The Iron Age 1935-06-27: Vol 135 Iss 26

CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET NEW YORK, Owned, Published and Copyrighted CHILTON COMPANY Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. C, A, MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC C. STEVENS, Vice-President JOSEPH 8S. HILDRETH, GEORGE H. GRIFFITHS, EVERIT B. TERHUNE, ERNEST C. HASTINGS, WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ J. FRANK, President J. H. VAN DEVENTER Managing Editor News Editor Machinery Editor Editor Emeritus Washington Chicago Cleveland JR. BURNHAM FINNEY GERARD FRAZAR MCINTOSH Pittsburgh Detroit Boston Cincinnati Contents June 27,1935 Skating Thin Ice Hot Strip Steel Rolled Steckel-Type Mill Role Metals the Railway Industry A.S.T.M. Investigates Hardness Testing Light Alloys Personals and Obituaries Rate Activity Capital Goods Statistics Metal-Working Activity Construction and Equipment Buying Products Advertised Index Advertisers BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau of Circulations ADVERTISING STAFF Member, Associated Business Papers Emerson Findley, 311 Union Cleveland B. L. Herman, 675 Delaware Ave.. Buffalo, Published every Thursday. Subscrip- H. K. Hottenstein. 802 Otis Bldg., Chicago tion Price: United States and Pes Peirce Lewis, 7310 Woodwatd Ave.. Detroit sessions, Mexico, Cuba, $6.00; Can- Charles Lundberg. Chilton B dg Chestnut & 56th Sts., Philadelphia, Pa. C. H. Ober, 239 W. 39th St.. New York B. Robinson, 428 Park Bldg... Pittsburgh C. Sweetser, 239 West 39th St.. New York Cable Address, ‘‘Ironage, N. Y." ’. Warren, P. 0. Box 81, Hartford, Conn. ada, $8.50, ineluding duty; Foreign $12.00 a year. Single copy, 25 cents. bor- that out ent in- nu- eet on. ing in- ‘ial 4 es 4 Complete Stocks All Kinds Sizes All the newer, finer alloys, the stainless and heat resisting steels are immediately available from Ryerson. You can sure the uniform quality, accuracy and finish that charac- terize all Ryerson products, and also Shipment meet any emergency requirements. For nearly century Ryerson has been meeting the steel requirements industry. Today ten complete plants with unequalled equipment and the latest metals are ready give you personal attention every order—in any territory. Draw the plant nearest you. you not have the current Ryerson Stock List, write and will glad send you copy. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Buffalo, Cleveland, Detroit, Boston, Philadelphia, Jersey City IRON AGE, June 27, 1935 Hot Rolled Alloys S.A.E. 2315, 2320, 2330, 2335, 2340, 2345, 2350, 3115, 3120, 3130, 3135, 3140, 3250, 4140, etc., etc. Rycase (hot rolled). Rytense A.A. (hot rolled) Cold Drawn Alloys S.A.E. 2315, 2320, 2330, 3115, 3120, 3135, etc. Heat Treated Alloys Ryco (hot rolled). Nikrome (hot rolled, cold drawn). Stainless and Heat Resisting Alloys Allegheny Metal (Sheets, Bars, Plates, Welding Rod, etc.). Cold Finished Steels Std. Shafting, Turned, Ground and Polished, Special Accuracy Stock, Rycase High Manganese Screw Stock, S.A.E. 1020, 1035, 1112, 1120, etc. Tool Steels Ryerson B.F.D. Die Steel. Ryerson. Steel. Speed Mill Treated Bars, etc. General Steel Products steel products, such Bars, Structurals, Plates, Sheets, Strip Steel, Welding Rod, Tubes, etc., are carried stock for immediate shipment. 4 4 py : : . # . & ff : — A = THE IRON AGE JUNE 27, 1935 ESTABLISHED Vol. 135, No. Skating Thin Ice you remember the real old-fashioned winters that had when you were boy? And how the fellows looked forward the first freeze that they could get out their skates and indulge the risky pastime skim- ming over the ice? you kept going fast enough, you might get without ducking; although the thin ice would bend and form wave front your feet. Few would care repeat this experience today, for are older and know something about the risk involved and then too, have recollections, perhaps, playmates who broke through the fragile surface and were drowned the dark, chilly waters. Congress seems skating upon thin ice today, judging its actions. Apparently many its members are endeavoring glide over area where the constitutional footing attenuated that speed action all that keeps them from through. young, careless and full the joy better life, they play follow the forgetting altogether the sad demise their little playmate, NIRA, who broke through the ice just recently and whom diligent application Administrative pulmotors failed revive. the risk wandering from the firm grounds constitutionality were con- fined the venturesome souls Congress and the Administration who care for this pastime, none could complain and many would rejoice. Unfor- tunately, however, they insist making the entire population follow suit, that all stand get ducking, worse. Senator Wagner seems particu- larly without fear consequences the public, who are asked play snap- the-whip under the leadership his Social Security Act and his Labor Bill. Undoubtedly this rash pair will sooner later crash through the thin ice which they are skating and join NIRA the cold waters oblivion, but until they they promise give both capital and labor many chill and many spill. 4 ~ 7 4 af 2335, 3130, 3120, cold Bars, els curacy ganese 1035, icts ites, ‘ied HOT strip steel now being rolled com- mercial basis sin- gle-stand reversing mill the Steckel type. Small steel companies for the first time thus are enabled produce their own hot strip steel economically, using this type mill, which has out- that continuous strip mill and initial cost approximately one- sixth that continuous mill. The mill expected widely used foreign countries where tonnage requirements are limited and hence huge initial investments are not justified. One the new mills capable rolling strip in. wide has been put into operation the McLouth Steel Corpn., Detroit, and another production the Indiana Harbor, Ind., works the Youngs- town Sheet Tube Co. third mill, for rolling material in. wide, has recently been completed the plant Dominion Foundries Steel, Ltd., Hamilton, Ont. This mill rolls directly from slab ingot into strip without reheating. Other position install this type mill the future have made licensing agreements with the Cold Metal IRON AGE, June 27, 1935 