The Iron Age 1935-06-20: Vol 135 Iss 25

239 West 39th St., New York Owned, Published and Copyrighted CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. Cc. A. MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC STEVENS. Vice-President JOSEPH 8S. HILDRETH “ GEORGE GRIFFITHS EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT., Secretary FRITZ FRANK, President VAN DEVENTER Editor Managing Editor News Editor Machinery Editor Editor Emeritus Washington Chicago Cleveland Detroit Boston Cincinnati Contents June 20,1935 How Save the Constitution Grinding Facilitates Production Accurate Tool Parts Pennsylvania's Leadership Pig Threatened? Finish Manufacture Office Equipment Convention Report American Electroplaters Society New Equipment News Washington News Rate Activity Capital Goods Statistics Metal-Working Activity. Markets Personals Obituaries Construction and Equipment Buying Produéts Advertised Index Advertisers DIX, Manager, Reader Service 126 Member, Audit Bureau of Circulations ADVERTISING STAtF Member, Associated Business Papers Emerson Findley, 311 Union Bidg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo. N. ¥ Published every Thursday Subserip H. K. Hottenstein, $02 Otis Bihig., Chicago tion Price: United States and Pos Peirce Lewis, 7310 Woodward Ave., Detroit sessions, Mexico, Cuba, $6.00; Can Charles Lundberg, Chilton Bidg., Chestnut & 56th Sts.. Philadelphia, Pa C. H. Ober, 239 W. 39th St., New York ada, $8.50, including duty: Foreign $12.00 a year. Single copy 25 cents W. B. Robinson, 428 Park Bidg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address, ive, N. i) Warren. P. O. Box 81, Hartford, Conn ¢ the wil lize lux ble oes ; tes its it- ce wae a | are Wiregraph Alexander Calder, made Bethanized Wire Railway Right-of-Way Fences zinc coating Bethanized Wire can adjusted the requirements cor- rosive conditions. For railway right-of-way fences can either supplied with the standard weight coating that used for this severely- exposed application, can provided with coat- ing two, three more times heavier, thus increasing proportionately the life the fence. different Bethanized from ordinary galvanized wire that enforces reappraisal the uses which zinc-coated wire adapted. The coating applied elec- trolytically. far more tightly bonded than ordinary galvanizing. tougher and more ductile. smoother and more evenly distributed and, due its exceptional purity, has silvery lustre. 10—THE IRON AGE, June 20, 1935 Bethanized Wire can many cases substituted for more costly materials. Often its use results more attractive, longer-lasting and more readily salable product. can used for strand, for springs, for spokes bicycles and baby carriages. can woven into chain-link fence with coating two, three more times heavier than standard hot-dip galvanizing with- out cracking scaling the zinc, making galvanizing- after-weaving unnecessary. Bethanized Woven Fence, Bethanized Barbed Wire and Bethanized Smooth Wire rolls for variety purposes are now being manufactured Bethlehem Steel Company. Bethlehem metallurgists will glad answer questions about Bethanized Wire, and discuss its application specific problems. \ J ¥ ~ bed THE IRON AGE ... JUNE 20, 1935 ESTABLISHED 1885 Vol. 135, No. How Much Will You Spend Save the Constitution? engineers the Bausch Lomb Optical Co., who measure millionths inch means light waves, tell interesting fact about the sensitivity steel. They state that the weight common housefly lighting the end half inch iron bar projecting foot from vise sufficient deflect the bar one millionth inch. Business great deal more sensitive than steel. The impact mere rumor from Washington sufficient send Mr. Average Businessman high the and deflect millions dollars from investment expenditure finan- cial The economic tinkers and social experimenters whose pastime was rudely interrupted the Supreme Court will undoubtedly capitalize upon this situa- tion increasing the output rumors and threats. fact, the increased pro- duction already apparent. The union labor propaganda factory already flooding the newspapers with fictitious reports wage and hour chiseling; there the threat national coal strike unless the Guffey bill passed and from high quarters comes the disturbing hint that the Constitution getting old Calder, fashioned. Wire All which calculated, course, give business men the and thus cause the necessary downturn business that will give the tinkers new lease upon life through public mandate. The shoe now upon the other foot. Whereas prior the demise NRA, upturn would have justified the experimenters, now would defeat them. This gives business opportunity has not had for two years more, namely more abandon the uncomfortable position has played backstop and pitch salable few fast balls itself. ings, for Business now has unique opportunity make social experimenting and woven bureaucratic unpopular for time come and take from the more public mind all desire for junking the Constitution whole part. The way with- this place orders, now, for the capital equipment that you want, need and know that you must have, sooner later. That little difference between sooner later will not cost much but will put the experimenters permanently Wire rout and save the Constitution. riety Business has thought that could not outtalk $4,800,000,000 the court thlehem public opinion. Eighteen and half billion dollars, which the present industrial glad need for reequipment, will outtalk four and eight-tenths billions any time and any- and where. And our bankers should willing play their part this worthy cause with the more than thirty-six billions idle credit now available. How much will you spend, now, save the Constitution? Ay <4 » ¥ ws en | ied | 2—In taper seat this heat-treated friction clutch part, variation from standard size permissible. common with the other machines the arinders for this work are 12—THE IRON AGE, June 20, 1935 steel, turret lathe are accurately sized and finished plain Convenient work racks are provided nd the ightina system of the entire department i srranaed te facilitate accurate work FRED JACOBS CLOSE any opera- tion are impossible with- out accurate machine tools. built machine tools enjoy high