The Iron Age 1936-03-19: Vol 137 Iss 12

19, outh Dearborn Street- Chicago, Sheets Strip Tin Plate Rails Track Accessories Plates Structurals Piling Bars Rivets Billets { j ‘ | = 3 +, | q io CUTTING THE COST Producers transmission and dif- new methods metallurgical con- STEEL ferential gears, suspension parts, 3100 king pins and other carburized, Steels give results that are compar- quenched oil hardened parts and many cases superior are finding weleome economy those obtained from many the adoption Im- priced alloys. proved Series 3100 Steels. you are interested analyses, these Improved the cost carburized parts, Steels not differ from standard write Department for data 3100 compositions. But, made Improved 3100 Steels. ALLOY STEEL DIVISION, MASSILLON, OFFICES: CLEVELAND, OHIO 2—THE IRON AGE, March 19, 1936 - THE IRON AGE, published every Thursday the CO., (INC.), 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. Pr 4 \ te 100 par- rior s matter CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET Owned and Published CHILTON COMPANY (Incorporated) Executive and Publication Offices. Chestnut and 56th Sts., Philadelphia, Pa. C. A. MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR Secretary Managing Editor Editor Emeritus NEW YORK, FRITZ FRANK, President VAN DEVENTER Editor Machinery Editor Washington Chicago Cleveland Pittsburgh Detroit Boston Cincinnati March 19, 1936 The Great Un-American Wire Tapping Plot....... Elastic Assembly Line White Truck Production...... Internal Cleaning Closed End Bottle-Neck Forging ana Heat Treating Locomotive Parts. Composite Steels for Jails New Checker for Regenerator Chambers Forecasting the Growth the Steel Industry. Existing Facilities Adapted Prefabricated Construction New Equipment Automotive Industry Rate Activity Capital Goods Markets Construction and Buying 106 Products Advertised Index Advertisers 156 Copyright 1936 Chilton Company (Inc.) BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Burean of Cireulations IDVERTISING STAFF Member, Associated Business Papers Emerson Findley, 311 Union Bldg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo Published every Thursday Subscrip H. K. Hottenstein, 802 Otis Bldg., Chicago ti rice: "nited States and Price: Unite tes and Peirce Lewis, 7310 Woodward Detroit sessions, Mexic Cuba, $6.00: Can- ‘hi Mexico, Can Charles Lundberg, Chilton Bldg., Chestnut ada, $8.50, ineluding duty: Foreign 6th Sts., Philadelphia, Pa. $12.00 a year. Single copy, 25 cents. C. H. Ober, 229 W. 39th St.. New York W. B. Robinson, 428 Park Bldg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address, ‘‘Ironage, N. Y."" PD. C. Warren, P. O. Box 81. Hartford, Conn. — | | = = \ =p) ats] any = | : — ‘ Sp When Need Good Steel Hot and Cold Rolled Alloys, Stain- less, Tool Steel, Screw Stock, Shapes, Sheets, Plates, Bars, Welding Rod, etc., stock for IMMEDIATE SHIPMENT. JOSEPH RYERSON SON, INC., CHICAGO MILWAUKEE ST.LOUIS CINCINNATI DETROIT CLEVELAND BUFFALO BOSTON PHILADELPHIA JERSEY CITY 26—THE IRON AGE, March 19, 1936 2 i > j 7 é # | ... THE IRON MARCH 19, 1936 ESTABLISHED 1855 Vol. 136, No. The Great Un-American Wire Tapping Plot ing intolerance. The Russian OGPU may justified the fact that part state absolutism which frankly prohibits contrary po- litical opinion. the United States, however, which still professes freedom speech and opinion, excuse can exculpate the Black Committee for the cam- paign terroristic wire-tapping that has perpetrated against political opponents the Administration. escape singeing from his own frying pan, Senator Black paints his activities perfectly legal, declaring that proper subpoenas were issued Spanish Inquisition may condoned upon the grounds prevail- for the messages seized. This reminds the quaint excuse the cattle rustler who said that his actions were beyond criticism because all the cattle his possession the time his arrest carried his own brand. The issuing subpoenas after the act illegal seizure does not absolve from crime any more than does rebranding stolen steer. has now been disclosed that the Federal Communications Commis- sion, Government body which holds and power over the Federally licensed commercial communications services, did the pre- liminary snooping for the Black committee. Through pressure brought bear upon Western Union, Postal Tele- graph and RCA, employees this commission the files these companies, making thousands copies confidential messages and with- out the formality search warrant subpoena. Singularly enough, these wholly unconstitutional seizures private property were confined mes- sages sent received known opponents the New Deal. After the Federal Communications Commission had thus acted cat's- paw for the Black committee, was easy for the latter rebrand the stolen steers issuing detailed subpoenas. The companies involved this matter, whose good will and future business depend upon the confidence customers who intrust their private messages them, should certainly welcome opportunity put the blame where belongs. And the public should welcome opportunity discover the ominous threat liberty involved the Federal licensing any business. j } | | : } | | - | lastic Features the difficult problems that turers motor trucks devise means for the progressive assembly chassis that will make practical the assembly different models chassis the same as- sembly line the same time, se- cure the maximum proficiency and speed assembly and keep steady flow trucks process assembly. Furthermore keep the men working the assembly line constantly employed that there will curtailment their earnings, and avoid increases the various costs assembly the models, regardless whether not the consecutive assemblies are one several different models. Production set-ups, conveyor speeds and other factors are com- paratively simple work out for chassis assembly line auto- mobile plant turning out hundreds one very similar models passenger car chassis day. However conditions are entirely different motor truck plant where there are innumerable mod- els, several which may the same assembly line the same time. Process time important factor inasmuch the majority trucks are assembled fill cus- tomers’ orders, instead for stock. 