The Iron Age 1935-01-24: Vol 135 Iss 4

rom the hile tion ated sol- all ‘rom re- cost CODE 1935 Registration Ne. A-3:31-0-1590 VAN DEVENTER Editor Managing Editor News Editor Machinery Editor FEF’. J. WINTERS T. W. LIPPERT Editor Emeritus Washington Chicago Cleveland EHRNSTROM, JR. BURNHAM FINNEY GERARD FRAZAR McINTOSH Pittsburgh Detroit Boston Cincinnati The Art Defamation Puncturing the American Bogey Manufacture and Uses Nickel-Clad Stee! Weided Vs. Cast Jigs and Fixtures Nickel Wrought New Product Late Laboratories and Mills Engineering Aspect High-Strength Steels New Equipment Meeting Scrap Institute News Washington News Markets Construction and Equipment Buying Products Advertised Index Advertisers THE IRON AGE PUBLISHING COMPANY FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager DIX, Manager, Reader Service PUBLICATION OFFICE: Corner Chestnut and Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th St., New York, N. Y., U.S. A. Member, Audit Bureau of Circulations ADVERTISING STAFF Member, Associated Business Findley, 311 Union Cleveland Herman, 675 Delaware Ave., Buffalo, Published every Thursday. Hettenstein, $02 Otis Chicago tion Price: United States and Pos Peiree Lewis, 7310 Woodward Ave., Detroit, sessions. Mexico, Cuba, $6.00: Can- Charles Lundberg. Chilton Bidg.. Chestnut & ada, $8.50, including duty; Foreign 2.00 a year. Single copy 25 Cents. Robinson, 428 Park Bldg., Pittsburg W. C. Sweetser, 239 West 39th St.. New York Owned CHILTON COMPANY (Incorporated) C. A. MUSSELMAN, President FRITZ J. FRANK, Evecutive Vice-President FREDERIC C. STEVENS. JOSEPH 8S. HILDRETH, GEORGE H. GRIFFITHS, EVERIT B. TERHUNE, ERNEST C. HASTINGS, Vice-Presidents WILLIAM A. BARBER, Treasurer. JOHN BLAIR MOFFETT, Secretary q n- Rage ne, ely our sid- not ~ full range special alloys, tool steels, stainless and heat resisting steels are immediately available through the Ryerson Steel-Service Plants. Stocks include all the major specifications. Ten plants strategically located provide for immediate distribution throughout the principal industrial areas. All other steel and allied products are also carried for immediate ship- ment. Experienced organization and unequalled equipment assure depend- ability, accuracy and speed. Whether you need few pounds carload, your order will have our personal attention and will shipped once. Write for the Ryerson Stock Immediate Steel. JOSEPH RYERSON SON, INC., Chicago, Milwaukee, St. Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City RYERSON SEF 6—THE IRON AGE, January 24, 1935 f 2 i ... THE IRON AGE JANUARY 24, 1935 ESTABLISHED 1855 Vol. 135, No. art defamation not new, fact one man's earliest accomplishments. The Children Israel must have been conversant with the days Moses; else why the commandment: shalt not bear false witness against thy Like all ancient inventions which have survived the present day, this art has been materially improved. Slander, ancient days, was handicapped having travel word mouth. Today, thanks the facilities the printed word, radio and the motion picture, who would appear whiter blackening his neighbor finds the marvelous modern facilities for mass dissemination misin- formation available for his use. The writer had the misfortune having sit recently through the showing mediocre moving picture entitled President The theme this picture that peace-loving President who goes the extreme getting himself kidnapped because munitions cabal attempting force the country into steel industry, typified steel the judiciary, typified judge, congress, typified senator, great newspaper publisher and other supposedly substantial members our society are depicted wolfish principled rascals who form the clique which represented selfishly forcing the President's hand. far could judged observer, the object this picture, least its effect, was not much that condemning war arousing hatred steel manufacturers, judges, newspaper publishers, congressmen and others who have had the temerity achieve some degree success and social distinction. One might have well wondered the effort was not intended communistic coup d'état, the mission which was destroy military preparedness and social dis- tinctions based upon achievement one fell blow. One might, perhaps, expect such melodramas with mission defamation from some the haywire brains Hollywood. One would not, however, expect find the halls congress. commend our readers, therefore, careful reading the article which immediately follows this editorial. devoted common-sense analysis the American bugaboo, now being prominently paraded Senator Nye and his committee associates. This article, too, has Itis expose the childish fallacies which underlie the latest defamation American industry. 2 = J 4 ‘ | wo 5 sey Cily « 7 1 uncturing the GEORGE ALCOCK munitions inquiry, called, that being con- ducted the investigating committee headed Senator Nye creating impressions that are both er- roneous and damaging public security. building the minds the public the belief that were forced into the world war the profit greed cabal American who were Judases anxious turn their blood into money. Such accusations are not merely unfair; they are silly. sponsored good faith and not desire for the limelight which follows the successful efforts sensation mongers, their conception denotes moronic lack understanding both the material requirements war and the elements industrial production. Common sense all that necessary demolish this canard. Common sense, plus first hand knowledge in- dustrial production both for the purposes war and peace, applied this subject the author this article. dedicate the industries which are being unjustly maligned and the public which being grossly misled. 