The Iron Age 1935-03-21: Vol 135 Iss 12

‘Steel $3,. pro- other roject > also cost ntorg New itina, 10,000 roll. loco- quip- 239 West 39th St., New York Owned, Published and Copyrighted CHILTON COMPANY (Inc.) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. Cc. A. MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC C. STEVENS, Vice-President JOSEPH 8S. HILDRETH, GEORGE H. GRIFFITHS, EVERIT B. TERHUNE, ERNEST HASTINGS, WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ FRANK, President J. H. VAN DEVENTER Editor News Editor MILLER Machinery Editor LACHER Managing Editor Editor Emeritus Washington Chicago Cleveland Pittsburgh Detroit Boston Cincinnati Contents—March 91, 1935 Direct Rolling ... Flash Welded Meta! Burial Vaults Refining Knee Action Manufacture New Equipment Personals and Obituaries Washington News .... Statistics Metal-Working Activity Construction and Equipment Buying Index Advertisers. 140 BAUR, General Advertising Manager DIX, Manager, Reader Service ADVERTISING STAFF Emerson Findley, 311 Union Bidg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo, x. ¥. Member, Audit Bureau of Circulations Member, Associated Business Papers Published every Thursday. Subscrip H. K. 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 Bldg., Ghestnut & 56th Sts., Philadelphia, Pa. ©. H. Ober, 239 W. 39th 8t., New York W. B. Robinson, 428 Park Bidg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address, ‘‘Ironage, N. Y."’ I). ©. Warren, P. O. Box 81, Hartford, Conn. ada, $8.50, including duty; Foreign $12.00 a year. Single copy 25 Cents q " ship- Co., large aniz- ll be com- tina, for Tafi d.c. itch- 43 ec- the ite, lia, gh. ha- ha- lon rs’ of ODE 1935 his ‘or ec ad, rk. ial i! ar i 8—THE IRON AGE, March 21, 1935 More Than Immediate Steel! Today—it assumed that Ryerson has the steel and will ship once. But that not enough—we must have special qualities, exact analyses— cut production costs—to meet the increasing speeds capacities required your own product. —Or you may require entirely new steel secure finer finish insurance against corrosion. Today you expect more Ryerson Steel-Service and you get it. There steel too new remote—no quantity too large secured —or order too small receive intelligent personal attention. Write for the Ryerson Stock these Stocks Steel. JOSEPH RYERSON SON, INC., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Save Money with Ryerson Steel will get harder—change shape less—and retain finer grain structure than most other water hardening steels. prove that gives superior performance lower Try few bars, ask for free sample test. Permite Speed Length Bars Permite Leaded Phosphor Bronze Bars, cast ft. lengths, cut bearing and parts pro- duction costs. They permit economical pro- duction parts screw machines and tur- ret before possible. Write for complete information these new bars. Address the nearest Ryerson Plant. Buffalo, Boston, Philadelphia, Jersey City. RYERSO Special Steels full range special alloys, tool steels, stainless and heat resisting steels are imme- diately available through the Ryerson Steel- Service plants. Stocks include all the major specifications wide range sizes. Ex- perienced engineers and steel men are always ready help with any your steel prob- ... THE IRON MARCH 21, 1935 Vol. 135, No. "Blessed A\re the HERE good old formula which still use American industry and which has enabled make remarkable showing under the most adverse conditions has ever met. That formula is: Avoid trouble, but when you can- not avoid trouble, eliminate it. The application this formula starts with design and applies through produc tion clear down the disposal the product. applies the relations machine elements one another and also the even more important relation- ships between men. Capable management recognizes that excessive friction, either mechanical will ruin the operation any mechanism any organization. Gears must work together, not fight each other, and too must men one have suc- cessful plant operation and avoid disastrous smash-up. because clear realization the truth this basic principle that the majority employers are averse unionization their plants along the other professional union lines. The philosophy such unionization not based upon peace and good will; frankly founded upon the acceptance the principle class antagonism and mass opposition. best leads nothing better than armed neutrality which suspicion stalks about constantly with chip upon its shoulder. The formula which professional labor leaders have found personally profitable follow just the opposite management's formula. this: Seek trouble and capitalize it. you cannot find trouble, create it. Unfortunately, this destructive formula now being borrowed and applied broader fields than that industrial relations. The Longs and the Coughlins and others their ilk are putting work effectively gain huge personal followings. What such capitalization trouble will the big economic machine, which our individual industries are cogs, serious question. Certainly the mass cultivation hatreds will not lead peace. recall that the One who drove the money changers from the temple also blessed the peace-makers and the meek. Trouble-makers were not included his benediction. // = —= Mu } —> — — — cs (= : Shh ; be 3 uf > v \ | <on | i} eels, teel- lajor Ex- rob- | are currently mostly concerned with refinements the direct rolling machine the left. soon steel commercial production means this direct rolling unit, entirely possible that the subsequent operations indicated the right will incorporated continuous unit. The detailed drawing below portrays the formation the steel metal strip between the revolving rolls. Entrance Metal, Detail the Formation oTrip As, ant G4 4h Rolls Strip from the Liquid ’ -ator } Shear. Variable Speed orming Pickling Washing Press Tank DIRECT ROLLING Actuality With Possibility With Steel! THIS age has been LIPPERT tries which have been notable for given many descrip- The Age, New their lack respect for precedent. tive qualifying ap- chine age, the steel age, the alloy age, the mechanical age, etc. Any all are justifiable and appro- priate, but just warrantable But the steel and non-ferrous