The Iron Age 1935-04-18: Vol 135 Iss 16

FRITZ FRANK, President J. H. VAN DEVENTER Editor Managing Editor News Editor Machinery Editor Editor Emeritus Washington Chicago Cleveland EHRNSTROM, JR. BURNHAM FINNEY GERARD FRAZER Pittsburgh Detroit Boston Cincinnati 239 West 39th St., New York Contents 18, 1935 Social Security Depends Business Security Highly Flexible Cylinder Block Equipment Attractive Finish Helps Metal Products Sales. Massive Machine Parts Welded Rolled Hardness Conversions for Carbon and Alloy Steels. Open-Hearth Technicians Review Developments. Late Returns From Laboratory and Mill. Activities Bearing Machine Tools Distribution. Automotive Industry 7 News Personals Washington News Markets Construction and Equipment Buying Products Advertised 118 Index Advertisers 138 BAUR, General Advertising Manager DIX, Manager, Reader Service si Member, Audit Bureau of Circulations ADVERTISING STAFF Member, Associated Business Papers Emerson Findley, 311 Union Cleveland Herman, 675 Delaware Ave.. Buffalo. | Owned, : Copvri -Published every Thursday Subscrip- H. K. Hottenstein, 802 Otis Bldg.. Chicago tion Price: United States and Pos Peirce Lewis, 7310 Woodward Ave.. Detroit | by sessions, Mexico, Cuba, $6.00; Can Charles Lundberg, Chilton Bldg., Chestnut & < ada, $8.50, including duty; Foreign 56th Sts.. Philadelphia. Pa. t . ® $12.00 t se Single copy 25 cents C. H. Ober, 239 W. 39th St.. New York q = an W. C. Sweetser, 239 West 39th St.. New York t Gg “aa Cable Address, ‘‘Ironage, N. Y."' D. C. Warren, P. O. Box 81, Hartford, Conn. Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. FRITZ FRANK, Executive Vice-President ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary 3 : ? i, 4 = i 7 “3 | : | ‘ SAVY. Bearing Bars HOT ROLLED ALLOYS S.A.E. 2315, 2320, 2330, 2335, 2340, 2345, 2350, 3115, 3120, 3130, 3135, 3140, 3250, 4140, etc. Rycase (Hot Rolled, machine Straightened) Rytense (Hot Rolled, machine Straightened) COLD DRAWN ALLOYS 2315, 2320, 2330, 3115, 3120, 3135, 3140, etc. HEAT TREATED ALLOYS Ryco (Hot Rolled, machine Straightened) Nikrome (Hot Rolled and cold drawn) STAINLESS AND HEAT RESISTING ALLOYS Allegheny Metals Bars, Welding Rod, etc. RYE 8—THE IRON AGE, April 18, 1935 Phosphor Bronze ft. Lengths The New Leaded Phosphor Bronze Bearing stock for screw machine and turret lathe production. Write for Bulletin. COLD FISHISHED STEELS Std. Shafting, Turned Ground and Polished, Special Accu- racy Stock, Rycase High Manganese Stock, S.A.E. 1112, 1120, etc. TOOL STEELS Ryerson XXX, XX, Ryerson B.F.D., Die Steel “4-Point” Chisel Steel High Speed Mill Treated Bars Diamond Carbon Steel Drill Rod GENERAL STEEL PRODUCTS Bars, Structural, Plates, Sheets, Shafting, Strip Steel, Welding Rod, Tubes, Babbitt Metal, bolts, nails, etc., are also car- ried stock for immediate shipment. Specializing the finer Your competitors are burning the midnight oil economizing—improving their products. are you! And the newer, finer steels that are accom- plishing miracles. The new stainless steels, high manganese alloys, new process tool steels, special accuracy bars, etc., etc.—these and many others are responsible. For this reason the Ryerson Special Steel Divi- sions are working overtime helping manufacturers whenever the problem steel arises. have experienced group special steel men awaiting beck and call, and hope you will take full advantage this most important service. not let well enough alone. not too easi- satisfied. Call Ryerson for suggestions that will economize and improve your product. will glad help you. The Ryerson Stock List your guide the most complete stocks steel and allied products carried for immediate shipment. NOTE: See the new Specifications the new Ryerson Stock List. you not have copy write and will glad send one once. Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City i | = q ‘ f — — | | | | i q | | £ 4 \ oil you! com- high are Divi- urers iting full will most THE IRON AGE ... APRIL 18, 1935 ESTABLISHED Vol. 135, No. Social Security Depends Business Security nor will oppose sound measures promote that end. But many busi- ness men, the risk being misunderstood, have expressed doubts the extent that legislation can insure society against economic hazards. enlightened American questions tie desirability greater social Why these doubts? Because the fundamental basis for social security has been overlooked. the depression years there has been frequent resort legislative enactment and Administrative mandate improve the economic condition large groups our population, but the results achieved have not come The problem unemployment remains unsolved; want still stalks millions. The explanation found the fact, still largely ignored but neverthe- less inescapable, that recovery and social security alike depend business security. Business does not demand protection from all risks. the contrary, the con- duct private enterprise implies taking chance. But capital must granted reasonable assurance gain before will venture into undertakings that spell activity and employment. And capital not synonymous with extreme wealth. Many thousands hard- working, thrifty people modest means have invested their savings business and industry. Many thousands more are indirectly dependent business profits through insurance companies, our greatest investing agencies. The interests this large group are deserving consideration those labor the debtor class. Emergency relief has been given certain circumstances debtors, and properly so, and wages have been commonly given precedence over dividends, but there are limits all things. The shareholder has waited his turn and waited patiently, but will not take new risks without some prospect return. Nor will corporate managements make expenditures for needed improvements unless they can see way paying for them. normal times the railroads are huge purchasers materials and equipment. They have just been granted rate increase, but the expected gain revenues will offset large part advance wage rates. the case the rail- roads accomplished fact, rather than fear, impedes revival buying power. With many other enterprises apprehension over what organized labor Wash- ington may do, rather than what they