4 q O N S ° ° ° ‘ Pre, 4 4 dil La af American munition makers lead, force cajole into the World War? History an- swers that question unmistakably the negative. were brought into the world war because Germany refused recognize our rights the high seas and torpedoed our ships carry- ing Allied and neutral President Wilson, protesting against any infringement our rights the high seas, simply lived his oath office, and maintained our national traditions. That any cabal steel makers, explosive manufacturers other munitions interests influenced him fallacious. create any other impression grossly distort facts. are not, and never have been, nation munition manu- facturers, the sense which this term used Europe. The plain truth that was primarily our farmers, and those engaged processing the prod- ucts the soil who first involved us. Long before any munitions maker received order from abroad, had been exporting raw and processed products the soil and farm. Wheat farmers, hog farmers, cotton farmers, sheep farmers, dairy farmers, lumber manufacturers, millers, tanners, woolen makers, cotton makers, au- tomobile builders all benefited through stimulated exports their goods long before dollar’s worth powder, shell cannon was purchased from any American maker. Horses and mules went over huge quantities; shiploads time. Tobacco growers and cigarette makers sent over tons their product months before any so-called munitions maker was able secure hearing from foreign war office. Ford automobiles were sold the Allied armies even though this helped prolong hostili- ties, and made impossible get the boys out the trenches before Christmas. There was nothing surreptitious mysterious about this. Before army can fight must trained and outfitted. Purchases clothing and food, shoes and blankets always precede the pur- chase munitions. all those engaged the peaceful fabrica- tion the products the farm and soil had refused sell their Bogey goods the Allied armies, Presi- dent Wilson would have been suc- cessful his effort keep out war. The Germans would have been Paris and the war would have been over long before any would have been purchased. Napoleon, military genius all time, and outstanding organizer and administrator, recognized the necessity efficient commis- French army Italy time when his government rupt, its credit wrecked, and its army demoralized, reported have told his men: “Soldiers, you are half starved and naked. The Government owes you much but can nothing for you. Your patience, your courage you honor, but give you glory, advantage. will lead you into the most fertile plains the world. There you will find flourishing cities, teeming provinces. There you will reap honor, glory and wealth.” Perhaps Napoleon never made such speech, but history records that after his first victory Italy assessed the territory ee : Pa ° ° d x 4 lie is ale é ; 7 had conquered, and used this money outfit his army, give them new shoes, decent food, and thereafter the morale his men was entirely changed. Peace Time Products, Not Muni- tions, Win Wars and Fight Them After army recruited and outfitted, immense stocks food, clothing, hospital supplies, and all the common necessities life must accumulated and stored stra- tegic points. There record that any those who supplied these innocent things are being blamed for our entry into the war, but certainly, the stand taken the Nye Committee sound, they and not the munitions makers should censured. Nothing gained bilking the Germany was unable maintain effective blockade French and English ports, and effort handicap the Allies securing the equipment and sup- plies necessary prosecute their marine warfare, preying ships flying the American flag regard- less whether not these ships were carrying food, livestock munitions. Knowing that was guilty the most flagrant infringe- ment the rights neutral the issue the assertion that the ships were carrying munitions. matter fact, the greater por- tion our exports our Allies from 1914 until the United States entered the war was not muni- tions, but those saries army which are themselves perfectly innocent. Common sense supports this as- IRON AGE, January 24, 1935 sertion. Shipping was too scarce very early stages the war both England and France made ex- haustive survey what could best secured overseas. They could both manufacture guns and shells. For over hundred years England had been making iron and steel products. Coal and iron are na- tive English soil. Foodstuffs, however, are not produced suffi- cient quantity even time peace. Canadian mutton, Argen- tine beef, Australian butter, wheat from all three countries, citrus fruits, tea and vegetables all ar- rived shiploads daily. During the war large quantities wool, cotton, and food stuffs necessary for the maintenance their army, necessity came from overseas. England and imported much larger quantities those in- nocent essentials life than they did powder, shell, cannon rifle. Let have the courage face the facts. entered the war for the reason that were unwilling forego our rights sovereign nation, and because these rights were violated. munitions, steel explosive maker forced us; Ger- many forced desperate effort cripple her enemies se- curing supplies. They staked all one colossal gamble lost. Had they been able intimidate our avowed pacifist Secretary State, might have placed embargo the shipment sup- plies, whether food, clothing munitions. Public opinion, how- ever, was too strong, and the President finally took decisive stand. Having been forced into the war, what was our position? were faced with state unprepared- ness almost unbelievable, when considered that for nearly two years had been writing vigor- ous threats desperate nation, which could have had only one ef- fect, force into war unless Germany retracted, and was evi- dent for twelve months before ap | ff 4 NG | declared war that they would not retract. This unpreparedness chargeable lack effort abil- ity the part the commissioned personnel the War Department. was definite part President Wilson’s carefully considered pol- icy. Almost the last sus- tained the hope that the bellig- erent nations would accept him mediator, and that would the Ambassador Peace. This was fixed part his defi- nite policy that, when General Pershing was appointed Com- mander Chief the American Expeditionary Force, found, has stated his “Experiences the World War,” that there was program any kind. Take the case shipping alone; knew that entered the war would have transport army France, yet effort any kind was made establish merchant marine until after war was de- clared, and then had depend the Allies, our ill-fated ship- ping program never really became effective, When General Pershing