28—THE IRON AGE, March 19, 1936 truck, being piece equip- ment purchased produce profit for the user, must built suit quirements vary greatly that use” truck cannot built which will fit all needs all truck users economically. The White Motor Co., Cleveland, manufacturer quality trucks and buses, has developed production methods for its assembly lines which have overcome the difficulties expressed the preceding para- graph. Experience has shown that not only has the company been able assemble varying models consecutively the same lines, but predetermined process time es- tablished, costs not vary, num- ber men employed reasonably constant, men’s earnings fluctuate excessively, maintained, supervision costs are minimum and material control rhythmic. This system being used three chassis assembly lines, the successful operation which re- the development rel- atively simple and unique method scheduling assembly time, conveyor speeds and spacing chassis conveyor; these three elements depending upon value total output required and cost OMMERCIAL transportation becoming style con- scious too. well feel mented this streamlined White pull his delivery door. OME time ago the White Motor Co. developed very unique production sys- tem for its chassis assembly lines permit the assembling different models the line the same time. Truck models are numerous and there might dozen dif- ferent models the line the same time, each requir- ing different amount work assemblying. Under the system that was adopted the chassis are spaced the line varying distances, which prede- termined the amount work required assembling assembly which turn determines the number men required the Whatever models are being as- sembled, the chassis spaced the conveyors predetermined dis- tances apart, move along the con- veyor speed which keeps all the men the line efficiently pied all times. Idle time elimi- ‘ ITHERTO the stake truck has been useful, modest, but not very beauti- ful. The one the right has obviously been with fine re- sults. White Truck Production each model, indicated the established labor cost for that particular unit. Under the system correctly determined quota work allotted for each man, elim- inating idle time and assuring that each man will kept busy every minute and thus earn his piece rate Under the operation the system, changes whatever are required the set-up. Should desired in- crease decrease produc- tion the line, this done simply changing the con- veyor speed and the number men the line. nated regardless the size as- sembly cost the chassis. That the system simple, flexible and practical has been proven its successful operation for more than year. this chassis assembly layout not only can chassis considerable variation size model as- sembled the same conveyor, but the process time assembly may varied desired without throwing the production schedule out bal- ance. This done simply changing the speed the conveyor, which variable quantity and which always depends the num- ber men employed. slowing down production desirable, this effected reducing the number men the line even fractions more easily re- distribute the work; and pro- portionate reduction the speed the conveyor chain. Complete planning for changes schedules involving increasing decreasing the number men the line accomplished very short time. The outstanding accomplishment this progressive assembly set-up that allots correctly deter- mined quota work each man. This allotment work deter- mined time study and insures that each man assigned min- utes work for each hour, and less; also that man expected more than minutes’ work each hour. The particular assembly line which will 640 ft. long and consists two power- driven conveyor chains moving opposite directions. Two conveyor chains for this line were provided ° ° ° FRED Cleveland Editor, The lron Age ° ° ° for the reason that the building not long enough have single chain sufficient length for this assembly unit. transfer there- fore made from one chain an- other partially assembled chas- sis. This particular assembly line, designated the light line, used for the assembly chassis for small trucks tons capacity. There also another line for heavy duty trucks and buses and third line for assembling street car type motor coaches. Chassis for eight more basic models are assembled along the light line. However, the possible variations from these eight basic models number into the hundreds. Ordinarily about chassis are as- sembled this line hr. day. The production control depart- ment sees that sub-assemblies and parts are supplied along the line the points assembly. Some large sub-assemblies such axles, transmissions and engines are as- sembled the basement and car- ried power hoists through openings the floor the as- sembly floor adjacent the point which they are assembled the chassis. Other parts are delivered needed synchronize with production schedules. Small THE IRON AGE, March 19, 1936—29 \ Le | > | é the assembly line shown the foreground. The line consists two parallel conveyor units moving opposite direction, partially assembled chassis being transferred the lower end the line shown the foreground the second line, rather indistinctly shown the right. The truck completely assembled leaving the latter line. aisle extends between the two assembly lines and small parts are stacked along this aisle and the sides the line points where needed. overhead hoist brings motors and axles the line from the basement openings the floor the side the line. parts are taken points where they are wanted tote boxes that are kept filled stock men. Many the smaller parts such bolts and nuts are the same for different models. Banks parts along the conveyor are always kept small. The scheduled operation the conveyor line has been worked out mathematical computations, the basis which the labor cost that has been established for as- sembling each chassis and all these figures are tabulated operat- ing chart. Group Piece Rates for Assemblers The labor cost for assembling each unit, which the average requires operations, estab- lished time studies and the total equally divided among the as- semblers under