The Iron Age 1936-05-21: Vol 137 Iss 21

rust-resisting corrosion-resisting c- ce es- e & Ive ers loy the in- 4 ill = little-finger push button—and tiny part moves large mechanism into ponderous motion. relays main cir- cuits, carrying from milli-amps multi-amps—Phosphor Bronze the universally accepted metal for the vital moving contact parts electrical Resilient, strong and arc- resisting higher degree than other commercial metals— point contact. substitute Phosphor Bronze the faithful ally electric circuits the for THE PHOSPHOR BRONZE SMELTING 2200 WASHINGTON AVENUE PHILADELPHIA, PA. INGOTS CASTINGS RODS WIRE SHEETS ROPE TUBING 4 3 : 4 Pink ‘ 2 4 4 4 a 7 q 3 | j q é IR BRONZE. FRITZ FRANK, President VAN DEVENTER Editor Managing Editor Editor Emeritus Machinery Editor Washington Chicago Cleveland Pittsburgh FRANK OLIVER GERARD FRAZAR McINTosH Detroit Boston Cincinnati CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices Horse and Buggy, Cylinders? Electro-Galvanizing Round Wire Late Returns from Laboratory and Mill ute Here, There and Everywhere Owned and Published CHILTON COMPANY (Incorporated) BAUR, General Advertising Manager Copyright 1936 Chilton Company (Inc.) Executive and Publication Offices, DIX, Manager Reader Service Chestnut and 56th Sts., Philadelphia, Pa. Member, Audit Bureau Circulations ADVERTISING STAFF MUSSELMAN, President Member, Associated Business 621 Union Bldg., Cleveland I 3 he Industrial Arts Index. ~ Ee . 675 Del Ave., Buffale. aye Published every Thursday. Subscrip- FREDERIC C. STEVENS, Vice-President _ H. K. Hottenstein, 802 Otis Bldg., Chicago JOSEPH S. HILDRETH “ tion Price: United States an * Peirce Lewis, 7310 Woodward Ave... Detroit sessions. Mexico, Cuba, $6.00; Can- Lundberg, Chilton Chestnut GEORGE GRIFFITHS, ada, $8.50, including duty; Foreign 56th Sts., Philadelphia. Pa. EVERIT B. TERHUNE, a $12.00 a year. Single copy, 25 cents. Cc. H. Ober, 239 W. 39th St., New York ERNEST HASTINGS, Sweetser, 239 West 39th St., New Yerk Cable Address, ‘‘Ironage, N. Y.'’ D. C Warren, P. O. Box 81, Hartford, Conn. WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary he the has.” < i 7 : jer Bethlehem can show you his- tory achievement the application alloy steels antedating the earliest motor vehicles. far back the early nineties Bethlehem was pioneer developing the latent possi- bilities the use various alloying elements handle the increasing burdens falling certain parts engines, ships and machinery many kinds. When the horseless carriage faded out and was replaced the new type vehicle that heralded the swift, fleet, graceful automobile today, was only natural that manufacturers should turn Bethlehem for the stronger, tougher steels needed vital parts. Right down the present time Bethlehem has played prominent role the development new steels and the refinements manufacture that have made possible the power-packed, safe, dependable motor vehicles today. J Bethlehem made alloy steel shaft for the ferris wheel the Columbian Exposition, Chicago, 1893. you would rather have the evidence gruelling, day-in and day-out service, spectacular stunt, processing difficulties ironed out, facilities rigid control manufacture, Bethlehem can show you equally strong reasons for utilizing this source alloy steel supply. YOUR (YARDSTICK FOR SOURCE- i> 32—THE IRON AGE, May 1936 | — THE IRON AGE ... MAY 21, 1936 ESTABLISHED 1855 Vol. 136, No. Horse and Buggy, Cylinders? RS. ROOSEVELT has joined her distinguished husband implying that un- employment by-product invention, improvement, mechanization and cost reduction. her scholarly column now appearing daily large newspaper chain, she recently referred unnamed industrial city which had become mechanized that while its production was the level, its workers num- bered less. justice the importance this subject man versus the machine, believe that such references, especially coming from those whose positions give them power mold public opinion, should very specific. Names should named and sources given that data can properly checked. are accustomed having the ma- chine condemned from the soap box, but not from the White House. The trouble with many amateur social and economic philosophers, not mention columnists, that they can build plausible interesting and sensational essay upon erroneous incomplete evidence. The jumper conclusions can perform remarkable mental gymnastics when grasps the trapeze mechanization his play- thing. she can start with the fact improved machine produc- ing more goods with less labor and arrive two three jumps social catastrophe and perpetual breadlines. filled with the accounts such conclusion jumpers starting with invention type and through the ages. The power loom was seen the end employment opportunity the textile business; safety razors were put barbers out work. These conclusion jumpers look what goes in, not what comes out. They add the minus signs but overlook the plusses. They see the monk whose hand engrosses manu- scripts put out job the printing press but they refuse count the thousands upon thousands machine compositors, proof-readers, press attendants, yes, even authors and columnists who are its employment product. The President and his wife might have told the people that there irrefutable evi- dence, Government census records, that the machine multiplies working opportunity, creates new jobs, opens new doors faster than closes old ones. That would have been sounder doctrine preach than imply that cost saving through invention tears down employment. would too bad the general public came believe that modernization condemned. that there would more electrified White House kitchens and our future Presidents might have depend upon "horse and buggy” in- 4 is ; = i =a : a = = ‘5 we — <3 f =e = tunt, . id ually 4 pply. 2 é 4 basic principles wire making have changed since the eighth century. when Theophilus described the use draw plates for the pro- duction lead-tin filaments. twentieth-century elaboration the primitive hand procedure the incredibly rapid and highly efficient drawing tured above. Although the draw- ing procedure unaltered, sub- sequent coating the wire has been given considerable attention within recent years. Perhaps one- fifth this country's wire hot galvanized, but, latterly, there has been definite trend toward ap- plying the zinc electrically. Bethle- hem Steel Co. has made the country con- scious, and, like all new processes, there interesting story be- hind the development the elec- tro-galvanizing procedure and its present mode operation. This article ably reviews these phases the subject. 