The Iron Age 1936-02-06: Vol 137 Iss 6

The extraordinary progress American largely been due the promptness and con- sistency with which incorrect principles have been abandoned and new principles adopted. When automotive engineers stopped trying make automobiles building over horse drawn buggies and began attack motor car design entirely vehicular problem, the automotive industry went ahead leaps and bounds. Imagine this industry plain bearings! When railroad engineers recognized that the attain- ment ultra high speeds was not merely matter building bigger locomotives, but demanded en- different type equipment, the modern stream- lined train was born—and with roller bearings, too. And when rolling mill engineers realized that mill speeds were increased, bearing life extended and costs reduced, radically different type neck bearing would required, friction was wperseded anti-friction roll neck bearing were eliminated and new era rolling nill operation was begun. mechanical principle fundamentally wrong, amount refinement can make successful. THE TIMKEN ROLLER BEARING COMPANY, CANTON, ENGINES NECK that ti es WI th 2—THE IRON AGE, February 1936 THE IRON AGE, published every Thursday the CO., Chestnut 56th Sts., Philadelphia, Pa. Entered second class matter November 1932, the Post Office Philadelphia under Act March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 137, No. FRITZ FRANK, President J. H. VAN DEVENTER Editor GERKEN Managing Editor FINDLEY Editor Emeritus Washington Chicago Cleveland Pittaburgh MILLER Machinery Editor FRANK OLIVER GERARD FRAZAR Detroit Boston Cincinuati 1936 CHESTNUT AND STREETS, PHILADELPHIA, PA. Let's Examine the Record WEST STREET NEW YORK, Welding Large Reflecting Telescopes How Cut Your Payroll Tax. Use Gas-Fired Radiant Tubes Enameling. Steel Castings—Properties and Design Van Stoning and Bending Pipe. Plans for and Steel Scrap Survey New Equipment The Age Staff Changes Automotive Industry January Pig Output Imports and Exports Last Year Washington News News Rate Activity Capital Goods Statistics Metal-Working Activity. Markets Construction and Equipment Buying. Index Advertisers Copyright 1936 Chilton Company BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau of Circulations ADVERTISING STAFF Member, Associated Business Papers Emerson Findley, 311 Union Cleveland Owned and Published CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. Cc. A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC C. STEVENS. Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFPFTT, Secretary Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50, including duty; Foreign $12.00 a year. Single copy, 25 cents. Cable Address, ‘‘Ironage, Y."’ B. L. Herman, Ave., Buffalo. Hottenstein, 802 Otis Bidg., Chicago Peirce Lewis, 7310 Woodward Ave., Detroit 56th Sts.. Philadelphia, Pa. C. H. Ober, 239 W. 39th St.. New York Robinson, 428 Park Pittsburgh Sweetser, 239 West New York Warren, Box 81, Hartford, Conn. eon OME A a — 4 SE RYERSON STOCKS INCLUDE BEAMS AND HEAVY STRUCTURALS CHANNELS, ANGLES, TEES AND ZEES RAILS, SPLICES, SPIKES, BOLTS, ETC. PLATES—SHEETS STRIP STEEL, FLAT WIRE, ETC. STAINLESS STEEL HOT ROLLED BARS—HOOPS AND BANDS COLD FINISHED SHAFTING AND SCREW STOCK EXTRA WIDE COLD FINISHED FLATS ALLOY STEELS—TOOL STEELS HEAT TREATED ALLOY STEEL BARS BOILER TUBES AND FITTINGS WELDING ROD—MECHANICAL TUBING RIVETS, BOLTS, NUTS, WASHERS, ETC. REINFORCING BARS AND STEEL BUILDING PRODUCTS COPPER AND BRASS BABBITT METAL AND SOLDER PERMITE LEADED BRONZE BARS Steel Every Kind, Size and Shape Ryerson Stock For Immediate Shipment Whatever your requirement standard alloy steels special cutting, bending emergency delivery—you can call Ryerson with full assurance that everything possible will done meet your requirements well within the time specified. Large stocks bars, all finishes, and sizes, together with all other steel products are stock for Immediate Shipment. crews with unequalled facilities—together with special dispatching methods —assure quick, accurate handling your orders. The Ryerson Stock List your guide these large stocks steel and allied products. you not have the current copy, write and will send it. Joseph Ryerson Son, Inc., Chicago, Milwaukee, Buffalo, Boston, Detroit, Cleveland, Cincinnati, St. Louis, Philadelphia, Jersey City. IRON AGE, February 1936 P . | | > THE IRON AGE... FEBRUARY 1936 ESTABLISHED 1855 Vol. 137, No. Examine the Record ATE ugly word. does ugly things. Fortunately, there not much the world business some people be- lieve there be. long and intimate contact with both sides industry has failed reveal employer who hated his workers and mighty few workers who have really hated their em- ployers the ordinary conduct their relations. Exception must made, course, for the handful Communists America whose religion hatred. Such people, however, not count, for there were one else hate, they would hate themselves. Doctors tell that hating unhealthful. That poisons the system the man who indulges it, ruins his digestion and shortens his must that the average American, high low, realizes this truth instinctively, because normal people try hard possible avoid it. typical American workman wakes the fact that hates his boss, tries find another one who will not arouse this unhealthful emotion. That one the advantages that the American System has over dictatorships where you cannot change jobs. The charge has been made that the New Deal has encouraged class hatred, particularly between employer and employed. Such serious charge deserves either disproof substan- tiation facts. There only one way that can measure the intensity antagonism between employ- ers and employed any given time and that the scarcity prevalence labor troubles expressed strikes. The United States Department Labor gives accurate measure this, for keeps record man-days lost because such conflicts. Here the record years, man-days lost through strikes since 1930— 2,730,368 6,386,183 1932— 6,462,973 1935—13,688,016 (first ten months available) During the three years immediately preceding the New Deal, there were man- days lost through strikes. During the three years immediately following the New Deal, there were 47,815,512 