The Iron Age 1935-05-23: Vol 135 Iss 21

THE IRON AGE MAY 23, 1935 ESTABLISHED 1855 Vol. 135, No. Somebody Shoot Santa Claus accept Government handouts, said that "nobody shoots Santa Santa Claus, meant, undoubtedly, the new spirit which has trans- formed once fairly Government into gigantic and Be- nevolent Association and Burying ALFRED SMITH, speaking about the general tendency The act magnificent giving creates rosy glow the heart the giver and also makes the recipient feel good too—until his name scratched off the giver's list. And, course, when used buy the presents, both giver and takers are not inclined worry about paying Santa's bill. But Santa Claus has paid and with compound interest; making presents, free gratis, anybody. And the recipients his particular, have pay particularly dear price for them. The farmer, for example, who receives dole for curtailing his cotton crop and another dole the form Government protection cotton price buying these the cost our loss export markets. trading his birthright for mess pottage. The locality which receives the public works project will pay many times its worth, for years come, through labor inefficiency and indifference which will soread from these scattered cells bureaucratic paternalism and inevitably in- fect neighboring private industry. The steel maker who finds part the $4.8 billion trickling from Uncle Sam's hope chest into his plant the form steel orders will eventually pay through the nose, increased taxes and amount, many many times the profit will make the business thus obtained. Most severe all will the payment exacted from many those who are receiving who have come, are coming, value pittance with- out work above opportunity find work and earn living thereby. They are paying for their dole through the foreclosure personal ambition. When the spirit economy and thrift flies out the window Government, long and arduous task coax back again. And all us, whether not are recipients modern Santa's favors, will pay dearly, for years come, for the glittering trinkets that are being broadcast from his pack. rel =) 4 | | Wa x LS 7% t 9 = rh average urn by a huge ventilator ob-galvanizing plant handles variety objects. This large plate nay followed few washers each the size small coin, and they trans-Atlantic liner. Zinc Chloride, Its Place this, the first series three articles, the author presents the interesting his- tory zinc the time hot-dip galvanizing also the subsequent growth and mechanization the hot-dip process. Likewise, the history and various applications aalvanizing industry hy- drochloric acid, ammonia THE “hot dip” galvan- izer today familiar with the three princi- pal ingredients gal- vanizing fluxes, zinc, hydro- Cleveland, Ohio. Hobbs, IRON AGE, May 23, 1935 zinc chloride and sal ammo- niac are reviewed. After bringing the galvanizing in- dustry the current period, the author gives brief résumé the apparent advantages and disadvan tages zinc ammonium chloride against sal am- moniac and hydrochloric chloric acid and ammonia. These materials, one more combina- tions, are used him under the names chloride, zinc am- monium chloride and ammonium chloride or, the latter best known the world over, sal am- moniac. should interest, history these ingredients and products, and “hot-dip” galvan- izing order build logical basis which erect discus- sion zinc ammonium chloride and its manifold uses and advan- tages. other things found the ruins Cameras, destroyed 500 B.C., were two bracelets filled with zine. Thus this offers us, per- haps, the first tangible fact con- nection with the use the metal, zinc. the works Aristotle, the fourth-century Greek philoso- Copper”, with the statement that was made melting copper with certain culiar earth” found the shores the Black Sea. supposed that this peculiar earth was what ° ° ° galvanizing pole line hardware fittings for high-power transmission lines. The fittings sre entering the bath the left, after which they travel under bridge and are the man the center Modern Galvanizing* now know calamine, one the most common ores from which zine obtained. Albertus Magnus, Dominican monk, eredited some authori- ties with the discovery zinc during the thirteenth century which called “marchasita au- However, first referred volume, “Corrus Triumphalis An- timonii”, which was written the fifteenth century Basil Valen- tine, although does not refer metal. The first reference zine metal would appear Phillipus Paracelsus, Swiss scientist, who lived during the six- Paracelsus states: “There another metal called the zinken which unknown the fraternity, and metal very singular kind.” During this latter period, trad- ers China and India were re- turning with cargoes and apparently the Chinese had been producing for some time. 1595 Libavius, one the first investigate zine and its prop- erties, referred the Chinese metal “peculiar kind tin” found the East Indies and called from the East Indies was sold English scientist, Latinized this Thus originated the designation which now the uni- versal term for slab zinc. While Johann Glauber stated the sixteenth century that cala- mine was ore zinc, was 1721 before Johann Henckel discovered and made known the fact that zine could obtained ° ° ° HOBBS Steel Service Engineer, Cleveland ° ° ° from calamine. 