The Iron Age 1934-07-19: Vol 134 Iss 3

just un- Iron mills. the spect- torial for ona them- and but Insti- years. neer- yme chart him Wwe but ac- erva- out. Managing Editor Consulting Editor News Editor Machinery Editor Pittsburgh Detroit Boston Chicago Editor Emeritus Washington Cincinnati Contents OUR PART Industry and Agriculture Have Common Interests Finish Helps Metal Products New Method Extrusion Improves Lead Sheath Wrought Iron and What Determines Its Quality Personals and Obituaries Washington News Automotive Industry Markets Construction and Equipment Buying Products Index Advertisers THE IRON AGE PUBLISHING COMPANY FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. OFFICES: 239 West 39th St., New York, ADVERTISING STAFF Emerson Findley, 311 Union Bldg., Cleveland Member, Audit Bureau of Circulations Member, Associated Business Papers B. L. Herman, 675 Delaware Ave., Buffalo, N. Y. Hottenstein, 802 Otis Bldg., Chicago Published every Thursday. Subscription Price: Peirce Lewis, 7310 Woodward Ave., Detroit | United States and Possessions, Mexico, Cuba, Charles Lundberg, Chilton Bldg., Chestnut & | $6.00; Canada, $8.50, including duty; Foreign 56th Sts., Philadelphia, Pa. $12.00 year. Single Copy Cents Ober, 239 39th St., New York W. B. Robinson, 428 Park Bldg., Pittsburgh Cable Address, ‘‘Ironage, Sweetser, 239 West 39th St., New York D. ©. Warren, P. O. Box 81, Hartford, Conn. EIGHTIETH YEAR SERVICE THE METAL WORKING INDUSTRY peaks North prob- three too the THE IRON JULY 19, 1934 different kind Nut... stronger, tougher Nut Nor all applications call for the Beth- lehem Hot-Forged Nut. But there’s many brutal task where nothing else will do. Wher- ever severe wrenching strains are involved, wherever the nut must drawn tight, that will stay tight, the Bethlehem Hot- Forged Nut emphatically the one use. Don't imagine it’s just extra-good nut, manufactured the ordinary way. The Bethle- hem Hot-Forged Nut made new, exclu- sive process. forging, and has the dense structure that forging gives. The threads are strong, tough, that they stand without stripping under the heaviest kind duty. Bethlehem engineers who are specialists bolt and nut manufacture developed and per- fected the Bethlehem Hot-Forged Nut. made our Lebanon, Pa., Plant, large, self- contained Bethlehem division devoted wholly Bethlehem Bolts and the manufacture bolts and nuts and related products. Lebanon Plant products include all kinds bolts, carbon, alloy, and corrosion-resisting steel. All kinds nuts, too, well the hot- forged. Also rivets, spikes, turnbuckles, etc. For service you, Bethlehem carries Leba- non Plant extensive range standard com- mercial items ready for immediate shipment. BETHLEHEM STEEL COMPANY, Pa. District Offices: Atlanta, Baltimore, Boston, Bridgeport, Buffalo, Chicago, Cincinnati, Cleveland, Dallas, Detroit, Houston, Indianapolis, Milwaukee, New York, Philadelphia, burgh, St. Louis, St. Paul, Washington, Wilkes-Barre, York. Pacific Coast tor: Pacific Coast Steel Corporation, San Francisco, Seattle, Los Angeles, Portland, Honolulu. Export Distributor: Bethlehem Steel Export Corporation, New York. » Page 1 ited hot- etc. eba- om- ent. Pa. eveland, York. THE IRON JULY 19, 1934 ESTABLISHED 1855 Vol. 134, No. Industry and Agriculture Have Common Interests; They Should Unite Defend Self-Government and Oppose Regimentation principles management both com- mercial and political, that you would impose responsibility you must also convey authority. largely per- mitting industry write its own codes, subject, course, the specific terms the Recovery Act, the NRA, believe, made wise move. One not likely disown his own child and has been one the accepted not want convey the im- pression that all smooth sailing for industry toward the port self-gov- ernment the NRA. Strange and variable winds from other quar- ters are continually ruffling the sur- face and the industrial navigators are continually dodging thunder bolts and water spouts. The great trouble that barometer can predict the weather day advance, hence navigator Condensed from address made before the representatives agricultural co- operative associations, July 13, the American Institute Uni- versity Wisconsin, Madison, Wis. JOHN VAN DEVENTER Editor, THE IRON AGE restoration the durable goods industries means the restoration full buying power 25,000,000 former buyers farm products who are now existing subsistence “Agriculture must profits its own right make good long-term customer for in- dustry exactly industry must make good long-term cus- tomer for agriculture. Neither one, Government dole sub- sidy, sound position con- under bureau- cratic control, the antithesis self-government through coopera- tion. The schoolboy does not co- operate; obeys the our problems are com- mon problems. should renew our kinship behalf and defense through can plan his course. Even the pole star shifted from time time with- out notice. These perplexing shifts, only fair say, hot proceed from NRA but from other quarters. The strongest wind the prevailing one for the day, whether comes from Congress, the Federal Trade Commission some other extraneous quarter. Speaking self-government in- relativity. There has never been complete self-government and there never will be. The part must regulated conformity the whole. The question is, how much govern- ment regulation necessary and wise. the face widespread unem- ployment, was clearly recognized that self-government could not ex- tend, yet, the assignment the number hours the working week the minimum wages paid workers. There were two reasons for this. First, industry was not or- ganized handle it; second, was not equipped, under its own powers, handle the chiseler. Government regulation was recognized neces- sary these instances. Regulation Horizontal Edict Government regulation horizon- tal edict the matter working hours per week, while admitted necessary the emergency, not scientific satisfactory long-term solution the unemployment prob- lem. Already, for example, there are serious shortages labor developing certain skilled occupations, while other occupations there con- siderable surplus. does the public interest good deprive skilled man additional working