The Iron Age 1934-06-28: Vol 133 Iss 26

New Departure Double N-D-Seal -:- MANAGEMENT JUNE 28, 1934 PROCESSES Sealed! NEW DEPARTURE DOUBLE N-D-SEAL ball bearing perma- nently sealed both sides retain lubricant and exclude dirt. The revolutionary idea high- efficient seals integral part the bearing instead the housing has been pioneered New Departure engineers. thoroughly have they de- veloped the fully enclosed ball bearing that under the moderate speeds for which intended, maintenance reduced zero. The Double N-D-Seal cated for life. Additional details will gladly supplied upon request. The New Departure Mfg. Co., Bristol, Detroit, Chicago, San London, 111 Rd. CONTENTS INDEX PAGE ing NTH YEAR SERVICE THE METAL WORKING INDUSTRY weak es 3S ‘ é % atk THE AGE JUNE 28, 1934 Page The Wire that Made Heat Possible the heat-treater automotive tool and die pleased send you our that de- this man proud his job, because knows its scribes Hoskins Electric Furnaces and Pyrometers. Hoskins t ti — ry 7 ty ~ importance, and because day after day, turns out fine Manufacturing Co., Detroit, Michigan. Hoskins work Electric Furnace. Therefore, his boss thinks wel! him and their relations are pleasant. And even the summer time, with three furnaces like this heat, the room not uncomfortably hot. The man likes his job, the boss likes the man, and they both like the furnaces. Surely, here, these Hoskins Furnaces represent good investment. similar investment would any interest you Pa. Executive Offices: 239 39th New York, Y., second class matter the Post Office under March S., Canada $8.50, Foreign $12.00. Vol. 133, No. 26. ~ J. H. VAN DEVENTER G. L. Editor Made I. J. WINTERS Possible F. L. PRENTISS Cleveland WE DO OUR PART F. J Member, Audit Bureau of Circulations Member, Published every United $6.00; THE IRON FRANK, President G. PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. Canada, LACHER Ww. W. MACON T. H. GERKEN Managing Editor Consulting Editor News Editor . LIPPERT G. EMRNSTROM, JR. BURNHAM FINNEY Pittsburgh Detroit R. A. FIske A. I. FINDLEY L. W. Morretr Chicago Editor Emeritus Washington Contents The Fable the Cows and the Foxes X-Raying Welded Heat Exchanger Shells Raticnalization Manual Labor Free-Machining Corrosion Resisting Steel Attractive Finish Helps Metal Products Sales Fabrication Observatory Dome Ingot Mold Inserts Used Produce Composite Steels New Equipment News Washington News Automotive Industry Markets Construction and Equipment Buying Products Advertised Index Advertisers THE IRON AGE PUBLISHING COMPANY H. GRIFFITHS, Secretary C. S. BAUR, General Advertisir EXECUTIVE OFFICES: 239 West 39th St., New York, LDVERTISING STAFI Emerson Findley, 311 Union Bldg., D. C. Warren, P. O. Box 81, Hartford, June 28, 1934 Clevel am R. E. MILLER Machinery Editor GERARD FRAZAR Boaton R. G. McIntosu Cincinnati 114 g Mar anid Associated Business Papers B. L. Herman, 675 Delaware Ave., Buffalo, N. Y H. K. Hottenstein, 802 Otis Bldg., Chicago Thursday. Subscription Price Peirce Lewis, 7310 Woodward Ave., Detroit States and Possessions, Mexico, Cuba Charles Lundberg, Chilton Bldg., Chestnut $8.50, including duty: Foreign 56th Sts., Philadelphia, Pa $12.00 a year. Single Copy 25 Cents C. H. Ober, 239 W. 39th St., New York W. B. Robinson, 428 Park Bldg., Pittsburch Cable Address, ‘‘Ironage, N. Y.’ W. C. Sweetser, 239 West 39th St... New York Conn 3 Re | 2 < A Hoskins LO SEVENTY-NINTH YEAR SERVICE THE METAL WORKING INDUSTRY THE IRON JUNE 28, 1934 Case Emergency —Or Guard Against Shortage good know that Ryerson has large and complete stocks iron and steel ready for immediate shipment. Plants conveniently located Chicago Milwaukee St. Louis Cincinnati Detroit Cleveland Buffalo Boston Philadelphia Jersey City Page THE IRON JUNE 28, 1934 ESTABLISHED 1855 Vol. 133, No. The Fable the Cows NCE upon time ambitious group foxes determined exercise their will upon herd cows. ‘We must control them,’ said they, ‘so that can get their milk and live upon it. Then will avoid the hard labor hunting our food and have easy living.’ thing do,’ said the conceited foxes, ‘is terrorize the herd with our sharp teeth, after which they will obey and pay tribute. Let us, therefore, show our power seizing few cows and tearing them pieces.’ was easier said than done, for the best that the conceited little foxes could was nip the legs the herd and annoy them. said one the foxes, ‘that cannot get what want this way. Let us, therefore, lay our case before the king elephant and enlist his help.’ and the Foxes with blood from the wounds the cows dripping from their noses, the foxes ran the elephant. ‘See, king,’ said they, ‘how roughly the rude cows have treated your loyal subjects, the foxes. They have assaulted and have given bloody noses. the name justice and new deal for the foxes, beseech your intercession our behalf. Make rulers over the cows, your majesty, that can obtain their milk and that hereafter they will our servants.’ which the king elephant—” but here, the ancient manuscript was torn away, that the conclusion miss- ing. You, dear reader, will have fin- ish the fable for yourself and also find the present-day moral it. We, our- that the king elephant was unjust unwise enough give the foxes power over the cows that they could not obtain otherwise than trickery. - rf he ‘= | 9 Welded Heat Exchanger Shells for keeping set-up time low possible, the same time providing maximum safety operation, are out- standing interest the new X-ray laboratory installed the West- inghouse South Philadelphia works for inspecting welded heat ex- changer shells, castings, and mis- cellaneous parts. battery-driven work holding truck, centralized push button controls, adjustments work and tube and the indi- cating devices designed facilitate setting-up are described; also the X-ray machine and the control room, which convertible into dark room and contains every con- venience for developing, fixing and drying films. The method devised for X-raying very small specimens outlined. Ease operation and freedom from physical and mental fatigue the part the oper- ators are noteworthy this installation. some years, the South Phila- delphia works the Westinghouse Electric Mfg. Co., has manufac- tured heat