sailed for France there was the en- tire Ordnance Department the United States Army total about men, some whom were almost the retiring age. Out this pitifully small force had create the nucleus two de- partments, one the front and one Washington. This depart- ment the one responsible for the production munitions war, covering everything from bacon tin the largest mobile gun, with all the millions items between, and these had produced for army 4,700,000 men out force less than 100 men all told, both West Point trained and civilian. William Jennings Bryan fought against decent prepared- ness for, said, army men would spring into being over night. Perhaps so, but the accoutrements and equipment for 1,000,000 men cannot spring into being overnight; furthermore, planned not for 1,000,000 men, but for almost 5,000,000, and be- fore they could fight had get them France. Munition Profit Possibilities Were Non-Existent Had there been clique forcing into war, stands reason that there would have been unlimited capacity available for the production munitions when war was finally declared, but exactly the reverse was the case. Before General Pershing’s require- ments could met, was neces- sary create facilities for the pro- duction practically every item the Army Ordnance program. peace-time Government could ex- panded with sufficient rapidity accomplishment this. Industry had depended upon provide the facilities, and these facilities were largely provided manufac- turers who had had previous experience producing ordnance. mittee room Washington years after hostilities have ceased, and ruminate how munitions should have been produced, but was another thing for those charged with meeting General Pershing’s program, secure this production when the German long range guns were bombarding Paris, when England had best week’s supply food hand, when were transporting army France, depending our Allies feed, clothe and arm them until could get our production supplies and equipment under way. compare the cost against any Government yardstick equally silly. Any one with the most ele- mentary knowledge manufac- ture knows two things, first that quantity production impossible achievement any plant oper- ated the Government, and, sec- ond, that Government agency has the slightest idea what ele- ments properly constitute cost. This neither hearsay nor heresy. clearly brought out the very admirable report the Con- gressional committee appointed investigate Government competi- tion with private enterprise, which the Hon. Joseph Shannon Missouri was chairman. This committee had this say Gov- ernment cost accounting: “The committee recommends that the Government departments and agencies required the Con- gress install and maintain uniform system accounting, con- taining all the elements cost finding, which the best practice has sanctioned for public utilities, and private industrial and commercial enterprise. “The Committee believes that the results such system ac- counting would invaluable Congress considering appropria- tions for public works and similar projects, well considering proposals for the continuance and maintenance existing Govern- ment departments, and business ac- tivities, and passing upon new undertakings which may sub- mitted for Congressional action. “The establishment such Gov- ernmental accounting methods will THE IRON AGE, January 24, vy ny i = 4 ne 4 ' 3 4 t also make possible comparison between public and private costs production and service.” Government Not Anxious Know the Production Costs Unfortunately bill introduced Congressman Shannon Con- gress make this recommendation effective has far failed pas- sage, account opposition from all the Government departments. With such arraignment Government cost finding methods, not, say the least, unfair indict industry for excessive cost compared with any hypothetical estimate the cost production Government plants? Acting Chief Ordnance Pierce, sional Sub-committee Nov. 28, 1922, stated, and this taken from the Shannon report: “Military overhead the six arsenals Ordnance Department computed Jan. 25. 1916, follows: Frankford Arsenal per cent Rock Island Arsenal 13.77 per cent Springfield Armory 16.15 per cent Watertown Arsenal 18.66 per cent Watervliet Arsenal 21.51 per cent Pictatinny Arsenal 22.03 per General Pierce admitted that these figures did not include all the items which are ordinarily in- cluded cost estimate, War De- partment administration stance being included 3.5 per cent. Can any manufacturer im- agine operating plant the size and with the expensive equip- ment necessary produce explo- sives heavy ordnance the overhead figures given? Let the members the Nye com- mittee read the speech the Hon. Robert Rich Pennsylvania the House Representatives June 15, 1934, the subject Govern- ment cost. said, speaking the investigations the Shannon committee which was member: Using Yardstick “The investigations our com- mittee disclosed very clearly that virtue the manner which accounts are kept public estab- lishments, frequently including costs only direct charges for material and labor, all the other costs which actually entered into the operations the Government establishment were ignored. Thus, the Government underbid its citi- 12—THE IRON AGE, January 24, 1935 zens proceeding though all other elements cost which were actually present were not there. went further. the Government establishment suffered loss, Congress replaced the estab- lishment, and the capital loss never appeared against the future prod- charges many the elements its cost appropriations other than the one under which di- rectly operates particular proj- ect, and thus escapes those ele- ments cost carried another board, bureau department.” the basis cost findings this kind that industry Government secrets state that time was the War Depart- ment able fulfill General Persh- ing’s requirements for his cam- paign 1918, even had the esti- mated production been realized. the productive capacity the country had been susceptible sufficiently permit doubling our shipments during 1918, what would have been the measure the Would have been fictitious figure pre- pared some Government arsenal the basis hypothetical figures for overhead