The Iron Age 1935-02-07: Vol 135 Iss 6

239 West 39th St., New York 1935 Registration No. A-3:31-0-1590 Owned, Published and Copyrighted CHILTON COMPANY (Incorporated ) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. ©. A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, JOSEPH HILDRETH GEORGE GRIFFITHS EVERIT PRNEST HASTINGS WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary Vice-President FRITZ FRANK, President VAN DEVENTER Editor Managing Editor News Editor Machinery Editor Editor Emeritus Washington Chicago Cleveland EHRNSTROM, FINNEY GERARD FRAZAR McINTOSH Pittsburgh Detroit Boston Cincinnati 1935 Determining Corrosion Resistance Stainless Steels. Pension Plans the and Steel Industry.......... Residential Stoker Industry Growing Outlet for Steel Short Week Panacea Won't Cure Variable Blow Hammer Insures Flexibility Forging...... Late Returns from Laboratory and Mill......... Light Weight Brick for Furnace Insulation Mountain Pipe Line Constructed Welding........... Automotive Industry Washington News ......... December Pig Production Construction and Equipment Buying Products Advertised 120 BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau of Circulations ADVERTISING STAFF Emerson Findley, 311 Union Bldg., Cleveland Member, Associated Business Papers B. L. Herman, 675 “ue Ave., Buffalo, Published every Thursday. Subscrip- Hottenstein, 802 Otis Bldg., Chicago tion Price: United States and Pos- Peirce Lewis, 7310 Woodward Ave., Detroit sessions, Mexico, Cuba, $6.00; Can- Charles Lundberg, Chilton Bidg., Chestnut & 56th Sts., Philadelphia, Pa. year. copy Robinson, 428 Park Bldg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address, ‘‘Ironage, Warren, Box 81, Hartford, Conn. nose aber the ased hav- ntly will ssia 2low rher the ,000 tons The con- us the nen, orks ela The tain hip. hip- The Buy Locally Ship from the Ryerson Plant Nearest Destination Buyers who must purchase material for use distant plants jobs find both economical well convenient place their orders with our local plants. The order entered and relayed the Ryerson Plant that nearest the point destination. This Ryerson Plant ships once with the same speed and accuracy that characterizes our local deliveries. this way you may deal with known source that familiar with your specifications—a firm you can depend and keep touch with through the telephone your desk. This national service aids economical centralized buying. Time saved placing orders—errors are eliminated— money saved thru saving time and freight—time again saved actual delivery. every point contact, Ryerson personal service assured, There separate Ryerson Stock List for each the ten plants. will glad furnish copies the books which you may interested. Address the nearest plant. Joseph Ryerson Son, Inc. Steel-service plants Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleve land, Buffalo, Boston, Philadelphia, Jersey City. NATIONAL STEEL SERVICE IRON AGE, February 1935 | | THE IRON AGE... FEBRUARY 1935 ESTABLISHED 1855 Thrift big family known the United States has had its billion dollar year Vol. 135, No. income cut half since has also increased its mortgage debt from When the income ordinary family cut half and its debts are increased some per cent, the best remedy the exercise high degree thrift. Thrift defined means making the money that one has his disposal further and better. Strangely enough, this common sense way out for family such straits, the good management way disciplining the pennies, forgotten nowadays when our rulers think terms public spending. One the ''show the New Deal has been the check writing depart- ment the A.A.A. Uncle Sam's money could not spent fast enough through writing checks the old fashioned way, marvelous array check writing and bookkeeping and tabulating machines was installed for the purpose speeding the flow money the farmers for not raising crops. This but one instance the enormous which Washing- ton has put together during the past two years for the purpose spending out our difficulties. And very large measure, this machine being run men who have had scant experience creating wealth earned income but whose chief expertness lies their ability generate outgo. Eventually, though payment may deferred, industry, which still wedded the old fashioned idea thrift, must inevitably foot most the bill for the operation our national subtracting machine. must set income adding machine which will work faster than does this income subtracting machine. —time How can this done the face the urge toward less work, shorter hours and the removal the incentives toward individual effort which necessarily accom- pany the cushioning the exigencies life paternalistic government? There only one way create new wealth the scale that will necessary. That the way reequip our industries with more efficient machinery. improved the machine the real symbol thrift, for makes the dollar expenditure further and more. put enough these income adding machines work may able balance the work the national subtracting machine. plants Cleve- A +) | A a Fh Method for Determining The Resistance Cr-Ni Steels the Chicago convention the American Society for Metals, 1930, Huey presented paper entitled “Corro- sion Test for Research and Inspec- tion Alloys.” recommended the testing chromium and chro- mium-nickel corrosion resisting steels prolonged boiling con- centrated nitric acid per cent acidity weight. This test meth- od, stated, had been the result extensive investigations con- ducted almost continuously since 1924 the laboratories the Pont Nemours Co., Inc. Huey sponsored the method fully meeting the requirements for (1) testing the reactions metals corrosion with view im- provement the metals, (2) the development better metals, and 12—THE IRON AGE, February 1935 MORRIS JOHNSON Chief Chemist, Crucible Steel Company America (3) forecast the performance metals under corrosive attack. The tests were made liter flasks fitted with return condensers connected ground glass hollow stoppers. These stoppers were in- applications corrosion re- sisting steels are varied that any accelerated laboratory test must carefully interpreted. the available short-time procedures, the method initiated