The Iron Age 1935-05-16: Vol 135 Iss 20

239 West 39th St., New York Owned, Published and Copyrighted by CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. C. A. MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC C,. STEVENS, Vice-President JOSEPH 8. HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ J. FRANK, President J. H. VAN DEVENTER Editor G. L. LACHER T. H. GERKEN R. E. MILLER Managing Editor News Editor FISKE Chicago MOFFETT Washington FINDLEY Editor Emeritus EHRNSTROM, BURNHAM FINNEY FRAZAR Pittsburgh Detroit Boston Machinery Editor PRENTISS Cleveland Cincinnati Contents May 16, 1935 Let Bootstraps—and Ears Cleanlined Machines Follow Modern Trend Special Atmospheres Heat Treatment and Brazing Cast Scrap Cupola with High Silicon Enameling and De-Enameling Washing Machine Tubs Assemblers Plant Devoted Production Problems Rural Industrial Location Cushion Shock Depression New Equipment Automotive Industry Personals and Obituaries Washington News Statistics Metal-Working Activity Products Advertised Index Advertisers BAUR, General Advertising Manager A. H. DIX, Manager, Reader Service Member, Audit Bureau of Circulations Member, Asxsoviated Business Papers B. L. Herman. 675 ADVERTISING STAFF Emerson Findley, 311 Union Bldg.. Delaware Ave.. leveland Buffalo. N. ¥ Published every Thursday Subscrip- H. K. Hottenstein, 802 Otis Bldg.. Chicago tion Price: United States and Pos Peirce Lewis. 7310 Woodward Ave.. Detroit sessions, Mexico, Cuba, $6.00; Can Charles Lundberg. Chilton Bldg.. Chestnut & 56 Sts.. Philadelphia. Pa ada, $8.50, including duty; Foreign 812.00 a year Single copy 25 cents. W. B. Robinson, 428 Park Bide W. C. Sweetser, 239 West 39th St C. H. Ober, 239 W. 39th St.. New York Pittsburgh New York Cable Address, ‘‘Ironage, N. Y.’ Db. C. Warren. P. O. Box 81. Hartford, Conn Xe 7 ‘ y je Construction and Equipment Buying 1935 oe - “> 4 Ryerson Has the New Alloy Steels Stock—And they Will Ship Today— Steels for Every Purpose Maintain production schedules and save time, trouble and money concentrating your steel and metal requirements through one reliable source. Ryerson Stocks are complete. They include all the newer alloys, special finish steels and allied metals such copper, brass, bronze, etc. And course you can depend immediate shipment. Ryerson men will glad work with you any special prob- lems. not hesitate call us. The Ryerson Stock List shows hundreds products that are ready for immediate use. you not have copy, write and will send once. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Philadelphia, Boston, Jersey City 12—THE IRON AGE, May 16, 1935 RYERSON Hot Rolled Alloys S.A.E. 2315, 2320, 2330, 2335, 2340, 2345, 2350, 3115, 3120, 3130, 3135, 3140, 3250, 4140, etc., Rycase straightened Rytense A.A. (hot rolled, chine straightened). Cold Drawn Alloys S.A.E. 2315, 2320, 2330, 3115, 3120, 3135, Heat Treated Alloys Ryco (hot rolled, machine Nikrome (hot rolled, cold drawn, machine straightened). Stainless and Heat Resisting Alloys Allegheny Metal (Sheets, Welding Rod, Cold Finished Steels Std. Shafting, Turned, Ground and Polished, Special Accuracy Stock, Rycase High Manganese Screw Stock, S.A.E. 1020, 1035, 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, are carried stock for imme- diate shipment. machine ma- Bars, ; THE IRON AGE ... MAY 16, 1935 ESTABLISHED 1855 Vol. 135, No. NCE upon time, they tell us, there was nation, more less ancient, whose people met with reverses. Things stopped going well with them formerly, for just what reason one really knew but about which many different opinions were expressed. Everyone agreed, however, that something should done about it, although what was moot question. One section the population, for example, said that the thing for the people was lift themselves out their difficulties pulling their bootstraps. great many the people, including some the Nation's rulers, had boot- straps immediately affixed their shoes and proceeded bend over and pull them. must admitted that this group was not easily discouraged, spite the fact that they did not seem get perhaps that was because the chief bootstrap lifters kept telling them that they were making fine progress and must patient. Another section this strange people was horrified the idea that progress could made pulling upward one's bootstraps. ‘The practice this doc- said they, surely lead chaos. The thing persuade our people keep their feet the ground any the members this group, and was not small one, proceeded insure that their feet should stay the ground the process seizing their ears their hands and pulling down- ward. much smaller group the people could not bring themselves belief either these methods self improvement. They could not see how pulling one's bootstraps pulling down ears could classified could get the practitioners anywhere. take advantage the situation, while these fellows are thus said they, use our hands These things they proceeded do, disregarding the discouraging example the bootstrap and ear pullers alike, and with such good effect that they were shortly out their difficulties. that goes after, gits, spite hell and high +? > = ut = rey wa ¢ Ry Ate te J ‘ fea. Gar = Fes = 13 4 THE maker machine tools may little con- cerned with STREAM- lining, its generally accepted meaning, especially when proposed for application the design lines the equipments which offers for becoming more and more CLEAN- LINING conscious. Yet the art cleanlining may only one de- gree removed from stream- lining and that only through drop- ping the factor aerodynamics. Streamlining dramatizes equip- ments having locomotive abilities. General conception the art design does not particularly asso- ciate with the human effort relation station- ary equipments. Cleanlining proper terminol- ogy and when applied certain type better- ment which can made distinctive new machine tool period. 