The Iron Age 1934-11-29: Vol 134 Iss 22

mea- THE IRON AGE ber 29, 1934 Editor Managing Editor Consulting Editor News Editor Machinery Editor the Pittsburgh Detroit Boston Cleveland Emeritus Washington Cincinnati ride the bud- un- ontents CODE 1934 Peace and Good Will Toward Men ing Registration Pearlitic Steels for High-Temperature Service Combined Wire Drawing and cut reached Blast Furnace Fuels ton and revolve} How Commerce Department Aids Machinery Industry stant. High Pressure Die Castings also Thirty-Hour Week Will Lower Living Standard and New Equipment high- itil the ich the Washington News button table Automotive Industry min. used Personals and Obituaries can selector Markets ion ,,Construction and Equipment bottom Advertised unusual the Index Advertisers anel are rranged THE IRON AGE PUBLISHING COMPANY S$ The F. J. FRANK, President G. H. GRIFFITHS, Secretary ©. 8. BAUR, General Advertising Manager corre PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. push EXECUTIVE OFFICES: 239 West 39th St., New York, the dicators. ADVERTISING STAFF show Member, Audit Bureau Circulations Emerson Findley, 311 Union Bldg., Cleveland the ram Member, Associated Business Papers Herman, 675 Delaware Ave., Buffalo, hree ; H. K. Hottenstein, 802 Otis Bldg., Chicago thr Published every Thursday. Subscription Price: Peirce Lewis, 7310 Woodward Ave., Detroit feed United States and Possessions, Mexico, Cuba, Charles Lundberg, Chilton Chestnut minute. $6.00; Canada, $8.50, including duty; Foreign 56th Sts., Philadelphia, Pa. P $12.00 a year. Single Copy 25 Cents. ©. H. Ober, 239 W. 39th St., New York om this W. B. Robinson, 428 Park Bldg., Pittsburgh rows all Cable Address, ‘‘Ironage, Sweetser, 239 West 39th New York station- D. C. Warren, P. O. Box 81, Hartford, Conn. coolant EIGHTIETH YEAR SERVICE THE METAL WORKING INDUSTRY set. | | | | | THE IRON 29, 1934 Page The Only Stock ries the only stocks Nickel Steel Plates (.30-.40 carbon). These plates may flame cut special shapes relatively low cost. Flat alloy bars most any width are also cut from them. longer need there delay securing special shapes and fiat sizes alloy steel. Draw these stocks. Save Money with V.D. Ryerson V.D. Tool will get harder—change shape less —and retain finer grain struc- ture than most other water hardening tool steels. Judge V.D. solely its merits. Let prove that gives superior performance lower costs. Try few bars, ask for free sample test. Flame Cut Vs. Cast Many have replaced their former expensive castings and forged parts with rolled steel plate flame cut shape. Ryerson equipment will burn the shapes from steel almost any thickness and any quality. cuts, holes and cut outs are made readily outside cuts. Write for complete data this service. Special Steels full range special alloys, tool steels, and heat resisting steels are immedi- ately available through the Ryerson Steel-Service plants. Stocks include all the major specifications wide range sizes. Experienced engineers and steel men are always ready help with any your steel problems. WRITE FOR THE RYERSON STOCK LIST—“KEY” IMMEDIATE STEEL. JOSEPH RYERSON SON, INC. Plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City ESTAI 4 | = 7 | : ! q 7 4 4 7 7 ESTABLISHED 1855 NOVEMBER 29, 1934 Vol. 134, No. Peace and Good Will Toward Men most heartening development. Moods mean more than statistics. nation which has been drinking deep the cup bitter- ness and despair for five long years, emotional excesses are finally passing and calmer counsel gaining hearing. The state mind which demanded action for the sake action and bold experimenta- tion regardless risk giving way spirit growing caution. Not that experimentation has entirely failed, but rather that those who led the blazing new paths have learned the difference between theory and practice and are now ready give ear business experience. accepting the olive branch extended the Administration, business has both opportunity and responsibility. Its oppor- tunity lies allaying unnecessary fears and bolstering confidence, and, most important all, devising constructive and practical plans for stimulating the revival private enterprise. Its responsibility embraces fuller appreciation the Administration’s continuing problem providing relief for the idle and overcoming the spirit unrest, animosity and vindictiveness that adversity has instilled into the unfortunate. condemn blind radicalism not destroy it. The idle, and especially the new generation youth now search- ing vain for work, provide ready tinder for the demogogic spark. want Hitler this country. But that danger waning rather than waxing. Faith panaceas passing. Discrimination replacing generalization. The sins the few are longer attributed the many. Business, labor and Government are beginning recognize that recrimination must give way collaboration. While organized labor has chosen con- tinued strife preference the generous terms truce offered the great steel industry, its decision out keeping with the prevailing spirit the time. may hinder, but, with determined leadership Washington, can not prevent the growth ation and concord nation weary agitation and contention. Peace and good will toward men, appropriate the Christmas season approaches, promise finish the task surmounting the obstacles business recovery. LACHER, Managing Editor, The Iron Age. the nts. ajor nge ady teel Pearlitic Alloy Steels For improvements processes oil refineries and steam power plants order capitalize the benefits higher operating temperatures and pres- sures have created large demand for alloy steel tubing. The highly-alloyed steels were the first special materials selected for high-temperature service because they had the unique exhibiting excellent high- temperature strength well corrosion and oxidation resistance. While the large initial costs the stainless steels are justified many cases, there are some applications for which low-priced pearlitic alloy steels, though less re- sistant corrosion and oxidation, would more economical. The authors herein discuss the properties pearlitic alloy steels and show how such steels are admirably suited for applications that are too severe for carbon steel but for which the stainless