in- dustries, despite their preeminence have progressed more slowly than number other lines techni- one end and finished prod- cal developments therefore its designation age con- ucts drop off conveyor the have been charged, whether right- tinuous processes. other end. The constant effort wrongly, with failing keep The efforts all manufacturers achieve this ultimate ideal all pace with the tempo modern are directed toward transforming the end lowering costs, increas- age. common comment that the independent units their ing efficiency, and obtaining uni- the whole process steel making plants into straight-line installa- formity product. Such results fundamentally unchanged from tions, wherein raw materials flow have been secured some indus- decade ago, that its melting IRON AGE, March 1935 Ae } | | 47 N for dent. in- ence eme, than fore ght- keep that king rom ting technique highly inefficient, that the production and treatment semi-finished steel are devious and costly, that finishing operations are lengthy and complex. Admittedly the research labora- tories steel mills have turned out quantities instructive data fundamental problems and have also had degree success the development new alloys and spe- cial steels. However, pointed out that radical changes have been made the methods melt- ing and forming steels. The blast furnace hearth processes are condemned waste- ful, and changes these units are dismissed being limited minor improvements construction and routine details operation, all which are along lines prac- tice laid down decades ago. These familiar criticisms must now cease, for can longer said that nothing radical being attempted the technique metal production. The inventive genius one man has long been focused revolutionary method rolling and, with extensive co- operation from engineers sev- eral American companies, has developed process which mately may result far-reaching changes the steel and non-fer- rous metal industries. Produces Steel Directly One the commonest objections current practice that liquid steel frozen into solid masses be- fore rolled into finished prod- ucts. When the molten metal cast into large ingots, which cool slowly, the originally homogeneous liquid metal far from homo- geneous the time has solidi- fied. The imperfections directly traceable the casting and freez- ing the ingot remain the metal through all subsequent roll- ings. has, therefore, often been asked why the steel industry can- not emulate the prominent auto- mobile manufacturer who showed the world was possible make plate glass from continuous stream molten raw product. The same thing has been done with steel! And the same thing commercial production with non- ferrous alloys having lower melt- ing point than steel. The following description this revolutionary process direct rolling metals and steels the first appear the American foreign press. Much secrecy has been (and is) thrown around this method, mostly protection against over-pub- licity, which often dangerous new and basically different idea. Consider the sketch Fig. Two rolls, water cooled, support quantity molten metal. the rolls rotate, continuous strip metal formed all the delicate- balanced conditions are favor- able. The speed and separation the roll, the static pressure and temperature the metal, the tem- perature the rolls, the metal itself, are all variables which must carefully controlled success achieved. When all these con- ditions have been satisfactorily ad- hered to, the emerging strip can immediately further reduced hot rolling, after which the usual physical properties can secured conventional cold rolling. Although the operation consid- erably more complex than indicated Fig. the sketch does give 2—One the chines, which con- tinuously casting 36- in. lead strip the per minute. This mil! vamped order stainless and common steels. fair idea the process. far the procedure has only been car- ried the formation strip from the liquid phase. The continued procedure thereafter, indicated the sketch, development for the future. That is, entirely possible take the freshly formed strip through reducing gas and re- roll before cools. may then normalized, pickled, washed, leveled, sheared, and finally formed press—all one continuous operation. Oddly enough, the temperature the rolls kept near 200 deg. means water sprays.. Not great deal heat taken from the metal steel—the skin the strip chilled, whereas the inte- rior may quite hot. For cast- ing metals the hollow rolls are made copper, but for rolling steels they are solid steel forgings castings. The contact with the molten steel naturally causes some fire cracking the rolls; there- fore they must occasionally re- moved and redressed. 7 } = ‘ > th met 7 The implications this process are startling. and when com- pletely successful with steel, will mean elimination ingot casting, soaking pits, blooming mills and breakdown mills. will mean much cheaper product and much smaller capital investment for the steel industry for steel consum- ers for each ton steel produced. First Success Obtained With Metals developing such method this, the natural approach produce non-ferrous metals first. This follows from the fact many metals have lower melting points and are much easier work than steel. Also, their simple structures permit easier and more satisfac- tory formation. The direct method now dis- tinctly successful with brass (melt- ing point 940 deg. C.) and with copper (melting point 1083 deg. C.). new unit now experi- mental production for the direct rolling metals with melting points 1500 deg. C., and some degree success has been secured with the plain and complex steels (melting points from 1400 1500 deg. C.). One the original casting ma- chines shown operation Fig. This machine has turned out over ton 36-in. strip low melting point metal each min- ute. This same unit now being converted for the rolling steels, both plain and complex. outgrowth this experi- mental machine the commercial unit shown Fig. This diag- onal view shows the delivery the 12-in. brass strip, and also illus- ° ° 5—High purity brass cast the tinuous casting ma- NH,OH+H.0O.. 12—THE IRON AGE, March 1935 livery end brass casting and rolling machine