per cent; for Thomas rail steel, not more than 0.07 per cent, and for open- hearth steel not more than 0.04 per cent. would more correct assume that the allowable content phosphorus does not affect brittleness the low temperatures. investigation carried out Prof. Dobrovidov Tomsk helps way solve the problem. The rail steel was subjected heat treatment improve its microstruc- ture, mechanical properties and the Charpy impact resistance. The prob- lem word consists providing the whole section the rail with uniform sorbitic structure. Fig. shown the relationship a Fig. resistance rail steel, 0.099 per cent phosphorus, improved heat treatment follows: Curve quenched from 740 deg. oil, drawn 640 deg. for hr., with Charpy impact value deg. 6.0 AILROAD experience Tomsk, Siberia, that steel fractures have direct relation atmos- pheric temperature, being greater number the lower the temper- ature and particularly numerous bottom levels. Investigations means impact tests indicate that minimum resistance impact reached deg. below zero, which regarded the critical temperature. Lower temperatures appear cause measurable in- crease brittleness. Conclusions, fortified studies Tomsk and elsewhere, are that for Siberian use either heat-treated carbon steel rails alloy steel rails are required. between the testing temperature and the Charpy impact resistance heat- treated specimens rail steel con- taining 0.099 per cent phosphorus. similar set curves for steel con- taining 0.054 per cent phosphorus and 0.6 per cent manganese, showed that the impact resistance the heat- treated specimens was approximately four times greater than that the untreated steel deg. and ten times greater —40 deg. (—40 deg. F.) Thus, treating the rails produce sorbitic structure, their impact resistance improved, the critical temperature the low- temperature brittleness lowered, while the Brinell hardness slightly increased from 190 for the raw rail steel 210 for the heat-treated steel. complete the information refer- ence may made investigations kgm. per sq. cm. Curve quenched from 840 deg. C., drawn 640 deg. for hr., with impact value 5.3 kgm. per sq. cm. Curve quenched from 840 deg. C., drawn 640 deg. for hr., with impact value deg., 4.8 kgm. per sq. cm. Curve raw specimen with- Impact Resistance, per Sq.Cm out heat treatment, Charpy impact 2.5 kgm. per sq. cm. -200 Temperature, Deg. The Iron Age, February 1934—19 — an T 5.0 : ; 1.0 =) @ Impact Resistance, Kgm. per Sq.Cm. Temperature, Deg.C +200 +300 Fig. tests made Aachen over range from deg. nearly deg. the following steels: Basic Bessemer (Th) (SM) Silicon steel (A) ... Union Bau (B) .... Cu-Mn-Si steel (C). Prof. Rotscher and Dr. Ing. Fink the Technical High School Aachen. Fig. shows results im- 0.01 0.37 0.066 0.046 0.09 0.01 0.57 0.024 0.030 0.18 0.89 1.12 0.053 0.036 0.10 0.36 0.87 0.022 0.026 0.85 0.50 1.09 0.016 0.025 0.60 pact tests five different steels temperatures from —190 deg. (—310 deg. F.), 500 deg. (932 Rail Removals from Tomsk Railroad Track Owing “Cross-section” Fractures Types Temperature— per 48% Ib. Max. deg. Min. deg. Average yard per yd. Total deg. 198 149 396 —43.4 9.2 355 541 +15.1 —54.2 —18.0 148 236 +40.1 —39.8 +18.0 Barges Built Record Time Are Welding plate plus welding equip- ment plus men plus two weeks equals two ft. barges Galves- ton, Texas. 20—The Iron Age, February 1934 This believed record speed for barge construction. was made the Kane Boiler Works, Galveston, barges built for the United Dredg- ing Co. New York. The barges are ft. long, ft. wide and ft. deep. Forty welding operators were Annealing Temp. deg. 930, cooled air 930, cooled air 850, cooled furnace 0.51 850, cooled furnace 850, cooled furnace deg. F.). The parts the curves for the lower temperatures, from zero —190 deg. C., show that the Bes- semer Thomas steel and the open- hearth steel possess lower Charpy value than the alloy steels the Need for Heat Treatment Alloying Grade steel appears have special advantage and one draws the conclusion that neither the basic Bes- process capable imparting high impact resistance low temperature and therefore not suitable for rail- road rails Siberia. The final con- clusion that the rail problem re- quires either proper heat treatment carbon rail steel the use suit- able alloys for rails. employed. All welding was done the shielded arc process using Fleet- weld electrodes and machines manu- factured The Lincoln Electric Co., Cleveland. Upon completion the barges, they were tested without single leak appearing. -_ é 1 — | | | A | | | B Cc Cc | 1 urves Bes- the the Bes- steel high rail- con- nent suit- leet- Co., the Lubrication Rolling Mill Gear Units 1929 1930 specify good grade mineral oil (about 2100 Saybolt 100 deg. F.) for large mill drives and lighter grade for the bearings; the splash and ring oiling bearing sys- tem was most common. was common practice about There are certainly hundreds these drives still operating satisfac- torily and is, therefore, open question whether extreme pres- sure lubricants are any consider- able advantage the majority drives which are properly designed with