steels would not economical choice Thus shown that the pearlitic alloys will give dependable and long service tem- peratures from 1000 1200 deg. alloy steels for high-temperature service may defined steels containing small amounts one more the special elements molyb- denum, chrome, tungsten, vanadium, nickel and aluminum. The amount special elements seldom ex- ceeds per cent, and only one-half per cent the standard carbon- molybdenum type. Each these low- alloy steels will offer certain corrosion and oxidation resistance, high-tem- perature mechanical properties, and stability governed the individual chemical composition the material. one time was supposed that all pearlitic steels would show substan- tially the same creep characteristics plain carbon steel. This impres- sion has since been corrected after was demonstrated that many pearlitic alloy steels have higher creep strength than carbon steel and some have near- great resistance creep the 18-8 stainless steel temperatures Carbon steel can used success- fully temperatures 900 deg. Broadly speaking, the stainless practical purposes the pearlitic University Michigan; Research Engi- neer, Department Engineering Re- search, University Michigan, and Metallurgical Engineer, The Timken Steel Tube. Co. Iron Age, November 29, 1934 steels are capable satisfying gen- eral service requirements pos- sibly 1500 deg. The pearlitic alloy steels are intended for applications that are too severe for carbon steel but not sufficiently severe necessi- tate the use stainless steels. The pearlitic steels have working temperature from 900 1200 deg. The commercial impor- tance these steels has prompted the authors give them fuller descrip- tion than they have been accorded heretofore. Most the data has been taken from researches completed re- cently selected group steels that are now regular use are suited specific applications high- Comparisons have been drawn against conven- tional killed plain carbon steel, which simply pearlitic steel without al- loying elements. The chemical composition, heat treatment, hardness and grain size five selected alloy tube steels are given Table together with similar data for killed plain carbon steel that has been used for comparisons. The DM, and 4615 are steels developed exploited the Timken Steel Tube Co. for various high-tempera- ture applications, and the C-Mo and 4-6 Cr-Mo are steels made that company conform with the analyses Manufacturers’ Standards No. 100 and No. 200 respectively. All the steels investigated were made the electric furnace avoid unfair comparisons dissimilar anal- yses when one steel might normally produced the electric furnace, another the open-hearth furnace. The 4-6 Cr-Mo steel logically steel made the electric furnace be- cause the relatively high chromium content, but the plain carbon and C-Mo types are usually open-hearth steels. The DM, and 4615 steels though the electric furnace grade recommended for important high-tem- perature applications. With the exception the 4-6 Cr-Mo steel, which normally has grain size determined the car- burizing test, the steels would classified coarse-grained materials 4-5 grain size. The DM, 4-6 Cr-Mo, C-Mo, and carbon steels were fully annealed obtain stable structure low hardness. The samples MM9 and 4615 were normalized and tem- pered develop better high-tempera- ture properties and good stability for continuous operation temperatures 1000 deg. The hardness all the steels low enough assure satisfactory manipulation tubes users. Ductility Gains With Temperature Rise The ultimate strength, yield strength and proportional limit deter- mined the short-time tensile tests elevated temperatures may serve the basis tube design the proper factor safety employed. Even the cases when tubes are designed with the long-time properties view, the yield strength the short-time tensile test becomes measure the casional overloads. Table shows the short-time tensile properties the pearlitic alloy steels selected for study. The general tendency for the steels elon crea neig the pact beer | men pera loys posi proy func pera and the High- emperature Service alyses 100 were avoid anal- rmally rnace, steel and steels ade h-tem- Cr-Mo No. car- terials fully ucture MM9 tem- npera- ity for atures ess assure bes ature yield deter- tests proper ven signed view, the the the study. steels lose strength and gain ductility the tem- perature increases. The elongation value de- creases somewhat the neighborhood 900 deg. 1000 deg. F., corresponding the brittle range observed hot im- pact tests the same steels. Aside from any usefulness that may attached the tensile properties such, the tabulation demonstrates other points interest. has been known for some time that the initial physical condition steel affects the high-temperature proper- ties. contrasted with annealing, the normalizing and tempering treat- ment seen give high ratio proportional limit ultimate strength that persists until fairly high tem- peratures are reached. Beyond 1000 deg. the effects preliminary heat treatment are not noticeable. Among the annealed steels are al- loys quite different chemical com- position that show much the same properties room temperature. This often not recognized and has led misunderstandings regarding the function the alloying elements the special steels. Elements can added steel retard creep im- prove the corrosion oxidation re- sistance the alloy without making significant change the room tem- perature properties the fully an- nealed steel. also noteworthy that the and 4-6 Cr-Mo steels, which exhibit the best combination short-time tensile properties 1400 deg. F., are the only two steels the list that transform temperature above 1400 deg. The carbon change-points the other four steels fall between 1300 deg. and 1400 deg. F., that heating 1400 deg. has already started the transformation these steels. This probably accounts part for the disappearance the propor- tional limit the C-Mo, MM9 and carbon steels 1400 deg. The creep the six steels was mea- sured temperatures ranging from 800 deg. 1300 deg. The single- step method loading was employed with not fewer than four different stresses applied each steel each temperature. The tests were