man-days lost through strikes. matter how idealistic its professed aim, any deal, old new, that makes such definite record tripling the symptoms class antagonism not the kind deal that the average American will want continued. Hatred will ruin the economic system country readily will poison the blood-stream individual. cf 7 7 4 SF 43 ae ith ° % ite Sr 9 ANYONE who has had the privilege seeing the Planetarium Chi- cago must have come the marvelous engineering skill and ingenuity built into mechanism which capable reproducing, with marvelous accuracy, the travel heavenly bodies. While this interesting and in- structive apparatus may seen anyone visiting Chicago, in- spection the equally marvelous reflecting telescopes America 20—THE IRON AGE, February 1936 away with profound respect for centerpiece and cylinder the 82-in. telescope. After welding, the center- piece was stress lieved 1200 and then chined. not easy. Located, they are, usually out the way places, operated almost entirely night, few laymen have the opportunity see them. Through the generosity McDonald, bequest $900,000 was made the University for the erection ob- servatory. The Warner Swasey Co., Cleveland, builder machine tools and telescopes for years, was awarded the contract for the design and construction the ob- servatory and its 82-in. reflecting telescope. This article has with the building the larger parts the telescope, particularly those fabri- cated welding. This work was performed the shops the Well- man Engineering Co., Cleveland. Several years ago, was found elding the ° ° Vice-President, Wellman Engineering Co., Cleveland. advisable construct certain parts the Perkins telescope, de- signed the Warner Swasey Co. for the Ohio Wesleyan Uni- versity, very much lower weight than had previously been possible. accomplish this, the Warner Swasey company, consulting with the engineering staff the Well- man Engineering Co., worked out welded design which proved emi- nently successful from saving standpoint. Naturally, designing this new and larger in- strument Burrell, chief engi- neer, Warner Swasey Co., selected welding the fabricating medium for those high strength, rigidity and low weight were essential. Fig. shows the centerpiece and cylinder the telescope. The centerpiece, the lower section the assembly, the part which attached the polar axis. This part must constructed that When considered that this detail, which attached the mirror cell (shown Fig. car- rying the 82-in. diameter 12-in. thick glass mirror, practically 360 deg. both hori- zontal and vertical planes, will seen that rigidity and strength are vital importance. The upper structure Fig. also welded ° ° ° > abrication Large steel, composed octagonal shaped horizontal I-beam members welded eight vertical I-beam posts. The tie rods and turnbuckles are alloy steel welded the panel points. The upper and lower rings this cylinder were welded, stress relieved and machined be- fore assembly. Due the fact that absolute parallelism the two faces was required, great care ment and freedom from warpage welding. This was accomplished working from true floor plates, using plumb bobs and accurate, over-all height pin gages. Centerpiece Construction The centerpiece referred above shown the drawing Fig. will noted that the frame this structure consists number circumferential and vertical beams, interlaced and se- curely welded together, enclosed with cover plate, forming cyl- inder 104 in. diameter 82% in. high. This cylinder sected another cylinder right 2—Centerpiece the telescope, constructed cir- cumferential beams. This welded structure consists intersecting cylinders with forged steel spindle. Note the details the welded joints, many in- welds complete penetration the metal. angles, the latter having incorpo- rated its construction forged steel center and seats for 54-in. and 14%-in. Timken roller bear- ings, also flange ring which attached worm wheel for turning the vertical plane. The horizontal circular ribs were Veld after Bending Symmetrical about Center 1254 28-0 These Axis must Intersect and made 10-in. I-beams, split two sections, removing in. the web, rolled the proper diameter and welded together form cir- cular beams in. high. Fig. shows the fixture used aline properly the skeleton frame secure the accuracy re- 3°63 (exact) Cut Hus Flange Flush with Web this Point only Weld Shell Plate Plates 0" SS Closing Plates Dia 254 28 0 Plate 83 Dia.x If ' ' ‘Bar qx 27-0 THE IRON AGE, February : igre - al 9] 6 /b. ay Vi, ° ° = quired. Referring again Fig. will seen that the two faces the centerpiece are machined angles the planes the roller bearings. When realized that the vertical flange (against which right angles the main cylinder was not out plane over 1/32 in. required welding and thermal stress relief realized. Fig. shows the 0.40 per cent carbon trunnion forging welded 2-in. plate. The outer end this forging forms the seat for the diameter Immediately beyond the radial ribs located the heavy ring which provides the seat for the 54-in. rol- ler bearing. Welded Joints Stronger Than Rolled Plate _ seen that all joints highly stressed are 100 per cent 3—The centerpiece was welded fixtures assure correct reinforced where possible with fillet alinement the various parts. After all parts were tacked se- welds order obtain welded curely, the centerpiece was removed from the fixture for com- joint strengths greater than that IG. pleted piece being ma- chined ft. boring mill. This unit 104 in. and in. high. . = 22—THE IRON AGE, February 1936 ‘ drawing, will noted that each joint definitely detailed show the preparation the steel for welding and the amount pene- penetration, form weld, type electrode welding current char- acteristics was left the hunch the welding operator. Every step the welding procedure, in- cluding positioning the parts during welding, definitely planned. Fig. shows the centerpiece being faced 18-ft. diameter vertical boring mill. Extreme care was exercised these facing op- erations assure proper alinement the top and bottom flanges with the roller bearing seats. These seats were specified within 0.0003 in. out roundness and 0.0005 in. diameter. The mirror cell used