14—THE IRON AGE, May 16, 1935 giving comparative thought the ship illustrations herewith, only required, gain the point, that recall mind the outlines earlier ships, many which are the right the consultant- engineer-designer, Otto Kuhler, shows for further comparison the next approaching step, viewed from the outside, the ac- complishment perfected details which are directly re- lated both appeal and reduction maintenance cost. Included these de- tails the factor safety. life boats and rafts are in- closed and that loading and docking apparatus are longer sight. ° ° ° me The superstructures these are involved labyrinth angles, protruding ells with dirt collecting corners, and have general scheme ql al | design-characteristics which re- quires constant attention from angles cleaning, touching up, painting and maintenance repairs. Unhoused davits, exposed lifeboats ° ° ° lustrated the left, pre- sents lines showing the development sistible trend toward affecting purchase decisions connection with transpor- tation. When compared with the design lines steam- ships which are easily re- called mind, the marked trend toward the elimination all crudeness and the sub- stitution lines which carry appeal, well serve the reduction maintenance cost, becomes evident. ° ° and rafts, not only contribute expense constant inspection, often under conditions dangerous human life, but tend foster accidents and increasingly build a maintenance and replacement costs. glance the illustration the left reveals clearly evident comparative advantage gained the superstructure design the Manhattan. The old cus- tomary angles and corners have sufficiently disappeared for one visualize little necessity, com- parison for fatiguing effort dislodging any accumulations which might successfully resist air cur- rents gravity. However, glance the illus- tration below convinces that the engineer-consultant uncovers addi- tional opportunity for further com- parative gain, which means main- tenance-expense reduction. Otto Kuhler, designer, collaborat- ing with marine engineers these proffered examples, demonstrates the fact that the artist-consultant can cooperatively apply his art practical way while creating ap- peal. There have been many other practical demonstrations trans- portation fields, trains, airships and automobiles; all maintained greatly reduced expense, compara- tively. The sales angle appearance today becoming paramount. This has been recognized many in- dustries. Others have recognized its importance but hate admit it. Because the development this trend, whether like not, the day the old angled and cornered designs for machine tools fading. get the heightening the trend only necessary observe design lines many the machine tools illustrated the 4 THE IRON AGE, May © LA it te Way | | rot rotogravure pages THE IRON AGE May This coming modern machine tool design not only adds shop morale, operator pride and shop reputation through the agency appearance which normally dis- regarded only the slothful, but involves increased productive minutes through the avoidance constant wiping and cleaning, for example. Also the point can made that this design sets period-date equipment manufacture which can- not obliterated scraping tool the hands those who would foist upon industry, through claimed rejuvenation, glanded equipments previous decades and superseded produc- tion accomplishments. Thus many machine derelicts other decades can forced into the scrap pile, whence they can render real ser- vice through the cupola. Additionally, should not overlooked that bankers vestors are far more susceptible obvious evidences good man- agement and up-to-date tendencies than they are interested fected mechanisms which they know little, that are housed present the eye little the way progressive appeal. Modern machine tools, the mas- ter tools industry, can well given appealing design, indicative definite line demarkation between pre-depression period and the approaching period which machines must operate less ex- pense and manner further reduce human fatigue. The Original Streamlined Steam Locomotive 1928 the original conception the streamlined shown first color illustration be- NDUSTRIES times find themselves rowed loss customer esteem. For release, they must ultimately their public—those who buy what they have offer. To- day this step requires clearly visible evidence new progressive spirit. Today the visible evidence must carry appeal—some characteristic symbolic higher service establishing line de- markation indicating the period complacency. 16—THE IRON AGE, May 16, 1935 type streamlined steam | | | low Sta tim bet gin sen gir she sul the ° iginal lined original conception streamline i 4 | low, was presented the United States Otto Kuhler. Practically went begging until 1931, which time the American Locomotive Works arranged for collaboration between its engineers and the en- gineer-consultant who sented it. The gines, presented the transporta- tion world few days ago, and shown bottom page are the re- sult this cooperative effort. the meantime the idea colors had come into its own. The interiors the streamlined trains are steam Kuhler element cost reduction main- tenance. Cooperative Development two illustrations directly be- low are typical the coopera- tive factors entering into the work the designer-engineer con- sultant. The illustration the left that splendid type engine which, 1931, was possibly con- the last word efficient engine design. The illustration the right represents the design which was Locomotive Co. considered probably necessary meet new requirements engine construction. This, after con- siderable period cooperation strictly engineering sort the determination just how the ad- vantages original design might made available with sacri- fice demonstrated advantages. The “Milwaukee” type, adopted the Milwaukee road the Hiawatha train service, the final result high-speed, high- powered, streamlined locomotive. This engine shown the bottom. the page. HIS remittent indus- trial activity consti- tutes the closest known approach perpetua motion and might called grind which the streamlined train the grist the moment, possibly followed CLEANLINED chine tools. THE IRON AGE, May 16, < | ; | | ATMOSPHERIC major all new heat treating equipment, well modernizing existing equipment for the purpose meeting modern requirements. The application furnaces with atmospheric control the heat treatment