con- ducted for periods ranging from 500 1600 hr., and the elongation due creep was determined means optical extensometer system sensitive 2.8 millionths inch per inch the standard tensile specimen. While few any creep tests have been conducted for very long periods time, customary report re- sults terms the stresses required produce creep the rate one per cent 100,000 hr. and one per cent 10,000 hr. well one per cent 1000 hr. The practice founded the assumption that creep rate 0.01 per cent 1000 hr. and 0.10 per cent 1000 hr. are equivalent one per cent 100,000 hr. and one per cent 10,- 000 hr. respectively. This assumption appears jus- tified, especially for slow rates creep, because the slopes the time- elongation curves continue decrease the time the test prolonged. Errors the creep strength corre- sponding fixed rate creep would therefore the side safety. Table are listed the creep strengths the steels various tem- peratures for three different rates creep. Large differences are apparent the creep characteristics some the steels that compared closely the short-time tensile tests. the outstanding steel for high creep strength above 950 deg. F., while the steel has the highest creep strength temperatures below 950 deg. The other alloy steels are in- termediate between the carbon steel and over most the temperature range. Nevertheless, the: creep strength the carbon steel 900 deg. compares quite favor- ably with that the low-alloy steels. The results few calorized speci- mens have been included, the and C-Mo steels retain good strength temperatures where oxidation be- comes serious. The calorized surface the specimens seemingly has effect the creep the steel. considering the impact resistance steels elevated temperatures, TABLE Compositions, Properties, and Treatments Pearlitic Alloy Tube Steels for High-Temperature Service Chemical Composition 0.07 0.42 0.72 1.24 0.54 4-6 Cr-Mo 0.10 0.45 0.18 5.09 0.55 C-Mo 0.16 0.47 0.23 0.42 MM9 0.15 1.25 0.19 0.25 4615 0.14 0.53 0.28 0.25 Carbon 0.15 0.50 0.23 0.015 0.014 Annealed 1550 deg. 0.015 0.017 Annealed at 1550 deg. 0.015 0.016 Annealed at 1550 deg. Treatment (Deg. F.) Brinell Grain Size 123 4to5 128 7 126 4to5 0.018 0.026 Normalized 1725 deg. and tempered 1200 deg. 140 4to5 0.016 0.019 Normalized 1725 deg. and tempered 1200 deg. 149 0.029 0.025 Annealed 1550 deg. 126 4to5 The Iron Age, November 29, Saw —~ TABLE 2—HIGH-TEMPERATURE TENSILE PROPERTIES PEARLITIC ALLOY TUBE STEELS Tem- Ultimate Yield Proportional Elongation Reduction Steel perature Strength Strength* Limit In. Area Deg. if 85 66,500 35,200 24,000 36.5 72.7 750 71,650 26,400 18,000 27.0 67.8 1,000 57,750 24,900 15,000 25.5 73.3 1,200 33,300 16,000 3,500 36.5 88.2 1,400 13,800 7,000 1,500 72.5 98.4 85 66,600 26,300 19,000 39.0 80.5 750 51,800 21,100 14,000 30.5 76.7 4-6 Cr-Mo 1,000 44,500 17,300 7,500 28.5 73.5 1,200 25,800 11,300 1,500 46.0 91.0 1,400 13,300 7,300 1,500 65.0 95.9 64,100 32,500 25,000 37.0 62.7 750 68,100 23,500 12,000 29.0 61.7 C-Mo 1,000 50,500 22,800 8,100 32.5 1,200 28,100 15,100 2,000 56.0 88.6 | 1,400 11,700 5,900 0 83.0 89.0 72,100 51,300 45,000 36.0 71.9 750 74,500 35,800 23,750 26.0 64.2 MM9 ; 1,000 52,300 30.900 15,600 32.0 $2.0 ,200 30,000 17,400 4,000 53.0 90.0 1,400 13,400 6,100 80.5 72,500 52,500 47,500 37.5 70.0 | 750 65,300 32,800 24,500 29.0 69.6 4615 } 1,000 43,500 25,500 8,000 25.0 $1.5 1,200 25,000 12,000 4,300 59.0 79.9 42,000 34,500 36.0 67.5 750 58,000 24,700 13,100 34.5 67.0 Carbon 4 1,000 36,500 20,100 8,750 42.5 76.9 1,200 20,000 10,200 1,875 54.5 1,400 9,000 3,750 70.0 76.9 *Yield strength values are for two-tenths per cent of permanent set. may desirable know the effect heating time the hot shock value the materials. For this purpose the hot impact test can regarded simple mechanical test ignor- ing the probable changes the sta- bility the materials. The Charpy impact values the selected steels various temperatures are given Table Specimens were broken after being held heat one hour and 1000 hr. accentuate the effect soaking time the shock value. The steels showed good impact strength all cases, with the lowest values the temperature range 900 TABLE 3—CREEP STRENGTHS PEARLITIC ALLOY TUBE STEELS DIFFERENT TEMPERATURES Temperature, Stress for Designated Rate Creep One Per Cent One Per Cent One Per Cent Steel Deg. per 100,000 Hr. per 10,000 Hr. per 1,000 Hr. 800 20,000 29,000 42,500 1,000 15,000 24,000 37,500 DM 1,100 4,300 6,800 10,800 1,200 1,950 3,950 8,100 (Calorized 1,300 700 1,800 3,900 4-6 Cr-Mo 800 14,250 22,000 34,000 4-6 Cr-Mo 1,000 7,000 10,250 12,900 4-6 Cr-Mo 1,200 900 2,500 5,250 C-Mo 800 15,500 26,000 44,500 C-Mo 1,000 10,700 17,800 29,200 C-Mo 1,100 2,700 7,000 15,000 C-Mo 1,200 480 2,000 4,050 C-Mo (Calorized) 1,300 210 840 1,900 MM9 800 27,000 38,500 55,000 MM9 900 21,000 31,500 46,500 MM9 1,000 7,400 14,000 18,250 MM9 1,200 460 1,075 2,500 4615 1,000 4,600 7,700 13,000 Carbon 800 18,500 26,800 38,500 Carbon 900 12,800 16,900 22,100 Carbon 1,000 2,700 5,750 12,100 Carbon 1,100 840 1,800 3,850 Carbon 1,200 290 620 1,300 16—The Iron Age, November 29, 1934 deg. 1000 deg. However, even these minimum values would seem provide adequate protection against damage impact. Although the test specimens were not under stress ing the heating, believed that stress more likely influence the shock resistance the steel after has cooled atmospheric tempera- ture than while hot. This feature high temperature impact testing can now considered. learn whether these steels are stable when subjected stress for long periods time elevated tem- peratures, number tests includ- ing tensile, Izod impact and metallo- graphic determinations were made the creep specimens after the creep tests were four differ- ent creep specimens were taken for each steel each temperature two them were available for short-time while the remaining two were used for Izod impact tests and microscopic tests were made the steels the original heat-treated condition that changes the physical proper- ties could traced the compari- sons. Space will not permit com- plete tabulation the tensile test re- sults, but the data can summarized briefly follows: None the steels showed appreciable change ten- sile properties temperatures 