The Iron Age 1936-07-16: Vol 138 Iss 3

GREATER OVER-ALL Send copy the new Thomas Handbook information cold rolled strip steel ‘THE THOMAS STEEL COMPANY WARREN, OHIO SPECIALIZED PRODUCERS COLD ROLLED STRIP STEEL JULY 16, 1936 PHOSPH BRONZ The service record Elephant Brand Phosphor Bronze the field gives ample proof the ability this material stand most severe conditions. This gruelling, testing service indeed! ness, toughness, durability and elasticity, addition anti-friction recommend for many applications innumerable kinds equipment Why not investigate the possibilities Elephant Bronze for your use? made just the right analysis for every THE PHOSPHOR BRONZE SMELTING 2200 WASHINGTON AVENUE PHILADELPHIA, Furnished the form ingots, castings, rods, wire sheet, ropes and Time-proven fer the mos if WEST 39TH STREET Sales Offices Owned and Published CHILTON COMPANY (Incerporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. Cc. A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, BYERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary NEW YORK, CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. FRITZ FRANK, President VAN DEVENTER Editor Managing Editor FINDLEY Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Washington Chicago Cleveland Pittsburgh Detroit Conten July 16, 1936 Some Recent Developments Chromium All-Welded Structural Steel Flat Pouring-Pit Refractories and Alloy Steel Quality......... Radium Inspection Metal Blooming Mill Modernization for Quality Steels......... Bonderizing Process for Zinc Copyright 1936 Chilton Company (Inc.) BAUR, General Advertising Manager DIX, Manager Reader Service ADVERTISING STAFF Member, Associated Business Papers Emerson Findley, 621 Union Cleveland Herman, 675 Delaware Ave., Buffalo, Y.. and Chilton Bidg., Chestnut 56th Published every Thursday. Subscrip- Sts., Philadelphia, Pa. tion Price: United States and Pos- H. K. Hottenstein, 802 Otis Bidg., Chicago Peirce Lewis, 7310 Woodward Ave.. Detroit Ober, 239 39th St., New York Robinson, 428 Park Pittsburgh Sweetser, 239 West 39th St., New York Member, Audit Bureau Circulations Indexed the Industrial Arts Index. sessions, Mexico, Cuba, $6.00; Can- ada, $8.50, including duty; Foreign $12.00 year. Single copy, cents. D. C. Warren, P. O. Box 81, Hartford, Conn. * No. Bethlehem ensures free movement floodgates HEN river like the Mississippi swells into surg- yellow sea, the opening dam floodgates must not hindered corroded metal surfaces. The gates must move freely, even the first time they have been opened several years. For this reason, for sure, swift action emergency, stainless steel being widely used the Taintor gates, roller tracks and arma- ture plates many dams. Bethlehem has supplied stainless steels for number the new Mississippi River dams. these, every other successful installation stainless steel, careful evaluation the service and fabricating requirements was essential. Only when every factor has been weighed and considered can the correct grade stainless steel prescribed and produced for the specific application. With complete facilities for both research and pro- duction their disposal, Bethlehem metallurgists have done important pioneering work the production stainless steels for both usual and out-of-the-ordinary services. The practical knowledge and broad experience thus acquired make Bethlehem logical source reference whenever question securing the grade stainless steel which fulfills all service and fabricating requirements. d | { i | 36—THE IRON AGE, July 16, 1936 JULY 16, 1936 ESTABLISHED Vol. 138, No. The Keeley Motor the old horse and buggy days, bright chap named Keeley created stir mechanical and financial circles exhibiting motor which apparently gave out more energy than was put into it. Stock his device sold like wildfire here and abroad until investigator discovered concealed and secret compressed air line running through the base the motor which surreptitiously provided the mysterious excess power. Thus was exploded, disastrously for those who had foot the bill, another the bright bubbles delusion through which men hope take out more than they put in. cannot done, either the field physical and chemical science, the field human effort the field finance. not strange that this simple law quid pro quo, which should self-evident all us, disregarded present-day economic considerations? The philosophy hoping take out more putting less the field human effort the minds the many who are urged believe that decreased output will bring higher wages. Those who urge the 30-hour week suffer from this hallucina- tion. Their motor" will not work without hidden pipe line the public treasury, fed with dollars the expense the American public. the field finance, unbalanced budget, private public, signifies the existence another sort Keeley motor. also will run just long the deficit between income and outgo made through the hidden pipe line leading the public treasury. Our National Keeley motor now operating the basis units financial energy put units taken out. That the ratio between Government receipts and expenditures for the past year. our present exorbitant taxes are only sufficient provide per cent the financial power keep our government motor running, think the burden that will inevitably fall upon the next generation when their unpaid power