1739 John Champion, Englishman, was granted patent his “distilla- tion downward” process obtain- ing zinc, and year later commenced the first commercial production this metal Eu- rope. However, while Champion actually produced zinc, the great bulk Europe’s consumption con- tinued imported from China for many years. Having made study Cham- pion’s work and having learned the art making England, one Kammerassessor Johann Ruh- berg, Pless, Germany, built the first zinc furnace Silesia 1798 1799. about the same time, man the name Dillinger, Klagenfurt, Austria, invented practica! method for smelting zinc, and him that credit given most authorities for hav- THE IRON AGE, May 23, aed ing built the first zine distillation furnace the European conti- nent. Unaware the work Ruh- berg and Klagenfurt, Abbé Daniel Dony, Belgian chemist, after years experimentation, the year 1805 discovered method extracting zinc from ore. But, Dony’s attempts produce commercial way were un- successful and died few years later ruined man. However, 1818, Dominique Mosselman, enterprising manufacturer and financial backer Dony, carried Dony’s work, and his efforts culminated what has since been known the Belgian process smelting zinc. Zine was first produced Amer- ica 1838 the Washington Arsenal. Commercial distillation was attempted 1850, but was not until 1860, when Belgian process furnace was installed and operated Bethlehem, Pa., the Lehigh Zinc Co., that the production zine country became an_ established Hot-Dip Galvanizing Inaugurated 1820 The word “galvanize” derived from the name Dr. Luigi Gal- vani, scientist, who, during the latter part the eighteenth century, impor- tant discoveries connection with the use electric current de- posit one metal another. For many years the term was used designate all coated products regardless the metal used for the coating, its specific use with reference zinc-coated products being confined the last half century. While one Paul Jacob Malouin’ said have invented process for coating iron with zine 1742, the first practical work “hot dip” galvanizing’ seems have been done Morewood Eng- land 1820, when coated sheets Historical data zine was for the most part obtained from and Properties Zinc,” In- galls, 1902, Pages 1-15, and lurgy Zinc and Cadmium,” Hofman, 1922, Page Revue Metallurgie, 1912, Vol. Page 21. and Development Gal- vanizing, the Meaker Co., Chicago, 1914, ‘British Patent 7355, April, 1837. Patent 11476, December, 846. British Patent 2144, September, 860. data muriatic acid obtained for the most part from “In- organic and Theoretical Mellor, Vol. Page 20. IRON AGE, May 23, 1935 iron with tin the “wash tin” method and then immersed the tinned sheets into molten zinc. Morewood was granted patent his process 1821. Englishman, for intro- ducing the basic principles “hot dip” galvanizing, and various fea- tures his process, which patent was issued 1837, are used modern galvanizing. Crau- ford successfully galvanized sheets, link chain, cut nails and wire. Rogers England were granted patent process for running sheets continuously through mol- ten zinc; and 1860 George Bed- also England, secured patent the process continuous annealing, cleaning and galvaniz- ing wire. Hydrochloric Acid Identified Fifteenth Century acid one the most important ingredients the manufacture both zinc chloride and sal ammoniac, and, from consumption point view, second importance all the commer- cial acids; yet considerably less known its history than what obtainable most the products which into the making steel and its allied products. The first reference this acid would appear Caius Pliny, the Elder, his Historia Natu- which describes the purification gold heating with salt, misy (iron copper this mixture giving off fumes hydrogen chloride. Arabian alchemists, although unaware its pure form, em- ployed hydrochloric acid the making “aqua regia,” which from their writings learn was made distilling saltpetre, sal ammoniac and iron sulphate. the fifteenth century Basil Valentine identified hydrochloric acid for the first time. called “spirits salt” and obtained tilling iron sulphate with sodium chloride. the seventeenth cen- tury Johann Glauber obtained distilling sodium chloride with sulphuric acid; and 1727 Stephen Hale, England, obtained distilling sulphuric acid with sal ammoniac. The first pure preparation gaseous hydrochloric acid was ob- England, who called his discovery “Marine Acid Air”, reference its production from sea-salt. How- ever, 1789, Antoine Lavoisier, eminent French scientist, his “Elements Chemistry” gave Priestley’s discovery the name “muriatic acid” with the following explanation: “Although have not yet been able, either compose decompound this acid sea-salt, cannot have the smallest doubt that it, like all other acids, composed the union oxygen with acidifiable base. have, therefore, called this un- known substance the muriatic base muriatic radical, deriving this name, after the example Mr. Bergman and Mr. Morveau, from the Latin word ‘muria,’ which was anciently used signify Lavoisier goes state that further experiments brought about the complete identification acid, was quite likely that new bases radicals would discovered which would cause receive new designation, and this came pass with the adoption the name “hydro- acid” when Sir Humphrey Davy 1810 conclusively identi- fied Priestley’s “marine acid hydrogen derivative chlo- rine. Nevertheless, hydrochloric acid still known and used the consuming industry Ammonia Was Known Fifth Century Ammonia, one the major chemicals the composition sal ammoniac, has interesting his- tory. Although the first mention have been Johann Kunkel 1677, who observed that white cloud was formed when the vapors came into proximity with volatile acid, the discovery pure am- monia gas 1774 credited Priestley England, who gave the name “Alkaline Air”. Chemical identification Priest- ley’s “alkaline was made Austin 1788, with credit for the first complete analysis compo- sition ammonia given the former. 1805 Berthollet’s work was further confirmed Berthollet. However, from point in- terest the galvanizing industry, would appear that compounds “ 7 4 ( ‘ ‘ ‘ | ammonia were known and men- tioned early the fifth century B.C. Herodotus, the historian, re- fers the “Ammonians who live the hills Libya”; and the third century B.C., Hippocrates, the Greek scientist, uses the word the first century A.D., Caius Pliny, the Elder, his ANOTHER scene showing the galvanizing pole line hardware. ticularly remarked its “vehement and the same century the scientist, Apicius, re- ferred the use “sal ammoni- acum cooking”. the eighth century, Geber, Arabian scientist, whose full name and life shrouded mystery, his “De investigione applies the term “sal ammoni- acum” what now known sal ammoniac. His reference reads follows: “Sal Ammoniae made from two parts human urine, one part the sweat (sudoris) the same, one Historical data ammonia ob- tained for the most part from “In- organic and Theoretical Mellor, Vol. Pages 144-145. part of common salt, and one and a half parts the soot logs sticks. When these have been heated together until the