reputation for accuracy, but this was not brought about recently, processes re- finement have been developed grad- ually over the past years more. With the general introduc- tion precision grinding some years ago, machine tool makers be- gan take advantage this pre- cision method. The development has been gradual, sure, but today grinding employed machine tool plants for operations that were unheard the early days grinding. This article illustrates and describes few precision op- erations performed the plant the Warner Swasey Co., Cleve- iand, builder turret lathes and telescopes. Because machine tools cannot made under intensive production methods lots several thousand time, the straight-line produc- tion plan not practicable. Thus the departmental system must followed. Such plan offers many advantages, the chief which that manufacturing operations given kind can performed di- rectly under the supervision department foreman long trained that particular class work, (5 d | | it | d ti ° ° f provided fixtures for local lighting. A\ccurate the grinding department question. considering few practical everyday grinding operations, tur- ret lathe spindles offer excellent example, they can accurately sized and finished grinding much cheaper than other meth- ods. Referring Fig. the oper- ation consists finishing alloy steel turret lathe spindles which the following sizes are ground: in. diameter in. long; in. diameter 27/16 in. long, this portion being for the spindle nose thread; in. diameter 311/16 in. long; in. diameter 15/16 in. long; in. diameter in. long; in. diameter 3—Heat-treated parts are straightened before grinding. The in. long. part held between centers and rotated and the run-out de- ermined bringing dial indicator against it. The high spots The machine used for this oper- are marked then Landis plain grinder ca- pable accommodating work in. diameter and in. length. fitted with alundum wheel, in. diameter, 3-in. face, 1924 grit, grade. This wheel oper- ated approximate surface speed 5500 ft. per min. The work speed about ft. per min., but often varied suit the cutting action the wheel. When mounted for grinding, the work held special centers in- serted each end, the spindle hollow. Once mounted for grind- ing, all surfaces that must con- centric are finished one setting, thus assuring the necessary accu- racy. The tolerances the ma- jority the finished diameters are very close, 0.0002-in. plus minus. The work sized with micrometers which are inspected periodically make that they are accurate. Also, standard size gages are fur- nished for many operations; means these the operator can transfer the desired size the fin- THE IRON AGE, June 20, = | | D —— : grinding hardened steel roll jaw. The spindle { ia ron 5—Finishing diameter, 5-in. long bore heat- treated sleeve gear. The machine also employed for bushings, well for other ished piece regardless whether his micrometer off slightly. Fig. also shows the type work rack for accommodating the spindles. consists two cast- iron ends tied together, the entire assembly being provided with cast- ers for ready transportation. The locating brackets for holding the work are faced with soft brass marring the work. The chain hoist & and trolley the right are for handling heavy work this ma- chine used for number other precision operations heavy work. excellent idea the lighting system can had from Fig. both sides the grinding depart- ment are large windows which are washed frequent intervals that full advantage can taken daylight. Electric lights, ar- ranged shown, give ample light blanks are surface ground this machine, six blanks in. diameter being finished one setting. The 14—THE IRON AGE, June 20, 1935 dark days and during the winter mornings evenings. These lights are design that gives maximum illumination without ob- jectionable glare. Adequate light- ing essential any grinding de- partment for without eye-strain results and this gives rise inac- curate work. Size Variation Clutch Taper Seat many grinding operations the Warner Swasey plant variation from given standard size permitted. This true the operation illustrated Fig. which consists grinding 60- deg. included taper seat ma- heat-treated friction clutch part. The piece in. diameter the large end and the ground seat in. long. The machine employed Lan- dis 72-in. grinder, fitted with alundum wheel, in. diam- eter, 2-in. face, 1924 grit, grade. This wheel operated surface speed approximately 5600 ft. per min., while the work speed about ft. per min. the illus- tration shows, the werk mounted arbor between centers the usual way, the pleten being set over deg. slight variation the diameter slight conse- quence, but the 60-deg. angle must exact. Otherwise the clutch would not bear fully its seat. this operation the work smeared with Prussian blue and tested accurate female gage. bears evenly all along its length this signifies that the platen has been set over the correct angle. slight variation shown, however, the machine must reset cut-and-try operation until the desired results are at- tained. Once the machine set can relied upon grind any number parts the required accurate angle, provided, course, that the wheel cutting properly and generating true cone. Fig. also shows the type individual light with which most the ma- chines are equipped. fitted with shade prevent glare, and adjustable, that the light can directed just where the operator desires. Parts Straightened Before Grinding finishing heat-treated parts grinding, straightening opera- tion should precede the grinding. Otherwise the part might run out iter ese ves ob- extent that would prevent correct finishing. straightening operation shown Fig. The operator places the part between centers and notes its run-out means dial indicator brought against the part the part ro- tated. The high spot marked with chalk and the part set the V-blocks shown the illustration and subjected screw pressure. experienced operator can tell just about how much pressure exert regardless the diameter length. Two three tests gener- ally suffice bring the part within 0.001-in. running true, which close enough for work ground afterward. High-Speed Internal Grinding high-speed internal grinding operation