The Iron Age 1935-12-05: Vol 136 Iss 23

CHESTNUT AND S6TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET Owned, Published and Copyrighted CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Pa. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, JOSEPH 8. HILDRETH, 2% GEORGE H. GRIFFITHS, EVERIT B. TERHUNE, ERNEST C. HASTINGS, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary NEW YORK, FRITZ FRANK, President VAN DEVENTER MILLER Machinery GERKEN News Editor LACHER Managing Editor Editor Emeritus Washington Chicago Cleveland Pittsburgh Detroit Boston the Collectors Little Hoards New Pioneers New Frontier Color Possibilities Porcelain Enamel. Trends Refractory Processes and Materials Corrosion After Pickling Oil and Grease Forced-Feed Lubricators Arc Welding Cross Field Principle. Washington News News November Pig Output Statistics Metal-Working Activity Construction and Equipment Products Advertisea 148 BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau Circulations Member, Associated Business Papers Emerson Findley, 311 Union Bidg., Cleveland Published every Subscrip- Hottenstein, 802 Otis Chicago tion Price: United States and Pos- Peirce Lewis, Woodward Detroit sessions, Mexico, Cuba, $6.00; Can- Charles Lundberg. Chilton Bidg., Chestnut & 56 W. C. GSweetser, 239 West 39th &t.. New York ain gh. he. | els ith le, rle lo. ith : te | — characteristics carbon-steel bars that determine their fitness for given pur- pose originate the open-hearth. Steel for Bethlehem Carbon Bars made with precision open-hearth practice that possible only organization with long ex- making fine steels. the selection materials, the control refining, science and mature human judgment work hand-in-glove lay the foundation Bethlehem Carbon-Bar quality which customer satisfaction depends. if | IRON AGE, December 1935 — THE IRON AGE ... DECEMBER 1935 ESTABLISHED 1855 Vol. 136, No. OST us, when hear capitalism condemned, think that the soap box boys and the pink parlor professors are shooting the big fellows. have not regarded our- selves capitalists. have defined him man who has more money than have. But, course, when you think it, this sort definition will not hold water. For there generally someone found that has less money than you which would automatically put into the capitalist class. Every person, strictly speaking, who has money invested invest capitalist. Every man and woman who has shares stock, money the bank, real estate life insurance premium. There are some million such people the United States today. may surprise you learn that little fellows who have believed thrift, saving for rainy day for building competence for old age, are class enemies who are obstructing the forward march social progress. This horrible indictment not mere gossip hearsay. comes from source "close the indeed from the lips none other than Under Secretary Rexford Tugwell. For comrade Tugwell, excoriating the enemies class consciousness his recent address Los Angeles, paid particular attention the little together with the unearned income and their hangers The man who invests life insurance, even you and little and the widows and children who may live upon the proceeds that saving are surely the unearned income and their hangers exponents the principle thrift and saving, our small way, have, seems, been obstructing the "rising common men, the irresistible strength which may sweep forward into the ostensibly future which there shall capitalists, large small, and Constitution. You can away with capitalists, comrade Tugwell, but you cannot away with capitalism. You might transfer the savings and holdings our million thrifty Americans and the control capital into the hands small group politicians comprising the National Capitalistic Comintern. But capitalism must have until some one finds substitute for money. And that has not been discovered even your admired Russia. desired price representing cost production and mailing. Please address Reader Service Department, THE 229 West 39th St., New York City. Because the many requests for reprints editorials appearing Tue Iron Aas, the publishers have ar- ranged make such reprints available any quantity A x- : 4, RALPH FLANDERS THE greatest fact American history has been the existence the frontier. For centuries the centers industry, commerce agriculture lay the East, ex- panding decade decade westward progress that was un- interrupted and successful. The border line that movement was held the pioneers. Before them lay the unknown regions which the imagination pictured teeming with wealth forest, mine and soil. Behind them came the set- tlers, who found developed the underlying realities the pioneer’s dream. This physical, geographical fron- tier for many generations served our nation three important ways: gave unlimited tunity youth; furnished seemingly boundless field for the profitable investment capital; and generated favorable psy- chology throughout the whole structure American society. The opportunity for youth was this gathering tonight. the eastern farming regions the proc- 20—THE IRON AGE, December 1935 ess was almost automatic. With the large families generation two ago was obviously im- possible for all gain good living the restricted home acres. The boys due time moved out- ward, some the cities (them- selves growing with the growing commerce and from the fron- tier) and others directly the virgin soil and forest the newly opened lands, where they could find the opportunity and the room make new lives for themselves more ample scale. But wide-spreading and rich was the Western domain that the expanding population the East- ern seaboard was insufficient occupy and develop its resources. Their numbers. were swelled the millions from the crowded countries Europe, who descried the opportunities swarmed into the trans-Atlantic shipping, and crowded the immi- grant trains into our virgin ter- ritory. The numbers immigrants were numbered the millions and tens millions. Our own population growth did not suffice. There was room for all. Money was needed well men. There were farms equipped, mines opened, roads and railroads built, cities erected. For genera- tions the savings the settled East poured across