The Iron Age 1935-05-02: Vol 135 Iss 18

239 West 39th St., New York Owned, Published and Copyrighted CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. Cc. A. MUSSELMAN, President FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ FRANK, President VAN DEVENTER Editor Managing Editor News Editor Machinery Editor Editor Emeritus Washington Chicago Cleveland EHRNSTROM, Jk. BURNHAM FINNEY Pittsburgh Detroit Boston Cincinnati Contents May 1935 Practical Training Logic..... Flame Cutting Curved Plates for Dam Penstocks Finishing Steel Barrels for Food Containers Carburizing Axle Shafts Gas-Fired Furnaces. and Steel Making Technique Laggard. Influence Roll Neck Deflection Bearing Life Convention and Steel Electrical Engineers Openside Planer Features Extensive Electrification New Equipment ........ Automotive Industry ......... Washington News Statistics Metal-Working Activity Construction and Equipment Buying Products Advertised ....... Index Advertisers ......... 166 BAUR, General Advertising DIX, Manager, Reader Service Member, Audit Bureau of Circulations ADVERTISING STAFF Associated Business Papers Emerson Findley, 311 Union Cleveland ; B. L. Herman, 675 Delaware Ave suffalo. Published every Thursday. Subscrip- H. K. Hottenstein, *02 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.. Chestnut & 56th Sts.. Philadelphia, Pa. ads $8.50, ine reig $12.00 a year. Single copy 25 cent: A 13.00 Single copy conte Robinson, 428 Park Pittsburgh W. C. Sweetser. 239 West 39th St.. New York Cable Address, ‘‘Ironage, N. Y."’ D. C. Warren, Pf. O. Box %1. Hartford. Conn. — ~< My are rg = 4 1935 4 <> «a= . 4 Should You Using One the Newer Steels? Does one newer steels offer you better working qualities—tougher, stronger finish—or lower The Ryerson Special Steels Division will glad check for you. Experienced men will study your particular problem, furnish prac- tical operating data and make suggestions that may lead economy and improvement. Write and ask for suggestions. Ryerson stocks include full range special alloys, tool steels, stainless and heat re- sisting steels. Ten plants strategically located provide for immediate distribution through- out the principal industrial areas. Whether you need pound carload, your order will have personal attention and will shipped once. Write for the Ryerson Stock Immediate Steel. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. IRON AGE, May 1935 Hot Rolled Alloys 2315, 2320, 2330, 2335, 2340, 2345, 2350, 3115, 3120, 3130, 3135, 3140, 3250, 6145, etc., etc. Rycase (hot rolled, machine straightened). Rytense A.A. (hot rolled, machine Cold Drawn Alloys S.A.E. 2315, 2320, 2330, 3115, 3120, 3135, Heat Treated Alloys Ryco (hot rolled, machine straightened). Nikrome (hot rolled, cold drawn, straight- ened). Stainless and Heat Resisting Alloys Allegheny Metal (Sheets, Bars, Welding Rod, etc.). Cold Finished Steels Std. Shafting, Turned, Ground and Polished, Special curacy Stock, Rycase High Manganese Screw Stock, S.A.E. 1020, 1035, 1112, 1120, etc. Tool Steels Ryerson XX, XXX. Ryerson B.F.D. Die Steel. Ryerson Steel. Ryerson High Speed Mill Treated Bars. Ryerson Special High Speed Tool Holder Bits. Permite Leaded Phos- phor Bearing Bronze ft. speed length bars for screw machine production bushings, bearings and parts. General Steel Products All steel products such Bars, Structurals, Plates, Sheets, Strip Steel, Welding Rod, Tubes, etc., are carried stock for immediate ship- ment. ESTA 5 ... THE IRON AGE ESTABLISHED 1855 Vol. 135, No. Practical Training Logic principles the New Deal, the metal-working industry would placed near the top. This does not mean that the industry has refused play ball according the present rules. the contrary, has record compliance that second none, spite the instinctive feeling among the players that the rules are not what they should be, and that neither the public, the employer the worker can win under them. Why this feeling, which honest conviction and one not based upon politics personal profit considerations, prevalent this industry? because its members are reactionaries, Tories, men immune thoughts progress for mankind? No. The answer this question lies another quarter. The men the metal- working industry have had intensive training logic, through their association with machinery. The machine the true exponent logic. there anything wrong prin- ciple connection with its construction, cannot made work. Those who deal with machines cannot afford fool themselves, they must con- stantly seek the truth. There can operative fallacies mechanism. All the legislative bodies earth would find impossible compel pitch gear mesh with pitch gear. Men our industry know instinctively and through experience that there can such thing perpetual motion, engine that will deliver more energy one form than fed another. Once upon time, there was gentleman named Keeley who exhibited new deal the form engine which apparently would that very thing. sold stock rapidly the public until canny mechanic discovered the concealed com- pressed air line which ran the engine through the floor and which enabled perform the supposed miracle producing something from nothing. When this pipe was disconnected, the miracle vanished thin air, together with the funds that investors had put into it. Mechanically-minded men are wondering what will happen the new deal economics when the feed pipe Government spending ceases function. j if ’ 4 hy ' ry i» 2 | 4 Ay Flame Cutting Curved Plates For the construction Boulder Dam many new machines and methods have neces- sity been developed because the gigantic size the project and the enormous scale which opera- tions are conducted. Installation the penstock system has been exception. fabricating the penstock pipes, the largest ever constructed, unusual demands have been made oxy-acetylene cut- ting. Branch outlets the di- ameter conduits have particular ARIZONA NEVADA IRON AGE, May 1935 WALKER Welding Engineer, Linde Air Products Co., Cleveland required new type machine flame cutting. These outlets are made from number plates, which, after being formed into the proper curved shapes, must ac- curately trimmed for final line-up and welding