hours when there one take his place. When have progressed somewhat further along the road self-govern- ment industry should find the part industry’s problem assum- ing responsibility for the spread employment its employable. This, too, the direction solving the problem technological unemploy- ment, whereas the Governmental restriction working hours not. all the codified industries, can think none that has gone further the road self-regulation during the past year than has the steel industry. Its code astonish- ingly complete even the regulation details trade practice. re- sults relative the intent the Re- covery Act, there industry that can show better performance. Em- ployment has been increased ap- proximately the 1929 level, wage rates have been increased the ex- tent per cent above 1929 level and prices are per cent lower than the 1929 level, measured THE IRON AGE composite for finished steel. Its 400,000 workers are well satisfied, spite the representa- tions labor leaders whom satisfied labor spells merely prospective loss “gate receipts.” The one “fly the that very few steel companies are making any money, but least most them have stopped losing it, and that, today, indeed source optimism. Self-Government Basic Industries One the reasons why self-govern- ment has apparently made such good progress the steel industry should interest agriculture. Steel, like agriculture, basic primary industry. but one step away from the soil. Such industries offer more opportunity, perhaps less dif- ficulty, self-regulation than the industries that are two more steps removed from the basic strata. For 12—The Iron Age, July 19, 1934 one reason, there less complexity product these basic industries and higher degree common in- terest among their members. The ex- perience steel, coal, lumber and other basic industries under the aegis NRA makes one wonder the same principles self-regulation would not work similar advantage agricul- ture. This applies very forcibly the matter price control, whether absolute price-fixing, open price arrangement simply the prohibition selling below cost. Whether one approves disapproves any all these methods price control must admit that feasibility price control maximum with the basic commodities and this feasibility dimin- ishes rapidly you encounter the more diversified and less standardized products industries two more steps removed from the basic com- modities. quite feasible, for ex- ample, establish uniform prices steel but would not all feasible establish uniform prices motor cars fancy dress costumes. Beneficial Price Stabilization The self-regulation price the steel industry, through the open price association with its complete price publicity has eliminated the chiseler and enabled the small consumer obtain his steel exactly the same price that his large competitor pays. has taken the steel selling game classification and has put busi- ness basis. From the standpoint the producer, employer, this pos- sibility eliminating suicidal price cutting has been the big code accom- plishment; the one big thing that has gotten out that makes worth what has cost. this privi- lege exercising some practical form competitive price stabilization were removed the game would not worth the candle. NRA’s Relation Agriculture Thus far have been looking NRA from the industrial viewpoint. Now would like dwell for few moments what industry’s experi- ence the past year means the farmer. One year ago the general index all commodities excepting farm and food products stood 70.1 and the day, the last reported week, the commodity price index was 78.5 and the index farm products was 64.8. other words, since the recovery movement manufac- tured commodity prices moved up, whole, 11.9 per cent and farm prices, whole, moved 13.8 per cent. Since the buying power the farmer income measured terms the selling price manufactured goods, this showing means that, the whole, the NRA has helped the farmer and not hurt him. course, averages are deceptive, and there are, doubt, specific cases where the reverse true. There another beneficial angle NRA affects agriculture, and that the fact that industrial workers form large part the mar- ket for what the farmer has sell. The increased wages paid indus- try under NRA have also helped the farmer; also the fact that some 4,- 000,000 additional workers have been put position earn wages and buy farm and food products. Most the codified industries feel that their experience under NRA such warrant their support its principles, least for some time come. would seem agricul- ture, because its indirect benefits from NRA, should have similar in- terest. Industry and agriculture are, fact, closely allied interest many current matters that closer cooperation between them would heneficial both. Certainly the en- lightened men industry recognize their own interest having prosper- ous farmers for customers. What Capital Goods Prosperity Means Agriculture One situation that seriously affects the farmer, for example, that the capital goods industries. you are aware, the consumer goods industries, employment and wages, are rapidly approaching normal, whereas the capi- tal goods industries are still very much depressed. Practically all the remaining unemployment close 10,000,000 workers either the capital goods industries the re- lated industries and services depend- ent upon them. One might say that the farmer had particular stake the capital goods industries’ welfare, aside from the minority well-to-do farmers who have invested stocks bonds such companies. That quite un- true. The 10,000,000 unemployed wage earners and their dependents, who are without income because the depressed state the capital goods industries, represent, conservatively, with their dependents, 25,000,000 food consumers tomers who are living either char- ity carefully conserved savings and minimum subsistence level. | > * ~ ; P 0 7 | cent. armer the whole, and rages angle and indus- the 4,- been and feel time rricul- in- re, est closer ild en- ognize osper- rity affects the are capi- very all close the the re- epend- had capital from who nds ite un- ndents, the goods atively, food savings level. help remove the obstacles which keep these 25,000,000 