The Iron Age 1935-10-24: Vol 136 Iss 17

CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET NEW YORK, Owned, Published and Copyrighted CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and Sts., Philadelphia, Pa. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ FRANK, President VAN DEVENTER Editor Managing News Editor Machinery Editor Editor Emeritus Washington Chicago Cleveland Pittsburgh Detroit Boston Cincinnati Buying Security, Who Pays for Freight Containers Here and Tomorrow's Machine Tools Are With Today.......... Late Returns from Laboratory and Mill............... Resistance Process Applied Welding Tubes......... Thermit Fells Century Progress Skyride Tower......... Gear Makers Hold Semi-Annual Construction and Equipment Buying.................. BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau Circulations ADVERTISING Emerson Findley, 311 Union Bidg., Cleveland an. Member, Associated Business Papers Published every Thursday. Hottenstein, Otis Bidg., Chicago tion Price: United States and Pos- Peirce Lewis, 1310 Woodward Ave., Detroit Mexico, Cuba, $6.00; Can- Landberg, Chilton Bidg., Chestnut sessions, $12.00 year. Single copy, cents. Robinson, 428 Park Pittsburgh Sweetser, 239 West 39th New York Cable Address, ‘‘Ironage, Warren, Box Hartford, Conn. 4 | | | | : ae | | ‘ > { BETHLEHEM STEEL PLATE ITEMS SIX TIMES LONGER SERVICE RECORD NEW PLATES Abrasive-Resisting Plate Use Reveals Economy and Good Fabricating Qualities Cylindrical rotating screens for washing gravel are used buyer Bethlehem Abrasive-Resisting Steel Plate. More than year ago the com- pany decided apply the Bethle- hem Abrasive-Resisting Plate this service. “The screens lasted twelve months times long the screens used formerly, made ordinary steel,” this user reported. “During this time they were handling about 1500 cu. yds. hard quartzite each hours.” The fabricating quality well the economy Bethlehem Abrasive- Resisting Plate illustrated its use these screens. Each screen in. diameter and ft. long, made plates perforated with in. drilled holes. RESISTS WEAR Stone crusher, containing screens made Bethlehem Abrasive-Resisting Plate. The ap- plication similar that the gravel screens described above, which Bethlehem Abrasive- Resisting Plate lasted six times long ordinary plate, the user said. Bethlehem Abrasive-Resisting Steel Plate now being used road-build- ing equipment, the brick and other ceramic industries and the handling coal, coke, gravel and many other abrasive materials. Its low cost and ability take simple forming opera- tions make this Bethlehem Plate the logical choice for applications exposed abrasive wear. HEADS BETHLEHEM SHOP STYLES FLANGED HEAD Flanged and Dished Head Dished Only Head Standard Flanged and Head Flanged Only Head Flanged Head Flange Flanged and Dished Head Reversed Dished Head Dished Cover Head wide variety types and sizes Flanged only, Dished only Flanged and Dished Heads produced modern equipment the Bethlehem Flange Shop. The location the shop, next door our plate mill, and near open-hearths and even blast furnaces, enables Bethlehem quickly fill the largest orders. LARGE HEAD ORDERS SHIPPED PROMPTLY Flange Shop Geared for Quick Service The location the Bethlehem Flanging Shop, with plate mills and open-hearth furnaces, even blast fur- naces, right hand, enables Beth- lehem quickly fill the largest orders. Even when the necessary steel plates have rolled, not un- common for Bethlehem complete and ship orders substantial size for flanged and dished heads within from hours after the orders are placed. Elliptical Dished Head Flanged Head Toed Out Flange Flanged Only Head Shallow Type —Flanged and Dished Head Tank Car Head | q | | | | | | | | q | 4 q » fi 5 — | IRON AGE, October 24, 1935 OCTOBER 24, 1935 ESTABLISHED 1855 Vol. 136, No. Buying Security, Who Pays for What? Uncle Sam conducts competition with private business en- terprise, his customers usually pay well for what they buy. Take the case the Social Security Act. has the commendable purpose providing pensions workers the age through six per cent tax all payrolls and also limited unemployment insurance additional three per cent tax. One-third this paid the worker through automatic deductions from his wages. The other two- thirds tax paid the employer but eventually it—out pay envelopes. Ostensibly, the pays two-thirds the insurance bill. But does he? The tax paid the boss, remember, not tax profits. Like the AAA processing taxes, direct addition cost production. increases the labor cost all production exactly six per axiomatic that the buyer product pays the entire cost production. makes difference what the cost items include. The consumer pays the labor bill, large small, well the cost raw materials, supervision, power and all the other items. Even the mem- bers our are not naive enough hold different belief. Thus the consumer must pay the bill, imposed this pay roll tax, just the consumer paying the bill, through increased food prices, for the AAA processing taxes. And since over per cent the consumers our country depend directly marriage upon pay envelopes, obvious that the wage earner will contribute much more than his direct per cent check-off for what gets the way security. Leaving aside the question who pays the bill, what does Uncle Sam give for the money received? Take the case worker years age earning $1800 year. The cost his insurance, per cent, will $162 year. case unemployment, can draw $15 week for ten weeks. age 65, will entitled pension $61.25 per month for the rest his life until $2520 has been refunded his estate. this same premium were paid regularly any one our first class insurance compa- nies, cash values accruing would provide the insured, after five years, with $15 week for weeks; after years with $15 week for 232 weeks. the age would eligible for pension $83 month for life until $12,058 had been refunded his estate. When Uncle Sam competes with private initiative, offers his customers bargains. 