Huey probably the best, partly because the discrepancies due oxygen concentration and stagnant liquid films are reduced minimum. The original Huey apparatus, how- ever, has several drawbacks. There- fore this improved method most timely, for new corrosion resisting steels are being developed daily, and utmost importance that accurate predictions can quickly made their life expectancy various media. terchangeable, i.e., they would fit any boiling flask. photo the original apparatus shown Fig. the following paragraphs the glass parts the original Huey equipment and the improvements made the writer will de- scribed. The boiling flask, Fig. has capacity 1060 ml. the base the ground glass neck. This neck has inside diameter 5.9 cm., and 5.4 em. long. The entire flask 19.7 high and 12.8 cm. wide near the bottom bilge. order maintain the strength acid per cent weight, the flasks are fitted with glass con- densers shown Fig. The hol- low glass stoppers (Fig. these condensers (6, Fig. are ground accurately fit the flask shown Fig. These stoppers are interchangeable, i.e., will fit any boiling flask. These stoppers and necks fit well enough se- cure tight joint without twisting with any great force. The neck the condenser (A) Fig. 2.4 em. O.D. cm. long. The extension tube the top the ° ° ° | | =_ condenser measures 1.7 em. O.D. and 7.5 long. The total over- all length the condenser, includ- ing the ground glass, hollow inter- changeable stopper, cm. putting the original Huey apparatus (Fig. into service, the little glass hooks the inside the stopper (shown Fig. soon began jump off. the specimens are supported glass rods from these hooks, the break- ing the hooks rendered the con- denser unserviceable. withdrawing the stopper, also has tendency stick the ground glass neck after 48-hr. run. The comparatively heavy pieces steel (Fig. are de- cided danger dropping off the hooks when the stopper removed. Thus there possibility the specimens falling into the boiling flask and breaking it, thereby re- leasing 800 ml. hot concentrated acid. The powerful acid would violently attack the steel top the electric heater, thereby en- dangering the operators. was decided abandon the hook supports and suspend the test pieces with glass rod swings. These swings can easily bent from mm. diameter rods support sheet samples, and from mm. rods for heavy tests such bar samples. These swings are shown Figs. and These rods mere- lean against the walls the boiling flask. Where the test sam- ples are small, many disks can suspended one boil- ing flask. None the samples touch each other the side wall the boiling flask. The use these swings does away with the inner hooks satisfactory manner. Consequent- much time saved, usually the hooks drop off fast they are used. Also, has been found that there longer any need for the larger glass hooks the outside the ground glass neck the flasks, shown Figs. and Standard Apparatus Used The method clamping and supporting the rather long and heavy condensers shown Fig. removes any need the outside glass hooks the boiling flasks. Ordinary large ring stands are used, and the asbestos-covered jaws the extension clamp grip the condenser firmly place, taking its weight off the boiling flask. Such arrangement gives flexi- bility and made entirely from standard parts obtainable from dealers chemical apparatus. Three boiling flasks accom- modated one Rezistal pan, necessary. Fig. there are two flasks each pan, although there plenty space for third one. Fig. illustrates four flasks op- erating the same time. The cooling water enters (1), passes through all condensers, and leaves (2) the sink. catch any possible spills large quantities the boiling, con- centrated nitric acid, the flasks rest Rezistal pans. This metal not appreciably attacked the hot acid. The pan dimensions are 30.5 inside diameter, cm. deep, and cm. across the top. Com- plete protection thus provided for the operator and the steel top the electric hot plate. Asbestos wool placed loosely the Rezistal pan around the flasks order hasten boiling. See (3) Fig. The electric hot plate can regulated give high, medium low temperature. electric heater should used for this work wherever possible, gives uniform temperature over long period time with ne- cessity for adjustment. All the operator needs watch that the acid boiling slowly, that the con- denser tubes feel cool the hand, and that the tap water passing through them moderate speed. When the steel specimens and the acid are the flask, the ground glass stopper of. the condenser set the neck the flask. This should done carefully and firm- ly, and the stopper should not twisted too tightly. twisted tightly the operator may find trouble disconnecting the con- denser the end the run. When the test period over, the con- denser disconnected once from the flask prevent sticking, which much worse when the apparatus gets cold. Preparation the Specimens Huey used metal sample 1.875 0.875 0.375 in., with 0.25-in. diameter hole the center one original Huey apparatus (below) for rapidly testing the corrosion resistance chromium and chromium-nickel alloys. The data obtained are used forecast the performance these alloys service. 2—Lower part the glass condenser the Huey apparatus. The glass hooks sup- porting the specimens often break thereby re- leasing the samples which turn fracture the acid-filled beaker. the improved Johnson equipment, the hooks are abandoned favor glass rod swings, shown Figs. and THE IRON AGE, February ° ° ° g. ¢ 4 end about 0.25 in. from the edge. also recommended diame- ter disks for round specimens. Huey finished the machined surface with 120 French emery, and avoided heating the surface ex- cessive friction. Visible scratches were removed, but mirror-like polish was not regarded neces- sary. actual practice all sorts di- mensions and surfaces are mitted, depending the shape and condition the finished mill prod- uct. The specific gravity deter- mined the usual manner weighing the stéel accurately air. Then weighed, suspended silk thread, distilled water possible. The difference between these two weights divided into the weight air. The quotient the specific gravity. Steels differing composition should not tested