exchanger apparatus for power plants, petroleum and chemical industries, and for other industrial and marine applications. very often required that such apparatus designed and manufactured con- form the unfired pressure vessel section the A.S.M.E. Boiler Code, 10—The Iron Age, June 28, 1934 similar codes promulgated other engineering societies, insurance companies, the several States departments the Federal Govern- ment. Fusion welding employed today very considerable extent the manufacture heat exchanger ap- paratus. The various codes referred provide standard practice for the approval welders and for accept- ance tests the case vessels the highest classes. required the case Class vessels the M.E. Code, and similar classes under other codes, that the longitudinal and girth seams examined means X-rays, the gamma rays radium, prove the sufficiency the welding. X-raying also provides excellent non-destructive means examining ferrous and non-ferrous castings in- tended for critical service; use- ful for the development foundry technique and for the examination automotive and numerous other me- chanical parts. extend its field service in- dustry, and assure further the re- liability important parts its manufactured product, the South Philadelphia works has installed new X-ray laboratory, brief de- scription which may interest because several novel features. should emphasized that the apparatus was designed primarily permit the rapid examination heat exchanger shells cylindrical form, a a (Facing page) Shutter plate ray machine removed show tube, which operates ma. and 180 with reserve 250 kv. Radiographs may made rapid succession without overheating the tube. (At View X-ray room, showing chine, control room, driven truck transporting welded cylinder from the shop. Complete push button control truck. ~ wl ( >. the the under and means the nining in- use- undry ion me- in- re- South de- the heat form, room, room, driven ler from omplete control the MOCHEL and BATES Metallurgist and Works Engineer, Respectively, Philadelphia Works, Westinghouse Electric Mfg. Co. with without flanges the ends. Secondarily, was desired provide means for X-raying castings, nozzles, dished heads, miscellaneous parts. Westinghouse Diex Generator Used The X-ray generator modifica- tion the Westinghouse Diex, which will deliver ma. current the X-ray tube potentials high 220,000 volts. This assures ample X-ray penetration greatest thicknesses material examined this plant. The high tension transformer constructed two sections, and rectification the high tension current obtained means two thermionic rectifying tubes mounted horizontally above the transformer tanks. The regulation variable factors, including current, potential and time, pro- vided for remote control panel located the control room and con- nected the transformers flexi- ble cable leading the X-ray cabinet. The X-ray tube also mounted the cabinet space adjacent the transformers, the rays emerging the horizontal direction the front side the cabinet. stated, the equipment was de- signed and built primarily X-ray cylinders. Particular attention has been given keeping set-up time low possible and the same time maintain the best possible conditions for safety the operator. Neces- Inspected apidly X-Ray q d sary protective devices have been in- stalled that practically im- possible injure anyone the op- eration this equipment, opening any door leading the X-ray room will shut down the equip- ment. Battery-Driven Truck Operates Between Weldery and X-Ray Room All the apparatus is_ installed within room ft. The gen- eral arrangement shown two the accompanying illustrations. One corner the room walled off form control room for the equip- ment, and this room readily con- vertible into dark room for the de- veloping the radiographic films. curtain lead thick sur- rounds the room; extends ft. above the floor and bolted the walls with lead head bolts. The large doors leading from the main shop are the swinging type with the same lead treatment. window lead glass provided the wall the control room looking into the X-ray room. more than in. thick and opaque X-rays the ex- tent in. lead. battery-driven truck operates be- tween the welding shop and the X-ray has machine within the room. maximum speed ft. per min., and with suitable push button con- trol may slowed down al- most imperceptible speed for accurate setting. the truck are mounted two rows rubber-covered wheels. The row nearest the X-ray cabinet fixed with relation the truck; motor driven and the wheels may equipped also with push button con- trol. The other row wheels made slide transversely the truck and can located self- centering device any one six positions, depending upon the size the cylinder X-rayed. readily seen that two motions can given cylinder resting upon the rollers; one motion along the track and the other rotative mo- tion about the axis the cylinder. X-Ray Cabinet Has Two Adjustments Resting track right angles the truck track the X-ray ma- chine itself. consists frame chassis mounted wheels, the chassis having vertical screw each its four corners. Each screw driven worm and gear speed reducer. The screws each side The Iron Age, June 28, , | i yes = 4 * | 4 a “4 = q 7 ee ~ Ay which ma. with 250 may id the 7 ge the X-ray machine cabinet are driven common shaft, and the two shafts are driven together single motor and two roller chains, one chain each shaft. For each screw, there nut bolted the frame the cabinet that houses the X-ray generator and the tube. this device that raises lowers the tube until its center and the cylin- der axis can made rest the same horizontal plane. For the next operation, which set the tube center the desired dis- tance from the photographic film, this case in., merely necessary operate motor located beneath the cabinet. This motor drives gear the center which spherically seated nut that rotates (At Left) The cassette set with telescoping rod that pointed both ends and inclosed spring holds firmly Focal gage, elevator gage, plate adjusting the X-ray cabinet) from the truck plat- form. (At Top Facing Page) Westinghouse kv. Diex generator with control and rectifying side the X-ray cabi- net. The X-ray tube compartment the