Furnace » Hot Steel Rolled Process Co., Youngstown, Ohio, which possesses exclusive patents covering mills Steckel design. Licensees include the Weirton Steel Co., Great Lakes Steel Corpn., Fol- lansbee Brothers Co., Continental Can Co., Allegheny Steel Co. and Inland Steel Co., addition the steel companies already mentioned. The raw steel rolled into strip this single-stand reversing hot mill may slab ingot slab fairly heavy plate, de- pending the plant facilities available. some instances, espe- cially where high production sought, universal plate mill placed ahead the hot strip mill. The slab first rolled the uni- versal mill thickness about in. and then, without being reheated, passed the strip mill, which rolls the desired gage. claimed that the com- bination the universal mill and the strip mill results production approximately one-half the ton- nage secured modern continu- ous hot strip mill. Rolling procedure the single- stand hot strip mill special interest. The slab heated slab-heating furnace the usual manner, being ejected from the furnace the approach table front the mill. passes through edging stand control the width the finished material. this point scale removed from the slab means high-pressure water sprays. The slab then moves the mill, which, for the first strip steel now being rolled commer- cially single-stand revers- ing mill the Steckel type. Economy initial investment and operating costs claimed for the new mill, which enables small steel companies produce their few passes, operated the same fashion reversing plate mill. The edging rolls, too, are employed for several passes. either side the mill, placed sufficiently above the center line the table that the slab may move freely underneath, coiling fur- nace which coiling reels are lo- After the strip has been re- LE: Pinch Rolls J — — — € Reversing Coiling Furnace in. passed into one the fur- naces, the end the strip being diverted into deflecting apron. During the flat passes, the apron lowered that the steel passes over it, but without making contact. Aprons are located own hot strip steel. article describes the manu- facture strip this proc- ess and enumerates the ad- vantages claimed for it. detailed account the installation the McLouth Steel Corpn. plant, Detroit, given. either side the mill below the coiling furnaces. the entrance each furnace roller around which the strip passes coils the coiling reel. Because the strip bent angle greater than right angle, the secondary scale removed the bending operation. After most the strip has been wound the coiling reel, the end passes entirely through the mill, stopping under the pinch rolls nearest the fur- nace which the steel has been coiled. The mill then reversed, with the pinch roll serving the necessary power introduce the strip into the mill stand. The de- flecting apron the opposite side the mill raised divert the end the strip into the other coil- ing chamber. This back-and-forth operation repeated until the strip has been reduced the de- sired gage. After the final gage has been reached the strip moves the runout table and either cut length coiled the un- loading coiler. The coiling furnaces which the reels rotate are maintained temperature 1400 1700 deg. during the rolling passes order maintain the strip the proper heat. The heating medium may gas oil. The mill driven d.c. variable-speed motor. sepa- rate drive provided for the pinch rolls and reels. Control main- tained means the Ward-Leon- ard system. Hot strip steel rolled the sin- gle-stand reversing mill claimed have smooth edge free from checks cracks because the edges the strip are the hottest portion the roiled material. This free- dom from detects particularly desirable when the strip cold rolled into sheets tin automobile wheels other parts are spun formed from it. the strip during the rolling process the temperature most desirable considering the quality the ma- terial being rolled and the metal- lurgical results required. Consid- erable leeway possible with respect maximum and minimum temperatures. likewise pos- siole vary the number drafts. Since uniform temperature can maintained, strip rolled accu- rately gage and with minimum center crown (difference thickness between the center the strip and the edges). Considerable quantities hot strip are reported have been rolled this type mill which there was center crown about 0.00i in. material in. wide with finished thick- ness 0.109 in. the rolling low-carbon steel desirable produce large coils. The new mill capable rolling coils weighing 300 lb. per in. width. For example, steel company now contemplating instal- THE IRON AGE, June 27, | e lation one the new mills figuring rolling 54-in. strip coils weighing 16,000 lb. this particular case the limiting factor the size the ingot produced. The operating cost single- stand reversing hot strip mill claimed exceptionally low be- cause the long life the rolls and consequently the small roll cost. Power cost also economical oil-fired con- tinuous slab heats for hot roliing tons slabs per long and wide. placed rails front pusher head crane and are pushed through furnace oil hydraulic pusher having stroke 4!/2 ft. The pusher has slow forward stroke with much faster re- turn stroke facili- tate slabs charging hearth. 14—THE IRON AGE, June 27, 1935 because “stand-by losses” are re- stand mill having only one motor. mill capable rolling strip building 300 ft. The small space required cuts down the in- vestment land and buildings. Fixed charges are kept relatively low, too, the fact that produc- tion single-stand mill line * with consuming requirements and can operated relatively higher average rate than larger mills. Roll changes can made less than one hour, since only one pair rolls used. addition rolling strip, this mill suitable for rolling univer- sal plate and skelp. slabs slab ingots may employed the raw material. the pres- versing mill has periphery speed 430 935 ft. per min. Rolls are in. ameter body and in. face. Roll necks, anti-friction ings. The mill driven 2100 hp. variable speed 230 500 ° ° ° RIGHT ing vertical edging one the coiling back- Mill actuated hp., tor dependent, inclosed reducing drive. Rolls twin screws, the pass opening