the Alleghan- ies, across the Mississippi, across the Continental Divide and found profitable investment these new and rich territories. Fortunes were lost, but more fortunes were made. There was never word “over- investment.” The thought was ioneers ridiculous that the words were unneeded and un-invented. Millions From Europe for Investment with men, with money. The savings the East were inadequate the needs and op- portunities the West. con- sequence, millions dollars came pouring out the coffers Europe finance the settlement Western America, and the ex- pansion Eastern commerce and industry which Western grew into billions before the de- mand was satisfied and the stream slacked its flow. All, this produced national psychology fortunate sort. were convinced that the future held more for than the present and the past. were willing rick time and money pro- ductive enterprise. The future, were sure, would not betray us— nor did it. Even our physical surrounding made our psychology, our psychology made our fu- ture. The process was natural, healthful, fortunate beyond accounting. But—the frontier gone! doubt will continue, now and then, find new oil fields. New areas fertile soil will irrigated and added our inher- itance arable land. New min- eral deposits will found and exploited. All this will continuously for many years, yet the total effect will small. will not constitute the outstanding, controlling fact our nation’s history, did for nearly three = 4 Z 3 = » fs : e | New Frontier RALPH FLANDERS Presidential Address, American Society Mechanical Engineers, December 1935 hundred years. Sometime the period since the turn the cen- turn—not any given day any given year—the physical fron- tier the grand sense disap- peared, and disappeared forever. The Frontier Disappears This was the greatest event our times. are looking for some effective cause for the evils which have been afflicting us, why look further? build our false inadequate theories “over-production,” when have never had decent general stand- ard living this country; “technological unemployment,” when technology alone can found our hopes for the higher standards the future; “over- investment,” when adequate provision goods and services the mass our fellow citizens requires larger and more efficient productive facilities than have ever dreamed of. All these explanations and many more are shallow and inadequate. The outstanding historical event our generation the disappear- ance the frontier, consequent disappearance the old, trusted and tried opportuni- ties for youth and the profitable investment capital; and with these gone there beginning that favorable, constructive type national psychology which has energized our progress hitherto. What shall the face Two courses are open us. can readjust our social, polit- ical and industrial institutions future limited opportunities for men and for money, with national outlook keyed down safety our objective, instead the old purposeful advance toward better future. The alternative that find equivalent for the lost frontier—an equivalent which will effectively open new opportunities for men and for capital, and make possible for retain our constructive na- tional psychology. For the time being, seem making the first and poorer choice. some directions delib- erately and others indirec- tion, are slowing down our production goods and services. place confident advance toward business risk and personal adventure, are all playing safe—business men, worker and farmer. are this moment organizing new world re- stricted restricted human enjoyment and restricted opportunity for the coming gen- eration. have chosen play the lesser part. need not this and must not it. For the effective equivalent the old physical frontier lies ready our hands for our occupation, development and enjoyment. That frontier lies our notice. Its separate features are familiar that have missed its significance whole. For the new frontier not distant physical region, ever-present social This new social frontier greatly raised standard living for the mass our fellow-citizens first sight this proposal for new frontier may seem trite and inadequate. But let examine before passing hasty judgment. Let consider first and prin- cipally its material characteristics. what are they composed? higher material standard living does not mean higher wages, higher salaries higher dividends. does not mean higher prices for goods services—least all does mean restriction output. does mean more and more goods and services lower and lower prices relative incomes. first consider whether higher standard living, defined these terms, physically pos- sible. Next, let see whether attained, can take the the lost frontier furnishing opportunity for youth and for capital, and providing fav- orable national psychology. ally, these inquiries lead favorable conclusions, let see what that prevents our occu- pation this new frontier, that may remove the hindrances and proceed with our new social ad- vance. Living Standards Can Rise There can surely question rising standard living. have the material resources required. The very abundance our coal fields, oil wells and fertile soil have embarrassed our clumsy in- stitutions until have imagined blessing. For the materials need and not have there are ample stores native products for (CONTINUED PAGE 110) THE IRON AGE, December —— | ‘ 7 ° ° ! | | q ~ | if \ | 4 > Color Porcelain Ename New ALUMINUM ceiling left and make the color and frit control laboratory “daylight 2 LABORATORIES with most their walls fin- ished porcelain enam- have recently been completed the Chicago Vitreous Enamel Product Co., Cicero, These laboratories are unique be- cause they have been designed the most efficient their kind for conducting research and developing enamel cover the walls and ceiling the analytical chemi- cal laboratory. ; ; | 4 4 a | i a ‘ = wea. 4 ¢ 22—THE IRON AGE, December 1935 e wan Possibilities Shown Finish Laboratories walls are “velvet ROGERS FISKE The ceiling green and bone white. Desk, Western Editor, The Age filing cabinet and ta- new porcelain enamels, and for the reason that the method construc- booth and tion used introduces new dipping practical method