1000 deg. 1200 deg. F., which was the highest temperature reached the tests, the and 4-6 Cr-Mo steels were still practically unchanged. Between 1000 deg. and 1200 deg. there progressive softening the MM9, C-Mo and carbon steels, char- acterized gradual loss strength and gain ductile properties. The 4615 steel was not tested above 1000 deg. The results the Izod impact tests are given Table making the Izod specimens was necessary finish them somewhat smaller than the standard size because they had machined from the creep specimens, which were 0.505 in. diameter. However, the same specimen size was used tests the original materials order keep the results compara- tive. should noted that these tests resemble the tests made de- termine the susceptibility steels temper -embrittlement, here stresses are acting the steels during the heating high tempera- tures. The cold shock resistances the DM, MM9 and 4-6 Cr-Mo steels are almost unaffected temperature and stress for quite long periods tem- peratures high 1200 deg. C-Mo steel first loses shock value good plain sider trem Stre: cree der stru nall cha are cep and one cal duc are cer mit dat con tri bas the ~ dey even gainst test dur- that the npera- esting are tem- for t-time ature, used scopic Iden- els roper- com- re- steels ten- which ached eg. f the char- ength The 1000 tests the the mens, was erials para- these de- els that steels 800 deg. 1000 deg. then gains toughness impressively 1200 deg. F.; and carbon steel, after showing good cold shock resistance 1100 deg. under stress, begins lose toughness 1200 deg. Although plain carbon steel ordinarily con- sidered free from temper-embrit- tlement, examples are known par- tial loss cold impact resistance after the material has undergone ex- treme spheroidization service. Stress Has Little Effect Structure For the examination the steels, specimens were taken from the centers the gage sections the test-pieces used the creep determinations. each steel was examined the origi- nal condition and after two different stresses each temperature the creep tests. magnification 100 diameters was used reveal the gen- eral features the structures and 1000 diameters was resorted or- der bring out the details the structures. The annealed 4-6 Cr-Mo ‘steel was spheroidized start with and showed change structure even 1200 deg. under stress 4000 lb. per sq. in. The other steels, which were not spheroidized origi- nally, exhibited change 1000 deg. F., but 1200 deg. numerous very small carbide particles had been precipitated the ferrite, and the carbides the pearlite had begun coalesce. The carbon steel seemed have spheroidized more quickly then the DM, C-Mo and MM9 steels. thus seems that all these pearlitic alloy steels are quite stable me- chanical properties and structure 1000 deg. 1200 deg. there are signs structural changes ex- cept the 4-6 Cr-Mo steel; the and 4-6 Cr-Mo steels are the only ones that maintain the same mechani- cal properties room temperature after period heating under stress 1200 deg. New steels can seldom duced for applications which cor- rosion may encountered unless they are manifestly resistant attack certain accelerated corrosion tests. one test unanimously accepted the criterion for judging the utility materials, but almost everyone ad- mits the necessity having few data from accelerated corrosion tests encourage the trial new alloy commercially. Once steel has been tried and proved experimental basis under actual service conditions, the results the service tests prop- erly supersede the data the less dependable accelerated corrosion tests. TABLE 4—CHARPY IMPACT RESISTANCE ALLOY TUBE STEELS DIFFERENT TEMPERATURES (Each Value is an Average of Three Tests) Time Held at Temperature of Test in Deg. F. ——_——_——_———_ Material Temperature 500 600 750 900 1,000 1.100 1,200 68.0 63.3 65.5 64.0 38.3 34.8 38.6 60.0 1,000 hr. ae 69.7 68.8 57.6 45.8 43.3 41.7 4-6 Cr-Mo 1 hr. 81.3 68.7 72.5 75.0 64.5 58.7 54.3 53.7 1,000 hr. 77.0 80.66 73.3 52.0 61.0 56.0 C-Mo hr. 38.7 26.3 25.5 31.0 56.0 1,000 hr. 44.3 46.5 35.0 26.7 30.0 38.0 MM9 1 hr. 59.7 63.3 56.7 51.7 38.7 34.0 53.7 67.3 1,000 hr. i 58.3 59.8 50.0 36.7 37.0 43.7 nee 4615 hr. 61.7 59.5 48.5 32.3 24.7 55.3 70.3 1,000 hr. 65.0 64.3 50.0 37. 39.8 Carbon 1 hr. 40.7 45.3 48.7 36.3 29.0 30.3 39.3 59.0 1,000 hr. 45.3 42.0 40.0 28.8 30.0 32.5 Among the group pearlitic alloy ing, these materials are intended steels being considered are several types that have passed the experi- mental stage and for which reliable service data are available. Tubing the 4-6 Cr-Mo steel, for instance, has already been commercial use about four years with record good performance large number re- fineries processing various grades crude oil. Tubes the and C-Mo steels have likewise been used re- finery service nearly two years. the basis the service data can conservatively estimated that the 4-6 Cr-Mo steel will last five times long The specimens were the form carbon steel cracking furnace small cylinders in. diameter and tubes, the steel two three times in. length. Oxidation the long, and C-Mo steel about the pieces was accomplished un- same carbon steel. Similar service sealed electric muffle furnace with records the MM9 and 4615 are lack- (Concluded Page 74) primarily for applications lower temperatures where corrosion less severe. Unlike the accelerated corrosion tests, oxidation tests made steels the laboratory afford quite satis- factory relative measure the oxida- tion resistance the materials service. The oxidation resistance these selected pearlitic alloy steels was determined 1000 deg. F., 1250 deg. F., and 1500 deg. heating three specimens each steel each temperature continuously for 1000 hr. TABLE 5—TEMPERATURE-STRESS EFFECTS THE COLD IMPACT RESIST- ANCE PEARLITIC ALLOY TUBE STEELS Heating and Loading Conditions Prior Cold Impact Testing Room Tem- perature Izod Temperature, Stress Duration Impact Values, Steel Deg. Lb. per Sq. In. Stress Hr. Ft.