being shown dial the top the BELOW FTER has duced thickness passed into coiling furnace con- taining coiling reels. Because the strip bent greater than right secondary scale removed the bending oper- ation. ent time low-carbon and high-car- bon steel, stainless steel, high-sili- con steel, Monel metal, nickel, cop- per and brass have been rolled, either commercially experimen- tally, this type mill. estimated that the single- stand mill will roll tons per ft. width per hr. No. gage material. This would equiva- lent tons per hr. when rolling 36-in. strip. When the mill used mill, similar the installation the Indiana Harbor plant the Youngstown Sheet Tube Co., the capacity raised 12% tons per ft. width per hr., 25,000 30,000 tons per month 36-in. strip. Equipment the McLouth Steel Corpn. comprised two stands edging rolls and two-high, 20- in. reversing mill. The pinch rolls, fact, are integral part the roller table that the first roll the heating furnace end forms the lower roll the pinch rolls. They are carried housings attached the table beams. The table rollers are in. diameter, in. long and spaced 4-ft. centers. They are driven through bevel gearing 35-hp., 600-r.p.m. motor, oper- ating speed 875 ft. per min. The vertical edging mill actu- ated 100-hp., 475-r.p.m. motor through independent, completely inclosed reducing drive. The rolls have pass diameter 12% in. and are turned with necks in. diameter and in. long for mount- ing bronze bushings. They are power-adjusted twin screws, the pass opening being shown large dial the top the mill. The maximum the pass opening 16% in., the minimum in. pinch roll attachment incorpo- rated the table control the vertical alinement the strip the edging pass. THE IRON AGE, June 27, coiling has pair pinch rolls and three bending rolls, each in. diameter, and two coiling rolls in. diameter. connection with the machine framework with seven quide rollers which swings out from the coil means air cylinder allow coiled strip in. diameter and in. wide removed. The runout table ft. long. The slab moves from the edging Roll necks, which are in. di- mill stand pinch rolls the ameter, operate duplex type equipped with two pairs 12-in. diameter rolls in. long. The upper rolls are raised and lowered and the driving pres- sure between each the rolls maintained system air cyl- inders. set trip rollers, which part the mechanism, auto- matically reverses the direction rotation the pinch rolls and the table. Pinch rolls are driven through combination reduction gear set and pinion stand 35- hp. motor. The lower pinch rolls and table rollers are driven through flexible coupling the floating shaft type. One upper roll coupling spindle, the second upper roll through sprocket and chain from the first upper roll. the opposite side the mill sec- ond stand pinch rolls similar the one described. Equipped with rolls 21% in. and in. the face, the two- high reversing mill has periphery speed 430 935 ft. per min. IRON AGE, June 27, 1935 bearings. The bottom roll driven through machined splined spindle and coupling boxes. The upper roll, balanced counterweights lo- cated beneath the housings, actu- ated through universal coupling spindle. The spindles are connect- through stand mill pinions and gear reduction 2100-hp. variable-speed motor running 230 500 r.p.m. Speeds the motors operating the reels the coiling furnace are synchronized with those the 2100-hp. motor driving the two- high reversing mill. They are au- tomatically adjusted compensate for the increasing diameter the coil the winding reel and for the decreasing diameter the coil the unwinding reel. Operation smooth that there ten- dency for the strip buckle under unusual tension during the rolling process. Reels, pinch rolls, and front and back mill tables re- verse with the mill motor. Speeds pinch rolls and front and back tables correspond that the mill motor. The runout table from the mill the coiling machine about ft. long. It, and also the mill ap- proach table, has rollers in. diameter and in. long, actuated ft. per min. Side guides are ad- justable hand means screws and chain, the maximum d | Se equipment for the mill housed small separate room. ndle pper lo- ling 1ect- ions ting are the width being in. and the mini- mum in. The coiling machine has pair pinch rolls and three bending rolls, each in. di- ameter, and two coiling rolls in. diameter. All the rolls are in. long. The lower pinch roll and the two lower bending rolls are adjustable hand-operated worm, worm wheel and screw. connection with the coiling machine framework with seven guide rollers which swings out from the coil means air cylinder allow coiled strip in. diameter and in. wide removed. Side guides with long rollers are mounted heavy base which spans the two roll housings. The pinch, bending and coiling reels are driven speed motor. The driving gear shafts, driven rolls and all guide rolls are equipped with roller bear- ings. The coiling machine de- signed and powered handle wider strip case any changes might desired the future. oil-fired continuous slab heat- ing furnace heats for hot rolling tons slabs per hour from cold state 2200 deg. Slabs width and from ft. length. The furnace ft. long and ft. wide. Slabs heated are placed rails front the pusher head magnet crane and are pushed through the fur- nace means oil hydraulic pusher having stroke ft. This provides space for loading four more slabs front the pusher. The pusher propelled forward two cylinders tied together insure uniform movement means pinions mounted common shaft the pusher carriage and engaging stationary racks located the charging platform. This ar- rangement insures uniform move- ment the two ends the pusher head. The pusher has rather slow forward stroke with much faster return stroke facilitate placing slabs the charging hearth. The control valve located the discharge end enable the op- erator the discharging mechan- ism advance slabs through the furnace. Slabs are pushed out through side discharge door manually controlled pusher bar actuated hydraulic double pinch roller located the door. The rollers this device are elec- trically operated and controlled means controller within con- venient reach the operator the pusher