background. The mil- liammeter and X-ray filament meter the far corner are visible from control room. around screw. The opposite end the screw connected the cabinet frame universal joint. Flexibility seemed necessary avoid possible binding. With push but- ton control the tube cabinet can set any required distance from the cylinder examined. Two more adjustments are thus provided take care every posi- 12—The Iron Age, June 28, 1934 4 the stal for insi ther set holds vator index X-ray isible plat- ‘acing 250 and in- cabi- tube lined the mil- X-ray the visible ‘ontrol end the joint. avoid but- the thus posi- tion the tube relative the cylin- der. The motions, four all, may summarized follows: tudinal seam moving the truck. rotative motion for setting the longitudinal and periph- eral welds, which taken care the truck. Elevation the tube the horizontal plane the cylin- der axis—done the elevat- cabinet. Spacing the tube with re- means the fore-or-aft mo- tion the cabinet itself. All these motions are controlled the operator, through push buttons, while standing the truck. the bottom the cabinet the side nearest the truck the com- partment containing the X-ray tube. This compartment lined with lead in. thick. Back and within the cabinet placed the Diex gen- erator. Indicating Devices Reduce Setting-Up Time Very interesting features the in- stallation are the indicating devices for setting-up the work. First, the operator measures the inside diameter and wall thickness then obtains from chart mounted Left) Standing the con- trols, the operator peers through lead- glass window ob- serve meters welded cylinders. (Middle) Located the con- the film dryer contributes quick inspection weld radiographs. (At Right) With developing tanks the control may inspected within few minutes and, sary, retakes may made immediately. the front the cabinet index number for setting the transversely adjustable wheels the platform the truck. Next, sets these wheels and places the cylinder X-rayed upon them. This done, the operator refers the same chart for another index number, and then sets the elevator adjustment indicator this second number pressing the push button raise lower the cabinet the case may require. Once made, this X-raying either longitudinal girth welds given cylinder. The equipment simple. The ele- vator adjustment dial consists pulley in. circumference which drives the indicating pointers. The pulley counter-weighted return the pointers counter-clockwise di- rection. steel piano wire passed around this pulley and over other pulleys, and anchored the chassis the cabinet. When the cabinet raised, the wire pulls the pointer clockwise direction and when the weight rotates the opposite di- rection. Simple Focal Adjustment Indicator The indicator for focal adjustment equally simple. pointer located the side the X-ray cabinet connected dial indicator that similar and located beside the elevator adjustment dial. The pointer arranged that may moved and from the X-ray cabinet. When moved back toward the cabinet, means the counterweight, the dial indicator shows minimum read- ing. The pointer moved outward from the cabinet and made touch the cylinder X-rayed pulling downward the push button cord, which connected the pointer cable that passes over suitable pulleys. This pointer located the The Iron Age, June 28, 1934—13 pee, t same horizontal plane the center the X-ray tube and axis the cylinder. The indicator the focal adjustment dial made rotate clockwise direction steel piano wire arranged over suitable pulleys and attached the pointer. Pressing the proper causes the cabinet move toward the cylinder X-rayed. This, turn, pushes the pointer toward the cabinet and causes the indicator The radiograph above (617) shows ac- ceptable weld material. The one right (607), material thick, shows porosity and slag in- clusions the weld. the rotate counter-clockwise index number that had been ob- tained previously from another chart the front the cabinet. From this point on, the operation setting the cassette containing the sensitized film and screen similar other X-ray work. The setting- time for each cylinder has been reduced about min. Unique Holders for Cassettes Other devices worthy mention include the holders When X-raying horizontal seams, board with spacing strips each edge clamped inside thé cylinders with the spacers spanning the weld. Iron Age, June 28, 1934 The spacers keep the board away from the inside the cylinder dis- tance equal the thickness the cassette plus small clearance. They also provide groove for the cassette slide in, and the board keeps the cassette adjacent the shell. then becomes unnecessary for the operator enter the cylinder. inserts the cassette the groove and pushes the proper location cylinder with measuring stick al- ready laid off film lengths; and removes them the same way. For girth welds, which are usually near the ends, places the cassette position and holds with spring loaded telescoping device. with many industrial opera- tions, the time required for setting work often more than that for performing it. This particularly true with castings and welds with usual devices. Reduction setting-up time was kept mind constantly during the development this machine. All controls cated conveniently that the opera- tor can stand one place and per- form every setting-up operation. given perfect control his work with clock-like indicators. ab- solutely safe from all radiations and reradiations the rays. All data posure time are carefully charted; readily obtainable. Control Room Combines Dark Room the control room, which con- vert:ble into dark room closing Radiographs typical results with the new equip- ment installed the Westinghouse South Philadelphia works for examining welded heat exchanger shells are shown left and below. the doors and one shutter over the window, the operator performs the work developing, fixing, and dry- ing films. Hot, cold, and iced water are hand, and the temperature the baths controlled automatically. The dark room well ventilated with Every convenience afforded for ease operation, speed, safety, and comfort the operator. turntable the shop outside the X-ray room provides means for versing the truck, and placing into