such General Pierce produced before the Con- gressional subcommittee Nov. 28, 1922, would the cost have been analyzed the basis its effect ending the war. Had been able, the expenditure any sum, increase our produc- tion the necessities war, certain that President Wilson, and his secretaries Baker and Daniels, would have felt the expense well worth while, brought the end the war only single day nearer. Again, much the high cost munitions was due entirely Governmental policy, and lack unanimity opinion the high command, but certainly these things are not chargeable in- dustry. common knowledge that there was marked difference the views General Pershing the front, and General March, Chief Staff, Washington. President Wilson also enunciated the policy maintaining national identity for the American Army. Insignificant these things may seem, they had tremendous influ- ence the cost production. Army men deplored the delay securing detail plans the ord- nance finally adopted for our Ex- peditionary would have been cheerfully placed our disposal France months before entered the war, that, the event were finally forced throw our lot with them would ready into produc- tion. This was directly opposed President Wilson’s policy, how- ever, that nothing whatever was done until after hostilities were started. Although turers were manufacturing ma- chine guns for practically all the Allied nations, one them be- ing the invention American Army officer, and these machine guns were successful use all the fighting fronts, none them was considered good enough for American troops, and after war was declared undertook put into production entirely new machine gun—the Browning. tool factories and put intri- cate piece mechanism this kind into quantity production be- fore has been subjected elabo- rate field tests extremely hazardous venture. The natural result was endless delay and un- necessary cost, for which industry now blamed. army rifle was the Springfield 1903, and there were less than 300,000 these available. was, however, considered obsolete. The British Enfield was production private plants and this was adopted, but modifications were made use the American bullet, with the usual corollary delay and expense. Trench warfare had its incep- tion small scale General Grant’s campaign before Peters- burg, over years before en- tered the war. should have known that the war which had elected engage was being waged largely trenches, and that all the Allied troops, and those the enemy were equipped with trench helmets. This information could have been secured from the public press months before en- tered the war. When did de- clare war not only had facilities for the production trench helmets, but the very shape itself was not decided upon months after had started the embarkation troops. Gas warfare and aerial warfare were entirely new us. not | | u a ] I é = ( ( ‘ ‘ 4 1 f | | | only had equipment for these idea what equipment was re- quired. All this had evolved after General Pershing reached France. When entered the war our standard field gun was the 4.7 used the Spanish-American War. entirely new line artillery was put into production, including the mm., mm., 155 mm. gun and howitzer, anti-aircraft guns and trench mortars. These guns, the shells, cartridge cases, loading bags, fuses, boosters and adapters, gun carriages, caissons and limbers were all strange American plants. The Munitions Idea Exploded Facts The tremendous task creat- ing plant capacity, securing ma- chinery and tooling shops for new designs ordnance, the quantities required General Pershing’s plans for combat army almost 5,000,000 men, was heartbreaking, when tions under which the work had undertaken considered. Cost. course, was high. How could otherwise? But the fault does not lie with industry. Can anyone seriously contend that there was munitions clique into war, but yet inefficient that not even the slightest semblance program had been fore declared war? Our tragic unpreparedness, now matter historical fact, the absolute refu- tation the assertion that any group steel makers, munitions makers explosive makers ever made any effort influence the Administration. any further refutation needed look the manufacturers contributed most the production ordnance. Mostly peaceful factories who had never before had any experience the production ordnance. Instances such above could adduced ad_ They are the inevitable experience peaceful people turned war. The years 1914 1917 changed the whole aspect war, but had for our standard the equip- ment 1898. The fact that our War Department had under- take these heartbreaking develop- ments after hostilities were started and troops were waiting for equip- ment naturally cost. Anyone familiar with the condi- tions which existed 1918 will testify plants tooled for pro- duction, waiting weeks and some- times months for decisions vital points. Confusion program, design, explosive and pro- GEORGE ALCOCK pelling powders are matters common knowledge. Government Had the Power Commandeer Private Plants Perhaps now felt that better results would obtained the future the Government should commandeer plants over and undertake the work production. significant that had abso- lute power this 1917 and 1918, but was exercised only rare cases, and then with dis- astrous effects far increased production was concerned. easy stop the wheels plant from turning, but another start them again. Those manufac- turers who took contracts based the Government supplying them with material can well remember the days, weeks and months their plants were either totally idle working much reduced capacity waiting for the Government agen- cies function. absolute lack raw mate- rials, and the development sub- stitutes new sources supply, also caused endless expense. Mr. Baruch has pointed out the Nye Committee our lack tin. the latter part 1917 precision glass was matter grave concern. Precision glass was not then one our accomplishments. The days when batteries were trained sight bodies massed troops went out with the Civil War. knew guns trained range find- ers unseen foes required accu- rate gun sights, but still de- pended Germany for glass, and unfortunately that supply was cut off. After