into complete nozzle. The speedy and economical trim- ming these curved POWER PLANT being done with portable oxy- acetylene cutting machine, especial- altered for this difficult job. The tremendous size the pen- stock system, being fabricated and installed the Babcock Wilcox Co., may seen Fig. The four main conduits leading from the intake towers are ft. diameter, from 11/16 in. wall thickness, and will have total length about 4700 ft. The penstocks, ft. diameter, branch from the main conduits the hydraulic turbines located the power house below the dam. Plug Outlet ” Canyon Valve House Cableway Colorac <> 100 150 200 Headers Valves & > | \ \ \ ke 7, - \ \ \ Zz Ga. = = (2 Of Boulder Dam Penstocks There are penstocks all, rang- ing wall thickness from 15/16 5/16 in., and having total length 5600 ft. Below the pen- stock branches, the main conduits are reduced ft. diameter. Each conduit finally reduces six diameter branches leading control valves located farther down the stream from the power house. The 25-ft. diameter sections the conduits range wall thick- ness from 5/16 in. and LEFT Boulder Dam pen stock system being fabricated talled the Bab- ock Wilcox Co. The four main con- leading from the intake towers are ind ° ° 4 RIGHT diameter, fabricat section ready tor penstock system. consists six plates, fillet-insert sec- tion for stiffening ring, and supporting brackets. total 1900 ft. length. The ft. diameter branches are 2300 ft. length and range thickness from in. Approximately 45,000 tons steel plate will used this penstock system, which will have total length including its branches, 14,500 ft. Since most this piping much too large diameter ship railroad, the steel plate shipped from the mill fabri- cating plant built near the dam. ABRICATION the branch outlets the 30- ft. diameter conduits the penstock system Boulder Dam has made unusual de- mands oxy-acetylene cut- ting. These outlets are made from number plates which after being formed must trimmed accurately, the job, for final line-up and welding into complete nozzle. The trimming required flame cutting machine especially arranged both guide the blowpipe torch over irregularly curved plates and also give the cut edge slight scarf bevel. De- tails the work, well the equipment developed it, are given this article, which from paper presented Mr. Walker recent meeting the Cleveland section the American Welding Society. Welding, X-raying and other equipment the notable Boulder Dam field fabricat- ing plant the Babcock Wilcox Co., has been pic- tured previous issues THE IRON AGE. Fig. shown one the 30-ft. diameter sections entirely fabri- cated and ready taken the job and installed the penstock system. This section consists six plates, each about ft., fillet-insert section for stiffen- ing ring, and supporting brackets. The total length each section slightly less than ft. All seams this section are joined fusion welding accordance with the A.S.M.E. Boiler Construction Code, Unfired Pressure Vessel Section, class welding. Over 400,000 linear feet welding will re- quired the entire job. The heaviest the 30-ft. diameter pipe sections will weigh approximately 170 tons each. stated before, the plates for the penstock system thickness from in. Some the larger plates are such weight that only two THE IRON AGE, May = x haat? 4, ra ? 3 4 \ 7 - “3 in wall thickneacc é 4 4 4 — branch outlet main conduits. Tremendous pressures are needed for forming the eight plate sections required for each outlet. Plates Required Required Plates Required IG. showing shape and size flat plates required branch outlet. Thickness these plates ranges from in. flame cutting machine operating position one the curved plates. follows template, tack welded the work, give the irregular curve desired. The oxy-acetylene blowpipe, torch, cuts 4-in. plate speed in. per min. 18—THE IRON AGE, May 1935 shipped one car the field plant near the dam. manufac- turing the steel plate the mill, ingots are first reduced slabs approximately ft. thickness. These are cut the proper length for the finished plates ma- chine flame cutting and are then rolled the required thickness. The final step the mill flame cut the plates the ordered size, this cutting within in. The ordered size in. larger each side than the final dimensions the plate used the assembly the sections Boulder Dam. Mechanically driven blowpipes are used for cutting the plate the mill. Not all the penstock system, however, prepared for fabrica- tion the field plant near the dam. Plates for the branch out- lets from the main conduits are shipped the Barberton, Ohio, plant the Babcock Wilcox Co., where special presses needed for bending the plates making the outlets are available. After the plates have been formed shape and dimensions Barberton, they are shipped Boulder Dam for assembly and fabrication weld- ing. The branch outlets are the so- called design shown Fig. 3—very desirable from hydraulic standpoint. Special dies and tremendous presses are needed for forming the various plate sec- tions, eight which are required for each outlet. The penstocks are deg. from perpendicular the. conduits, the angle found best for hydraulic efficiency. Trimming Plates After Forming The problem trimming the plates after forming that they would fit together accurately was real one. Obviously flame was the answer but work with the hand blowpipe would not smooth enough. Further, there were machines available that would guide blowpipe over irregularly curved plates and give the slightly edge desired. Modified radial cutting required for this type construction. true radial cutting the blowpipe kept per- pendicular the plane tangent the curved surface the plate. this work was desired give the cut edge slight scarf bevel aid forming the joint be- tween plates. Actually then, radial. REG 2 | — = UN cu av me ¥ ¥ Ww WEIGHTED HORIZONTAL CENTER POINT BLOW PIPE ADJUSTMENT LEFT 6.