shown Fig. This part hardened steel roll jaw, the ground hole being in. di- ameter, plus minus nothing. The part in. wide. the illus- tration shows, the work held faceplate fixture means one clamp. Back the clamp the illustration 5/16-in. hole which slips over locating pin provided for the purpose. This machine Rivett high- speed internal grinder fitted with alundum wheel, in. diameter, in. wide, 3860 grit, grade. The wheel spindle operates speed 16,800 r.p.m. The internal grinding operation shown Fig. consists finish- ing the bore heat-treated ma- chine-steel sleeve gear. This unit has bore in. diameter and in. depth. the illustration shows, the work located large three-jaw chuck the work- head spindle. This machine Heald internal grinder fitted with alundum wheel, in. diame- ter, face, 1946 grit, grade, operated surface speed 5000 ft. per min. The work speed ap- proximates ft. per min. This machine also used for grinding other gears various diameters, large bushings, etc. Variety Flat Parts Ground Blanchard surface grinders are used for finishing variety flat parts, one which shown Fig. The parts place the chuck are gear blanks in. diameter, in. width, and the illustration shows, the chuck ac- commodates six blanks one set- ting. The chuck in. di- ameter. some cases the work 7—For finishing the outer surface cast iron turning head, surface grinder this type employed. The work, in. long and 7-in. wide, held special fixture the chuck. must held within ring prevent the wheel action from forcing the pieces out place. the present instance, however, the locating surface sufficient afford enough mag- netic attraction hold the parts securely. The wheel used alun- dum, in. diameter, grit, 5000 ft. per min. the rim. The ABOVE IG. 9—Sets mounted cast iron holder here shown, facilitate setting crometers where wor held exact dimen- sions. chuck speed about r.p.m., but this speed often reduced. Parts finished this manner have par- allel surfaces, which the condi- tion desired. This machine also used for finishing diversity other parts, fact, for any sur- face-grinding operation within its limits. (CONTINUED PAGE 102) BELOW 8—The body sections the spline shaft the are finished machine equipped with cam attachment. three-point special micrometer employed for measuring the three-section surface finished THE IRON AGE, June 20, th le. ce | in 1 - 3 Pennsylvania PENNSYLVANIA be- gan produce pig iron 1720, and soon led the Colonies ton- nage charcoal iron made and the number blast furnaces built. This leadership continued throughout the second century the charcoal iron era this coun- try. the last year exclu- sively charcoal pig iron, the year 1839, Pennsylvania made nearly per cent all the pig iron pro- duced the United States (see Chart I). During the past two centuries more iron blast furnaces have been built within the State Pennsylvania than any other four States combined the past three centuries. Out total 1857 (possibly more) blast fur- naces built this country since its settlement, 683 them were built Pennsylvania (THE IRON AGE, Nov. 29, 1934, page 27). all counties except one more blast furnaces have been built one time another since 1720. Pennsylvania took the lead the introduction and use min- eral fuels the beginning the mineral era 1840 and held throughout the entire anthracite period, and throughout the entire beehive coke period. product coke was introduced the Nineties, Pennsylvania continued hold her prestige big iron producer. Now something else has happened. Today that leadership challenged, and for two years— 1932 and 1933—Pennsylvania has been eclipsed the State Ohio; the preliminary figures for 1934 indicate that Pennsylvania slightly the lead again. those who have taken active part this tremendous production iron within the bord- ers single State there comes the question whether this passing leadership permanent Paper presented second annual metallurgical conference vania State College, May 1935 IRON AGE, June 20, 1935 whether Pennsylvania can re- gain and hold first place pro- ducer iron, seeking the answer this question must first look for, and find, the underlying sources that leadership throughout continuous period 200 years. Sources Leadership The double foundation the iron and steel industry made units iron the iron ores, and units carbon the fuels, either natural manufactured. Pennsylvania has produced within her own borders abundance all five the fuels used the iron blast furnace, wit:—char- coal, anthracite, raw coal (“block beehive coke and by-product coke; other State, other country, has been richly endowed with this half the requisite double foundation the iron and steel industry. The forests Pennsylvania fur- nished plenty wood for the char- coal furnaces that were built every part the State, with the exception the northern tier counties and the east and southwest counties where there was ore suitable for smelt- ing. The production charcoal pig iron Pennsylvania continued until 1921. Eagle Furnace, typical cold blast charcoal furnace, Curtin, Center County, was the last make charcoal iron. But the mineral fuels that Pennsylvania surpasses all other States kinds and nage. The coking coals the Pittsburgh seam form the basis for the blast furnace fuels, not only Pennsylvania but her great- est rival, the State Ohio; present Ohio does not produce suit- able for by-product coke, and depends almost entirely Penn- sylvania, West Virginia and Ken- tucky for her blast furnace fuels. The other half the founda- Blast ENNSYLVANIA has led number and output blast furnaces almost since the inception iron ore smelting this country. The history the changes blast furnace practice the United States was, for many years, mainly chronicle developments the Key- stone State. Latterly the pic- ture has been changing and two the last three years pig iron production Ohio exceeded that vania, despite the latter's much larger capacity. The author traces the tion, iron ore, has also been mined large quantities within the State, and during the charcoal iron period practically all the iron ore smelted was mined there; but far the greatest part the ore smelted within the State for the past years has come from the Lake Superior region. This