war was declared had learn make precision glass, painfully slow and expen- sive process, the records the Bureau Standards will show. learn slowly, however, the press recently stated that notwithstanding Mr. Baruch’s sug- gestion steps would taken create supply tin this time, that would give the impression that were preparing for war. Surely the monument Muscle Shoals should shudder the thought leaving the Government the creation facilities for the production mu- nitions. This was the Govern- ment’s contribution the supply nitrates, and the Nye Commit- tee might well investigate the cost this portion the explosive program. Let written into the record this committee that had had depend the Government forces produce the facilities for the manufacture the things nec- essary wage war, feed, clothe and equip army five million men, these facilities would never have been created, regardless cost, and never will created Government forces any similar emergency the future. task huge enough itself was, and will be, formulate the program met, and American industry was, and must left the task from there. Let further written into the record that American business will not found lacking either patriot- ism, energy ability. War Would Tax Our Entire Production Capacity country such ours can ever expected have capacity for equipping combat army with- out calling the entire produc- tive capacity the country. think otherwise futile. The day small armies past and gone. Any war the future will waged with enormous forces land, sea and air. create the facilities required equip such forces republic such ours (CONCLUDED PAGE 54) THE IRON AGE, January 24, 1935—13 p é = 4 inf A j = i q | _ PM H 730, a ay t ¥ > > y 4 acy 1 > 1 t ANUFACTURE clad steel the plant Lukens Steel Co., Coates- ville, Pa., starts with bloom flange quality steel and slab pure nickel. and steel have practically the same coefficient expansion under heat and this not only advantage plates but also prevents strains the material when used under con- ditions expansion and contrac- tion service. The usual propor- tion thickness nickel steel cladding may range from per cent nickel heavier per cent the case ice cream freezer shells where the in- side surface machined after the shell rolled and welded. Assuming that the usual ratio prevail, and that the ini- in., then the steel bloom pre- pared for bonding rolling thickness in., trimming approximate size with the gas torch, and carefully flattening flattening press. After this the IRON AGE, January 24, 1935 surface which bonded with the nickel sand blasted with fine iron powder blast. This blast cleaning im- portant part the process. done modern sand blast room with adequate exhaust and with specially prepared clean abrasive. The nickel this point follows through sequence operations similar that the steel. That is, the slab rolled down the desired thickness, in., and then trimmed under shears, flat- tened press, and one surface abrasive blasted much the case blast opera- tions are carried and the two plates which are bonded are placed contact reduce minimum any tendency toward oxidation the introduc- tion foreign gases. Two pairs plates are rolled together, that is, two steel plates and two nickel plates, the steel being the outside and the nickel the inside, with parting com- pound between the method joining nickel and steel described this article that developed the Lukens Steel Co., and the Inter- national Nickel Co. The prod- uct, nickel-clad steel, used principally where against corrosion desired combination with the economy plain steel. plates. facilitate sealing this assembly welding, the steel left extending short distance, perhaps in., beyond the nickel all edges. this method sealed assembly rolling which has spelled success for the process, this way the nickel protected throughout the rolling ing procedure. Method Rolling The assembly four plates for rolling usually built fol- lows: The first steel plate, which frequently ft. square, placed supporting table with its cleaned surface up, the table being such height that the edges the plates are convenient posi- tion for welding. top this steel plate then placed the first nickel plate with its cleaned sur- face contact with Then comes the parting paste, fol- lowed the second nickel plate with its sanded surface upward, and, turn, the second steel plate with its surface against the nickel complete the These plates, stated, assembly. 3 q } — are all set place immediately after the sanding has been com- pleted. The projecting edges the steel plates then are quickly welded together across the edges the nickel plates com- pletely seal the nickel. section this assembly four plates shown the accompany- ing sketch. may supposed, the discov- ery suitable parting paste was one the most important steps the development the whole Lu- kens cladding process. composition came only after long and difficult research work and its exact character one the com- pany’s trade formulae. The de- mands such parting material are rigorous. must resist the high heat required for the bonding and rolling the plates. must spread evenly and thoroughly be- tween the two nickel plates during the rolling, because otherwise the plates will come contact and will bond together, necessitating scrap- ping the entire plate combina- tion. Also, the parting material must easily removable after rolling and after the two sections are separated. And course must not any way injure the surface the nickel create pressure which would destroy the sealing weld. This welding done electrically, using steel welding rod ap- proximately the same composition the steel the plates. The welding done chiefly keep rases away from the nickel the time high temperature, the nickel being very sensitive sul- phur the 2300 2400 deg. required for bonding. After welding, the assembly placed furnace and brought slowly 2400 deg. then transferred quickly the rolls, that the first pass will occur HERBERT SIMONDS temperature above 2300. this first pass which creates the bond between the nickel and the steel, and subsequent rolling merely reduce the bonded plates the desired thickness. fact, subse- quent rolling operations follow ONSTRUCTION di- ameter, 29-ft. deep nickel-clad