4 3 - q 5 4 4 “ & 3 THE wizardry mod- ern scientific control thermal operations the contemporary iron steel plant has, without doubt, banished many an_ method producing and main- taining essential heat metal- lurgical furnaces. Man’s amazing progress this respect may best appreciated brief glance backward over the span sev- eral centuries. Thus, for example, the heating industrial furnaces means wood and charcoal Agricola’s period has long since been supplanted applied com- bustion liquid and gaseous fuels through the use burners more modern design and construction, thereby attaining temperatures and efficiencies impos- sible. result these tendencies, the engineer today depends more than ever the accuracy well reliability the numer- ous technological tests, from which may able select the specific type fuel best suited his par- ticular purpose. The importance and value similar information were therefore clearly demon- strated the practical utilization data pertaining fundamental properties fuel oils and some extent also those modern lub- ricants. Unfortunately, desirable infor- mation respect some these properties has not been very widely disseminated the engineering 20—THE IRON AGE, October 24, 1935 cometer. The the right. means this instrument, the viscosity any oil expressed the for air bubble rise the oil definite distance. profession, for which reason wise application many impor- tant characteristics liquid fuels not all comprehensive. This particularly true reference the technical supervision steel plants and ferrous foundries, where until recently single test —the determination gravity— seemed indicative the qual- ity lack quality particu- lar shipment fuel oil. The conventional practice grading fuel oils gravity slowly being abandoned favor more elaborate laboratory tests. Chemical and especially physical characteristics fuel oils are con- stantly being stressed most specifications issued iron steel manufacturers. Accurate laboratory tests are required order determine gravity, chem- ical analysis, calorific value, ash, basic sediment and water, flash and fire points, pouring properties low temperatures, color and vis- cosity. While all these items play role the future burner effi- ciency and should, for this reason, taken into consideration the metallurgist and fuel engineer, there rarely plant the United States which determines all these properties with every tank received fuel oil. order illustrate the subsequent explan- ation for this apparent lack con- trol several series tests made with oils varying origin are presented Table When scrutinizing the data this table, once apparent that the chemical composition fuel oils varies within relatively narrow limits. That is, light heavy fuel oils disclose almost identical concentrations carbon, hydrogen, nitrogen and oxygen, but differ their sulphur con- tents. The variations calorific values are also small, their range being from about 18,500 19,450 B.t.u. per lb. the remaining characteristics, specific gravity index also flash and fire points. The relationship between the sev- eral expressions gravity and the calorific values fuel oils has been amply described the United States Bureau Standards, for which reason discussion may omitted this article. Routine inspections fuel oils may consequently made least two principal directions, namely regard gravity and with refer- ence viscosity. Gravity easily hydrometers else accordance with analytical methods. The con- temporary procedures for testing viscosity vary many industrial countries the world. Accord- ingly, the Saybolt test used the United States, the Barbey test France, the Engler test Cen- tral Europe, the Redwood test Great Britain, the Lamansky-Nobel test Russia, etc. Saybolt Test Questioned For many years, the majority American oil producers and conse- r= ) | | | 4 4 aig ae ] | | | | | | | | | | | | | i i | | | quently the entire steel industry have accepted the Saybolt Univer- sal Saybolt Furol Viscosimeter their standard method test- ing the viscosity fuel oils. The American Society for Testing Materials has incorporated this test its standard No. D88-33, the American Petroleum Institute standardized its No. 518-33 and the American Standards Asso- ciation finally adopted 11.2- numerous oil technologists, metal- lurgists and chemists agree the speed the Saybolt test. This particularly true when testing oils higher temperatures. Success- ful performance metallurgical furnaces fired with oil hinges directly the kinematic proper- ties the fuel elevated tem- peratures. Standardization arbitrarily selected temperatures which test oil for its viscosity does not give any clue its behavior known that fuel oils used generally for industrial heating may meet exactly some specified viscosity one the standardized tempera- tures and yet they may have radi- different properties below above that temperature. the contrary, complete viscosity curves which include the actual temper- atures which the oil reaches the furnace burner may serve in- dices its resistance future atomization vaporization respec- tively. The usefulness viscosity curves grading fuel oils was, the past, markedly curtailed the noted when plotting such diagrams from standardized temperature-viscosity measurements. This fact may plain the scarcity similar curves either the technical press reports managements indus- Metallurgical Fuel trial plants. order enhance the general reliability viscosity data and particularly viscosity curves, some comments are offered the following paragraphs the most modern procedures for test- ing this important property fuel oils. The conventional Saybolt test based the exact measurement time consumed definite amount oil (60 pass through accurately dimensioned orifice the bottom small container. The hydraulically sim- ple phenomenon steady dis- charge liquid matter through opening, accompanied con- version the pressure head into ACH steel mills con- sume enormous amount fuel oil their furnaces. The quality these oil shipments estimated finding the specific gravities, although gravity determinations are generally known give inaccurate picture the suitability oils for metal- lurgical purposes. The author herein points out that accurate check the vis- cosity would more valu- able, and describes the Steiner test, which shown quicker and simpler operation and also more ac- curate than the better known Saybolt test for viscosity. The