from being good cus- tomers. Greatest Obstacle Mutual Recovery What are these obstacles which the farmer, with his great political in- fluence, can effectively help re- move? The greatest obstacle the present reluctance private capital invest money private enterprise. The amount funds flowing into se- which normally provide capi- tal for the capital goods industries has shrunk from 10-year average from 1921 1930 $4,000,000,000 year present average but $160,000,000 per year 1933. per cent reduction. This was clearly revealed the recent report the Durable Goods Committee the Presi- dent. The committee, consisting eminent industrialists appointed the Administration study and re- port the capital goods situation, cited the following conditions requi- site the recovery the capital goods industries and the consequent reemployment the remaining large number unemployed: (a) free flow private capital into private business. (b) sound real estate mortgage busi- ness, (c) Industrial relations basis which will assure cooperation instead strife. (d) price between agricultural commodities and manufac- tured goods. confidence—most important all. essential the establishment confidence, the committee cited the following: (a) Assurance enterprise that the profit incentive will continue receive public approval energizing motive for economic activity. (b) Publie recognition that the only legitimate purpose taxation pro- vide the necessary revenue for govern- ment and not effect punitive redis- tribution wealth which paralyzes busi- ness initiative for any other purpose. (c) Removal through permanent bal- ancing the budget the threat un- controlled inflation. (d) Removal any remaining threat sudden and arbitrary change our monetary policies. (e) Assurance that companies which have adjusted their business methods and the temporary emergency pro- NRA will free from the un- certainties unreasonable arbitrary (f) Clarification the toward measures trends Which are inconsistent with our economic System. Restoring 25,000,000 Farm Customers The work this committee not merely behalf the industries that JOHN VAN DEVENTER Editor, The Age its report has covered, nor behalf the unemployed those industries. great interest agriculture, indeed vital interest you these days agricultural surpluses. try- ing find the way restore full buying power 25,000,000 your former customers that they may buy more wheat, more cotton, more meat, more dairy products. you suppose that these unfortunates now buy oranges grape fruit new cotton sheets pillow cases any the hundreds farm products that they must their poverty now un- willingly consider Think what tremendous stimulus agricultural-product consumption would follow the restoration earn- ing and spending power the un- employed workers the capital goods industries who represent this great market. This your problem much industry’s problem. say you that would great public ser- vice agriculture the cooperatives this country represented here such impressive membership would study carefully this report the Durable Goods Committee, comes conclusion the soundness its facts and its recommendations and then officially express this conclusion the President, the National Re- covery Administration and your Congressional representatives. Mutuality Interests This illustration mutuality interest between agriculture and in- dustry that have cited but one many. could multiplied many fold. Have you for instance, what the determined effort “close shop” American industry and turn over union labor, with its seniority rules and its restrictions output, will cost the farmer should successful? not, may illumi- nating figure what proportion your return for bushel wheat must paid for freight today compared with the proportion paid for before the war-time capitulation the railway brotherhoods. You may imagine that agriculture immune from the effects such legislative measures the Wagner bill the Black 30-hour bill, because there has been drive undertaken yet unionize farm labor there has been industrial labor. But you are not immune. these measures eventuate, you will help pay the piper willy-nilly, for the con- tents the farm working hour that you exchange for the contents the industrial working hour selling and buying—not dollars. Necessities for Prosperity Industry, turn, may imagine that has immediate interest what happens the farmer under AAA, curtail the farmer’s buying power for the purchase manufactured goods. But that not true, the best minds industry already well know. Agri- culture must make real profits its own right make good long-term customer for industry, exactly in- dustry must good long- term customer for agriculture. Neither one, Government dole subsidy, position contribute soundly the other’s prosperity. Agriculture has job self-inter- pretation industry and indus- try has one agriculture. Industry would give great deal know whether the objective self- government through cooperative ef- fort, promised NRA, will sustained higher authorities, overthrown them. should think that agriculture would want know the answer this question, too, (Concluded Page 78) The Age, July 19, 4 How Finish Hel metal part wears down similar way, coatings hard metal may successfully applied soft metal production work. metal subject cor- rosion may coated with zinc, cadmium, aluminum, that will resist corrosion under differ- ent conditions. This process metal spraying relatively new this country, and the possibil- ities the method fabricat- ing means industry are just becoming apparent This series being prepared under the direction Mr. Simonds for The Age. Mr. Tickle charge metal spraying the Arthur Tickle Engineering Works, Inc. conditions, onto solid metal surface will adhere that surface with tenacity which, for many purposes, satisfactory were actually part the sur- face metal. This fact the basis recent development metal finish- ing known metal spraying and ap- parently destined become im- portant industrial process. Powder spraying, the atomizing ‘metals for decorative purposes such gilding, very old art— older fact than the Christian era —but that art the tiny particles used invariably were made from the solid metal. The modern sprayed molten metal coating