-Lb. 800 21,800 625 89.5 1,000 20,500 525 90.5 1,100 10,000 1,335 90.0 1,200 4,200 650 89.5 99.0 Cr-M 800 20,660 570 96.0 1,000 12,500 450 3.5 1,200 4,000 97.5 7.0 800 24,250 570 33.0 C-Mo 1,000 20,000 500 38.5 1,200 3,000 500 66.0 800 40,000 500 95.0 MM9 1,000 14,750 600 91.5 1,200 3,000 500 91.0 1,000 12,500 550 96.0 78.5 800 30,000 1,070 76.5 900 20,000 590 77.0 1,000 6,000 1,050 $2.0 1,100 2,500 1,020 74.0 1,200 1,750 1,590 53.0 The Iron Age, November 29, pera- the are and tem- turing bolts continuous com- bined operations with wire drawer that attached cold heading machine, and which draws and coats the wire and feeds into the header intermittently needed, recent development the bolt manufacturing industry. The wire drawing machine operated power supplied from the header. wire and manufac- Combination units wire blocks and double-stroke machines are being used the plant the Wasmer Bolt Nut Co., Cleve- land, and have resulted marked economies This method converting wire rod directly into finished bolt claimed and nut plant that not large enough maintain wire drawing plant. The wire drawer set directly front the bolt header and the die moved back and forth along the wire rod instead having stationary die and pulling the rod through the die draw down size. The wire drawing equipment simple operation. The stock fed into the heading machine the reg- ular feed rolls the usual manner. During the periods between feeds the wire held securely grips and the drawing die pushed back along the rod distance equal the amount fed. When the feed occurs the grips release and the drawing die and the slide which carries move forward with the rod, being pushed back again during the next stationary period. The slide which carries the drawing die box shape the top and 18—The Iron Age, November 29, 1934 The operating parts the wire drawer. “A” the straight- ener bushing; “B” the “C” the inching grip; “D” drawing die slide and automatic grips. filled with drawing powder lubricant ously coats the stock for cold heading and extruding operations. Motion imparted the drawing die slide vertical lever fulcrumed the drawer frame beneath the slide, which turn derives its motion through long horizontal connecting rod located under the header from adjustable crankpin the back the heading machine. This pin the end crankshaft mounted independent housing rigidly connect- the front drawer frame spacer bolts and driven chain and sprocket from the crankshaft the header. The stroke the mechanism that actuates the die slide adjustable that each cycle the length the wire that drawn the length the bolt that being headed, plus enough material make the head. The wire drawn during the idle time the header the return stroke the cross-head, when the machine requires reduced amount power, that there appreci- able increase power required be- cause the addition the wire drawing equipment. The standard headers with which the blocks are equipped are driven the same mo- tors that were used before the wire blocks were attached the header. For starting the end new coils rod “inching” feed provided. This starting mechanism consists auxiliary grip and feed slide with short stroke hooked and operating from the vertical lever. This feed slide pushes the rod for- Combined Equipment ward one three inches time and the auxiliary grips hold during drawing until the main drawer grips and feed rolls the header are reached, when the operation sumed. The use the “inching” feed makes the pointing swaging the rod unnecessary, except for and smaller sizes, before goes into the heading dies. The coil wire rod set front the wire drawer and, the ma- terial straightened going through the block, wire enters the header perfectly straight. addition, the heat generated drawing claimed sufficient cause the metal flow more easily the header dies and prolong the life these dies. Another factor that tends extend the life the header dies that the freshly drawn wire clean, while wire that has been kept storage bins becomes dirty and often collects emery dust which hard the dies. set tungsten carbide dies has been used one the bolt headers since the first wire block was attached the machine over year ago, and still good condition. Another advantage claimed for the use this wire drawing equipment that because successive coils are drawn through the same die there variation diameter the wire produced. Considerable saving production costs, particularly raw material, has been effected the Wasmer com- pany drawing wire and heading bolts with the combined equipment. The saving cost wire rods compared with wire about $15 per ton for plain steel and much higher for alloy steels. The amount ventory has been reduced one-third, the number sizes carried stock has been cut down and the floor required for raw stock has been duced per cent. The cost draw- ing the wire entirely separate wire drawing operation, estimated 7 fre Vie ) pla | | 7 7 Drawing and Heading Used Bolt Making one size now used for making wire two three sizes and instead carrying sizes wire stock the stock now consists nine sizes rods. Formerly wire 150-ft. coils was used, but these have been replaced coils wire rods weighing 350 lb. that the stock started into the header less than half the former frequency, thus saving time. The only increase floor space that required about ft. the front each header that taken the wire block. Wire plain carbon steel drawn diameters from 7/32 in., the size being controlled the capacity the header. Drafts are usually held 0.025 in. 0.030 in., although reduction high 0.090 in. has PRENTISS Resident Editor, The Age, Cleveland been this wire block. The wire drawing machine describ- ed, which designated the Hogue wire drawer, now being built and placed the market under exclu- sive license the Ajax Mfg. Co., Cleveland, which will make the ma- chine standard sizes from No. inclusive, for drawing %-in. diameter rods. ~ 7 4 | Ba gar The Iron Age, November 29, 1934—19 ime re- eed the and the ont na- igh der the ned the age cts ies. has ers ind the are ire ion ial, m- ing nt. ate last Furnace Fuels: Their order approach this question self, which the essential foundation sup the light past history, which the iron and steel industry. to, RRESTING questions, glimps- “the mold prophecy,” need- dual foundation, however—units bee! ing likely changes the pig- ful review the records the and units carbon. rule making process and suggest- ing all the blast furnaces the obvious that there can abl ing the ascendancy