Steiner test gives vis- cosity one temperature: moreover, complete tem- perature-viscosity curve can quickly obtained even unskilled workers. ° ° ° JOHN HRUSKA Metallurgical Engineer, Berwyn, Ill. velocity head within the orifice, becomes considerably obscured numerous influences: precision testing becomes inevitable in- troduce corrective factors with reference temperature differ- ences, cooling heating effects the point discharge, contraction various temperatures, friction, factors connection with existing and recently developed methods testing viscosity seems indicate quite clearly that something like reversal the principle Say- bolt, Redwood, Engler and similar tests should advocated. With this mind, Steiner Czecho- slovakia developed new viscosim- eter whereby viscosity expressed the number seconds required for air bubble rise through very small (about one-twelfth the amount needed the Saybolt test) sample oil investi- gated. Since temperature tests are easily made heating cool- ing the entire apparatus, all neces- sary determinations for complete temperature-viscosity curve may made within half hour—with far greater accuracy than any the standardized methods. Steiner Test Described Probably the principal part the new Steiner viscometer thoroughly calibrated glass tube, both ends which are ground in- side and may closed tightly fitting glass stoppers. mounted into the apparatus, this tube sur- rounded glass cylinder. The space between the tube and the cylinder filled with 220 gm. glycerine, which amount fluid suffices maintain uniform tem- perature the tested fuel oi] in- side the measuring tube. space above the glycerine left for thermal expansion when mak- ing high temperature tests. This THE IRON AGE, October 24, or’. 4 it ¥ r Table Technological Properties Fuel Oils Used the Iron and Steel Industry Calorific Chemical Composition Flash Fire Value Grade Specific Gravity Per Cent Point Point 0.986 83.4 2.3 0.1 298 315 18,600 United ........... 0.912 85.2 1.6 1.6 19,150 0.960 84.4 11.0 2.9 0.7 226 261 18,820 0.984 86.1 11.9 0.8 301 322 18,540 space obviously represents vacuum. Both ends tube and cylinder are held together duraluminum blocks and rods. For convenient handling the blocks are topped with material. The Steiner viscosimeter made two types, one being labora- tory model whereas the other intended for the sales engineer and strictly portable. These two types are shown Fig. Both types are held cardan joint order insure perfectly verti- cal position the tube when carry- ing out the determination. For laboratory use, the cardan joint securely fastened cast iron base. mentioned above, the actual Steiner test consists measuring the time consumed during the rise air bubble the tested oil. For that purpose, one the plugs tightened and the sample poured from the opposite direction into the tube using small funnel. The tube filled about in. the top. The other glass plug then inserted and the instrument turned permit slow rise the air bubble through the sample oil. The time travel between the marks and “2” determined means stop watch decimal fractions second. The moment passing the marks noted scrupulously observing the upper meniscus the air bubble. The distance travel 100 mm. 15/16 in.). case testing very dark fuel oils, the writer applies electric light back the viscosimeter, which makes the readings more convenient and precise. Tempera- 22—THE IRON AGE, October 24, 1935 ture readings the precision thermometer (attached the measuring tube) are taken before and after the test, and the averages both are recorded together with the Steiner seconds. This pro- cedure enables the operator also determine directly the kinematic viscosity centistokes, which unit was adopted and recommended physically definable one the Table Viscosity Tests Various Tempera- tures Conducted with No. Fuel Oil Means the Steiner Viscometer Average Outside Temperature Equalled 76.4 Deg. Average Temperature Observed Viscosity Steiner Deg. Seconds Centistokes 171.6 4.8 160.9 5.1 150.0 5.6 5.8 140.9 6.0 137.8 6.3 134.6 6.9 131.4 7.2 129.3 8.0 128.0 8.3 126.1 8.6 123.7 9.1 122.1 9.5 120.7 10.2 118.0 10.8 115.6 11.3 112.6 12.4 111.0 13.0 109.3 13.6 107.8 14.1 105.1 15.9 103.4 102.9 17.4 101.2 18.4 100.2 18.8 99.9 19.2 98.4 20.3 103 95.6 26.0 132 90.0 29.1 148 85.3 36.5 185 78.3 50.5 256 1933 World’s Petroleum Congress London, However, conversion tables and diagrams are furnished with the viscosimeter that viscosity may readily reported Saybolt Redwood seconds Engler de- grees. Viscosity tests may made means the standard instru- ment from 210 deg., but there exist instruments the same principle for tests outside this range. The total length the standard apparatus 12% in.—excluding the stand—and the weight the viscosimeter without the stand and without the sample oil, but with the glycerine filling, and order illustrate complete set viscosity determinations, the author has tested three grades industrial fuel oils, conforming Nos. and gravity ranges. About fifty individual determina- tions were made with each the three samples. Excerpts from the complete set values for the No. oil are shown Table This oil very dark brown, has gravity deg. Bé., flash point 300 deg. F., 320 deg. fire point, calorific value 18,650 B.t.u. per and viscosity 100 deg. the Universal Saybolt test 525 seconds. discussion the observed values offered the following paragraphs. Viscosity Curves Criteria for Uniformity According technical defi- viscosity curves are dia- grammatic representations nu- merical viscosity values various temperatures. Their accuracy de- } 7 pe i} 7 ce 4 | | | | | | | i | i | i pends therefore the analytical dexterity the testing engineer, the devices employed for the de- terminations. From the latter viewpoint, the new viscosimeter should distinct step toward greater precision applied vis- cosimetry. With just little care conducting the individual tests, the results check within 0.5 per cent even less divergency. This brings viscosity curves plotted the following formula for viscosity curves: where the kinematic viscosity centistokes, the absolute temperature deg. C., and are constants, and constant, approximately equal 0.8. While the above expression has been the outcome speculative endeavor, actual measurements viscosities various temperatures have confirmed the correctness latter diagram, thereby confirm- ing the above statement. Very pure fuel oils and mineral oils general approach straight lines when plotted loglog field. Mixtures two more oils well impure oils disclose in- variably loglog viscosity curves somewhat curved. Dilution light hydrocarbons produces vis- cosity curves, which are precisely parallel those the undiluted oil. This means that the per- ity Centistokes Kinematic Temperature Oil, deg. 110 130 Kinematic Viscosity Centistokes Viscosity Steiner Seconds 100 Viscosity Steiner Seconds Temperature Oil,deg.C. 130 150 Temperature Oil,deg. ABOVE 1G. 3—The experimental curves Fig. have been replotted here loglog field. These straight lines validate theoretical viscosity formula. 