which now daily commercial tion. This unit turns out about 200 per minute brass strip 0.150 in. thick. The metal poured into the rolls above, shown Fiq. trates the gas and water connec- tions. The pouring platform this machine shown Fig. The brass melting furnace the background, and one flanged roll the casting machine clearly visible the center foreground. annealing this machine cast and rolled brass required, and the coils are immediately ready for cold rolling. Inasmuch the material best coiled comes from the liquid rolling ma- chine, condition most suit- able for cold reduction tension- type cold-rolling equipment. Many coils this material have been reduced various gages, including 0.011, 0.015, 0.020 and 0.029 in. There are special problems involved cold rolling— the machine cast and rolled prod- uct acts satisfactorily during the reductions and requires inter- mediate annealing. Many tons this cold-rolled brass have already been further processed into con- sumer products and sold the market along with articles pro- duced from brass cast and rolled the conventional manner. That this brass casting and roll- ing machine produces superior product best illustrated data secured the plant the prin- cipal maker this product. Nu- merous comparative tests have been made the metallurgical and physical properties special com- mon high brass produced the regular chill cast process, co e de- of a and chine daily opera- turns 150 in. rolls latform reqular chill cast brass (left) and machine cast brass (right) after having been reduced per cent cold rolling. Regular cast specimen diameters and machine cast specimen 250 diameters. Both etched against the product turned out the casting machine. special common high brass used both processes high purity and made from selected scrap. The ap- proximate composition 64.5 66.5 per cent copper, 0.07 maxi- mum lead, 0.03 maximum iron. and the balance zinc. The following samples were re- moved and examined from regular chill cast brass: (a) from regular cast bar cut far enough back from the gate end that the bar was sound and free from gas pockets dirt inclusions, (b) the same bar following per cent rolling re- duction without anneal, (c) the ing platform the commercial brass casting and rolling machine. Note the brass melting furnace the center rear, and the roll the machine the center fore ground. a — it with same bar after had been rolled per cent without any anneal. composite analysis these three samples gave 65.54 per cent copper, 0.003 lead, 0.01 iron and 34.447 zinc. For comparative purposes, the following samples were taken from brass strip produced the con- tinuous casting machine: (a) from the center the strip “as rolled” the machine, (b) the same sam- ple reduced per cent rolling and without any anneal, (c) sample rolled per cent, also without any anneal. composite analysis these three samples gave composition 66.82 per a 7—Comparative views high purity brass, cast the conventional chill method (left) and the continuous casting machine (right), after -old reduction per cent. Both 250 di- ameters. Etched cent copper, 0.037 lead, 0.02 iron and 33.123 zinc. The comparative structure “as cast” each process [(a) for each case above] well demon- strated Fig. Note that the cast specimen has typi- cal cast dendritic structure with beta surrounding the alpha crys- tals. the other hand, the struc- ture the machine cast brass shows hot-worked ar- rangement consisting equiaxed twin crystals. The micrographs Fig. show the comparative structures these two differently processed brasses after they had been reduced ere nnec- ig. one enter chine ately much ma- suit- sion- have and ecial TABLE I—Physical Properties Brass Emerges From the Continuous Casting Machine Description No. 0.499 No. 0.496 No. 3—Longitudinal 0.501 0.501 No. 5—Transverse 0.503 No. 6—Transverse 0.502 Dimension Inches 0.129 0.938 in. thickness, per Likewise Fig. shows the com- parative structures after the ma- terial had been reduced 0.625 in. thickness, per cent reduc- tion, cold work. means these microphoto- graph examples clear that brass produced the continuous costing machine entirely differ- ent from brass processed the conventional chill cast method. The machine cast brass has structure identical with that hot-rolled brass chill cast brass which has been homogenized subsequent cold rolling and annealing. That is, the machine produces 0.125-in. thick brass one quick, continu- ous operation which equivalent metal produced ordinary mill methods jected series treatments, consisting overhauling, anneal- ing and cold rolling, homogenize the structure the metal. show one slight difference between the machine-processed ma- terial and conventional chill cast material, sets longitudinal sec- tions were taken from sheets, illustrated Fig. The micro- photos Fig. are the three different specimens cut from the de 14—THE IRON AGE, March 21, 1935 Yield Point, Lb. per Sq. In. Area Sq. In. 0.06637 0.06795 0.06613 0.06463 0.06640 0.06467 21,800 21,200 21,200 22,100 21,800 22,100 Strength, Elongation, Lb. per Sq. In. Per Cent In. 50,900 58.0 49,900 55.0 49,500 46.0 49,700 33.0 50,300 48,900 31.0 ocation of Micrograph IG. 8—Showing the location longitudinal samples taken for Po ling Direction mi- crographic studies the structure machine cast brass and conventional chill cast brass. center brass sheets rolled the continuous casting machine. This sheet was 12% in. wide 0.125 in. thick. The angularity micro- structure near the surfaces the sheet clearly discernible. For comparison, similar sam- ples completely processed brass produced the regular chill cast method are shown Fig. 10. These specimens were taken from regularly cast %-in. bar, after had been cold rolled 0.625-in. thickness, annealed 680 deg. for hr., then cold rolled 0.250 in. and annealed 520 deg. for hr., and then cold rolled 0.125-in. thickness and annealed 400 deg. for hr. The structure represents typically annealed alpha brass. Physical Properties Very Satisfactory data the longitudinal and trans- verse physical properties brass the condition which emerges from the continuous cast- ing machine. The yield points, ten- sile strengths and elongations various sizes specimens