drifting the sources iron from mines within the State those outside the State Penn- sylvania shown Table and Chart Men Vision sides natural resources iron ores and fuels build great iron and steel industry. requires men vision. Pennsylvania has always had such men. his book entitled, Concise History the Iron Manufacture the American Colonies the Revolution and Pennsylvania until the Present 1876, John Pearse said, our progress due the Society for the Promotion Internal Improve- Threatened? changes blast furnace prac- tice that came about with the adoption different fuels and notes the marked reduction effected the amount raw charged per ton pig iron produced. the Lake ores now used declinina iron content, furnace men are again faced with the neces- sity using larger quantities materials. One source economy, however, has not yet been fully ex- plored and that the nitrogen content the air blast. ment the Commonwealth Pennsylvania,” and then gives the names nine men represen- tatives the society who promul- gated “the policy internal im- provement, beginning 1826, maintain the character and stand- ing the State, and preserve her strength and resources, and which bore immediate fruit the growth the iron trade between 1830 and 1842.” One the results the efforts this society was the act March 29, 1836, whereby the legis- lature the Commonwealth Pennsylvania authorized geolog- ical and mineralogical survey the State. The first annual report State Geologist Rogers was that year. Furthermore, the legislature that same year 1836 passed act authorizing the Governor grant charters cor- porations for making iron with coke mineral fuel exceedingly favorable terms. Besides the men vision was necessary have men technical skill devotion, men who were willing risk thing, even their lives, for the sake carrying through their visions and experiments. Among those de- voted men was Dr. Friederich Geissenhainer, Lutheran minister New York City, whom was issued Dec. 19, 1833, one the very first, not the first, patents relating the use anthracite coal smelting iron ores. The date early that there not even number his patent and not printed form, but file the United States Patent Office Washington writ- ten out long hand. “Letters Pat- ent, and making part the same,” contain description the words his improvement the manufac- ture iron and steel the appli- Geissenhainer claimed invented discovered new and useful improvement the manu- facture iron and steel the application anthracite coal smelting iron ore into pigs cast iron.” his statement the patent office Dr. Geissenhainer claimed that had made his dis- covery and had drawn ac- count signed and witnessed the thirty-first day August, 1831, and that was filed the patent office Sept. 1831. According James Swank his book “Tron All Ages,” Dr. Geissen- hainer successfully operated his little furnace Silver Creek, Schuylkill County, Pa., about miles northeast Pottsville, August and September, 1836, using anthracite coal for fuel. break- down the machinery, sickness and then the death Dr. Geissen- hainer May, 1838, prevented fur- ther operations. The executors Dr. Geissen- hainer sold his patent George Crane London, England, who, ° ° ° RALPH SWEETSER Consultant Blast Furnace Practice, New York ° ° ° Philadelphia newspaper, charged royalty 25c. ton for rights use anthracite blast furnace fuel. this same George Crane, subject the king Great was issued United States Letters Patent, No. 1024, dated Nov. 29, 1838, which claimea his invention, “the application anthracite stone coal and culm combined with the using hot air blast the smelting and stone, mine, ore, above de- scribed.” The application for the patent was filed March 29, 1837. this letters patent issued George Crane good definition coke. said that “according the ordinary practice obtain- ing iron from iron-stone, mine, ore this country, the iron-stone, mine, ore (either calcined the raw state according its respective qualities) put into suitable furnaces with coke pro- duced from bituminous coal—for- merly called ‘pit-coal,’ contra- distinction charcoal produced from wood, which was the fuel employed this country previous the introduction pit-coal the smelting and manufacture iron.” Mr. Crane further said that did not claim the using hot air blast separately, nor did claim the application anthra- cite coal stone-coal the manu- facture smelting iron when uncombined with the using hot air blast. Another name that “should held the front rank honor one the pioneers that industry which has made Pennsylvania special manner famous,” that William Lyman Boston, who his book entitled, “Historical Sketch Geological Explorations Pennsylvania and Other States” (Harrisburg, 1876), Mr. Lesley says “the year 1839 was remark- able for Pennsylvania geology THE IRON AGE, June 20, a — d p >a d e le ) l | the experiments Mr. William Ly- man Boston Pottsville smelting iron ores with anthracite coal; and also the arrival Mr. David Thomas and his family from Wales attempt the same feat near Allentown. Mr. Lyman, after many months anxiety, first alone, and afterward with the assistance Mr. Thomas, was suc- but his exposure and labors day and night under- mined his constitution and died few years afterward New England.” According James Swank, all pig iron produced this coun- try previous 1840 was made with charcoal the blast furnace fuel. The happenings vania the decade previous 1840 have been briefly mentioned because the great importance the combination beginnings. That stirring period was remark- able for the which were started, especially the State Pennsylvania. The discovery the uses anthracite, the introduction railroad trans- portation and all the other fav- orable influences are very clearly described John Birkinbine his report the “Manufacture Pig Iron Pennsylvania,” published 1895. says this paper “the manufacture pig iron will divided into three general eras, designated the charcoal era prior 1840, the era develop- ment, 1840-1876, and the technical era, 1876 further says that “the intro- duction railroad transportation, the use hot blast stoves heat the air driven into blast furnace and the application steam for the motive power for the blowing apparatus, were