150 Temperature LEFT 2—Actual viscosity curves for Nos. and fuel oils, which oils are generally used for firing the metallurgical furnaces leading steel plants. These curves are obtained from measurements with Steiner viscometer. the new method such degree reliability that they may serve actual criteria for the uniform- ity fuel oils and other viscous fluids, basis specifications for the most important branches metallurgical and machinery in- dustries. Reliable viscosity curves have also added considerably the theoretical aspect the relation- ship between viscosity numerals and temperatures. his fundamental research work oils mineral origin, Steiner developed Steiner’s deductions. Thus, geometrical transformation ordi- nary coordinates viscosity dia- grams into loglog field should give theoretically straight lines ideal viscosity curves. what extent this true for fuel oils may best comprehended from com- parison the three test series conducted the writer. The ordi- nary viscosity curves for the three oils reproduced Fig. have been replotted the loglog field shown Fig. Practically straight lines may noted this centual dilution may directly ascertained from comparison viscosity curves the original oil with that the diluted oil con- taining definite experi- mentally added) amount the dilu- ant. obvious that the viscosity curves diluted oils are always lower than that undiluted oil the same grade. detailed dis- cussion the practical effects lower viscosity upon burner effici- ency metallurgical furnaces outside the scope this paper. (CONTINUED PAGE 92) THE IRON AGE, October 24, 1935—23 500 Rustless steel freight container introduced the United States. MOTOR TRUCK com- petition causing the railroads creasing attention demountable containers for trans- fer from freight car highway vehicle. The containers make possible give door-to-door ser- vice smaller shipments and the same time retain the major part the haul. Various types containers use this country were described THE IRON AGE Dec. 1934, page 45. These containers were made carbon steel and were adapted handling skids. demonstrate the use stain- less steel for light-weight contain- ers the Rustless Iron Corpn. America, Baltimore, recently built container unit RR-11 rustless steel, metal containing upward per cent chromium and from 0.05 0.07 per cent carbon. The container par- ticularly for its saving weight compared with units built conventional materials. has total weight 1300 which 1105 represents the alloy steel used and 195 lb. wood floor. The dimensions are follows: Outside overall—7 ft. in. wide, ft. in. long, ft. in. high. Inside ft. in. wide, ft. in. long, ft. in. high. Opening opposite ends—6 ft. in. wide, ft. in. high. 24—THE IRON AGE, October 24, 1935 Double door each end. Volume capacity—428% cu. ft. Load capacity—9000 Ib. The container fabricated from corrugated sheets and channels electrically spot welded into panels. The panels are assembled into the body continuous are welding the NTEREST freight con- tainers for transfer from freight car highway ve- hicle growing motor truck competition with the railroads becomes more in- tense. The latest container developed this country stainless steel unit brought edges, joining the channels inside and outside. The calculated fiber stress 40,000 lb. for load. The loading capacity the floor 160 lb. per sq. ft., providing for accumulative spring load which will developed transit while going over crossings and switches container, timber lined, with fluted sides and ends, used London Midland Load capacity, tons. Scottish Railway. =. | a * | | } | | | | } Containers out the Rustless Corpn. Europe and Great Britain, the use freight containers much more widespread this country. brief resumé British experience with containers given here. and when hauling truck when the container resting legs loaded condition. The side panels per sq. ft., this load the side panel being equal inertia force container load accelerated retarded ft. per sec. Progress the use demount- Locomotive crane transferring freight container from freight car platform wagon. able freight containers has been more rapid abroad than this country. Although the use stain- less steel has not been reported foreign countries, duralumin has been employed for the construction containers Germany and France. most countries, how- ever, the materials commonly used Another container use Great Britain. are carbon steel wood. Great Britain the transfer containers from car road vehicle chiefly crane. The number stations equipped with stationary cranes comparatively large and other points mobile cranes are frequently The use automobile cranes the United Kingdom facili- tated the fact that the rails are cunk flush most freight stations, permitting easy movement high- way vehicles across the tracks. the Continent, containers are more commonly equipped with swivel wheels castors, sometimes with arrangements for suppressing the wheel gear when loaded freight cars, are moved rollers. Containers have come into most general use the British Isles, where they were introduced before the war. The British railrouds now have close 10,000 containers operation. first the containers were built entirely wood, but later all-steel construction was adopted with view increasing strength, resistance shock and durability. One reason for the