the same flask, electrical action may speed the corrosion one kind steel and the same time retard action the other samples. Also, speci- mens should not touch each other the walls the boiling flask. Samples must weighed clean, dry condition, both before and after the boiling acid. 14—THE IRON AGE, February 1935 LEFT 3—Method sup- porting sheet samples the Johnson appar- atus. The samples not touch each other the flask wall. RIGHT 4—Method sup- porting heavy bar samples. The glass rod swings rest against the walls the boiling flask, and the samples hang freely with only one point contact with glass. After the corrosion test, the sam- ples are rinsed hot tap water and the surfaces are rubbed with the hand until all sludge removed. Then the sample rinsed with dis- tilled water and dried once 100 deg. cooled room temperature dessicator and then weighed again. The loss weight found recorded parts gram. the specifica- tions require second 48-hr. boil, then fresh acid put the boil- ing flask and the specimens are put through again the first instance, and weighed The average loss for two 48-hr. boiling periods inserted the Huey formula, which is: AST gram for the boiling period. face the steel. specific gravity the steel. total boiling time hours. 43.9 factor for converting cubic units linear measure and hours months. inches penetration per month; this the desired result. The area circular disk in- cludes the two faces and the cylin- drical edge. The area the two faces gotten multiplying the square the radius 3.1416 and then two. The area the edge thickness the edge the diame- ter the disk, and then multiply- ing the result 3.1416. The area edge added that the two faces get the total area. customary some testing, least, ignore the area the %-in. hole, which really deductible from the total area. The cutting the hole exposes some additional surface, that the total area would less two circles in. diameter and increased the area cylindrical hole di- ameter the thickness the disk. For sheets and rectangular speci- mens, the area obtained mul- tiplying the width each face, edge, and end the length each. Add all and multiply the total area two, there are two each. Simplified Formula Used For work where the tests are number steels practically the gravity, the writer has deduced time-saving formula. is: (1) 16387.06 ° ° ° : penetration for each test period. Loss milligrams per sq. in. per test period, i.e., milligram loss whole number, 1.0 the formula. loss 2.5 milli- grams per sq. in. inserted for 2.5, and on. the total loss milligrams per sq. in. that obtained running one 48-hr. test, then the inches penetration per month will be: 16387.06 inches penetration per month. Usually two 48-hr. tests are run and the average the two losses inserted formula (2) for One milligram loss per sq. in. hav- ing the value whole number. Formulas (1) and (2) are deduced follows: inches penetration per test pe- riod. loss milligrams per sq. in. per test period; one milligram being whole number the for- mula. men. penetration millimeters per test period. The formula derived the following manner: square inch 25.4 25.4 sq. mil- limeters. Hence 25.4 25.4 surface exposed). Therefore 6451.6 Since 25.4 inches; Therefore, 25.4 6451.6 25.4 Performing the calculations indi- cated the above equation, the following equation secured: (1) = ————— = RP 25.4 16387.06 The formulas can further sim- plified for per cent chromium and 18-8 steels. per 5—The improved Huey testing equipment devised Morris Johnson. These four flasks are operating the same time. cent chromium steels, 7.73 should substituted for thereby ob- taining 16387.06 7.73 126672 Then the test period hr., Inches pene- 126672 tration per month days. Dividing 126672 will eliminate this factor, and then 8444.8 like manner, for 18-8 steels, sub- stitute 7.9 for Then 16387.06 7.9 129457.7 With 48-hr. test periods, 129457.7 inches penetration per month. These quite simple formulas (3) and (4), course, reduce calcula- tion labors. like manner, for- mulas can derived for any type testing from the parent formula 16387.06 Obviously formula (1) holds good for any metal any corrosive solu- tion that does not appreciably at- tack the glass. Application the Formulas Consider the case per cent chromium steel; the data are quan- titative. Total loss for hr. 0.0638 gm. Exposed area (sum areas two faces, edges, and ends) 2.93 sq. Loss milligrams per sq. in. Specific gravity 7.73 Substituting the Huey formula: 43.9 43.9 0.0638 AST 2.93 7.73 0.00258 in. Substituting the writer’s formu- for this grade: 21.77 8445 8445 in. With the following data for 18-8 steel, the solution would be: (CONCLUDED PAGE 84) THE IRON AGE, February 4 . ot | ae the neighborhood pension plans the various branches the iron and steel industry. That would comprise iron and production, fabrication and related machine tool and machinery lines, and henceforth this broad sense that the term “iron and steel” industry employed. These pension plans have de- veloped preconceived, agreed upon program. They are the individual manufacturer’s an- swer what believes might done practically, take care the employee who grows old his service. While there are certain marks imitation, usually the plan leader the industry, the respective separate, important provisions show the greatest pos- sible range treatment. fact, scarcely two plans are exactly alike some important element. For example, what ages shall em- ployees both sexes retired, after how many years service, and shall such retirement com- pulsory, voluntary discretionary, and what age service levels? there are pension plans, will find different and ingenious answers this question. Plans Developed Empirically The development plans the iron and steel indus- try has proceeded empirically, trial and error process. But the time has come take stock and evaluate what has been done. may possible for the industry its component branches decide upon some more uniform basis, from which pensions, the light accumulated experience, may henceforth proceed. Nor be- lieve wise wait upon the passage State Federal legis- lation, which unlikely afford equitable complete answer 16—THE IRON AGE, February 1935 Pension Plans the lron the pension