nearly contempo- raneous with the employment mineral coal for smelting iron ores; consequently the changes blast furnace construction and operation between 1720 and 1840 were com- paratively few, consisting mainly enlarging moderately the stack dimensions, tures, substituting barrows for hand baskets and boxes, increasing the capacity blowing machinery and augmenting the output metal per furnace.” The production pig iron Pennsylvania the end this exclusively charcoal amounted 190,090 gross tons pig iron out total 239,000 18—THE IRON AGE, June 20, 1935 tons for the whole United States, per cent. Pig iron records that period were not care- fully kept they are now, but the records show that the year 1841 there were anthracite blast fur- naces operating Pennsylvania with total output 150,000 tons compared with 179,000 tons pig iron made 218 fur- naces. Some anthracite pig iron had been produced during 1840 and the end that year the records show that anthracite furnaces had been built Penn- sylvania, including the Crane Iron Co.’s furnace Catasauqua, which was blown David Thomas July Increase Bulk Raw Materials quences going from charcoal mineral fuels that remarkable decade beginning with the year 1840 was great increase ton- nage and bulk the raw materials required produce ton pig iron. According Dr. Walter Johnson’s book, the Use Anthracite the Manufacture Iron,” published 1841, re- quired the following quantities produce ton anthracite pig iron the furnace the Crane Iron Co.: Iron ore 2.08 tons Anthracite 1.38 tons Limestone 1.04 tons Total 4.50 tons Air 34.00 tons Grand total 38.50 tons The anthracite was from the Le- high Coal Co. near Mauch Chunk. course did not require tons air burn 1.38 tons anthracite, but that what was blown. the Columbia furnace Dan- ville they used Shamokin anthra- cite, and low grade iron ore. The record shows the following quanti- ties per ton pig iron: Iron ore= 2.96 tons 2.58 tons Limestone 2.03 tons Air 20.40 tons — Grand total 27.97 tons Fifteen years later when David Thomas operated his own blast furnaces average quantities used per ton pig iron (A.I.M.E. vol. IV, page 223—Prof. John Church), were follows: Iron ore == 2.55 tons Anthracite 2.43 tons Limestone 1.60 tons Total materials 6.58 tons The quantity air not recorded, but must have been very large amount. 1875 the same Thomas Iron Co. furnaces were using less raw materials, but higher prices, es- pecially for the ore. Iron ore 1.94 tons Anthracite 1.75 tons Limestone 1.15 tons —— Total materials 4.84 tons Although evident from the records that considerable low-grade ore was used the charcoal blast furnaces, yet also apparent that the requirements for limestone were very much less, and the fuei per ton pig iron was less with charcoal than with anthracite. The technique anthracite prac- tice was violently opposite that charcoal iron practice that was remarkable achievement that took place that ten-year period. Those who have actually ex- perienced charcoal iron and anthra- cite iron practice will readily see the force that word, “violently”; wonder the machinery broke down when the blast pressure was more than doubled and trebled passing from the gentlest and most easily combustible all blast fur- nace fuels the densest and the least known. Moreover, the an- thracite was used great lumps accordance with the false theory keeping the furnace “open” the use big “man-size” lumps ore, fuel, and limestone. Anthracite pig never did reach much economy reduction useless bulk ma- terials per ton pig iron. The anthracite blast furnace had passed out the picture before the gen- eral practice low ash coke was known, and before the advantages sizing the coke were discovered. The last the anthracite furnaces were the Lehigh Valley, where the furnacemen were dolomite limestone was the best flux, and they continued use excess bulk for their slag, thus in- creasing the bulk fuel and blast, and consequently demanding still more flux. The gradual decrease bulk raw materials and volume blast | 4 | vere led, rge ron ‘aw will further discussed later this paper, and will now turn the other natural blast furnace fuel, raw coal, sometimes “block coal.” Raw Coal Blast Furnaces interesting note that the first use Lake Superior iron ore Pennsylvania blast furnace was furnace Sharpsville, Mercer County, owned David and John Park Agnew, 1853, using 100 per cent raw bitum- inous coal for the fuel.* relative posi- tion vania and Ohio producers and piq iron. Per Cent Total Pig Iron Made United States The use raw coal blast fur- nace fuel depends upon such pe- culiar kind bituminous coal that there were only few places the whole country where there were any chances success. Mercer County Pennsylvania had such coal but the iron ores that region were such low grade that the industry did not prosper. least nine raw coal blast furnaces were built Mer- cer County between 1845 and 1850, but several them were aban- doned within years, hive coke .became the almost uni- versal blast furnace fuel that region, together with iron ores from the Lake Superior region. Ohio was different, and raw coal blast furnaces were built from 1845 1888 when the last raw *Progressive Rec- ord the Remarkable Industrial De- velopment of the Keystone State’’- las. Swank, coal furnace the Hocking Valley was erected, span only years. The building new anthra- cite furnaces began 1838 and ended 1886, span years, compared with span 267 years from the erection the first char- coal blast furnace this country 1645 (about) 1912, when the last one was built. Coke Furnaces Pennsylvania The use anthracite advanced much more rapidly than the use coke. 1849 there were an- > says that 1835 William Firm- stone, native England, suc- ceeded making good forge for one month the end blast the Mary Ann charcoal furnace Huntington County, using coke made from Broad Top coal. The pig was taken forge three miles distant and made into blooms. phant made quantity coke pig iron Fairchance, Fayette Coun- ty, 1837. There were four coke blast furnaces built the Great Western Iron Works Brady’s 2 Pennsylvania and Ohio + Pig Iron Produced ny Pennsylvania and Ohio thracite blast furnaces Pennsyl- vania and only coke furnaces, out total 298 