wide vogue containers Britain that the four large railroad companies have operated door-to-door and motor transport services for consider- able period. The container reduces total transportation costs because the railroads themselves handle the PAGE 90) THE IRON AGE, October 24, BX 566 a proud the fact that always have been some way associated with the machine tool industry, has family over period more than 100 years, lay claim prophetic powers—being neither the seventh son seventh son nor crystal gazer. has been said someone that the discussion his- tory fairly safe pastime, also indulgence prophecy—provided that the first case the historian delves far enough into the past sure that one else knows the real facts, and the second case that project himself far into the future that neither nor any his audience will earth when and the prophecies mate- rialize. this paper going deal with matters which are close us— practical matters which practical builders and practical users machine tools are vitally interested. Basing years close observation the machine tool building and using industries, and time and its economic tides which affect the metalworking in- dustries, say emphatically and with firm conviction: “Gentlemen— tomorrow’s machine tools are with today!” When make this statement re- fer the machine tools exhibited the Machine Tool Show 1935, and “tomorrow” mean period about five years come—which will the working life many the high production machines they are pushed their productive limit, many them are destined tobe. now are stepping over imaginary line between period economic depression and intense 26—THE IRON AGE, October 24, 1935 ° ° ° GUY HUBBARD Engineer, Cone Automatic Machine Co. technical stimulation, into what hope and expect will period intensive production during which engineering brains will, for con- siderable period, switched from the problems inventing improved machine tools the problems manufacturing these improved ma- chines large numbers and tool- ing them meet the needs rising tide users who already have begun demand this service uncertain way. Machines Have Power and Speed Meet Future Demands What does all this mean the prospective purchasers machine tools? means that they can buy the new machines which have been demonstrated the Cleveland Show with reasonable assurance that they are not untried experiments, that they will not outmoded next year even within their fair economic life, and that they have built into them such reserve power and speed and rigidity that the cutting tools tomorrow—even though they hard diamonds and toughness now unknown—can made perform capably them. other words, these machines are capable being retooled meet conditions cutting tools and prod- ucts far beyond anything with which now have contend. What does all this mean ma- chine tool builders? means that after five the most difficult, ex- pensive and brain-wearying years through which the industry ever has passed there hand economic and engineering “breathing spell” during which—through revived ac- tivity machine tool building and machine tool sales—this basic in- dustry about reap least some the reward which richly deserves. Changes Will Affect Tools and Accessories Not that there will further progress machine tool design— not that there will progress manufacturing technique within the next five years. There will be, but destined affect tools, attach- ments and accessories more than the “foundation machine tools,” may coin phrase. Nor are engineers going thrown out work. Rather, there will not enough good ones available and the field the available good ones who have weathered the depression with undimmed powers will broadened greatly into the realms produc- tion engineering, and service and sales engineering. The machine tools tomorrow are not going themselves—at least not for while yet—and they most certainly are going the most difficult machines build quantities any the industrial history the world. see visions, they cer- tainly are not engineers any others the machine tool industry taking their breathing spell lying down. will simply read- justment activities within the in- dustry. Machine Tool Industry Become One Its Own Good Customers Tomorrow’s machine tools may here today, but not all sure that the machine tool plant to- morrow with yet. any rate, not common. While may unkind bring the old adage the effect that “Shoemaker’s chil- dren often barefoot,” fact that when the machine tools to- | | i EQN ~ | S \ | H | | | | i { i i | | i | | | morrow are demanded large num- bers machine tool builder will have tool room large enough permit their continued manufac- ture therein. Machine tools are go- ing manufactured shops where the equipment and shop prac- tice are wholly different from what they were the 1920-1930 decade. The finest the equipment which machine tool builders now are of- fering other industries will have applied the machine tool industry itself. Gaging and measur- ing systems which formerly were confined the inner sanctum the tool experimental room must come forth into the big shop. The big shop may even have air- conditioned, not simply promote the comfort and efficiency the workmen (as already the case some fine plants), but that finer degree necessary maintain the constant accuracy gages and measuring instruments working limits better expressed multiples millionths the inch than subdivisions thousandths. Thema- chine tool plant tomorrow really will huge mechanical labora- tory the equipping which every builder fine machines going play part. other words, the machine tool industry must one its own good cus- tomers—and that very soon. Building Master Tools Still Require Skilled Workmen Regardless the quality the manufacturing equipment with which machine tool builders provide themselves, the master tools in- dustry will continue “built” rather than “manufactured,” be- cause into these “machines which build machines” there has built something the accuracy, the skill and even the intelligence the engineers and artisans who con- ceive and create them. With auto- Are With Today matic operation, automatic gaging and self-adjustment production tools common such features now are, the possibility that