position before the tube opening that side the truck table that free the rubber-covered wheels. This vides ample space for quickly placing no pl. tic pli sli — per me ess ica ing tic str the sul sys ing de} lizi for bin bui cas pla ets ser work ab- ons and data ‘harted; Room con- closing secured equip- led the works welded iger shells left and iw. over the and dry- water ‘ature natically. ited with rded for and tside the for into that free This placing nozzles, dished heads, castings, other parts position for X-raying. stand special design has also been provided for X-raying plates test samples. Being roller- mounted, may rolled into posi- tion before the tube. very flexible clamping arrangement permits test plates any size readily placed position for X-raying, and the cas- settes slide into position behind the test plate, much the plate holder slides into position the photograph- camera. test plates play very considerable part most weld- ing experiments and developments, this feature quite important. Sheet steel cassettes (film holders) with bakelite front, and removable back with flat spring retainer, and screens perma- nently mounted front and back, are used. 4-in. 10-in size has been found convenient for girth seams and 17-in. size for longi- tudinal seams. Radiographs typical results se- cured with the equipment described above are included the illustrations accompanying this article. Very Small Specimens X-Rayed method for X-raying very small specimens has been devised. When inspecting old boilers shells, often possible burn out drill out piece in. diameter for test purposes. Even smaller pieces have examined. casting such specimens into sheet plate lead lead-base babbitt, approxi- mately the same thickness the test been Sprays Metals Repair Cavitation Damage DETERMINE the practicabil- ity repairing cavitated water turbine runners means the metallizing, metal spraying, proc- ess, impressive experiment was made the Metallizing Co. Amer- ica, Inc., Los Angeles, amounting applying seven different types metal the worn spots and examin- ing the results after year’s operat- ing wear. this procedure the prac- ticability the process whole was regarded definitely demon- strated and determination made the metal alloy best suited the For the test, runner unit No. the Cohoes hydro-station the New York Power Light Corpn., subsidiary the Niagara-Hudson system, was chosen. The accompany- ing illustration shows the eroded cavitated corners the runner. The depressions were filled metal- lizing, different metal being used for each blade, stated. The tur- bine was one the Francis type, built for head ft., and had cast iron buckets. The turbine was made the Morgan Smith Co., York, Pa. The metallizing was done from Oct. 21, 1932, with the turbine place and the unit therefore not dis- mantled. Oct. 23, 1933, the buck- ets were inspected and the behavior the spray deposited metals was ob- served discover how they withstood full year the cavitation effect. For spraying, the metallizer made the Metallizing company was used, portable gun that receives given metal wire form and melts and sprays the material cov- ered. The repair work vised Summers, superintend- ent the power station, and Axline, engineer for the Metallizing company. The cavitated parts were prepared for the metallizing sand blasting, using 200-lb. sand blast with aw i 4 specimen, that the specimen completely surrounded the lead, and supporting this sheet plate the special stand referred above, the specimen may exposed the rays and excellent results obtained. the resulting radiographs, the im- age the test specimen appears very plainly otherwise transparent film. Two more test specimens may cast into the same plate and examined the same time. The equipment described above has been service for about six months. has behaved excellently, and the results have been very satisfactory. The ability the tube operate con- tinuously for long periods time and the ease operation and freedom from physical and mental fatigue the part the operators have been noteworthy. mesh hard silica sand. Approxi- mately min. sand blasting time sufficed for each bucket. The cavi- ties were approximately sq. in. area and varied from in. depth. There were two cavities each runner. The accompanying table gives the particulars the metal- lizing. inspection the end the year was made Mr. Summers, who reported follows: No. Found this metal half gone. No. bucket metallized with bronze. This metal looks good, sign water action, small hole the metallized work approximately ™% x 1 x 2 in. No. bucket metallized with aluminum. with Found this metal half gone. No. bucket metallized with copper (Concluded Page 76) Cavitation repairs this water-turbine runner, which drove 7200-kw. General Electric alternator, were made the Metallizing process. The cavities were approximately sq. in. area and much in. deep. The Iron Age, June 28, 1934—15 Re i SRP 4 he <3 rr, 7 4 70% Piece per Minute Fig. 1—Record the results experiment industrial physiology the molding operation. Calories per Piece Calories per Minute Piece per Minute Fig. 2—Record results experiment the molding operation which the sifting the fine sand was performed with pneumatic shaking 5001 8 3500 90 Br 9 Fig. 3—Record results experiment in- dustrial physiology the separate manipulations the molding operation. a 16—The Iron Age, June 28, 1934 the experiments that have been performed date the expenditure energy during work, the object view has been most cases increase the out- put work the elimination inappropriate, unnecessary and time-robbing movements; other words, better performance with the same expenditure time. The experiments the con- sumption energy the opera- Ernest Simonson, the director the Industrial Physiology Depart- that one has deal with, the ex- penditure energy obtained the determination the number calories consumed. this the amount oxygen taken the worker, the amount carbon dioxide given off and the amount air used the process are ascertained. For this purpose so-called respiration apparatus was employed, which the main current used air passed through gas meter, thus measuring the amount air used, while small portions were caught small rub- ber bags adapted this