steel soap boiling kettle large turer. The joints are welded are made pure nickel. YS Some Uses Nickel-Clad exactly the same manner would the case with solid steel plate the same dimensions. After once having secured tween the nickel and the steel, roll- ing may continue until any desired thickness plate secured, the constant. After rolling has been com- pleted, the plate trimmed four sides, usually under shears, and the two parts are then sepa- ~ in EX | > ng, . A atin BES ex! SECTION SHOWING ARRANGEMENT METALS Berore ROLLING STEEL NICKEL PARTING building sections steel and nickel for bondina and rolling. Two-bi-metal plates are produced at ne rolling and the two are ther separated the centra parting line. indicated, the sembly consist steel plate, then nickel plate close contact, then parting mpound, second nickel plate, and finally second steel plate clo: tact. The steel plat project beyond the nickel and the whole assembly sled weld the An +, te + ther LEFT rated. The power shear the STRIP Lukens plant has capacity for plate that cutting plate in. thick has been twisted and 200 in. wide. Above these di- test the bond tween the nickel and the steel. mensions the gas torch rotary saws are used. The trimming the two pairs clad plates re- moves the weld around the edge RIGHT the constructi large tank heads the plates are trim med circular disks required diameter and then are spun over approximate form this heavy spinning machine. The position the roller at the riqht which does the forn ing, controlled the operator. The size the machine may judged the man the back IRON AGE, January 24, 1935 HIS shows one two 8000-gal. tank ars built of nickel sd steel by tl American Car Foundry and leaves the two bonded pairs plates free for separation which done means wooden wedges. After this, the parting material washed off plate inspected and trimmed final size ready for shipping. Part the inspection includes tapping with small hammer determine the closeness adherence the nickel the steel. The largest nickel-clad plate far produced the Lukens plant was one 170 in. wide, 240 in. long, and in. thick, made for one the largest heavy ducers. The nature the bond between the nickel and the steel not accu- rately known. Section specimens when polished always show clear line demarcation between the two metals, but engineers the Lukens company state that having once secured good bond this way they have never known the two plates separating, matter how severe subsequent drawing | | ] é | é ] | ° ° i 4 j and forming operations may have been. The tensile strength than that steel plate the same overall thickness. tests using identical steel, unclad and clad, with the clad specimens hav- ing per cent nickel, the yield point for the steel alone averaged 42,200 and for the bimetal per sq. in. Use Diverse Industries April, 1932, the New York Central put into service locomo- tive equipped with steel fire-box. This locomotive and its fire-box were thoroughly tested and found perfect condi- tion November, 1934, after the engine had made 215,000 miles. Thus two-year life seemed as- sured. Records the life stand- ard steel fire-boxes exactly simi- lar service show average about one year before replacement necessary. The list uses nickel-clad HIS rather unusual view unusual drawing and forming press might entitled Detroit plants Fisher Body and helps make the for enclosed automobile bodies. detailed description this and other presses and processes used for this work appeared The steel constantly growing. seven colleges Yale University nickel-clad steel drinking water storage tanks are service. Die tanks the textile industry, var- nish kettles, nitriding ovens, indus- trial storage water heaters, and settling tanks are typical instances where nickel-clad steel proving valuable. the case vacuum tanks the use nickel-clad plate has made certain types con- struction possible for the time, steel tanks with non-clad protective linings often proved un- satisfactory due the collapsing the linings. the paper in- dustry often important high grade stock keep every trace iron out the alum and size tanks and this frequently done using nickel-clad tanks with pure nickel pipes and fittings. Tank trucks clad steel are coming into popular- ity for sugar, syrup, etc. Mixers, evaporators, and boiling kettles the soap in- dustry are Some this apparatus when made with the bi-metal plate said several times expensive the plain steel, but the added life and freedom from impurities make this advance price warranted. the chemical industry bleach- ing tanks for fatty acids and stor- age tanks for caustics are fre- quently made nickel-clad plate. one the new alkali plants, more than 400,000 clad was used for equipment. metal tanks are used for process- ing kettles and nickel-clad tanks for storing and transporting phe- nol are coming into use. Other typical applications nickel-clad handling chemicals are mixing tanks for caustic soda and sodium carbonate used manufacturing tri-sodium phosphate, storage tanks for high grade gelatine used photographic work, tanks secure purity the manufacture vis- cose rayon, and much apparatus for research work organic chemistry. r 7 Welded vs. Cast Jigs building jigs and fix- tures electrically welding fabricated steel, after five years use have advantages over the cast iron body type. The most important advantage the method the saving the initial cost the tools, which BOILER PLATE .20 CARBON S.A.E. ranges from per cent, and some cases high per cent. general rule, the larger, the more complicated the jigs fixtures, the greater the saving. The pattern shop and the foundry are eliminated when this method used, and therefore delays from these sources are avoided. co.o ORAWN The equipment required consists pantograph type oxy-acetylene cutting machine, with radius at- tachment for circular work, electric welder and square surface plate with machined T-slots both directions. The surface plate and series 90-deg. knees, strap T-slot and clamps, bolts RECTANGULAR COLO ORAWN STD.BLANK BOSSES LENGTH 4 GENERAL NOTES: WHEN A STOCK MATERIAL USED THE WARNER SWASEY CO. IRON AGE, January 24, 1935 AR SIZES 00 NOT USE HOT ROLLED ST, WHEREVE USE STANDAR POSSIBLE= COL ! OSSES