the ma- chine tools tomorrow can built successfully unskilled workmen culiar fact that the more the ma- chine tool industry does make possible the use relatively un- skilled workmen other industries, the greater becomes the need for very highly skilled men within the machine tool industry itself. There can but one answer—the machine tools tomorrow are destined very soon built the apprentices today. behooves the machine tool industry, therefore, immediate- revive and thoroughly over- haul its apprenticeship system meet what coming, and make the industry attractive enough trained men that they will not drift out it. Machine Tool Plant Expansion Unlikely Speaking plants, many ma- chine tool builders were caught overexpansion the close the war and upon the collapse the 1929 boom that will some time before there much activity plant building this industry. Rather, business expands, re- markable things will done ex- isting plants push the pro- duction the machine tools tomorrow the floor space now available. The use new machine tools machine tool plants will help very materially faster and more compact. The use more and better materials handling and storage equipment play important part. Beyond this, however, see the widening use parts and sub-assemblies made outside specialists tak- ing major load off the builders the machine tools tomorrow, still HERE will further progress machine tool design and manufacturing technique within the next five years, but destined affect tools, attachments, and accessories more than will the machine states Mr. Hubbard this paper, which was pre- sented session the Machine Tool Congress, held Sept. |7, under the direction the Cleveland Engineering Society. After five the most difficult years that the machine tool industry has ever known there hand economic and engineering breathing spell through re- vived activity machine tool building and sales. further postponing the day plant expansion. Not only will bearings superlative grade furnished outside specialists, but the same will true far more than the moment coolant and lubricating systems; feed works, both mechan- ical and hydraulic; mechanical, hy- draulic controls; chucks and collets; and even such major elements spindles, gears and gear sets, and main frames— particularly the latter fabri- cated welding. Breathing Spell Tooling-Up Granted that now will have “breathing spell” machine tool design, equally certain that will not have breathing spell the realm the tooling-up the machine tools tomorrow. One the greatest lessons the Machine Tool Show 1935 that there are today least three effective but very different ways the com- mon run machining operations. there one best way job, the advocates the other methods certainly are not going admit until they have exhausted their last bit skill and ingenuity making theirs the one best method through improved tooling the machine tools tomorrow, which—as pre- viously have stressed—have been designed handle effectively tools and work way beyond those the moment. This “battle methods” (CONTINUED PAGE 81) THE IRON AGE, October 24, \ q 4 4 3 - 4 bed 4 r q - — OR. parts are pickled prior calorizing, and this type lead- lined wooden pickle tank used. unique feature the heating equipment which employs gas burners firing directly into lead pipe coils submerged the acid bath. ALORIZING, well known, process whereby aluminum driven into the surface another metal, usually mild steel, form aluminum al- loy. This alloy, where mild steel the base metal, practically im- temperature 1650 deg. for continuous work and 1800 deg. for intermittent work. Cal- orized steel will also withstand many corrosive elements such high-sulphur and combustion prod- ucts and oil, and demand for oil still tubes, air heater tubes, gas burners, annealing pots, carburiz- ing pots, pyrometer tubes, bolts and nuts and many miscellaneous items. Recent research has materially 28—THE IRON AGE, October 24, 1935 improved the process calorizing. Flaking the coat eliminated, this new process produces very tough, iron-aluminum alloy, harder than the toughest tool steel. fact, effective this new calor- izing process that thin steel may completely converted iron- aluminum alloy, desired, though surface conversion depth 0.030 in. 0.060 in. has been found very effective for most installa- tions. The Calorizing Co., Wilkinsburg, Pa., has large plant for process- ing all kinds work, chiefly pipe, tubes and fittings. For pipe the new process follows: (1) The pipe and calorizing mix- ture are sealed steel retorts Calorizing mproved NEALEY American Gas Association diameter with wall thickness in. The retort then charged into gas-fired furnace, where revolved while being heated temperatures 1500 deg. 1800 deg. (2) The pipe then removed and cleaned tank boiling water heated with gas burners. (3) resealed retort and reheated another gas-fired fur- nace. (4) finally straightened, sized and ground the ends. There are five calorizing fur- naces brick and steel construc- tion, with the roof arches sec- tions that they can removed crane and hoist for loading and unloading. These furnaces are | | 1 | » | | | | ft. square cross-section and they are made sections that each furnace may built any desired length. Each section ft. long and built steel frame that can easily moved crane. The portable roof arches fit these sections. Each section provided with two four gas burners and when furnace made all the burners are coupled main supply line. The retort extends beyond both ends the furnace, each end being mounted pair rollers, one pair which rotated motor revolve the retort. Pots and other items which, due their shape, cannot put into retorts are sealed large steel boxes and charged into car- bottom type furnace. There are two these furnaces, one being gas burners. These burners are divided between the two sides and half them fire tangentially the roof while the rest fire between the piers the car top supporting the boxes. The other furnace ft. high and heated with gas burners similarly arranged. Miscellaneous parts are pickled prior calorizing and for this work there lead-lined wooden tank ft. ft. deep. The heating this tank unique that use made four gas burn- ers which fire into lead pipe immer- sion coils. Lead pipe in. diam- eter used and extends the entire length the tank, where turns with elbow form vertical stack. The pipes extend through the tank wall that the gas burn- ers fire into them from the outside. They are placed in. above the tank floor lead supports, insure circulation below. Wood grates protect them from the heavy work. per cent sulphuric acid solu- tion used 180 deg. Original- steam was employed but this diluted the solution and caused seri- ous variations the pickling oper- ation. Gas burners adopted, the new immersion system materially reducing gas consump- tion. The work handled and out the tank with crane and hoist. Immersion gas burners are also employed heat the water the cleaning tank, which ft. and in. depth. Dip calorizing equipment pro- vided for treating work which re- quires bright coat pure alumi- num. This process similar hot-dip galvanizing. 