end for chem- ical analysis. subject for the experiments healthy worker was chosen who account several years’ experience was able perform the manipulation the investigation with the same ex- penditure energy usually found practice. His consumption oxy- gen while rest was first ascertained and thus values for later calculation and reference were obtained. Experi- ments, which stamping machine (process I), lever press operated Calories per Piece Calories per Minute NNN 11497 LLA 10,000} 5000} 1.0 vv 4049 1000+ 4000} 0.1 fava’ 0.9 4/00 0.6 0.5 0.444 0.3 e i 4000 — u 0 e ( c labor the ex- his the the dioxide used For the passed small all rub- chem- who ame found oxy- Experi- machine ‘ated ment the Social Hygiene Re- search Board, Frankfort Main, carried out the foundry the Bamberger, Leroi, Frankfort M., show that the better per- formance which rationalized man- agement boasts obtained cost increased expenditure energy (body fatigue) per unit time the part the worker. These results are not universally true for every kind work. Each individual case must tested itself the application the highly illuminating, objective meth- ods industrial physiology. hand (process II) and press (process III) were employed, were carried out find out the total calory consumption per unit time and per unit work. Process con- sisted separate movements, process and process III 13. The number calories needed for each move was ascertained order determine for which manipulation would expedient replace man- ual labor with machines. The results the experiments are recorded Fig. this diagram one learns that technical rationaliza- tion the processes and III leads one hand reduction the amount energy consumed per piece from 11,497 cal/piece 5820 production from 0.353 pieces/min. 0.978 pieces/min. the other hand, causes rise the expenditure energy per unit time from 4049 creased efficiency obtained with the aid better technical equipment was able attained only greater demand upon the worker. Industrial Physiology Fig. further shows that process must marked inferior proc- ess III from the point view in- dustrial physiology. The amount energy needed process not much less than that required proc- ess III (5110 cal/min. 5640 cal/ min.) spite the fact that pro- duced only half many pieces process III (0.518 pieces/min. 0.978 pieces/min.). When the processes and the sifting the fine sand manual labor was replaced pneumatic shaking device there resulted in- crease the output and reduction the expenditure energy per piece output (in all three processes); see Fig. The results that were got the in- vestigation the individual move- ments and which are recorded Fig. are worthy notice. One sees that the pounding operation process requires the highest expenditure energy, namely, 2200 calories/pieces while the same work process (molding with the lever press) de- mands only 338.4 cal/piece. The shov- eling sand into the molding boxes, Total Consumption RENE LEONHARDT Berlin (Germany) the setting the empty boxes, the removal the filled boxes, well the stroking off the excess sub- stance the filled boxes, require great amount energy. Fig. shows even more clearly what part the total energy con- sumption these separate operations take. seen that the very effi- cient process III the subordinate work consumes 76.9 per cent the total energy, that the performance this auxiliary work helper the considered. The investigations Dr. Ernest Simonson, who recently became direc- tor the institute industrial phys- iology, Narkomtrud, R., show that even today possible increase the efficiency the worker the application the methods industrial physiology with- out making any greater demand him than the times the lower efficiency. The main requisite only the elimination energy-consuming subordinate operations and their re- placement with machines. f Excess troking Off of Exce =9.6% =22.3% Shoveling =30.9 ° $4.6 4i.ae Percentage Fig. 4—Record the part the total energy con- sumption the subordinate work takes the molding operation. The Iron Age, June 28, 1934—17 3 have work, out- ion and other j with con- tor Total Consumption , 9560 9000 8000 | 1000 Total Consumption 5820 0 here One the electric furnaces (6-ton) for melting Bethalon. EVERAL methods producing free-machining corrosion resist- ing steels have been made public but they all have for their common object the introduction least 0.30 per cent sulphur. One com- pany said substitute certain amount selenium for sulphur and there are other methods accom- plish the introduction the sulphur its equivalent. can stated, however, that essentially the sulphur content which bestows the free-machining properties not some other added element. estab- lished that sulphide chromium present quantity. Iron Age, June 28, 1934 Two special brands are produced the Bethlehem company, under the trade names: Bethalon and Betha- lon The type analyses and physi- cal properties these two brands are given the table. Besides these two main brands there also special Bethalon which the same the type except that contains per cent chromium instead per cent. Another special brand Bethalon which has per cent nickel and about per cent chromium. Each these two special brands can made suit unusual conditions. The function the in- troduce the sulphur but the latter can EDWIN CONE and often brought into the com- position straight addition These steels are all made electric furnaces, usually the type. Actual analyses heats the and types are follows: Per cent Per cent 0.09 0.12 0.012 Trace 9.86 See Chart Properties Bethalon and Taking the various special prop- erties Bethalons and may stated that the type, cor- rosion-resisting properties, those characteristics straight car- bon-chromium irons. The type has all the excellent corrosion-resisting properties the regular straight and brand. recommended for uses where the rapid performance intricate machining operations im- portant. must, however, ma- chined somewhat lower speed than screw stock. The cutting speed some extent dependent the speeds from surface ft. per min. can maintained without the necessity for too frequent regrinding tools. The brand type can drilled, turned, bored threaded easily ordinary screw stock with the same tool set-up and