metals not new, but its acceptance has advanced appreciably only during the past three years, following the devel- opment equipment and methods permitting the production suit- able atmospheric gases for elimi- nation oxidization very low costs. The gases used for such opera- tions bright annealing, brazing and other kindred operations prior about three years ago were for the most part tank hydrogen, gas composed approximately per cent hydrogen and per cent nitrogen, which produced the dissociation ammonia. IRON AGE, May 16, 1935 WEST Research Engineer The Electric Furnace Co., Salem, Ohio The cost these gases the user usually ranged from $3.25 up- ward $10 per 1000 cu. ft., de- pending upon the quired for the operations involved, and the method producing them. Because their high cost, the gases referred necessarily had used very sparingly. Elabo- rate furnace designs, particularly with regard entrance and exit openings, were developed order conserve their use. was generally believed that time that furnace atmosphere suitable for bright annealing, braz- ing, had very rich SPECIAL batch-type furnace which was designed for the brazing evapo- rators used me- tors. This furnace has been opera- tion for approxi- mately months and the third this type installed the same plant. ° ° ° hydrogen and other reducing com- ponents, and, therefore, several other methods producing highly reducing atmospheres final costs were experimented with, but the desired results were not fully realized because the fact that oxygen could not elimi- nated from the the methods employed. has since been established that very high percentages reducing components are not only unneces- sary but many cases undesir- able, provided that suitable meth- ods are employed the production special atmosphere elimi- nate oxygen and remove mois- ture the necessary degree for the problem involved. this lat- ter regard, have found that under certain conditions quite possible process material per- fectly bright gases which have not been dehydrated all, but for the protection the equipment in- volved desirable all cases q Pa. > ; ° ° ° the Heat Treatment and Brazing Metals remove large portion the mois- ture from the atmosphere. Recognizing the fact that there could appreciable acceptance atmospherically controlled fur- naces unless satisfactory atmos- pheric gas could produced very reasonable cost, the problem was submitted our research di- vision with the following results: long and exhaustive series experiments were conducted utilizing various types gas-pro- ducing apparatus and many mix- tures gaseous elements vari- ous temperatures for reacting the elements mixtures elements the presence various types catalytic materials. All the resultant atmos- pheric gases were applied use practical production furnace the heat treatment ferrous and non-ferrous metals, throughout ° ° pusher-type furnaces used for the brazing great many assemblies steel products used mechanical refrigeration units and the automotive industry. The material conveyed through the furnace and the attached hood special heat- resisting alloy shoes, .which are equipped with removable upper supports designed suit the sizes and shapes the vari- ous products involved the pro- duction program. The operation equipment, with the ex- ception manual loading and placing the shoes before the pusher head, entirely auto matic, and the mechanically ejected loaded shoes are returned to the starting point the entire range practical metal temperatures for the materials in- volved, and the results with regard surface conditions, properties, etc., were recorded for test. During the process elimi- nation discovered that the gases which are used the furnace ex- hibits which are follow, and which choose call Elfurno gases were not only the cheapest produce but most desirable for the reason that they provide for flexibility control which was not, heretofore, obtainable. found that when were success- ful eliminating practically all oxygen from the atmospheric gas did not need excessive amounts hydrogen and other reducing components, which feature resulted m THE IRON AGE, May 16, | | 4 lowering the cost atmospheric gases beyond our expectations. Made Burning Carbonaceous Gases The Elfurno gas atmosphere produced the simple process combustion carbonaceous gases suitably proportioned with quanti- ties air special gas-produc- ing apparatus properly con- ranging from 10c. 20c. per 1000 cu. ft., including maintenance cost for the gas-producing appa- ratus. will readily appreciated that atmosphere which can produced cheaply can applied large furnaces the processing relatively materials, where large entrance openings are necessary for the pas- sage materials, and still minor item manufacturing cost. Taking advantage this fact, became entirely practical util- ize quite simple designs equip- ment with regard entrance and exit openings, thus tending toward lower first cost equipment and hazards from the standpoint shutdowns and maintenance. operating Among the first large commer- cial installations utilizing Elfurno gas atmospheres three straight through pusher-type fur- were naces for copper brazing steel refrigerator parts, and one contin- uous conveyor-type furnace for 20—THE IRON AGE, May 16, 1935 bright annealing copper tubing long, straight lengths and coils high. These units referred have been substantially continuous oper- ation going three The success these large instal- lations has resulted the installa- tion over additional atmos- pherically controlled furnaces relatively large capacities, which furnaces are used for processing wide variety materials. These equipments were all built during period when large appro- priations were most difficult ob- tain, and only the large savings and increased quality the prod- ucts effected the new methods made possible obtain the nec- essary funds make these instal- lations. ° ° ° CONVENTIONAL wire mest belt nveyor type turna 41 + slin + na ¢t ote Thi na marily braz c T the wet T aispiac } nina. The bra 3 na e minat aU Tailur na >| ana nt pu an Several designs furnace equip- ment lend themselves practical applications con- trol, such special batch