are given Note the extreme uniformity the tensile strength and yield point this machine ° ° ° IG. Microstruc- tures high purity brass rolled the continuous casting ma- chine. The locations the longitudinal samples are shown Fiq. Reading from left right specimen (a), (b), and (c), respec- tively. Note the an- qularity ture near the surfaces diameters, and etched with ° ° 0.133 0.137 0.132 0.129 0.132 | Surface Sheet a“ | | a cast material. The grain size and physical properties correspond those regular chill cast brass which has been rolled and fully heat treated the regular mill schedule, and finally anneal-tem- pered 375 425 deg. indication the extreme ductility this machine cast brass best shown the data Table II. The material tested was taken directly from the continous casting machine and cold reduced from 0.125-in. thickness ten- sion-type cold rolling mill. The width the sheet produced was about 11% in. From all these data the prop- erties continuously cast brass, apparent that the advantages this method compared with the regular standard practice are follows: (1) The saving all the labor and other expense involved roll- ing and annealing the material from the conventional cast bar 0.125 in. thickness. (2) Ductility and soundness the metal, which are superior practice. (3) lends itself admirably large unit operation. sheet metal weighing 7000 8000 can continuously processed direct from the casting machine through the operations slitting, rolling, annealing and coiling. This extensive description the casting brass machine was made because the data presented are the first ever made public, be- cause the brass rolled this man- rer the first metal pro- cessed, because the tained are conspicuously success- ful, and because the experience gained with this machine has opened the way direct rolling other metals, and ultimately the ° ° ° IG. brass, cold rolled and heat treated stated the text. These three specimens were cut from sheet shown and are shown here (a), (b), and from left right respectively. These views diameters represent nealed alpha brass. The size js-0.024 MM. o ° TABLE Data Demonstrate the Extreme Ductility Brass Rolled the Continuous Casting Machine (After Cold Rolling) Description Specimen Grain Size No. 1—Longitudinal 0.040 Transverse No, 2—Longitudinal 0.035 Transverse No. 0.038 Transverse No. 4—Longitudinal 0.040 Transverse No. 5—Longitudinal 0.055 MM Transverse No. 6—Longitudinal 0.050 MM Transverse No. 7—Longitudinal 0.040 Transverse No. 0.045 Transverse No. 9—Longitudinal 0.050 Transverse No. 10—Longitudinal 0.045 Transverse (Hard Worked) Tensile Elonga- Gage Strength, Lb. tion, Per Inches per Centin2In. 101,300 0.039 110,300 104,700 0.032 115,700 106,500 0.032 114,900 86,400 0.078 93,300 86,700 0.080 89,800 86,000 0.078 99,300 106,500 0.075 95,500 97,600 3% 0.045 104,800 102,600 0.044 108,600 probable commercial rolling steel this manner. That the many difficulties at- tendant upon the rolling higher melting-point metals fu’: solved best exemplified the machine shown Fig. 11. This large and impressive unit shows promise commercial operation for the direct rolling the rea- THE IRON AGE, March In. the his (25 the 10. om led old hr. ine st- en- ire te" large casting and rolling mill, recently completed, being used for developing the direct rolling process for metals pouring temperature 1600 deg. The pouring station the platform above, and the strip emerges from the chute the base the machine. sonably near future pure metals pouring 1600 deg. This unit will turn out strip 0.1 0.140 in. thick various widths, depend- ing the rolls being used. Con- siderable success has already been achieved the owners this ma- chine. Since the metal rolled the machine Fig. has melting point the neighborhood that for steels, would seem that the problem direct rolling steel will soon solved. However, the complete solution the problems encountered the direct rolling machine with very promising results. steel are far from simple they might appear first glance. turn out even mediocre steel strip this method tated the solution many per- verse and unexpected difficulties mechanics, materials, thermal equi- librium and heat flows. The prob- lem securing satisfactory steel structures has been the bane many experimenters with this type equipment, but sufficient refine- ment has lately rewarded their efforts cause one company order large machine and plant built for this purpose. This mill first step the direct rolling stainless steel. ladle being emptied into runner leading directly the turning rolls. All the more important non-ferrous metals have been rolled this type will operation within the year, after which time will estimate the type steel pro- duced. within the line good rea- soning state that the future may witness the elimination ingot casting, soaking pits and blooming mills for the production certain grades steel. The direct rolling machine comparatively inexpen- sive, and the results far ob- tained show that may the in- strument for quantitative, cheap and labor-saving production hot strip stainless 18-8 steel shown here emerging from the rolls. ‘ = steel. the most simplified set-up possible, the means transferring molten steel di- rectly usable form without any intermediate, time-consuming and costly manufacturing oper- ations. Also importance the element safety this direct rolling method. There nothing the process dangerous the op- erators, despite the false rumor circulated Europe that one man had been killed this country while working the machine. experiments one company with the direct rolling steel. These experiments are typical results obtained several other Ameri- can mills. Oddly enough, much the research has been performed with stainless steels, Monel metal. all which are difficult roll satisfactorily the conven- tional manner. Quite desirable stainless steel has been produced this direct rolling machine experimental batches. Likewise plain carbon steels have been turned out small quantities. might pointed out that far back 1865, Henry Bessemer predicted the British Iron and Steel Institute that method would eventually used for the production steel. fact, Bessemer’s patent sketches such machine appear