process, which given credit for originating, may described follows: Metal the form wire fed automatically into oxygas flame where melted. The thin stream molten metal broken into finely divided condi- tion means powerful jet compressed air, and finally carried projected onto prepared metal sur- face. molten metal blown, under During this operation, metal transformed from wire into sheet metal which, many applications, mentioned, may considered integral part the base metal. The Iron Age, July 19, 1934 metal thus applied made multiplicity semi-molten plastic particles, which are flattened out impact and interlocked with the base metal and subsequently with each other. The apparatus for processing ingenious instrument called spray- ing pistol which uses oxy-acetylene, oxy-hydrogen, oxygen and city gas for melting the wire. the expe- rience The Arthur Tickle Engi- neering Works, Inc., Brooklyn, which probably the chief exponent the sprayed metal process this coun- try, the wire ranges size from pushed into the nozzle the pistol uniform rate that, the end the wire melted and atomized, the position the end with respect The best size wire use has been determined careful tests, and varies for metals sprayed. Different sized tips are used correspond the wire The process metal spraying present most extensively ysed building worn parts such crank shaft bearings, valve stems, and guide rods. One the routine jobs handled the Tickle plant the building plating press cylinders, and description this more less stand- ardized process will serve explain the nature metal spraying. The cylinders are in. long and in, diameter, made fine grain gray iron casting with blowholes. These cylinders develop hollows service. This possibly due cor- Fig. metal spraying pistol may mounted the tool rest ordinary lathe. Revolutions work about twenty per minute. Feed about 1/32 in. ct Re re it re, j q the end spect been and used wire ndled Iding ind tand- plain The holes. lathe. Metal Products Sales rosion from the acid cleaner used remove ink. The job repairing such cylinder two-fold, first, build in., and second, apply coating stainless steel which will protect against subsequent corrosion similar character. The cylinders, after reaching the Tickle plant, are first calibered and then turned down uniform diam- eter. They are then sand blasted and placed the spray machine for coat- ing. The spray machine essentially lathe with two more spray pis- tol attachments mounted the tool slides. two spray pistols are used, one placed the end the cyl- inder and the other the center, and the feed then arranged that the entire surface covered both pistols through half the length the cylinder. The pistols are set that the point where the wire melts about in. Fig. 2—Interiors Diesel engine pistons are coated with aluminum and zinc Protection against temperature and cor- rosion. 22—Coating with Sprayed Metal from the surface the cylinder. The cylinder itself revolved approxi- mately r.p.m., and the feed the pistols across the surface about 1/32 in. per revolution. this means uniform layer stainless steel, the depth 1/32 in., will applied about hr. What Happens Spraying Comparatively little known about the microscopic structure the coating applied spraying. When Fig. containers used the food industry are easily coated with pro- tective metal spraying. the tiny molten metal particles are hurled through the air great force, they come rest they splash against the rough metal surface, and doing they flatten out and inter- lock with the surface irregularities and with each other. Each tiny par- ticle flattened into microscopically thin and when realized that the structure the sprayed coating consists mechanically interlocked scales, becomes obvious that there will loss tensile strength and gain porosity compared with the original solid metal the wire. Despite this, properly applied sprayed coating will exhibit some re- markable qualities. Valve stems used marine engines are repaired after Fig. 4—After little practice operator able apply metal tanks about simply would spray paint. packing wear spraying high car- bon steel the worn mild steel shaft, and these repaired shafts have never been known wear down again, although the work has been going for several years. the opinion the Tickle company that the sprayed coating high carbon resist wear this particular serv- ice than would ordinary rolled steel shaft with case equal hard- ness that the sprayed metal coat- ing. The theory that the slightly porous nature the sprayed coating becomes self-lubricating after oil has been applied, because the oil sinks deep into the pores the coating. The individual particles the sprayed coating must exceedingly The Iron Age, July 19, 1934—15 minute because they not interfere with accurate grinding and polishing. Printing press cylinders, after spray surfacing, are ground tolerance within 0.0002 in. Technique Spraying The preparation the surface determines large measure the degree adherence the coating. good method blast the surface with steel shot high pressure. This cleans and roughens the surface and leaves small elevations and depres- sions, keys. actual practice the Tickle company never allows un- coated surface remain more than hr. without applying metal. This eliminates any chance oxidation the surface, the gathering mois- ture dust the surface. Every effort should made con- trol the melting the wire evenly obtain fine grain metal structure. This important for two reasons. First, the metal lumpy not uniform its application, the tiny particles will too large fit the crevices made blasting the base metal surface, and insecure bond will the result. Second, the applied metal will not have adequate density and will therefore permit access moisture. Also, the metal structure will weak “powdery.” must remembered that the mechanical bond the process depends upon properly roughened surface, and upon properly melted and atomized sprayed metal coating. wide range metals may successfully applied among which are high carbon steel, aluminum, lead, zinc, tin, copper, bronze, brass, nickel, monel, stainless steel, silver, gold, molybdenum, tan- talum, and nichrome. fact any metal can sprayed that can ob- tained