moisture evap- orated, true and useful sal ammoniac sublimed. Mix the product with common salt and sublimate again, when the preparation complete.” the fifteenth century Basil Valentine spoke sal ammoniac, Armenian Salt, salt from Armenia, and Armenia sal ammoniac; and from the sixteenth century on, dipping the water tank. various writers have used the term “Sal Ammaniacum” “Sal Ar- meniacum” for ammonium ride, for salts containing vola- tile alkali distinct from those containing fixed alkali. Approach- ing the seventeenth century the term “sal ammoniac” was almost generally used for ammonium chloride. During the fourteenth century many references are found “spiritus urina” “spiritus vola- tilis salis and was about this time that three scien- tists, Tachen, Dossie, and Sala, stated that “spiritus urina” (aqua mixed with “spiritus salis” (hy- acid) the product would the extreme all respects like ordinary sal ammoniac. This considered the first direct synthesis am- monium chloride. The term “spiritus urina” soon became “volatile salis and was the subsequent work and treatment this chemical with acids, alkalis and lime, Johann Kunkel, Raymond Lully, right the coating being set Boyle, and others, that led Stephen Hale’s experiments the heating sal ammoniac and lime. continuation Hale’s work Priestley, who used mercury entrap the gas, served bring about the isolation am- monia gas From data currently these facts comprise the historical background the three ingredi- ents, zinc, hydrochloric acid and ammonia, which make the galvanizing fluxes which are known today: zine chloric acid the manufac- ture chloride, and hydro- chloric acid and ammonia the manufacture sal ammoniac. (CONTINUED PAGE 84) THE IRON AGE, May 23, jo e e 14—THE IRON AGE, May 23, 1935 Cast asting macl vith ladle on car in background. trans- fer ladle iS suspen j- 1 from the ove head crane +o temp at ° OURING end casting machine showing ing ladle and car, together with opera- tor and remote con ~ \Without Chill THE deLavaud centrif- ugal process mak- ing cast employs water-cooled rotating steel mold into which the molten iron charged from specially designed trough. The original process produced chilled castings, the chill being removed the annealing oven. was re- cently discovered that the chill could obviated, and that the physical characteristics the cast- ing produced could further improved suitable heat treat- ment. This product became known super-deLavaud pipe. The deLavaud casting machine consists essentially steel mold mounted rollers water bath. This mold can rotated high speed electric motor. The water jacket, propelled draulic piston, mounted turn wheels which run slightly inclined track. also water cooled, placed that when the mold the upper end the track the trough extends into the mold for almost its entire length and when the mold the lower end the trough wholly ex- There also ladle, electrically Spray operated, and designed deliver uniform quantity iron the trough during the casting opera- tion. The casting cycle begins when the mold the head the track. Into the bell end the mold there has been inserted dry-sand ring core form the socket. The mold rotating and the ladle tilted deliver uni- form stream iron the trough. soon the bell space full, the rotating mold slowly moved down the track the same time iron being delivered the mold from the trough. Centrifugal force does the rest, fusing the stream metal into homogeneous pipe against the steel walls and hold- ing there until has set. Powder Blown Mold Surface The method producing super- deLavaud pipe, the new un- chilled castings are called, ac- complished mechanism which places thin layer ferroalloy powder against the inside walls the mold just advance the poured. motor-driven mecha- nism used supply the correct quantity powder, which blown Spray lance NEALEY American Gas Association the mold surface com- pressed air. The effectiveness the small amount powdered ma- terial preventing chill due the fact that the particles impelled the carrier gas against the are surrounded ab- sorbed film gas. This film, for appreciable time after the pow- der deposited, forms effec- tive part the coating and performs important function bringing about the absence chill and desirable structure the casting. castings produced greatly im- proved, and this further im- proved suitable heat treat- ment gas-fired oven which both continuous and automatic operation and temperature con- trol. The method casting super- deLavaud pipe, well the heat treatment, was devised and devel- oped the research engineers the United States Pipe Foundry Co., and the two existing centrif- ugal plants that company, wit: Birmingham, Ala., and Bur- lington, J., were adapted manufacture super-deLavaud pipe. addition, centrifugal unit comprising five casting machines Feeding device casting machine showing mold, spout, trough, pulverant spray nozzle, ladle and feeding device. THE IRON AGE, May 23, ° ° ° bet é 2 = j | > gre > \ NS was installed Bessemer, Ala. The new plant Bessemer has three cupolas, two forehearths and one gas-fired annealing oven. The forehearths, which are used one time, are preheated through the top. Their function purify the molten metal and, ence full, they retain their heat such degree that the gas burner may shut off. transfer ladle carried crane takes the iron from the forehearth and distributes the machine ladles. Pipe Rolled Through Annealing Furnace The annealing furnace brick and refractory construction, insulated and held within steel case. equipped with two big closed looped chain conveyors, motor driven. Many upright fin- gers are attached the chain links such way that the pipe rolls instead being pushed through the furnace. This rolling incline, the hearth line ele- vated toward the discharge end, this design being adapted pre- vent any movement except that under the control the conveyor. The spacing the fingers allows for pipe sizes ranging from in. What known the hearth Head Molddriven box core >. {from this end : Wah Puler block Extracted Ladle Refilled Castine cycle for super-deLavaud pipe. IRON AGE, May 23, 1935 Travel (a)-Head Core Put Place series alloy pipe skids split into 140 sections staggered and pitched eliminate con- tinuous