group piece rate system. With this cost fixed, any portion of, complete assembly finished within specified period time that will keep the labor cost the fixed figure and the same time permit the men earn their established hourly earning rate. The lowest labor cost for as- sembling unit tabulated the chart and the range for other types chassis varies $13.75 each. Spacing assemblies the line computed with the assembly cost the job the basis. ratio 30—THE IRON AGE, March 19, 1936 spacing feet and the labor costs, ft. spacing for each dollar labor cost for assembly. This means that costs as- semble chassis, that particular chassis must allotted feet assembly line space. job follows job the line, the job allotted feet space. This spacing principle maintained and always the distance between sim- ilar points each chassis, accord- ing cost assembling. There are two variable factors the chassis assembly layout. These are the number men the line and the speed the con- veyor chain, both which unit are regulated meet produc- tion requirements. Should require- ments call for greater output chassis, the increase effected adding more men and speeding the line proportionally. Certain production schedules are predetermined, and must main- tained. After schedules have been determined, the two variables man load and speed conveyor can determined. This accom- plished the following manner: Assume that $357 worth assem- bly work performed per hr. day over period time, and that the earning rate per hr. Dividing $357 $5.25 (which the amount earned hr. day 70c. per hr.), find that the line will require men. Since the conveyor earns for every ft. travel, the earn- ings per foot are per hr. represents earning $0.- per min. per man; times per min. equals $0.8033 per min.; $0.8033 per min. divided per ft. equals 4.8196 ft. per min. 57.84 in. per min. making this computation conveyor speed the scheduled speed set fractionally above the mathe- matically developed speed. Hence, the case the example illus- trated, the speed the conveyor set in. per min. The time interval spacing chassis the line determined dividing the spacing inches the number representing the speed per minute. chassis cost- ing assemble are spaced Gul \ a \ f NS other end the conveyor lines. The overhead hoist transfers the partly assembled truck from the end the line the right the line the left, and cabs, shields, headlights and various equipment are installed the chassis while moving along this line. The first line passes through ft., 432 in. apart assembly line moving in. per min., new assembly started every 7.5 min., which indicated dividing 432 58. Using the method compu- tation, chassis costing assem- ble would placed the line every 6.3 min. The formulae that have been worked out for this system chas- sis assembly control are follows: Let assembly F=Feet space allotted earnings per man spacing allotted D=450 min. (normal work- ing day) utes Then And P And From these formulae table has been prepared giving all the data needed for any possible production schedules based the company’s hourly earning rate for assembly work. This table shows all the necessary factors that enter into the assembly scheduling. Starting with minimum men the assembly line, columns figures are provided for spacing the conveyor chain, speeds, for each two additional men 98. Tabulations are provided for sched- uling chassis costing from $13.75 each labor for assem- bling; spacing units the con- veyor from ft. 82.5 ft. apart, speed conveyor chain from ft. in. ft. in. per min. and intervals spacing time from 3.5 min. 29.1 min. This shows the head the chassis assembly department, glance, when new set-up made, what should the conveyor speed and number men produce the re- quired assemblies and enable the workmen receive their piece rate earnings; the factors entering into the speed being only the as- sembling cost per unit and the number men employed. assembly schedule for each day the week made out, and from this schedule for the day posted each morning black- a spray booth shown the right which chassis are spray painted while moving the conveyor. board the start the assembly lines. Opposite line numbers from 98, the consecutive num- bers representing the sequence the units scheduled for the day’s assembly, are columns carrying the car number and the time each unit unit No. the fifteenth chassis assembled during the day, scheduled start the assembly line 10.08 m., delay from the scheduled time not more than min. permitted. maintain the proper sequence delivery parts the assembly line, similar blackboard located various points where units are assembled. One located the basement from where the engines and other sub assemblies are de- livered the line and another the wiring department from where the cowl comes onto the line. The engine, cowl, cab, front and rear axle, propeller shafts, etc., are each tagged with number correspond- ing chassis numbers which they are assembled which as- sures the delivery the correct parts for each chassis assembled. speedometer the line shows the speed the conveyor inches per minute and also how many feet the conveyor has moved given time. This constant visible record which shows the men the line how they are maintaining their schedules. Should the conveyor chain stop, red light shown each end warning signal. THE IRON AGE, March 19, n- ie, be a ve $1 1es led ft. eed 4 ice, lus- ned ost- 36 dah / FRANKLIN BRILL General Plastics, Inc. ANY view plastics competitor for their business. There doubting that applications plastics have multiplied, therefore amine specific applications and the various limitations the last few months many new products have appeared with molded plastic cases parts which heretofore major would have been stamped cast metal. Consequently, metal fabri- molded products either threat, helpful ally, mixture both. analysis the problem the end determining which these three categories plastics rightfully belong. study the problem, the fol- lowing factors should consid- ered: Are the products possible only plastics? Did they replace metal, are they applications where metal couldn’t qualify any- way? Why was plastic material used instead metal? 