wire form and that has melting point within the range the heating mechanism the pistol. One the variables spraying which must watched carefully the distance from the pistol the work. About five inches the usual distance. Other variables are: Speed work r.p.m. Feed travel pistols. Air pressure, Temperature. Spraying Pistols typical American spraying pistol shown accompanying illustra- tion. The nozzle may considered consisting three concentric tubes. The wire sprayed advanced through the central one, the gaseous 16—The Iron Age, July 19, 1934 mixture (acetylene with oxygen) through the next, and the compressed air through the third outer an- nular space. The gaseous mixture, burning the orifice, melts the wire the inner part the conical flame, and the compressed air accomplishes the atomizing and spraying the wire feed mechanisin the pis- tol employed draw the wire from coil and feed through the oxy- acetylene flame where melted Fig. 5—This shows the English type pistol. uses reservoir molten metal while the American type uses wire fed into melting frame. fast emerges. The driving mech- anism for feeding the wire small air turbine driven the compressed air used for spraying the metal. The range from lb. The com- pressed air pressure ranges from The English method somewhat different from that described above, the following quotation from Mel- lowes Co., Ltd., Sheffield, will indi- cate: “All metal work must sand- blasted before spraying, remove any rust scale, and provide suitable surface which the metal spray can adhere. With other mate- rials only necessary for the sur- face dry and free from grease. “The metal sprayed first melted small gas heated crucible, from which the container the pis- tol filled about every min. Bunsen type flame under the contain- er, the gas for which obtained connecting the pistol the ordinary gas mains means rubber hose, keeps the metal molten condition while spraying. The pistol also con- nected rubber hose com- sq. in., and when the molten metal flows the nozzle meets the pre- heated compressed air, which very finely atomizes it, that the minute particles metal are blown against the surface covered tre- mendous velocity and adhere firmly, forming continuous metallic coat- ing with fine matte finish. “The thickness this coating ap- proximately 0.004 in. and the speed application sq. ft. per min., but this coating can increased any desired thickness allowing the pistol travel slower rate across the surface sprayed.” special type pistol has been developed America for coating the inside long tubes and pipes with soft metals. This pistol has tiny re- volving nozzle its tip, which throws the metal particles laterally against the walls the pipe. With this special pistol, pipes 1-1/4 in. inside diameter and ft. long have been spray coated. Applications description few actual metal spraying jobs, performed the plant the Tickle company, will serve illustrate some the prac- tical details the process. Two Medart rolls, one approximately in. diameter and in. long, and the other, hour glass, in. the largest diameter and in. long, were successfully repaired. These rolls are used for straightening brass and bronze rounds in. diameter. The bronze bgrs, after extrusion, are pushed through the rolls which pol- ish and straighten them for finished stock. The rolls are subjected ter- rific wear and heavy pressure the same time. When these rolls were received for coating, they were worn about 1/16 in. They were built with high car- bon steel and ground original size, and are now service where the new coating expected show better wearing qualities than the base metal. tail shaft for yacht, ft. long and in. diameter, with two bronze bearings, was received for re- pair. Between the two bearings the steel shaft was badly pitted and cor- roded. Adjacent the bearings the steel shaft, the condition the shaft was particularly bad. The stern gland liner was worn. paired follows: The two low, badly corroded areas i | a, | ters hose, dition con- com- per metal pre- very rainst tre- coat- ap- speed min., the rate been the with which With in. have metal the will prac- Two in. the the were are and The are pol- ished ter- the for 1/16 car- size, new etter two re- the cor- the re- 7 adjacent the bronze areas were filled with low carbon iron, bring- ing the shaft back size. The steel shaft, for distance ft. between the two bearings, was then sprayed with cadmium resist salt water corrosion and the reoccurrence this condition. The tail end bearing was built with phosphor bronze and turned original size. This job was done great saving time and expense, with the repaired shaft bet- ter than new one. closing machine valve and seat, which are the main parts vacuum pack machine, were worn and were giving inefficient service. The valve was in. diameter with 12-in. face. was built with high car- bon steel and ground size. The seat had developed several low areas. These areas were filled separately with alloy metal and machined suit the temperature the valve. The machine now running with the saving per cent. the automobile industry many parts are reclaimed advantage metal spraying. Crank shafts are built the journals and ground original size. Rear axles and king pins are similarly prepared, using hard wearing metal for spraving. Leaky cylinder blocks may filled with alloy metal where hair line cracks develop between the valve seat and the cylinder. Wear resistant metal, such alloy steel, has been successfully used coat brake drum lining faces. Another application that gaining favor repair automobiles the spraying aluminum the com- bustion chambers high pressure motors. This retards carbon and aids complete combustion the gasoline. recent development applying high speed babbitt for bearings bids thickness 1/64 in. 1/16 in. may applied, and such coating used cases where was only practical use bronze the past. Apparently babbitt, when sprayed, free from blowholes defects the finished layer, and the bond, when the base metal prepared blast- ing, better than most cases where the babbitt poured hot into place. Another valuable feature the babitt the control the composition. Not only may coat- ings the purest metals applied, but two metals may applied