bill handed them for settlement! : >» Sys | % Ms Mitre > | % | we € ig ° ° ° HERBERT SIMONDS ° STYLES change metal finish they most all marketed products, and lacquer, color bright polish must bow turn vogue and fancy. Chromium plate and stainless steel shared the limelight decorative design for several years, but now trend away from white metal notice- able the finish the multitude small metal articles every- day use. Fortunately for chromium, more metal articles are being used the public that the loss due style change largely offset broadening application. Also chro- mium plating not dependent 38—THE IRON AGE, July 16, 1936 T-bar placed the center the brush bristles, cated here. solely decorative effects for its industrial favor. Its use pro- tective coating resist abrasion firmly established without serious rival sight. The net result that chromium plating today steadily increasing both process manufacturing and factor general plating business. the technical side, things have been happening also and re- cently dramatic fashion. The strong patent situation which has protected the established practice chromium plating has been up- held the courts after attack commercial interests. But now sev- eral new processes have appeared which, claimed, not infringe existing patents. Most these processes involve new types baths for tank plating and leave the other plating conditions practi- cally unchanged. One interesting innovation dispenses with the tank and plates with brush much painter would paint. Established Practice Before describing some features the new processes may well ECENT visitors England have brought back ports keen interest metal finishing with ments some fields beyond the practice here. Two methods chromium plat- ing, new America, are de- scribed this article and one review the high lights chro- mium plating now practiced al- most universally. The tank lined with antimonial lead with glass and should provided with steam coils other means for both heating and cooling. The bath con- sists solution warm water and chromic acid, with its concen- tration varying from oz. chromic acid per gal. water oz. per gal. The chromic acid frequently contains some sul- phur impurity, but this im- purity becomes advantage be- cause sulphuric acid, which required bath constitu- ent. Usual technique calls for total per cent sulphuric acid the completed bath. Therefore after the water and chromic acid have been mixed, the solution tested for sulphuric acid and any deficiency below the required per cent offset with the proper sul- acid addition. When finally prepared and put operation, the bath fairly simply maintained with occasional additions chro- mic acid and less frequent adjust- ment sulphuric acid content. use, the solution kept warm, the temperature varying from 120 deg. 160 deg. with the type work being plated. alloy anodes are used and present tech- nique calls for per cent anti- monial lead, which the same the lead used for the tank lining. | 4 P ° ° ° i these has been practical use Coleman Appleby, Ltd., Birmingham, England, for approximately three years. Mr. Simonds vice-pres- ident Metal Products Ex- hibits, Inc., Rockefeller Center, New York. When new tank with its solu- tion put into operation, the first step condition the anodes. This done running the electric current reverse order. other words, having the anodes be- come the cathodes the electric circuit. This builds thin film surrounding the lead anodes, which important. The proper condi- tion the anode determined its appearance, trial. experienced plater knows instantly whether his anodes are good condition for plating. The time re- quired for this conditioning may ten minutes may even hour more. Critics this technique often dwell the length time required for this conditioning and there seems some mystery about even otherwise well-sys- tematized shops. Manufacturers plating supplies offer fully condi- tioned, ready-for-use anodes, but the fact remains that most good platers are careful put their own final touch the process anode conditioning. When everything else set, the -well-cleaned work immersed the bath contact with the cath- ode bars terminals, and low voltage current turned on. This current varies voltage from more per sq. ft. work sur- face. flows from the anodes through the intervening solution the work surface and deposits that surface minute grains me- tallic chromium out the solution. brief terms that the process chromium plating. Actually many other factors, such agita- tion the solution, variation the voltage, and shape the anodes, enter into the question. New Methods This year two three new meth- ods chromium plating have ap- peared and the claim made that these not infringe the exist- ing patent situation. The Amer- ican patents cover, among other features, the use acid radical with the chromic bath. Usually this sulphate radical. One the new methods which has been placed the market within the past three months that Nickel Chromium Prod- ucts Co., New York. This method developed England Coleman Appleby, Ltd., Bir- mingham, which company has had the process use for three years. The technique seems sim- plicity itself, only necessary add salts which are shipped from HIS shows the location the antimonial lead anode inside the brush and about in. from the tip the bristles. England the usual