contact with These are supported chairs passing through and out the bottom the furnace spe- cial adjusting pedestals. The hearth must maintained within 1/32 in. throughout the entire area the furnace refers the flat surface relation pipe contact. One the interesting features this furnace that the slight out-of-roundness pipe, that is, the pope accurately straightened the movement its course through the furnace. This furnace ft. long and ft. wide and heated with gas burners, each side. Eight these gas burners, four each side, are located the first ft. the furnace, while the remainder are located the next ft. two rows. These burners are the nozzle mixing type, and air supplied them lb. pressure from large air blower. This air, well the gas, piped the burners three separate mani- folds which segregate the burners into three distinct sets. Each set has separate automatic tempera- ture control the potentiometer type actuating solenoid valve. ahead iron stream ahe Nozzle Position Thus the furnace divided three hot zones and cooling zone. Annealing Period One Hour The hot zone ft. high ft. long and the cooling zone ft. high and ft. long, and the hot products combustion are sucked out through flues located between the hot and cooling sec- tions. The annealing period ap- proximately one hour and Shore hardness the annealed pipe the limit allowed. Record- ing pyrometers and other control instruments are located cen- tral control house. The three zones the heating section consist two gas burners that take care the heat loss the swinging door and the pre-heat work saturat- ing zone, while the last con- trolled separate zone each side the furnace. This provides additional heat for the bell end the pipe, which, course, heavier than the other sections. Pipe made this process has 100 per cent more impact resist- ance, greater ductility and tough- ness, greater carrying capacity, and easier cut and tap. The pipe discharged from the fur- nace runway where the inside reamed out with rotary grinders, the ends ground, and the (CONTINUED PAGE 94) 4 iron So th Mh Nozzle Maver} operating Coating being applied the pulverant directly the iron stream. Section through Nozzle ULVERANT distributing nozzle, showing above and section through nozzle below. Chute (b)- Start Cast Returns rom LIPPERT The Iron Age, New York ERMANENT molds stone, discovered Cornwall, England, are estimated have been used over 3000 years ago. German inves- tigators report the beneficial effects copper inoculations into cast iron; English researches have announced the elimination pinholes aluminum castings through the application high pressures, and unique method rapidly testing the corrosion resistance letter from Siberia indicates the current status steel industry. Permanent Molds Used 2000 subject permanent molds has occupied the attention foundrymen for great many years, and the problem even now far from completely solved. There- fore with considerable respect that the industry 1935 views example permanent mold cast- ing which must have enjoyed con- siderable success nearly four thou- sand years ago. Toward the end 1934 work- man employed quarry St. Teath, Cornwall, England, exca- vated two hollowed each half bearing the form battle axe. The pieces were easily fitted together make the top and bottom portions stone mold; archeologists judge the stones have been used 1000 2000 This mold, since its dis- covery, has been used cast white metal axehead which bears the decoration engraved the original stones. The mold and ex- perimental casting are shown Fig. The mold made what called freestone, softer stone than that the quarry which in. and weighs about lb. The soft stone was probably used that the mold maker could work with harder stone tool. has hitherto been supposed that following the Stone Age, which all weapons were fashioned stone, there oc- curred the Bronze Age. Native ores copper and tin were prob- ably sufficiently near the surface primitive plow and, mitted accidentally deliberately the heat fire, the metal had sufficiently low melting point run off and form primitive ingot. has generally been held that the resulting bronze, being malleable, was shaped stone tools what- ever purpose the aborigines de- sired, after being heated primitive wind furnace. The mold Fig. shows that these early men knew the value casting di- rectly the shape desired. The THE IRON AGE, May 23, Papen 4 = ° ° ° aes |: é holiowed out stones, each This example permanent molding judged have been used England the casting bronze axes. experimental white meta 2000 B.C. for Messrs. Oliver Sons, St. Teath, Cornwall, are looking for buyer. Copper Improves Gray Cast Iron GIESSEREI has just re- ported extensive study the effect copper related mechanical and physical properties cast iron. The base analyzed per cent total 2.2 2.6 Si, 0.7 Mn, and The experimental copper content was varied from 0.56 1.92 per cent. Precipitated were found the annealed test bars, and the quantity precipitated increased with higher copper content. the as-cast bars, copper particles could detected. The transverse and shear strength the iron increased 1.5 per cent copper, and then decreased. The deflection decreased continu- ously. The increase strength must attributed the finely- divided copper particles. Subse- quent annealing the precipita- tion range copper (400 600 deg. C.) gave further increase hardness, which shows that the bars had been fully age-hardened the mold. Copper additions were found substantially improve the resist- ance the iron rolling friction. Likewise, sliding friction resistance was improved copper additions. Magnetic coercive force and rem- anence advanced with increasing copper content both the annealed IRON AGE, May 23, 1935 pe half bearing the form battle axe. Ne the mold and as-cast bars, but the copper was found have little effect the corrosion resistance the iron the attack tap and sea water. The Proletariat Makes Steel HERE considerable confusion this country the cur- rent status the Russian steel Stainless industry. Therefore inter- est quote recent letter Leo Reinartz, American Rolling Mill Co., from Vaill, Freyn Engineering Co., who now West Siberia. problems which confront the Russians are, mind, en- tirely