for utilizing the large laboratory elec- occupy main room. THE AGE, December 4 — unusual finishes and variety colors offered porcelain enamel building material. main laboratory room, analyt- ical chemical laboratory, office the director research, color and frit control laboratory, physical instru- ment room, experimental smelting department, smelt record room and shower and locker room, form the main divisions and occupy total ‘ area approximately 10,000 sq. ft. Exactly 12,718 sq. ft. porcelain enamel were used finishing the walls, light fixtures, columns, show- and toilet stalls, furniture, and, two the rooms, the ceilings. special acid-resisting ‘‘satin matt” porcelain enamel, developed for architectural purposes, was used for most the interior finish. keeping with the attractive SECTION the main laboratory room devoted accurate color matching and the development new color finishes and shades. surroundings the new laboratory, which provide added incentive for work, considerable thought was given the design the shower and locker room. This contains lockers for the laboratory person- nel, two toilet stalls, two tories and shower stall. fea- ture the latter non-skid floor porcelain enamel. Extending around the room, and even the THE main laboratory, 100 houses three miniature porcelain enameling plants. Decorative features are indirect lighting the and columns, and horizontal porcelain-enameled panels graduated shades biue. 24—THE IRON AGE, December 1935 q — & NATURE the work performed the physical instrument room calls for “darkroom,” which fact determined the color scheme and light- ing effects. The walls are burgundy red enamel panels and the ceiling, furniture and blinds are painted front the toilet and shower stalls, porcelain enameled mural marine design resembling aquar- ium. The ceiling and upper walls are black porcelain enamel with horizontal stainless steel strips. Make Study Hygiene HYGIENE FOUNDA- TION AMERICA, INC., has been formed group representing industries, with headquarters Thackeray Avenue and O’Hara Street, Pitts- The purposes this organization are conduct in- vestigations and stimulate research problems the air hygiene and gather and disseminate factual information relating thereto. The foundation will also cooper- ate with and assist agencies active this field and will collab- outstanding feature the laboratory the fact that com- pletely air-conditioned through the use water from the company’s own well. The filtering air pre- vents foreign materials from com- orate the coordination such research efforis. sive investigation has been begun Research, Pittsburgh, under sup- port Air Hygiene Foundation America, which the hygienic, technologic, and economic aspects air contamination, especially dust the industries, will studied. Meller, who has been ap- pointed managing director Air Hygiene Foundation America, will head this investigation Mel- lon Mr. Meller has been active research air pollution since 1920 and generally re- garded authority that subject. attended the Univer- sity Pennsylvania and the Uni- ing into the rooms. This unit housed the smelt record room, where records from every smelt the plant the Chicago Vitreous Enamel Product Co. are filed for reference. versity Pittsburgh and then joined the faculty the Univer- sity Pittsburgh instructor mining, 1909 1911. was as- sistant professor mining engi- neering 1911 and 1912, and professor mining from 1912 1923. was vice- dean the School Mines the University Pittsburgh from 1912 1914, and dean school from 1914 1923. During the past years has beon charge the program for the abatement smoke and dust Pittsburgh and since 1923 has headed the air pollution investiga- tion Institute. has made numerous contributions the literature the municipal smoke problem and its control. THE IRON AGE, December : ives 4 & x 4 LOUIS TROSTEL Chief Chemist, General Refractories Co. THE production re- fractories without burning, equally good fired ones, has always fascinated the refractories producer. This follows from the fact that not only could thereby eliminate costly item from his balance sheet but could also re- duce the time get his product through the plant from five six weeks many days. Further, there could cut down the enor- mous inventories finished prod- ucts, which all refractories manu- facturers carry order make quick deliveries. Practically all these advantages would shared the consumer well, that the final development unburned refractories commercial quanti- ties and standard sizes deserves special mention. Earlier attempts some manu- facturers brick, particularly magnesite, gen- erally resulted chemically (or- ganic) bonded mixtures, which were strong drying and sintered fairly well under the heat the furnace when used. However, two outstanding technical defects usu- ally developed, namely, sintering was accompanied shrinkage and the sintering was limited the hot face the refractory. The parts the brick intermediate tem- peratures lacked strength after the chemical bond was burned out. An- other practical disadvantage some the unburned products was that they could not always furn- ished standard sizes. Lack bond and volume stabil- 26—THE IRON AGE, December 1935 THE first half this article presented Nov. 21, the author cited the novel principles manufacturing which have proved refractories. number newer types refractories were discussed. this second and last section pointed out that improved re- fractories are making possible better applications materials, par- ticularly where basic fluxes and oxides are present. displacing fireclay and high-alumina brick for cement kiln linings and glass regenerator checkers. Electrocast and bonded ity have been overcome the re- fractories recently developed the General Refractories Co. their Ritex process which three distinct improvements the unit operations are involved. the interfitting the grains has been developed maximum using only selected band sizes and adding them proper proportions. Second, the forming pressure mold the brick has been stepped from about 1000 10,000 per sq. in. order reduce the voids between grains. This careful siz- ing has greatly intensified the ef- fect the ten-fold increase pressure. Third, refractory