types, chain conveyor chain belt con- veyor types, roller-hearth types, straight through pusher types and counterflow return recuperative pusher types. The selection equipment for any given problem depends upon such factors operating tempera- tures, shapes, sizes and weights products, quantity production, continuance frequency opera- tron, ultimate results desired and costs labor, power, gas, water and other elements entering into manufacturing costs. this respect well note that single type equipment applicable all the problems encountered, and very serious dif- ficulties may encountered with regard maintenance the wrong type equipment selected for such operations brazing, where the furnace alloys are subjected temperatures near their upper lim- its. paratively small furnace given type with regard conveying means may ideally suited the high temperature brazing given product, whereas large furnace the same general type may entirely unsuited eco- nomically impractical, even though the problem looks parallel one not versed the practical values : $ A p p é rl Cc Juction in manutacturing c r x hanges design which were permissible with the brazina i ad >. ° ° TANDARD chain belt design furnace used for the clean and bright hardening bolts, screws and many other small and medium-size finished products. This fur- nace porates cast link alloy conveyor which runs inside the furnace, except for short sectionwhich exposed the charging end fa- cilitate loading the parts heated. Fundamen- tally, the design the furnace deviates from large number previous installa- tions its type only that the furnace made gas tight and Elfurno nosphere used prevent oxidiza- the material heated quenching. heat-resisting alloys with re- these very high temperatures. few the practical uses Elfurno gases incorporated the above are briefly outlined fol- lows: Brazing Ferrous and Non- Ferrous Metals The union two more parts forming assembly continu- ous furnace brazing operation, re- placing such methods joining riveting, bolting, crimping, staking and the various forms welding, provides for greater economies, neater assemblies and elimination pickling operations because oxides are formed the brazing operation. Further, there compromise with regard me- chanical strength the assemblies thus formed. Where electric furnaces are used for the brazing operation, the parts are heated temperatures rang- ing from approximately 1400 deg. where silver-bearing alloys are used brazing medium, approxi- mately 1850 deg. where copper- zine alloys are used the brazing 2100 deg. where copper used the brazing medium. The requirements leading the successful brazing assembly stampings, forgings and screw machine parts are that they rea- sonably clean upon entering the furnace, that the joints reason- ably tight and that the assembly self-sustaining with regard maintaining proper registration the parts during the travel the assembly through equipment. Excepting for very special braz- ing operations, the brazing medium the form wire placed upon the assembly, around each joint section united, adjacent the point union and not between the parts. cases where wires cannot used because inability sus- tain them their proper relation the desired point contact, resort the use stripe paint made finely powdered copper, lacquer and thinner applied around the joint adjacent the junction the parts question. Assuming that the assembly has been suitably prepared, then placed upon the furnace conveyor and, passing through the fur- nace, heated temperature slightly above the melting point the brazing medium. Capillary at- traction comes into play this point and the liquid brazing ma- terial drawn through each joint. The assembly then passes into cooling chamber which attached the furnace where the assembly cooled the gas atmosphere temperature below the discolor- ing range. The normal result the opera- tion union parts which for all practical purposes indestruc- tible, and the case hollow re- ceptacles sufficiently tight hold many types gases liquids pressures the bursting point the metals from which the assembly has been fabricated. Bright Annealing Ferrous and Non-Ferrous Metals The bright annealing normal- izing many steel products such tubing, sheet, strip steel, stamp- ings, ete., has been reduced quite simple practice hearth type, conveyor type and pusher recuperative type furnaces. Generally speaking, the operating temperatures for this class work range from 1350 deg. for some annealing operating low-carbon steel products 1750 deg. for normalizing similar products, and high 2000 deg. for processing special silicon steel. Bright annealing copper tub- THE IRON AGE, May 16, 4 ee type furnace used tor re ts. this type equipment, strip products are annealed normalized temperatures ranging from approximately 1350 deg. 2050 deg. F., depending upon the materials involved and the physical properties desired the finished materials + the discharge end, which ing standard commercial practice today the plants four large manufacturers product, utilizing electric furnaces conveyor type, and special atmos- pheres, produced the same general methods previously de- scribed, except for certain addi- tions the gas producer equip- ment for the purpose removing sulphur which would ing discoloration the surface the copper tubes not elimi- important contribution the art bright annealing during the past year has been the development apparatus and methods pro- can applied necessary quanti- ties for the requirements continuous furnace used for bright annealing very thin electrolytic other forms non-deoxidized copper strip temperatures 1000 deg. without injuring the properties. The operation has been 22—THE IRON AGE, May 16, 1935 peration this equipment involves the use bright annealing cold-rolled strip, special silicon steel strip and other strip demonstrated large production furnace using heating and cool- ing cycle which hours, and the were entirely satisfactory. Clean Annealing Controlled Oxidization atmosphere the starting point involves the same ciples for producing more simple atmospheres, but certain compo- nents the atmospheres have controlled finer degree than