bar. The furnace arranged for fir- ing with oil means low-pres- sure oil burners, all which are desirable flame condition and tends yield uniform heating condi- tion throughout the furnace. the design this furnace every effort was made insure soft, uniform heat throughout the slab, contrast with the usual method sharp heating process with are pushed out the slab heating furnace through side discharge door manually controlled pusher bar actuated hydraulic double pinch roller located the door. Rollers this device are electrically operated and controlled means within convenient reach the operator the pusher bar. placed across the front the fur- nace. The burners are divided into two separately and automatically controlled zones. The air for com- bustion purposes supplied motor-driven blower which takes the supply air from over roof the furnace and under insulated cover preheated. This firing arrangement provides relatively high temperature gradi- ent. The furnace temperature automatically controlled means control instruments operating conjunction with automatic valves fuel supply lines. With this ar- rangement the fuel changed, small increments and (CONTINUED PAGE 78) THE IRON AGE, June 27, the olls, eeds 4 a ¥ Sas reg THE railroad Amer- ica’s oldest large indus- try. way contrast, the automobile industry still largely dominated the same man who helped create it. When that man started there was already well-established science materials. When the railroads started there were neither suitable materials nor definite knowledge such did exist. The railroads created both. Perhaps few high- lights the history railway de- velopment will best illustrate its technical heritage. The first rails consisted iron bands, spiked timbers which were laid partly the ground. Next came cast iron flats about in. wide and ft. long. These weighed some and herein may lie the origin the custom gaging rails many pounds per yard. These flats were laid stones the earth. The cross-tie was not used owing the very practical consideration towing the train home horse. The first profiled rail rolled America came out 1844. was inverted 1846 the T-rail followed, and this the progenitor our rail section today. These rails weighed some Ib. per yard and were about ft. long. Steel rails did not appear until 1865. The 4-ft. 8%-in. track gage did not become standardized the United States until 1886. that time varied from ft. some Southern roads ft. the Erie. However, not all difficulties were confined the rails. The first mooted question about locomotives concerned traction. tists insisted that rail friction was enough; the engine ought geared the track. While the earlier development steam engines stood the railroads good stead, there was still lack suitable material well technique for handling that which was available. One early boiler had fire flues made old gun barrels. The safety valve often consisted mere wooden plug driven home with bung-starter. When blew out, often did grades, passengers joined the train crew “hunting the plug.” The idea spare plug never seemed have found favor. metal meant IRON AGE, June 27, 1935 The Role Metals wrought iron—was sparingly used possible. All structures, they cars bridges, were made wood. The first iron bridges were built the late while all- metal coaches were not introduced until 1907—some years after. Long before the came concerned with the proper use proper materials, they were confronted with shop problem. Standardization track gage meant interchange rolling equipment. also meant that cars must made serviceable shops, not necessarily the home line. This one factor has had much with the shaping railway equipment standards. still has, and rightfully so. Railway engineers are not un- sympathetic progress; they simply dare not defy the many in- hibiting factors peculiar rail- road operation. all well and good upset convention, but when doing the result leads na- tion-wide confusion the accom- plishment doubtful worth. With this mind, becomes understandable how materials malleable, cast steel and structural shapes can persist metals. They are universally avail- able and they require special technique application would the heat-treatable alloys. must further understand that until very recently the rail- road management has been abso- lutely indifferent weight ex- cesses, long equipment has complied with its ideas main- tenance, safety and_ serviceable life. this respect, railroad en- gineers have built even better than they knew. Over per cent available locomotives today are over years old. Coaches built for useful life years are still running after 25. The sup- posedly obsolete wooden passenger cars have not yet been fully re- tired, and were not for wrecks freight equipment would seeming- last forever. Just what price has been charge- able continued operation the obsolete and the excessively heavy will never known. only know that conditions have changed. The business offered itable, regardless the plant en- gaged it. Unfortunately, while business quickly adapts itself changed conditions, the railroads have created for themselves, had imposed upon them, large and unwieldy structure finance, or- ganization and equipment. change here will slow and de- liberate, but will come, for the railroad fundamentally still the ideal carrier goods and people. Ever since transportation came commercial venture, the basis revenue well cost operation has always been fig- ured weight. The carrier nat- urally only gets paid for the weight the cargo offered for shipment. pays, however, for the movement both cargo and vehicle. his interest then maintain reasonable relation between the weights each. Just how far our railroads have departed from this sound premise has been the subject matter many surveys and reports—most them dated since 1929. true, however, that freight rev- enue still calculated the basis weight, but how? There are over 5000 different freight classi- fications and few the distinctions bear any relation cost ser- vice. But, even under the most ideal conditions find, for in- stance, that one ton mile train movement required for every one ton mile coal hauled. The proportion for other classifications even less favorable. f the Railway