chromic acid and hot water produce plating bath ready use. The composi- tion these English salts se- cret and forms part the propri- etary interest Nickel Chromi- Products Co. The quantity secret salts amounts about 1/15. the chromic acid used. That is, the total addition the hot chromic acid and lb. will the English addition. Many features are claimed for this new bath, perhaps the chief one being that ready work once without .the necessity conditioning the anodes. im- portant, however, use high- purity chromic acid, impurities such sulphur create sulphate radical which not only causes infringement patents this country but which interferes well with the effectiveness the process. Another requirement that the tank and anodes made THE IRON AGE, July 16, 1936—39 | t 7% ; | 1 SEE vial = Pip ° ° ° i | iad = 4 with high-grade antimonial lead. Some difficulty has been reported when the tank has inferior lead lining. tanks are generally used and such tanks have certain advantages. this country the danger break- age seems steer platers away from the glass-lined tank. Throwing Power The bane most chromium plat- ers the poor throwing power chromium solutions. Herein lies one the chief advantages claimed for the English salts process—bet- ter throwing power. The bath said have greater conductivity and therefore greater throwing power than the previous baths. proof, deep dishes have been suc- cessfully plated with the new solu- tion without the use special anodes, even though old-time plat- ers this country have claimed that could not done. Many platers, attempt increase the throwing power for concave surfaces, increase the amperage per sq. ft. This, according English chemists, the wrong procedure, especially with the Nickel Chro- mium company bath, for which current density per sq. ft. and temperatures deg. are rec- ommended. Most the usual pre- cautions voltage, apply with this method the same with previous practice. For or- dinary work voltage volts rec- ommended, de- pending upon the thickness desired. For concave sur- faces in- creased voltage necessary and deeply recessed articles might need volts more for few seconds when spe- cial anodes are not used. For this reason variable voltage current custom-plating plater, using improvised equipment, successfully using the English secret salt method chromium plating. used. 40—THE IRON AGE, July 16, 1936 CONVENIENT kit provided con- taining three brushes and two ex- tension cords. When plating started, volts applied between the work and the anodes for initial period sec. allow the work attain the temperature the solution. The work should hung that the deepest recesses face the anodes, and where the recesses are excessive the work may have placed closer the anodes than otherwise would necessary. Other conditions which apply this English method well most chromium plating include the smallest possible time between the preceding nickel finish chromium plating, freedom from grease and finger marks, the proper use refreshing salts, and thor- ough rinsing and cleaning. After plating parts are rinsed cold water, then neutralized hot so- dium carbonate oz. per gal.), then rinsed cold water and finally clear hot water, followed drying sawdust. Brush Plating Another English development brush plating, which, with some American improvements, now the market practical and com- mercial process. simplest terms, this consists attaching the nega- tive wire low voltage direct current circuit the work plated and the positive wire the binding post the end brush which looks very much like paint- ter’s brush, but which has the center the bristles metal anode. The brush first dipped moist, jelly-like solution chromic acid and then used very much painter would use coat the metal parts. necessary, course, have the metal surface clean, and the metal not al- ready copper nickel, the chro- mium plating process works better the metal first nickel plated. This nickel plat- ing can also done this same brush method using exactly the same equipment, but dipping the brush into moist nickel sal paste instead the chromium paste. Small transform- and rectifier units are avail- able which can plugged into any light socket, and fairly simple plate part which may difficult remove for tank immer- sion, such han- dles and trim buses and trains, plumbing fixtures { t | s. i — — ABOVE ARINE service severe test for any plating. However, surfaces such this may retouched with portable outfit. hotels, and general household hardware. This brush plating unit seems appeal particularly chefs large hotels, for instead sending cutlery away plated, can done continuous basis, small batch time, simply plugging the brush plating unit some convenient place. The unit consists small motor generator set which operates standard 110- volt alternating current and gives direct current output from volts. Suitable cords and connecting devices complete the outfit. Because brush plating tively new this country, some the general considerations are here included. The current electricity which passes from the anode through brush bristles the work starts the vari- ous chrome atoms, groups atoms the paste, move either toward the anode toward the work, depending upon whether they are positively negatively charged. the electrolyte em- ployed for brush plating, the chrome atoms always become