32—THE IRON AGE, March 19, 1936 this comparatively new ma- terial. The author cites these limitations, but for the most part concentrates certain molded items, with particular emphasis the reasons why plastics were chosen for these parts rather than pressed cast metal. Seeking answers these ques- tions, General Plastics, Inc., re- cently sent out questionnaires the chief engineers number companies using structural molded plastic parts preference metal, asking them the reasons for their choice. The replies fell into the following seven classifications: The job required permanent finish that wouldn't chip. The lightest possible weight was (3) The insulating properties plastics were desirable. (4) pleasing, non-metallic touch reaction major sales point. (5) The shape didn't lend itself stamping. (6) There greater design pos- sibilities plastics. (7) The lower cost plastics. Although these products ranged from adding-machine cases radio parts and auto accessories, they represent only small part the metal fabrication market. Thus plastics can not yet considered major threat, for plastics have the following definite limitations: The tensile strength phenolic material runs between 5000 and 10,000 lb. per sq. in. against over 13,000 for zine and 75,000 100,000 for stamped steel; their transverse strength runs 12,000 lb. per sq. in. against approxi- mately 10,000 for and about 20,000 for aluminum. There are also limits the prac- tical size molding, which when exceeded, makes the unit price ex- stable most metals, but ordi- narily absorbs some moisture from steam humid atmospheres. Against this, though, one can cite that phenolic moldings when prop- erly designed, have adequate strength for all but heavy-duty ap- plications, and can made into such pieces 18-in. scale housings less cost than porcelain-enameled iron. The absorption moisture humid air phenolic material its molded gravity 1.35 against over for and 2.70 for aluminum alloy. appar- ent, therefore, that molded plastics ~ ° ° 4 i ‘ ° ° ° = 14 — ym es. ite ite ito led ire tics bases have usually been die-cast and japanned. pany now turning out this type molded plastic base lower cost. Me- tal parts the in- strument are also shown here. have definite, but limited, scope use making today’s products. Applications Plastics Definite applications can cited illustrate the scope plastics. Telephone handles have been made phenolic plastics for years, and hard rubber before that, but the hand-set bases have heretofore been die-cast and japanned. consid- ering various materials, Leich Electric Co. was attracted mainly the fact that molded plastic bases, unlike most enameled metal surfaces, could not chipped scuffed scratched, and that they would lighter weight than any metal. Molded bases are shown Fig. When costs were figured, they found the molded base was actually less expensive than japanned die-cast base, mostly be- cause the base comes from the mold with its shiny finish automatically formed. Fig. also shows the many metal parts used Leich tele- phone, viz., cast cradle and switch and stamped dial plate, threaded bushings and rings, in- serts, Next consider vacuum wind- shield defroster illustrated Fig. and made Bishop Babcock Mfg. Co. The chief engineer, Findley, says that, “The shape the case didn’t lend itself stamp- ing, and since weight was prime factor, plastic material was select- ed. Variety finishes obtainable plastics was another reason. Also decided mold the inter- nal parts, rotor wheel, fan and bearing case cover, the same material because its light weight made externally and internally plas tics. the maker had only metal choose from, doubtful whether this item would have been put into production. and lack resonance high-speed air-current noises.” Therefore, this application plastic used for product that probably wouldn’t have been made the manufacturer had only stamped and die-cast metal choose from. Its intricate interior and exterior couldn’t have been weight would have been excessive die cast. Cost was secondary here, but moldings are usually com- petitive cost with well-finished die-castings and fairly com- stampings. Taking another auto accessory example, consider the case the Arvin radio control which Co. molded case used instead metal for the following reasons: Sales appeal, arising from the smooth, lustrous finish which matches motor-car interiors; dura- ble surface, which means that the finish can’t wear off might from constant handling enameled die-casting; light weight and non-resonance vibration pe- riods; and, finally, transparency the ivory molded bezel when the control unit lighted. Cost Comparison For direct cost comparison be- tween stampings phenolic THE IRON AGE,March 19, 1936—33 } | AP moldings, the illustrated Fig. good ex- ample. Formerly stamping was used which required nine produc- tion operations, e., blanking, forming, trimming, grinding, sand- blasting, phosphate-finishing, scratch-brushing, japanning and baking. The box now phenolic molding which pops from the mold complete one machine operation, except for fin removal which quick file operation. The fact that the finished mold- ing was less costly even though the molding powder much more ex- pensive than sheet steel simply because the fewer hand opera- tions required. Actually, the decid- ing factor that swung the job plastics was not much the cost the durability the plastic fin- ish. That is, chair-legs and tables could not chip off and hard bumps could not dent it. Although most readers are prob- ably familiar with the molding review briefly the operation. The machine used hydraulic press, fitted with cored steel mold con- sisting multiple cavities and plungers, through which steam circulated heat about 350 deg. Into the cavities are loaded pellets powder (processed from chemicals, mostly phenol), the press closed and then opened after the powder 34—THE IRON AGE, March 19, 1936 5—Four devices with molded Durez filled the cavities and hardened, which takes from few seconds several minutes depending the size the piece. Fin removal the only other operation required after the pieces are ejected. Returning cases again, note the molded plastic housings the four machines