Industry senger service, the preponderance dous. However, passengers pay the head and not the pound, is, ‘perhaps, only fair figure train weight per person. This varies from two ten ton miles for every passenger mile. The passenger pays here the East that service. the same tonnage used accommodate him were of- fered freight, the tariff would many times greater. Obviously something has got roads. They have got re- the basis carry- ing goods rather than encumbered the methods doing business. The traffic must analyzed for simplification movement and for the type equipment best suited make that movement. Much old rolling stock still economically usable. New equipment should considered, first, for those services where the old obviously unsuited, and second, where new business may attracted. Only very few railroads America make money passenger business, and here that beginning has been made. Light-weight trains make for reduced operating cost, the one hand, while speed with its concomitant streamlining are attract new business. But, above all, weight reduction the order the day. Weight reduction, however, does not fit into the railroad man’s picture safety and endurance. The feel- ing that “weight strength” too long standing readily argued away. Past failures have been too often corrected use more metal inspire confidence any reduction. These seemingly irreconcilable desires reduced weight and even better endur- ance, have been finally adjusted through introduction what may call “light-weight construc- tion.” Light-weight construction may defined more efficient use mgre efficient material. for instance, may represent fairly poor use mild steel, especially when compared highly bridge girder where: this same material uni- materials combi- nation with new are bringing about profound changes railroad equip- ment. appraisal the problems involved the use new materials and the possibilities such applications offer for the future was made the author address, reproduced here substantially full, before the American Society for Metals New York, May 24. Ragsdale's views are particular interest be- cause speaks with the authority one who has played leading part developing the streamlined stainless steel passenger train. formly stressed its working limit. Substituting high-tensile steel having three the strength into the I-beam may in- crease the strength that beam but built instead into the girder, this may then conceiv- ably six times strong the spirit light-weight construction. One well built girder same weight material does the conventional section, but re- places six them. Aviation knows this relation “strength-weight ratio.” Chief Engineer, Railway Division, Budd Mfg. Co., Philadelphia Interpreted into building, this works out about follows. The roof and floor are indispens- able members, anyhow, why not use them top and bottom chords beam? All that required organize the equally neces- sary side walls into shear mem- bers. Contrasting this the con- ventional railway coach which built heavy center and side sills with the walls below the win- dows acting support. The being insufficiently attached against horizontal shear, merely acts separate stiffening mem- ber, but does not become in- tegral part the structure whole. other words, the mild steel constituting the car structure has not been used best advan- tage. Having decided upon utilization material, the next step involves selection that ma- terial. This more difficult. Two metals automatically suggest themselves; the aluminum alloys and Both balance out any strength- weight comparison. With weight ratio approximately three one, ultimate strength, yield point and modulus elasticity show ratio one three. Further- more the cost per pound also about the same, namely about 35c. Decision between these two dis- similar types metals will rest upon conditions other than those structural equivalents. Methods design, endurance, shop prac- tice and even prejudice will de- termining. More aggravating the ques- tion whether not either these materials can econom- ically justified. There are cases where other material serves the purpose, and then again, there are where use these alloys simply wasteful procedure. THE IRON AGE, June 27, ° ° ° ° ° 4 e e = | | between lies border zone highly debatable application. This zone being narrowed from the bottom new series low al- loy steels and from the top cheaper applications aluminum and stainless. The price differen- tial between 5c. for the former and 35c. for the latter would seem make decision obvious, but such are the newly recognized econom- ics weight that base prices may become very fallacious indicator. Just here, might well state that this paper, which en- titled the “Role ap- pears deal more with economic considerations than with the char- acteristics metals. But, after all the true role materials any sort the serving eco- purpose. brought metals into prominence the first place, and now revision our economic viewpoint results the introduction newer ma- terials. nomic With the premise granted that rolling equipment must lighter and yet unreduced either en- durance factor safety, both new design and superior ma- terials are automatically indicated. The cost and extent the light- ening will balanced against ex- pected savings operation. The arithmetic really quite simple, which accounts, perhaps for the numerous and, often, dis- cordant answers obtained. Less simple but far more defi- nite the structural analysis. proceeds the basis that pas- senger coach, for instance, made body; one-third appointments, and one-third trucks. Reduc- tion appointment weight per- mits reduction body structure, and this, turn, permits still further structural reduction. The eventual weights body and ap- pointments determine loading and hence also its weight. weight reduction, well, how- ever, bear mind that can just vicious taken re- verse. Every pound added structure adds just much structural requirement. How Passenger Train Weights Can Pyramided interesting example how weights can pyramided of- fered study the Burlington Zephyr. 