correct materials and normal pressures, although there gain where excessive tooth pressures exist. This condition much better avoided, however, and can generally ef- fected sufficient care taken proportioning gears and selecting materials. Case Extreme Pressure Lubricants interesting note that ex- treme pressure lubricants became prominent the time gear pressures back axle gears were increased from 1200 1850 per in. face and that long the extreme pres- sure lubricants were used the teeth apparently did not but when ordinary service station grease was used the gears failed. even more interesting note the behavior pair mill gears about the same time. These gears were made alloy and carbon steels about sclero- scope hardness and even though the heaviest grade extreme pressure rolling mill re- duction gear units was dis- cussed Thomas Holloway, gear consultant, United Engineering Foundry Co., Pittsburgh, before the annual meeting the Association Iron and Steel Electrical Engi- neers. His address whole was devoted the design the gear units, and THE IRON AGE Jan. 25, his contribution the gear question was reviewed some length. the following outlined what had say lubrication. lubricant was used they scored and cut under the extreme service which they were subjected. They were then re-cut and hardened about scleroscope, and placed back into ser- vice with the same lubricant. The teeth are now polished and look good for indefinite service. would seem, therefore, that while there are undoubtedly differences the quality lubricants, there not present sufficient accurate informa- tion available that results can predicted, and that the best policy the designer proportion each set gears that with the use ordinary lubricants reasonable cost they will operate satisfactorily. The best lubrication system the simplest that can used successfully. For units with moderate pressures and such proportions that the splash and flood system practicable, this the best use. The same oil used for bearings and gears and continuously circulated splash and gravity. With proper baffles and dust rings the loss very slight and filter unnecessary. Such drives should operate without attention for months. Drives with gears under heavy pres- sure such ratio that the splash insufficient flood the bearings should designed for splash for the gears and ring oiling from separate reservoirs for the bearings but where the peripheral speed 2000 ft. over forced feed the bearings and sprays the gear teeth should employed. Central Lubricating Systems the case the drive for rough- ing stand continuous strip mill, the lubricating system designed for separate lubricants for bearings and gears. The drive one ten similar size connected central sys- tem containing about 4000 gal. gear lubricant and about 500 gal. bearing lubricant; the whole system filtered centrifugal filters. From latest information received, the sep- aration the lubricant success- ful that out all this continuous circulation over 4000 gal. oil, maximum two pails foreign mat- ter recovered from the filters. This foreign matter will include some the heavy lubricant filler, some foreign (Concluded Page 78) Fig. staggered arrangement roller bearings were applied the pinion stand for four-high mill. Fig. 2—A combination pinion stand and main drive were equipped with roller bearings development the staggered principle. The Iron Age, February 1934—21 y > : Pikes ve hie MON _ author’s experience and re- work non-ferrous fields with some the largest valve, en- gineering specialties and plumbing goods companies show that the foun- dry foreman’s chief worry how reduce losses castings through porosity. This applies castings for pressure work regular run non- ferrous castings, especially when the products are nickel chromium plated. Defects are often found after being chromium plated which are not discovered even after polishing and the castings have scrapped. This very costly, all the foundry, machine, polishing and plating work lost. Articles technical magazines tell what the trouble and how find it, but they not say how get rid it.. was this fact that led the author work out system help foundrymen this particular. The practice hereinafter outlined has been installed some leading companies and when followed closely has resulted success. The practice eliminates the cut and try method. can hold the total foundry and shop scrap, due foundry faults, below per cent. Foundry scrap has always been problem and late years keen com- petition has demanded that economy practiced more than ever. Manu- facturers have come realize that losses incurred through foundry scrap often exceed their profits. These facts have created demand for trained foundry engineers, who have proved such profitable asset that colleges have started, within the last few years, formulate and specialize foundry engineering courses. The day past when foundrymen doctor metal with elements from their vest pockets and personally see that they put the magic touch every pot metal poured. The juggler being replaced engineer who, order efficient, must order his raw materials specification and see that WY | } Ay ™ Fig. oxide inclusions, black (CuO) red magnification 100 times; not etched. 