blast furnaces the State. Almost exactly 100 years ago Farrandsville, Clinton County, extensive experiments were carried vain attempt smelt iron ores with coke. James Swank says his report Part the tenth United States Census—1880 was sunk Boston company the disastrous attempt smelt the neighboring iron ores with coke. The company began mining coal 1833 and the fur- nace was blown the summer 1837, and was run till probably 1839. About 3500 tons pig iron was made, but such cost, owing the impurity the coal and the distance the ore, further efforts make iron with coke were aban- the same census report Swank Cent Total Iron Ore Mined United State Bend, beginning 1840; but the coke blast furnaces were slow developing. late 1854, after anthracite blast furnaces had been built, there were only coke furnaces the whole country. his book, “The Manufacture Iron” (Philadelphia, 1854), Fred- erick Overman said, “But few blast furnaces work coke this coun- prospect addition the num- coke furnaces which now exist, shall devote but limited space this subject.” “The beginning the manufac- ture Connellsville coke dates commercially from the winter 1841 and 1842 when two beehive coke ovens were built the farm John Taylor the Youghio- gheny River few miles below Connellsville. The product these ovens was shipped Cincin- nati 1842 and sold with much THE IRON AGE, June 20, | \ | | | | | } 40 + + + + + + — at \ | X- | \> 1e d 4 (Progressive vania—Swank—1908.) spite the rapid advance mineral fuel blast furnaces, the building charcoal blast furnaces continued even greater rate than before, and the tonnage charcoal pig iron increased for years, and the peak year for char- coal pig iron production was not reached until 1890. that period revolutionary activity the iron industry this country, especially the 10-year period beginning with 1845, there were more blast furnaces built the United States than any other decade the history our coun- try. sure, they were very small blast furnaces. The records show the following: Blast Furnaces Built United Fuel Stacks Charcoal 223 Anthracite Raw coal ...... 15 2: hard find trustworthy statistics for pig iron production that time, but the late John Birkin- bine authority for the statement years 1841 and 1856, follows: Total pig iron made, 1845 Total pig iron made, 1854—724,833 gross tons and coking coals from points out- side the State, has surpassed Penn- sylvania for consecutive years. This question transportation the raw materials for blast fur- naces greater importance the railroads than understood the Interstate Commerce Commis- sion the railroad officials themselves, else greater atten- tion would have been given the possibility moving much larger tonnage iron ore rail than now being done. More- over, the raising freight rates iron ore and coke not conducive all-the-year-around movement iron ores the large volume States in the 10 Years 1845-1854 -490,000 gross tons that possible for the blast fur- naces Pennsylvania. Pennsylvania Blast Furnaces Year Charcoal Anthracite Coal Coke Total Total U.S. 1841 218 12 0 0 230 353 1856 143 93 6 21 263 580** Pennsylvania Pig Iron Production (Gross Tons) 1841 179,000 15,000 0 194,000 265,000 1856 96,154 306,972 8,417 39,953 451,496 788,515 Le sley, page 759, Part II, “The Iron This total 580 blast furnaces the United States recorded Guide the Furnaces, Forges and Rolling Mills the United States, with Discussion Iron Chemical Element,” 1859. Transportation our search for the answer the question whether Penn- sylvania can regain her leadership producing pig iron, have found that the possession iron ores and/or metallurgical coals within the borders State does not necessarily insure leadership producer pig iron these days by-product coke. Some- thing has happened these natural advantages, and evi- dently that something was con- nection with transportation, cause Ohio, hauling all her iron ore 20—THE IRON AGE, June 20, 1935 Earlier this article are shown the excessive tonnages ore, fuel and flux required make ton pig iron the mineral fuel fur- naces the middle the last cen- tury. Gradually the lower grade raw materials were eliminated the competition rich ores from the Lake Superior region and the Old Basin Connellsville coke; au- tomatically the amount stone decreased. But there came time when “the best apples the barrel were all gone,” and again the blast furnaces Pennsylvania were using low grade ores and high ash coke—and some them are still doing it. Considerable attention has been given the elimination much ash the coking coals pos- sible before shipment avoid paying freight useless impuri- ties. The same sort beneficia- tion now being applied the Lake Superior iron ores, which have been decreasing richness for many years. Pennsylvania has not progressed far Ohio the obtaining low-ash coking coals, else the coke consumption per ton pig iron would lower than now is. Conclusions preparing the data for this article many interesting statements and statistics relating the pig iron production Pennsylvania have been found. The one out- standing fact that can warn- ing the present generation furnace men was the excessive cost manufacture due the use low-grade raw materials. The fur- nace managers century ago were using two three tons iron ore per ton pig iron because that kind ore was convenient get; they used ton and half dolemite flux stone and thought not unusual; they used two tons more anthracite coal per ton pig iron and yet made profit their pig iron because for while they were all using the same waste- ful blast furnace practice. certain respects the blast fur- nace managers the by-product coke era have made great steps toward economical tice, especially the beneficiation their iron ores, coking coals and fluxes, but one most important item they are just thoughtless and wasteful their predecessors century ago. far the records go, one this country now beneficiating the most vol- uminous the raw materials used making ton pig iron, wit, the atmospheric air-blast. That eminent furnace man, the late James Gayley, was the only one practically beneficiate the air-blast, and only reduced the rather small percentage moisture pres- ent. have enriched our ore burden per cent iron, and