20—THE IRON AGE, June 27, 1935 electric train built stainless steel, originally weighed 208,000 lb. Actually the amount stain- less involved was only 46,000 would scarcely seem less valuable metal could sig- nificant and, yet, had this train been built low alloy steel, its final weight would have been 320,- 000 increase over per cent. Considering that the low alloyed steels have about half the strength properties cold-rolled stainless and none its tance, about two pounds one would required replace one pound the other. The first in- crement then 46,000 This the load and accordingly involves some 24,000 more metal ment. Both items reflect them- selves increased truck weight 15,000 lb. and now the re- lation between train weight and available power has become dis- turbed that the original 600-hp. engine longer suffices. re- quires instead 900-hp. engine which brings the total train weight from original 208,000 lb. 320,000 lb. other words, for each pound added the load, there has been another pound and half picked the car structure, the trucks and the power plant. The worst all is, however, not that the train weighs more. but that economy attempted through use cheaper material has resulted actual extrava- gance. The cost the stainless steel built into the Zephyr was $20,000. (It would less today.) That the low alloy steel offered its place would have been $5,800. This apparent saving $14,200 immediately offset $31,000 increase the cost the power plant. So, use cheaper metal shows already net loss $15,- 800. Add this $4,000 year in- creased operating expense and will found that the experiment substituting low-priced steel for the much more expensive stain- less has tied capital invest- ment nearly $100,000. But, strong the impression created high metal cost, and little appreciated are the econ- omics rolling weight, that one readily balks the first and swal- lows the second. the whole cost the stainless steel the Zephyr amounted only per cent the total train cost. Far more significant would seem the fact that the three Zephyr-type trains now service the Burlington road are show- ing earning capacity equal about per cent return the original investment. These trains will pay for themselves years. Why worry then about the relatively small item for the metal which has contributed largely the successful operation and the attractiveness the train? the above analysis, the de- termining factors have been: fairly high power cost, high per- formance, factor safety keeping with greater speeds, very low cost operation and, above all capacity attract pub- lic favor. The cumulative effect these not only justifies use the best available materials, almost regard- less cost, but makes such seem- ingly inevitable. Less favorable, for instance, the situation with reference freight cars. While these contribute very much larger proportion railway move- ment than passenger cars, and while they particularly invite re- duction weight, there are other considerations limit the cost which this can accomplished. the first place, freight car rarely remains the home line. When off it, the home line receives flat rental one dollar day. When requiring repair, the home line billed for such. There is, consequence, little incentive reduce cost haulage the ex- pense higher first cost, but there great incentive toward lowered liability damage. Freight cars are, after all, chiefly (CONTINUED PAGE 80) ay > a¢ SS = 2 S 4 J etal 1ent ain- est- and Investigates Hardness MEETING Detroit, members the American Society Testing Materials are deliberating some technical papers and over reports from various committees. Not only are many the tentative standards being broadened, but number the technical reports cover original investigations particular inter- est the ferrous and non-ferrous industries. Two papers are de- voted aluminum alloys, namely, the correct method determining hardness values and the creep characteristics various tempera- tures. There test used more fre- quently laboratories than the hardness test, one type an- other. The hardness tests most widely used this country are the Rockwell, scleroscope and Brinell, and the success attained apply- ing these hardness tests ferrous metal products has quite naturally suggested similar uses the non- ferrous fields. However, fields the metals softer, with the result that certain modifications the test conditions must made satisfactory re- sults are These changes test procedure usually involve lower loads the pene- trators, larger penetrators, both, the case the Rockwell and Brinell tests; and larger strik- ing face radius the hammer (lower contact pressure) the case the scleroscope. These more obvious differences condi- tions make quite difficult com- pare values ferrous and non- ferrous metals when using the prevailing standard methods. the application these hard- ness tests the light alloys the non-ferrous metals, still other dif- ficulties have been encountered that make comparisons hardness values for products quite unsatisfactory. some specific instances, however, the hardness tests can and are very useful controlling the uni- formity certain operations ap- plied some the light-metal products. These specific instances were reviewed considerable plin the Aluminum Co. America, paper entitled The Hardness Testing Light Metals and Alloys. The first phase hardness test- ing light alloys discussed Mr. Templin was the application the test. stated that the Brinell hardness light non-fer- rous metals defined the ratio given load (in kilograms), applied hard metal ball given size for given time, the spherical area (in meters) the recovered impres- sion made the test specimen. The basic conditions generally rec- ognized for the test require the use 500-kg. load 10-mm. diameter steel ball for sec. Both analysis and experiment have dem- onstrated that departures from this load and ball size can made with quite satisfactory results the load used maintained equal five times the square the diam- eter the ball used. commer- Table Values Obtained Wrought Aluminum Alloys With and Surface Condition eshly machined original oxide coating 0.0002-in. oxide coating oxide coating Material freshly machined original oxide coating oxide coating oxide coating Without Oxide Coatings All Specimens Thick Brinell Hardness Rockwell Hardness * Scleroscope Vickers Hardness Load, Load, Ball