34—THE IRON AGE, May 1936 one inquired few years ago about elec- tro-galvanized round wire would learn, his surprise, that this product was not being made the United States, although was extensively used Europe. The fact that flat wire, strip and pipe could had galvanized added the surprise and begged the question why the steel mills this country had stopped round wire. Since that time electro-galvanized wire has made its entry into this country, and within short time has become established staple product. The history this manufacture mostly record fruitless at- tempts deal with problem which had taxed the ingenuity many inventors. More interesting still the fact that the cause the difficulty was known from the earliest beginning. The earliest record the sub- ject patent granted Fox, Britain, 1879. This patent was never exploited commercially, Round ARNOLD WEISSELBERG Consulting Engineer, New York fate which most subsequent pat- ents shared. The efforts those engaged that time improving the art seemed center the re- duction equipment size. ac- count the low current densities employed, the length the tanks became prohibitive when operating anywhere near the speeds occurring hot galvanizing. Hence the per- sistent attempts electro-galvan- ize wire winding reels drums immersed plating tanks. This answer the problem intro- duced new difficulties, which one was the proper arrangement anodes insure uniform coating. this class belong the patents Wallace, Hennings and Rawson. the end the last century three methods had attained fair measure commercial success. Sherard Cowper Coles was forging France, and Herman Germany. the United States process had been developed the United States Electro-Galvanizing Co., which now the United States Galvanizing — Galvanizing Plating Equipment Co. the meantime, number patents had been issued various compositions electrolytes for zine plating. Only very thin coatings could obtained, fairly adhesive when great care was ex- ercised the manufacture. Never- theless tests samples produced still baths the laboratory held out great promises for this type wire coating only the difficulties encountered continuous manu- facture could overcome. The English post office, 1894, Wes apparently very pressed with the results labora- tory tests galvanized telegraph wire which showed that cold-gal- vanized wire was superior hot- galvanized. This question superi- ority electro-galvanized coatings peared every few years. The claim that for the same thickness the electrically deposited zine affords greater corrosive protection, how- ever, never went unchallenged those who represented the hot gal- vanizing interests. Nor commercially produced product those who propounded electro-gal- vanizing. States, interest seemed peter out. the Continent, however, the Herman process seemed making slow but definite progress. The coatings were thin, only 0.1 0.15 oz. per sq. ft., but they ad- hered well and the results were consistently uniform. The firm Langbein Co., which later be- Works, began installing one plant after another, until the begin- ning the World War there were installations operation scat- tered all over Europe. that time coatings 0.3 oz. per sq. ft. were being obtained and the number wires per galvanizing unit had increased 52. Heavier coatings than 0.3 oz. did not appear until after the war, but the demand for heavier coatings than 0.5 oz. seemed limited, since prevailing opinion was that such coatings were equal those hot galvan- ized wire twice the thickness. Several telephone and telegraph companies the Continent began specifying electro-galvanized wire. Also manufacturers wire prod- ucts began showing preference for the electro-galvanized product. In- terest wire was, therefore, revived England after the war and several firms heavily experiments electro-galvanized wire having less than coating apparent- could compete with hot galvan- ized wire. Above this weight, process. Outstanding among these electro-galvanized wire firms were Craddock Wakefield command the price quality and Hill Cambran. All the proc- product for which, however, there esses proved lamentable failures, was only limited market. Toward both from and finan- the end the last decade 1.0- cial point view. 1925 the oz. coating was, therefore, consid- latter plant was taken over ered the limit. Whitehead, Hill and Co., which company after few years ad- Developments the United States ditional development and improve- ment succeeded producing commercially salable product. the writer’s knowledge, still the only plant England manu- facturing electro-galvanized wire. This plant the single-wire type using upper and lower drum over which the wire winds. United States develop- ments took different course. Electro-galvanizing had been con- fined flat wire and narrow strip. The thickness the coating was limited 0.3 oz. per sq. ft., and produce such coatings hot dipping followed wiping would much more expensive than elec- tro-galvanizing. For coatings, needing comparatively little adherence the base or- der meet market requirements, the older methods electro-gal- vanizing were adequate. For heavy coatings flat wire and strip, electro-galvanizing would probably growth plating the one hand and the ability produce such coatings satisfactorily and more the Continent, the increasing demand for electro-galvanized wire resulted the erection more plants. 1930 the Langbein- Pfanhauser Works completed the erection the fiftieth plant. Some these plants were designed coat wire 1.0 oz. per sq. ft., but the majority still continued pro- duce coatings less than 0.5 oz. per sq. ft. The reason for this may found the cost, inasmuch TABLE PHYSICAL PROPERTIES WIRE BEFORE AND AFTER ELECTRO-GALVANIZING WIRE Bessemer steel, gage, coated 1.5 oz. Zn. per sq. ft. Before Galvanizing After Galvanizing Bending (no. of bends—A.S.T.M.).............. 