requirements the iron and steel industry. The preliminary step, which least desirable, the collection all available information existing pension systems the iron and steel industry, the analy- sis and digesting this informa- tion, and the discussion and ex- change opinion thereon those executives the industry under whose jurisdictions pensions come. Certain tentative standards practice may thus suggested. The point should like em- phasize that pensions are not the concern isolated companies more than the matter the depreciation plant and equip- ment. human depreciation, we, too, have inescapable element which our operating sheets must provide for and our prices for steel and iron products include. The times may not propitious for many additional iron and steel you have pen- sion plan your busi- ness, designed take care superannuated employees. Perhaps still the speak, and therefore well within the bounds sup- portability. But plans this sort have way growing up, especially the companies where labor turnover low. And when pension plans grow up, rather the pensioners do, watch out for the growth cost operation. manufacturers assume the bur- den fully contractual pension plan, but, far possible, the competitive advantage the less progressive manufacturer should equalized. Some Pertinent Questions short article this nature, possible indicate only some the pension matters which should probed the industry whole: 1—The underlying social, economic and operating factors that make pen- sions matter practical importance. 2—Who shall bear the cost the pensions, the employer alone, or shall the worker contribute? I shall later refer this matter more detail. ages for retirement shall and Steel Industry Industrial conceived enlightened managers private enter- prise, will not superseded any Government pension plan. The latter, matter how may camouflaged, really nothing but more economical and efficient way community solution the almshouse problem. Private pension plans will continue: but they should have industry breadth and uniformity and not penalize, competitively, the public-spirited employer. be invoked, and how many years of service shall entitle to full pension benefits? 4—What pension benefits shall paid? Shall maximum and minimum amounts set, shall anything ac- crue to the pensioner’s dependents upon his decease? What provision shall made for past service? carried company, shall there be an industry-wide pension fund? Shall funds be set aside or reserves merely created? These are but sampling pension matters should forcedly include consideration proposed governmental legislation upon which the combined judgment the industry will helpful. There are, course, many prece- dents for the type study suggesting. nothing new strange the iron and steel in- dustry. should like refer greater detail the matter employee participation. number, about per cent the pension systems the iron and steel industry are non-contributory, that the em- ployer bears the full cost. The percentage much higher from the viewpoint the pension bene- fits paid. fact, know only three pension plans any conse- quence the iron and steel indus- try that are contributory. Now that situation, believe, funda- mentally wrong. may work out well for num- ber years. Here, for example, are some statistics the pension experience the Bethlehem Steel Co., drawn from the eleventh an- nual report the operations the plan, which shows that the cost still very modest. The total amount money paid pension- ers during 1933 was $814,567, rep- resenting 1.73 per cent the pay- roll. The average monthly pension for the 184 pensions granted dur- ing 1933 amounts $35.16. The average period service for the 184 employees was 34.47 years. Their average age was 66.51 years. The average duration pension payments for the 116 terminated pensions the year was 5.51 years. The shortest duration pension payments was 0.17 year and the longest duration was 16.83 years. Since 1923 the aver- age duration pension payments ARTHUR LAZARUS the 1120 terminated pensions was 5.15 years. Here plan whose present cost clearly sup- portable, but the plan only years old, and pension plans have the deceptive quality costing very little the early years their operation. The Steel Pension Plan Let look older plan, that the United States Steel Corpn., established 1911. The informa- tion presented drawn from the excellent annual reports this company. Let consider first the average monthly pension payment. This runs follows for employees re- tired during the years 1927 1933 inclusive: 1929 55.70 1931 69.45 57.85 1931, minimum and maximum pension allowances nated. Effective April 1933, pen- sion rates were reduced for all pen- sioners, except those receiving $35 and less per month. The reductions ranged from per cent the case those receiving monthly pen- sions from $35.01 $40 per cent the case pensioners the highest group. Suppose now consider the number employees the pen- sion roll comparison with the (CONTINUED PAGE 84) THE IRON AGE, February 4 2 = ig > Residential ECHANICAL refrigeration, washing machine and other electrical appliances designed make housekeeping easier, have done much provide comfort the home, and more re- cently air conditioning, having the same purpose, has made consider- able headway. Another line ac- tivity the home equipment field that also has the object increas- ing home comforts niences, activity that perhaps less conspicuous and less spectacu- lar than some others this field, has made rapid progress the past two three years. That the household stoker installation with hot water heating boiler. IRON AGE, February 1935 toker Industry Growing manufacture automatically con- trolled coal stokers for the home. This industry that creating increasing demand for iron and steel, well for motors, blowers, electric control and other equip- ment. While the quantity metal re- quired the manufacture small stoker adaptable for home varies according the make and design, stated that average from 700 800 lb. metal used residential type stoker. this, 100 150 rolled steel and the remainder cast parts. mechanical house stoker the usual under-feed type consists hopper, feed tube, conveyor spiral feed worm and retort the heating unit into which the conveyor delivers the fuel from the hopper. Set top the retort tuyere which there are ports through which air for combustion supplied the fuel bed. fuel agitator the hopper driven the feed worm. The stoker driven through gears located gear housing. 