22—The Iron Age, February 1934 Causes Porosity they are received accordingly. must standardize processes which involve much test and research work before being adopted. must then formulate from his processes standard practices for every person’s work and see that they are near fool-proof must absolutetly know how gain the respect the company and the men who follow his instructions. Last, but not least, must exercise con- stant vigilance over these processes and standard practices; must police each phase the business and see that none “rest their oars” slacken up, the wrong core sand oil will mean loss cores, loss molding, melting, cleaning, and down the line, until the cost has lost the company all its profit and maybe more. Six Groups Melting Fluxes The writer has found that the melt- ing metal one the most im- portant duties the foundry division. well known fact that all metals have affinity for foreign elements which have removed counter- acted metallic and non-metallic elements commonly Melting fluxes are used alone com- pounded for several purposes, some which, coin few words, are: Deoxidizing Purifying Degasifying Densifying Hardening CHEETHAM Factory Chance Co., Centralia, Mo. necessary consider each item, the type melting furnace, fuel, metal mixture, class and quality metals used, before judging the proper flux use. One hears great deal about oxidized metal, porous castings, men can tell looking castings even the results fracture, phy- sical test bars, what the trouble whether the metal needs purifier, deoxidizer, strengthener. The following general apply: Small shiny specks (round pin holes) surface, generally appear- ing cope side collectively large shiny cavity with small ones around cope drag after skin cast- ing removed, are due gas caused mechanical faults. This called porosity and the metal needs degasify- ing. Various colors fracture, small irregular specks metal oxide separately distributed, which show when buffed and polished, indicate chemical fault. These imperfections may detected the surface cope drag, fracture, from leaky castings during test. They are due oxides which are generally the Fig. 2—85-4-5-6 mixture; porosity from gas; mag- nification 100, unetched. Fig. 3—85-4-5-6 mixture; porosity from SO: caused reducing flame (excess oil); magnification, 100 diameters, unetched. met all i cau cau giv: ela: nac sho cre tro ox metal before using, improper alloying improper melting. This called oxidized metal. Rotten cast- ings leaky castings are sometimes caused shrinks and draws resulting from improper design gating. The cause can readily determined. When metal mixtures that should give strength weak strength and elasticity the cause the result improper alloying improper fur- nace working. The fracture will often show the elements properly amalgamated and the metal can often remedied flux purify the metal adding element in- crease its density. Oxidized Metal Oxidized metal mostly chemical trouble resulting mainly from the use poor materials. Oxidized metal shows castings eutectic seg- regation giving low tensile strength and leaky castings. Any metal will oxidize more readily high tem- perature improper timing oxidizing flame reducing flame during the melting process. de- oxidize metal remove combined oxygen metallic oxides which are already the metal formed the Fig. 4—Snap shot actual casting poured high temperature, 2250 deg., and mod- erate per cent mois- ture mold. absorption oxygen the metal during high melting process. mainly eliminated careful furnace work fluxes. Gasified Metal Gasified metal mostly caused mechanical trouble, such improper furnace work, pouring, mold condi- tions and causes porousness (pin holes), cavities, and sponginess. Ex- cessive heating soaking metal the furnace the main cause for absorption gases. degasify metal mainly remove oxygen, sulphur dioxide, carbon dioxide. All metals take certain amount oxygen which unites freely with common metals, especially copper, and forms deleterious gases. the molten metal comes contact with coal, coke, high sulphur content oil, will absorb certain percentage sulphur the form sulphur dioxide gas. reducing flame used (caused excess oil), the metal will absorb carbon from the oil, and form clinkers.” These gases are dissolved while the metal its molten state and are generally liberat- while the casting cooling. metal poured too cold, the casting air pocket H.O gas; small H.O gas 100 from Fig. un- etched. Fig. 6—Snap shot ground key stop key showing effect steam caused wet molding sand. faulty brass, bronze and other non-ferrous castings are detailed the accompanying article. Two articles follow will list preventives. Mr. Cheetham THE IRON AGE Dec. and 21, last year, drew from his experi- ence totally different subject, namely, piston rings, telling the re- quirements they must meet and how they are cast and machined satisfy those needs. will complete but after the skin taken off, shows large shiny holes about the size pin head the end opposite the gate. This