support the 82-in. diameter reflecting mir- ror seen Fig. This design consists interlocking 6-in. beams base welded flanged cylinder. The completely welded structure was stress relieved 1150 deg. before machining. The ever-increasing progress welded construction, where light weight, high strength and great are required, indicated this interesting piece fabrica- tion. When considered that the entire investment $900,000 depends, great extent, the proper functioning these two pieces welded fabrication, the confidence the designing engi- neer the efficiency welded con- struction fine testimonial the progress the welding art. drawing the 82-in. reflecting telescope. The welded details shown Figs. and can seen supported the polar axis. THE IRON AGE, February 1936—23 5—Welded mirror cell for supporting 82-in. reflecting mirror. Cut Your The one method for reducing the payroll tax which began New Day ° ° ° HARING ° THE “Social Security” program was enacted the closing days Congress, last August. Amid the welter new laws, at- tracted little attention among em- ployers until January first ap- proached. Upon that day the tax payrolls became effective, rum- blings elaborate reports took form, and business suddenly awoke the fact that the heaviest tax ever imposed now upon us. The plan “Social Security” history’s most ambitious welfare scheme, going far deeper into relief than all previous laws lumped to- gether. For revenue support the relief, the new law follows the workmen’s compensation method: lays tax the payroll. But 24—THE IRON AGE, February 1936 the law exceedingly complicated. The combination unemployment ‘insurance with old-age pensions loss calculate the cost. The tax for one purpose, unem- ployment, begins with the first day 1936; for the other purpose, old- age pensions, one year later. Both taxes gradually with the years. Under the Federal law, the rates are shown this table. RATES UNDER FEDERAL LAW Cent Tl » mT 1949 and there- these totals the states may add either for (1) the fund itself (2) for the cost state ad- ministration. Should the state tax less than Federal totals, the em- ployer must pay the Federal sum. the state taxes him more, the burden the employer much the heavier. Wisconsin, for ex- ample, the 1936 rate per cent; Utah, Ten states, plus the District Columbia, already have cooperating laws. Nearly every re- maining state will enact law within three months, because not Federal money within the state. But, whether your state has law not makes little difference, be- cause the Federal law catches you for the tax. The second part the new tax, that for old-age pension, still year away. The first part, for unemploy- ment, already effect. shall, for that reason, confine our discus- sion how cut the tax the _ ‘ unemployment feature only. Nor shall dig into the “benefits” paid employees laid off the company they being, general, the payment half the going wage for each week idleness after brief waiting period and, even then, covering about four months each year unemployment. Our thought will pierce more directly the tax —that is, the price paid you for protection your workers, What Can About When you query your attorney, your tax counsellor, “What can about it?” his reply cer- tain be: “Not much.” The fact that escape from the whole bur- den nearly impossible. Hope confined methods for reducing the tax, under clauses the law itself. Even then, the pos- sibilities are limited single method—but most alluring busi- ness opportunity for awake management. All the laws open with clause this sort: “The purpose promote regularization employ- ment industry....” Therefore, the laws, although deeply hidden among the pages detail, sort “saving clause” held out in- dustry that employer may escape the tax (all but per cent) doing for himself what the law contemplates for society whole. employer will “regularize” “stabilize” his employment, will let off from the major portion the tax. These two and for purposes these laws seem mean “prevent unemployment your men” “devise means reduce lay-offs,” or, final measure, “set schedule unemployment benefits for your own men when idle through fault their own.” Due allowance made for idleness because disputes strikes, vaca- tion work and seasonal employment, incompetent dishonest workers, etc. shall take account these problems, order examine the principal task, namely, that guaranteeing regular employment your workers. The Federal law was, like many another, enacted hurry. Even Congress recognized that some em- Ployers already had insurance effect for protection their work- ers, and that others had for years guaranteed employment paid benefits when lay-off did occur. order treat fairly these em- ployers, Congress provision for supplemental legisla- tion based investigation. The intention establish “merit rating” “preferred basis” for such concerns relieve them the new tax. Perhaps the following clear does from Congress: Federal Policy ‘Because unemployment large- economic problem beyond the control individual employer and because the policies one in- dustry often cause unemployment another, some extent all em- ployers should required share one another’s burdens. Recogniz- ing, however, that unemployment also due policies the individual employer and that some extent can stabilize his employment, the bill provides for variation contributions the fund within certain limits.” The state New York has ap- pointed Advisory Council citizens, Massachusetts “committee and other states similar bodies, for the pur- pose, stated the law New York: “Shall investigate and study the operation this act with view classifying employers with respect the frequency severity unemployment, report the practicability rating system, and encourage the stabilization employment industry.” Yet another group states have not hesitated inaugurate once “merit Wisconsin, for two years past, has operated such plan. California, New Hamp- shire, Oregon and Washington have legislated plans even tiniest details. The purpose encourage em- ployers reduce lay-offs. em- ployer with good record re- warded—through reduction his tax. Two methods prevail. Both are found, ordinarily, the same law. Near and Far Rewards First the more