quite similar the present-day unit. One great difference exists, how- ever. Bessemer’s machine did not work, whereas the unit which has been described herein does operate with conspicuous success. Natu- rally all the phases this new machine have been patented this and all foreign countries. show the recent success with direct rolling stainless steel, con- sider Figs. 14. These views show the steps for forming the steel strip from the liquid state one operation. Microphotos this ture. metal specimen taken directly from the strip produced the casting and rolling machine. cupped portion which demonstrates its ductility. Conical Roller Bearings for Boulder Dam Gate Hoists ANTAM CO., South Bend, Ind., has been awarded the contract for the coni- cal roller thrust bearings, together with alining seats the cylinder gate hoists for the four intake tow- ers Boulder Dam, through the general contractor, the Consoli- dated Steel Co., Los Angeles. These bearings will support the two bronze lifting nuts which en- gage the threaded ends the stems raise and lower the upper and lower cylinder gates respec- tively, and are 14-in. I.D. 24%- in. O.D. 49/16 in. thick and have load-carrying capacity 1,000,000 operating speed. Rollers and races are S.A.E. 52100 high carbon chromium steel, heat treated the company’s differen- tial hardening method. One-piece lubricating type bronze cages are used for retaining the rollers. One gate hoist will mounted the floor each tne four intake towers and will operate separately simultaneously the two cylinder gates installed each tower. The cylinder gates will mounted one above the other the vertical shaft each intake tower and will used shutoff gates for the 30-ft. diameter penstocks LEFT IG. drawn from the machine and lying the ground cool. This quantity about ten minutes production. RIGHT IG. section alloy strip the con- dition came from the machine. The portion has been cupped demonstrate the duc- tility the metal. center extending from the base each tower the power plant and out- let works. The upper and lower gates will approximately 190 ft. and 340 ft. respectively below the intake tower operating floor. The normal operating lift each gate will ft., but maximum travel ft. will available facili- tate inspection and maintenance the gates when the gate chambers are unwatered. The hoist drive will consist housing containing central gear case which will mounted two separate gearing systems, each driven separate vertical gear motor mounted the drive hous- ing. Each motor will coupled, through multiple disk, spring- loaded clutch coupling, splined shaft which will mounted miter gear which will drive three pinions, each connected through flexible couplings and shafting worm shaft mounting each the three hoisting head hous- ings. Contact circuits will pro- vided whereby emergency closure the cylinder gates can accom- plished remote control from the power house, but normally the cyl- inder gates will operated from the control panels mounted each hoist drive housing. ] ras pe - ry . in » z Is Metal Burial Vaults Flash PRENTISS Cleveland Resident Editor The Iron Age FLASH burial vaults was one the outstanding de- velopments the weld- ing industry during the past year. resistance welding machine, one the most massive welders ever built, was designed for welding metal burial vaults mass pro- duction basis. One these weld- ers recently was placed opera- tion the Galion Metallic Vault Co., Galion, Ohio, leading manu- 18—THE IRON AGE, March 21, 1935 facturer that field, and one the same type was installed another Ohio vault manufacturer. The special-type welder for burial vault work was designed and built the Federal Machine Welder Co., Warren, Ohio. Marked changes the manufac- ture metal burial vaults, ing the design and forming the vault members, were made the Galion plant with the introduction flash welding equipment. new production line was provided, and the welding machine located this line might designated the heart the entire production sys- tem the plant. Manufacturing economies have been effected and production has been speeded with the new weld- ing equipment and the vault has been redesigned for the new welded models, making its lines more — | / ° ° ° | ° ° ° — new and this the have has veld- has nore graceful and its appearance more attractive and increasing its strength. burial vault welded less than five minutes with the new self-contained welding machine, the operations consisting welding two ends the main member dome form the entire dome sec- tion. Daily production this welded dome the Galion Metallic Vault Co. plant from 125 150 units Before adopting the flash welding method the company arc welded its vaults, and the arc weld- ing method still being used for open-end models. Finishing important step the manufacture the metal vaults, coatings being applied both for resistance corrosion and for ornamental effect. comania process finishings, for some time used for decorating in- strument boards and some other automobile parts, recently was adopted the Galion company for providing marble finish vaults and this indicates important ex- pansion the use transfers for beautifying metal. Metallic bronze finishes over vari- ous priming coats also are used, being applied various colors. The Galion plant arranged for the progressive movement work for successive operations, thus minimizing handling and effecting economies production. Virtually the only backtracking the RIGHT dome and head their welding po- sition the machine. One the inner ex- panding dies about lowered into the machine. ° ° ° LEFT BURIAL vault shown being ered into the flash welding machine, which the two ends are welded the main section dome. One the sets dies used the weld- ing operation car- ried arms and are posi- tion for lowering into the vault. The second arm and die directly back the unit the foreground are barely the picture. XPANDING rapidly the the past few years, the metal vault industry has be- come important consumer sheet steel. Metal burial vault manufacturers country now number 55. About per cent the vaults are made Ohio and the city Galion with five vault manufacturers seems the center the industry. finishing department, where