novel Americans. These fellows here are curious, have thrown away all conservatism, and investigate all aspects mill and open-hearth problems. They tice, and are not satisfied with German technique. They are try- ing wean themselves away from their old tices; they study night and day, and they try anything once. They are developing metallurgically astounding rate. Over 70,000 tons steel were produced last month from furnaces, and Siberian winter fight every hour; ten-hour heats (and not bad ones) from 150-ton furnaces, using per cent iron charges.” Compares Steels Photo-Electrically years chemists and physicists have and metals corrosive action, and Reflecting Power Atmospheric Corrosion Westminster White Blotting Paper (reflecting =/00) used comparison for measurements Exposure Time, hours 2—Five steels compared their ability resist the action industrial atmospheres. Photo-electric equipment was used for this rapid test, and indications are that this method will qain favor for the measuring corrosion resistances. 4 | 100 | | \ NM, Cr Oop. . NG . \ Is ! chronicled the loss weight varying analyses the photographing notorious examples wastage. When corrosion films are relative- thick deposits oxides, sul- phides chlorides, chemical analy- sis the final and quick method determination. But time are necessary deposits form. For this reason, therefore, thin films are occasional- studied, even though the analy- sis microscopic films has usually been slow and complicated. Recently the Engineer gave de- method used determine the loss steel order compare the rela- tive intensity action corrosive attack atmosphere and near industrial centers. The apparatus consists standard lamp draw- ing specified current, the light from which diffuses through reflected light measured photo-electric lamp conjunction with galvanometer. The tion from piece white blotting paper considered equal 100 and taken standard against which all steel surfaces are com- pared. Prior exposure, the steels are highly polished. Care taken remove all traces the polish washing methylated spirit and rinsing distilled water. Read- ings are taken these samples, after which they are exposed. frequent periods the samples were washed free dust, soot and other deposited adherent matter after which readings are taken and Will Present Foundry Papers Europe HREE members the Ameri- can Foundrymen’s Association have been chosen present papers American practice before meet- ings European foundry associ- ations held this summer. This exchange papers among the leading foundry organizations the world has been followed for several years and has resulted the holding International Foundry Congresses, the last one having been held Philadelphia October, 1934, under the aus- pices the A.F.A. George Batty, technical direc- IG. 3—These ink con- tact prints show the ability pressure re- move pinholes alum- inum alloy castings. The the left solidi- fied under atmospheric pressure and the one the right solidified under |b. per sq. in. pres- sure. graphed. Fig. there are graphed numerous data variety steels. can seen that 13.5-Cr stainless steel resists corrosion the best whereas 18-8 stainless next best retaining reflecting power. far corre- lation has been made these data with the direct measurements detailed chemical analysis. But the method believed have con- siderable value quick and ac- curate method measuring cor- rosion resistance metals and steels. Pinholes Aluminum Castings Eliminated IRMINGHAM UNIVERSITY has just released data ex- periments which aluminum alloy melts were cast sand molds and allowed solidify under ex- traneous pressure air nitro- gen. this procedure pinholes can completely eliminated suitable adjustment mental conditions, result con- sidered great interest from both theoretical tical aspects. green-sand molds were placed position auto- tor, Crucible Steel Castings Co., Lansdowne, Pa., and director entitled Solidification Steel Castings” before the June meeting the In- stitute British Foundrymen. Dr. Harry Schwartz, director research, National Malleable Steel Castings Co., Cleveland, present paper before the September meeting the Associ- ation Technique Fonderie Belgique, the Doctor Schwartz’s paper will present the commercial bilities malleable cast iron. The Belgian Congress will held Liege. clave and the cover was bolted down. quantity stock alloy was melted electric furnace and the temperature increased 750 deg. The metal was then poured via funnel into the molds, the pouring inlet closed, and predetermined pres- sure gas was turned on. Sub- sequently, the ingot produced was sectioned, polished and etched for visual examination pinholes. The ink contact prints Fig. show how pressure markedly re- duces the quantity pinholes. The application gaseous pres- sure during solidification improves the density and soundness all aluminum alloys which have been examined. With those alloys which show more marked tendency form internal shrinkage cavities, such the eutectic silicon-alumi- num alloy and the eutectic nickel- aluminum alloy, the increase size this cavity with pressure noted. Pressure cast aluminum al- loys show marked hardness, amounting much Brinell points under pres- sure 200 per sq. in. This hardness increase comes from the greater soundness the castings, metallographical change has been noted. For the October Congress the French Technical Foundry Asso- ciation, which will held Paris, the A.F.A. exchange paper will presented Reichert, met- allurgist, Singer Mfg. Co., Eliza- beth, Mr. Reichert’s paper will deal with the “Present Status Investigation and Control Molding Sands.” The American Radiator Co. has announced that its Pierce plant Buffalo will production July August, following three years idleness. General contract for the rehabilitation the plant reported have been let the Austin Co., Cleveland. THE IRON AGE, May 23, > d \ >. a ¥ \ =. } <3 ab ° ° ° WOOD General Manager, Railway and Trans- portation Sales, Sherwin-Williams Co. ° ° THE Comet, stream- lined train the New York, New Haven Hartford, incorporates for the first time any train streamlining with colors. Both the inside and outside the train rep- resent the most advanced applica- tion color fundamentally sound