grouped together Fig. each job, the reasons for the selection plastics were different: The Barrett adding ma- chine housing was molded for per- manence finish, because the sur- face office equipment like this receives lot rubbing and han- dling. Light-weight and non-reso- nance were again factors, too, and the cost the molding was slight- less. The satchel-shaped device with the glass vessel front the Hanau dental electroplater, and its housing was molded because splash- ing the plating acid would have damaged most enamel finishes. This acid does not effect the inert plastic. The molded case stopped electric shocks, and had lighter weight and greater resistance scratches and dents additional advantages. The cost about the same cast metal aluminum. Also interest the reason given the Andiss Mfg. Co. for the selection phenolic moldings for the giant Speed-Whip fountain mixer case, illustrated Fig. Since cleanliness paramount fountain appliances, Andis design- ers were afraid that enameled stampings and castings might chip, exposing rust-forming and germ-harboring pits. Weight was also considered, and since the in- ternals the Speed-Whip heavy load for one person, would have been seriously excessive 4—A former metal stamping displaced surface. Also, seven produc usings, chosen preference chip-proof surface, and, 7 one by ae . rence nd, produc had been cast. Many the sup- porting parts, terminals, oilless bearings, threaded were molded into the plastic parts, further reducing weight. Cost the moldings was slightly less than die-castings. Still another device shown Fig. automatic card shuf- tion operations are avoided. ath ‘ © P metal because the plastic lighter weight, wear proof, has one case, must acid proof. fler made the I-Deal Corpn. Metal was not even considered be- cause the need for surface pleasing the touch and ex- tremely light-weight housing. This device passed around card tables and receives considerable handling and thus the peculiarly pleasant, not-too-cold-not-too-warm molded surface advantage. Even the hinged front cover molded, most- match the main housing and simplify attaching the metal parts and hinges. From the above, one interpreta- tion could that plastics are al- ready competitor metal; the Useful Data Lubricating Greases SEFUL information for plant executives, engineers and oth- ers responsible for the selection greases contained 80-page bulletin “American Lubricating Greases,” written James Clower, assistant professor ma- chine design; and published the Virginia Polytechnic Institute, Blacksburg, Va. The bulletin dis- other that present they are supplementing metal and taking only small percentage business from the older materials. Certain- there room for both metals and plastics the rapidly enlarg- ing manufacturing scene. And when one considers the tonnage steels used the plastics industry, processing the chemicals, grind- ing, shipping and pre-forming the powder, the huge presses, and ever-changing steel dies, one won- ders whether plastics aren’t actual- benefiting rather than threaten- ing the growth the metal in- dustry. cusses manufacture, uses, testing and application greases, the data being presented from the viewpoint the user rather than that the manufacturer. contains il- lustrations, tables and large three-fold condensed inserted table giving various classifications, the ingredients and uses number greases. Copies may ob- tained from either Professor Clow- the Virginia Institute. ously published bulletin “Lubri- Oil Tests” also available. THE IRON AGE, March 19, 1936—35 THE illustrated metal cleaning and drying equipment serves the removal oil, grit, and odor from supercharger bulbs such are employed connection with syphon bottles, common the mix- ing beverages. The cleaning takes place two stages bulb production; Fig. drawn, with open end trimmed; Fig. open end reduced final contour. The machine, designed Metal- wash Machinery Co., Haynes Avenue, Newark, J., consists heavily constructed steel tank, reinforced and supported 36—THE IRON AGE, March 19, 1936 Internal Cleaning Bottle-Nec WAITE structural members. Welding employed throughout and involves over-lapping double welded seams, welded entire lengths. Each end the base provided tomatically eject retain The retainers are permanently at tached conveyor- with extension upon which the driving mechanism equipment are oppositely mounted. Above these, table extensions pro- vide ample space for magazine ABOVE IGS. and cleaning the par ticular closed-end bottle-necked parts cleaning operations are performed two stages parts pro- duction. The first after drawing and but prior closing the reduced diam- eter the second after the parts have been contoured necked final form. = | w J ie rotat- ing end unit slidably mounted and provided with screw adjustment shown cover affords pro- tection but easily lifted and when process. loading and discharge one end, Fig. and for work-in-process in- spection and any necessary chain take-up screw adjustment, the other end, Fig. chain conveyor travels longi- tudinally within the machine cham- bers, but vertically positioned with respect loading table and 5—The sousing guard, the has its covered sections where serves take the force solution under pressure and re-direct for con- tinuous washing duty. driving sprockets. for the attachment vertical magazine each chain “link,” for carrying the work pieces through the processes cleaning and dry- ing. The drive through verti- cal shaft means motor driven speed reducer and variable speed pulley, shown Fig. Adjustably timed halting the conveyor feed crank motion, operated from the output shaft the vertical speed reducer. This motion operates pawl and ratchet, intermittently turning the vertical drive shaft, thus giving desired periods “stop,” “go” and spac- [CONCLUDED PAGE 104] THE IRON AGE, March 19, 1936—37 4 q | = | | Forging and Heat ocomotive ONE greatest transport sys- tems, the Pennsylvania Railroad, maintains ex- tensive shops Altoona, Pa., for the repair and building cars, locomotives and tenders. Here were built the new and famous streamlined electric locomotives (GG-1 type) which broke all pre- vious speed records the trial run