due metal being too sluggish liberate the oxygen absorbed while melting during the pouring process. Increase Density Eutectic segregation generally means oxide film the void space around the crystals. metallic allows under pressure for leaks through the metal shows low tensile strength and low elastic limit. Metal various ele- ments cement together and the alloy the cement stronger than the pure element, hence the reason that fractures show true crystal effects. when this cement ruined heat foreign elements that so- called eutectic segregation occurs. render metal dense counteract separation the metals. Sometimes space left between the crystals which shows spongy casting. This condition prevalent all cop- per base mixtures through certain Fig. 7—Porosity and gas inclusions H.O and magnification 100 Fig. un- etched. The Iron Age, February 1934—23 > i ‘ 4 = 4 d iat , e ec ‘ ~ > Fe". * Pat 3 8—85-4-5-6 mixture; eutectic segregation, coarse crystals; dark spots are lead segregation containing alumi- num; magnification 100; etched with and factors, such the presence alumi- num, iron, excessive lead phos- phorus, combinations elements such silicon and lead. Purifying Metal Impure metal known metal which has certain elements segregated and not thoroughly amalgamated metal contaminated with undesirable elements which are detrimental for the purpose intended. purify metal remove detrimental elements which interfere with the physical re- quirements, such high conductivity current. Metal often doctored the addition foreign elements make homogeneous and dense re- move occlusion gases absorbed dur- ing the melting the mold. When metal not properly treated, often results making matters worse that gives “off mixture,” eutectic segregation (see Figs. and and, the case electrical copper, reduces the conductivity such extent that makes the material practically useless. Promoting Fluidity Sluggish metal causes dirty cast- ings, mis-runs, and often segregation Fig. 9—85-4-5-6 mixture; eutectic segregation, coarse crystals; magnification 100; etched with per cent in H.CO,. the elements. metal most desirable the general foun- dryman and accomplished the addition elements which thin agitate the metal bring impurities the surface skimmed off. The benefits gained making the metal increasingly fluid often leads overdose, which more detrimental than the good obtained. Hardening Metal Some alloys are often too soft for their proper uses. eliminate ex- cessive wear frictional applications, necessary add one more elements increase the hardness and close the grains. increase the hardness naturally means increase the density, but the density can increased often and not the hardness. Fluxes Having stated the shortcomings non-ferrous castings and their causes, now necessary point out how counteracting agents. The foundry- man, trying reduce losses, has been somewhat like drowing man grasping each straw save him- self, only sink deeper. his con- stant grasping has encouraged Phosphorus-—fluidizer, purifier, deoxidizer, deoxidizer. Aluminum—fluidizer Melt. Deg. Nickel—purifier, densifier, strengthener, 2646 Manganese—hardener, strengthener, purifier, deoxidizer, densifier.... 2237 Magnesium—hardener, 1204 Silicon—purifier, hardener, deoxidizer, 2588 Sodium carbonate (soda ash)—deoxidizer, 1564 Iron—hardener, densifier Calcium hydroxide (slack lime—purifier, deoxidizer.. 3623 Calcium sulphate (plaster of Paris)—purifier, deoxidizer. . 2480 Ammonium chloride (salammoniac)—fluidizer, deoxodizer, degasifier. . . Zine chloride—fluidizer, deoxodizer, Bicarbonate soda (baking powder)..... . Decomposes 689 Iron Age, February 1934 flooding the market with fluxes claimed wonders. remains that some the fluxes are very ef- fective, and order condense the subject for practical reference, the author has covered some the most popular and effective remedies eliminate each the mentioned trou- bles. Some flux combinations sili- cons, calciums, sodiums, are omitted because their impracti- some owing high cost and others because more effective available element. few the flux elements and gen- eral uses are shown the table be- low. two additional articles the author will describe the ways the diseases non-ferrous castings. Research Enameling Mellon Institute EDWARD WEIDLEIN, di- rector, Mellon Institute Indus- trial Research, Pittsburgh, Pa., has announced that the Hommel Co., Pittsburgh, has founded indus- trial fellowship the Institute for the purpose conducting scientific research problems enamel tech- nology. particular, expected that this Fellowship will acquire tech- nical information, through its investi- gations the laboratory and plants, supplemented the experi- ence specialists the Hommel and cooperating organizations, including Enamelers’ Guild, Pittsburgh, that will enable serve clearing- house dependable facts regarding frits and their industrial use. Re- search the fellowship will pub- lished for the benefit enamelers; and advice and information enamel- ing, and assistance solving plant problems and making evaluations other practical tests frits, will extended gratis companies that wish