aerodynamic design. Tak- ing cue from the sales appeal well-designed and colorful products and packages, the New Haven rail- road made every effort study, not only materials, but the most effective treatment these mate- rials with view making the Comet look streamline the out- side and feel streamline within. The train actually only about half the weight standard equip- ment per passenger capacity. capable faster speeds and quicker acceleration, and has center gravity about per cent lower than former equipment. But aside from features was the desire psycho- logically reproduce them the ap- pearance the train. accom- plish this the Goodyear-Zeppelin Corpn., the New York, New Haven Hartford and Sherwin-Williams engineers got together work out color scheme that would enhance the streamline effect, increase the color motif, starting with brown the floor level ous pastel shades the ceiling, which pink-white combining dirt resistance with soft difusion light. 20—THE IRON AGE, May 23, 1935 Se, ¥ > > a 3 interior was given sinc and being carried out var A apparent length the train, and that would suggest speed, stability and grace. Actually the problem the decorator has been simpli- fied the wider latitude pos- sible colors and the simpler streamline train. Logically, the most effective color treatment one that keeping with that very simplicity and lends itself the natural flow lines the train. Bands Run Length Train the case the Comet, the engineers decided upon three col- ors. These are applied bands running the length the train, and serve make the train ap- pear lower well longer. The roof finished gray enamel closely matching the natural tones the aluminum alloy which the train constructed with the ex- ception the trucks. The first wide ribbon the natural aluminum machined brilliant whorled effect and given two coats clear synthetic var- nish protect the shiny aluminum from tarnishing. Lending contrast the alumi- num finish ultramarine blue enamel ribbon just slightly wider than the window panels and the window level. This band encircles the entire train. Parallel and narrower darker blue band which skirts the train. This darker skirting band gives feeling strength and weight the lower portions and emphasizes the lower center gravity. The blue band the window F hele ribbon of aluminum machined to a brilliant whorled effect runs the jenath (CONTINUED PAGE 96) narrower, blue band, which skirts the train. The roof finished ara THE IRON AGE, May 23, 3 a 3 4 7 wy 2 4 | oa — ud < wey | Precision Mills for Rolling Strip, Discussions OBERG, Carnegie Steel Co., SMITH, Republic Steel Youngstown, Ohio—J. SOMERS, Wyckoff Drawn Steel Co., Pittsburgh, Pa. past years have brought about numerous de- velopments the art roll- ing metals. outstanding achievement has been the progress made the rolling thin, wide sections continuous strip and sheet mills. Ten years ago progress roll- ing strip steel stopped. Existing mills were able roll hot strip commercially about in. wide gage. Narrower widths were obtainable thin gages wider than in. could produced only great sacrifice length coil, consid- erable increase power and de- creased tonnage output. permit rolling wider strips was necessary increase roll diameters. inevitable increase rolling load, due increased contact between rolls and strip, was the result. Thus roll- neck friction was further increased with consequent greater power consumption. The only solution was design mill with relatively small work- ing-roll diameters, which was stiff enough permit strip within commercial tolerances. Thus the use backing-rolls ap- peared the only logical step. The four-high mill, which had been tried out the rolling wide plates, offered the best pos- sibilities. Since the power cost important the rolling thin material, the use roller bearings such mills became prime im- portance. This type bearing was also great factor the elimination excessive heating the high delivery speeds involved and, course, reduced so-called bearing wear almost infini- tesimal figure. the rolling thick material this wear not prime importance but did be- *Abstract paper read before the general meeting the American Iron and Steel Institute, New York, May 23. 22—THE IRON AGE, May 23, 1935 come vital rolling material gage. Accordingly roller bearing man- ufacturers cooperation with mill builders conducted series tests which dictated the design proper bearings. The roller bearing operates prac- tically without heat wear and particularly adapted high speeds. Since any suitable ratio roll diameters may used the four-high mill, can built around the proper bearings. other words, roller bearings ample load-carrying capacity es- tablish the size rolls used. + | heat Furra - aby 7, an > AWE toy 2, bina | Ss al > | shing 4H Finishing M. Ae chyr Ad } | Finishing | + strip This definite departure from the principle the old types mill where roll sizes determine bearing sizes. roll diameters four-high mills, important point out the ously stated that increasing roll diameters advance sures and consequently increases neck-friction. The friction loss roller bearings extremely small, and power savings per cent and over have been recorded. Con- sequently larger working-roll di- ameters, capable withstanding greater stresses, can used with almost effect the total power consumption. For the cold-rolling wide strip, the four-high mill was even greater importance. Strip gage, and the rolling loads encountered are greater than those experienced hot rolling. Such reductions are now being made continuous reversing mills with delivery speeds 800 ft. per min. The accuracy rolling with these mills remarkable. hot- mills rolling wide strip not uncommon roll with variations thickness less than 0.002 in. from edge center and from end end. Four-high mills rolling thin gage material must classed pre- cision mills. thousandths inch are dealt with and the equipment must made accordingly. Trained crews must employed obtain the desired results. Center Fullness Necessary The metal rolled must care- fully watched the early stages rolling. order guide long strips properly through the mill they must rolled with slight fullness the center. The guides are importance only insure that the path