7, 7,47 WIRE spring wire, gage, coated 1.01 oz. Zn. per sq. ft. Before Galvanizing Torsion (number—A.8.T.M.) .....ccccsccccccess 15, 15, 16, 15, 16 After Galvanizing 16, 16, 16, 16, 195,000 198,000 TABLE AGING EFFECTS ELECTRO-GALVANIZED STEEL WIRE WIRE 0.13 gage, annealed, coated with 1.0 oz. Zn. per sq. ft. Before After One Four Gal- Gal- Year Years vanizing vanizing Later Later Bending (no. 12, 12, 16, 13, 13, 11, 12, 11, 12, 10, 10, 11, Torsion ........ 44, 50, 43, 37, 37, 35, 40, 41, 37, 40, 38, 39, 43, 44 40 37 40, 42 51,000 for 62,500 60,000 WIRE 0.04 gage, annealed, coated with oz. Zn. per sq. ft. Before After One Four Gal- Gal- Year Years vanizing vanizing Later Later Bending (no. 26, 25, 19, 22, 22, 16, 19, 19, 14, 15, Torsion ........ 96, 67, 67, 68,68, 68, 61, 48, 45, 65, 71, 60, 84,94 for 39,200 THE IRON AGE, May 1936—35 = } r > ~ > 4 n ley Dy economically hot dipping the other. The advantage the elec- tro process providing wire screening with thin protective also obvious that the hot-dipping process would not suitable for galvanizing vanized conduit piping coated only with 0.3 which quite satisfactory for indoor use and stands bending much better than dipped coatings equal thickness. rather than the method which applied which determines the resistance corrosion, providing uniform and adherent. This paper, the writer’s opin- ion, marked the turning point the development electro-galvan- ized wire the United States. first was detrimental the elec- tro-galvanizing cause, because denied the claim that the plated coating being pure zinc superior ing zine coatings commercial- economical scale. the elec- tro-galvanized wire coming into wider use, new advantages are found for it, and seems safe prediction that its application the ascendency. Technical Facts and Considerations Insufficient adherence seems the chief cause the repeated setbacks failures methods known had the fault that they deleteriously The test specifications that zinc coatings round wire must meet TABLE are, however, more drastic. The INFLUENCE BRIGHTENING PROCESS WIRE DIMENSION wrapping test mandrel equal Dimension Zine Tensile Strength the wire diameter called for (Inches) (oz. per sq. ft.) (Ib. per sq. in.) much stronger bond between coat- Gage Before After Before After Before After ing and base than required the 0.1665 0.1653 0.95 96,700 case the other Bessemer (ld. 0.1653 0.1634 1.015 0.925 64,900 66,850 Telephone stock annealed)...... 0.1075 1.04 0.995 81,600 physical properties the wire, matter considerable importance round wire. With the advent the demand for heavier coatings, the electro-galvanizing wire presented increasingly difficult problem. There were repeated attempts even before the World War pro- duce electro-galvanized round wire, but the results were far from sat- isfactory and brought this product into this country. recently 1932 the writer found that strong opinion prevailed among the majority manufac- turers and users that electro-gal- vanizing impairs the physical prop- erties the base metal, especially high-carbon steels, and that elec- tro-galvanized wire was too ex- pensive produce and that the coating could not made ad- here well. the other hand, hot galvaniz- ing had undergone steady im- provement. The brittleness the ferrous zinc layer forming ad- jacent the base had been re- duced that the coatings would more ductile and adherent. 1930 Hippensteel, Horgman and Farnsworth presented paper en- titled “Observation the Outdoor Atmospheric Corrosion Protec- tive Coatings,” stating that the weight the zinc coatings 1In April, 1921, the Air Service In- formation Circular Aviation pub- lished the results investigation correct the prevailing erroneous opin- ion that the “wire was embrittled unsatisfactory for use.” the con- trary, stated that “zinc plating has tendency increase fatigue resis- ance.” 36—THE IRON AGE, May 1936 and resists corrosion better than hot galvanizing. Apparently all that remained claimed for electro-galvanizing was more uni- form thickness and freedom from the heating effect the hot spel- ter which made the latter unsuit- able for tempered high carbon steel wire. However, actually hap- pened, this report turned out boost The report made quite obvious that the life the wire would in- crease the same proportion the weight the coatings. As- suming the mechanical and eco- nomical question solved, much heavier coatings could duced electro-galvanizing than possible with Coatings 1.2 oz. per sq. ft. ap- pear the limit for the latter. The Bethlehem Steel Co. must credited with the vision future market for electro-galvan- ized wire with zinc coatings heavier than producible with hot galvan- izing. was before the above- mentioned report appeared that Bethlehem Steel became interested electro-galvanized wire, influ- enced probably developments Europe. Experiments with the process invented Tainton began 1928. 1932 the diffi- ironed out and the product known Bethanized wire was placed the market 1933. Europe, also, the Langbein Pfanhauser process had undergone some major improvement, making possible produce heavy, strongly adher- which marked the development electro-galvanized wire. That this was due the inadequate prep- aration the wire seems have been recognized from the very be- ginning, revealed article American Supplement Jan. 19, 1895. stated that “thor- oughly clean the surface coated found the principal difficulty the application any electro-chemical process for zinc.” Apparently this requirement was not fully appreciated judging the fact that subsequent efforts improve the process centered main- the plating end the proc- ess. When heavier coatings came in, was not only necessary find ways and means reduce the plating time, but also devise still better cleaning methods lest the coating should fail test. The difficulty properly clean- ing the wire will more readily realized one considers the fol- lowing: (1) Being quite different from still plating, continuous proc- ess the time within which the cleaning has completed very short, only fraction minute commercial operation. (2) The cleaning method must insure uniform results within the short time available. this last mentioned requi- site that has been the despair the