ordinarily necessary. The actual control these com- ponents has, however, been worked out provide for very simple op- eration and its use commercially practical for production purposes. Another problem for controlled atmosphere what choose call clean annealing, the produc- tion controlled oxide steel products electric furnace containing atmosphere for this purpose. G suitable unreeling equipment the charging end and reeling equipment nized with the speeds the driven rollers forming the conveying means the furnace certain cases have found which was coated with thin, tight oxide, neutral atmosphere which there would reduction the existing oxide and addi- tion oxide that already evidence. other cases, the desired result was produce very light oxide rendering them more resistant corrosion than they would nor- mally delivered from the fur- nace equipment with bright sur- face. These results through modifications the fur- nace atmosphere. Clean Hardening and Carbon Control Another use for controlled at- free heating for quenching and drawing very wide variety (CONTINUED PAGE 7 3 od y Use Cast Scrap Cupola Expedite CAST IRON scrap has been regular part the cupola charge since the beginning the gray iron industry. any foundry there certain accumulation scrap cast iron from rises, sprues, gates, imperfect This material constitutes from per cent the iron poured. The most way dis- posing this iron charge back into the cupola. Hence, practically every gray iron foundry this “return” scrap forms im- portant part the raw material charged into the cupola. former years the practice followed was make the re- mainder the charge with pig iron the foundry grade, usually No. grade with silicon 1.75- 2.25 per cent. recent years the practice adding some steel scrap the charge has become quite common. This steel substituted for equivalent amount iron. The loss silicon due the addi- tion steel made ordinarily using the correct amount silicon alloy the charge, usually silicon (silvery) pig iron (Si per cent). The resulting iron, proper cupola practice followed, usually harder, strong- er, and tougher than that produced from pig and return-scrap mix. The improved properties this so-called high-test iron semi- steel are due the lowered graphi- tic carbon content brought about the use steel scrap the charge. The lower total carbon carry the silicon content somewhat above normal proper graphitiza- Decreasing the percentage carbon the charge brings with *Abstract investigation made the Ohio State University Engi- neering Experiment Station, coop- ration with the Globe Iron Co.. Ohio. DIERKER Senior Research Engineer, ing and Experiment Station, and Schneider, Assistant Professor In- dustrial Engineering, Ohio State University, Columbus, Ohio. increasing difficulties melting and casting. The machinablity the iron also decreases. For these reasons, the percentage steel scrap the mix most cases, except strengths are desired, kept un- der 20. Pressed with the need the last few years for lowered costs, the foundryman has turned his atten- tion cast iron scrap. Large quantities good quality this material have appeared market, often very low prices. appreciable quantities this material can used the cupola charge, marked saving the material costs can made. Many foundries, course, have made practice using quantities foreign cast iron their charge. most cases this kind has been found desirable increase the silicon content the charge ferro-silicon additions some suitable form. Little information, however, available concerning the general results using large percentages cast iron scrap the cupola charge. Details Investigation attempt secure some comparative data this subject, series melts were run small cupola using various propor- tions scrap the charges. The cupola used located the foun- dry the industrial engineering department, Ohio State University. The shell was in. diameter and was lined down in. inside fireclay cupola blocks. Blast was furnished small forge blower. Without means either measur- ing controlling blast pressure, the equipment was not perfect. Nevertheless, was felt have one advantage, that the results secured should reproducible the average small foundry with similar equipment. The cupola described used for instructional work foundry practice. Small, thin section cast- ings are molded and poured en- gineering students. For this pur- pose the iron kept soft and easily machinable. return scrap from sprues, risers, defec- tive castings, rather high, might expected. The make-up the regular charge shown No. Table This mix was used starting point for our investigation. For determining physical prop- erties, the iron was poured into standard arbitration bars 1.2 in. diameter in. long. each case least three sets bars were poured, one set near the be- ginning the melt, one near the middle, and the third close the end. The bars were tested transverse- 18-in. centers the set-up shown Fig. Deflection read- ings were taken each 500 increase load. The tensile bars were machined from half the transverse bar. These were machined 0.800 in. diam- eter according A.S.T.M. tenta- tive specifications, 48-32T for gray iron castings. addition, unbroken 1.2 in. transverse bar was machined 0.875 in. diam- eter and tested transversely 12-in. centers. was felt that the ratio strength between this THE IRON AGE, May 16, 1935—23 | 7 3 t Sy, ° ° ° . ° we ~ ASS _ ro i q Sew J bar and the standard unmachined bar indication the formity the metal uni- from surface center the castings. The results the test the standard transverse 1.2-in. diam- bar were plotted, load against The area under the curve was carefully measured and the results inch pounds reported This tion the impact resiliency resiliency. resistance FicguRES SHOW PER Melt No. 2 No. 1 Machinery Ni Pig Pig Scrap 9 ) ‘ 1f 15 TABLE ANALYSI No. Pig 3.5 4.0 Cast Mach. Scrap...... 5.41 Stove Plate Scrap...... 3.50 High Carbon Steel.... 