between New York and Phila- delphia. greatest interest many are the two forge shops Altoona, known Blacksmith Shop No. and Black- smith Shop No. where many the parts for these locomotives were forged. these shops can de- scribed two long buildings with rows furnaces, steam hammers, forging presses and jib cranes both sides. Overhead cranes serve Blacksmith Shop No. There also boiler shop where large steel plate parts are formed. Gas the standardized fuel throughout. Only carbon steels are used for the forg- ings, the analyses which are given herewith tabular form. Shop No. ft. 516 ft. long and contains furnaces serv- ing hammers various types and sizes with several giant steam hammers the center. Heavy sec- tions are worked mostly double frame hammers and are handled jib cranes. Parts such piston rods, locomotive driving rods and equalizers, center plates, spring hangars, brake levers, adjusting rod boxes, king bolts, knuckle joint pins, shifting valve covers, etc., etc., are forged here. The furnaces are brick and refractory con- struction, steel encased, and va- rious sizes and types. Blacksmith Shop No. there are installed two three chamber furnaces used the forging main and side rods. These rods are afterwards heat treated and 38—THE IRON AGE, March 19, 1936 NEALEY American Gas Association is, therefore, very important that the cold billets are not subjected immediately excessive heat. These three-compartment furnaces are designed that the waste gas products formed the two outer chambers are discharged through heat tunnels the center chamber, thereby maintaining this center chamber temperature approxi- mately 800 1000 deg. The cold billets are placed this chamber and after being heated approximately 900 deg. are then transferred either one the end forging chambers, where they are heated forging tempera- ture about 2250 deg. Ap- proximately hr. required author explains de- tail the forging and heat treating practices well the equipment used the Pennsylvania Railroad shops Altoona, Pa. pointed out that several economies were effected when furnaces the shops were changed from producer gas oil over city gas. Likewise the author mentions the methods which old scrap re- claimed, not remelting but reheating, after which forged into new shapes for new uses. Thus the railroad can profitably use accumu- lated wrought iron scrap, old axles, etc. bring the billets from 900 deg. 2250 deg. There are two drop forge fur- naces, each ft. ft. long, with two front doors and four gas burn- ers, two each end. One these center wall, which rises part way the roof, was installed that the operators can work out either compartment without mate- rially reducing the heat the other. One these hammers rated 12,000 and the other 16,000 lb. hydraulic trimmer close by. Most the other fur- naces are about the same size and type, but contain only one chamber. The hearths the smaller ones Formerly, the furnaces these shops were producer gas oil fired but the changeover city gas effected several economies and practically eliminated the smoke nuisance. Venturi type gas burners are used, lb. air inspirating gas dropped zero pressure gov- ernor. The burners fire through refractory tunnel blocks set the furnace wall and space in. left between the burner tip and the steel shell the furnace. This reduces the furnace pressure and eliminates stingers flames from around the doors. Scrap Reclaimed Reclamation scrap large item here, example being small bloomed into billets. This accom- plished making cross pile old wrought iron arch bars and miscellaneous short pieces, which are charged into furnace with pallet swung from jib crane. When hot, the mass removed with tongs and put under ham- mer, where worked into billets and shapes and these drop forged into various items such 200-lb. locomotive equalizers. \ Kat ae | te ar ° ° ° y | ~ | | f | | RAILROAD'S dependability taken matter course, in- asmuch all important lines have for many years concentrated the de- velopment trustworthy and fool-proof equipment. Many the vital members this modern lo- comotive are forged heat treated, and the generally excellent service life these parts testimonial correct production practices com- pany shops. detailed résumé these practices contained the article which follows. Some this done forging the working heat and then finish- ing reheat. Freight car center plates are formed from hot scrap under drop hammers shape and then trimmed the same heat. either forging drop forg- ing, care should exercised selecting the grade and approxi- mate size the material. Sufficient reduction should made the points maximum stress in- sure “packing” the grain. Forgings and drop forgings should made that the grain fiber does not end abruptly any one point, but will preserve continu- ity fiber, thus eliminating any tendency for sudden rupture. The rate and duration heating should carefully guarded, either op- eration performed improperly not conducive sound finished product. Old axles are sometimes heated and worked down into rectangular square sections and forging blanks cut from these. and other items are made this way. All dies for this and other work are made the company’s own tool and die shop. No. Shop ft. 400 ft. long and contains six drop hammer furnaces, smaller furnaces for swing belt hammers and forging machines, forges tool dressing hardening, six car-bottom and four cylindrical vertical furnaces for various kinds heat treat- ment. The furnaces serving the hammers are the gas-fired box type, similar those already de- scribed. Annealing, prior machining, accomplished the car-bottom furnaces. Each these ft. ft. long and fired with gas burners, eight each side. The burners are arranged fire both above and below the work, the lower ones firing through re- fractory tunnel blocks which form the car top and which rests hearth. The hot products com- bustion rise around the sides and into the furnace chamber. Each side wall contains four verti- cal vents for the waste heat. Drive rods, piston rods, crankpins, cross- head pins, valve gear motion parts and other locomotive parts are treated these. The work put into furnace with temperature 300 deg. and brought 1450 1500 deg. the