have actually done, quite effectively holding back purchases. probably significant that, recent trip made the writer, business activity accelerated the distance from the loudspeakers the national capital lengthened. Present uncertainty, most its phases, political those who would legislate into social security would give more heed busi- ness security they would achieve their avowed aim sooner. LACHER Managing Editor, The Age | 4 4 ~ 4 5 | > a 1 ites 2 ¢ Mis yey one-way vertical multiple drill. KEEN competition for the consumer’s dollar, chasing power has been below normal the depression years, has led quick shifts the design products and hence especially necessary changes manufac- turing methods. These shifts must made with due regard for the fact that retail prices cannot advanced much without restricting markets and that costs mate- rials and labor have risen substan- IRON AGE, April 18, 1935 tially under NRA. The situation, then, one which management longer can afford pour out unlimited sums money (except few extraordinary cases) for equipment which must written off within year two. Yet man- agement realizes that, more than ever before, must avail itself economies resulting from use the most modern equipment. This was the faced the Packard Motor Car Co., Detroit, when decided expand Packard Installs Highly Cylinder Block ° ° BURNHAM FINNEY Detroit Editor, THe IRON Ace its line cars include lower- price eight known the One Hundred Twenty. wanted ma- chinery which would specified job lowest cost without occasion for discarding when changes were made. wanted ma- chinery which can easily and sim- ply converted from one type equipment another, with min- imum delay. wanted ma- chinery which case break- down could put into commission again short order without dis- pe ° ° ° q rupting the even flow parts chrough the plant. installed line for machining the One Hundred Twenty cylinder biock consisting Power Pack machines built the Ingersoll Milling Machine Co., Rockford, This line was sold Packard complete functioning unit capable producing machined blocks the rate hour end agreed-upon direct labor cost plus specified degree ac- curacy. as a The Packard line regarded establishing machine shop practice. marks the first time that complete pro- duction line has been built common elements machines and fixtures, including machines using differing processes removing metal, which are approximately changes the design the block should made later. also the first time that serious effort has been made embody artistry machine tools. And might added that the modernistic effect created the equipment, much after the manner the architec- ture predominant the Century Progress, has given the Packard factory pleasing appear- ance without any extra cost. Single-purpose machines, they must junked the end production run, are costly. Their lack adaptation more than one job unfits them for use most shops. the other hand, some standard machine tools little better from the standpoint Ingersoll, connection with the Packard plant, has now large scale ideas interchange- ability units developed over the last five years. The versatility the machine tools used the new Packard line due the fact that their range gearing, adjustable heads), their angle approach changed and their size (converting one-way horizontal drilling machine into three-way vertical machine), and the method removing metal changed (milling machine can POWER Pack milling machine with three traveling heads, two horizontal and one ACKARD has installed the lowest cost cylinder block line the automobile indus- try. The equipment, consist- ing Power Pack ma- chines, approximately per cent salvageable, conse- quently will not have discarded when models are changed. can con- verted from one type equipment another with minimum delay. em- bodies artistry well util- ity, thus giving appearance the Packard factory. converted into drilling machine). All these desirable features are obtained through the use seven common elements comprising every Ingersoll machine the Packard plant: the fixture pedestal, bed wing, slide, saddle, Power Pack, work unit, and fixture. Each element performs speci- fied function and self-contained, although the Power Pack itself has multiplicity functions. The Power Pack all-electric unit providing driving and feeding power for the work done. contains the control mechanism for governing the feed cycle. thus eliminating all external connec- tions. The cycles for drilling, tap- ping, boring, and milling are gov- erned the position small handle protruding from the case. The fixture pedestal raises the work convenient working height and wired all four sides for easy “plugging in” circuit. The bed wing raises the machine the same con- venient working height. The slide allows the cutting tools ap- proach the work and retreat from it. The saddle provides means for carrying the Power Pack and work unit the slide. The work unit the tools and the fix- ture holds the work. The Power Pack contains per cent the mechanism the entire machine and case trouble can replaced min. One re- serve shop plenty. Ingersoll has designed its drilling ma- chines that they can converted into tapping machines turning button one end the Power Pack. Like the machines, the fix- tures are made out common gether, the Packard line ma- chines has been built from machine elements. Construction the machines Packard shown the accom- panying phantom view three- way vertical drilling machine. The machine consists fixture ped- estal, three bed wings, vertical housing, three slides, three saddles, three Power Packs, three work units and one fixture. This ma- changed into horizontal machine hr. Any one the three Power Pack units chine could ast ; a 5 7 is + Ke 4 drill, equipped with two 5-hp. Power Pack units, used drill the oil holes in two cylinder blocks. ° ° machines consist of P< wer units attached at the proper angle eyor three spindle diillin machine for rough drilling the oil pump hole, the distributor hole and the suction hole cam and crank ines are and finish bored two boring machines equipped with 30-hp. Power Packs. The blocks are inserted upside down, each machine having device for clampina the block position. q a 12—THE