have washed our coking coals per cent carbon our blast furnace coke, but are still using per cent oxygen air-blast. “history them been nuch pos- ivoid puri- ficia- . the the pig is. this pig out- cost fur- ago ause iste- fur- duct teps rac- tion and tant less sors the vol- ‘ials ron, late ast, ther res- den per lace per the mold prophecy,” then suc- ceeding generations will wonder that the blast furnace men 1935 used raw material containing per cent inert and wasteful ingredient that continuously car- ried heat from out the top the furnace. For many the metallurgists have dreamed the time when oxygen could sepa- rated from the atmospheric nitro- gen cost sufficiently low permit its use the iron and steel industry profitably. According article the May, 1935, Mining and Metallurgy, that time has now come. (“Low-cost Oxygen for Met- allurgical Operations,” Theo- dore Nagel.) Since will necessary for Pennsylvania look sources outside the State for iron ores, obvious that the Lake Superior ores will cost more delivered Pittsburgh than any Ohio fur- nace; the blast furnaces eastern Pennsylvania cannot afford use them all. Therefore, the ores must come from the magnetite mines northern New Jersey and New York, else from foreign mines; either case the rail haul cost less than the total freight Lake Superior ores the same Pennsylvania blast furnaces. Un- less the railroads Pennsylvania and New York State see that the freight rates coking coals and iron ores are conducive the continuance Pennsylva- nia’s blast furnaces, then most that voluminous iron ore, coke, stone and pig iron will ir- retrievably lost. Table shows conclusively that the leadership Pennsylvania and Ohio the production pig iron has not been dependent the ton- nage iron ore produced the respective States; the bulk the iron ores both States during the mineral fuel era has been transported from other States, especially the Lake Superior Re- gion. During the charcoal iron era both States smelted local ores almost exclusively. shows that, with an- nual capacity almost exactly per cent more than Ohio, the blast furnaces Pennsylvania have pro- duced less pig iron and ferroalloys than the furnaces Ohio for two the past three years, and also that time recent years have the Pennsylvania furnaces produced high rate their capacity have the Ohio fur- naces. TABLE IRON ORE PRODUCED PENNSYLVANIA, OHIO AND UNITED STATES SHOWING PERCENTAGES PRODUCED EACH STATE Compiled Ralph Sweetser from Pearse, James Swank, United States Census, United States Bureau Mines and American Iron and Steel Institute Pennsylvania Ohio United States Pennsylvania Ohio Gross Gross Gross Per Cent Per Cent Year Tons, Ore Tons, Ore Tons, Ore U.S. U.S. 1839 1850 140,610 1,56 0, 442 4 55.50 9.00 : 1860 288,977 2,396,485 56.50 12.06 1870 5,250,402 44.00 11.61 1880 1,951,495 488,750 7,489,464 26.00 6.51 1890 1,560,23 254,294 13,458,808 10.70 1.89 1900 61,066 27,553,161 3.18 0.22 1910 739,799 22,320 57,014,906 1.29 0.039 1913 489,056 61,980,437 0.79 1914 406,326 5,138 41,435 "36 0.98 0.012 1915 363,309 3,455 55,526,490 0.65 0.006 ie ae 1916 559,431 1,800 75,167,672 0.74 0.002 ee 1917 546,700 en 75,288,851 0.72 ee 1918 69,658,278 0.75 1919 627,167 60,965,418 1.03 1921 29,490, 978 0.49 1923 993,441 re 69,361,422 1.42 bs 1924 807,208 54,267,419 1.48 1925 955,955 ee 61,907,997 1.58 = 1926 1,095,505 67,623,000 1.65 1927 61,741,100 1.80 1928 1,023,870 ea 62,197,088 1.64 1929 1,092,013 73,027,720 1.49 1930 964,638 58,408,664 1.62 1931 31,131,502 1.18 1932 102,838 “ee 9,846,916 1.04 1933 264,366 aa 17,553,188 1.50 1934 24,587,617 2.13 TABLE PENNSYLVANIA’S LEADERSHIP THE MINERAL FUEL ERA BLAST FURNACES PIG IRON PRODUCED GROSS TONS PENNSYLVANIA, OHIO AND UNITED STATES, SHOWING PERCENTAGES PRODUCED EACH STATE Compiled Ralph Sweetser from Pearse, Lesley, James Swank, United States Census, United States Bureau Mines and American Iron and Steel Institute Pennsylvania Ohio Per Cent Per Cent Year Pennsylvania Ohio United States U.S 1839 239,000 79.50 1841 194,500 265,000 73.40 1847 389,350 800,000 48.67 1849 253,370 650,000 1856 $51,496 aes 788,515 57.25 1864 1,014,281 68.52 1872 1,251,336 356,913 2,548,713 49.11 1873 1,246,440 362,517 2,560,963 48.67 14.15 1875 857,932 371,333 42.39 18.34 1880 1,859,298 601,970 3,835,191 48.48 15.69 1885 2,183,478 494.647 4,044,526 54.00 12.23 1890 $,415,329 1,240,330 9 202,703 47.98 13.48 1895 1,463,789 49.76 15.49 1900 6,365,935 17.92 1905 10,579,127 4,586,110 $6.01 19.94 1910 11,272,323 5,752,112 27, 41.28 21.06 1915 12,790,668 6,912,962 24 "016. 213 42.75 23.11 1920 13,983,134 8,533,470 36,925,987 37.37 23.11 1925 12,523,485 36 33.57 24.15 1930 10,304,886 31,752, 32.13 21.56 193 5,233,22 18,426,35 28.05 22.95 1932 2,188,374 8,781,453 24.60 27.92 1933 3,892,637 13,345,602 28.68 30.14 *1934 4,409,342 16,138,573 27.32 .60 or *“Subject to revision,” American Iron and Steel Institute, May 6, °35. According report Committee Special Survey Capacity, American Iron and Steel Institute (page 20, 1931 issue Statistics), the annual capacity blast furnaces Pennsylvania, Ohio and United States, was follows Dec. 31, 1931: Pennsylvania (including 586,000 tons ferroalloys), 17,501,475 tons, 34.21 per cent Ohio (including 135,000 tons ferroalloys), 11,611,700 tons, 22.44 per cent. United States (including 802,400 tons ferroalloys), 51,740,175 tons, 100.00 per cent. THE IRON AGE, June 20, ‘> q 3 7 Finishing Plays Important Part Manufacture ice PRENTISS Cleveland Resident Editor, The Age METAL finishing plays important part the manufacture of- fice equipment the Addressograph-Multigraph Corpn., Cleveland. Following the trend to- ward modernistic design, mechani- cal equipment that comes under this classification and has become almost indispensable office work, has been changed contour, and plain straight lines have replaced the curves that predominated the models few years ago. 22—THE IRON AGE, June 20, 1935 ° line with these changes design, metal finishing has been given increasing amount attention. That attractive finishes are valu- able for their sales appeal this ognized, although office equipment built for service rather than looks. While there attempt produce striking decorative effects office equipment harmonious colors, six different metal finishes ARTS are given morocco better coating for work and much easier the smooth, amel The pieces are hung racks and baked the shown. 