simultaneously successively merely altering the mechanica! fea- tures the spray pistol. com- bination zine and aluminum has been found excellent for resisting the corrosive attack atmospheres high sulphur dioxide. example the practical ap- plication aluminum iron illus- trated the coating drum used for extracting caffeine from coffee. The drum question ft. diameter and ft. long, and sub- ject great changes temperature use, and also the action solvents used the process. orig- inally made, the drum had coating enamel the interior, but con- stant expanding and contracting un- Fig. tanks the chemical in- dustry are spray coated with aluminum. Air Blast Mixed Gases -Wire Fig. 7—This section through the nozzle the American type spray pistol. There are three concentric spaces, one for the wire, one for the melting gases, and one for the air blast. der temperature changes caused this chip off. The aluminum applied 0.015 in. thick, and not only has been successful protective layer, but was found that the flavor the coffee has been improved. Some Advantages Since preheating done during the spray coating part, some objectionable features welding are eliminated. unnecessary dis- mantle equipment order facili- tate repair spray coating. The worn mis-machined sections can treated without interfering any way with the rest the equipment. After the coatings are applied they may used their unfinished state, which matte sanded surface. They can filed, ground polished just the same ordinary metals. sum up, any metal can applied the same metal any other commercial metal, and any base surfaces such wood, plaster, stone, glass, concrete, rubber molded Sprayed metal coatings may used many cases for protecting ferrous metals against corrosion, but the process not simple just applying any non-corroding metal steel. The electro-chemical theory corrosion must followed through closely the application sprayed metal for protection. Zine anodic towards iron and close the electro- chemical series. corrosive conditions natural protective coat- ing compound (hydrocarbon- ates and oxychlorides) forms and adds materially the life the zine. sprayed coating zine for at- superior zine coatings applied other methods. Zine can applied thicker and there are fluxes traces acid present the base. has been shown many cases that protective coating cadmium pos- sesses distinct advantages over zinc. Cadmium stands closer iron the electro-chemical series and will not, therefore, deteriorate quickly zine account anodic attack. protects like zine accordance with well-established electro-chemical principles, and far more resistant the attack acids chlorides. One the most practical and economical methods producing protective coating aluminum steel metal spraying. Aluminum anodic iron and resistant much chemical action. For the pro- tection steel, which exposed high temperatures, sprayed alum- inum has been found to: Retard oxidation. Prevent clinkers from adhering surface. Increase the life the object from four ten times. extreme cases heat treatment applied the coated piece, the aluminum thereby penetrating considerable depth, and consequently raising the resistance still higher temperature range. Governmental tinkering with the industrial structure, regulation, attempted regimentation and other artificial restrictions and handicaps imposed upon industry are Farrel-Birmingham Ansonia, discussions economic and business topics current interest. The Iron Age, July 19. 1934—17 New Methods Extrusion EARLY quarter million tons lead are required each year this country for cable and electric conductor covering, and practically all this heavy tonnage applied extrusion. Therefore, any improvement the art ex- trusion assumes widespread impor- tance. Starting with this hypothesis, Sherman John Robertson Co., Brooklyn, recently began ex- haustive investigation the subject attempt improve not only dies and equipment, but principally improve the quality extruded lead products. cylinder and then pressure squeeze the lead out through opening, you will have extruded product its crudest form. The nature such product will depend upon large number variables, which the following are few the most important: Design dies through which the metal extruded. Design cylinder contour. Pressure. Iron Age, July 19, 1934 HERBERT SIMONDS Temperature metal time ex- trusion. Bond between the metal and the walls cylinder. Two processes extrusion for lead are general use today. These are called the poured-in process and the slug process. process results closer bond be- tween the metal and the walls the cylinder and therefore under pres- sure there more “working” the metal before reaches the extruded form. This process develops products much better quality than the other process, but somewhat more ex- pensive. the slug process, billets lead are placed the press solid form and extruded promptly. For most ordinary equipment possible practically double the ca- pacity this method. Therefore, widely used where quality secondary importance, the case when lead tube used mold for making rubber hose such garden hose. this case the rubber products are vulcanized the lead covering, and the lead subsequently stripped off and remelted peated use. Other products extruded this slug process are solder wire and shapes and strips used for gaskets and for decorative molding. Inasmuch Mr. Sherman’s work was designed primarily improve the quality the extruded product, was carried almost entirely connection with the poured-in process. test cylinder about in. diameter and in. long was designed that the billet could readily re- moved any point the process. This cylinder was preheated 220 deg. Fahr. the start, and decreased 202 deg. Fahr. the time the last slug was removed for photographing. The lead used was new pig Omaha and Grant, and this was melted small pot and then poured into the test cylinder. lubricant was used, and setting pressure tons was applied for period min. Figs. 1-6—This sequence six views shows the crystal structure different stages the extrusion process. The one the left was taken just after extrusion had started under pressure The others sequence were taken during the extrusion full cylinder, each interval representing