IRON AGE, April 18, 1935 can removed and new one in- serted min. Several machines the line con- sist Power Pack units attached the proper angle fixture built over the conveyor line. spindle drilling machine for rough drilling the oil pump hole, the dis- tributor hole and the pump suc- tion hole. The machine made fixture, one 1-hp. Power Pack and two 3-hp. Power Packs. roller conveyor along which cylinder blocks move operation the next integral part the Packard line. some cases the conveyor passes through machines that the straight line movement blocks not inter- rupted. Wherever blocks must shunted off the main conveyor into machines, they are rolled along “cut-off” directly into the proper work position without the neces- sity being lifted hoists ’ = — hand. Incidentally, the legs the conveyor structure are de- signed fit into the mod- ernistic scheme the machines themselves. The Power Pack type equip- ment, protected patents, has been tested thoroughly under pro- duction conditions. The first in- stallation was the White Motor Co. Cleveland for machining its Pancake engine and the second the Citroen plant France. Be- cause improvements made the last year two, the Packard in- stallation has the distinction being the most modern and the most complete well the low- est cost line yet built. Unique machine tool prac- tice was the setting the en- tire cylinder block line the Ingersoll plant Rockford prior its shipment Packard De- troit. Four hundred blocks were run through the line see that everything smoothly and insure Packard time when was anxious get into production its One Hundred Twenty models rapidly pos- sible. 4 q q ling machine em- line bore the valve tappets and ides and size ream the valve tappet and vaive qu ide hol es. build-up three-way vertical drill- ing machines common elements shown left. This machine could into horizontal machine hr. Any one the three Power Pack units can removed and newone inserted min. THE IRON AGE, April 18, two views are study contrasts before and after the use bright paint. Sherwin-Williams Co ° ° ° Courte sy Finish Painting Aid Production NEARLY per cent all our impressions are received through our eyes, according the Better Vision Institute. When consider this become aware that light and shade and color are more significance our lives than safe say that the importance the quality and intensity light seldom exaggerated, and that even those who are “lighting conscious” usually stop half way the ulti- mate goal. the shop worker fol- lowing through production opera- tions, obliged read micrometers perform any the many diffi- cult visual tasks industrial occu- pation, the energy output and time wasted are excessive and costly IRON AGE, April 18, 1935 where illumination either inade- quate the wrong sort. Poor visibility has its source three factors: first, insufficient daylight; second, insufficient ar- tificial light; and, third, the poor control both. The principal fac- tors the control day arti- ficial light are: suitable reflecting surfaces, sufficient diffusing light glass diffusers, the use paints sufficiently matte avoid specular mirror-like reflections, and the elimination exposed lamp bulbs and sharp contrasts between light and dark areas. From this may judged that the proper use paint shop may production aid mean value. actual practice, paint and attractive finish ma- chine tool may increase sales, but has utilitarian value well. will help the man who operates the tool produce neat, accurate will increase his output and better his morale. The same thing true not only tools but all shop equipment including lighting must hand hand give efficient illumination and high manufacturing output. Thus foundry avoided having cut new windows old building the liberal use bright-colored | | | j | | | - c é St a — ar m Ca \ ni Metal Products Sales walls and fixtures. Bright, pleasing colors help production. And this article, which tells how paint can made pay its way manu- plant, included this series even though deals but in- directly with sales. This the thir- ty-fifth article series metal finishing. and whenever more daylight more artificial light needed, paint can usually counted fur- nish part it. Machine tool builders have found that the use contrasting colors for moving and stationary actually increases the speed pro- duction tool giving the op- erator more confidence his move- ments. The same result may secured larger scale proper selection colors for entire shop. fact, someone has said production agent lathe parts shaper. various tests conducted Staley, Walter Sturrock, Ward Harrison, and others the Nela Park Engineering Department the General Electric Co., was found that differences several seconds resulted the perform- ance even the simplest visual tasks where seeing conditions were favorable one case and poor - HASSON Head, Industrial Division The Sherwin-Williams Co. another. Not only are visual re- sponses much slower, they are less accurate; and moving objects ap- pear traveling much faster where illumination poor. This means increased spoilage and greater number accidents. Ac- cording Chamberlin, writing Review Reviews for Septem- ber, 1934, from recent research “It estimated that manufacturers the lose billion dollars year because industrial acci- dents; $150,000,000 this can charged poor illumination.” The census experts investigating 268,491 plants having total an- nual output found that spoilage these plants totaled the staggering sum $150,000,000. This spoilage was THE IRON AGE, April 18, } VES a he nt. considered due large measure poor visibility. Yet these figures take account wasted human energy, ruined eyesight, losses from retarded rate Intensity Light Inasmuch the major portion useful light reflected from upper walls and ceilings, the use paint with high reflection standpoint good seeing, and the interest economical produc- tion and lighting. With the aid the foot-candle sight-meter instruments that measure the in- tensity illumination means photo-electric cell, can obtain physical measurement light that far more accurate than that the human eye. Tests conducted the Sherwin-Williams Co. using these instruments and utilizing in- direct illumination three minia- ture rooms