WHEREVER POSSIBLE. WELOED JIGS FIXTURES OR. Br- F.V.K OVER DETAIL PARTS, SAME SHOULD BE OLLED ONLY WHERE HOT ROLLED. |2x2% URNED FRO Te. IZE REQO. 1S NOT LISTED IN HOT ROLLED. | $.A.E.X-1315 FOR SPECIAL BOSSES(WHICH BORED TAPPED) USE FREE MACHINING STEEL. and Fixtures C-clamps are indispensable, inas- much setting tack-weld the parts consumes large portion the welder’s time. Data Sheets Essential The average tool designer fur- nished with set data sheets showing the bar stock and boiler plate sizes hand and also stand- ard welded joints used can readily adapt himself this method designing. The data sheet shown Fig. contains complete list square and rectangular bar sizes, both hot and cold finished, nesses boiler plate and also LEFT HIS data sheet easily obtain- able standard stock materials simplifies the work the engineer charged with the develop- ment welded jigs fixtures. RIGHT HESE welded joint simplify the prob- fabrication welded and fixtures the Warner Swasey Co. plant, and with tions, cover require ments. THE WARNER & SWASEY CO. REINFORCED STOP GEORGE KLUTER The Warner Swasey Co., Cleveland standard jig bosses. the War- ner Swasey Co. stock kept hand all times and will fill the requirements for all jigs and fixtures, well many other parts that are fabricated. beyond the range bar sizes, irregular shape, are burned out boiler plate. The data sheet shown Fig. illustrates the standard welded joints used. These joints are all very simple, and with but very few exceptions cover the require- ments jig and fixture design. The saving welded jig con- struction starts the tool design CORNER WELO TEE WELO BOSsEes FLUSH TYPE WELO PARTS TO BE CHAMFEREO BEFORE WELOING. on. department. The designer can build jig fixture more rap- idly with steel blocks and plates because the worries coring and strength overhanging lugs and close clearance due draft castings are eliminated. The wall sections and ribs can cut down from per cent those required for cast iron, thereby making the jig lighter and smaller. The breakage due rough han- dling eliminated, and the wear- ing surfaces, where hardened but- tons plates are not required, stand better. CORNER LAP WELD LAP wWELO FOR OFFSET SHOP TOOL DESIGN STANOAROS SHEET NOS THE IRON AGE, January 24, 4 ax i | N . =3 | ‘ | Y on | The welder must furnished with full-size layout all parts burned from the boiler plate. This layout can made trac- ing transparent sketch paper from the original tool drawing and should made 1/16 in. oversize all edges burned. This will allow for what lost the width the burning flame, which thick plate. The layout should made 3/16 in. oversize all edges requiring finishing, leaving in. for finish. making the burning layout plate which has numerous bosses, att 7 lugs and ribs welded it, great deal the layout time saved these are all traced position the layout. The welder places this layout top the burned plate, using template, pricks punches for all the locations and proceeds tack weld. Layout Used Template the case rush job, the average jig fixture drawing can sent the welding department the morning and the afternoon the same day will find this welded body the heat-treating department for normalizing. The welded body then placed the regular carburizing oven, which just cooling from the regular day’s production work. then heated about 1100 deg. and allowed cool the oven overnight, thereby removing all welding then sent the tool room machined. The machining time welded body seldom per cent more than that cast iron. 20—THE IRON AGE, January 24, 1935 most cases approximately the same, and some cases less. The reasons are: less stock allowed for finish; shorter bores for bush- ings and studs; and the case plate jigs, surface grind only required clean up. The points above discussed may specific cases. Examples and Tabulations Comparative Costs Fig. shows welded steel drill jig used for drilling from three directions. The fork | iy t ssibility of breakaaqe when the more brittle metals are ised, is well illus trated this fix drilled shown the right the jig. The significance welded con- struction most appreciated mental picture formed cast iron jig for the Note particular the overhang the legs. This could not per- mitted cast iron construction. Rough handling the jig might break the legs, since cast iron comparatively brittle. WELDED STEEL Burning and welding—4 hr. $1.75.. hr. $1.75.. Weight—22 Ib. @ $0.035 The next points importance are the bushing and locating lugs. These lugs are made very light construction, and welded their proper locations without any the worries the cooling strains due thin and uneven sections, which are present cast iron construc- tion. cast the lugs shown, several cores and tional design interest the designer only concerns the usage the jig. Since sections can and much the reinforcing overhanging parts eliminated, the jig becomes lighter and smaller. Excess weight and size beyond the strength requirement tion consumes non-productive en- ergy too costly permitted. this case the actual burning and welding time was hr. (An estimated time hr. was ob- tained from the pattern depart- ment for making pattern for ‘ast iron body answer the same purpose. The accompanying table comparative statement cost. other words, the welded steel construction cost approximately per cent that cast iron the above case. Fig. shows milling fixture for 9-in. 24-in. face gear Notice should taken the lugs which hold the locating and thrust buttons. These lugs not only take the thrust the cutter, but also the stresses created the horizontal clamp screw and the toe clamp. Although the sections are smaller and the ribs are fewer than those required cast iron, this fixture very rigid. Bending moments are more readily taken care steel construction than one CONSTRUCTION CAST IRON CONSTRUCTION Estimated pattern hr. $1.75.. Machining time—15 hr. @ $1.75... He Total tatio: Welded steel, 34.02; Cast iron, 48. j | | | Ca m < cu pa m co possible, comparatively, reduce the amount netal required for strength maintain necessary this milling machine tixture which its design invite rouble if strenath is missing. cast iron. Note the open design, which eliminates chip pockets and makes cleaning easier. This design would