—General eatures N CONNECTING “y-a etylene cutting LOCK HOSE BLC machine are shown this init may equip ped with track f traight-line work, snd, as here pictur with radius bar uttina it le ON AND OFF GEARS, DIFFERENTIAL MOTOR. TOTALLY ENCLOSED 7. For cutting materia! thicker than in., water soled blowpips iS ised. This view shows machine equip PROTRACTOR ped cutting through travel speed in- per min. KNURLED KNOB ANO REVERSE CONTROLLING LEVER DIFFERENTIAL cutting was carried out except for this ma- the fact that the blowpipe was chine cutting held approximately. deg. the 4-in. plate away from the speed in. measured cross-ways the line per min. travel. This machine was finally found possible also commonly the radial cutting required used for cutting making certain alterations lines portable cutting machine employed when running for cutting the flat plates ap- the proximate shape for forming. plied with it. Fig. shows the gen- eral features the machine with tached ting circles, for which work the The preliminary cutting the plates done somewhat oversize and the flat position. Fig. are shown the shape and size the flat plates required for one stream- line branch outlet. The thickness these plates varies from in. These nozzles must ne- cessity thicker than the main conduits the penstocks, because the higher stresses around the directly plate. The small levers shown are Cutting Machine Follows Templet the dual The portable flame cutting ma- the reversing chine used for this work shown gear lever set the Oxweld Monitor, designed and free-wheeled into marketed the Linde Air Prod- position for cut- ucts Co. follows the templet, ting. The speed which tack-welded the work, regulator, near give the irregular curve desired. the handle, may The oxy-acetylene blowpipe mount- set for any THE IRON AGE, May BLOW PIPE 4 2 > =i) speed in. per min. The higher speeds are needed when cut- ting inside circles thin plate when plate edge preparation done. The turret head, which one two blowpipes may mounted, may swung through horizontal are 250 deg. This makes pos- sible locate the blowpipes any point desired the sides front the machine. Vertical and horizontal adjustments the blowpipe make for flexible opera- tion. The universal joint adjust- ment the arm holding the blow- pipe allows the blowpipe tilted deg. either direction parallel the machine and deg. right angles from the side. This valuable for beveling plates, and giving leading angle the nozzle, where this assists the eutting. Protractor scales are pro- vided that the desired angle can quickly and accurately set. differential the driving axle assures good traction both drive wheels, opposite sides the ma- chine. This especially desirable for cutting circles and curves. The knurled knob the drive wheel, visible the illustration, for locking the differential gear, when desired, for straight cutting. The weight the machine and its IRON AGE, May 1935 close speed are necessary give smooth cuts, free from the re- sults vibration. The machine may equipped with two blowpipes for simultan- eous operation cutting flange rings from plate, for cutting long sections with parallel edges from plate. For cutting material thicker than in., heavy-duty, water- cooled blowpipe used with the machine. machine equipped with this blowpipe pictured Fig. cutting through in. steel. moves along in. minute and « in +} } wing ne Thre whee Tr 1 oT ! 1 plate the oxygen pressure the regu- lator lb. per sq. in. Driving Wheel Arrangement Changed The changes made permit the tandard Oxweld Monitor oper- ate curved plates the branch outlets are seen the bot- tom view the machine, shown Fig. Normally the machine runs four wheels. The two front wheels the right furnish the drive and the two rear wheels are idlers. Since three-point support was necessary the curved sur- faces, the idler wheel the lower left was removed entirely. The low- right-hand driving wheel was moved back approximately the center the machine and coupled with the driving axle sprocket chain. This arrangement the driving wheel still permits the dif- machine traveling curved line. The chain driven wheel was knurled and lowered the proper amount compensate for the tem- plet which the two grooved wheels run. The blowpipe was mounted opposite the chain driven wheel, direct line with it, that deviated very little from being the proper angle the curved along the cut. Finished Plates Jig Assembled Views some the curved plates are shown Figs. 9-11, after having been trimmed with the machine altered the manner described. The difficulty this sec- ond cutting operation evident when realized that the ma- chine must not only keep the blow- pipe approximately radial the changing curvature the plate travels along. must also fol- low the templet for curvature three dimensions and must and down grade even speed. The machine’s electric motor gives ample power climb per cent grade, and con- stant speed with changing loads insured the centrifugal type governor. The accuracy with which the formed and trimmed plates fit to- gether due radial cutting shown Fig. 12. The plates are assembled jig check fit be- fore shipment the individual plate sections Boulder Dam. Boulder Dam they are again as- sembled and securely tack-welded position and then fusion welded together make complete branch outlet. Single welds are used with the bulk the welding being done from the outside. The com- pletely welded branch outlet then fusion welded the ft. conduit section, serving the junction sec- tion between branch and main header. The final view the plates as- sembled for welding gives good idea the complex curves cut the portable machine. was not originally intended for such special work but with the few alterations has been relatively easy this rather unique job mechani- cal flame cutting. | | “4 1 ) ‘ 7 = % ¥ é F's 8—Bottom view of the cutting machir ipport for +ting curve | plates which make outlets, after trimming the modified flame cutting machine shown Figs. ana = BELOW IG. assembly making branch to To welding. 