identical every re- spect save for the wall and ceiling surfaces, showed the extremely low reading but foot-candles for the unpainted brick walls, foot- candles for the painted though dirty and dingy walls, and jump foot-candles for the new white painted walls. though less the case direct illumination, are still surprisingly large. George Kramer, superintendent the Standard Textile Products Co., figure that paint saving about per cent lighting the same time this company has increased the foot-candles merely the applica- tion white paint upper areas. Good grades white paint have reflection value high 82-89 per cent. From tests made the New Jersey Co. rooms equipped with indirect lighting, white room reflected per cent more light than identical room yellow, per cent more light than like room green, and per cent more light than the iden- room gray. These colors were all light tints having white base. For delicate operations, for read- ing scales, for handling non-con- trasting materials, increasing- important that the level lumination over the entire floor area kept high. The eye sees reflected light and differentiates color contrasts. Sight-meter read- ings normally high for ordinary IRON AGE, April 18, 1935 colored machine tools not inspire the operator Courtesy Toledo Scale Co. work fairly light surfaces must therefore increased where con- trast low and but little light reflected from the darker, light-ab- sorbing colors. Avoiding Glare Actually sight-meter reading taken the point the cutting tool lathe may show high, yet the visibility low because the ob- ject seen dark because intense light, the eyes the operator, coming from windows lamp bulb. The pupil the eye contracts shut out the glare and thus the operator may working partially blinded. Higher levels general illumination will reduce this glare from dark and light areas. the comparison see- ing automobile headlight burn- ing daylight opposed night time. The less difference there between the intensities local and general illumination, the easier the visibility and the greater the effi- ciency, provided both levels are suf- ficiently high meet visual re- quirements. The level illumination will markedly increased and glare avoided using flat egg-shell paints having high reflection values. The more matte the sur- face, the greater diffusion scat- tering the light rays. This type reflection avoids the annoyance from specular mirror-like reflec- tion common highly polished gloss surfaces. Where gloss paints are desirable from maintenance standpoint, annoyance from specu- lar reflection may overcome the use diffusing frosted glass windows the event sun rays are strong and direct, and the use opal other diffusing lumi- naries for the control artificial light. Both gloss and egg-shell paints are washable and should washed maintain high reflection value. Courts offer another opportunity for increase the level il- lumination rooms opening from them. has been proved that “daylight illumination the in- closed court can increased times painting the dark-colored court walls with white light tint paint,” according Ran- dall and Martin article which appeared Transactions the Illuminating Engineering So- ciety. Use Color Color applied lower walls and machinery and equipment one important phase plant operation and maintenance that has only be- gun receive its due considera- tion. Applied lower walls, color beautifies, and soft, pleasing shade chosen will prove defi- | | i I 4 me HIS shows the same two presses illustration opposite page, after they have been painted bright contrasting alare R thic nite psychological both men and workers. Restful colors such soft greens buffs will also afford the desired re- lief eyes that might fatigued too bright walls eye level. bit from the modern and colorful family kitchen, num- ber companies have adopted va- rious colors that depart radically from the drab and depressing ma- chine gray and black. Some manu- facturers machinery report that pastel greens, softened oranges, buffs and other colors are being specified present purchasers who find the dressed-up product com- bines good appearance with im- proved employee esprit and produc- tion capacity. Not only oper- ators take real pride colorful equipment, but they work better and more efficiently, for there are practical aspects well esthetic the adoption color. lathe becomes distinctly easier see cuts the paint chosen has fair light reflection value. One radio tube manufac- turer adopted orange paint make stemming against the blues and the greens the gas flames. Pastel blue was adopted his hot room for the cooler feeling created the minds the operators, and there were fewer complaints. The result this painting program was means alone, the output was appreciably improve quality and amount. Ce urtesy Toledo Scale C per cent reduction tube rejec- tions during the first week. The Freeman Shoe Co. has adopt- colors for machines lend con- trast the colors the leathers being handled. result, com- plaints from eyestrain have been overcome and finer workmanship has been made possible faster rate. The Simonds Saw Steel Co., Toledo Seale Co., Pratt Whitney Co., Packard Motor Car Co., Amer- ican Rolling Mill Co., name but few, have all adopted color machinery and agree that color both psychologically and economi- cally justified. Danger zones are usually marked with red. Oper- ating levers are given sharp con- trasting finishes facilitate quick and precise handling. Pipes and conduits that are against walls ceilings are usually painted the color those surfaces and identi- fied color bands. Heat treating rooms are usually done blue reduce complaints from heat. Rest rooms, cafeterias and other rooms are done restful and cheerful colors. Psychology and Production Logically the difference pro- ductivity two men performing like operations identical ma- chines will depend upon the differ- ence their states mind. plant which man spends half his wakeful hours cheerful and pleasant will work better. Contrasting colors applied mov- ing parts will facilitate accurate handling and promote dustry has learned its first lessons applying attractive and colorful finishes its products make them presentable saleable. Good housekeeping