new ex- Colonies and the States the smelting without iron ores, what- the isting centers, Union; study the influences that ever fuel may used; but has throughout the accompanying study brought about the location blast been fact the history iron mil Mr. Sweetser. analysis furnaces the places they were built making that the iron ore was either the part played the geography the steel industry blast fur- nace fuels and represents pains- taking search records that here compiled give information hitherto not available. The article brings together some historical facts that will probably many readers and some technical facts that have probably never before been published. HAT the next fuel for the making iron? Charcoal, anthracite, raw coal (“block bee-hive coke and now by-product coke have each succes- sion predominated the blast fur- nace fuel used this country. For nearly two hundred years charcoal was the only fuel used for making pig iron, from the early Colonial days about 1840; mineral fuels, nat- ural and processed, have predominated for the past years. Anthracite ruled the pig iron industry for years, and then was supplanted bee-hive coke for the next years; by-product coke gradually became the almost exclusive blast furnace fuel since the World War. How soon will by-product coke give way the next fuel? There are some who have had experience with all five these fuels, and have seen the com- plete dismantling the 275 anthra- cite blast furnaces, the disappearance all but five charcoal furnaces, the passing all the strictly raw coal furnaces, and the reduction total active blast furnaces from the peak number 716 the year that Presi- and what caused their disappearance their continuance that region; study the influences that caused the movement the iron-making centers from the shores Massachusetts westward through the valley the Hoosatonic, the Hudson Valley, the valleys eastern Pennsylvania, the valleys eastern Ohio and the headwaters the Ohio River. Will water coal that deter- mines the next blast furnace fuel, will combination the two? Charcoal has been used from the be- ginning the present; why? Will anthracite come back, ever? Why raw coal still used mixed with coke making quality product? The two “natural” fuels need coke ovens, but are distinctly regional their influence. Will electricity? And, so, will the regional influences elec- tricity the fuel for smelting iron ores control the location the iron and steel centers the future, the same manner the other five fuels have done the past? will help decentralize? Will the pro- posed four great hydroelectric power regions the “New Deal” become the sources our alloy steels? Blast Furnace Fuels anthracite, raw coal, bee-hive coke and by-product coke, each their turn, have had control- ling influences, not only the art smelting iron ores, but also the choice the location the iron blast furnaces themselves; and also the building the subsequent iron and steel centers this country. The located near the source fuel wol States which All Blast Furnaces are now CH. R.C. Raw =Coke dent Garfield was shot down the influence fuel determining the states ocation the 1857 blast furnaces built the present number 275 blast furnaces location blast furnaces has been shortly after was settled 1629, Cal un still the active list. 20—The Iron Age, November 29, 1934 greater than that the iron ore it- shows also the states and the District | // Yj supply else the ore was transported to, toward the fuel. There have its been some notable exceptions this rule which have resulted unprofit- able operation. One such case was what- the plant Sault Ste. Marie, Canada, where bee-hive coke was hauled 900 miles more meet iron ore that was hauled another 450 miles; would have been better have built x xx Regional Influences the enterprise Canadian re- sources iron ores and fuels. This has been partly remedied the build- ing by-product coke plant “The Soo.” The present modern blast furnace practice America built almost entirely around by-product coke the fuel, and not much remains the influences charcoal, anthracite and CH. TOTAL TOTAL RALPH SWEETSER Consultant Blast Furnace Practice, Associate, Stuart, James Cooke, Inc., New York raw coal the art smelting iron ores, except some traces the old operating customs. some cases, like the Sunday shut-down for in- stance, old customs have been put into present practice and considered something new. the other hand, however, the effects the regional influences these fuels still persist, and, together with the influences inci- CH. 107 TOTAL and the District Columbia, since the erection the first little charcoal furnace near Lynn, the building the last big coke furnaces 1928, Fairfield, Ala., shown Table This map Columbia, which once had blast furnaces, but longer have single active stack within their borders. The Iron Age, November 29, G VA, C. 4 CH. 296 C | C. & C. 33 A CH. 9 VA. A. 8 »4 COKE PERIOD Average Pig Iron Year tons Pig Iron PERIOD Average Average Piglron per Year per Year 1840 1850 1860 1880 1900 1910 1920 1933 Years Chart No. 1—Blast Furnace Fuels Used the Production Pig Iron. CHARCOAL: Predominating fuel used during period yr., produc- ing total 9,851,000 tons pig iron; previous 1840, CHARCOAL was the only fuel used. ANTHRACITE: Predominating fuel used during period yr., producing total 18,898,792 tons pig iron. BEEHIVE COKE: Predominating fuel used during period yr., producing total 635,888,026 tons pig iron. BY-PRODUCT COKE: Predominating fuel used since 1919, producing total 435,877,544 tons pig iron 1933. dent the making by-product coke, are the predominating factors main- taining the centers the iron and steel industry where they now are. And fuel will the controlling factor any future shifting these cen- ters, even the source heat should electricity. Momentous Changes Making Pig Portend view the present evident trend toward regional operations, seems appropriate take look the rec- ord blast furnace fuels this coun- try from the early days the Colo- nies down the present time the New Deal. Like many other indus- trial developments, the centers pig iron manufacture have moved inland and westward from the Atlantic Coast. The first continuing blast furnaces