1.30 Silvery Pig Std.. 1.75 Silvery Pig High Transverse physical properties the impressions were made the cen- ter the broken transverse bar close the point fracture. The modulus rupture was figured ac- cording the standard formula for steel beam supported both ends and loaded the middle. Source Raw Materials The analyses the raw ma- terials used the charges are Committee A-3, Proceed- gs A.S.T.M., Vol. 33, Part 1, p. 87, MAKE-UP CHARGES FOR THE MELTS SHOWN TOTAL CHARGE Stove Retur Plate Steel Std High Mn. 50 0 5 2 5 RAW MATERIALS S P 1 ‘ 0295 2.02 060 35 1.57 094 9.15 nan 40 n6 10.50 02 100 10.56 025 2.93 A.S.T.M. TRANSVERSE BAR Tensile Strength Deflection Brinell Strength Melt N Lbs I 1 Lbs Ni ber Ibs. /sq. in 1847 290 329 20760 é 19 =o 2750 3538 168 24450 2288 284 60930 379 197 33650 2550 24 67550 347 sit 35640 7 1670 248 44650 231 16 22400 2040 55400 29g 179 26500 9 6020 ra 176 1{ TABLE IV RESULTS OF TEST OF .875 IN. X 15 IN Melt I nsverse Modulus 970 14200 226 57100 159 172 54800 TABLE ANALYSES OF MELTS Melt N ~ ~ 2.07 O4 7% 6 3.01 17 64 2.98 1.9¢ 102 262 7 43 2.9 060 20% 59 H. Bor ein, AF VOL BE, 4,3 e, 1992 24—THE IRON AGE, May 16, 1935 shown Table II. The return scrap was obtained from pile that had the foun- dry. The No. pig iron was standard grade this material. The machinery scrap steel from local scrap dealer. The stove plate scrap consisted broken blacksmith Silicon was introduced the form blast furnace ferro- silicon. (Silvery iron). Blast furnace ferro-silicon essentially alloy which the carbon decreases the silicon increases. has melting point and density com- parable that ordinary foun- dry pig iron. This coupled with the fact that the silicon dilute form makes possible uniform distribution this element the melt with minimum melting loss. scrap were obtained forges. Manganese was using two grades high silvery iron, and one low man- The analysis these two grades shown Table II. The coke used consisted half by-product foundry coke and half bee-hive foundry coke, being obtained from local foun- dries. Limestone equivalent per cent the coke charge was placed each charge. Ten pounds was placed the coke bed itself before the start charging. only four charges were run each melt, the slag was not tapped. The coke ratio was The height the coke bed averaged in. above the tuyeres. The results the physical tests the various irons are clearly shown Tables III and IV. most cases good pearlitic struc- ture was throughout. Melts and were designed primarily for enameling purposes. poured from these successfully the laboratory. However, since enameling much, not more, the enamel and technique employed the metal used, these tests are not considered conclusive. Metals and were suc- cessfully poured gray sec- tion castings. Irons this type should prove satisfactory for cast- ings quite thin section, say in. and under. suc- used High physical strength, how- ever, not always suitable measure quality iron. Good mac tial iror com inte val eXé tel col 7 * J TABLE in q machinability often more essen- tial than strength. Bornstein’, substituting cast iron for pig iron and maintaining constant composition, found the resulting iron for the purpose the absence massive ce- mentite, machinability undoubtedly varies with the size and distribu- tion the graphite flakes. For example, iron from melt No. might expected have about the same machinability iron from melt No. this basis machinability should control- able regulating the silicon con- tent the charges. Although comparative tests were made, all the listed the tables showed good machining qualities. These tests demonstrated that high percentage cast iron scrap the cupola charge not neces- sarily indicative low quality iron. fact, with careful selec- tion scrap and proper cupola practice, should possible consistently produce quality iron Fig. Method making transverse test with small percentages pig iron the charge. Proper control silicon and manganese is, course, important, but the use two High Living Standards Technological percentage the popula- tion gainfully employed the United States increased from 32.4 per cent 39.8 per cent dur- ing the years from 1870 1930, while the same time the total population increased from 38.5 mil- lions 122.7 millions, nearly three times, according study the National Industrial Confer- ence Board for the National Ma- chine Tool Builders Association. the end this period, which was marked rapid technological improvements industry, vast in- troduction labor-saving devices, and enormous mechanization in- dustry, larger proportion the total population was employed producing goods and services than the beginning, the conference board states. This study one series be- Persons Gainful Occupations, Persons engaged gainful occu Per cent engaged in gainful occt Compared with Total Population ing made for the National Ma- chine Tool Builders the confer- ence board. Upon completion the series expected the first comprehensive survey mechani- zation industry and its effect upon the country from both so- cial and economic point view. “In 1870 about seven million workers, more than one-half the total labor force, were engaged agricultural pursuits,” the confer- ence board states. “By 1900 the number agricultural workers increased almost million, and has remained practically un- changed since that time. During this 60-year period, however, the proportion agricultural workers the total working population has declined steadily, until 1930 farmers represented only little more than one-fifth all workers. grades blast furnace ferrosili- con (one low and one high convenient and effective. The introduction machinery was primarily responsible for enabling agriculture dispense with large proportion its workers for the benefit new and growing in- dustries and still produce sufficient volume foodstuffs and agricultural raw materials sup- ply the domestic demand and for export.” The total number persons en- gaged gainful occupations the end 1930 was 42,829,920, 39.8 per cent the population, cent, the end 1870, according the tabulation below. conclusion, the conference board points out that the machine made possible the transformation nation predominantly depen- dent upon agriculture into coun- try with extremely diversified eco- nomic interests and high standards living, utilizing things which were undreamed little used the beginning the 60-year period, and which are now