make very simple pattern were cast from iron, yet the comparative statement below shown saving per cent. Fig. shows boring and back- facing fixture for bar-feed head. picture the work ma- chined shown the right the fixture, the large hole being diameter, and the boss faced diameter. dis- cussing this fixture the same points are important those mentioned with respect Figs. and The open construction this fixture allows the operator conveniently insert the back-facing cutter, and also observe and measure the cut. again apparent that the pattern time will exceed the burn- ing and welding time. Further- more, made cast iron, the weight would increase. The com- parative statement below again shows saving over the old method. other words, the welded steel construction cost approximately per cent that cast iron the above case. time through eliminating the necessity pattern making the con- truction this boring and fixture evident from study this illustration. The possibility for thinner walls and therefore less weight, apparent. WELDED STEEL CONSTRUCTION 10 hr. @ $1.75 Machining 41 hr. @ $1.75 Burning and welding Weight—275 Ib. @ $0.035.... Total CAST IRON CONSTRUCTION Estimated pattern time—1l14 hr. @ $1.75.. Estimated pattern material Machining time—37 hr. @ $1.75..... Estimated weight—300 $0.07.. Ratio: Welded steel, 98.88; Cast iron, 112.75 WELDED STEEL CONSTRUCTION Burning and hr. $1.75.. Machining—38 hr. $1.75. Weight—155 Ib. $0.035.... Total Estimated pattern time—1l14 hr. @ $1.75.... Estimated pattern material. hr. Total . «ax ‘ Welded steel, S6.81; Ratio: THE IRON AGE, January 24, $17.50 71.75 9.63 $98.88 $24.50 2.50 64.75 21.00 $112.75 per cent $14.88 66,50 5.43 SS6.81 $24.50 3.50 63.00 13.30 $104.30 = per cent | — 43 CAST IRON CONSTRUCTION 5 nae oft wr UG after surplus ired from ladle. CONE several thousand years, prob- ably far back 2000 B.C., genuine wrought iron has found fa- vor with builders and artisans, for during the greater portion this pe- riod was the only ductile ferrous metal However, late years wrought iron has encountered serious competition from steels and irons which have been greatly im- proved the addition alloying ele- ments. But with the successful al- loying wrought iron the last few years, all indications point toward wider use this material. Wrought iron containing 3.50 per cent nickel today being made Byers Co., Pittsburgh. The Aston Byers process employed its man- ufacture and, although much has been written about this method, the follow- ing description included order that the review the new nickel-iron complete. The Aston process for the manufac- ture genuine wrought iron note- worthy that eliminates laborious and expensive hand labor without loss two fundamental and very im- portant characteristics the iron, i.e., purity the base metal and the iron silicate slag content. These two characteristics confer upon wrought iron its desirable properties sistance corrosion, high strength and fatigue resistance. Briefly, the Byers process involves the melting suitable pig iron cupola, after which refined converter. Prior the re- fining the iron subjected spe- cial desulphurizing process. the same time special slag iron sili- cate being prepared from iron oxide and sand special open-hearth fur- nace. proper time this slag tapped from the furnace and carried ladles station directly beneath so-called processing platform, which the ladle containing the refined metal purified iron from the con- verters has also been conveyed. The next operation the key the entire process—that refined metal disintegration and slag incorporation. That is, the refined iron poured specified rate into ladle containing the molten slag. The ladle containing the iron automatically moved back- ward and forward insure uniform distribution the metal throughout the slag. Since the temperature the molten slag maintained several hundred de- grees below the “freezing point” the metal, the latter rapidly solidified. This rapid freezing causes the gases dissolved the metal liberated with sufficient force shatter the into small fragments. These fragments settle the bottom the slag ladle, The surplus slag poured off, leaving sponge-like ball metal impregnated with slag. The sponge balls, weighing from 6000 8000 are produced the rate about one every five minutes. The sponge ball the slag ladle conveyed 900-ton electrically driven press, where the ball pressed into bloom, which subsequently rolled into the desired product. This series the photos iron the essary thi: tained for or un¢ nickel Carb Mang The mately for The tions iron i? fol a ‘ | 7 nicl Shaped | As | 4 3 sist cor | pen hearth int ladie | Sulpl 4 é Silica Nicke Slag al sq ensj per Redu per | | | New Product URING the last five years sev- eral companies have success- fully experimented with alloying additions wrought iron, usually nickel, copper, molybdenum. result this ancient material has been modernized and, would expected, better strength and im- proved fatigue and corrosion re- sistances are now available. Nickel wrought iron being produced commercially the Byers Co., Pittsburgh, and this article describes the cycle operations its manufacture. regular wrought iron, this new metal processed the Aston method; with per cent nickel the mechan- ical properties can enhanced heat treatment. The nickel addition improves the hardness and resist- ance impact, and raises the yield point and ultimate strength. series operations from the melting the iron the rolling the bloom portrayed the accompanying produce nickel alloy wrought iron this process, nickel added the molten iron the amount nec- essary give the desired composition. this way even distribution ob- tained. wrought iron containing per cent nickel possible, but for most practical purposes per cent under most satisfactory. typical chemical analysis nickel wrought iron follows: Per Cent Carbon.. 0.04 under Manganese 0.05 or under 0.10 to 0.12 0.03 or under The composition unalloyed standard wrought iron approxi- mately the same that shown except for the nickel content. The comparative physical specifica- tions for the two classes wrought iron the same form product are follows: Nickel Standard Wrought Wrought Iron Iron Yield point, per Tensile