1/3-hp. motor drives the feeding mechanism and also 10- fan, which supplies air for com- bustion. Automatic control equip- ment includes thermostat and re- lay and limit switches. Hoppers and hopper bases one leading type stoker are made copper-bearing sheet steel 16-gage welded construction. Steel stampings are also used for some other parts. The conveyor screw and spider-type agitator are nickel alloy steel castings, this ma- terial being used because its corrosion and heat-resisting quali- ties. The retort and tuyeres are cast iron. Gears are bronze. Steady Increase Stoker Sales The American home provides very large potential market for the small stoker. During the depres- sion sales stokers for residence purposes showed steady increase volume, and manufacturing fa- cilities were enlarged. Sales do- mestic stokers 1934 broke all records. present about 50,000 homes the anthracite and bi- tuminous coal-consuming territories are equipped with mechanical household stokers, and, with about 25,000,000 one two-family dwellings this country, manu- facturers claim the market has barely been touched. Improvements refinements stokers are being made fre- quently and this helps increase sales. During 1934 there were ap- proximately stalled, which per cent, — 4 PRENTISS Cleveland Resident Editor, The lron Age 24,000, were the hold size with capacity 100 lb. coal per hr. less. Not all these went into homes, small stokers are used bakeries, green- houses and for other small heating plants. The common range pacity for home stokers lb. coal per hr. All types house-heating equip- ment have been made more effi- cient the past few years im- provements and refinements, and hold-type the stoker industry seems have kept pace with the improvement heating units. Automatic heat has become favorite expression with makers heating equipment when pointing out the advantages products, this being true whether the equipment designed burn gas, oil solid fuels. Competition among coal, gas and oil fuels for the home probably keener present than ever be- fore, and this competition evidently equally sharp among manu- facturers equipment for burn- ing the different types fuels. coke produced the iron and steel companies their by-product plants has become vigorous competitor other fuels for house-heating purposes, and in- cidentally might mentioned that very recent development the stoker industry which will prove aid disposing by- product domestic coke the bring- ing out Chicago company line stokers for mechanically serving house-heating plants and other heating units that use coke fuel. Envision Sale 100,000 Stokers Year Stoker manufacturers feel that view the advantages offered the use mechanical stokers compared with hand firing meth- ods and the very small percentage coal and coke-heated homes now equipped with stokers, sales do- mestic stokers within the next five six years will reach 100,000 units annually, most which will into homes and small apart- ments. the manufacture that number, 35,000 40,000 tons iron and steel would used. Some the later models do- stokers are the bin feed type, which obviates the necessity (CONCLUDED PAGE 88) THE IRON AGE, February > q Blanket Short much has been talked and written unemployment that seems there room for yet one more factual statement which will clear some the misapprehensions which exist both the lay and professional mind. The currently prevailing thought that the adop- tion the machine has created labor consuming Frankenstein, which responsible for the ac- knowledged unbalance our eco- nomic system, requires refutation, otherwise there danger that ill- considered action will engen- which value most highly, e., the American standard living. Diagram based the Census returns, clearly indicates the trends the last years, and close examination the figures brings out some interesting facts. From the years 1910 1930, in- clusive, the amount labor em- ployed the production farm produce has decreased despite the fact that there has been material increase population and pro- portionate growth the number farm products produced. With- out doubt this shrinkage em- ployment due part in- creased efficiency production brought about many ways the increased use farm ma- chinery. the right hand side the chart recording the growth in- dustrial activity, will noted that the number people gain- fully employed the producing industries has increased during the same period from 12,000,000 15,- 000,000. The net results the two activities, e., farming and industry, being loss labor ab- sorption respect farming 20—THE IRON AGE, February 1935 2,000,000 people, and gain in- dustry 3,000,000. should noted, however, that both activities have the common characteristic having greatly expanded the quantity units and total value their products; fact, this expansion value units produced has been much more greatly accelerated rate than would indicated the normal growth population. ognized fact that during the period under review, the mechanization industry has progressed much higher rate than has the mechani- zation farming operations. The most remarkable feature brought out the diagram and the establishment basic working week, but be- lieves that blanket basis, covering all industry, not feasible. industries, which are strong com- petitive position, states, could perhaps with 20-hour week, where others, particularly those subjected foreign competition, might require week hours. This thesis developed the accompanying article. accompanying figures, however, the fact that the service industries have during the years 1910 1930 expanded the use man power from million, and this turn leads the following logical conclusions: The expansion the service industries keeping with the phenomenal growth what term the United States standard living, these services being bought with some the profits accruing farm and industrial operations. Here again the question regarding the influence mechanization Panacea