methods and colorful surroundings have simi- lar weight within the industry methods both employees and cus- tomers. also makes possible ac- quiring higher type employee lower wage limits. the move adopt white paint and colors spreads more and more, facts and figures are piling prove there great deal more can paint than just paint! Paint and Maintenance From strict maintenance stand- point, paints remain outstanding factor and their proper selection means just much the reduc- tion maintenance costs does the application paint reduce costs from corrosion and rotting. The major problem industry the protection iron and steel from the ravages corro- sion. Something like $100,000,000 estimated the annual loss from cortosion this country alone. The loss would even greater were measures not taken prevent corrosion. Paint re- mains the most universally satis- factory means prevention, but paints vary their anti-corrosion properties and their life. Some paints actually induce corrosion. According Henry Gardner, chief the scientific section the Paint Manufacturing Association the United States, who has made tests various paint pig- ments. American Vermillion (basic lead chromate) superior all other steel iron primer paints. Sublimed blue lead ranked slightly lower. Red lead having per cent litharge added stood better than straight red lead pig- ment. Not only did the lead chro- mate base paint surpass all others, but, properly made, applies more easily brush spray, due the lighter pigment, and less expensive than good primers. Other advantages the lead chromate base primer are: ability stand months weather- ing preceding finishing coats, abil- (CONTINUED PAGE THE IRON AGE, April 18, 7 “as > a j= f : | q uw Ww ~~ tt | O ¢ c Cc oc * 4 © ¥ ° = ° longitudinal el se ste in. in. front end section for rat oO - cU 2 @e ow dd = > re > —— Q @-O oo IRON AGE, April 18, 1935 > a ti n pres i stee guides are welded in place. \ \ | Massive RAPID strides the use rolled steel sec- tions which are cut and built weld- ing into complicated and massive machine parts are well illustrated the accompanying pictures. The character ultimate use the part made prime im- portance the study design, and therefore the center not alone welding and shop practices, but also what expected the machine and its parts. These factors de- termine stresses and the general character design. Then follow the layout and weld design which determine cool- ing stresses that must trolled, that the part when ready for the normalizing fur- nace more distorted un- der stress than the best practice permits. Flame shap- ing employed for some mem- bers, and edges machine sure clean metal sur- faces. Laying-out accurately per- formed and prop- tacking ex- tremely necessary the final as- sembly turn out accurate all dimensions. The sec- tions for main part chine does not any way limit the ROGERS FISKE Western Editor, The Age use castings where castings are advantageous. the plant Danly Machine Specialties, Inc., Chicago, and the Smith Corpn., Milwaukee, where the elec- tric are welding process the Smith Corpn. used both companies under cooperative agree- ment, castings are often welded rolled steel members after giving special attention the design the casting, its placement the Machine Parts Made elded Rolled Steel machine part and the actual weld. Any skimping proportions and design the cast part results situation which the weld, matter how perfectly fused, well adjacent members are worked under stress and conditions that are prohibitive satisfactory and extended service. careful lay- out, welding and normalizing entirely practicable locate cast- ings large diameter and long length for bearings guides, that minimum amount stock need allowed for machining the bore. Normalizing plays two impor- (CONCLUDED PAGE 96) steel crown for 700-ton press. Its weight 19,700 THE IRON AGE, April 18, « ie fig ° ° ° f : af q Pod : SOME technicians are opposed the utiliza- tion hardness con- version tables dia- grams, but the importance and value this work have never been more clearly demonstrated than the last two three years in- dustrial stagnation. New develop- ments and improvements exist- ing methods have broadened the scope hardness testing beyond the capacities even fairly com- plete testing laboratories. These conditions well simple plant economy have brought about con- siderable interest well the greatest possible precision the compilation comparative hard- ness tests carried out for the bene- fit those seeking data the re- lative magnitudes various hard- ness numerals. Since the advent modern hard- ness testing metals over original studies the conversion hardness numbers, have been presented the world’s technical press, the first dating back 1909. reviewing the contents this initial paper, interesting note that the need for some uni- fication hardness numerals was felt even that early date. order show some proportionality the then known hardness num- bers, the Brinell values were di- vided six and the resulting quotient compared with the rela- tive Shore indices. The first two columns Table indicate some the original data for few ferrous materials. Contrary the contention some investigators, scratch hardness—as determined Turner’s sclerometer—is also good agreement with the foregoing methods, which the third column the mentioned table ample proof. his 1909 paper Turner de- duced from his researches the IRON AGE, April 18, 1935 ANY studies have been made obtain accu- rate conversions hardness numerals. However, the usual procedure has been com- pare only few the better known testing methods, and the data various investi- gators have shown surprising variations. This article reviews all the usual testing meth- ods, and the accompanying table gives comparative fig- ures which are believed the most accurate yet as- sembled. Not only has the author conducted many thou- sands tests compara- tive nature, but has also assembled all the data other investigators order secure the most repre- sentative results. subject that and non-deformative hard- instruments “must measure one and the same physical property,” giving “results which are either actual agreement with, proportional to, the results TABLE Turner’s