3 THE IRON AGE, May GAR 4 on = | re inishing Steel Barrels Used A\s Food Containers STEEL food containers are spray-coated with special food lacquer and dried air-conditioned room the plant the National Steel Barrel Co., Cleveland. Air that purified filtering con- ome: 4 £ ij 22—THE IRON AGE, May 1935 stantly circulated room system and drawn out exhaust fans pre- vent dirt and dust from entering the room and becoming deposited the inside the barrels and later causing contamination their food contents. PRENTISS Cleveland Resident Editor, The The barrels are similar the ordinary steel drums except that they have open top and cover which held place lever- type locking ring. containers for lard, shortening, packers’ malt and other food products many these barrels are now being used ucts whic hund wide and two room cu. the near are ping brou outs roon sary wint the haus spra whic seep fum cove ers ° ° ° wif nte manufacturers these prod- ucts place wooden barrels. paint room, which recently was provided for finishing the barrels, hundred feet long and about ft. wide. inclosed three sides brick walls, has windows and only three doors which are seldom opened. Air delivered two fans, one each end the room, having capacity 20,000 cu. ft. per min., and these force the air through banks filters near the ceiling. The filter banks are built the wall between the finishing room and adjoining ship- ping room from which the air brought. the air the shipping room several degrees cooler than the outside air, the circulation air from this room makes the finishing room comfortable summer. Heat from the ovens makes unneces- sary heat the incoming air the winter. The air circulates down the floor and carried out ex- haust fans above the ovens and spray booths. The room under slight air pressure all times, which prevents dust-laden air from seeping through doors and the fumes from the spray booths from mixing with the room air. The barrels leave the room with their covers sealed place and the cov- ers are not removed until the con- LEFT the air- conditioned room for applying internal ings steel barrels used for food prod- ucts. Barrels come into this room gravity conveyor the extreme pass through spray booth for terior coating, and from there bak- ing oven back the booth. Covers are delivered the ad- joining conveyor and are sprayed the man standing front the small booth. ‘At the left the oven for baking the exterior coatina. ° ° ° RIGHT ARRELS being dis- from the interior coat baking oven. Directly under the hood the small for hand- ling barrel covers. application sanitary food con- tainers made tin plate lacquers familiar practice. Recently sanitary lacquers have been developed that can ap- plied directly steel, mak- ing possible the use large containers for food products. this article the fabrication and the coating barrels for use food containers described. tainers are filled the customers’ plants. addition the provision the air-conditioning finishing room, the barrel plant recently was re- arranged, and power and gravity conveyors, ovens and other new equipment were added increase plant efficiency eliminating han- dling, speeding work and in- creasing output. With the work moving continuously through the takes only from min. for sheet steel reach the ship- ping room the form fin- ished barrel. The manufacture steel bar- rels for food containers starts with the shearing the sheet size. The pieces are then rolled cylindrical shape bending rolls and move gravity conveyor Federal flash-welding machine which welds the longitudinal seam the rate ft. per min. From the welder the cylinder goes stripping machine, which removes the burr from both sides the welded seam. This operates similar shaper except that has cutting tools above and below take off the burr both the inner and outer side the shell. The inside seam then smoothed off passing the shell car- riage under power-driven brush. Then the shell set end press which the upper edge curled. Then one operation two beads rolling hoops are pressed into the The barrel assembled double seaming the bottom the cylinder, the latter being fabricated another pro- duction line. After assembling, the testing machine where the seam and bottom are tested for leaks, after which goes cleaning station where the barrels and tops (CONTINUED PAGE 82) THE IRON May 1935—23 4 4 4 . the automotive world which has long been symbol quality. Un- til this year the Packard Motor Car Co. was identified only with the manufacture cars what termed the high-price group. When decided recently broad- its line include its One Hun- dred Twenty series passenger cars the medium-price class, wished maintain its reputation for putting materials and parts the finest quality into its products. Accordingly, spent several mil- lion dollars install new equip- ment and evolve new processes assure maintenance that qual- ity the lowest possible cost. Two its new installations con- sist atmosphere-controlled, gas-fired heat-treating furnace for carburizing axle shafts and batch-type gas carburizing furnace for camshafts. The axle shaft equipment comprises hardening furnace through which axle shafts are transported individually conveyor, washer and draw furnace. Axle shafts enter the furnace through horizontal circular swinging door designed prevent escape the furnace atmosphere. They then meet twin-type spe- cially designed screw conveyor which carries them through the furnace. the shafts enter the muffle, they fall between pair correlated flights each screw four alloy steel sup- porting rails attached the alloy steel muffle. These rails are lo- cated alongside the screws, one either side. the screws are ro- tated, shafts are advanced through the muffle while supported the rails. The screws are geared to- gether and driven chain drive. Controlled Atmosphere Used Internal width the furnace ft. in. and internal length ft. Within this area gas- tight alloy muffle though which the shafts pass while being heated. the muffle chamber rich carbon monoxide atmosphere maintained 24—THE IRON AGE, May 1935 Packard A\xle Carbu prevent scale formation the shafts. This atmosphere Sur- face Combustion gas prepared standard gas preparation machine. The furnace has capa- city for handling 520 lb. steel ABOVE XLE shafts pass on a4 conveyor through gas-fired hardening furnace the and thence through quench tank, wash- ing machine and draw furnace. Bot! furnaces are equip- ped with automatic temperature control hour, axle shafts, which are heated from cold state 1540 deg. takes min. heat the work 1540 deg., after which soaks for min. The shafts move the conveyor