raised, and the natural corollary is, that mechanization, reducing the unit cost service, has con- tributed its quota the expansion and made possible for 9,000,000 extra people earn their living occupations coming within this category during the years inter- vening between 1910 and 1930. Factors Influencing Profitable Operation Having regard the fact that farming and productive industrial earning industries, well give consideration the elements which make possible for these industries earn profit. The major element, course, the power absorption existent our vast domestic market, but also major importance our ability secure reasonable quota for- eign trade. The personnel the service industries, e., that 23,- 000,000 people gainfully em- ployed and recorded the center column, also constitute great con- suming entity. The service indus- tries are what might considered the equalizing buffer organization which makes available all the benefits secured the profit- able operations the two basic industries farming and industry proper. Foreign Markets Reference Diagram clearly indicates what has happened our foreign markets for farm and in- dustrial products, and the natural question arises why these shrinkages have occurred. The evidence grows that the prices which our manufacturers goods other than those produced mass production basis, which are now being quoted, are too high command the former large pro- portion the foreign world market which one time enjoyed. Similar evidence also available which indicates that the high prices not represent effort extract undue amount profit out the foreign market, but are rather brought about high costs pr dit tel eff us wi pa ‘ ier mi as CO) tr! CO) wo do COs fol ele po wo ain | O / | an 1920 1930 J | Al Farm production. Naturally, the ques- tion arises why these costs production should dispropor- tionately high, and the answer in- dicated that what might termed our dollar manufacturing efficiency low, due high labor costs and disproportionately high overhead charges. However, purpose the moment would served debating this particular phase the matter other than point out that well quality basis, and the concession price should tributed the elements over- head and labor. competitors the world market work much longer hours than for considerably lower rates pay, hence must make the cost deficiency increased manu- facturing efficiency, and logically follows that when the overhead element has been reduced far possible the next contribution must made the number hours worked per day. Labor The problem are confronted with the regaining foreign business what might termed the capital goods industries, and the issue plain that this cannot accomplished when quote prices which are too high com- mand the prospective business. Our foreign customers past, actual, and potential, are not the slightest way interested the maintenance high standard living the United States. Hence, lacking sub- and such other artificial stim- ulants for our foreign business capital goods, the only way avail- able which can re-enter the market reduced cost basis, and all elements the costs should contribute their quota, the ac- ceptance reduced profit in- vestment, increasing the num- ber hours worked, and re- duction sales costs which could probably most efficiently accom- plished our domestic manufac- turers taking advantage the pro- visions the Webb-Pomerene Act, which permits them combine ° ° Chairman, Machine Shop Practice Division, American Society Mechanical Engineers ° ° price agreement for the explora- tion any and all foreign markets. Domestic Market Conditions far greater importance the scheme things, however, the restoration our vast domestic market which practically all times represents per cent our total business. Another fact respect the domestic market which should not lose sight that our increasing productive efficiency due mechanized manu- facture continually forcing working population into the service industries. However, this should not any way cause for healthy trend and corresponds its characteristics entirely with the growth quality the American standard living. the whole the citizens this country enjoy greater measure buyable ser- vices than the residents any other country the world, and (CONTINUED PAGE 73) 29.0 Total Total Gainfully Exports Exports 14.0 Exports Exports Industry Total Gainfully 49.0 70.0 Total Exports mineral and industrial. Farm Exports (Unprocessed) ABOVE Export Proportion Total Production labor, millions workers. THE IRON AGE, February Z fit t se he to ed on F I it 6><« 22.4 h = workers, 4 New Variable-Blow Insures Forging President, The Tool Co. HERE are many forging jobs requiring forging get the stock into proper shape for easy filling out impressions, for which long usage has dictated the steam ham- mer because its flexibility compared with board drop hammer. ex- ample, connecting rods are usually forged comparatively heavy bil lets, necessitating the drawing out the center the billet for the small section the rod, leaving the ends heavier. This accom- plished with succession rather light, rapid blows, stock rapidly possible and finishing with the heaviest blows bring the forging size and fill out the impression. This flexibility lacking the conventional board drop hammer which the speed and force the blow are fixed, and the forger has his choice complicated die obtain the right amount forging, wasting stock hammering billet into the finishing impression. the latter, the forging may next impossible produce, due 22—THE AGE, February 1935 thin sections cooling before the forging reduced size. any event the wear dies obvious when excess material forced out through thin pre-forging properly carried satisfied with the effi- ciency the conven- tional steam and board hammers for certain classes c Co., Cleveland, proceeded develop hammer along his own ideas. visioned the need and has per- fected board drop hammer with variable blow one that will deliver light rapid blows heavy blows, the change blow being made instantly the op- erator with foot treadle. Mr. Vichek's em- bodied small working model hammer that beina operated for demonstration ourposes the Vichek plant. out, using hammer possessing