re- garded necessities. Source: 1 3.371 50,155,783 62,62 23 31 34.7 United States Bureau Census 1930 105,710,620 22,775,046 41,614,248 48,829,920 39.4 39.8 THE IRON AGE, May 16, 1935—25 \ | > 4 7 4 4 | Census Years n tian 29 H Enameling THE large increase the sale washing machines the past few years and the almost universal use present ma- chines with porcelain enamel tubs has spurred tub manufacturers improve the efficiency their mass production methods and the qual- ity their workmanship. enameling plant largely for enameling washing machine tubs was built the Youngstown Pressed Steel Co. 1930 and has been improved various ways since that time increase output, effect greater production econ- omies and improve the product. This one the largest plants the country for enameling washing machine tubs. has capacity for enameling 1800 tubs hr. Por- celain enamel sinks are more re- cent product this company, for 26—THE IRON May 1935 PRENTISS Resident Cleveland Editor, The lron Age which additional other equipment has been installed. Not only have production meth- ods been improved but costly losses that result from scrapping work because defective enamel coat- ings have been reduced through the salvaging de-enameling tubs and sinks having enamel coat- ings that not pass inspection. Operations Are the press shop tubs are pro- duced one drawing operation eature from circular steel blank. They are then carried chain con- veyor 5800 ft. long the pickling room one end the enameling plant. Here they either directly into the pickling tanks are stacked the floor. For pickling, the tubs are placed racks which are handled overhead hoist. Standardized pickling methods are followed. Leaving the pickling department, the tubs move the racks roller track through gas-heated dryer which temperature 300 350 deg. maintained. The tubs are then hung overhead conveyor, which they are handled during spraying and other operations except burning. First they dip tanks for the ground coat, which cobalt blue black coat. Pickling and the ONTINUOUS U-type enamel ing furnace for washing machine tubs. The tubs enter the furnace the left and, after traveling ft. during which the ename! fired approximately deg. F., emerge the right. leav- ing the tubs are loaded On racks. | ° ° ° on ° ° ° ’ a tu F ni a t e : t 4 ground coat work done the night shift and the cover coat work done the day force. After dipping, the pieces are hung back the conveyor and pass through gas-heated dryer for removal the surplus moisture. Then the tubs are transferred another chain conveyor which they loop through U-type continuous burn- ing furnace. This 600-kw. fur- nace ft. long, and divided into three zones, one for bringing the tubs heat, one for maintain- ing fusing temperature and third cooling zone. The work remains the burning furnace about min. Tubs, leaving the burning furnace, are loaded large wheel-type racks from which they are hung back the enam- eling conveyor line and moved through the spray booths for the cover the cover coat the spray booths. The basket arrying the tub nechanically re- ves through the booth, permitting the operator spray taces without re- Ovin qa the tub from its basket. enameling washing machine tubs has been developed high point efficiency the plant the Youngstown Pressed Steel Co. less important than improvement the enameling process provision for de-enameling defective work. Formerly enameled work with defective coatings had scrapped. Now reclaimed. Tubs Rotated While Spray Booths There are eight spray booths for tubs and these are arranged staggered position, the conveyor looping from booth booth and making circuit through each booth. The enameling consists two conveyor chains. each driven. Work carried basket, the top which attached the upper chain and the bottom the lower chain. The tub passing through spray booth means pinion the carriage which meshes with the rack attached the spray booth, making easy for the gun operator spray the entire interior and outer surfaces, including the under side the tubs, without removing them from the basket. The enameling con- veyor moves speed ft. per min. Each spray gun operator performs separate spraying op- eration every other tub. THE IRON AGE, May 16, 1935—27 Phe ] <= kink has enameling been wringer adopted post hole and drain hole the bottom the tub. the ground coat more plastic than the hard finish the cover coat and pro- vides better seat for gaskets, = 28—THE IRON AGE, May 16, 1935 found desirable use only the ground coat around the edges these holes. Instead wiping off the cover coat around the holes, wiping plug inserted the two holes before the cover coat ap- plied. Because the greater plas- IPING cover coat the ™Trom ~U rim the tut after drying and before burning. ticity the ground coat, making less liable chip, the rim given only this coat. this case the cover coat wiped from the rim. This blue black coat makes pleasing color combination with the lighter colors used the tubs. € | is fe } the tanks gravity the spraying ment below. After spraying, the tubs through the dryer, are wiped and air blast applied the in- terior blow out any dust that may have accumulated the sur- face. Then they the continu- ous enameling furnace. When ad- ditional cover coats are applied the operations are repeated, moved gravity conveyor from which they pass to.a power- driven which takes them age room. Separate Conveyor for Sinks separate conveyor line and six spray booths have been provided for sinks. After being’ sprayed, they are hung the sink conveyor which carries them through the dryer and then down the length the plant burning furnace. This gas-fired, box-type fur- nace the side the con- tinuous furnace. Work charged into the furnace two forks. While one load being fused the furnace the other fork being unloaded and reloaded. Sinks, and also combination sinks and laundry tray covers, are given the ground coat and two cover coats and addition acid-re- sisting coat enamel. Enameling Materials Fed Gravity Spray Guns Enameling materials are stored directly above the grinding room and are dumped through hoppers into four ball-type grinding mills. The material drawn from the