vaults are routed back gravity roller conveyors for consecutive coating, baking and drying operations. Sheets and other raw material enter the plant from two side doors the lower end. Rail shipments come one side and truck ship- ments the opposite side. The sheets are stacked the raw stock storage base that end the building. Two methods fabrication are followed the company making vaults. the new model that flash welded two ends are formed with in. draw, the drawn portion providing flange that depth, the same size and contour the dome section. The two ends and dome are welded together, the transverse joint around the dome being the same distance from the ends the depth draw the end members. The completed dome fits snugly over pressed steel base in. and locked the base after the casket has been lowered into the vault. The open-end model hinged door the end. All vaults are made 12-gage sheet steel. Armco ingot iron used the manufacture the more expensive model designated the Cryptorium, and copper-bear- ing steel used making cheaper type vault. Pickled stock usually used. The dome for standard-size vault made from sheet 84% in. 86% in. For the base sheet 7/16 in. 7/16 in. used. Dome Made Hydraulic Press For making the dome and dome ends very large single ram-type hydraulic press with ram pres- sure 750 tons and pressure 250 tons the pad was installed recently. This has 24- in. stroke and in. “daylight” be- tween the bolster and the platen when the ram its top position. The press equipped for hand control with push button lever, for fully automatic control. The press was built the Hydraulic Press Mfg. Co., Mount Gilead, Ohio. The two sides the dome are formed the same time, giving the piece U-shape, and during THE IRON AGE, March 21, | 4 | te = al ina = the dies are lowered into the vault they, with the outer contracting dies, hold the two parts the vault position for welding and provide the electrical contact. The welding cycle was under way when this picture was taken. this single operation flanges are formed the longitudinal edges the dome for reinforcing pur- poses and provide base hold the locking mechanism. Then the top the dome formed cor- rect radius assure the sym- metrical appearance the finished dome. The two ends heads are drawn one operation the hydraulic press and are trimmed Quickwork metal forming and cutting machine. Meehanite iron and welded steel dies are used for the most part, the pads and filler backs being steel. Massive forming dies are required, tons. The dies are handled with 5-ton overhead crane. After the dome formed handle studs are welded the sides, and the dome and the two ends the welding machine. Welding Machine Massive The massive size the welding machine indicated its height, which ft., when the dies are open, and its weight, which 90,000 For convenience handling work the machine set pit ft. deep and extends ft. above the factory floor the working platform level. The domes and ends are delivered the ma- chine with pneumatic hoist at- tached jib crane. The dome 20—THE IRON AGE, March 21, 1935 handled fixture hooked the hoist. This fixture clamped inside the dome two clamping dogs, and when the dome lowered into the welding machine the fix- ture assists locating the proper position. The dome and head are held position for welding two outer contracting dies the machine, one for each member, and two inner expand- ing dies carried hinged die arms which are lowered into place after the dome and head have been set the ma- chine. Then the die arms carrying the internal expanding dies are closed and locked position, and pressure ap- plied during the downward motion the die arms four air cylinders. This pressure expands the inner expanding and outer contracting dies against thedome and head, and this pressure two parts position for welding and pro- vides the electrical contact for the flow current into the parts that are joined. Two air cylinders push the dome against the head, bringing the edges contact. Electrical contact made, the current turned and the cycle welding operations be- gins. Burning away the edges and leaving the baking oven the right and q 7 fat ] 4 | bringing the metal welding tem- perature requires 2/5 sec. The forcing the edges together, which requires 3/5 sec. pressure tons applied for upsetting. The length each welded seam vault standard size in. When the welding the low heat oven the left roller conveyors. the painting department showing three the spray booths and some the roller conveyors. The depressed cross finished the die arms are given upward motion release the dies, and this causes release the electrical contact the vault. Then the die arms are unlocked and raised perpendicular posi- tion two electrical hoists. Then the vault lifted out, turned around and put back the machine and the head welded the oppo- site end. Remote push button control provided for con- trolling the electrical current. Air cylin- ders are controlled three-way air valves. Heating current supplied two 250- kva. transformers. Because the se- vere surge placed the incoming power line was found necessary use motor generator set supply electrical energy and cor- rect the power fac- tor the plant. This set, furnished the Ideal Electric Mfg. Co., Mansfield, Ohio, consists chronous motor oper- ating 2300-volt, conveyor track allows transverse movement the vaults. 60-cycle current, d.c. exciter, switch panel and voltage regula- tor. The alternator phase 440-volt, 60-cycle unit with direct-connected exciter. The Finishing Operations After welding, the vault placed roller gravity conveyor with two working platforms between conveyor sections. the first, the flash produced upsetting chipped off with pneumatic chip- ping hammer. This chipped sur- face smoothed grinding the next station. Then the vault tested for leaks being immersed The vault then ready for its protective and decorating coats. reaching the paint department which moves through this de- partment and through the ovens for various operations. not taken off the pallet until reaches the packing department where crated for shipment. The vault first cleaned and the surface inside and out prepared for painting. flat priming coat sprayed the interior. Then the vault goes another spray booth, turned over and prim- ing coat sprayed the outside. The priming coat serves corro- sion resistant and also bond- ing for the subsequent lacquer coat. THE IRON AGE, March 21, 4 4 4 oth : ed. | : 1 YDRAULIC press 750 tons capacity that used form the domes and end members. Some the latter are shown the truck. During spraying, the vault rests venient working height. Vaults air-controlled pedestal per- are made with mitting placed con- finishes various colors. These the flash welding machine before its installation. This machine located pit, the greater part below floor level. 