were built along the eastern Massachusetts and Rhode Island, and from there they spread across the Salisbury district southwestern Massachusetts and northwestern Con- necticut, the magnetic iron ores the Hudson Valley New York and northern New Jersey, and then the valleys eastern Pennsylvania. For the first one hundred years after the settling Massachusetts 22—The Iron Age, November 29, 1934 that colony led the production iron. For the next two centuries Pennsylvania held the leadership con- tinuously, the year 1933, when the State Ohio made more pig iron than any other state. Pennsylvania, because its abundance charcoal, anthracite, block coal, and coking coals, and not because its iron ores, important they are, has led the country the production pig iron throughout the successive eras these fuels; only the pro- duction pig iron made with raw coal has any other state—Ohio—ex- ceeded Pennsylvania. Why? Whether not this leadership Pennsylvania producer pig iron, held for nearly two centuries, has passed Ohio only temporarily question that will settled soon probably favor Pennsylvania, because Pennsylvania alone all the states has within its borders all five the blast furnace fuels that have far predominated the smelting iron ores. the making pig iron, many other things, are now transition period that may bring about momentous changes that period nearly one hundred years ago when anthracite, raw coal and coke were introduced blast furnace fuels all within the same decade. These three mineral fuels (two them be- ing natural fuels) threatened the supremacy charcoal, which had been the only blast furnace fuel for 200 years; but, shown Chart No. other fuel predominated until 1855 when anthracite took the lead for the next twenty years. Chart No. shows the great activity the building new charcoal blast furnaces during that period. Four Periods Blast Furnace Fuels have been four distinct blast furnace fuel eras this country from the days the first Colonial blast furnace down the present time, follows: The Charcoal period from 1645 1855 The Anthracite period from 1855 1875 The Bee-hive Coke period from 1875 1919 The By-product Coke period from 1919 Chart No. these periods are shown beginning with 1830 and ended with 1933, but the first char- coal blast furnace began operate about 1645, earlier, near Lynn Massachusetts. The periods are di- vided according the annual ton- nage pig iron made with each fuel. Swank (10th Census, S., 1880) des- ignates the total period previous 1840 “the charcoal iron era,” but inasmuch charcoal iron predom- inated till 1855 seems more fitting extend the charcoal period the year when anthracite pig iron surpassed charcoal pig iron tonnage made, i.e., the year The fuels overlap each other shown Chart No. and interesting note that charcoal pig iron has persisted throughout all four periods. separate period designated for raw coal, which began little later than the other “natural” fuel (anthra- cite) and the building strictly raw coal blast furnaces ended sooner (in 1887), shown Chart No. For while was possible keep the records raw coal furnaces separate from the coke furnaces, but for over half century the statistical reports have listed all bituminous coal (raw coal) furnaces under the same head- ing the coke furnaces. Except rare cases, such Jackson County, Ohio, where there still some the Sharon No. coal, raw coal (either hard soft) used blast furnace fuel, spite the excellence the pig iron made with it. The regional influences the five blast furnace fuels can expressed terms the means transporta- tion employed each period. Here, Waite ; : fuels These been 200 1855 the shows uring Fuels blast untry lonial 1855 1919 are and char- erate di- ton- fuel. des- but dom- more eriod pig The hown sting has for later thra- raw (in For the over ead- inty, the nace the five ssed [ere, too, there much overlapping, but the fuels and the transportation fa- cilities are characteristic each period, seen below. Fuel Transportation Charcoal Pack horse—rafts—ox- cart Anthracite Canal boat—railroad Bee-hive Coke Railroad—ore boats By-product Coke Railroad ore boats motor truck The two charts, No. and No. showing the number new blast fur- naces built this country each year from 1740 the present time, give good idea the close connec- tion between activity the erection new blast furnaces and the build- ing canals and railroads. Prior the year 1740 there had been built the Colonies least little char- Number Blast Furnaces Built Chart No. 3—Num- ber Anthracite and Raw Coal Blast Fur- naces Built Each Year. First charcoal fur- nace built 1645; last, 1912. First anthracite furnace built 1838; last, 1891. First raw coal fur- nace built 1845; last, 1887. First coke furnace built 1837; 1928. Total Number Furnaces Built Compiled Ralph Sweetser. Oo ~ 1835 1840 1845 1850 1855 1865 coal blast furnaces, nine New England, Pennsylvania, three Maryland, and one each New Jer- sey and Delaware; the first furnace New York was built 1740. The Reign Charcoal other fuel than charcoal was used United States blast fur- naces until about 1840” (James Swank, 10th Census S., 1880; Part II, page 59), and many small charcoal blast furnaces were built throughout New England and all the other Colonies, and later every state east the Mississippi River, with the single exception Florida. The total production was not great, even for all the first hundred years, throughout which Massachusetts was Total Blast Furnaces Anthracite furnaces Raw furnaces the greatest pig iron producer, and even late 1810 the annual pro- duction for the whole country was 53,808 tons charcoal pig iron. The statistics for those years are rather uncertain and even Lesley and Swank (J. Lesley and James Swank, secretaries the American Iron Association and (later) the American Iron and Steel Association, respectively) expressed doubts tonnages previous 1840. Pig iron, forge iron and air furnace iron ton- nages were not carefully separated the reports. Swank says (10th Cen- sus, S., 1880) that “about 1840 revolution was created the iron in- dustry the country the intro- duction bituminous and anthracite coal the blast furnace.” Tonnages the several kinds pig iron made Chart No. 2—Num- ber Charcoal