distant reward, won after three years’ trial the new law. employer shows excess payments into the fund over benefits paid his em- ployees, his tax reduced from the basic per cent (which will the Federal rate January, 1938). this excess equals per cent the average annual payroll, the per cent tax becomes per cent; the excess mounts per cent, the tax drops per cent; excess per cent, the tax per cent; and, for per cent more excess, the tax drops per cent. Second immediate relief from the full tax, under what the states call “guaranteed employment plans.” such case the law authorizes the Commission exempt (from the tax and from other provisions clearly inapplicable guaranteed employment plans) any employer who guarantees, under plan ap- proved the Commission, tinuous employment” advance for each worker, now employed hereafter hired. “Continuous” does not mean exactly “uninterrupted” but, the law’s wording, the em- ploved guarantees “for one-year periods, least that number weeks work wages for least that number hours each week set forth the following table”: Minimum Minimum Number Weeks per Year Each Such Week These Column vary slightly among the states. Each employer, addition, required specify the wage rate both for active service and for “unemploy- ment wage benefit.” And, uniform- the laws, the phrase: “Pro- vided, the Commission satisfied that the employer can and will make good his promise under all Trend Legislation These two methods show the trend lawmaking. Indications are that the Federal law will incor- porate similar “encouragement” employers. Several states, in- cluding New York and Massachu- setts, are likely alter their laws, after this same pattern, before the first payment the new tax falls due, March 31. But, whether they act thus promptly not becomes (CONTINUED PAGE 93) THE IRON AGE, February 1936—25 ’ * i | | . ~ «2 - 4 = j l . t ihe My ’ - A\pplication Gas-Fired Radiant THE Detroit Michigan Stove Co. the manu- facturer the well- Jewel, Garland and Laurel lines gas cooking and heating appliances. also makes the Jewel and Garland lines gas hotel ranges and broilers. Millions American homes, restaurants, hotels and in- 7 26—THE IRON AGE, February 1936 GEHRIG Assistant Superintendent, Detroit Michigan Stove Co. stitutions are using these appli- ances, the manufacture which started more than years ago. The equipment required pro- duce these appliances has under- gone constant changes, just the designs the stoves change from year year. Perhaps equip- ment has had more changes from engineering standpoint than the enameling furnaces the enamel- ing plant. For some the equipment has consisted six gas fired, box type muffle furnaces and one continuous hairpin type enameling furnace. 4 Although both these furnace types represent the best design and engineering know today, yet, matter fact, they still have certain deficiencies. Heat the ware the furnace chamber transmitted through muffle, which its best, inefficient. Muffles are not impervious. Sooner later combustion enter burning chamber and since the atmosphere surrounding the ware then very uncertain, various contemporane- ous difficulties arise connection with firing the ware. IG. range ovens entering radiant tube enamel- ing furnace. | ° ° ° } — 3 q Tubes Porcelain Enameling New Development Offers Many Advantages Enamelers The method applying heat and the resulting furnace atmosphere are chiefly responsible the physical appearance the enamel surface well the bonding the ground coat. strictly oxidiz- ing furnace atmosphere the prime requisite for best operating results. Muffle repairs replace- ments are barriers against con- tinuity operation. They are costly and often are the cause unexpected Electric furnaces have the whole fine record performance despite the fact that operating costs are high and the danger caused short circuits always prevalent. shutdowns & tubes within porce lain enameling fur nace. Over period years there have been number improvements gas fired enameling furnaces. How- ever, studies instigated the Committee Industrial Gas Re- search the American Gas Associ- tion indicated that rather radical changes design methods applying gas heat were possible and that these changes gave prom- ise incorporating every feature electric furnaces with some ad- vantages over the latter, notably lower operating cost. The Com- reached the conclusion that these objectives could obtained heating enameling furnaces with gas fired radiant tubes placed the furnaces manner similar the way electric heating ele- ments are installed. Gas fired radi- ant tubes the past few years have been developed the point where practically any heating ca- pacity can readily taken care of. The adaptation these tubes enameling first, engineering problem and, second, the need for demonstrating the practicability this whole method firing. Gas has always been used many enameling installations but, perhaps, with some degree un- certainty haziness the ef- fect the ware. However, with ras fired radiant tubes, the furnace atmosphere becomes free from THE IRON AGE, February 1936—27 ‘qe by _ contamination any existing type enameling furnace the mar- ket today. The conversion the furnace merely entailed removal the fur- nace muffle and its substitution radiant tubes. The result was gas furnace possessing every ad- vantage electric heat applied static surface heating. Fig. shows work entering furnace this type, and Fig. gives idea the arrangement the ra- diant tubes the furnace. The furnace has now been continuous operation for over four months, and the results obtained are very gratifying both from pro- duction and economical standpoint. The work performed has been equal quality, not better, than that obtained from full muffle furnace. The more lustrous strictly oxidizing furnace atmos- phere which all times free from harmful gases and very necessary requirement for vitreous enameling. fact. gas radiant tubes the heating agent for porcelain enameling are not only practical but basically economical because the high radiant heat emissivity alloy tubes and the proximity the work the source heat. The working dimensions the box type furnace were not affected the conversion. There are six