22—THE IRON AGE, March 1935 are designated cobweb, pine tree, and marble finishes. How Embossed Effect Produced Embossing, which produces the figured effect for the cobweb and pine tree finishes, effected baking the priming coat tem- perature 350 deg. This coat baked min. that tempera- ture continuous oil-fired oven, 114 ft. long. The pallet holding the vault pushed into the oven the roller conveyor and picked which carries through the oven. -After baking, the vault goes third spray booth which lacquer bronze applied any half dozen colors. Then the outer coat dried min. low-heat oven temperature 145 deg. The marble finish supplied two designs which are reproduc- tions Grecian and Italian mar- bles. After the primer coat baked thin sheet cellulose product with design represent marble and having coat one side make stick the metal applied over the surface the vault. Then this coating dried small oven, after which coating clear lacquer applied over the like finish. Then the vault goes through the drying oven and the packing department. Making Open-End Type Vaults The same production equipment except for welding used man- ufacturing the open-end type vaults, and the same methods are followed the painting depart- ment where similar coatings are applied. Joints the open-end type are made are welding. the construction this type there longitudinal seam extending the length the vault dome either side which made with Lincoln automatic seam welder Ends this type are fabricated with standard hand-type arc welder. gasket the face angle iron reinforcement welded the ends the dome the inside provides method mak- ing the vault air tight when the door closed. The gasket com- position material vulcanized 350 deg. the metal back it. This vault tested for leaks being submerged tank water, where air pressure lb. into the interior. 4 f wet the and tem- pera- oven, oven icked eyor, oven. alf coat oven mar- ulose esent esive stick the this oven, clear rble- goes ults ment nan- are are -end here ding min. ated arc the nak- the OLD AGE PENSIONS Expertence and Estimates this, the second and concluding article old age pensions, deal with cost experience and cost estimates. Actual cost experience available connection with State and county plans, all non-contributory, which have been operation for number years. The results, com- pared with the cost old age relief through almshouse methods, distinctly favor the pension plan. When comes the pension plan advocated Senator Wagner, part his Social Security Bill, cost experience lacking and have depend upon estimates. These indicate that horizontal payroll tax, proposed, impractical and would bankrupt some groups industries where the proportion wage cost profits large. Material these studies drawn from comprehensive study old age pensions made committee the National Conference Business Paper Editors. Copies the full report may secured cost cents each from the Associated Business Papers, 330 West Forty-Second Street, New York, any consideration which may useful estimating pension plans, the what such plans may cost else- question costs as- where. sumes significance During the first three years determining importance. only its operation the California plan during recent years, after the adop- pensioned 15,813 persons. Deaths tion pension laws number states, that fairly adequate in- formation cost pensions has become available. Particularly for California and New York, states which have had pension plans operation since 1929 and 1930, respectively, con- siderable information available and other causes reduced the num- ber 12,520 the end 1932. The average pension paid the latter date was $22.08 per month and payments for the three years totaled $3,057,000. every 100 persons the state years age older, 3.4 were getting pension. The proportion de- pendent aged rural sections was substantially higher than urban centers; pensioners represented per cent per cent the aged Los Angeles and San Francisco, but from per cent per cent rural counties. The experience New York has been much the same. During the first two years operation its law 64,636 pensions were granted. the end 1932, 54,185 were left, their total cost during the year was $15,454,000, $23.80 per month per pensioner. The per capita cost every person the state for this relief was $1.23 for the year. Taxpayers paid 26.5 cents per $1,000 assessed taxable real property for this purpose. the end 1932 8.1 per cent all persons years old more were getting pension, 4.3 per thou- sand all inhabitants. The aver- age monthly grant New York City 1932 was $28.60, and $19.59 for the rest the state. Total monthly cost pensien payments reached high average $1,300,- 000 March, 1932, but had drop- ped $1,052,000 December, 1933. Table are assembled cost (CONTINUED PAGE 76) THE IRON AGE, March 1935—23 | 7 pine 4 ° ° 4 is 4 and rear halves the housing through operations prior welding. Here are the halves the left-hand unit showing the successive operations; similar series reversed form required for the right-hand unit. The bottom row shows the rear half blank and draw; second reduce; first form; finish form; size; pierce; trim. The front half (top row) operations are the same except that reduced but once. The welded housing shows the pair shock absorber holes and main bearing hole the front half. The rectangular opening the rear THE adoption nu- merous machines en- tirely new design, built especially for opera- tions peculiar the manufacture and assembly inclosed type in- dividual front wheel suspension (knee-action) units, and oughgoing revision the plant