and Coke Blast Furances Built Each Year Compiled from Tenth Census the United States, American Associa- tion, American and Steel Institute and other sources Ralph Sweetser. The Iron Age, November 29, 1934—23 1740 1790 1800 1860 1880 1890 1900 1910 1920 1930 1940 that decade following the “revo- lution” are not accurately recorded. The regional influences blast furnace fuel still persists today when there are only five “ac- charcoal furnaces left all the country, four Michigan and one Tennessee. All five them are parts by-product plants the hardwood distillation industry. These by-product charcoal plants, with wood alcohol, acetate lime and charcoal prime products, had find adequate market for the bulky char- coal just the manufactured gas plants had find similar market for by-product coke. The iron blast furnace was the logical outlet both cases; the location the by-product plant decided the site for the blast furnace. “For hundred years after its set- tlement 1620, Massachusetts was the chief seat iron manufacturing this continent” (Swank, 10th Cen- sus 1880). The fear that the iron works would create scarcity timber made the proprietors “the first successful iron works established the Colonies (near Lynn, Mass.) unpopular and their plant finally ceased operations about 1681.” Grad- ually the charcoal iron industry was spread westward the regions where there was plenty timber addi- tion supply iron ore, even though those iron ore deposits were often only “bog ore” very low iron contents. Throughout the period which Swank called the “charcoal era,” previous 1840, certain that the making iron was confined those regions that had enough timber supply wood for the charcoal used the lit- tle blast furnaces. The records show that these furnaces were near enough the charcoal pits that all the fuel could hauled ox-carts. modern times there have been cases where the wood, and even the char- coal, was transported considerable distances railroad cars. the largest charcoal blast furnace the world, operated the Algoma Steel Co., Sault Ste. Marie, Ont., 1905, part the charcoal was hauled over the Algoma Central Railroad from the brick charcoal kilns erected the forest miles away. The wood supply could not keep with the furnace when demanded cord wood pile half mile long every hr. After about 200 years making charcoal pig iron this country the annual production reached 165,000 tons 1830; and the time the introduction the use mineral Iron Age, November 29, 1934 fuels, 1840, the production was 315,000 tons; was years later that the peak tonnage charcoal pig iron—628,145 tons 1890—was reached. Every year since the start the Colonies (Massachusetts about 1645; Rhode Island 1675; Connecticut 1663), charcoal pig iron made this country. Fortunately for the charcoal industry, the pig iron made with charcoal superior quality all other pig iron. Just why this so, has not yet been found out. Charcoal blast furnaces have been built different states and the District Columbia, can seen Table No. This table shows total 982 charcoal blast furnaces erected; possible that few have been overlooked. Every state east the Mississippi River, with the single exception Florida, has had one more charcoal blast furnaces; Colo- rado the only iron-producing state that never had charcoal furnace. Pennsylvania had more charcoal fur- naces than the next three highest states. The regional influence charcoal blast furnace fuel was positively decentralizing; for nearly two cen- turies was frontier industry sup- plying the local market with “hollow- ware” and blooms for the blacksmiths and nailers. Lewis Mumford his “Technics and Civilization,” calls the “Eotechnic Era.” Usually the furnaces were built along the ridges and “coves” the Blue Ridge and Allegheny Mountains, far away from the centers population. Ten Centers Close Charcoal Period Just after the end the charcoal period and the early years the anthracite period, there were (accord- ing John Peter Lesley, secretary, American Iron Association, book, “The Iron Manufacturer’s Guide the Furnaces, Forges and Rolling Mills the United States.”—1859) the close 1856 ten iron centers follows: No. Northern New York, which formerly included Vermont—40 bloomaries and few blast now anthracite—from prim- itive ores (the Adirondack magnetites); fuel chiefly charcoal. No. Hematite and primary ore belt the Highlands, beginning the Salisbury dis- trict western Massachusetts and northwest- ern Connecticut, through northern New Jersey into Pennsylvania, containing charcoal and anthracite furnaces and forges (most them making iron from the ore). No. Eastern Pennsylvania, and north- eastern Maryland, the greatest iron region the Union, anthracite and 103 charcoal furnaces and 117 forges (none which last produce iron from the ore). No. Northwest Virginia and southwest Pennsylvania, with its coal measures, bonate furnaces and forges— Cambria works this region. No. Northwest and east corner Ohio—66 blast furnaces—ore and other carbonaceous ores northern outcrop the great bituminous coal region. All the forging done the rolling mills Pittsburgh and other centers trade Ohio waters. No. The Region—45 furnaces Ohio side and Kentucky side, use coal the mine for fuel” (most the Kentucky furnaces that time used coal. R.H.S.), and all used iron ores the coal measures. and eastern Virginia, prolongation the Pennsylvania region, with the same brown hematite and magnetite furnaces Blue Ridge and furnaces west Blue Ridge. No. Northern east Terinessee and north- west corner North furnaces (charcoal) South Carolina has No. Western Tennessee and western Ken- tucky, with its peculiar ores and furnaces (all charcoal). No. 10. Missouri—a beginning been made with the Iron Mountain region center—already furnaces blast brown ore and primitive ore (magnetic). Speaking the iron industry that day (1857), Lesley said, “There are nearly 1200 efficient works the Union; these produce 850,000 tons iron per year valued, ordinary year, $50,000,000, which $35,- 000,000 expended for labor alone.” Charcoal unique that the only fuel that can perpetuate itself (by reforestation and cutting ro- the highest quality and purest pig iron; requires the greatest amount labor, all which