the lowering the metal the cylinder in. a mold ibber lead ently ruded wire for ding. work prove igned re- 220 eased last hing. the used, tons min. 7 Improve Lead Sheath After this the pressure was increased tons, when extrusion started. The first slug was then removed, cut longitudinally, then etched and photo- graphed, and the crystal structure shown Fig. was the result. Studying Grain Structure The second slug was made re- peating the process, that is, pour- ing lead into the test cylinder the same height for the first photo- graph, applying the tons setting pressure for period min., and then again increasing this pressure about tons cause extrusion. Extrusion was continued until the piston applying the pressure the cylinder had moved down other words, the second slug was re- moved after extrusion had continued until in. the metal the inder had been used up. The second slug was then removed and photo- graphed the same way was the first. This process was continued until the height the metal remaining the cylinder had been reduced in. The successive photographs show the different stages. will noted that the metal tends cling the side the cylinder, thus forcing the center portion down into the dies first. The grain structure the base the slug keeps improving the working the metal breaks the larger crystals, and finally, Fig. homogeneous close-grained product secured. The reason that tests were made without the use any lubrication due the fact that this the desired practice because the introduction lubricant frequently causes dirt streaks, especially the time re- filling when particularly desir- able have the surface the old metal the cylinder clean pos- sible. studying the photographs was possible follow the move- ment the through the various sections the dies, and, from this, redesign the dies for better metal working conditions and therefore bet- ter grain structure. example, die with sharp recess has tendency hold metal stationary such recess, with the result that the dies are never thoroughly clean old metal. the process coating cable, die design particular importance be- cause the metal separates surround the cable and meets again the op- posite side, giving cause for weak point the junction. This weak point can overcome using the proper design die and being sure keep the metal absolutely clean. attempt correct any possi- bility separation and joining the inflowing metal, some designers de- viated sharply from the type die block shown Fig. and completely surrounded the core tube with com- previous extrusion. This type die, while overcoming some the difficulties, developed new ones, and means new art. Scotch firm sent extrusion press firm Pennsylvania before the Civil War, and the same press (with some new parts) oper- ation today. However, the possi- fabricating, have been glimpsed but recently, and many companies are now producing planning produce shapes and forms thought impossible make extrusion even late 1925. The accom- panying article describes some the research work now being done this interesting field under the its use has therefore been somewhat limited. Design Dies Fig. illustrates the basic principle applying lead sheath cable. Here the die block consists core tube die, both These leave adjustable opening between the core tube and the die, which furnishes means for con- trolling the thickness and diameter the sheath. The entire block assembly placed underneath large cylinder for receiving molten lead, and both are then placed hydraulic press. John Shea, the Western Elec- tric Co., describing the method coating cable for the Bell Telephone System, says: “The latest type press used Baltimore known the 34-in. inverted press. Its stroke in. and the diameter the ram 10% in., giving lead alloy ca- pacity 1800 lb. per charge, and maximum extrusion rate 5680 per hr.” Presses this type, which are shown Fig. are ft. height above the floor-line, and have the water cylinder mounted between the four columns the top the press. The water ram, which in. diameter, bolted direct the lead ram, which 10% in. diam- eter, and this way when hydraulic pressure applied the water greater pressure the lead cylinder. actual practice, water 5500 lb. per sq. in. used, which exerts pressure approximately 59,000 per sq. in. the lead. The machines are ruggedly built, and the dies and other parts are stationary, facilitat- ing handling the cable and insur- ing that the cable core always enters The Iron Age, July 19, 1934—19 7 7 7 gue — LEAD CYLINDER \ \ \\\ \ \\\\\\ Fig. 7—The die block used for lead coating cable designed protect the cable from the lead. and leaves the die block the same angle. Concentricity the sheath one the important considerations, and not only rugged construction important for this, but uniform ap- plication heat also factor. one part the sheath ap- plied warmer than another part, the uniform pressure will produce eccentric wall. Another factor speed ex- trusion, which usually controlled trained operator. Indicating in- struments are used show not only temperatures various parts the die block, but temperature the molten lead and the cylinder itself. Temperatures different points are automatically controlled. the lead covered cable leaves the press wound either wood steel reels, depending upon its type. full reel may weigh much 10,000 and the modern type machine, such reel when automatically 20—The Iron Age, July 19, 1934 ejected means small hydraulic cylinder. One important feature extrusion lead the introduction the new Formerly, such lead was delivered skids overhead traveling crane. The new described Mr. Shea, consists melting the lead alloy large furnace central location, and distributing thi molten lead through long-loop pipe- line running back the presses. This line returns the furnace closed circuit. The line itself electrically heated and the lead kept con- stant circulation. order take full advantage such system, the presses were placed close together, indicated Fig. The central furnace, heat- ing unit, consists three oil-heated kettles, the middle kettle being used for melting and preparing the alloy. One the outside kettles used ¥ main supply connected the dis- tributing system, and the other spare which may cut