Gas-Fired Furnaces through the furnace the dis- charge end, where they meet operated lowerator. The lowerator carefully lowers the shafts into the quenching medium, where they are deposited the quench tank conveyors trans- ported the washing machine and then the draw furnace. The atmosphere hardening fur- nace heated standard low- pressure burners LEFT are carburized Eutectrol horizontal batch ing furnace. the end carburizing cycle, the special transfer table the cooling cham- ber (extreme right). located along the side walls the furnace and arranged fire both above and below the muffle. The draw furnace heated the same type burners placed the side walls and arranged fire into in- dividual ducts beneath the convey- the furnace chamber. por- tion the burned gases lated within the chamber, thereby affording uniform distribution heat any cross section the furnace. The heating cycle min., shafts being heated 850 deg. and soaked min. Both the hardening and draw furnaces are equipped with automatic tem- perature controls. horizontal batch gas carburizing furnace used carburize camshafts. Shafts are loaded trays which are placed the cast alloy muffle the fur- nace, the maximum net charge be- ing about 1694 lb. Here the shafts are surrounded “CG” carbur- izing gas atmosphere provided Surface Combustion “CG” gas machine. The muffle in. wide, ft. long and in. high from the top the skid rails the spring the muffle. heated standard low pressure velocity burners mounted the side walls and firing both above and below the muffle. After the (trays and camshafts) has been heated 1700 deg. F., held hr. secure case depth 0.07 in. Since hr. required for heat- each and camshafts weighing 13-hr. cycle. the end the cycle, the work transferred special transfer table which takes the cooling chamber. This unit consists two cast steel muffle sections, each the same size provided for the carburizing furnace, mounted structural steel frame, with rails facilitate loading and door which closes tightly. When cam- shafts are placed this chamber cool, atmosphere intro- duced during the cooling period. THE IRON AGE, May 1935—25 2 7 |, time depression the critics are the saddle. Not only established economic and practices attacked, but the question mark also put existing productive nique. Only recently the iron and industry was subjected scathing in- dictment backwardness the develop- ment processes and equip- ment. This attack outsiders THE ebb and flow business not only dis- turbs the commercial mind but also prone processes. The depression valleys, with their apparently bottomless despair, are full tions just are the boom peaks with their apparently limitless buoyancy; but these manifesta- tions should tempered and re- strained when applied the scien- tific background the iron and steel industry, whose foundations are sound and will withstand pass- ing doubt. All steel-making processes have Physics, heat and electricity are the handmaids the fundamental- chemical transformations from ores finished products. The 26—THE IRON AGE, May JOSEPH SHADGEN Ing. A.M.M., New York answered this article one who has long had intimate knowledge tech- nical problems iron and steel making. The author concludes that revo- lutionary changes cesses and equipment are unlikely, but that accumu- lated obsolescence due the economic conditions the past five years will stimu- late the improvement and refinement established methoas knowledge chemistry consid- ered necessity all interested metallurgy, which iron and steel manufacturing one the most important branches. Hardly anyone will deny the extreme use- fulness the basic chemical science and its countless valuable contri- butions the progress and evolu- tion the whole industry. Many will wonder why these commonplace statements are made. This the reason: Recently out- side, self-appointed critics accused the iron and steel technologist even greater backwardness than the New Dealer attributes the rugged individualist the pre- Roosevelt era. the chemical point view was used the key- note the attack the industry, the readers THE IRON AGE are reminded obvioustruths and facts nique and Steel order restore their peace wellas their mental balance. Broadsides the nature referred usually miss their often well- intentioned aim account the sweeping nature their condem- nations, the lack specific details their suggestions and the neglect economic considerations that dic- tate last analysis all practical solutions. The economic angle is, course, the most important and can never lost sight of. Steel prices are low and costs must compressed —those are two inescapable laws that govern all decisions the steel trade. Most trade figures iron prod- ucts are quoted ton lots, while the majority other materials and chemicals are quoted pound lots. Ores, limestone, coke, slag, pig iron and steel are tonnage products, while zine and copper, lead and aluminum pound products. comparison pig iron per lb., steel per (1% for shapes), against 9c. for copper, 4c. for and for aluminum ingot form. The yearly production sta- tistics the non-ferrous metals are “pounds” against “tons” for the ferrous group. corollaries large quantities are low prices and small margins transformation costs. All processes must eco- nomical and efficient survive the exacting demands competition. All frills and fancies have long been eliminated the back-break- ° ° ° ° ing sal re co / se a Sst a \ " 7 Look the Record ing routine feeding the never satisfied appetites Gargantuan furnaces and the arduous labors handling thousands tons products. Essentials are quickly recognized and appreciated owing their contributing values dol- lars and cents. The preferred formula reduce conversion costs the various iron and steel-making processes has been increase the size the production unit. result, im- posing blast furnaces silhouette the with hoists, stacks, stoves and pipe lines, and these are usually complemented massive coke oven batteries and seemingly endless rows furnaces and mills. Unit production from 500 1000 tons per day may sound commonplace, but these fig- ures are large, sometimes uncom- fortably so, any and any industry and any coun- try. The natural