the same feed, speed, and depth cut. Excellent threads can cut 150 175 surface ft. a ~ e com- rites. prop- may COr- car- has for im- ma- speed speed the but per the nding rilled, ily same speed, reads ft. per min. can smooth turned 200 surface ft. per min. decided value are the heat-re- sisting properties Bethalon parts subject heat 1100 deg. F., remains practically scale- free and retains great strength that Where maximum strength and absolute freedom from seale are not essential, can used 1400 deg. This type can also easily and quickly ground, taking excellent finish without heating loading the wheel. can rapidly polished, taking bright lustre. Forged Higher Temperatures Forgings can produced from both and brands. The brand usually forged somewhat higher temperatures than those which ordinary steels that composition are forged. The maximum forging temperature for both brands 2300 deg. feature the type these free-machining steels that can hardened quenching oil from 1750 1850 deg. F., followed drawing the purpose for which intended. The chart clearly shows the proper drawing tempera- ture acquire the Brinell hardness desired. The physical properties are also given for the various drawing temperatures. will noted that Resisting Steels for Many Uses NTIL the introduction the high-chromium chromium- nickel steels, the only free-ma- chining steels were the ordinary carbon, high sulphur screw stock brands. These were satisfactory for many purposes, and still are, but they will not stand where corrosive and other conditions are serious factor. meet the demand for free- machining material which would stand during operations involv- ing severe corrosive conditions there the market several high- chromium high chromium- nickel steels. Among these are the various brands made the Bethlehem Steel Co., Bethlehem, Pa.—The Author. drawing temperatures 1000 deg. may employed without de- creasing strength elastic limit. should added that for use the manufacture electrical equip- appreciably tensile ment the specific electrical resistance compared with for hard steel, 18.9 for lead, 15.9 for soft steel, for iron and 1.6 for copper. course the type non-magnetic its 190,000 assortment products ma- chined | £ 40 | + al Elongation 400 500 600 800 900 1000 1100 1300 Quenched Oil from HART showing Bethalon Brinell numbers The Iron Age, June 28, 1934—19 ~ 3 a é ent % Se t ES ES \ wits Photomicrographs sample Bethalon showing size and distribution the sulphide inclu- sions. One from transverse and the other longitudinal (right) section rolled bar. Both are 100 diameters. Unetched. fully softened condition; has permeability about 1.04. Photomicrographs are reproduced showing the distribution and general shape the sulphide inclusions Bethalon There also the repro- duction photograph highly ma- parts made from one these free-cutting corrosion-resisting steels. should stated that the pour- ing into ingots, the rolling into billets and follows the usual procedure for such steels. Both the and brands are available the following forms corditions: Annealed bars within bar mill sizes; ground bars, in. 3-in. round; cold-drawn bars; heat-treated bars; forging bil- lets; drop forgings; press forgings; wire rods and wire. can thus realized from the foregoing discussion this type Broad British Studies Corrosion Problems intensive study being made corrosion well exemplified what known the second re- port the corrosion committee pre- sented the recent meeting the Iron and Steel Institute London, 298 pages the regular size the institute’s proceedings and withal reality merely record progress since the first report was published 1931. The committee joint body the Iron and Steel Institute and the British Iron and Steel Federation, comprising some thirty experts all the branches the subject from pure scientific investigation the study the behavior finished structures. Field Tests All Over the World For so-called field tests corrosion stations have been set the British Isles and Singapore and Nigeria, South Africa and northern Sweden, establish case histories under widely 20—T Iron Age, June 28, 1934 varied climatic conditions. The first series tests concerned with the corrosion ordinary mild structural steel, both unalloyed and with the ad- dition and 0.5 per cent cop- per respectively. For this purpose, three complete ingots were taken from 250-ton heat made basic-lined tilting furnace, which was poured into three separate 75-ton ladles; the necessary quantities copper were added two the ladies. this way, three steels were obtained which the copper content was the only appreciable variable, the casting conditions and rolling proce- dure being otherwise identical all respects. Companion ingots those used for the production the test samples have been examined the committee the heterogeneity steel ingots, and full details the melting and rolling procedure were taken during the preparation the specimens, that complete informa- Table Composition and Physical Properties the Bethalon Steels Manganese ....... 0.30 0.30 Chromium 18.00 8.00 phide (Mo 0.50 0.50 Yield point, per Ultimate per sq. 95,000 Elong. in. per Reduction area, 50.0 45.0 Brinell harness 152 Specific gravity 7.777 7.89 Coefficient linear expansion: Between limits and 100 deg. C.. 0.0000109 Between limits and 1,000 deg. 0.0000136 Between and 200 0.0000175 Between and 500 Physical properties the annealed condition. tPhysical properties the fully sof- tened condition. steels that here available steel which can freely machined into all manner products and that they can ing conditions well other applications which the ordinary machine free-cutting steels would not stand up. tion any sample The effect copper, such, is, however, only one feature this series tests; addition, the effect surface condition being investi- gated. One the most important factors under this head the char- acter the mill scale, which, well known, may profoundly af- fected variations incidental the normal commercial processes hot- rolling. The committee has therefore arranged, not only this, but all series tests, conduct tests specimens rolled under two more different conditions, which are ac- curately defined pyrometric and other observations taken during