the required flexibility, that is, one able deliver the will the operator either succession light, rapid blows, heavy, solid blows, the speed produc- tion greatly improved and wear dies and equipment tremen- dously decreased. Drop Hammer Has Limitations Unfortunately this has, the past, been possible only with the steam hammer, which, must allowed, wonderfully There has seemed the writer, however, field which forgers have suffered because shortcom- ings their equipment. have mind those drop hammer shops which jobs, such described above, come with fair regular- ity, yet which the expense installing maintaining steam plant either objectionable prohibitive. Such situation calls for multiplicity equipment; halve-hammers and drop hammers, sometimes upsetters, combina- tion for the proper sequence pre-forging and finishing. The of ful sul tin or bil m . ° di 0 - e a ( machines single forging, and either maintaining crew for full utilization the assembly machines, the other hand suffering only one machine ous. Again, there are which are the border tween requiring steam hammer board drop hammer, which the forger turns over the steam hammer because its extra flexi- bility, but which regrets his inability use the more economi- cal board hammer. for this field work which the writer visions the variable ment, the economy the board hammer, requiring steam plant, fully retained. the same time the flexibility the steam hammer retained. Roll Release Under Pedal Control between the action the variable- blow hammer that have developed and the present automatic board drop hammer. The bottom knock- off and top roll release tained, with the essential differ- ence that the position the roll release movable the will the operator and creasing releasing the pressure his foot stroke-regulating pedal. This pedal located the center the customary treadle, that the same movement which starts the hammer places the op- erator’s foot position operate the stroke-regulating pedal. The layout the stroke-regu- lating mechanism extremely sim- ple: the roll release mounted carrier, which guided verti- cally one the uprights. The position the roll-release carrier, and, therefore, the length stroke, screw, which driven from one the overhead shafts may driven independently. the ham- through reversing clutch, which actuated the stroke regulat- ing pedal. The carrier limited either top bottom position means travel limiting dogs, which automatically and positively disengage the screw driving mech- anism, even against the continued pressure the operator’s foot. slightly the foot pres- sure the stroke-regulating pedal stops the action the mechanism, EW variable-blow hammer that will deliver light rapid blows long heavy blows, the anae nade instantly the operator with and the carrier held fixed position. From the above condensed de- scription will evident that the operator has his instant dis- posal flexibility operation ranging from the longest drop which the hammer will permit the shortest blow which will en- gage the knock-off. This tained, not choice between high and low drop, but steps small large desired between blows. The height drop may changed continuously either di- rection while forging. While the mechanism have been built into hammer with the conventional friction bar, this did not seem advisable, for reasons given above. was de- sired eliminate far pos- sible the impact knock-off and roll release, and also compensate both clamping and engaging the rolls for the greater board wear near the pick- spot the boards, due the use shorter strokes during part the operation. For these reasons, toggle-like connection was made between the eccentrics thus causing both rolls move toward away from the boards simultaneously. tion, instead the suspended fric- tion bar, toggle-operating cam employed, which engages the ec- centrics with greatly reduced im- pact. Finally, the toggle-operating cam mounted vertical shaft, which are fastened wing-like cams receiving motion from hori- zontal pushers, one for roll release and one for roll engagement. These have been referred roll release and bottom knock-off. The latter term certainly not descrip- tive the action, the impact, strain and vibration the fric- tion bar when engaged the knock-off the conventional ham- mer are absent; their place much smoother movement. Foundrymen Meet With Engineers Chicago section the Amer- ican Foundrymen’s Association, the Western Society Engineers and the Chicago section the American Society Mechanical Engineers are sponsoring joint meeting “Engineering Uses Modern Cast Metals,” held March 18, the auditorium the Building, 205 West Wacker Drive, Chicago. Advances gray iron will chemist and metallurgist, Deere Co., Moline, Progress mal- leable iron will considered Forbes, president and gen- eral manager, Gunite Foundries Corpn., Rockford, and devel- opments the cast steel field will metallurgist, National Malleable Steel Castings Co., Melrose Park, exhibit showing the develop- ments foundry technique, physi- cal properties and special applica- tions cast ferrous metals spe- cial interest designing engi- neers will held conjunction with the meeting. THE IRON AGE, February 1935—23 2255 E : Sone Gig 2 j i- foot tread ie 1- r Ss, i ’ Dust Injection Blast Furnace Reduces Ore Costs URING the operation blast furnace great quan- tity valuable flue dust comes through the downcomer. This dust separated dust catcher and prepared for recharg- ing into the furnace. The usual procedure briquett sinter the dust special preparation plant, after which returned the ore bunker, ultimately charged again the furnace top. Like the ore, part this pre- pared dust will again blown out the top the furnace dust. Thus the process goes on, and great economical importance that more efficient methods de- veloped utilize this dust. One good process throat-dust injection was developed Hes- kamp and described Stahl und the same magazine, Otto Wehr- heim presented detailed data con- cerning throat-dust injection into two belonging the Koninklijke Nederlandsche govens Staalfabricken Ymui- den, Holland. Fig. shows detailed set-up installation. Flue dust transferred from the collectors power screw through sieve and then into pressure container. then