successive pieces | | Lo | Reni ler Vex t Scale Breaker Broadside Bars and Rods’ the same part the roll. The control the strip the mill accomplished almost entirely the careful adjustment and shap- ing the rolls. Turned rolls cannot used sat- isfactorily strip mills. The rolls must ground with extreme ac- curacy. Whether they should ground concave full depen- dent entirely the stiffness the mill and based solely careful judgment and experience. The shape roll the grinder not the same when actu- ally rolling steel. When rolling pressure on, the roll flattens and bends matter how stiff both backing and working rolls are ground straight, the mill will deliver strip full the center. The amount fullness will de- pend the reduction, the width and the shape the entering strip. Increasing the load will change the shape the rolls and strip. is. cold-rolling, and occasionally hot-rolling, local application heat employed shape the rolls. Properly directed gas flames streams hot compounded oils are applied the back-up rolls. The heat develops the desired con- tour the rolls. The shaping rolls increas- ing the rolling load presents serious problem from point bearing life. Bearings are designed give desired expected life under given rolling loads. continuous slight increase roll- ing loads results considerable decrease bearing life. For this reason, protection bearing life, strongly recommended ments incorporated all four- high stands, especially “AL WECKSTEIN, assistant chief engi- neer the Timken Roller Bearing Co., was graduated from Stevens Institute Technology 1923 with the degree M.E. 1923 joined the industrial engineering department the Timken Roller Bearing Co., where made special study the design and applica- tion bearings indus- trial equipment. 1926 was placed charge that department. 1927 the industrial engi- neering and rolling mills divisions were combined and Mr. Weckstein took charge the new depart- ment. Since that time has been engaged anti- friction bearing develop- ments, particularly the industrial field, and has specialized the applica- tions involved rolling mills. mills. this way reductions per pass can properly balanced that additional loads imposed the screws for the shaping the rolls will not make the total roll- ing load greater than the recom- and 2—Layout skid bed; ac transter table for stands merchant ° ° ° WECKSTEIN Timken Roller Bearing Co., Canton, Ohio ° ° ° While attention was focused the manufacture precision prod- ucts from four-high mills, little development work was being done bar and rod mills. With the introduction knee-action springs automobiles immediate de- mand was created for precision rounds. Prevailing commercial standard tolerances were not sat- isfactory and the hot-rolled prod- uct coming off the mill could not used without cold-drawing Some mills immediately tackled this problem and after consider- able experimentation offered hot- rolled product held one-half standard tolerances. mill found possible roll even closer tolerances but decided ac- cept orders only the basis one-half prevailing standard erances. The results were made possible suitable mill arrangement, proper mill practice and proper equipment. Mill arrangement depends tirely range products, orders, diversity orders size plant. The continuous mill and the semi-continuous mill are the two general types con- sidered. en- size and of The continuous mill has the ad- vantage low first cost and low operating cost. adapted rolling large tonnages narrow strip, skelp, flats, angles and mer- chant bars. justified large steel plants where tonnage require- ments are large and range prod- ucts limited, but not suited the average merchant bar plant. the rolling strip the prod- uct must accurate gage mended separating force the and width. Mill rolls can set mill. beforehand and roll speed con- 9-10 T TT T TIT SS 11-16 Lo “<4 Roll stands are indicated numbers indicates charging table 10: the transfer table for stands indicates flying crop pack annealing cooling approach table the rod reels; and indicates back shear table. THE IRON AGE, May 23, 1935—23 i 4 — het 19 ind trolled maintain proper loops between stands. Adjustment for gage can made the last few stands; width can maintained edging rolls. When comes rolling rounds different problem. The de- livery accurate round from the finishing stand dependent upon the delivery exact sec- tion from the next preceding stand the mill and this section turn dependent upon the delivery accurate section from the preceding stands. other words, the accuracy the finished prod- uct function, not alone the finishing pass, but each preced- ing pass. assure this accuracy, considerable skil! required the part the operator the adjust- ment the sections the various roll stands. Since the product section area and delivery speed must constant for all roll stands, can readily seen that ad- justment section any stand must accompanied corre- sponding roll speed. section adjustment one stand may require adjustments some the other stands, both sec- tion and roll speed. This means that the operators must con- stantly controlling roll speed and section adjustments. The semi-continuous mill more suited the production high- quality products. easily adapted the rolling special- ties and jobbing orders tonnages. These mills are usually arranged with several roughing stands for continuous rolling. In- termediate and finishing stands are arranged permit the prod- uct rolled run free after each pass. This means that interme- diate and finishing stands are in- dependent each other far speed concerned. The passes can 24—THE IRON AGE, May 23, 1935 then individually adjusted give the desired accuracy. Proper mill practice equipment are important and gov- ern the accuracy the finished product. Attention must given proper heating billets, con- trol temperature during rolling, contrel scale, elimination un- due stretching and twisting ma- terial during rolling, efficient han- dling and rolling after the product leaves the mill, and roll design and roll mounting. very important that all bil- lets heated uniformly; the tem- perature should not billet billet. Even more impor- tant, the temperature different parts the same billet should uniform. Varying