experimenters. The cleaning method employed would operate satisfactorily only break down f | | ! | | i ' — j | completely after relative short period operation. Many pat- ents have been granted the sub- ject. Some the methods disclosed did not prove satisfactory when put test for conditions such the application heavy coat- ings imposes. Tainton hit upon excellent idea for obtaining stability when suggested that the wire elec- trolytically cleaned fused caus- temperatures the Tainton bath are not without advantage when desired combine, when feasi- ble, the cleaning with the anneal- ing operation. special method cleaning disclosed the Parker Process used Whitehead, Hall Co., Ltd. Unsatisfactory cleaning has been the chief source trouble this plant. Many the difficulties have been overcome, although TABLE COST ELECTRO-GALVANIZING WIRE (25 tons production hr.) Power (including drives) mills per kw. Labor 65¢ per man Chemicals, steam and water, maintenance and repair, including Cost per net ton bare Cost per net ton galvanized wire......... 0.6 oz. per 1.0 oz. per sq. ft. Coating sq. ft. Coating $35.00 $50.00 105.00 174.00 250.00 $350.00 tic soda and soda ash bath. The bath kept heated lead pan temperature more than 1200 deg. The nascent metallic sodium deposited from this bath the wire, which made the cath- ode, has high affinity for oxygen and reduces the iron oxide the wire surface pure iron. The sodium thereby returned the electrolyte. This action makes for stable conditions. Practical operation, however, proved that this cleaning method need followed still another electrolytic cleaning method em- ploying acid solution insure complete removal all the ox- ide and other impurities existing the wire surface. Another cleaning method which has proved successful for prepar- ing round wire for subsequent ap- plication heavy zine deposits that developed abroad Lang- bein-Pfanhauser. Information from European wire mills licensed use this process the effect that both simple and economical operation. The foreign patents only disclose acid solution and current density 200 amp. per sq. ft., which makes obvious that the principal information which the success this method hinges has been withheld. The moderate temperatures which operates places advantage where high carbon and spring wire are galvanized, although the high still not regarded suitable for high quality wires severe cleaning conditions, the physical proper- ties the wire must preserved. the better known domestic elec- tro-plating engineering firms such Hanson, Van Winkle, Muning, United States Galvanizing and Plating Equipment Co. and Meaker, entirely conjectural whether they have developed satisfactory cleaning process for the round wire, view the ab- sence commercial installations using such method. far the deposition zinc concerned, none the commer- cial processes can lay claim novelty ideas. The zinc sulphate electrolyte may vary composi- tion from one process another due addition agents with the view improving the throwing power brightening the de- posit, but basically they are the same. The use lead anodes connection with regenerative elec- with recirculating electrolyte employed the Tain- ton process, which the zinc deposited directly from the con- centrated ore, dates back 1895 Sherard Cowper Cowles. Only the method purifying the solution has undergone substantial improve- ments and silver-lead anodes have been substituted for the lead an- odes. The advantage dispensing with the replacement anodes offset the that higher potential (10 volts) must employed than required with zinc anodes volts). generally conceded that higher voltage does not yield tough deposit that obtained with lower voltage, and this especially true with heavy deposits. Also, the electrolyte must have much higher acid concen- tration. outstanding fact the new methods electro-galvanizing wire the tremendous increase the current densities. Whereas current densities 200 amp. per sq. ft. were considered high few years ago, densities double and triple this figure are now custo- mary. Only this increase current density could the electro- galvanizing heavy coating wire become suc- cess. the Tainton process, current densities even more than 700 amp. per sq. ft. are employed. The use such high current densities make more difficult obtain dense and pore-free deposits. Both the heat and hydrogen liberation such high current densities are tremendous and the tendency formation porous deposits ac- cordingly increased. Also one the difficulties thus created the more intensive washing required after galvanizing order re- move the last traces acid from the pores, otherwise corrosion will start these pores. The necessary after treatment the wire remove the unsight- appearance the deposit should also charged against the use such high current densities. Effect Physical Properties has already been mentioned how serious the deleterious effect the physical properties the wire was the older methods galvanizing. Especially high-car- bon steels, the words report the English wire manufactur- ers, “were rendered worthless.” This longer applies. properly electro-galvanized hard-drawn wire any carbon content will have the same physical properties with respect torsion and bending before galvanizing. typical anal- ysis shown Table Annealed wires behave different- ly. Age, well known, has (CONCLUDED PAGE 106) THE IRON AGE, May 1936—37 ) : é er fic C- ise ast ily ol- ust the ing last Cupola The British Cast lron Research Association HIS type cupola has found considerable favor England and finding in- creasing use this country. Throughi its use, coke con- sumption reduced and poorer grades coke can used with good results. Sulphur pick-up from fuel very low. heated iron readily avail- able the balanced cupola, and the unit particularly adaptable highly mechan- ized continuous foundries. ALTHOUGH new types melting equipment are constantly being de- veloped, the cupola still, and likely remain, the most popular form melting unit the iron foundry. During re- cent years has been proved that the melting conditions the cu- British Patent 333,322; Pat- ent 1,853,120. Shepherd, “Some Experiences with the Balanced Blast Cupola,” Foundry Trade Journal, Dec. 29, 1932, and Jan. and 12, 1933. Wharton, “Cupola Control, Its Progress, Practice and Value the Foundry,” Foun- dry Trade Journal, Feb. 16, 1933. Buchanan, “The Balanced Blast Cupola,” Foundry Trade Journal, Jan. 16, 1936. THE IRON AGE, Dec. 19, 1935. 