the rolling the specimens. The com- mittee’s tests should therefore throw light the different characteristics rolling scales steel, whether un- alloyed copper-bearing. Further, order eliminate the effect rolling scale, specimens that have been de- scaled various treatments, includ- ing pickling, sandblasting, machining and polishing, are also exposed, that comparison the materials made several different surface con- ditions. (Concluded Page 78) he: ru m g u oO 175 186 all can sist- ther eels How Finish Helps Metal Products Sales 20—The Preparation for Paint OMEN, generally, are sup- posed have little interest metallurgy, but the auto- mobile has brought many changes society, and today not unusual hear even the feminine purchaser ask, “Are the fenders this car protected against rust?” Gradually the buying public has become rust conscious, until now, never before, rust-proofing strong selling factor the steel products in- dustry, even though the process fre- quently hidden under coating paint enamel. Rust-proofing and preparing for paint the treatment steel surfaces are often identical processes, for almost always good rust-proofing treatment produces etched surface which affords ex- cellent base for paint. The proper application paint any metal product involves fun- damental process, preparation the metal surface receive the paint. the public mind, first consideration given the quality the coating material itself, but manufacturing ex- perience demonstrates that paint fail- ure metal products more fre- quently caused improper prepara- tion the surface, than the use inferior coating materials. Plain polished sheet steel not itself ideal paint base. Unlike wood, lacks porosity permit penetra- tion, and so, when untreated, paint for the most part will simply lie the smooth glass-like surface and, mat- ter how adherent may seem when applied, the bond not secure. addition this lack bond, the smooth steel surface presents another disadvantage base for painting, because with the admission mois- ture the metal through any cause, either through porosity the paint preparation metal sur- face which paint enamel the life and service the coating, and the quality the paint itself often may less importance the final result than the quality the surface preparation. Improved technique prepainting treatment has extended the use the cor- rodible metals well the use paint the metal working industry. Some the features such surface preparation are described this twentieth article extended series metal finishing. film abrasion the coating, con- dition favorable corrosion tends develop and, once started, such con- dition favorable corrosion tends spread. The outward sign may Fig. showing electrochemi- cal theory corrosion. tiny spot rust, but pernicious ac- tivity may set under the paint and, allowed progress, whole sections the coating will become detached. Alkaline Reaction Whatever theory corrosion ac- cepted, laboratory research has estab- lished the fact that addition the visible growth rust the point actual abrasion, the surrounding area develops alkaline reaction which creeps back between the metal and the applied finish, neutralizing the ad- hesion over ever-widening surface. Tanner, Metal Finishing Re- search Corpn., his extensive work this field, has confirmed the fact that when piece steel strained, certain parts become electro- positive and other parts electro-nega- tive. This condition may demon- strated tests, for the surface area some parts will give strong fer- rous iron reaction, and other parts, equally strong hydroxyl ion alkaline reaction. When these respective areas are immersed agar-agar jell, which has been added potassium ferri- cyanide and phenolphthalein, blue color develops where the ferrous iron dissolves, and pink develops where the surface alkaline. This rela- tively simple test indicates several things. First, proves that there condition favorable corrosion, and second, indicates method clean- ing steel for paint which should avoided. When bare steel sheet treated with most any kind acid before subjecting this test, the concentration alkali greater than for similar sheet untreated with acid. This seems strange first, but when realized that any pickling The Iron Age, June 28, Are fz ble. this ant af- 10t- ore all de- * effect tends cause iron dissolve more rapidly, the increased tration referred seems more logical. well known that most pickling, without subsequent treatment, leaves iron favorable state for corro- sion. When steel sheet dipped five per cent phosphoric acid solu- tion and then placed agar-agar jell blue color appears imme- diately, indicating solution the iron. Under such condition usually takes longer for the pink color show the sheet because the hydroxyl ion must first neutralize the hydrogen ion from the acid remain- ing the surface the sheet. When this neutralization has once taken place, the phenolphthalein indicator turns decidedly red. Comparison Plain and Treated Steel. Total micrograph enlarged Fig. (Right) Plain polished carbon steel sheet. Fig. (Left) The same material with chem- ically produced phosphate coat- ing. Fig. and indicate two small pieces sheet steel connected wire and immersed water solution any salt which will give the solution conductivity. This the diagram suggested Mr. chemical theory corrosion. assume that both and are neutral, then corrosion take place, some iron must dissolve, which means that hydrogen gas liberated the metal surface. such corrosion takes place for in- stance, the iron which dissolves takes into solution with charges for each iron ion, and this leaves negative with respect due the fact that left with more negative charges than positive, and since the two pieces are con- nected conducting wire, circuit formed through the wire, with its return through the solution. Since now positive electrode, any hydroxy] ions migrate this elec- trode and fairly high concentration alkali established. the con- necting wire severed between and the current cannot flow, course, and corrosion from this source ceases. This illustrates one the impor- tant features developed pre- paring surface for paint. some means the positive and nega- tive areas the surface can in- sulated, one from the