rate 200 deg. per hr., after which soaked this heat for hr. The gas burners are then turned off and allowed cool the furnace. Most these parts have carbon ranges 0.40 0.50 and 0.45 0.60. Some these parts are later hardened and both the cylindrical vertical and car-bottom type fur- naces.are employed for this pur- THE IRON AGE, March 19, 1936—39 | | pose. Each cylindrical vertical ft. diameter and ft. deep and they stand pits about ft. deep. Heat supplied each gas burners arranged spirally around the furnace and firing tan- gentially the inner wall. The quench tank rectangular and concrete and ft. square and ft. deep. The cylindrical oil quench tank located one cor- ner the large water quench for such parts require cooling oil. The water around this tank tends cool the oil. The work han- dled fixture, swung from overhead crane and hoist. Parts made from steel the lower car- bon range 0.40 0.55 are heated 1450 1500 deg. F., quenched water and drawn 1000 1100 deg. F., while those the upper carbon range 0.45 0.60 are cooled air after heating, and drawn using the tures. The heat treating furnaces are all equipped with automatic tem- perature controls. All work that heat treated bears serial heat number and that heat number also put the pyrometer chart. This chart filed that the event failure unsatisfactory performance the heat treated 40—THE IRON AGE, March 19, 1936 part, referring the serial number the piece question, the chart can produced and treatment shown. Carburizing Practice Other parts such knuckle joint pins and bushings, valve motion pins and bushings, brake rigging pins and are car- burized and hardened depth 3/32 in. For this purpose there are two single-door box-type fur- naces ft. ft., and each heated with three burners underfiring the hearth from one side only. One these furnaces pictured Fig. The parts are ft. long, which are pressed from hot steel plate betwen dies hydraulic press the boiler shop. Ordinary carburizing compound employed. Selective carburizing used bushings, the inside sur- face only case hardened. number these are piled and bolted rigidly together between two plates. The center filled with the compound and the whole heated. carbon steel, Grade these parts are carburized 1750 deg. F., cooled the box, removed from the box when cold, and are reheated 1450 deg. F., for quenching. The same furnaces are used for the second heat but the compound and boxes are omitted. There central control room where visual pyrometers for all these furnaces are located panels. The boiler shop ft. 723 ft. long with overhead cranes and much the heavy plate work formed, machined and fabricated here. interest are two hydraulic presses 700 and 1200 tons re- spectively, served two large IS. |—Two or forge hammers Shop are sup plied with billets from furnaces one which shown here. This door type with partial separating wall. City used, firing througt two burners eact end. double-end gas-fired furnaces. This set-up employed heat and form heavy boiler plate into loco- motive throat sheets, crown sheets, domes, fire box sheets and other locomotive and car parts. One these furnaces, shown Fig. outside, and inside ft. high from hearth top arch. Heat supplied gas burners, five each side. The front and back doors are built three sections admit partially formed sheets; the two side sections move back and forth rollers and rails, while the center and upper section lifted hoist. The bed the largest press ft. ft. and holds platen with die, ~ 2—One the furnaces Shop No. used car- burize various loco- motive parts. This type furnace having three burners under-firing the hearth side. draulic piston against stationary die attached the top platen. The top platen held place four heavy steel posts. This press has 8-ft. stroke. The work heated 1700 deg. for forming. Causes for failure steel parts IG. the boil- heavy plates are pressed into locomotive throat sheets, crown sheets, domes, etc. This one the furnaces used for this work. Heat supplied gas burners, each side. The door made three sec- tions. service are many some the most common being: (1) faulty design, (2) rough sur- faces, poor quality steel, (4) improper forging temperatures practices, and (5) improper heat treating temperatures methods. = “3 Briefly analyzed, causes are follows: (1) Faulty design often permits sharp corners where quite possible place healthy fillet radius and thus eliminate point where stresses may concentrate, THE IRON AGE, March 19, improper distribution weights relation static repeated stresses under service conditions. (2) Rough machining often leaves deep scars tool marks which are excellent places for frac- tures start, commonly called detail fracture but properly named “progressive fracture.” (3) Poor quality steel such “unsound,” “segregated,” rous,” “seamed,” “lapped,” more often the cause failure. has frequently been found that steel unsound constitution has TABLE Specifications for Cabon Steel Billets A Minimum and Maximum Content, Per Cent Min. Max. Manganese ...... 0.30 0.50 Chromium Min. Max. Min. Max. 0.40 0.55 0.45 0.60 0.40 0.70 0.60 0.90 0.10 0.30 0.10 0.30 0.05 0.05 0.05 0.05 0.30 ae 0.30 0.40 0.40 TABLE Specifications for Steel Bars These specifications cover the various classes steel bars used for locomotive, car and stationary boiler construction, classified follows: Class used for bars for locomotives, cars and general service. Class used for bars for stationary boilers. Class used for bars specified “axle steel,” for bolts and other purposes. Class used for bars for superheater header bolts and for set screws. Class used for bars for drop forgings. Minimum and Maximum Content, Per Cent Min. Phosphorus Sulphur Max. Min. Max. Min. Max. 0.70 0.30 0.70 0.40 0.80 0.05 0.04 0.05 0.06 0.05 0.05 Min. Max. Min. Max. 0.50 0.60 0.12 0.40 0.80 0.30 0.70 0.05 0.05 0.05 0.06 withstood the strains set heat treatment (all heat treated hardened steel unstable state equilibrium) and has with- stood proof testing only subse- quently fail after short service time. This failure usually dis- closes gas slag inclusions segregations constituents. (4) Already discussed. (5) The heat treating operation which, the past, has been the object