38—THE IRON AGE, May 1936 pola have great influence the structure and properties the metal which melted it. Realiz- ing the importance this fact, the British Cast Iron Research Asso- ciation carried out considerable work order determine how the best melting conditions could obtained. new design furnace was finally developed Fletcher, which has become known the balanced blast cupola’. During the past five years the design has aroused very considerable amount interest and several independent statements users have appeared the British technical the present time over 100 these cupolas are operation, including number Australia, India, the Europe. The furnace being used the production all types and sizes gray iron castings, rang- ing from light castings and pipes high test engineering castings, and also the production mal- leable iron and refined pig iron and for making steel castings conjunction with converter. The balanced blast system can ap- plied either existing new furnaces all sizes from tons per hr. upwards. The largest size far installed in. internal diameter, capable hourly out- put approximately tons, but the design can furnished for furnaces in. internal diam- eter, having output tons per hr. Principle Operation The principle operation can Four rows tuyeres are used which all deliver air from the wind belt. The bottom row main tuyeres are each fitted with ad- justable screw valves that the air supplied through these tuyeres may controlled, necessary, during the melt within very fine limits. The upper three rows con- tain smaller, auxiliary tuyeres, and each these adjustable that the air supplied each can controlled. These upper tuyeres, when once set, are not altered dur- ing the melt. converting existing cupola the new design, new wind belt, large enough accommodate the three rows quired. The photograph Fig. shows two 48-in. internal anced blast cupolas the foundry Babcock Wilcox, Ltd., Ren- frew. The cupolas are fitted with forehearths and metal tapped continuously for mechanical cast- ing plant. Eight main valves are fitted each cupola underneath ! J \ the wind belt and the handwheel controls some these valves are clearly shown, are also the three rows auxiliary tuyeres fitted the wind belt. The melting rate these cu- polas between and tons per hr. Between two the main valves the left side each cupola can seen one the spe- cial tuyeres used for rapidly kin- dling the coke bed. These tuyeres are stopped with sand before the cupola charged. When new converted cupola being put into commission, the British Cast Iron Research Asso- ciation supplies detailed working instructions which enable the foun- dry executive quickly arrive the most suitable settings for the main and auxiliary tuyeres, and the size the metal and coke charges, etc. When these are de- termined there need for alter- ation the tuyere settings unless there some radical change the type mixture being melted, some modification required the output the furnace. far the cupola attendant concerned, there very little difference be- 48-in. balanced blast cupolas fitted with forehearths cox Ltd., Renfrew, England. The melting rate between and tons per hr., and the metal tapped continuously forehearth. tween the operation balanced blast cupola and normal cupola, and usually after the first sec- ond melt will operate the new design furnace with complete confidence. well known that normal cupola practice extremely diffi- cult obtain complete combustion the coke carbon and that analysis the top gases usual- reveals the presence con- siderable quantity CO. Camp- bell and recently published paper, state that under favorable conditions normal cu- polas, about per cent found the top gases and that the amount may high per cent. The formation this gas the cupola represents con- siderable amount heat which entirely wasted the gas al- escape the atmosphere burn the charging hole. Gas Burned Inside designs cupola the top gases are exhausted and the burned outside the furnace, the heat produced being utilized for preheating the blast. the bal- anced blast design cupola, al- though produced the lower levels the coke bed, possible carefully balancing the amount secondary air admitted through the auxiliary tuyeres burn this gas inside the furnace, the heat being utilized where produced for melting and preheating the metal charges. Almost complete combustion the coke carbon obtained and the fuel consumption the new furnace consequently considerably lower than nor- mally designed cupola. per cent per cent less coke required the charges, when producing metal similar even higher temperature that obtained from normal cupola. The higher efficiency the fur- THE IRON AGE, May 21, an ed in ° res ine we so es, an re- ws al- en- ith st- are ath nace shown the analysis the top gases, which usually con- tain less than per cent CO. Table gives the average analysis the gases from two 14-ton per hr. cupolas, which were originally identical, one having verted the balanced blast sys- tem. Both were producing metal the same temperature, the un- amount coke used, often possible use higher sulphur, cheaper coke, without increasing the sulphur pick-up the metal. Also, due the completeness combustion, high temperature metal may obtained with coke which not first quality. Table shows comparison be- tween the sulphur picked IG. 2—A balanced blast cupola the foundry John Lang Sons Ltd., John- stone, near Glasgow. This unit supplies tons metal per hr. for machine tool castings. Tapping continuous and slag trap incorporated the tapping spout. The slag run off into bogie, which can seen the right the tapping spout near the cupola. soon one ladle filled with metal the stream diverted into the second ladle. converted cupola working with per cent coke and the balanced blast cupola with 7.5 per cent. The analyses are average figures taken over period three hours. Gas the analysis discharged the top the stack balanced blast cupola does not burn the charging hole and the absence heat has been found added ad- vantage, especially during the sum- mer months, where hand charging employed. consequence the smaller 40—THE IRON AGE, May 1936 metal the balanced blast cupola and similar metal normal cu- pola, both using similar coke. these tests was found that the balanced blast cupola only per cent the sulphur entering the furnace from the fuel was taken the metal, while the nor- mal cupola per cent the sul- phur was taken up. general rule the economy coke obtained sufficient pay the cost conversion several times over the first year, but TABLE Analyses Gas from Normal and Balanced Cupolas Gas Analysis Volume (Per Cent) CO, Normal Cupola... 