Ball Load 35.4 34.5 35.1 38.6 36.4 40.2 as 36.8 44.3 $9.2 S6.0 s9.0 $1.1 87.3 $1.2 97.2 91.0 104.8 *"“E” scale—100-kg. major load, ‘%-in. ball (red or “B” scale) “S” scale 60-kg. major load, ball (red scale) Hardness, Magnifier Load Scale Seale Hammer 38.3 38.7 79 14 39.7 t So 14 40.9 92.8 109 90.3 109 92.0 109 109 THE IRON AGE, June 27, one the Ors em ree w- the ins wo tal le- cial testing balls from 1/16 9/16 in. diameter are used. Etched Hultgren balls are some- times used brightly finished products assist reading im- pression diameters. Little any attention given the question ball lubrication testing light Table Brinell Hard- ness Values and Rockwell and Scale Values for Wrought Aluminum Alloy Rockwell Hardness Brinell 14 —30 15 — 20 on 25 40 30 11 33 22 34 25 Hx 35 28 38 77 41 13 42 $5 8 3 47 45 51 85 46 52 47 54 48 56 ga 53 63 +4 55 65 5 »6 66 96 Ss 68 a8 58 69 60 7e aa 100 100 63 73 70 79 75 82 80 85 100 105 110 115 120 106 Based 500-kg. load, 10-mm. ball sec. 100-kg. major lead, in. ball (red “B” scale). Scale—60-kg. major load, in. ball (red scale metals. differences that can ascribed lubrication are indicated results obtained with etched Hultgren balls (dry) and polished steel balls lubricated with heavy colloidal graphite grease. For Brinell hardness tests made using the 500-kg. load, 10-mm. ball combination, the depths impres- sions will vary from 0.0313 in. for Brinell value 20, 0.0063 in. for value 100. The depths the impressions made other sizes balls under the proper loads will directly proportional the di- ameters the balls. The Society’s standard methods Brinell hardness testing me- tallic materials 27) state that the thickness the specimen should not less than ten times the depth the Brinell impression, and according Moore the depth impression should not exceed one-seventh the thickness the specimen comparable values are expected. The less conservative these limitations would mean minimum thickness specimen 0.219 in. when its Brinell value 20, minimum thickness 0.042 in. when its Brinell value 100. change the Brinell value about 24, for annealed commercial- pure wrought aluminum, found when using the 500-kg. load, 10-mm. ball specimens somewhat less than 1/16 in. are tested. Again, this set test conditions can used without change hardness values, the harder alloys having Brinell values around 100, the specimens are not less than 1/32 in. would appear, therefore, that for satisfactory results the case the wrought aluminum alloys, the thickness Brinell specimens for the softer alloys needs but little, any, more than twice the depth impression, and for the harder alloys not more than five times the depth impression. Distortion Permissible static indentation hardness tests light metals, differences results are noticeable when either hard soft steel an- vils specimen supports are used, provided the specimens are suit- able thickness, previously indi- cated. When soft anvils other metals are used effects can ob- served, but since such supports are not ordinarily used considered commercial testing they will not discussed further herein. Another rule, which appears the standard methods for Brinell hardness tests metals, states that when the side the specimen opposite the impression shows dis- tortion caused the impression, the results are questionable. the case light metals, however, considerable distortion can occur before there any appreciable ef- fect the hardness tained. The hardness values ob- tained tests light metals may be, and often are, appreciably af- fected the surface conditions the specimens used. Many the light-metal products, such com- mon alloy sheet, bar and extruded shapes, have smooth, bright sur- faces which require additional Table Composition and Heat Treatment Aluminum Alloys Used Determine Creep Characteristics High Temperatures Solution Aging Treatment Chemical Composition, Per Cent Mag- Man- Deg. Time, Deg. Time, Alloy Silicon nesium Nickel ganese Hr. Hr. No. 3.90 0.21 1.60 2.22 950 375 No. 1-A°* 3.91 0.35 0.13 1.68 2.22 ‘ 950 5 375 5 No. 9.64 1.08 0.22 0.23 925 375 No. 3' 1.18 0.26 4.61 0.58 980 16 440 $ No. 0.78 12.64 0.96 0.91 0.02 No, 6¢,4 2.96 0.53 13.18 1.04 3.08 ‘ No. 1.06 0.62 0.21 0.47 2.12 0.01 No. 0.37 0.19 5.96 1.49 1.00 None quenched cold water conclusion solution treatment. alloys. Wrought alloys. Alloys supplied heat-treated condition. reported. Method heat treatment was not 22—THE IRON AGE, June 27, 1935 4 for treatment order make them suitable for hardness tests. Most the sand castings and rough forgings, Table Rates Aluminum Alloys for however, require additional surface Total Dura- Secondary but preparation. For routine commer- Extension Creep the Temp., ing Period, Test, Cent per done filing, scraping, Alloy Deg. In. per In. Hr. Remarks grinding. some instances fur 0.000083 313 0.00 ther finishing may done us- 100 0.000124 312 0.01 ing fine emery cloth followed 400 10,000 0.000206 503 0.02 buffing. The alloys that are heat 12,500 532 0.05 ‘eated have oxide coatings whic treated have oxide coatings which 17,500 0.000735 460 0.12 are somewhat thicker than those 20.000 0.001726 460 0.29 the cold-worked 22,500 0.004078 293 Bar failed, 300 hr. an- and some the products have com- 1,300 0.000273 145 0.00 indi- obtain better corrosion resistance 600 5,000 0.017813 251 ther paint adherence, both. No. 1-A.. 15,000 0.000875 556 0.11 ob- the case such products dif- 100 20,000 0.010090 532 are ficult obtain satisfactory hard- 600 2,500 0.002688 317 0.69 are tested without removing the No. 5,000 0.000322 511 0.01 > > > > > depen ing upon the 0.010905 in. per in. nell load-penetrator combination used. 20,000 0.012269 Bar failed, 28.5 hr. ates Removal the coating involves 600 1,300 0.000644 383 0.12 ate: 90 411710 ».43 600 250 0.0033 312 99 dis led. 3,400 0.019899 175 riations hardness two mate- 5,000 0.0740 In rials with different amounts of N Dr ile 100 5.000 0.000413 503 0.05 ver, oxide coating are shown Table 7,500 0.000570 579 0.07 cur may noted that the greater 10,000 0.000908 0.12 ef- variations occur when using the oo 0.006705 o10 loads. The type Brinell impres- 1,900 0.001205 312 0.25 ob- sion obtained anodically coated 600 2,500 0.004640 310 1.38 aluminum shown the enlarged 