blown back into the furnace. The injection nozzles placed far above the tuyere level possible. Thus the inject- dust has maximum distance travel down the tuyere level, but zone where the dust may picked already softened particles the burden. the process carried out with due 24—THE IRON AGE, February 1935 Returns rom and Mill LIPPERT The lron Age, New York care, disturbance the opera- tion the furnace nor off-grade iron and slag need feared. Also, the process permits extensive and rapid regulation the furnace operation, simply increasing decreasing the amount dust in- Blast Furnace No.3 Dust Filter IG A Germar arrangement tor the This process has been found to be very d—Spiral for pushing dust; e—Dust sieve: h—Gas i—Blast pipe (du Pre sure injec Blast Furnace tron of throat gas into Diast furnaces economical when applied two furnaces Ymuiden, Holland. a—Dust catcher; b—Secondary dust collector; c—Dust pipe: container: feed- e qualizer der COS bri pel wil thi tin thi dei tio or jec sin res sta pr: tio Q or¢ cre = ou 4 k 43 uc ex: to x Sec m¢ tio CO) Extensive studies the Ymui- den stacks have shown that the cost injecting the dust con- sistently lower than the cost briquetting sintering. ex- periments stack No. iron with content between and per cent was made using throat dust injection part the time and ordinary charging through the top during the remain- der. was found that produc- tion yields were raised per cent more when the dust in- jected. This procedure about the simplest and cheapest means restoring blast furnace dust the stack fully equivalent ore. The circuit entirely closed and proof. Considerable experimenta- tion has shown the process equally adaptable furnaces making General stallation the Chicago plant the American Manganese Steel Co., which daily being used inspect manganese steel sections ation which year ago was in- trusted gamma rays. visual proof this shown Fig. manganese steel. tion does not the radiograph justice, but three dark bands are clearly discernible. These bands represent slots the interior the steel 0.3, 0.2, and 0.1 in. thickness respectively. Consequent- the 0.1 in. slit corresponds definition per cent the in. section. The exposure time was min. This equipment being used daily the American Manganese Steel Co. routine examinations Cutting Force Fis view f anew ver Seal : Jeterminina tt ut for protecting Plug overloading. ordinary iron and furnaces ex- clusively making high-quality spe- cial irons. ve X-Rayed With Per Cent Definition increasingly rigid specifica- tions for cast assembled parts seem guarantee in- creasing interest and use vari- ous non-destructive tests. Both the X-ray and gamma ray methods have become important tools manufacturers who turn out prod- ucts with minimum internal imperfections. Although the use gamma rays has usually been preferred for the examination sections over in. thick, the manufacturers X-ray equipment have constantly pushed the voltage tubes order adapt their method the larger sections. The penetrating power gamma rays corresponds X-rays excited 600,000 volts more, and there every indica- tion that the further will witness commercial X-ray installations ap- proaching this level. For instance, consider the new pilot castings each lot manganese steel and chromium- nickel alloy castings produced. Tool Holder Indicates Cutting Pressure alloys present many ma- chining the speeding finishing opera- tions products made fa- miliar steels and metals requires intensive study speeds, tool pressures, tool angles, shapes, Reliable mechanical instruments for quickly and accurately record- ing tool pressures greatly simplify such investigations. instrument for this purpose has been placed the market Schiess-Defries A.G., Germany. This indicating tool holder, shown Fig. in- tended both for the exact separate measurement the cutting pres- sure machining and auto- matic overload protection for the machine and tool during regular operation. The tool holder small even the standard slides au- tomatic screw machines. The IG. 2—An exograph in. man ganese steel. The three dark bands present slit sections 0.3, 0.2, and in. thickness respectively. The in. the top corresponds definition per cent. carrying member body pivoted ball bearings. From Fig. the operation this device almost self-evident. Variations toll pressure are transmitted steel membrane, which turn alters the cross-sec- tion column electrolyte tra- versed electrical current. The varying electrical resistance the electrolyte can then suit- ably recorded. turning plug provided the bottom, the gaging element proper can moved rel- ative the membrane and the measuring range thereby varied within wide limits. Movements the tool this holder are small actual operation rigid tool. (CONCLUDED PAGE 75) At 200 dian r thi te Ww + + + tu but areas are shown to be tine pearlite. THE IRON AGE, February 1935—25 5 { tee ¥ = ‘<= Ns. ay » Fie, —_ | 45,4 i WOOD Industrial Department, Light Heat Co., NSULATING brick low ther- mal conductivity and light weight manufactured the Armstrong Cork Insulation Co., Lancaster, Pa., its Beaver Falls, Pa., plant. One the ingredients used making the brick diato- maceous earth, light cellular min- eral that has very low heat con- ductivity. and mixed with ground cork and this earth molded into brick and fired kiln. The cork burned out, leaving additional air that qualities. Brick Made Large Presses The brick are made the soft mud process, which consists mixing the materials with water obtain the right plasticity, fill- ing multi-cavity molds with this mixture, and subjecting high pressure large presses. The molds are moved out the presses and mechanically upset that the brick and shapes fall traveling belt conveyors which take them the dryers. These consist long rooms with tiers shelves both sides, and conveyor runs down through the center. Operators re- move the brick and pile them the shelves, where they are dried with heat from steam coils. Large spe- cial shapes are molded hand. Firing accomplished one two gas-fired kilns, each 300 ft. long. These are parallel, with three loading and unloading tracks 26—THE IRON AGE, February 1935 between, and transfer tracks each end which the cars are transferre