hairpin type radiant stalled, four the furnace hearth support for the work and one each side wall. The tubes are fired from the rear the furnace means special diffusion gas burners, indicated Fig. The operation the radiant tube very simple and easy. The tubes are all times under negative pressure suction, which pro- duced injecting blower air into small stack eductor the end each tube. This suction serves three purposes. First, permits the fuel gas entering the firing end the tube draw just enough air for complete combustion, and second, preserves the non-turbu- lent flow the highly luminous flame thus developed throughout the entire length the tube which assures uniformity heat distri- bution. Third, maintains nega- tive pressure within the tubes with the result that there can never any discharge combustion gases 28—THE IRON AGE, February 1936 ‘tas 3—Rear view radiant tube enameling furnace showing the lo- cation and arrangement burners. into the working chamber the furnace. Combustion within the tube can maintained almost the point lowest flue loss. This quite evident the enameler who has been accustomed see gases belching forth from the flues muffle furnace. The tubes op- erate with perfect safety both ends the tubes always being open the atmosphere. Adjustment the burners can maintained easily. Maximum temperatures inside the tube wall not exceed 1850 deg. F., which sufficient pro- duce furnace outside tube tem- perature 1600 deg. which temperature our furnace gener- ally operated. Compared with muf- fle furnaces, temperatures 2000 2200 deg. are necessary obtain 1600 deg. the furnace proper. These figures undoubtedly represent economies fuel con- sumption, yet producing normal comeback which indicates that the important contributing factor lies the rapid heat transmission the alloy tubes upon which the ware placed and burned. enameling furnace there always drop temperature caused opening the door, together with the weight the cold material when charging new load. The time required regain the original temperature commonly termed the “come-back” the furnace. any new type furnace, the pertinent question asked is, come-back has this furnace?” The gas-fired radiant tube enameling furnace has normal come-back compared with muffle furnace. This was demonstrated running the same charge the same tem- perature the same operators for more than three-day period. one can say that the stored heat muffles not altogether neces- sary produce normal come- back. the box furnace has suf- ficient depth its walls together with good layer insulation, these walls then provide sufficient stored heat compensate for the sudden drop temperature. This highly augmented the fact that the radiant energy released the tube directly transmitted the ware itself, giving extreme flexibility operation. Door losses are dependent the lift the door and can hardly altered owing the loading condi- tions and the shape the ware which determine the duration and height the lift. However, the loss through the door itself, the door openings, can materially minimized the use proper de- sign and insulating material. The heating-up period the gas- fired radiant tube furnace fast one might desire the heat readily transferred the effec- tive areas inside the furnace. clearer idea can ascertained from the week-end curve given Fig. which shows comparison between the two fur- naces, muffle and radiant tube. the contrary, the cooling-off (Fig. the radiant tube furnace over week-end shut downs for instance, much slower than one would an- ticipate view its rapid heat- — 3 | RIGHT 4—Comparing the week- radiant tube and naces. Note that the radiant ubes quickly transmit heat the interior the furnace. BELOW showing the temperature | | A- Radiant Tube -fue/ Rate -2 900 Cu. per Hr C ty Gas + + + four week-end shut down. The radiant tube furnace cools off ] ) ? 3 mu more | wily than one 10 4 A.M would anticipate. yf When Each Furnace Wa Down 1400} 1200 1000 800 60 400 8: Regular Muffle Furnace ¢ Fequ/ar furnace with Autornat Damper > Radiant Tube Furnace ing-up facilities. The retarded rate cooling-off the furnace and tubes undoubtedly due the lack vents flue passages within the furnace structure. From the plant operator’s stand- point, the greatest factor all the radiant tube applica- New NEW type structure formed sections insulated steel sheets has been developed Ger- many, according report from Berlin the Department Com- merce. According the inventor, there have been number develop- ments steel panels for section- built construction, but claims that most cases these required one operation erect the steel frame, another screw the sections panels, another fit the inner insulation material, and still another finish off the inside walls, while separate operations took care the installation windows, doors and other parts. tion the ability foresee breakdown or, better yet, the ability repair defective tubes without disabling the major unit. This fea- ture itself represents very tangible saving costly repairs, lessening the loss production and damage done repaired fur- get back into production. the event that tube should time become defective, which not impossible, the situation becomes indeed most favorable. The solu- tion would keep piece repair tube hand, each ra- diant tube can and easily removed. only matter letting the temperature drop, remove the burner casings the outside the fur- nace, repair replace the defec- tive tube, and operations can unheeded. These facilities will con- siderably cut the repair cost over conventional furnaces and reduce the lost production mini- mum. Type Steel House Germany The newly developed panels are made sheets 1/16 in. thick rein- forced with angles. this one sheet are placed three layers corrugated pasteboard which are stretched and maintained proper intervals wood lath. These pasteboard layers are thermos in- sulation. this another steel sheet 1/16 thick and this mm. (0.59 in.) plate insulite. The whole hermetically sealed together. The outer surface painted, and the inner surface insulite may painted papered. The panels are about 1.22 meters (4ft) wide, about ft.) high and weigh kg. (17.6 lb.). The plates are the sec- tions the house. Some