layout procure the orderly prog- ress component parts from raw material finished units, have been combined facilitate produc- tion and improve the product the Chevrolet gear and axle plant, Detroit. Chevrolet’s knee action units are virtually unchanged from the 1934 models. Slight modifica- tions the size the bearings and wheel supporting members have been made, but year’s use disclosed need for any departure 24—THE IRON AGE, March 21, 1935 half for welding the steering knuckle forging. HEVROLET has improved its knee-action units and facilitated their production new design and re- arrangement manufactur- ing processes, which included the bringing under one roof all operations excepting forging and the making coil springs. comprehen- sive system conveyors, totaling 10,865 ft., insures efficient handling parts. complete system gaging progressive steps stops de- fective work that op- erations are performed parts which later will have rejected. from the principles and construc- tion the original design. Never- theless, Chevrolet manufacturing authorities rate the current units greatly improved over last year’s because refinements machining, inspecting, and testing. single example improved results manufacture, stated that the compressed-air test de- tect leaks completed housings now shows but one every requiring correction. The use machines especially designed for the job has bettered the product almost every stage its manufacture, while com- plete system gaging progres- sive steps stops defective work whatever stage completion has reached, that operations are performed parts that will have rejected later. — | 4 | equal importance the re- fining the product, from the point view the manufacturer who looks for efficiency and econ- omy production, the effect the newly completed revision the plant layout, which has brought all manufacturing operations (ex- cept forging and coil spring manu- housing are joined specially designed welding machine which eight have been built for Chevrolet. The halves are laid open end toward the front. operation, the tures are advanced cam action, req- ulated bring the edges the halves contact and control the size the Timing the ma- chine automatic. JOHN BONBRIGHT facture) under one roof. The plant management has rearranged all machines correct sequence operations, and provided for the orderly progress each component part arrive the right time and the right quantity the point other parts. Thus, the stamping, drawing, and forming operations required prior welding the front and rear halves the knee-action housing, and the upper and lower halves the king-pin support (the cross-member that supplants the front axle), and the welding op- erations well, all which formerly were handled distant THE IRON AGE, March 21, 1935—25 ba different sections within the knee- action building itself. building, are now consolidated single building which all sub- sequent manufacturing unusually comprehensive sys- sembling operations are performed. tem conveyors, totaling 10,865 Not only long-haul inter-plant ft., has been installed bring trucking eliminated, but also the about the most efficient handling use industrial trucks between parts. These power-driven con- veyors are J me — SS | 4 ~ SS wry ~ 26—THE IRON AGE, March 21, 1935 FTER each stroke chine, the operator removes the trimmed housings two vertical fixtures, transfers the two from the horizontal dies the vertical fixtures, and places two more the horizontal each stroke the machine shears the welding flash from the exterior the two housings and broaches the interior the pair previous- trimmed outside. supplemented with gravity chutes between machines that comprise series equally timed steps manufacture. Thus, for each the five presses which blanks for housings king-pin supports are formed, there ADS near the ends the king- pin support are sur- face this special machine provide full con- tact alinement when the support bolted the chassis frame. Here the operator placing the support the machine, the pads (on top) not yet position for machining. The two with edges are in. wide and have 35- in. stroke. Each broach has hydraulic drive, each capable 10-ton effort. : stroke ma- erator mmed the ‘tures, two zontal the the the from the and terior /ious- with ines ally sses separate battery drawing and forming presses, keeping pace with one another, served gravity chutes into which the work ejected from each machine, slide the next machine. the ends the parallel batteries, the work placed conveyors that carry that section the plant which the next series operations performed. Probably the greatest improve- ment the conveyor system whole the adoption two separate lines parallel, one de- voted exclusively right side, the other left side, parts and as- semblies—the two knee-action units for each car, course, being formed reverse image each other, and requiring many parts reversed shape and the loca- tion attachments, machined faces, perforations, ete. The sys- tem dual conveyors extends from the beginning the series operations all the way the final assembly line. method, the operators machines equipped with dies jigs for work only one particular half the housing now receive constant supply parts, and longer are required select them from among parts they cannot handle. New Dies for King-Pin Support While the knee units themselves are only slightly changed this year, the king-pin support for 1935 entirely new design. heavier and more rigid, being deeper section and including ad- ditional welded reinforcements. dies use this year are new, and many additional machining opera- tions are performed procure ac- curate shaping the support and provide for its being assembled the chassis more securely and more accurately positioned. example, all punched) are now drilled jigs multiple drills, while the sur- faces where the support contacts with the chassis frame are now faced and located the same plane specially developed external broaching machines. Correct aline- ment the support the chassis, upon which depends front wheel alinement, assured these im- The routing sheets for work both the housing and king-pin sup- ports show many additional altered operations compared with the 1934 job,