drawback this trend toward size inflexibility and predominance investment burden compared with operating This the real reason for the conservatism the indus- try, which often wardness its critics. Research Pilot Plant Scale the industry comprises only comparatively small number large corporations, the above con- dition prompts the suggestion that one plant set aside pilot plant for experimentation, explore and find out what good, what not good and what bad. The re- sults trials carried conclu- sion the pilot plant could transferred the other plants with the least disturbance. Well scale eliminates many errors due size, and reduces human surprising note that the well- integrated business units the in- dustry have arrived policy this sort, since such move would stop endless personal controversies and would eliminate the natural disparity between operation and re- search, between repetition and ex- ploration, between knowledge and the desire find new limits and pioneer the un- known. not only good com- mon sense but also excellent busi- ness judgment consider research necessary adjunct, keep abreast and look ahead. many the scientific fields remain hazy and mysterious that there danger running out prob- lems. Neither there scarcity exploring talent. Production Steps Are Logical The iron and steel industry subdivided into two large produc- ing departments—the reducing the ores pig iron and the refining the pig scrap into iron and steel. The first step concentrates ores with content varying from per cent per cent pig iron with per cent Fe. The second step jumps from this limit average per cent more less. this “step” procedure logical? The answer yes. better pro- cedure now available. funda- mental improvement sight upset this method making steel. Pig iron not only economical final product itself but also economical transition product well. has steady, fixed analy- sis and definite, comparatively low melting point; offered less than varieties definite composition; easily produced efficient shaft furnace, char- acterized automatic operation features that are unusual. All efforts circumvent the blast furnace have failed date. Yet millions have been spent the United States and Europe many attempts during the past half century. These experiments were not vain, although most them were carried under the veils mystery. has always been the habit the steel indus- try bury its dead silence. The medical profession more prac- tical this respect; studies the causes deaths and often makes postmortem investigations avoid repetition mistakes the fu- ture and draw definite conclu- sions from the lessons the past for the benefit the public. Blast Furnaces Very Efficient The so-called direct reduction processes, aiming making iron low-carbon content (less than 1.0 per cent spongy, granu- lated form compared with pig iron with average 3.5 per cent molten, liquid form have their theoretical fascination but also their THE IRON AGE, May 1935—27 ty 4 RE - per’ > = 7 practical The coexistence the various reducing reactions be- tween ore and stone, air, gas and coke are very definite their tem- perature (heat potential) balance well their B.t.u. (heat quantity) equilibrium the shaft furnace with its great height, its hermetic tightness, its countercur- rent principle, its intimate mixture solids and gases and its progres- sive zones. The blast furnace will hard beat any other device. The pig iron, melting comparatively low temperatures (2250 deg. 2200 deg. average), heavy eutec- tic solution that quickly and easily separates from the lighter slags, fluid the same temperature, with minimum loss iron (about per cent) the slags. Fig. the material balance average blast furnace given corresponding American standard operation. appears that lb. materials are handled produce pig iron. About 2.45 lb. burden (ore and stone), little less than lb. coke and about 3.75 air. The prod- ucts are lb. iron, about 0.6 slag and 5.40 lb. gases. This picture focuses the attention the lb. nitrogen that has handled without change for every pound pig iron produced. The suggestion has often been made eliminate this burdensome handling the nitrogen because apparently valueless. This looks quite possible least paper the art concentrating the oxygen the air gressed the past decades high degree efficiency. The first and main handicap translating this suggestion into brick and mor- tar cost. The volumes air treated are beyond the size any commercial installation exist- ing present. Second, very questionable whether the blast fur- ance process itself would im- proved removing the effect the nitrogen. The tem- perature balance all probability hard foretell what would hap- pen. One thing sure, the pres- ent operating conditions are right the temperature zoning, and no- body can guarantee that these con- ditions would equalled the use air enriched oxygen con- tent. The third consideration favor 28—THE IRON AGE, May 1935 Concentrated maintaining the nitrogen fly- wheel the cheapness the air. While the air weights are large expenses pounds they are small when expressed dollar values; hence, the cost margin gained reality small compared with the possible advantages and its concurrent risks. the dollar balance the raw materials per ton pig iron the ores average some $5.50, the coke $3.50, the limestone less than and the air less than 50c., sum- ming overall total $10 per ton. course the advocates radical changes infer that the coke rate will materially re- duced the same time. But this only inference and not all certain—not all established indisputable way analysis the underlying chemical reac- tions. conclusion may said that these various considerations have enough weight postpone any at- tempt operating blast furnace concentrated oxygen not in- definitely, least later, re- mote date. The blast furnace process con- tinuous. The charging done definite cycles with great regular- ity assure the mixing burden and fuel their downward path. The injection the air under pres- sure through the bustle pipes and tuyere nozzle practically con- tinuous, the take-off the | OUTPUT gases except for few short in- terruptions now and then. The bleeding off the slag intermittent. The