mills into contain- ers and filtered through fine vibrator. Then goes through separator for the removal metallic particles. Sample panels are sprayed and baked determine whether the material meets color specifications. After this checking, dumped cans floor above the enam- eling room, one above each booth, and fed gravity the nozzle the spray guns. Reclaim Defective Enameled Parts The reclaiming defective enameled parts has been one the problems porcelain enameling industry, losses due poor enameling and chipping assembling and handling are heavy. Some attempts salvage the parts de-enameling have not proved satisfactory because the high cost length time required removing the enamel. some cases acids have been used for this purpose, but have proved unsatis- factory, addition removing the enamel they have eaten into the metal base.., Parts having de- fective enamel coatings are com- enameling plant recently installed connection with the Youngs- town Pressed Steel Co.’s enamel- ing plant. With this process re- moval the enamel rapid and economical. The plant located building adjoining the enameling department. Stee/ framed glass shield Gover | 4 4 A ARK SCX } Te KK Z STR Lnside ler F -/ 7 rod de-enameling furnace. Porcelain enamel removed trom detect par mersing them alkaline bath, the heating units for which are located walls the furnace adjoining the outside the tank. monly junked because they have value even scrap unless the enamel removed. furnace and process which are now being suc- cessfully used for de-enameling de- fective porcelain enamel parts have been developed the General Electric Co. and are used that company’s electric refrigerating plant Erie, Pa. This process and the General Electric de-enameling furnace are now used de- The porcelain enamel removed alkaline bath molten so- dium hydroxide. The furnace electrically heated and electrically controlled. The tank containing the bath set the heating chamber, and the heating units, consisting strips nickel-chromium alloy steel, are mounted sinuous loops the side walls the heating chamber adjoining the outer sur- face the tank. (CONTINUED PAGE 74) THE IRON AGE, May 1935—29 3 4 > AY 8 | 2 ax 2 i BELOW sub-assembly space layout for the mounting spindles with tapered roller bearings the spindle carrier. The indexing gear attached the ground split member and assembled after all finishing oper- ations upon have been com- pleted. 30—THE IRON AGE, May ABOVE IG. type and ar- rangement benches and the wood-block flooring used because its non-fatiguing qualities. The department housed one- story, saw-tooth structure which provides ideal light conditions. which point chucks LEFT holes 3.—Demonstrates the utility bored the portable too! cabinet with which each floor assembler 1-B-( provided. The type truck em- ployed supply parts transporta- bored tion shown. tionin 1935 r LLUSTRATING actual assembly Acme-Gridley automatic screw machines the National-Acme Co. plant Cleveland. Sub-assemblies the bench, for simplifying the work floor assembly, employ some men. Bench assemblies include other units, tool slides, trans- mission with gears and clutches, coolant pumps, spindles and spindle carriers, cam lever mechanisms, drilling and tapping at- tachments, etc. foreman, assistant foreman and department clerk exer- cise supervisory department control carrying out the details assembly procedure connection with the manufacturing schedule machine lots. ABOVE IG. the completed installation several sub-assemblies. A—Part transmission. B—Coolant pump. C—Transmission brake. D—Transmission hand levers. E—Operating throw for threading attachment. LEFT 5.—Other important sub-assemblies are stalled. attachment, fitted line accurately with the spindles. B—Tool slide guide block, doweled and held socket-head cap screws. tool slides. tool slides have hardened steel support-strips which are scraped supporting surfaces the spindle carrier housing. E—Spindle carrier index- ing assembly. lever assembly. and assemblies are shown relation each other but are not operating position. RIGHT IG. 6—A-B-C-D are four the six tool holders which are bored with single point tool held the spindle chucks: E-F-G-H, etc., six holes the machine head, are bored bar held the and piloted the etc., tool six holes, are bored with the boring bar piloted each member, are for posi- tioning tools attach- ments. THE IRON AGE, May 16, tie Rural Location Cushions Shock Depression town Wallingford, Vt., small one located val- ley the Green Mountains. There considerable farm land for subsistence farming, not for agricultural production large The factory the Ameri- can Fork Hoe Co. employs about 125 workers normally, and the only one the village except for clothes pin factory which employs only about men. The American Fork Hoe Co. plant has been Wallingford for well over 100 years, having started blacksmith shop. this shop the original owners forks hand, and now the pres- ent plant makes all sorts hand agricultural tools the most mod- ern machinery and methods. There are good many decen- tralized industries New England and elsewhere, but none has made greater effort take full ad- vantage its rural environment, especially from the standpoint its employee relations. order have clearly mind, let briefly summarize the advantages which are supposed accrue from locating manufacturing plant small town, and then compare them with our actual experience. The advantages include, among other things, better living condi- ditions for the workers, the pos- sibility their owning their own homes and having land cul- tivate, and on. the whole, the workers are supposed have greater degree economic se- curity. 32—THE IRON AGE, May 16, 1935 TAFT Manager, Batcheller Works, Ameri- can Fork Hoe Co., Wallingford, Vt., told Francis Westbrook, M.E. order retain and develop the class workers which need feel that important duty the management handle its employee relations such man- ner that they will not lose their personal initiative extent which will make impossible for them embrace the advantages which living and working the country hold out fer them. This particularly necessary because standardization, althou