chem- ical bond used which contributes the effect the first and second improvements. Both Ritex magnesite and Ri- tex chrome are now commercial production. The brick are strong and hard when cold, well bonded very high tempera- ture, and show only negligible vol- ume change when heated service temperatures. Their greatly in- creased density over burned brick contributes their slag-resisting properties. The increased density, and volume stability these products are also reflected outstanding property which dis- tinguishes them from burned mag- nesite and chrome, namely, high resistance spalling. The latter effect high-temperature furnaces course the resultant com- bination factors such textural changes resulting from shrinkage continued exposure high tem- perature and slag, well ther- mal shock. This property resisting spall- ing brought out effectively Fig. which shows representative samples Ritex chrome and regu- lar burned chrome brick after simulative service spalling This modification the A.S.T.M. panel test designed show under accelerated conditions the resistance combined thermal and structural spalling. this test the brick were laid panel, backed with in. insula- tion, and then heated 1650 deg. and soaked for hrs. After this treatment the panels were sub- jected spalling treatment con- sisting first heating 1200 deg. for min. and then cooling similar length time with blast air delivered the rate 1400 cu. ft. per min. The brick were and then the loss weight meas- ured. the left are shown the burned brick which vitrified, cracked and eventually lost about per cent their weight. the right are shown the Ritex chrome, which came through the test with = | | | | | | | | | | | | | | | | | | | ° ° | | | | | 7 | | ractory Processes and Materials mullite are replacing clay for glass tank flux blocks. Silica losing its importance for sidewall, port-end and roof construction metal fur- naces, because improvements the physical character basic brick. brick, while yielding heat economies the user, shown creating new problems for the maker refractories. Also referred are better clay brick checkers, quick setting magnesite grain for furnace bottoms, magnesite ladle nozzles replace clay, and the use super-duty fireclay brick for certain heating conditions involving severe spalling and slagging. weight. Most magnesite and chrome brick fail service spalling rather than fluxing shear under load. The superior develop- ment resistance this type failure means the Ritex proc- ess should prove important factor the expanding usage products made according this method. Use Insulating Brick One the important properties refractories which fit them for their special field engineering materials the ability confine heat. inducing high cellularity and proper strength refractory clays and other minerals, there have been developed the past few years refractories suitable for lining the interior furnaces, thereby greatly increasing their ability reduce heat losses. The cellularity the mass the commercial processes now ways, such (a) burning out carefully sized combustible like sawdust cork, (b) vaporizing drier temperatures volatile or- ganic material such naphtha- lene, and (c) combining gas bub- Bulletin No. 84, Ohio State Uni- versity Engineering Sta- tion, 25. bles with finely ground plastic mass slip. The bubbles may produced mechanical aeration gas from chemical reaction certain batch constituents, fol- lowed either case stabilizing the foam generated. The use expanding minerals such cyanite and vermiculite induce cellularity, while holding possibilities, has not been extensive for insulating firebrick for lining furnaces. Vermiculite, well diatomaceous earth, however, have been incorporated insulating brick for use furnace exteriors. Most efforts date have been directed toward producing brick with high thermal resistance possible without too much sac- rifice strength, the latter being generally directly proportional the bulk density the product. Fig. shows the variation ther- mal conductivity (K) several cellular clay bodies room tem- perature with density. The value the latter for fireclay insulating per cu. ft. amd the value from 1.1 1.3. earth brick one extreme have den- sity about Ib. per cu. ft. with value about 1.0, and regular commercial firebrick the other extreme with density nearly 130 per cu. ft., though not shown this curve, have value about the order 3.0. probable that the same relation- ships will hold furnace tempera- ture, since least for clay refrac- tories the value rises almost straight line function the mean temperature. general the average insulating firebrick will found have about one-third the density and thermal conductivity ordinary fireclay brick. Two other critical properties these refractories are the shrink- age and spalling furnace tem- peratures. Both properties are more exaggerated than usual refractory. The shrinkage dependent partly upon the clays used and the thin cell walls the product. The spalling tendency related the low conductivity which sets steep heat gradients and accompanying high stresses body naturally low mechani- cal strength. This can offset some extent inducing certain degree elasticity, properly designing the mix. Application Newer Refractories The application and uses these newer refractories are based the attempt the manufacturer supply materials suit chang- ing and more severe service needs the consuming industry, such increased temperatures, faster heating schedules and greater number operations intermit- tent character. There evi- dence that users refractories are redesigning adapting their fur- naces the refractories years ago. great many chemical and metallurgical processes operating high temperatures have long been confronted with the problem slags incidental the process the furnace refractories use. Typical these industries are those manufacturing cement and THE IRON AGE, December aft Ps | | | ‘ j 3 a | resistance spalling Ritex and burned dolomite clinker, glass, basic open- hearth steel and the smelting and refining copper. The basic re- fractories offered these consuming industries, until the last two three years, were generally satis- factory chemically but not struc- turally. particular