other, the effect will like severing the wire the illustration shown Fig. and the Fig. 3—This typical modern equipment, used for preparing enameling, illustrates the extensive auxili- ary equipment this field manufactur- ing. — 22—The Iron Age, June 28, 1934 re a n con- ircuit its elec- ‘ation con- and mpor- nt. nega- in- effect the the typical pment, for auxili- this factur- tendency corrode will have been retarded. Two Important Factors There are then two important qual- ilties sought preparing for paint: foothold for the paint. insulating, prevent electro- chemical development alkali. Both these objectives may at- tained single operation between the cleaning and finishing metal. One method create phosphate coating which gives greater adhesion and the same time arrests the flow electrical current. The effect such coating steel illustrated Figs. and 2B. These are photo- micrographs, each taken 100 diam- Fig. Automobile parts are here being conveyed bonder- izing tanks con- preparation and painting process. Comparative Life Plain Steel and Waterproofed Steel Under Enamel. Fig. (Left) Plain carbon steel with baked enamel after salt Spray test Fig. (Right) Same steel coated the same way and sub- jected the same test, but rust-proofed before enameling. eters. Fig. piece polished but untreated cold-rolled steel. Fig. similar piece which has been treated with typical phosphate coat- ing. this case Bonderite coating was used. Tests show that such treatment before painting will stop the spread rust underneath the paint film, even when the paint scratched sufficiently allow local corrosion take place. such treated specimen placed the agar-agar jell previously re- ferred to, there will practically color indicate either ferrous iron alkali. Even though rust itself tends loosen paint film, the alkali formed the result the corrosion more pernicious and causes more pronounced loosening the paint than does the rust itself. Figs. and illustrate another test. Here two identical pieces steel were taken. Both were cleaned. The one Fig. was untreated, and the one Fig. was given Bonderizing treatment. Both pieces were then covered with two coats baked enamel and after- ward each was pricked the center expose the metal. Both were then subjected 228 hr. salt spray. The light area Fig. shows where alkali has destroyed the paint film surrounding the abraded spot. Fig. slight rust appears the point abrasion, but spread corrosion alkali the surrounding area apparent. The process Bon- derizing, with some other phos- phate coatings, consists chemical action the metal itself, which The Iron Age, June 28, 1934—23 microscopicaily thin portion the surface converted minute crys- talline structure. the subsequent application paint, the fluid per meates the crystals and, when dry, securely keyed the metal. Figs. and show two shallow receptacles containing the agar-agar jell referred above. the one Fig. small piece untreated steel placed, and Fig. placed similar piece identical steel, but provided with phosphate coating. The dark spots Fig. in- dicate the blue development where iron has dissolved. The gray portion the piece was actually decided pink, indicating alkali. dark spots are visible Fig. 6B, and the small piece steel showed blue pink areas, indicating that corrosion had Rust-Proofing Rust-proofing closely identified with painting and enameling that means preparing metal for paint, and some its chief characteristics will considered here. For many years the rusting iron and steel was ignored far possible. The steel manufacturers themselves cer- tainly did not want call attention it, and fahricators metal prod- ucts realized that any aroused public sentiment the subject rusting might have the effect increasing the cost production forcing them turn some non-rusting materials. So, ignoring much possible the fact that untreated steel might rust, paint was used ample fashion. This was something like ostrich burying its head and thinking all would well. soon scratches appeared the paint, there was opening for rust start, and cor- rosion then spread under the paint coat. Even high class automobiles pre- vious 1915 were subject spread- ing corrosion the surface were bruised. One result the stock-taking period just after the war was the directing public at- tention the tremendous losses due widely, giving the estimated yearly loss dollars, and most these estimates ran upward from $100,000,- 000. result this, several things happened. 1.—The use copper and other non-fer- rous and non-rusting materials in- 2.—A movement toward the development rustless and was Started, and steel products was turned to the question rust-proofing methods and better painting practice. 24—The Iron Age, June 28, 1934 most cases better painting prac- tice meant more thorough cleaning be- fore painting, and greater care creating bond between the paint and the metal. quotation trom Govern- ment specifications some years ago will serve illustrate the character good rust-proofing process. steel shall processed after fabri cation some commercial method rust-proofing which will coat equally all surfaces, that samples the fabricated sections shall show rust The Agar-Agar Test. Fig.6A (Above) Untreated sample. Fig. (Below) Rust-proofed sample. after hr. continuous exposure room temperature the spray per cent salt solution. When painted and subsequently scratched the bare metal, there shall creeping rust under the paint away from the the end the salt spray test.” Three Methods Three commercial methods rust- proofing came into early prominence. These were galvanizing, and Parkerizing. When Leonard Hirsch, Philadelphia Rust-Proof Co., was asked what was the best process rust-proofing steel, said: “There can simple answer this ques- tion, because different articles and dif- ferent uses call for different proc- esses. Take, for instance, cleaning, For some products, alkali cleaning the cheapest. For others, acid pickling may necessary. And still other cases, the sand blast may the most efficient method.” the case some products, clean- ing and rust-proofing must done after assembling. This the expe- rience with steel casement window for which specific item Mr. Hirsch enumerates the following advantages and disadvan