12.30 10.05 0.37 Balanced Blast 1.21 0.54 79.95 apart from this are the benefits derived from the better melting conditions and their effect the quality the metal. Due the completeness the reaction which takes place between the air and the fuel the coke bed, the metal melted very high temperature and this has been found have remarkable influence its qual- ity. Users the cupola who are producing cheap castings, well those producing very high qual- ity castings, have benefited the improvement the metal and re- port reduction the amount foundry scrap. The metal rela- tively unoxidized and gas-free and lies very quietly the ladle and the mold that trouble from gas holes and shrinkage found diminished and some cases elim- inated. Very considerable savings have been effected reduction foundry scrap, even cases where the figures were extremely low be- fore the installation the cupola. Superheating Possible Highly superheated metal may obtained desired, and the cu- pola ideal for producing metal for automobile cylinder and other intricate castings where high tem- perature metal essential. Three the most important British auto- mobile works have already installed balanced blast cupolas. one these foundries the carbon and sili- con content the metal very rigidly controlled through 8-hr. melting period, each element being allowed maximum variation +0.05 per cent from the specified figure. (CONCLUDED PAGE 93) TABLE Pick-Up from Coke Normal and Balanced Cupolas Pound phur Coke Pick- Pick- ing Balanced Blast Cupola ..... 0.016 (6.8 per cent) Normal Cupola 0.22 0.20 (8.0 per cent) | Returns trom and LIPPERT Metallurgical Editor, AGE new machines help the fabricator English rotary shearing unit. Plates any size in. thick can handled, and any type bevel can produced either along straight line Recent tests England have established Cr-Ni alloy steels preferable for service requiring partial complete immersion sea water. English firms have found that induction furnaces are admirably suited efficient heat treating. German research has brought forth new tool steel for machining stain- less steel. this country, Dr. process for silicon-casing steel may place ordinary carbon steel competitive position for applications where heat and corrosion resistance are primary requisites. new lacquer being marketed which may extend the application plain steels into fields now dominated glass, plastics, plated steel expensive alloys. LATES from in. thick can sheared, beveled one side both sides, either straight line along any type curve means new rotary shearing machine made James Bennie Sons, Ltd., Glasgow, Scotland. This equipment was de- signed supersede flame cutting and conventional methods shear- ing and planing plates, Practi- any length plate can handled and various types bevels are possible either substituting suitable rotary cutters swinging square-edge cutters angle. The machine shown opera- tion Fig. Operation con- trolled from seat located above the rotary cutters, and the carriage mounted upon roller bearings and runs rails. One the rails secured the work table, and, also, the plate sheared secured the same stationary work table. Dial gages situated front the operator show the adjustment the cutters magnified scale. view the upper cutter shearing through plate shown The cutter shafts are driven through gearing means electric motor mounted upon the machine. cut started rotating hand wheel traverse the carriage until the rotary cutters grip the After that, the cutters themselves draw the machine and carriage along the rail track. The machine has two speeds and can cut either direction. Com- plex bevels, either straight line for circles, necessitate the sub- stitution special rotary cutters. Steel many centuries man has changed the structure steel surfaces through the infiltration some extraneous material high temperature. The objective has al- ways been maintain the strength and ease manufacture the or- dinary steel structure but secure surface harder, tougher, and more resistant corrosion and wear than possible with the parent metal alone. Ancient man was metallurgically ignorant, but knew that hot iron THE IRON May ime 7.28 +) 9.95 ich ire ire al- the la- la. ier li- ir. fe) ° It- g would absorb carbon from charcoal and give his soft iron tools su- perior surface. Modern man, like- wise, greatly dependent varia- tions this procedure. Similar processes for the impregnation other elements have only come the fore within recent years. For instance, zinc and aluminum pow- ders are absorbed heated steel surfaces reducing atmosphere the familiar sherardizing and calorizing processes. few years ago, the General Electric Co. chro- mized steel much the same man- ner. Subsequently, patent was issued another inventor for im- pregnating steel with silicon packing the steel objects boxes with metallic silicon high silice- ous materials, supplying chlorine- containing compound act energizer facilitate the transfer silicon into the steel, and, final- ly, applying heat until tempera- ture about 1800 deg. at- tained. This latter process particu- lar interest now inasmuch Harry Globe Steel Tubes Co., has revived interest the treating steel with silicon make the sur- faces resistant corrosion, heat and wear. details the produc- tion procedure have yet been issued, but known that many large companies are definitely interested the procedure and are using experimentally their plants. Ihrigized surfaces will withstand boiling per cent sulphuric 42—THE AGE, May 1936 acid for over 100 hr. When rod with Ihrigized surface boiled acid, the core