slag hole, being water-cooled, presents orifice that can easily plugged. The cycle slag runs mainly determined the slag cars avail- able, their size the uses which slag put, and the judgment the operator how much slag gives the best flywheel results. the low-grade ore districts with burden yields per cent the slag volume large that the tapping practically continu- ous. There gain economy operation expected from this angle. The removal the pig iron it- self intermittent for various rea- sons: first, the tap hole and its troubles; second, the size the ladle cars remove the product; third, the necessity giving the operator element control over the operation. The tween tapping vary from 6-hr. intervals down one hour. the tap hole good shape, four five ladles 100 tons can filled one after the other with- out trouble, but the refractory hole poor shape, the whole furnace has stopped while repairs this vital spot are made. during those moments that the helplessness the operator stalks everybody the face and \ SAAN AA . \ \ | / | / =) - oO \ | | : \ | 1/ x 2 ii FIG. Vi p W r ‘ a n ! é blast furnace, with combus- Pig Ore Stone ion B.t.u. per ton (2000 pig iron, melting 2150 deg. Note: All figures are rounded and represent average operating conditions. 2—Material balance typical open-hearth furnace with air ating 4.5 million B.t.u. per ton 2000 steel, melting 2650 Note: Round fiqures are used and represent operating conditions. Increased fuel consumption ves line further the makes all paper suggestions look very, very pale; they bring forth pious wishes, punctuated harsh words, for better refractory mate- Here real need: better ma- terials resisting heat, erosion, cor- rosion, wear and tear, slagging re- actions and forth. The refractory makers have considerable progress toward uniformity quantity, accuracy shapes, con- trol raw materials and kilning temperature but there seems room for further improvement. Too many theoretically known facts are buried the laboratories while they should currently applied the mixing rooms and yards the refractory manufacturers. Progress Auxiliaries and By-Products surveying blast furnace de- velopments, the greatest progress noticed the mechanical de- partments—hoists, blowing engines and accessory machinery—and the heat utilization the gases. The humidity the air—2 lb. out the 375 needed for 100 lb. pig iron—is forgotten today, yet was the spotlight years ago. The temperature the blast air increased slowly but surely and averages today 1100 deg. 1400 deg. The stoves increased their efficiency from per cent per cent but re- mained unchanged huge masses bricks built the regenerative principle and used cycles gas and blast—in con- junction with continuous furnace operation. scribed problem that has been neg- lected, especially compared with the achievement other branches the heat transfer science. The dollar efficiency modern blast stoves very low. The cumber- some equipment with many leaks and miles big pipe lacks unity, directness and proper coordination. The volume-flow angle, well the heat-flow point view, are given poor consideration say the least. Here specific weak spot the armor the blast furnace process that needs immediate at- tention and imaginative redesign- ing, incorporating all research data available today the heat tech- Blast furnace gas, which was changed from outright waste product years ago useful by-product years ago, has be- come valuable main product to- day. The cleaning problem has been satisfactorily solved during the past decades although minor improvements possible. Utilization the gas fuel metallurgical furnaces and ovens, full swing today because its advantages heat source are more and more appreciated. The second step making steel products the refining operation from pig iron scrap finished steel. The progressive elimination per cent impurities in- creased the melting point the iron from about 2200 deg. 2700 deg. more. This the out- standing fundamental characteris- tic which center most the practical difficulties. There are three making processes. Converter blow- ing was originated Bessemer about 1850 with acid linings and Thomas-Gilchrist around 1885 with basic linings. This operation Large volumes cold air are blown under pressure through the molten pig iron and burn the Mn, Si, and these reactions re- lease heat that raises the bath tem- perature sufficiently assure prac- tical control and success. About per cent the world production steel made this method. The Bessemer converter lost its popularity because phos- phor-free ores are necessary but searce; the silica-type refractory lining its vessel does not permit phosphorus. The Thomas converter the enormous development the Luxemburg-Lorraine iron and steel industry because the minette ores contain several per cent phos- phorus. This element eliminated the basic lining the Thomas vessels and additions the charge. Siemens-Martin open-hearth furnaces have either acid basic linings. This the most impor- tant steel-making process and responsible for over per cent the world’s production. The open-hearth process the most economical method steel making under present conditions. The main reasons are flexibility and control. There flexibility choice raw materials—pig iron scrap, solid liquid, any analysis, ore additions limestone additions, alloys, ete. control operations there progressive elimination impuri- ties, refining any desired de- gree, choice reagents, regulation temperatures, etc. The third method refining steel electric furnace melting. this case heat furnished the ohm law the Maxwell effect the This method confined quality products and alloys un- der present conditions. (CONTINUED PAGE 104) THE IRON AGE, May 1935—29 7 / \ / 4 ~ FIG. ? : ‘ [N \ | 30—THE IRON AGE, May 1935 \ ie I—If a bear a wher the deflects, the 0aaq is carried on edge the nearest the shown this view (B). Design shows sliding device permit chock movement and (C) shows knife i+ ch deff ac 2—Detailed analysis action the (C) arrange ment of Fig. |. Con- sidering the hori- zontal displacement the bearing cen- ter, would necessary for the rol shorten order obtain rocking action. (at permits the outward the load side