temperatures the billet will result different finished sections. obtain this naces maximum efficiency. Roll- ing and heating schedules must arranged assure continuity flow billets from the furnace through the mill. All billets should heated for the same length time and should take exactly the through all the stands. the continuous mill, tempera- ture during rolling cannot read- ily controlled and will depend en- tirely the temperature the billet leaving the furnace. This means that all billets leaving the furnace must exactly the same temperature assure that all materials will finished the same temperature. the semi- continuous mill, the bar may delayed the transfer tables and thus the same desired finishing temperature obtained. and twisting material during rolling must avoided. Entry guide-boxes must designed enter and hold the bar rod definite position relative the groove the roll. Delivery guide-boxes and twisters must equally accurate and proper design minimize the severity the twist and not re- strain the free passage the ma- terial. Adjustable guide-boxes may used their design such assure permanency and accu- racy the adjustment. Accuracy the finished prod- uct depends the grooving and necking the rolls. Often very little attention paid the neck- ing operation. should borne mind that turning and grooving roll bodies done from the necks and the accuracy obtained depends the accuracy the necking. The necks should with the body and all faces should accurate and exactly square with the neck and center line the roll. Grooving the rolls very im- portant. The determination the exact shape each groove matter long experience and will naturally vary with the number passes from billet product. obtain best results, too much time cannot spent machining the grooves make sure that they are accurately fin- ished specifications. slight sult extreme variation the product. Mill Housings Redesigned Mounting the rolls their hous- Provision must made the rolls definite and accurate position for maximum time. That is, there should wear the bearings sufficient per- mit the movement the rolls, either vertical lengthwise direction. the maintenance this accuracy and also the relief the operator from the necessity constant pass readjust- ment that roller bearings play important part. Plain bearings the radial type often show con- siderable wear with consequent change the vertical plane. Plain thrust bearings, due the diffi- lubrication which they present, show considerably more wear the lengthwise di- rection. Roller bearings are avail- able which not show any wear either direction, compared with many types ings. taking advantage this feature possible obtain per- fect alinement and setting rolls and maintain this setting indefi- nitely. also possible, prop- design, make provision the mill for adjusting devices which will permit setting the rolls or in at St al qt ri a a \ c “ x 4 if 0 } YANK} ro } A — {= = ._ = = ys r —_“_“_— ‘ ~ ena the tor sr botton R yht the tixed end ted changing the setting small increments minimum time and without the method used with plain bearings. Once adjusted, the operator can sure that the rolls will stay put and the only adjustments which need consider are quired compensate for wear the roll passes. With relief from constant readjustment passes the roughing stands, the roller can pay more attention the finishing stands and produce more accurate product. Together with roll mounting, considerable study should given the design mill housings. known fact that the housings well other parts the indi- vidual stands stretching and contributing the change the passes. For pre- cision stiffer possibly oversize housings should used. Careful control rolling loads, the balancing passes possibly reducing the work per pass and increasing the num- ber passes, will help consider- ably the final accuracy the } roduct. recently given vertical mills and number such mills have been installed. These have been the overhung-roll type and the full- sized roll type. one the plants where extremely accurate rolling has been done, vertical mill with full-sized rolls supported bear- ings both ends and with full complement roll passes, has been used. The rolls this mill are ad- ustable and down line properly with the passes the preceding horizontal stand. The rolls are also adjustable sidewise line with the passes the preceding stand. addition fine vernier adjustment for moving rolls longitudinally with respect each other obtain accurate pass alinement. The finished product taken off this vertical mill held less than one-third standard commercial tolerances. New Mill Suggested Some experimenting been done the use anti-friction bearing thrust units connection With ordinary plain bearings composition bearings. The theory this work has been that vadial wear could materially plain bearings the use composition bearings. friction thrust units are used the endwise position the rolls. The units are provided with accurate micrometer end- adjustment which makes sible accurately line passes the rolls. Complete re- sults the use these units are not available. has been found that not sufficient use such units only the finishing stand. They must also used farther back the mill and are conse- quently applicable only continu- ous mills. was found difficult job apply thrust unit roll with the required accu- Due the high speed the mill small amount misaline- ment caused considerable run-out with consequent pinching the bearings the thrust units. was further found that the condi- tion the wobblers and had watched carefully. Worn wobblers and pods caused end thrusts considerably excess the capacity the bearings used the job. Such condition can undoubtedly remedied the use universal couplings. Another suggestion for cision mill that backed-up mill which the designer describes follows: “The four-high bar rod mill stand unique that the rolling prevent endwise motion the work rolls. The pressure will force the convex surface the work roll into the surface the back roll, resulting wedg- ing action between the two rolls, Discussion HEN new mechanical de- velopment appears, any field which had established its eco- did hot rolling steel, series related industrial affairs dis- turbed. During