the basic refractories were weak their re- sistance spalling and ability carry loads high temperatures. Accordingly been made all along the line. One the recent outstanding accom- plishments the application refractories has been the ability the consumer who must contend with basic fluxes now obtain the proper refractory, both from chemical and structural viewpoint. For instance, the original type lining for the hot zone rotary cement and dolomite kilns was made fireclay brick. Later came the high alumina brick per cent alumina because had higher value (1820 deg. C.) compared with about (1700 deg. C.) for clay brick. Magnesite brick were recognized the logical refractory, but be- cause the high spalling char- acter the burned brick, prac- tically cement kiln operator ever used them. preferred get along with brick chemically wrong but physically better. Ritex magnesite now have shown several years extremely satisfactory cone equivalent (P.C.E.). Standard Definitions Terms Re- lating Reffractories (C71-31), 1933 Book 28—THE IRON AGE, December 1935 service this type kiln and some interesting data this con- nection have been compiled. one cement plant, former linings either the per cent alumina fireclay brick type lasted aver- trasted with 310 days for one Ritex lining and 421 days for the second. The production the second lin- ing has been about seven and one- half times that the older type linings, and the saving, based lining cost per barrel cement produced, three times the cost the lining. the manufacture glass, conducted such high tempera- tures 1300 1650 deg. C., the presence soda always prob- lem the use the refractories for the superstructure and regen- erator checkers. Furthermore, the glass which maintained well above its melting temperature B.t.u. per Hr. per Sq.Ft. per In. per fluid condition acts solvent the aluminum silicates used for the refractories constituting the flux, tank blocks, port sills and jambs. The extent corrosion increased, particularly since the industry has turned ma- chine-made ware with the use higher temperatures production per unit, making the necessity more acute for refrac- tories which are correct chemically well physically. Silica brick are still generally used roof brick because their load-carrying ability, although they are decidedly acid and suffer corrosion from the soda dust. Ad- vancement has been made, how- ever, refractories for the check- ers. Two well known properties magnesite brick have long sug- gested them the proper checkers for glass regenerators, namely, the fact that they have the highest heat capacity and conductivity per unit volume any type refrac- tory which might used, together with the ability resist fluxing the soda. Clay brick were used originally, then high alumina kaolin, and the past year Ritex magnesite. magnesite, ob- served after one year’s service, have kept clean They did not spall and could salvaged and reused, while kaolin and fireclay brick exposed simultaneously fluxed badly and had discarded. points where molten glass the problem, electrocast and bonded cyanite are being sub- stituted for clay increasing ton- nages. mullite ad- mirable for this purpose since the vorosity ‘only about 0.5 per cent compared with per cent clay flux blocks and the surface the refractory exposed for sol- Lb. per Cu.Ft 2—Variation thermal conductivity cellular clay bodies with weight. : 4 | q i | } | | { { | | 9 vent action reduced mini- mum. Both electrocast mullite and cyanite have the advantage P.C.E. value about com- pared with for clay brick, and margin safety acquired be- fore melting reaction can pro- ceed. the highly crystalline character these two refractories together creased resistance the solvent action the glass because the high alumina content the mul- lite make them improvements over clay brick. Refractories for Steel Making the field ferrous and non- ferrous melting, the use mag- nesite and chrome brick has long been established, particularly hearths and bottoms, because chemical resistance the basic slags present. Generally they have not been used above the slag line and for roofs, because their spalling weakness and lack suf- ficient volume stability under the heavy loads and. stresses the wide sprung-arch type roof con- struction used. acid refractory, silica, has been necessary points. The refractory problem has be- come more acute with the increasing use insulation the outside open-hearth sidewalls and roofs. Insulation has resulted raising the temperature the cooler side the brick from below dull red red heat, and increasing the severity fluxing and spalling conditions the fire face the brick. Improvements the physi- character chrome brick make them more resistant spal- ling and slagging both burned product and chrome have now made possible make the logical substitution these brick front and back walls, corner walls, ports and bulkheads, well intakes and division walls. definite heat economy further may realized the use the Ritex chrome brick because the unique character their thermal conductivity. indicated Fig. the conductivity deter- mined with apparatus the Wilkes type’ very much less than that burned chrome and the temperature coefficient nega- tive. temperatures above 400 deg. the conductivity even less 5G. Wilkes, Journal American Ceramic Society, (3) 125 (1933). Fahrenheit a uw > 1800 B.t.u. per Sq.Ft. per In.per Cal.per Sec. per Sq.Cm.per w 100 200 300 400 500 600 Degrees Centigrade Fic. 3—Thermal conductivity Ritex-chrome brick compared with fired chrome brick. than that silica brick and dense fireclay brick. These important improvements chrome brick point their eventual use roof brick. reverberatory furnaces for smelting and refining copper possible observe the same trend the substitution improved basic brick for silica brick points other than bottoms. Side- walls and roofs are now con- structed Ritex magnesite. These bricks have been used conjunc- tion with silica part roofs the sprung-arch type and entire roofs made Ritex magnesite the suspended arch type nearly 22-ft. span are regular practice. Such roofs have given much seven times the life silica roofs. Magnesium silica brick from oli- vine have also been tried. Refractories