200 deq. tained until the paint crackles, pro- ducing the morocco- and then increased for baking. are used the company the manufacture office equipment. These are selected both for appear- ance and for Parts are finished three kinds paint and three plated coatings —nickel plating, oxidized finish and ‘admium plating. Machines are made the com- pany about 100 models, includ- ing addressing, duplicating and typesetting machines, and recent- developed machine designated the Multilith for offset lithograph ° ° work. The equipment ranges size from hand addressing ma- machines occupying floor space The main and larger members the machines, including the frame sections, which are cast iron, and few stampings, are given morocco crackle finish. This was adopted place enamel finish formerly used, was found more serviceable and also more economical, that much easier apply finish. The morocco finish tough that not easily marred scratched; moreover, the cast parts not require perfect- smooth surface necessary when glossy smooth enamel finish used. Consequently, little finish- ing work required the cast parts. While slight imperfections the surface are conspicuously shown when metal enameled without first being given perfect- smooth surface, these rough spots are not revealed when the part has the coating. From the standpoint economy the use the morocco finish has resulted great saving, be- cause only coating the finish required compared with many coats when the parts were finished enamel. The use the latter also necessitated other oper- ations such applying filler, sand- ing between coatings and also bak- ing after each coat. appearance the morocco finish presents pleasing effect and ma- chine coated, the opinion the company’s management, looks more attractive than when finished glossy enamel. The coatings are two standard colors, black and green. per cent the surface the machines are given metal parts for ce equipment in the plant the Multiaraph Parts that are spray- painted include PRAY-PAINTING tabs. which are very mall pieces sheet steel. These, 000, are inserted ots racks, each holding 1000 tabs for spraying and baking, these racks are loaded ing oven. One these trucks. loaded with racks tabs, truck they the bak this coating, the exceptions being shafts, screws and parts that are plated. The morocco coating, which Chinese oil base paint, sprayed on. Equipment the painting de- partment includes six spray booths and three baking ovens. Two ovens are electrically heated and have HILE office machines strictly utilitarian their appearance receiving increasing attention both the part manufacturers and users. The various fin- ishes used and the methods employed apply them the operations large manufacturer are described the author. automatic control. The third gas-fired oven. Finishing work castings be- fore painting limited grinding and filing off burrs. Stampings are cleaned before painting and the smaller ones are tumbled take off the rough edges. Because the tough finish permits parts machined after painting without danger being marred, fully per cent the work painted be- fore the machine operations. This results considerable saving, for. machining preceded spraying, would necessary after painting clean the paint out the holes and scrape off bosses and other machine finished surfaces. The parts, after spraying, are loaded racks and pushed into the baking ovens. oven tem- perature 200 deg. main- tained for min., the time re- quired crackle the paint. Then the temperature increased 400 deg., which the parts are baked for hr. Drawers which have smooth finish are given dip coat enamel and baked. Drums, which are die castings and also cast iron, are given outside nickel flash coating the plating depart- ment and then the painting department for spray coat aluminum paint the inside, both appearance—the aluminum paint harmonizing with the nickel finish—and rust preventive. Hand wheels about in. di- ameter made cast iron are polished and nickel-plated all over. Then cast iron mask placed over the outer rim and the re- mainder the wheel sprayed with morocco paint both sides. After baking the nickel-plated rim buffed. The plating department occupies room adjoining the painting de- partment, along one side which double row polishing and buffing machines, tumbling barrels and other finishing equipment. Pol- ishing done with emery abrasives compressed 14-in. diameter pat- ent leather polishing wheels. These have 4-in. faces except for work requiring narrower wheels. For the first polishing No. 120 grain abrasives are used and this fol- lowed the use No. 180 and then No. 320 grain abrasive. Parts nickel plated are cleaned electric cleaner and then given acid and cyanide dip. Then flash copper plate de- posited, 0.00075 in. thick, and the copper plating buffed and then electrically cleaned and rinsed water. After rinsing, the work goes nickel plating tank and = ven finish, to be for work the The Own, nain- th e pro- and ased \ As - 0.001-in. nickel coating deposited. Buffing follows bring out special colors desired. However, not much the work buffed. Satin Finish Used for Parts Direct Vision Operator satin finish has replaced bright nickel finish for some the larger plated parts, particularly top plates that come under the di- rect vision the machine operator, the satin finish being regarded preferable because does not pro- duce the bright glare the plain nickel finish. For polishing parts that are have the satin finish the regular polishing wheels with the section the plating department. Both wood and steel tank No. 320 abrasive for finish polish- ing are replaced Tampico brush wheel with which emery cake about 300 grain size used. Cleaning follows, after which the parts are given bright coat copper and then deposit about 0.001 in. nickel. After the nickel plating they are again put under the Tampico wheel, which gives them the satin finish. Some Parts Given Black Oxidized Finish Various shafts and other small parts are oxidized give them black finish. These are first cleaned el