disappears leaving the shell unaffected. The case contains about per cent silicon, can given mirror finish and integral part the treated piece. The case not file hard but cannot cut with hacksaw. The surface about 160 Brinell hard, non-galling and resists highly oxidizing atmos- ing destroys all previous heat treat- ment, but heat treatment in- fluences the case once applied. Thus the core metal can given any properties desired. This process expected open entire new market for ordi- nary cheap carbon steel. Lacquered Steel ITHIN recent years there been trend toward alloys steel non-ferrous metals which are intrinsically resistant cor- roding media service hazards. the other hand, some observers believe that ordinary carbon steels will regain some lost favor through the development suit- able finishes and coatings which will produce surface able stand under corroding conditions. One the many steps toward this end the recent development synthetic enamel easily applied steel objects, which has at- tractive appearance, available multitude bright colors, and which fully resistant against cigarette burns, disintegration alcohol softening heat. This enamel, Roxyn 12-B, Roxalin Flexible Elizabeth, J., can applied spraying dipping and baked for one hour 300 deg. Various objects finished this have been immersed al- cohol for one hour without sign English rotary shearing machine. The upper view shows the operator cutting straight-line bevel, and below close- the upper cut- ter and the plate being sheared shown. All types bevels can ob- tained, either straight line along any type curve. very cleanly, there- fore there need for subsequent edge planing. failure and ash trays, for instance, have been used for months without any sign discoloration soften- ing. Thus, the way open for enameled articles compete more successfully with articles hitherto made glass, plastics electro- plated metal. Alloy Preferred CCELERATED corrosion test- ing some disrepute. The greatest attention now directed toward long-time testing under actual operating conditions. this latter category are the data col- > | | | j | J i | € ‘ VE lected the Sea Action Commit- tee the Institute Civil Engi- neers (British). For years this committee has studied the reaction various metals sea atmosphere while partially wholly sub- merged harbors scattered throughout the British Empire. The evidence brought forth these controlled scientific investiga- tions somewhat variance with what general experience has led ob- servers expect. For instance, the resistance corrosion high- chromium steels, both the hard and soft grades, although very sat- isfactory salt air and fresh water, definitely disappointing sea water when either completely partially immersed. These steels apparently have marked propen- sity localized pitting which should restrict their use consider- ably. The best and most reliable metal now available for this type ser- vice evidently per cent nickel alloy. But the high cost this steel serious deterrent wide application. Sir Robert Had- field the opinion that alloy containing per cent chro- mium and per cent nickel likely approach more nearly the ideal non-corrodible material than any the straight chromium steels do. This same committee has estab- lished that coating coal tar, neutralized the addition slaked lime, gives excellént results and much superior the iron- oxide and lead paints generally used for protecting plain carbon steel under sea water. Rapid Hardening IGH frequency induction heat- ing being made every- thing from melting metal pro- ducing artificial fever. recent important innovation this con- nection the hardening crank- shafts and similar machine parts. These steel articles are heated current about 2000 cycles car- ried hollow inductor coils, and then rapidly quenched water squirted through holes the coils. this manner, effective surface hardening secured very short time interval. typical op- eration has actual heating peri- only sec., and the complete including quenching and set- ting the coil, usually under sec. This short time interval particularly impressive when New Kaiser-Wilhelm Steel Research Bulletins Available for Iron and Steel Research, lent work 1935, spite the fact that there was general breaking housekeeping and disorganization incident moving new location. will seen from the following titles, the chem- ical side metallurgy well the mechanical side has been treated. Some these bulletins reveal fundamental truths, which the iron and steel industry has awaited eagerly. Those who can read Ger- man, will amply repaid study these bulletins, and those who have knowledge German will find profitable have few the bulletins translated. They can obtained one volume separately, and are published the Verlag Stahleisen, Dusseldorf, Germany. According Professor Trinks, the Carnegie Institute Technology, the titles these bul- letins are follows: Valuation iron ores. (272) Vibratory strength and damp- ing properties carbon steels function chemical com- position and heat treatment. (273) focusing chamber for X-ray reflection photography. (274) The effect carbon reduc- ing agent upon the reactions steel making with acid slag. (275) The influence the roll diam- eter cold rolling strip steel. (276) the shape stress-strain curves steel the tempera- ture range blue brittleness. (277) Effect age the properties newly rolled steel rails (of basic converter steel). (278) Influence die, lubricant, and velocity draw upon die resis- tance (power consumption) the drawing thin steel wires. (279) The equilibrium between iron and nickel and their saturated silicates. (280) Tests the sequence metal- lurgical events the making basic open-hearth steel heat compared with the hr. usually required for nitriding. Machining Stainless Steel OST companies use high-speed steel for turning and machin- ing austenitic stainless steel. How- ever, there demand for cheap- and more convenient tool steel, and recent article Stahl und Eisen describes substitute alloy for which considerable success claimed. The steel contains 1.2 per cent carbon and per cent tung- sten (Silberstahl). The tool quenched from 1470 deg. F., but only warmed about 265 deg. relieve strains. For machining stainless steel the tool