chock and the tilt- ing the chock for angularity roll mental period mount- ing anti-friction bear- ings mill necks, considerable amount trouble was experienced. Many these older mills, although since revised, continue show poor bear- ing life, and there are several rea- sons for the trouble. Rolling pressures were calculated from relatively small amount measured data. Methods pres- sure measurement were less ad- vanced than present, and there still much room for improvement. Operators quickly discovered the more severe rolling bearings with the result that roll- ing schedules quickly exceeded the capacity the equipment. This condition still exists and probably always will. And the problem particularly severe this time with many new alloys being brought into commercial impor- tance and with the methods roll- ing them still more less experimental stages. However, the greatest difficulty with bearings has been caused lack appreciation the severe effect roll neck deflection bear- ing life. This causes concentra- tion the load small portion the bearing and the major cause roll neck bearing failure today has been the past. result the failure com- pensate for this condition, has often been necessary continually increase the size roll neck bear- ings until the capacity the bear- ings has become sufficiently great *Presented before the convention Iron and Steel Electrical Engineers, Youngstown, Ohio, April 25, Frauenthal, the Bantam Ball Bear- ing Co. | | | | Poo |! pe é | | a | | Z that small portion the bearing capable carrying the entire load. practice results larger roll diameters and increase other mill parts proportion that now seems that each suc- ceeding mill larger than the last built for the same general pur- pose. Roll diameters reached the point where their pro- duction the foundry major problem and, one case least, more than year’s experience producing certain size roll has not resulted the ability pro- duce successful rolls the first attempt. Furthermore, larger rolls are constantly being considered the extent that will least greatly tax the present status roll foundry practice. This idea was previously expressed May, 1932, Lloyd Jones paper before this society. seems clear that roll neck bearings can arranged that the entire bearing instead only small portion operative, that much smaller bearings can used give satisfactory life. Likewise, the life large size bearings al- ready use the most modern mills will greatly lengthened. Therefore the economy resulting from this condition self-evident. examination bearings that have been service, especially bottom rolls, usually shows that the greatest portion the rolling load has been carried short length the bearing. This short length located toward the inside the mill and the portion the bear- ing nearest the roll barrel. The reason for this lies the fact that the rolling load produces considerable deflection the roll body and especially the roll neck, HEN roll deflects under load, the roll neck also deflects. Thus some pro- visions should made order that there will not concentration load part one bearing during this de- flection. The author herein describes new development the Bantam Ball Bearing Co.—a roller claimed compensate automatically for varying de- flections roll necks and keep loads evenly dis- tributed all times. This ac- tion said result much longer roller life and greater protection for both bearings and rolls. with the result that the bearing housing does not self-align the load the edge the bear- ing nearest the roll body, shown the exaggerated drawing Fig. This condition now universally recognized that various devices have been tried provide some means for self-alignment the chock bring the angle the bearing coincident with the angle the neck. Favors Knife Edge Mounting the early mills the chock bot- toms were flat, and these flat bot- toms operated the flat bottom the housing window. Obviously this permitted self-alignment the chock. The several designs used improve this condition while differing detail fall into one the three classes shown Fig. The method shown requires sliding the male spherical block the female spherical block permit chock movement. This sliding often never takes place due the extremely high friction. Any attempt lubricate these surfaces usually fails because lack the fundamental requirements for the formation oil film. The method shown vir- tual knife edge and, common with the method shown has its object rocking action permit the same angularity the chock the deflected roll neck. simple analysis this action shown Fig. from which clear from the horizontal displace- ment the bearing center that obtain rocking action would necessary for the roll shorten. this impossible rocking ac- tion can take place. necessary for the bottom the chock move outward sliding the housing under load. Again obvious that friction too high for any such sliding take place. Numerous observations number mills, both wide and narrow, show that there slid- However, compared with the old method mounting flat bottom chock the flat bottom the win- dow, believed there con- siderable value the knife edge mounting. Without the knife edge, that is, with the chock supported the bottom for its entire length, the def- ormation the chock under the concentrated load the end the bearing limited the elasticity the column metal under com- pression, and experience has shown that this mounting usually results rapid bearing failure. THE IRON AGE, May ¥t ‘ 7 2 ANS ip : ‘ ne » ra ae. Ary RIGHT show action aligner. The insertion roller under each chock permits the chock rock with varying roll deflections. When the chock made knife edge, the inside end the bottom not supported the mill hous- ing and consequently the deforma- tion the chock only limited the much greater elasticity the considerable length metal under tension. takes place and relieves the con- centration stress thereby improv- ing bearing life. This explains why some cases better bearing life obtained old mills where the chock rather thin the load side than more modern mills having very thick chocks the load side. Another method construction for heavy mills that two self- aligning bearings moun