Conversion for Three Hardness Scales | Brinell Sclero- numbers | Scleroscope metric Metal divided hardness hardness by 6 Softest Iron 14.5 Mild Steel 16 to 24 22.0 21.0 Soft Cast Tron 24.0 24.0 Rail Steel | 26to 35 27.0 | 24.0 Hard Cast Iron | 35.0 | 40.0 36.0 Hard White Lron 75.0 70.0 72.0 Hardened 93.0 95.0 Conversions for Carbon obtained the other forms tests.” Modern hardness seems point distinctly towards the existence more ac- curate relationships between the contemporary methods testing than has been surmised the past. Even though the term “hardness” may denote—according Bier- baum—five different properties, ac- tual data disclose that our present conception the property known “hardness” quite clear. contention irrespective the fact that physicists and philologists have failed far set forth unanimously acceptable definition for it. The main difficulty co- ordinating the various known methods hardness testing seems consist mechanical and human variables rather than some fundamentally wrong principle the design the most commonly used machines for the testing mechanical hardness. With the thoughts mind, the very perti- nent question arises the extent which the different meth- ods hardness testing agree for various individuals and also for various machines otherwise identical make design. Progress the construction testing equip- ment meant ultimately reason- ably complete eradication serious deficiencies the experimental error due inaccuracies han- dling, reading, etc. The latter fac- tors are greater significance attaining desirable and duplicat- able precision whenexamining hard- ness characteristics metals than many other technicalities. Conse- quently, this attitude was consid- ered main criterion the diver- gencies many conversion dia- grams and tabulations, for which reason all possible care has been exercised the present study + A\nd A\lloy Steels TABLE II—CONVERSION TABLE VARIOUS HARDNESS NUMERALS use only carefully calibrated ap- which would enable the prepara- tion generally useful conver- sion table. Whenever published values other investigators were taken into consideration this work, com- parative tests were made ascer- tain the reliability the respective sources. perhaps needless state that thousands tests and calculations were essential com- puting the figures given Table II. the preliminary compilations data, stress was laid the practical applicability the meth- ods testing finally accepted for further exploration. The methods thus selected represent the most commonly used procedures stat- ic, and scratch hardness testing. The first, e., static inden- tation test, included the methods Vickers (diamond pyramid), Bri- nell (steel and tungsten carbide ball), Rockwell (diamond cone and steel ball), AlphaDurometer (dia- mond cone), and Monotron (dia- mond ball). Dynamic kinetic testing methods comprised the drop hardness test (steel ball), the Her- bert Pendulum, the Shore sclero- scope and the Duroskop. the scratch methods, only the standard Moh scale was considered because the limited importance all other methods hardness testing metals. Detailed explanatory notes the observations made dur- ing this study are given the sub- sequent paragraphs. Comparative Study Made from the practical applications various methods and instruments hardness testing shows that the machine Vickers probably the least affected the previously (CONTINUED PAGE 90) This carbon, chromium, nickel, vanadium, molybdenum, silicon and manganese, none the alloys exceeding per cent. cold-worked steels are included. were those recommended the manufacturers the respective instruments. table applies only to chemically Vickers Firth tots 6:3 Diameter mm. Standard Ball \-in. Ball Tungsten Carbide Ball JOHN HRUSKA Metallurgical Engineer, Berwyn, ° and mechanically uniform steels containing Monotron Drop Hardness mm. kg. toto to to = ww OF Q 1200| 32| 52| 1005 53| 55| 910 56| 880 65| 675 630 268) 430 268) 415 86; 28 259) 40: 259) 395 38: 90} 26) 365) 92; 25 | 360 25) 23) 97| 22) 320 99 22 é 310 290 285 280 109 19 275) lil 18 27 113 18 265) 115 18 260 116 17 255 250 121 240 126, 127 15 22 128 14 22 THE IRON AGE, April 18, All testing methods used Scleroscope Duroskope a Moh | lniniale | 6 n 110 65) 110 66 95 61 } 20 " « BELOW base this swivel chair striking example what being done these days with die castings. few years ago the large scale produc- tion similar base would have in- volved long and labored method manufacture. Today the whole job done single operation the Doehler process. The beautiful precision the work evidenced the sharply defined surfaces the kick plates and depressed panels visible surfaces. Doehler Die Casting Co. has solved not taken seriously, least easily and quickly from refrigerator trays. The ice tray eliminates the old “hot water" treatment, and the tray featured all models the Westinghouse refrigerator. The principle embodied for the removal the cubes simple cam action. merely lifting the handles bearing the trade name seen the photograph, the user loosens all the cubes the tray. continuing swing the handles back arc, the cubes are raised clear the tray wall. The center division tapered die cast core operated down the cam action. Being tapered widest the bot- tom, the cubes are literally forced up- ward with this center division operated the handles. 