posi- tively charged and move toward the work. The acid radicals become negatively charged and migrate the anode. When the metal ions reach the work their charge given and the metal deposited. When the acid radical ions reach the anode their charge also neu- tralized and the ion either de- BELOW HROMIUM-PLATED bathroom fixtures, difficult remove for retouching, now may replated without removal the brush method. THE IRON AGE, July 16, 3 posited corrode the anode else escapes the form gas from the solution. The rate which this process takes place determined con- ditions the circuit. bath tank plating these conditions are relatively stable and the rate therefore easily determined. brush plating, while conditions general way are similar tank plating, the constantly changing due the movement the anodes and the closeness the anode the work. One the chief disad- vantages that only relatively small area the work can plated one time and special care must taken use electrolytes which will not etch the work. Preparation for Plating Before any work can brush- plated is, course, necessary small plating unit light enough transported easily. position the anode with respect the work, and the varying den- sity and quantity the paste be- tween the work and the anode makes difficult establish posi- tive rates for plating. However, experienced brush plater soon learns duplicate conditions from one job another fairly accurate- ly. fact, some who have plated with brushes claim greater than those possible tank plating can achieved. This 42—THE IRON AGE, July 16, 1936 clean thoroughly the surface the work, and the same instructions ap- ply here for tank plating. general, addition cleaning, necessary buff and polish. This, course, can done with portable outfits. Brush plating, like any other plating, will not cov- deep scratches, and where these exist necessary remove the with cloth wheels charged with emery some similar man- ner. For polishing, acme white soft cloth wheel The importance cleaning diffi- cult exaggerate either for brush plating tank plating. Generally speaking, surface may consid- ered sufficiently clean for plating when oxide visible its color and when, after rinsing, the water runs off the surface leaving uni- form film that unbroken streaks cracks. For removing oxides, dilute sodium cyanide recommended for copper and brass and muriatic acid for iron and steel. cases where unusually high gloss surface not required the cleaning this way will suffice without buffing. Often the case buffing away from established polishing de- partment the dirt left after the op- Oxides are the most common form surface “dirt,” but other foreign matter such grease chemical stains may encountered. Some greases and oils may saponified alkali washes, but other types oil, grease and stain may require special solvents. When neces- sary remove existing plate, stripping reversal current employed. This done with brush manner similar that used for plating except stripping solution used place the acid paste. frequent dipping the brush this stripping solution, good contact maintained and the plated material lifted from the surface the metal part and accumulates washed out. course, some the metal the so- lution deposited the electrode the brush, which this opera- tion the cathode. dipping the brush this stripping solution two things are accomplished, washing out dirt from the bristles and re- fortifying the bristles with the stripping solution. many cases the procedure plating parts, such bus handles, where previous plates have worn down the brass undercoat follows: Old plating stripped using the brush frequently im- mersed the stripping solution, and using the current the re- verse position. This takes about five minutes for brass handle ft. long and diameter. This stripping followed polishing either with portable buffing wheel hand. This may take from one five minutes. Buffing fol- lowed short cleaning any (CONTINUED PAGE 114) : hy 4 i x — | . flat car whose free under-light-weight height from top rail platform ft. in. The body this car is, substantially, one piece, fabricated welding standard production rolled steel structural members. structural flat the development car construction, the cars has been toward reduction over-all height, il- lustrated the design vania Railroad car class which the substitution one- piece, cast-steel underframe, for the regulation riveted, rolled steel con- struction permitted reduction height from rail floor line car ft. in. and material reduction light weight. further contribution the progressive trend railroad car construction, Bethlehem Steel Co. has developed unique construction the same basic design, which approximately the are achieved, through welded fab- rication rolled steel structural members. comparison with the under- frame weight the CHARLES SCHENCK Engineer Development, Bethlehem Steel Co., Bethlehem, Pa. rolled steel sections and riveted construction its over-all weight approximately per cent less and its height from top lower. These advantages were made possible through the effective utilization standard production structural sections for the con- struction its component parts such side and center sill girders, bolsters, striking plates, stake and push-pole pockets, which when as- sembled and welded place, re- sulted, substantially, one piece, rolled steel