ground shape consider- ably different from that used for high-speed steel. The chief shape feature reversed top rake deg., e., the top the tool inclined toward the work instead away from it. Similarly, the side rake about deg. and slopes down the cutting edge. Front and side clearances are about deg. The use coolant essential. per min. and feed 0.04 0.05 in., life min. common practice. (281) the mechanism the alpha- gamma transformation iron. (282) X-ray analysis the distribu- tion stress and excess stresses steel. (283) quenching strains. (284) the quenching power various liquids. (285) the rearrangement mole- cules iron between 160 and 1300 deg. (286) The use potentiometric analy- sis for the determination cobalt and manganese steel. (287) Changes crystal shape electrolytic iron. (288) new vacuum furnace and its use for determining oxygen steel. (289) Experiences with the roll pres- sure tester “Pasopos.” (290) Cold rolling strip fluence roll material, linear speed, width strip, and previ- ous cold deformation. (291) The reactions chromium with acid slags. (292) Influence stretching and aging the behavior steel under vibratory stress. (293) Mechanical properties drawn steel wire affected the linear speed lead patenting. THE IRON AGE, May 1936—43 | F nt - t- id “Steg as of ‘ { Dy. e, re ls BELOW the American Mining Congress Cincinnati, May shown this attractive and unusual exhibit the United States Steel Corp. which features the simulated reproduction coal mine entry showing complete track turn-out and new type mine car welded construction made from Cor-Ten steel and equipped with rolled steel wheels. Also display will working model coal mine tramway, and steel products every kind which enter into the construction and operation the modern coal mine. The exhibit the corporation occupied more than 1500 sq. ft. 44—THE IRON AGE, May 1936 vo LEFT display die-cast products large size now being used the automo- tive industry one the fea- tures comprehensive ex- hibit die-cast parts and articles, now being held Metal Products Exhibits, Inc., International Building, Rocke- feller Center, New York, under the sponsorship the Ameri- can Die Casting Institute. BELOW Sheet Aluminum Corp., Jackson, Mich., has desiqn- this wheelbarrow, which said weigh Ib. less than the ordinary product. High strength aluminum alloy called tire. This economy dead load weight allows increase per cent the pay load, and the air-filled tire aids creating more per- balance shock. “= 7. > reti ti RIGHT NEON sign with steel channel letters, one the larg- est its kind ever built, graces the front this Cincinnati clothing store. The letters and are in. high, and the others are proportion. The smallest letters are high. Armco stainless steel, manufactured the American Rolling Mill Co., Middletown, Ohio, was used the Quehl Sign Co., Cin- cinnati, builder the sign. avg GATE which not only strong and durable but which also attractive the eye has been installed Kokomo, Ind., the Cornell Works, Long Island City, These rolling steel grilles are constructed hard drawn galvanized bars, each bar running from side guide side guide with malleable iron links spaced with cadmium plated tubes. One the grilles operates electric motor and the indicated, controlled hand. The grilles coil overhead pipe shaft which the counterbalancing spring and the rotation the motor winds the grille around the pipe shaft. They have been tested pressure tons per ft. height, and will not pull out the side guides. Similar grilles have been made the Cornell company ft. widih. The design harmonizes with the brickwork alongside. BELOW ANGING the last section the superstructure the San Francisco-Oak- land Bay Bridge was completed April American Bridge Co. the actual steel work only the fioor system yet laid and this June 20. When the remaining 8000 tons steel are placed the final steel requirement will have totaled 150,000 tons. Pouring concrete well un- der way the east structure. When com- pleted November main structure will carry six lanes automobile traffic the upper deck and three lanes for trucks lines railroad tracks the lower. ABOVE BENJAMIN JAVITS Javits and Javits, Attorneys ° ° ° EVEN though our pres- ent economic system but haphazard, com- petitive struggle, ap- pallingly wasteful and inadequate present needs, order can brought into it. Business men can assured reasonable profits; agriculture fair return; labor security through regular employ- 46—THE IRON AGE, May 1936 ment, higher wages and other bene- fits; and all us, consumers, getting more and better goods lower prices. But the revamping the eco- nomic order must undertaken industry itself, with business, finance, labor and agriculture all cooperating for the common good. The difficulties encountered the New Deal confirm all our ex- perience the past, namely, that political acts and politicians are not the right implements for man- aging complex an_ The First Steo Toward Economic and economic structure ours. The one sure-fire technique for getting elected public office thunder vaguely against the inter- ests and big business. Small busi- ness men and without profits, well workers without jobs, willingly believe that big business and its bankers are ogres. The million voters who even normal times struggle along less than $2,000 year per family also provide sympathetic audi- ence for such demagogues. Once elected, politicians usually | a J i Less make more less effort put into effect some their campaign promises the forms laws which are intended regulate, punish, or, frequently, spite business. Seldom ever they have objective the creation order our national economy. Even NIRA, which first seemed promise some help industry, was designed primarily provide employment. Its chief aim shouid have been assure profits for business. Reemployment then would have followed matter course. The anti-business attitude politicians has resulted com- plicated structure Federal, State and municipal laws which catch the honest business man spider’s web restrictions, but which are frequently avoided for while least the dishonest— with resulting damage the law- abiding. has been said that some cases the business man, obeying one law thereby forced violate some other. Naturall