22—THE IRON AGE, April 18, 1935 cut up! But his custom- ers seem like the way that Henry Marx, Beverly Hills, turns sheet metal unique and at- tractive Work-in-proc- ess shows Cupid getting some- goat. i a RIGHT DIESEL power the sandblasting unit here shown prepar- ing the ship Lebec Terminal Island, Cal., for the recondi- tioning her decks, hull and super-struc- ture. Old paint and all traces rust are removed before the repainting com- pleted. LEFT IBRATION turbine blades studied means this ingenious 500-watt electromag- netic vibrator the laboratories the Westing- house Electric Mfg. company's South Philadel- phia works. Frequencies from 10,000 cycles per sec. can produced. Amplitudes and fre- quencies are measured and each specimen vi- brated constant amplitude until crack occurs, from which can calculated the endurance limit. RIGHT HIS giant drag-line bucket has the job chewing away some 40,000,000 cubic yards earth the construction the All-American Canal, 75-mile fed- eral irrigation project, Southern fornia. Its cu. yd. Occa- sionally must pause for dental atten- tion, when applied the electric arc welding process. » Photo Courtesy Lincoln Electric €o.. Cleveland THE IRON AGE, April 18, OME prophets have judged the open-hearth obsolete and inefficient instrument for melt- ing and refining steel. Neverthe- less, this unique batch making device has consistently fulfilled all the demands the rolling depart- ments. The modern open-hearth product comparatively cheap, the analysis may manipulated quickly and accurately, grade steel having definite de- sired characteristics may tapped despite the variety materials, both good and bad, delivered the charging platform. These attri- butes have not yet been dupli- cated equipment radically different design. Thus safe assume that the open-hearth for many years will continue the pri- mary and most important unit America’s steel industry. The rapid improvements open- hearth efficiency the past decade are traceable part the lively debate, friendly cooperation, and liberal swapping information each year superintendents at- tending the meetings the open- hearth committee the American Institute Mining and Metal- lurgical Engineers. these meet- ings was spread the gospel seal- ing furnaces from end end; widening and lengthening hearths; adopting new checker designs; introducing automatic controls and modernizing eliminating entirely troublesome and_ costly valves. April and were the two days devoted the 1935 open- hearth conference, and more than 230 superintendents reported the Netherland Plaza Hotel, Cin- cinnati, present and argue their mutual problems. Following few timely introductory remarks Chairman Leo Reinartz, extensive resume ladle and teem- ing practice was given Tranter. Although Mr. Tranter made attempt present cure- alls for the many problems pit operations, his remarks were illu- minating the excellent practices manufacturing its low-carbon the American Rolling Mill Co. 24—THE IRON AGE, April 18, 1935 Innovations (under 0.1) for sheet purposes. Mr. Tranter stated that the fac- tors affecting the origin de- fects ladle and teeming practice may summarized follows: (1) Running stoppers result- ing from mechanical failure of the stopper rod, stopper head, nozzle, or manipulating mecha- nism, (2) Failure properly clean and molds between pour- ings, poor lining practice, fail- ure the refractories, and too rapid pouring speeds. (3) Improper technique and manipulation metal from the ladle into the molds (4) Mold design, temperature molds time teeming, cleaning and conditioning molds, type and methods applying mold coatings. (5) Capping ingots, elapsed time for pulling, stripping and ingots into the soak- ing Enlarging these five factors, Mr. Tranter was the opinion that mechanical failure the stopper rod and operating mech- anism the most common cause running stoppers. Difficulties can usually traced faulty stopper heads, sleeve brick, as- sembly rod insufficient drying the rod before use. ciently dense prevent excessive slag penetration and should have the proper constituents resist the fusing action slag and metal. Tight joints the lining are obviously essential, taking into account the necessary allowance for expansion. using the prop- proportion brick shapes— arch, wedge, and squares—more uniform lining practice obtained. Stopper rod assembly should assigned regular stopper rod maker inasmuch the workman- ship specialized nature. The graphite stopper head affixed the lower end the stopper rod means bolt and key or, some plants, screw type head used. fitting the key type head the rod, should turn freely not loosely, order that sequent expansion may not cause splitting. the other hand, loose heads may burn off due molten steel penetrating the joint. tapered bottom sleeve into which the shank the stopper head fitted serves added protection this point. The bolt hole the stopper head plugged with moist compound usually obtained from the manufac- turer. Home-made compounds are none too reliable. Fire clay used pack the joints between the sleeve brick should flint base clay good quality. drying oven necessary, and vertical type particularly satisfactory. The ideal arrange- ment have the new rods enter one end and the dry rods emerge from the other. The furnace should equipped with recording py- rometer and definite drying cycle followed. oven having four compartments special advan- tage for taking care rods different sizes. After removal from the furnace, the rods should always held the vertical position avoid cracking the joints. Welded Ladle Per Cent Lighter Mr. Tranter was the opinion that nozzle setting extreme importance. Grinding the nozzle cup has given satisfactory results where slight imperfection pre- vented proper fit with the stopper head. Care must taken avoid grinding the surface too deeply. Otherwise the soft interior, be- yond which the surface firing has toughened the brick, will ex- posed. Nozzle size subject considerable debate. The larger nozzle more favorable ingot surface but has effect the interior structure from the standpoint blow holes, pipe and inclusions. Oval-shaped nozzles have come into more gen- eral use and have special advan- tages where slab-shaped ingots are poured, the metal stream has less tendency strike the mold wall the narrow dimension. Length nozzle also fac- tor, and the trend has been to- ward longer nozzles. number plants are now using nozzles in. more length. The longer length greatly reduces the spraying the metal stream. Many steel men continue ex- periment with ladle design order arrive the proper ratio height diameter. Oval ladles have been solution where in- creased depth would mental quality where clear- ance and limitations certain existing equipment would problem. Welded ladles have made pos- sible increase the size heats plants where. building columns, crane runways and ladle cranes carry heavier weights. The welded ladle approximately per cent lighter than other types the same capacity. The problem insulating ladles has been satisfactorily solved, re- sulting lower radiation loss open-hearth operators are