into service replace either the others. Each kettle has capacity 120,000 lead, and the melting capacity the system 80,000 per hr. Charging the metal kettle means special cable which in- troduces 100 billets standard size charge. The antimony in- troduced separate chamber be- low the surface the lead. Pipe Line for Lead The main-line piping made seamless steel tubing sup- ported roller-conveyor system take care the expansion and con- traction which amounts in. per 100 linear ft. 750 deg. Fahr., under normal working conditions for the system. The down spouts are seamless steel tubing and have steel valve each joint with the main line and service valve one corner the bend. All joints are oxy- acetylene welded, and fittings are used throughout the system. The lines are insulated with pipe cover- ing protected layer fireproofed canvas. They are heated initially series transformers which supply low-tension, high-amperage current directly into the pipe forming loop the supply and return line. Once circulation the lead has been established the piping system, the main line requires little additional heat from the transformers, Baltimore battery modern extrusion machines cover cable with lead alloy the rate 56,800 Ib. the alloy applied per hr. flo fo tic ir dit the 7 1 vice size through the die block. The bond between the moving metal and the sup- con- in. Fig. 9—In manufacturing garden for machines shown, for re-melting and line flow the lead ordinarily keep extrusion press passes over one the slack provides for the slight move- the line temperature. Approxi- more rollers and later wound ment the reel after the press has mately kva. are required each reels. space considerable slack stopped. Some manufacturers have are down spout while use. the cable left between the reel automatically governed the speed The This system has been operation supports and the reels, order the reel means idler which ver- for about nine months and has re- take any unevenness between the rests the slack cable. the reel ofed sulted higher quality lead speed extrusion and the positive movement too rapid, the cable will sheath due more uniform composi- drive the reel. This slack neces- tend rise, moving the idler and tion maintained. -In addition there sary any case where the operation operating electric regulating de- are considerable savings fuel, re- interrupted, because impos- vice. Similarly, the cable droops duction dross, and elimination sible stop the heavy weight the too much, the control large amount heavy manual ef- lead sheath all instantaneously, and speed the movement the reel. fort. The press room now clean and cool, resulting much better direct improvement the quality Assembling Automobile Knees Fair the the product. ONE the operations the with the deep pressed-steel channel Automatic Reel Control Chevrolet car assembly line that takes the place the conven- the Chicago Fair the mounting front axle. The front end cross- One the difficulties most knee action units the inverted member, knee actions, brakes and the extrusion processes now prac- chassis frame. The underneath ap- steering connections, which together tical use the necessity for inter- pearance the new construction form single assembly, are made rupting the operation regular in- the accompanying photograph shows Detroit for all the Chevrolet car as- tervals order recharge the cylin- the extremely rigid front-end member, sembly plants this country. operation have been tried, including q | a these methods have been discarded for the .single-cylinder poured-in process which present gives the best results. Presses for this method duction with greatest efficiency. A —, The Age, July 19, MECHANICAL coupling for high torque service, although may serve flexible con- nection between motor and load, can- not classed flexible coupling be- cause its chief function the auto- matic acceleration high inertia torque loads. Certain couplings this type due their construction are ca- pable moderate amount flexibil- ity, which some cases may ample for the requirements. Where ex- tremes lateral angular mis- alinement are probable, resort should made regular flexible coupling conjunction with the high torque coupling. The principle the coupling question similar the high start- ing-torque clutch that must constructed allow appreciable period automatic slip before the actual driving surfaces contact. accomplish this mechanically, the ac- tion centrifugal force utilized. efficient and dependable device for this service, known the slip- WILLIAM STANIAR Mechanical Power Transmission Engineer ring starting coupling illustrated Fig. 81. Its chief function con- nection with constant speed motors driving apparatus possessing heavy its object being impart the driven machine slow start with uniform accelera- tion. relieves both motor and ma- chine undue strain and shock, and addition renders unnecessary elab- orate electrical mechanical starting equipment. The motor can started simple switch, and, with further attention from the operator, the driven machinery brought full running speed the maximum desired rate. Slip-Ring Starters The slip-ring starter composed three elements: the spider, the fric- tion band and the drum. The spider keyed the motor shaft, while the drum keyed the driven shaft; the friction band weighted and lies inside the drum, one end engaged pin projecting from the spider the Right Drive—13 which the friction band pulled. The rear trailing end the band free. the motor accelerates, cen- trifugal force causes the band ex- pand and exert frictional drag the drum, the torque thus transmitted depending upon the speed, diameter drum and weight fric- tion band. Torque transmitted this device practically independent co-efficient friction, characteristic which differentiates from the aver- age frictional device. This results constancy which novel and ap- parently variance with previous en- gineering experience. actual installation this device shown Fig. 82. The driven ma- chine centrifugal dryer with ex- tremely high starting-torque. was originally driven hp. motor which started under 300 per cent over-load taking sec. reach full speed. The illustration shows hp. motor “across the line” started equipped with h