have been improved meet specific conditions other points the manufacture iron The high density achieved de-aired fireclay brick has increased their heat capacity and made them better heat ex- change media blast furnace stoves, open-hearth regenerator chambers, and similar types in- stallations. Lately magnesite which sets quickly displacing pure magnesite grains for building basic bottoms. Time saved burning bottoms and patching between heats and the lower price the material makes possible reduce the cost refractories per ton steel pro- duced. These high-lime magnesites contain only one-third one-half much the prepared com- mercial dolomite clinkers used for patching open-hearth bottoms. For pouring steel, clay ladle noz- zles have been general use. They suffer badly, however, from cut- ting out magnesite dioxide. Magnesite nozzles have been found very successful substitute. Boiler furnaces operated high ratings, such those central power stations and marine ser- vice, are proving field special application for the new super-duty fireclay refractories, because the excellent spalling and slag resistance these brick. small electric furnaces, do- mestic oil-fired heaters for fur- nace walls where special com- plex shapes are required, which costs not warrant making large amounts, has been the practice use rammed-in plastic linings various refractory ma- terials. now possible ob- tain refractories with hydraulic set which may cast place. refractory high alumina cement used and castable mixtures from practically all refractory materials may produced. Stated generally, the most ad- vantageous applications the new insulating refractories furnace linings are intermittently operated furnaces. shorten the time required for heat- ing-up, the heat lost storage the walls before they have become saturated. This aside from the structural advan- tage being able make lighter weight furnaces. (CONTINUED PAGE 95) THE IRON AGE, December a 3 Corrosion Pickling Major FOR many years prac- tical galvanizers have suspected that one the most prolific sources dross was the corrosion that forms the surface work after pickling. Anyone who has spent even short time the practical operating end hot-dip galvaniz- ing soon discovers that the amount dross produced direct pro- portion the production put through the bath. That is, the greater the production the greater the amount dross made. Therefore practical in- terest this time mention the different sources dross, although they will not discussed pres- ent. The purpose rather indicate how dross made, and where the materials come from. Inasmuch dross composed zine and iron, the feature inter- est show where the iron comes from. The sources iron form dross are (1) the zinc used, (2) iron oxides formed the surface the work after pickling, (3) iron salts the picking solutions, (4) iron from the galvanizing pot, (5) iron from the action the base material, and (6) iron fur- nished material lost the pot. this time attention given just one these sources iron. No. iron oxides formed the surface the work after pickling. The next practical question naturally, “What are these salts iron either left the work after pickling formed the surface corrosion?” The answer not difficult the practical facts are closely studied and then properly correlated with theory. Pickling done with either sul- muriatic acid. the President the Wallace Imhoff Co., consultant coating, Vine- land, 30—THE IRON AGE, December 1935 WALLACE IMHOFF* pickling done with sulphuric acid then the iron salts left the work will iron sulphates. the work dried very quickly these iron sulphates will the form white powder over the sur- face. This the dehydrated sul- phate, the white color the deposit being due the lack water. the other hand water present then the iron sulphate, which the form ferrous sulphate, green color. The deepness the green depends upon the amount water present, the amount iron present and the time exposure the air. the work has been either pickled muriatic acid given final dip muriatic acid, then these iron salts may iron chlo- rides instead iron sulphates. The salts formed with muriatic acid are ferrous chlorides, and they range color from different shades green almost yel- lowish tinge. The third corrosion product found the surface fresh pickled work and work that the dryer, iron oxide, the yellow, brown, and red ferric oxide. This corrosion product often the re- sult the secondary change that takes place exposing iron sul- phate iron chloride the action the air. The corrosion changes these sulphates and chlorides iron the insoluble iron oxide commonly known rust. The color the rust formed depends the amount water contains, the light yellow colors through light tan brown carrying consider- able water, while the dark browns, through dark red browns, deep red brown ferric oxides contain very little water chemical com- bination. Now that the sources iron and the different iron salts formed pickling and corrosion have been revealed, remains for very thorough research investigation definitely prove that the iron ob- tained form the largest quantity galvanizer’s dross, which iron and zinc, derived from this corrosion the surface the base metal the acids, and drying the water.while exposed the air and heat the dryer. The corrosion products formed are iron sulphates (ferrous sulphates), iron chlorides (ferrous chlorides), and various combinations iron rust (ferric oxide and water). The purpose the research in- vestigations herewith submitted definitely prove that the iron needed form very large quan- tities galvanizer’s dross de- rived from the corrosion formed the surface the base metal after pickling and during drying. Since most cases the final prod- uct corrosion rust, was decided start the investigations using the ferric oxide iron the corrosion product come contect with the molten zinc. Attention called the fact that since the investigations have been made the results show that the light ferrous sulphates and the fer- rous chlorides, well the yellow “sull” water rust formed corrosion, are all much more easily reduced molten galvanizing temperatures than the red ferric oxide. Believing that molten zinc hot-dip galvanizing temperatures was very