the sections have and doors already built into them. The var- ious sections fit together tightly means groove and tongue and they are further hermetically sealed felt strips mm. (0.16 in.) thick, placed the vertical side surfaces the steel panels and pressed together erection thickness mm. (0.118 in.). When the buildings are finally fin- ished, the outer grooves are put- tied. The inner walls and ceilings are made similar panels. The inventor claims that these walls are sound-proof and offer the same protection against heat and cold walls made three layers brick. THE IRON AGE, February 1936—29 | | | | } } + } + + } + + + + 2 | - 1200 + + + + 4 + + + + + + } | } = ] ° ° ° | | n RON) } + + + 4 4 4 4 4 4 4 + + + + Fick | | y | } A + + + + + + + + + ie Time ime ie 4 19) it } 1, it ie is ie 1- > | A | p n > e, t- E'LL Make Good Steel this picture. And good casting ensue, foundryman must have steel made the most con- trolled and practices, molds and cores must used in- telligently and equally important, the design the casting should such enable the molten steel solidify progressively and all these variables gently handled, the resultant cast- ing can, many cases, compete satisfactorily with forginas Photo MUDD the Midvale Co. this country the present speaker bered that these blocks are de- FROM time time one hears comparison steel castings and forgings chemical composition, often derogatory the former. Only this year Dr. Hatfield, the eminent British metallurgist, reply- steel castings could some con- ditions replace forgings satisfac- torily, used unequivocal “No.” qualified his definite opinion explanation, often used *Abstract paper presented before the Cleveland Chapter the American Society for Metals. 30—THE IRON AGE, February 1936 and others, detailing the varieties section and influences which must considered when casting made. There are two which could possibly advanced for any assumed superiorities forgings: First, the influence mechanical work the structure the steel, and, second, the influence design solidification phenomena the case the castings. This paper was written emphasize the fact that far the more important the two the second, and that the condition not any means be- yond remedy. illustrate this point, consider the physical properties exhibited sand-cast test blocks, heat- treated correctly and various ways. First, must remem- signed feed solid, and this means that after pouring they solidify progressively from the bottom and sides, fluid shrinkage being cared for adequately ample riser. Thus there obtained condition controlled design, and cast metal made sand mold not subjected any mechanical work such rolling forging, which could change affect the microstructure. therefore, that any physical prop- erties obtained treatment thermal type only are direct reflection the susceptibility cast structures the modifying in- fluence heat treatment. Thus any shortcomings the physical properties manifested, when com- pared with similar forged steels, vT be A could, the legiti- mately credited the absence mechanical work, assuming de- sign and feeding were perfectly arranged for. The writer has prepared and tested series cast steels which have been produced under most favorable conditions. course the physical tests not equal every detail the optimum figures obtainable from perfectly forged and treated samples steels similar analyses. But the tests did, however, generally exceed specification upon forgings, thus indicating exceedingly good response heat treatment applied cast struc- ture. Logically, then, this indicates that judging purely results ob- tained from perfectly designed and poured sand-cast block, there would appear reason why steel ‘astings should not encroach many fields hitherto looked upon almost sacred forgings. Assuming these founded upon facts, and believed they will confirmed carried out exhaustive tests from their material, must look else- where than the effect me- chanical work structure for any assumed accepted advantage forgings over castings. Individual Design opinion the onus thrown Straight back the question individual design. Many members Properties and FRANK MELMOTH Vice-President, Detroit Steel Castings Co. ° ° the steel foundry industry have stressed this point repeatedly, and the risk being accused tire- some repetition, proposed over this question again, with probably few added suggestions. Steelmaking, whether the prod- worked state, that rolled forged, cast shape without mechanical work steel castings, consists identical state affairs, combinations con- trolled reactions. even pos- sible that owing the respect which steelmaker attached foundry holds the unbalancing effect sand molds, such steel- maker increases his degree care, against the maker cast steel ingots. the case cast steel ingots, however, the shape the piece cast, and therefore cation progression, has been ar- rived careful investigation, and the steelmaker possesses perfect control. other words, can make ingot suitable not only the ultimate formation the desired forging, rolled prod- uct, but also shaped give the molten steel every opportunity solidify and cor- rectly. The engineering designer responsible for the ultimate shape the product designs merely the forging, but his efforts are little, all, related the solidifying conditions the molten steel. Steel casting practice, however, considerably different. The form which cast exactly that ° which put service, apart from any machining Therefore the person controlling its design, shape and contour defi- nitely has predicated its mode solidification throughout and from point point. This one factor has been the basis for the statement repeatedly made the founding industry, that all designers dealing with need adequate knowl- edge solidification phenomena. Where the appreciation diffi- culty, brought about knowledge, does not exist the designer, foundries whole are driven all kinds artificial methods order approach sec- tional soundness nearly pos- sible overcoming the natural and unavoidable changes occuring The curse the entire founding industry orthodoxy design. has never seemed logical the present speaker consider forg- ings and castings the same plane general