5,400 0.020691 af- photograph in Fig. 3; The radial N $ sou 2 500 0.000355 50a 0,04 5 ) ) 789 535 ical 400 7,000 0.001164 484 0.14 the ical. {O00 10,000 0.004368 510 making the Brinell test 600 1,300 0.000654 308 HOO 900 00 98 308 ur- obtained from two diameter mea- 600 0.015852 Bar failed, hr. nal surements the impression taken 0.000520 0.06 deg. apart. some instances, 100 7,500 0.000829 578 0.09 0.008339 in. per in. obtained which are appreciably out 600 1.300 0.000768 169 0.21 shape. The distortions observed 600 2,500 0.016071 266 practice may amount much 7,500 0.000553 574 0.07 ‘ as 15 per cent in the Brinell and 400 10,000 0.001445 TRS 0.14 5 00 0.016109 576 Vickers values, yet such materials ne, will exhibit but slight differences 600 1.900 0.003013 316 0.87 their tensile properties the 600 2,500 0.017090 340 various directions. No. 400 2.500 0.000256 523 0.03 any deductions concerning 400 5,000 0.000603 576 0.09 400 12,500 0.005260 557 rials, based the hardness tests, 1.300 0.001469 308 0.40 are likely quite misleading 600 1,900 0.004029 311 1.17 quantitatively. 600 2,500 0.025405 311 The errors involved making No. 2,500 0.001132 600 0.15 5.000 0.00303 527 0.42 sible testing machine load error 600 1.300 0.003104 313 0.86 per cent, error di- 1,900 0.007803 311 2.09 ameter which usually negligible 600 per cent, diameter impression THE IRON AGE, June 27, 1935—23 2 ¢ 4 : Par lp. Wee 7 « « 4 fa v ¥ a > 4 - - ~ > ‘ ~ \. - « measurement Which usually with- per cent and routine com- photograph Brinell impression made anodi- cally minum The radial the coating are quite typical for this material. light metals include major load mercial use, error resulting from ball with hardness values deter- hasty manipulation the test that hand-operated machines. Thus these errors, which are often ad- ditive, may total much per cent, but the average will per cent mined the red the dial (designated the Rockwell “E” scale hardness); and major load the same scale (designated the Rockwell “S” scale hardness). The within about per cent. latter these scales not recog- only fair point out, however, nized the Testing Society’s ten- that comparisons Brinell hard- tative methods Rockwell hard- ness results from different commer- cial laboratories, using the same test specimens, have shown ences much per cent. When using the smaller ball and load combinations for the test, necessary use com- pound filar microscope for measur- ing diameters impressions. Such microscope should permit estima- larged view ression obtained mm. Under these conditions the certain aluminum making Brinell hardness deter- Such minations rather slow and ex- distortion may pensive, with considerable much the Brinell and The Rockwell test may defined Vickers values, yet essentially the difference material will ex- depth between initial indenta- but slight dif- tion caused primary load (10 properties the kg.) and final indentation result- ing from larger secondary major load, while the penetrator held the final indentation primary load. commercial pr: tice quite variety loads penetrators are used. Those erally recognized for use testi tunity for errors manipulation. 24—THE IRON AGE, June 27, 1935 ness testing metallic materials comparison the hardness values obtained light metals using these two sets test conditions with the standard Brinell test given Table The relationships may expressed the following equations: 3570 2460 nnd BLHLN, Where B.H.N. Brinell hardness, the Rockwell hardness the “E” seale, and the Rockwell hardness the scale. From what has been pointed out discussing the Brinell test con- cerning limitations specimen thickness and depth impression, and the load-ball size conditions the Rockwell “E” and “S” scales, may seen that these two Rock- well hardness cover about the same range thickness for light-metal products which may satisfactorily tested with the different Brinell ball sizes, 1/16 diameter and larger. The Rockwell test more readily carried out than either the Brinell Vickers and probably involves less personal equation. attempt- ing use the test the commer- cial inspection light metals, however, difficulties have been encountered. These in- ‘rials mate these the Ss Is ships wing 1e€ss, the well out con- men ‘ion, 1ess hat sted lily nell ves als, in- clude troubles calibration and maintenance machines, errone- ous insufficient designation hardness values recorded, reading wrong scale dial, and use wrong load penetrator ma- chines equipped for various combi- nations these. mistake fre- quently made attempting test thin specimens superimpose number thin specimens. This leads erratic results. Near the lower ends the Rockwell hard- ness scales suitable for use light metals, quite large variations can obtained values, which have relatively little significance the tensile properties are used index the quality product. Near the upper ends the scales the opposite true. the case the use the smaller Brin- ell balls, for satisfactory results the Rockwell test will generally re- quire more careful surface prepa- ration the specimens than when using the larger balls the test. Vickers Test the Vickers test the penetrator used square diamond pyramid having total included angle 136 deg. The values for hardness are obtained dividing the load (in kilograms) the surface area the impression (in square milli- meters). Throughout the range loads generally used the hardness values are constant, which offers distinct advantage over the and Rockwell tests, and the loads can varied suit both the hard- ness and thickness mens without change penetrator. When using the smaller loads, from use the more accurate filar mi- croscope, the case the “baby” Brinell test. The limitations regarding speci- somewhat less severe for the Vick- ers than for the Brinell test and, therefore, cause little trouble tests light metals. practice the Vickers test can made about the same time required for the Brinell test. The impres- sions obtained are easier meas- ure because their square shape, the diagonals only being measured. Distorted impressions, however, oc- cur the Brinell test. the whole, the errors the Vickers test are probably somewhat less than the Brinell test. the Shore scleroscope hard- ness