strong reducing agent, the series tests were planned duplicate not only the action galvanizing temperatures, but far above any temperature ever attained galvanizing pots. The | | | | | | | | | | ° ° ° | | | | | | | | | following method procedure was employed. Experimental Procedure definite weighed amount zine and iron oxide was placed clay crucible free iron any form. This gave assurance that any iron found later the would have come from the iron reduction the iron oxide the molten zinc. This definite amount and iron oxide were heated together for hr. small en- closed furnace especially used for experimental purposes. Every two hours the melt was stirred with glass rod, order make sure the iron oxide was well mixed into the molten the end the six hour heating period the gas the furnace was turned off and the crucible and melt allowed cool the furnace over night. The next day the melt was examined, one half being used for analyzing the melt for iron, and the other half used for microscopic investigation note the action the molten zine the iron oxide. Fig. shows the various melts removed from the different clay crucibles after each test was made. will seen that the tests were made 800, 850, 900, 950, 1000, 1100, and 1565 deg. The critical and important tempera- tures from the practical galvan- izer’s standpoint are those from the melting point zine 950 deg. Very seldom galvaniz- ing baths ever higher than 950 deg. F., and even when they get 950 deg. previous investiga- tions have shown much damage has been done the quality the metal the bath. Too much detail will not given commenting each test. considered important however that some comment should made experimental data contained herein have never been released any- where before, and since they definitely prove that one the most prolific sources iron dross from corrosion after pickling and during drying, they should extreme in- terest all those interested galvanizing. This article covers the reducing action molten zinc rust and the ferric oxide iron formed corrosion, and the first section series three articles. The second section, which will appear follow- ing issue, studies under the same conditions the reduc- ing action zinc black and magnetic iron oxide, and the third section devoted the influence ordinary scale, which sometimes not ickled entirely off the work goes into the bath. each temperature bring out the facts, otherwise something might overlooked those not having had contact with the inves- tigation. advisable exam- ine carefully all the melts shown Fig. The view the left Fig. shows the following features interest: (1) The development zinc-iron alloy from the iron oxide granule; (2) the large particle iron oxide made round area which still iron oxide, dark area the dark green zinc- iron alloy, and small dross crystals both these areas; (3) clouded area zinc oxide around the particle; and (4) granular Source Dross zinc-iron alloy around the whole area (light area). Thus this first test made 800 deg. conclusively proves that molten zine galvanizing bath temperatures has reducing action iron oxide. This action would much faster and easier ac- complishment the soft yellow iron oxide known “sull” water rust. The middle view Fig. il- lustrates the reducing and alloying action the molten zinc iron oxide temperature 850 deg. The points interest are: (1) the light areas zinc-iron alloys which have formed from the vari- ous iron oxide granules, (2) the dark alloy developing into dross crystals (the rhom- bohedral and hexagonal forms can easily recognized), (3) the dross crystals forming the granular zinc-iron alloy area, and (4) the large rounded areas zinc-iron alloy which were origin- ally the iron oxide granules. The average galvanizing bath temperature about 850 deg. F., and although this little low for some work many kinds galvanizing furnish product this temperature. The results the test this tempera- ture show clearly that the molten has decided reducing action the iron oxide. closely examining the middle photo Fig. will seen that most the large iron oxide granule outlines can still seen. Two things have happened, namely, part the zinc formed zinc-iron alloy and part formed zine oxide during the attack the iron oxide. The iron has combined with the zine form zine-iron alloy and the oxygen the iron oxide has oxidized some the molten zine zine oxide. The illustration the right Fig. shows the action the THE IRON AGE, December “Ww > . 3 4 t 4 ; 4 ; 4 a z ZINC — 1.—Results obtained when molten zinc and iron oxide (ferric oxide) are heated together for hr. and cooled slowly. indicated, the tests were made various temperatures throughout the galvanizing range, final temperature 1565 deg. molten the iron oxide 900 deg. Practically all galvan- izing can done between the tem- peratures 820 and 870 deg. metalware the best temperature give beautiful finish has been found between 855 and 865 deg. F., but for heavier work like tubs the temperature will perhaps 870 875 deg. For small pipe the bath often carried high 880 deg. F., but sel- dom that temperatures over 885 deg. are ever reached good hot-dip gelvanizing plants. Thus 900 deg. the temperature just little above the usual gal- vanizing bath temperatures for any class work, although not uncommon find tempera- ture 900 deg. used some plents. Such high temperature course makes excessive dross and tends give short pot life. Results 900 Deg. Some very important things have happened 900 deg., and the fol- lowing features interest may seen the illustration the right Fig. (1) There are still large undigested iron oxide, (2) the structure the metal extremely porous, (3) there large amount zinc- iron alloy present, and (4) there segregation zinc-iron alloy seen the large spot the cen- ter. This test shows very clearly the strong tendency the zinc-iron alloy segregate form crys- tal. There seems two promi- nent components the zinc-iron alloy, namely, that formed mass from the reduced iron, and that segregated together and which has assumed the form crystal. The view the left Fig. shows this segregation tendency still stronger. Like the sample just described also shows the action temperature 900 deg. At- tention called the fact that the zinc-iron alloy spot the mid- dle practically clear from iron oxide any other material. examining this photograph the sequence seems first the zinc and iron oxide heated crucible made pure clay and containing iron maximum temperature 800 deg. F., 850 deg. and 900 deg. F., from left right respectively. Specimens maintained these maximum temperatures for hr., stirred every hr. and allowed cool slowly. All photos diameters. 