24-in. 24-in. 10-ft.-6-in. cast iron pot carries the aluminum bath. heated gas burners located un- derneath. Two pipes and gas burn- ers, similar those previously de- scribed, heat this tank. located diametrically opposite corners the pot. There large foundry con- nection with this plant where heat- enduring stainless steel castings are made. These products are known Calite alloys and include seven eight different analyses. Core baking and mold drying accomplished with gas fuel. fully equipped laboratory maintained research work and routine analysis. For the past three years extensive research pro- gram has been conducted for the Calorizing Co., under the direction White, University Michigan. Fic. 2—A gas fired calorizing furnace with retort place and last section the top being lowered THE AGE, October 24, q 4 > q » aS 4 tien < ty 3 ety Goes Back the would seem, from looking over accident statistics, that one the safest places partly due improved machine and tool design, but mostly due education among workmen and foremen. doubt the prime mover much this improvement has been the safety engineer safety man, smaller concerns the responsibility for safety frequently falls upon executive who has other duties. larger units more common employ safety man, and in- teresting note that recent survey was found that the large *Abstract address before the annual congress the National Safety Council Louisville, Ky., Oct. 14, 1935. 30—THE IRON AGE, October 24, 1935 units manufacturing had the best records frequency and severity. regrettable that both fre- quency and severity occupa- tional injury got little worse 1934. From our own experience. know that during 1934 em- ployed large numbers men who were never before employed the automobile industry, and was only expected that with the rapid introduction large num- bers inexperienced workers, in- dustry would have unfavorable ex- perience accidents, tool breakage and damaged work. Most the training job this large group new workers be- hind us, and the results the end this year are going show that much, not all, the ground lost has been recovered, WILLIAM KNUDSEN Executive Vice-President, General Motors Corpn., Detroit and know that other industries chare our convictions this re- gard. The conveyor, often pointed instrument for speeding work, which not, has per- haps been the greatest means for establishing order plants and has been the means keeping work off the floor, this way pre- venting untold number acci- dents due disorder—for which the old-time shop was famous. Oc- cupational accident statistics now show that accidents from stepping striking objects amount only about per cent the total accidents manufacturing. Conveyor Not Pacemaker When looked upon beast burden, sort continuous truck line you please, the conveyor placed correctly. When, however, placed. For anyone connected with manufacturing quantities knows that speed such produces in- crease output. Only quality and accuracy the operations indi- vidual units produce increase the output the assembly con- veyor. Early conveyors were rather crude affairs, and many were due parts dropping the drive, men getting caught the chain. Happily most conveyors to- day are the protected type, well enclosed, with safety links case jam, and the case men getting if 7 4 ‘ it | | | | q 4 | | | | \ | | ‘ q | | 7 i hurt conveyors practically unknown. Furthermore, since large single cause accidents industrial employment “handling objects,” evident that the extent which can turn this kind work over the conveyor, make rapid strides reducing accidents. Fixtures for both vertical and horizontal machines show substan- tial progress from safety stand- point. Cam locking devices and box fixtures and dies the sub-press variety with guide pins have not only eased the work setting and running, but also, have im- proved operating safety such extent that minor cuts and bruises represent the major part ac- cidents that kind work. In- cidentally, cuts, lacerations, bruises and contusions account for about per cent occupational acci- dents. Enforced use goggles and automatic trip-off presses with safety control have probably been the biggest discounts bad acci- dents, which formerly ranked high both severity and frequency. fact, today about per cent the injuries are temporary dis- abilities, with only per cent fatal resulting permanent total disability. new hazard has recent years been introduced into factory operations the increase elec- trical tools, supplementing air tools many instances, and ne- cessitating general power-wiring installations shops. While there were some careless installations the early days the adoption electricity for welding, heating and operating purposes, the main the number burns have been small and the progress great. The great- est benefit installations this kind have near possible standard hook-up throughout the plant and have wiring bus- bars and switches the latest ap- proved style. Much credit should given manufacturers this style equipment for the orderly progress made, and for the stand- ardization their product. Today occupational injuries from use electricity manufacturing are quite low. Fume and Dust Hazards Another hazard which has come the front recent years, and has had have the attention all us, the