using Therm-O-Flake insulation. This view in. plastic. Adhesion attained big-headed nails driven into Sharp Debates Year’s Developments Annual Convention through the shell the ladle. The insulation consists approximate- applied with trowel the inside the shell. This practice had for its original objective the use thinner lining, thereby increasing the capacity the ladle. The cal- culated radiation loss the thin- ner lining without insulation ma- terial was given trial and, after considerable experimenation, satisfactory insulating cement was found which served the purpose very well. While actual heat conductivity calculations have been made, the outside the ladle in- dicates only slight increase temperature the touch. Thus the thinner lining has been entirely satisfactory, and decrease service life has been noted. Greater importance, continued Mr. Tranter, being attached mold cleaning practice and its ef- fects quality and mold life. In- clusions, surface defects and mold stickers result from poorly cleaned molds. many cases haphazard cleaning job results where the mold yard gang are required stand top the mold perform the operation—the amount clean- ing this case being more less proportion the temperature the drag. This practice also serious safety hazard. better job cleaning, with time loss, done where movable platform operating over the train molds provides safe and ef- fective means for cleaning. This arrangement calls for fewer men, and safety hazards are practically eliminated. Concerning the capping in- gots heats, Mr. Tranter pointed out the beneficial effects resulting from removing the slag scum which formed during the effervescing action the molds before placing the cap the ingot. This scum can blown off with compressed air scraped off with wood pole paddle. This practice serves prevent ingots from “blowing up” spouting, quality and safety the neat appearance walls coated the wall the use chicken wire. THE IRON AGE, April 18, 1935—25 | > + hazard which otherwise frequently occurs where large slab ingots are poured. Pulling heats too quickly after teeming has been found have considerable bearing the forma- tion interor defects. Repeated experiments have demonstrated that certain types laminations result from moving the ingot too quickly after pouring, and charg- ing into the soaking pit too rapidly. dress, the question was asked the best method inspecting ladle trunnions for defects and flaws which develop frequently the result overflowing slag. was the opinion several opera- tors that thorough washing with kerosene was the simplest and best method for disclosing herent cracks. The attention the convention was next directed the experi- ments being conducted linings for ladles. During the past few years there has been great improvement steel quality due the reduction non-metallic in- clusions result changes furnace practice. Therefore, has seemed that further progress would made the pickup non-metallic impurities from ladle linings could also reduced. Tapping basic steel and basic slag into acid-lined ladle does not appear metallurgi- cally sound. Several years ago, according one operator, fairly extensive tests basic linings were carried out Anticipated improvements steel quality resulted, but serious me- chanical difficulties were encoun- tered. furnace operators, par- ticularly those pouring high-man- ganese steel such steel per cent man- ganese, impose very severe condi- tions when pouring acid ladle linings. The work with basic lin- ings was, therefore, extended this industry, and plastic basic wash was finally secured which gave marked improvement. With this progress the electric fur- nace field background, the Canadian Refractories Limited in- itiated tests its 695 plastic ce- ment for ladle linings. Results the use this basic lining are re- ported being excellent, and for about year now several steel pro- ducers have employed this practice continuously. The gain twofold. metallic impurities have been largely eliminated and the ladle lining life has been in- creased some five times. Basic Ladle Mixture Seems Likely This 695 cement marketed dry form with necessary bonds. 26—THE IRON AGE, April 18, 1935 tempered with water defi- nite consistency and rammed be- hind form directly against the ladle shell. After slow drying drive out all moisture, the lining ready for service. One user this mixture ob- jected the policy ramming directly against the shell inasmuch the product has fairly high con- ductivity and the shell may in- jured for that reason. Thus was suggested that insulation should first applied the ladle shell. Another operator sults number heats rail steel wherein basic lining was experimented with attempt avoid reversion phosphorus and loss manganese. Four ladles were lined with per cent Portland cement mixed with mag- nefrit, applied in. thick over brick lining. Each ladle made five six heats after which formed the bottom. ing this skull the lining was dam- aged and had renewed. The result this experiment basic ladle lining best expressed means slag tests. Such test taken before tained 16.50 and 0.910 phos- phorus. slag test taken from the ladle after the heat was poured contained 21.50 and the phos- phorus was unchanged. Using conventional ladle, slag test before tapping indicated 16.50 SiO, and 0.930 phosphorus; slag test from the ladle after the heat was poured showed 30.50 SiO. and 0.670 phosphorus. erator making these experiments was the opinion that basic lin- ing had definite future, but that present mechanical difficulties would indicate that fully success- ful lining will probably not all but will some optimum mixture. The next subject discussed was the importance constant main- tenance tap hole order secure good steel. One operator reported the use Canadian Re- fractories’ 695 cement for mak- ing tap holes, and through its use the hole life was creased 100 per cent but more often about per cent. can Rolling Mill Co., reported quite explicitly that com- pany’s procedure for maintaining tap holes. 6-in. pipe used the hole when the diameter grows in. When less than in. and more than in. the hole patched with ground chrome ore in. diameter. The second helper goes work the tap hole immediately after