32—THE IRON AGE, December 1935 formation alloy re- duction the iron oxide, alloying the zine with the iron and then segregation zinc-iron alloy caused the forces crystalliza- tion. The center picture Fig. shows the results the test the action molten zinc 950 deg. iron oxide. The picture shows many things extreme interest the practical man the galvan- izing shop, some which are -(1) the development vast number small dross crystals, (2) the entire field composed gran- ular zinc-iron alloy, (3) there total absence zinc, (4) the melt has spongy, porous character, (5) there thorough digestion the iron oxide granules the bottom the specimen, (6) there change from bright red dark blue any iron oxide granules found the top the specimen, and (7) there large area rich zinc-iron alloy showing the development the dark green shiny zinc-iron alloy. This area seen taking the shape parallelogram, with dross crystals developing inside the boundaries. The almost complete digestion the iron oxide and the existence large amount zinc-iron alloy demonstrate and prove conclusive- that dross formed from the iron oxides corrosion the re- ducing action the molten zinc the iron The photograph the right Fig. shows the results the re- ducing action molten iron oxide bath temperature 1000 deg. Temperatures this high are never reached galvan- izing baths except when the heat has gotten out control and the zinc badly overheated. The in- teresting facts that have resulted from the test this temperature are (1) the zinc | | | | | | } > IG. 3.—Molten zinc and iron oxide heated 900 deg. F., 950 deg. and 1000 deg. F., from left right respectively. Heated hr., stirred every hr. and allow- cool slowly. All photos diameters. Note the following: (Left) The iron oxide particles have been al- most digested, and the dross formed (zinc-iron alloy) has collected large spot the center; (middle) three distinct phases are seen, namely, undigested iron oxide, zinc-iron alloy segre- ation the center, and ormation small dross crystals; (right) at this tem- perature the iron oxide has practically all disappeared, and the melt consists zinc- iron alloy and dross crystals. changed zinc-iron alloy, (2) the large number dross crystals and their increase size, (3) the dis- tinct crystal forms the dross crystals and their darker appear- ance, (4) the homogeneity the alloy, (5) the complete absence the iron oxide granules the melt, and (6) large areas alloy filled with dross crystals. Temperature Bath Vital Factor Reduction Oxides now becoming very ap- parent that not only does dross form from the iron oxides due corrosion, but that the temperature the galvanizing bath vital factor the speed and complete- ness the reduction the iron oxides. Attention called the fact that above 900 deg. the crystallizing forces which shape the zinc-iron alloy into dross crystals become very strong. The reducing action the zinc bath the iron oxides becomes faster and more effective with each in- crease temperature the bath. The view the left Fig. longer leaves the slightest doubt IG. zinc and iron oxide heated 1100 deg. F., 1300 deg. and 1565 deg. F., from left right respectively. Heated for hr., stirred every hr. and allowed cool slowly. Note the following: (Left) The large zinc crystals with them like bar. Other dross crystals different angles are visible black the zinc (middle) this case the temperature high that oxidation has white borders around the dross crystals; (right) special interest the shape the dross lected this temperature. that formed from iron oxide corrosion the base ma- terial after Note how the bath has cleared and the formation has made clear-cut dis- tinct dross crystals. These are shown the photograph the very black crystals seen the large zine crystals. The assimila- tion the large black dross crys- stals the smaller ones can seen plainly. The outline form evidenced the strong tendency forces crystallization can seen number these uncom- pleted crystals. The features interest this test are (1) com- plete formation the dross crys- tals from the iron oxide, (2) ex- tremely large crystals formed, (3) clear appearance the crys- tals, (4) practical disappearance the granular zinc-iron alloy favor distinct dross crystals, (5) tendency for the granular zinc- iron alloy cut the crystals into irregular blocks, state the metal and its clear- ness, (7) total absence any iron oxide particles, (8) distinct paral- lelograms and forms the dross crystals, and (9) large crystals seem settling the bottom the melt indicating that they are heavier than the melt. The middle view Fig. shows that number important things happen when the molten zine and iron oxide have been heated temperature 1300 deg. The illustration just described was heated 1100 deg. and glance these two illustrations quite difference appearance. The following interesting things have happened this test 1300 deg.: (1) There complete the appearance the melt compared the one 1100 deg., (2) striking appearance oxidation the zinc, (3) the mass exceedingly fine dross crystal fragments, (4) the zine- iron alloy matrix, (5) complete absence zinc crystals, (6) com- plete absence any iron oxide, (7) dross crystals seem many and instead large ones seen 1100 deg., and (8) the metal was solid the specimen. important feature that be- comes apparent this tempera- (CONTINUED PAGE 116) THE IRON AGE, December , 7 with gas torch. This method eliminates the burn-off oven. the finishing and japanning fenders and other automobile parts the work first rinsed and dried washed, single oven through .which the parts are carried traveling conveyor. When the parts emerge from this oven they pass oper- ators with gas fired torches where huge flames are directed onto them. This method effective eliminates all handling parts and does away with t