question elimina- tion fumes, paint spray, acid interest the all-important factor eliminating accidents, says Mr. Knudsen. safety conscious going long way toward being quality conscious, and quality what factories grow on. Con- veyors have prevented untold number accidents, have the enforced use goggles and automatic trip- off presses with safety control. Hazards arising from use electrical tools and paint spray, acid fumes and dust have largely been eliminated. fumes and dust which modern processing brought in. Early in- stallations showed lack knowl- edge the problems met and the inadequacy the equipment developed that time, with resulting detriment the health the operators. are happy say, however, that due hearty cooperation engineers, men science and equipment manufac- turers, there today hardly single problem ventilation this sort which cannot handled that the operator’s health fully safeguarded, and dangers fire explosion eliminated. not any means pretend claim that manufacturers have gone all the route getting fool- proof devices, but substantial im- provement has been made and engineers are constantly working new wrinkles reduce further both the frequency and severity accidents. and large, the mechanics the safety prob- lem factories can said have made substantial progress, and the way more progress. Manufacturers realize that the workman, unaffected fears for his own safety and unaffected the shock injury fellow workman, better workman, and will produce better quality his day’s work. Safety education workmen, accident prevention work through the medium education, has made its best progress through so-called campaigns for accident prevention which most progressive factories inaugurate from time time. The prime formula for success this kind work get the foreman really enthusiastic about the stand- ing his department over peri- od, with the result that measures taken accomplish the objective become permanent feature and this way improve the situation for all time. Aside from safety campaigns, one the important things for the foreman the job give new man good, thorough explanation the haz- ards his machine, along with careful course instruction the machine’s operation before put work. Altogether too many accidents have been due faulty insufficient instruction new men when everybody busy and output behind. personal opinion that the American workman does not re- quire pushing speeding up. When has thoroughly learned the quality part his job and fully understands the requirements himself will take care the speed part it, and naturally resents any charges being slow. have found the corpora- tion that the foreman’s interest the safety problem the all-im- portant factor getting rid ac- cidents all kinds, cevere trivial. Human Salvage the Keynote recent visits many our plants, after the finish our last safety campaign, talked de- partment heads. The plaques pre- sented for best results were received politely. The frequency and severity standings the par- ticular campaign were received matter course, but when the caving fingers, eyes lives was explained being the direct result the improved standing, this made profound impression and was the real good the cam- paign had produced. Figures are figures. Some people like them, some hate them, but safety work you can convince foremen that they have actually been the means saving lives, eyes, limbs fingers, then your safety work under way real start. When the foreman has become thoroughly interested, the men automatically become interested. The older and more experienced be- gin look after the younger men (CONTINUED PAGE 81) THE IRON AGE, October 24, = 4 4 a q 4 3 q i ys 3 — Returns from Laboratory LIPPERT The Age, New York oxy-acetylene flame used with automatic machine developed Gleason harden gear teeth quickly and effectively. English firm has produced mixer for oxy-acetylene and coal gas. The flame produced and less hot than ordinary oxy- acetylene. new die casting alloy and new metallic resistor alloy are being marketed companies this country. process and analysis patent has been taken out Germany copper-nickel-iron magnet alloy. The International Tin Committee announces new cleaner for tinned ware which dissolves much less tin than ordinary alkaline solutions. Starbright the name salts marketed England for bright nickel plating baths. Data are given the thermal efficiency Ferro-Therm, heat insulator from ordinary black steel sheets. The use aluminum instead silver for mirrors described. ° Gear Teeth Flame Hardened idea surface hardening with oxy-acetylene flame long antedates Shorter’s experi- ments England, but Shorter belongs the credit for mechanizing and standardizing the process. Principally because his work, the flame hardening technique was revived for all classes work and showing indications becoming standard practice many machin- ery and heat-treating plants. How the Shorter process being adapted all types iron and steel products was described de- tail for the first time THE IRON AGE Aug. Experiments gear hardening with flames have not been confined England, for the Gleason Works this country has designed automatic machine which has been service its plant for well over year. This machine now being offered for sale under the protec- tion patents pending both here and abroad. The Gleason gear hardening machine employs two 32—THE IRON AGE, October 24, 1935 burners which heat the tooth both sides simultaneously, thus ob- viating any likelihood twisting, distortion checking the tooth. Also, the hardening naturally accomplished much with machines using only single blowpipe. shown Fig. each the water for immediate quenching. Thus hard surface obtained even though the body the gear unchanged, and there time for distortion set in. This last factor particularly important, since uniform bearing all teeth most desirable from wear standpoint. The operation the machine mechanical (other than indexing), thus elimi- nating the human factor. The hy- draulic control flexible, permit- ting variable speed travel which provides for uniform heating section variable thickness (such bevel gear tooth) and for speeding both ends pre- vent burning the corners. The recommended stee