underframe. Test re- sults obtained when the structure was subjected loads greatly excess its normal requirements provide sufficient evidence the practicability this type con- struction. Reasons for Development The development work that led the design and subsequent fabri- cation this car was predicated upon the successful fabrication and the satisfactory service ren- dered by, several all-welded, heavy- duty, 70-ton plant cars. But what prompted Bethlehem undertake the study the design that led the fabrication this type was the demand for 70-ton, 50-ft. flat car with over-all free under- light weight height 3-ft. in. from top rail top platform. This height represents the mini- mum for cars this type owing THE IRON AGE, July 16, 1936—43 { Ng i | | | | ° ° 4 ia the restrictions imposed the designer the dimensions the standard draft gear and its fixed height above the rail. developing this type car, accordance with definite and specific requirements, the work in- volved almost complete changes design practically every compon- ent part the underframe. Standard rolled steel structural members sufficient size meet load requirements were used for both side and center sill girders. The ends were modified, course, bring about the required reduc- tion height these sills over the truck bolsters. These four sills are the main load-carrying members and they extend the full length the car. The two center sills extend between the welded striker plates each end and take all drawbar and buffing stresses. The two side sills extend from end plate end plate. The center sills had their origin B26 sections weighing 144 per ft.; the side sills B21A section weighing 103 lb. per ft. meet the requirements for over-all platform height 3-ft. in. both side and center sill girders immediately over the bol- ster, were reduced 10% in. depth, simply removing suffi- cient metal from the web the 44—THE IRON AGE, July 16, 1936 ends the girder sections. This operation involved the flame cut- ting wedge-shaped piece from each end the girder sections for about one-third their length. The ends were then shaped form the characteristic fish-belly type girder before the webs were solidly welded. addition the saving height obtained this procedure was responsible for considerable saving weight. The inner flanges these center sills, beyond the bolsters, were cut away the web the beam and stop pieces were welded the flanges. Through this arrangement the draw bar and buffing stresses were received wholly the parent metal the girders. Body Bolster Welded The body bolster also welded construction throughout, details which may observed made totally inclosed member. Wherever was neces- sary provide openings through accommodate brake riggings and air lines, pipe thimbles were inserted and welded place. this way the bolster sealed and the entrance corrosive elements prevented. Striking plates are welded di- rectly the web and flanges the center sill. Stake pockets are placed the side sills. They had their origin the wedge-shaped pieces removed from the webs the sections used for side and center sill girders. Push-pole pockets, like the stake pockets, were cut from salvaged plate, formed somewhat moon- shaped and welded securely the end plates. Two channel members were used tween the end sill and the bolster one end. However, owing space restrictions the braking mechanism the channel member welded under- frame structure the 70-ton flat car appeared before was mounted the Note the shape its center sills. the opposite end was omitted. its place provided wide brake mechanism cover plate that con- pletely welded the end sill, center sill and bolster. Underframe Subjected Tests After these various parts were assembled and securely welded place form the bare yet com- pleted underframe, shown the accompanying illustration, was first weighed and then subjected severe deflection tests under dif- ferent conditions load. ap- proximately 27,100 lb. its weight about per cent under the weight — the same 70-ton welded underframe structure load 240,000 distributed crossbearers spaced ft. either side the center the underframe. riveted underframe the same capacity and dimensions. The load- ing tests provide indication the inherent strength possessed these welded structures. the two tests specified for this welded underframe, the first was less severe than the second, but permanent set was de- veloped either case. the first test, load 160,000 lb. made steel billets piled cross-bear- ers spaced ft. each side the underframe center, caused de- flection 25/32 in., compared measured deflection 29/32 in., compared calculated deflec- tion in. resulted from 240,- 000 load being placed cross- bearers that were spaced ft. each side the center the underframe. The method con- ducting these two tests shown means the accompanying il- lustration. With the loads placed shown the deflection mea- sured the center the under- frame. Since the construction this 50-ft. pilot car which now regular service Pennsylvania Lines, all-welded underframe 50-ton flat cars modified design were built for the Chesapeake Ohio railroad. Al- though they are similar outward appearance, the design differs that the rolled steel, center-sill girder sections, after being con- verted into the fish-belly type gird- ers, were welded into place without being shaped