shape and sectional dis- tribution. one adopts this form consideration, then becomes reasonable emphasize the ineffi- ciencies the cast form com- pared with the worked form, as, obviously, only the latter has had the advantage considered design applied during manufacture. Locally, therefore, casting suf- fers from poor solidification condi- tions degree dependent upon the success otherwise the contrivances used the foundry. these conditions, the inherent THE IRON AGE, February af | AS d¢ ~ ‘Sa id ier properties the metal used can- not demonstrated either test service conditions all parts the casting, and are only poten- tially present. the foundryman, and possibly most engineers, this prompts the query whether the condition necessarily need so, remedy pos- sible. The answer that gener- ally speaking, almost all designs are capable improvement, viewed from foundry standpoint. This statement may appear somewhat extreme, but can demonstrated correct quite easily. Solidification Phenomena During the last few years there has been marked tendency the literature the steel founding industry study the facts solidification with view de- termining their effect steel cast- ing soundness, and, coincidentally, the influence design upon solidi- fication. The reader referred especially the papers Briggs and Gezelius, the Naval Re- search Laboratory, which have been presented annually American Foundrymen’s Associa- tion, and the paper George Batty, Consultant Steel Cast- ings, Philadelphia, submitted this year the Institute British Foundrymen. The work these authors immense benefit steel founders, loosely held ideas established facts. must admitted that this all the good, but believe that the real value their work never can fully manifested until the designer also gives them the necessary study and application. After all, controlling shape solidification progression castings, always excepting the in- fluence various utilized the founder which are often inspired desperation. These remarks may convey listeners impression that the steel founder labors under den heavy difficulties the production his product. And there will curiosity what extent has succeeded overcoming them, evidenced the reliability his product. the ten years from 1920 1929 inclusive, 11,921,470 tons steel castings were produced this country, average over one million tons per year. These 32—THE IRON AGE, February 1936 castings were absorbed the various branches the engineer- ing industry such widespread fashion that true say that almost every unit the immense population this country trusts his her life the dependability steel castings every day. Every steamship and every locomotive, every freight and passenger car, commercial truck, and even many aeroplanes contain some vital part examples the steel found- ing art. Every power station and every bridge literally dependence castings, and fair statement say that the rarity cases where such reliance ill-placed remarkable. Breakdowns due lack depend- ability steel castings least infrequent the case any other constructional material. This suggests that founder has done good job overcoming, his own efforts, the drawbacks enumerated previously, and also opens grounds for conjecture just how far steel castings could were the facts fully appreciated, and steps taken design and use them the light up-to-date knowledge. Good Steel Imperative Obviously perfectly futile attempt the manufacture any steel casting unless made the most controlled and modern practices available. For steel casting used without any me- chanical work, such forging rolling, and the steel must such condition solidify with perfect structure possible, and must also free soundness the casting itself, such shrink cavities and blow- holes. Thus this requires com- pletely deoxidized product essential, that is, when viewed from normal standard de- oxidation. The steelmaker steel foun- dry must have before him promi- nently the following requirements: Regularity Analysis: Cast- ings are almost requirements design shape meet certain fixed conditions. There analysis determined, together with heat treatment, produce part exhibiting itself certain physical strength. fol- lows, therefore, that extremely unlikely that any casting “misfit” analysis can put into stock and used against some other and future requirements, and consequently they are definitely scrapped. Such conditions involve melting methods organized and controlled type main- tain analysis within the specified range all times. The Requisite Metal Tempera- ture for Job Poured: compared with ingot practice, sand castings vary much design and metal thickness, and the effect pouring temperature con- siderable, that steel must made full knowledge the type adjusted accordingly. Complete Freedom from Gases: passing through sand mold, particularly such mold made necessary that the steel should safety against these unsettling influences. this margin not present, disastrous unsoundness appears the casting. Freedom from Excessive Amount Non-Metallic Inclusions: Quite number papers have been pre- sented before the American Foun- drymen’s Association relative cause and effect non-metallics steel for foundry use. For our present purpose, sufficient say that clean steel decided adjunct the production good castings. Aside from their effect physical properties, exhibited test bars, non-metallic inclu- sions, more particularly the striated, stringy type, appear cause foundry trouble such un- usual liability cracking. perhaps debatable whether not this due the direct influence the inclusions themselves some condition, which the inclusions may only out- come corollary. Acid electric steels, which are very popular for steel foundry use, have been particularly prone this trouble, and much work has been done the last few years determine causes and stabilize i | i i H H | 2 operating conditions less likely produce inclusions definitely harmful type. Melting Equipment Regarding steel producing proc- esses used the modern steel foundry, every method use other branches the steel trade common use. The class melting equipment dependent upon the type work made the individual foundry. Makers heavy castings, course, find the open-hearth