much misplaced criticism very important and should 42—THE IRON AGE, March 19, 1936 governed all the safeguards modern science has offer. First, stated before, any unstable state equilibrium since during heat treatment certain strains must set ob- tain the desired physical proper- ties. The steel should such constitution that the strains neces- sarily set will not danger- ously approach the limits elas- ticity ultimate strength. The critical predetermined and the tempera- tures used should not exceed, any great degree, this limit; parts should initially preheated slowly that unequal expansion will not start ruptures; heats should advanced correct rates and maintained only long enough permit thorough and even heat- ing, any excess duration heating above the cal temperature tends increase grain size with corresponding loss strength. | (a) IG. set for casting the type bar. The larger in- serts hard steel are 134 in. and the smaller ones are in. Composite Meet RECENT adoption standard requirements New York State for institutions has set which other States are gradually accepting. While this trend for standard specifications places greater responsibility the steel maker produce steel capable meeting more rigid re- quirements, the same time simplifies his problem permit- ting concentrated effort research and development toward improved quality. Obviously, the primary specifica- tion for jail steel that nearly possible. “Composite” steels have been meet- ing this requirement effectively. This steel composed two more distinct types and analyses, the combination which highly resistant sawing and breaking, casting the typ hard steel inserts set for casting channels. Steels for Jail Use Must Speci ications the two most common methods jail breaking. Hard Steel Inserts Composite steels for this purpose are formed several methods which are more less general practice the industry. its construction, the important fea- ture the arrangement hard steel inserts which are covered with steel softer composition. arranging the hard steel in- serts the ingot from which bars and channels are made, the New York specifications require that there not less than such in- serts each bar, and that the covering soft steel not more than in. thick; the placed the bars not per- mit drilling any point with 14-in. drill more than in. depth. The illustrations show dif- ferent arrengemenis hard inserts they are placed molds ready receive the poured softer steel which the inserts are com- pletely enveloped, thus forming the ingot from which composite bars and channels are made. These arrangements the in- form what known the “bird-cage” type bar now specified New York State and general use today. producing this type bar multiplicity smaller in- serts the hard steel are arranged cross-section the mold. For ex- ample: the ingot has square cross-section, the inserts also are arranged square, but the square composed the inserts smaller than the mold. The per- centage soft material desired the finished bar determines the size the insert arrangement com- pared with the ingot cross-sec- [CONCLUDED PAGE THE IRON AGE, March 1936—43 i ‘ _ =! =! Par 5 -4 2 ‘ ” set up bar.. AS = New Checker Increases Regenerator Chambers ° ° ° MELLOTT Pittsburgh, Pa. ° THE need for greater efficiency the regen- erator chambers furnaces has resulted the design new open-hearth checker brick the William Bailey Co., Pittsburgh. designing this checker, con- sideration was given features, acknowledged im- portant obtaining maximum efficiency regenerator operation, greater heating surface, in- creased flue area, sufficient struc- tural strength, ease cleaning, and increased volume com- bustion air through the checker chamber. The checker made for any standard size flue, with brick thickness close in. com- mercially practical. Reference Fig. shows drawing the size used forming 5-in. flue. Ref- 44—THE IRON AGE, March 19, 1936 ° ° erence Fig. shows the dimen- sions four standard sizes. will noted illustration Fig. that laying the Su- perior checker checker cham- ber, each checker with adjoining checkers all four corners, and each course check- ers locked into the adjoining course, thereby preventing shifting twisting and the obstruction the flues. Free Area Important All studies the subject regenerator efficiency importance exposed heating sur- face the checker brick. edgment was given this feature designing the Superior checker. However, now acknowl- form checker recently developed William Bailey Co., Pittsburgh. edged fact that the free downward area per horizontal checker area equal importance, and for this reason, the designer endeavored obtain free area approxi- mately per cent, even though with certain brick sizes meant the sacrifice some exposed heat- ing surface. Results obtained producing maximum heating surface and free area with the Superior checker de- sign, compared standard in. in. in. bricks, are shown the following data. Also refer the table. The standard flue shows 4.70 sq. ft. heating surface per cu. ft. space, and per cent free area. The Su- perior checker, with the same size flue, shows 5.564 sq. ft. heating surface per cu. ft. space, and 52% per cent free area, increase per cent heating surface, and per cent free area, actual flue area per cross section. another case, stand- ard in. in. in. brick shows sq. ft. heating surface, but only per cent free area. comparison, the Superior checker with in. in. flue | | | ° ° ff 4 gave 6.15 sq. ft. heating sur- face with 48.9 per cent free area, free area and per cent heat- ing surface. The table also shows the number brick per cubic foot two standard sizes Superior check- ers, the weight per brick lb. per ward area per horizontal checker area, and the effective heating sur- 2—Overall dimensions four standard size Superior open-hearth checkers. face per cubic foot. The large free horizontal area obtained with the Superior checker through the checkers, thus assur- ing increase the quantity this primary air and thereby cor- 3—Photograph recting major degree one open-hearth the weakest points open-hearth This new checker wa’ placed checker brick. Note the market June this year. the rangement. the present time one the op