such technical aid. Jack Waggoner, the incumbent this fellowship, has been profes- sionally active the ceramic field for the past thirteen years chemical engineer and glass technologist. copy the 1934 issue the Year Book and Code Guide the Waste Material Dealers, Inc., can secured addressing the National Association Waste Material Deal- ers, Inc., Times Building, New York. The volume contains the recently re- vised commodity classifications, trade customs affecting the industry, arbi- tration rules, and information regard- ing foreign trade. The code fair competition the waste material trade and all related codes are also included, Dr. ar or nt Yr a ; a \ ] the the eal- ork. re- ade rbi- fair rial Dr. Mason, discoverer the method obtaining the improved reflecting surface, viewing his own reflection Alray surface. LUMINUM naturally bright metal and has long been used for reflectors. The usual com- mercial practice has been finish and brighten the surface polishing etching. With polished alumi- num reflectors, reflection factor per cent has usually been obtained. Commercially pure aluminum the type commonly used for reflectors too soft lend itself the at- tainment greater brightness commercial polishing methods. Polish- ing, course, gives specular mirror-like reflecting surface. many cases, as, for example, light- ing equipment with ultraviolet lamps used for therapeutic purposes, diffusely reflecting suface desir- able, and this readily obtained etching processes. brightens the metal and the same time roughens the surface give the desirable light-diffusing characteristics. Surface Staining Was the Problem The practical disadvantage re- flectors finished either these ways their liability surface stain- ing when exposed the weather the difficulty cleaning dirt al- lowed accumulate the reflecting surfaces. The problem requiring solution was give aluminum reflectors the bright- ness which the metal intrinsically pos- sesses and then provide this bright- ened reflector with transparent coat- ing which would protect during service. Great progress been made the last two years the protection aluminum electrolytic anodic oxidation. This process produces hard, abrasion-resistant oxide coating the metal. When ap- plied reflectors, however, the first result was marked decrease re- flectivity, amounting about per cent. The oxide coating left the metal with rather opaque and milky surface finish which markedly detracted from its value reflec- tor. was found that this loss brightness resulted from the presence impurities, partly metallic and partly non-metallic character, the surface the aluminum. seeking for improved reflecting surfaces, Dr. Mason discovered new reflecting surface with base aluminum was announced meeting the Engi- neering Society, held Cleveland Jan. 22. Aluminum finished the new process has reflectivity high per cent—not far be- low that silver. has the out- standing advantage, from the com- mercial standpoint, not tarnish- ing industrial atmospheres, being resistant weather, and being readily cleaned washing with soap and water. Papers the subject were read Dickerson, the General Electric Co., and Mr. Edwards, as- sistant director research the Aluminum Co. America, New Kensington, Pa. The discovery the improved reflecting surface was made Dr. Mason, Aluminum Research Laboratories. Reflectors aluminum. Neither did injure the specular characteristics the sur- face. result his investiga- tions, now possible take highly polished aluminum surface and the application what calls the “electrolytic brightening process,” increase its reflectivity, leaving the surface the same time very thin protecting oxide film. prove his point, Dr. Mason took aluminum reflector having reflectivity per cent, subjected the elec- trolytic brightening process, and gave cent without any roughening the surface. further fortunate advantage the process was that heavier pro- tective oxide coating could pro- duced after the electrolytic brighten- ing step second anodic process and without any substantial loss reflectivity. This was done means the Alumilite process. This process, well adapted for this purpose, means anodically coating aluminum electrolytes patented composition. The electrolytic brightening treatment appears re- move impurities from the surface the metal. After the brightening treatment, the Alumilite process can further employed oxidize the surface electrolytically. Coating Sealed Against Corrosion final step producing fin- ished reflector the oxide coating sealed special process make The sealing converts porous, mois- ture-adsorptive coating into im- pervious non-moisture-adsorptive coat- ing. Stains cannot, therefore, mar the coating and its servicea- bility The name The Iron Age, February 1934—25 xes = di has -ech- that ing- din ers; mel- ¥ lant that for Pe Wave Length Incident Light—p Fig. aluminum the various ranges the spectrum. has been given reflectors made this process. The development such highly reflecting surface will find new ave- nues usefulness for aluminum, The electrolytic brightening treatment will give added luster and life flood lights