furnace, either acid- basic-lined, according prefer- ence and available material, most suited for their purpose. con- verter, usually side-blown, still use some steel foundries, and capable hands excellent piece equipment for light and medium sized work. The electric furnace has many supporters owing its elasticity operation. almost all cases acid-lined. For the manufacture steel cast- ings the high alloy content, the more modern induction furnace use many foundries. had the good fortune when Europe this year present for several days what might called the steel foundry christening powdered fuel melting furnace. Excellent steel was produced and poured into castings, and, while true that there exist many points which further development work necessary before such furnace will take its full place melting equipment for steel, yet equally true that the results are promising that such out- come due time almost certain. Alloy Steels The steel trade generally now living what might termed only the beginning alloy age. Engineering development has wrought rapid changes demand steel foundries, and for many purposes the margin capability over service demand carbon steels was soon exhausted. Steel foundries generally have been prompt develop steels able fit the new conditions, and almost all classes alloy steels can now obtained cast form. realized that alloy additions, such, mean very little, and that ultimate satisfaction service be- havior can only the result combination witn balanced alloy content which subsequently adequately heat- treated. The growth interest alloy steels, and the remarkable results obtained their use, have been great factor making steel founders metallurgically minded. The foundries today are staffed with men very different kind training from that normal the past. The past ten years have seen more research, directly ap- plied steel casting problems, than ever before, and this research continuing rapid pace. tionally complex business, and the multiplicity factors which can adversely affect the product are all correlated. Research any one phase, therefore, necessarily must constantly keep mind the possible effect many other phases and their variations. Leaving aside the purely me- chanical side production, which largely engineering problem, research falls into four main sec- tions, namely, (1) steelmaking for castings, (2) control solidifica- tion after pouring, (3) material for molds and cores and their effect, and (4) final heat treat- ment. the first these items much progress has been made. realized that control composi- tion, control quality, and type non-metallic inclusions, while important, not any means cover the field necessary re- search. The influence tempera- ture also very significant, but the main requirement undoubt- edly the production steel immune possible the unbal- ancing effect the which poured, and free from weakness possible. These necessarily controlled orthodox composition. The method pro- duction the steel would appear exert quite influence. For instance, known that steel pro- duced without regard perfect condition both slag and metal, the final stages manufacture, although analysis showing the correct proportions the normal elements, very liable cracking the mold during cooling. promising field for research, there- fore, are the conditions affecting inter-crystalline strength tem- peratures just below solidification, period where most cracking steel castings seems occur. Fluidity, also, vital point the steel founder, and here again has been known for long time that the method adopted the melting furnace exerts influ- ence quite apart from orthodox composition and temperature. fully fifteen years since George Batty and the present speaker put forward the above suggestion, together with ideas control applied the electric furnace, only meet with the most profound skepticism. is, however, somewhat interesting observe that some the most active critics our conclusions that time now speak quite casually the lack definite relationship between fluidity and temperature only. The second promising field for research, the control solidifica- tion, probably the one which ex- erts the greatest possible effect the progress the steel found- ing industry, and, stated, this factor very largely one design. Methods feeding and gating, speeds pouring, condition mold during pouring and solidifica- tion, considered separately, and the chilling effect applied locally are each and all the subject con- stant investigation steel foun- dry technicians. The object all it, course, progressive solidification cast- ing that the solidification pro- ceeds steadily one more convenient points where feeder heads safely can attached care for ultimate shrinkage. Uniformity section not the answer, fact, the reverse easily might true. The tapered ingot mold, cast wide end up, per- fect example where departure from absolute uniformity fol- lowed solidification conditions favorable soundness. the opening part this talk (CONTINUED PAGE 94) THE IRON AGE, February 1936—33 7 a : ~ vg + "7 hs 4 \ A, STONE machine and furnace which pipe heated. Van Stoning and Bending Pipe LARGE and heavy pipe made withstand high pressures and high temperatures when fab- ricated usually made with flanges the ends, and the vari- ous lengths are bolted together with gaskets between. The forg- ing these end flanges requires special furnaces and forging ma- chines power presses, and this method known Van Stoning. This type joint used univer- sally throughout the power and re- fining industries. One the world’s largest fab- ricators pipe refineries, making such items headers, coils, bends, the Midwest Piping Supply Co., with two plants St. Louis and one each Passaic, J., and Los Angeles, Cal. The St. Louis fabricating plant 34—THE IRON AGE, February 1936 ° NEALEY American Gas Association housed building covering acres, being 420 ft. long with average width 265 ft. Two switch tracks from the Manufac- turers Railway and one track from the Missouri Pacific Railroad run into the building and there private manufacturer’s service switch along the entire frontage. One switch delivers incoming carloads raw material the warehouse for distribution stock, while t