otherwise. Also, the side sills are made from especially rolled channels that have slight bulb rolled the edge simulate flange the outer side. Under this load the underframe showed actual deflection 29/32 in. Following the design and fab- rication the all-welded pilot car, the progress made Bethlehem welded construction railroad rolling stock can best visualized the diversity application these composite welded structures. addition 135 railroad gon- dolas, each 70-ton capacity, and equipped with all-welded under- frames, there are caboose cars similarly equipped, are num- ber 40-ton cars used convey- ing copper ore. Also, welded body bolsters are now being used type car used carrying cement. Because the satisfac- tory service that being rendered these various types reason- assume that welded fabri- railway rolling equip- ment has passed beyond the de- stage. design this 50-ton flat car underframe different from that the 70-ton car that its center sills are not spread the center section. Also, its side sills were fabricated from especially rolled channels having slight bulb rolled the outer side simulate flange. THE IRON AGE, July 16, 1936—45 : § ladle into ingot molds equipped with clay hot tops. This equipment represents one step long line experiments reduce inclusions through the production and correct better refractories. ° ° CALLINAN Timken Steel Tube Co., Canton, Ohio ° ° MOLTEN and metal attack fractories exposed them chemically (cor- rosion) and mechanical action (erosion). Therefore, the mate- rials must have not only ample refractory value but also the correct physical and chem- ical properties, some extent the expense refractory value. Probably the greatest action oc- curs the ladle, due the violent the start tapping, the *Presented before Ohio Ceramic In- dustries Association, Columbus, Ohio, May 28. 46—THE IRON AGE, July 16, 1936 turbulent currents and splashing, and the sudden heat shock. Ladle design has very definite effect the life and utility ladle re- fractories, and any change de- sign must considered the light the effects will have the slag and steel and general teeming conditions. Thinning refractory in- fluenced the chemical proper- ties the slag and steel, their temperatures, and the time the steel remains the ladle. Much this refractory material rises through the steel and enters the slag, but some may trapped the steel and poured into the molds. The greatest erosion and contamination refractory ma- terial undoubtedly occurs the ladle nozzle. Here there com- bination high velocity, high pressure generated the ferro- static head and large contact area per volume steel. Design plays important part here since and affecting pouring and teeming conditions alloy steel production has drawn attention the refractories used these operations. Much may done mini- mize the chances ruining heats steel proper se- lection and use pouring refractories. This article points out that refractory in- clusions, originating the furnace, spout, ladle, mold helps control velocity, tem- perature and pressure. teeming, the mold hot top and plug may severe impact and perature change. Solidification the metal occurs rather rapidly the bottom and sides the mold because its high heat conduc- tivity, thus giving included par- ticles little time rise out the metal. Alloy steel producers are more concerned with the quality their steel affected refractories than they are with the refractory service life and cost per ton. Ladle Brick present-day (2840 deg. F.). Generally they are made rather siliceous clays, typical chemical analysis ladle brick showing per cent SiO, per cent 4.5 per cent iron and titanium oxides, and 0.4 per | will cause low cutter life and result high tooling cost the production machined parts. Inclusions will also weakness stress the product which may result failure service. result, steel producers are studying this problem, and with the cooperation the refrac- tories manufacturers, have gone far overcoming its worst phases. cent CaO. The remainder consists mainly magnesium, sodium and potassium oxides. Maximum firing temperature about cone (2201 deg. F.), firing treatment being closely controlled and progressing very slow rate, being more than usual importance produc- ing satisfactory ware. The fired brick are quite hard and dense, per cent. However, the brick not appear highly vitrified. These properties are essential preventing penetration ing action slag and steel. Theoretically per cent silica fireclay brick entirely un- suited for basic steel ladles. basic brick would better. How- ever, magnesite brick and basic neutral rammed-in linings have not been fully successful as, due their higher heat conductivity, they tend form skull the ladle. They also spall; although the author has never observed any ladle brick which has been entirely covered with slag steel. The fireclay brick seems slough off thin layer during each pour, the resulting surface being smooth and evenly eroded. regular first quality fire brick does not give satisfactory ser- vice does the more siliceous ladle brick. seems wear more rapidly, probably because its higher porosity and lesser degree vitrification, and tends off,” the slag adhering and pulling off thin layer the un- contaminated brick. Breaks occur around the large grog grains. This may explained the fact that frequently the grog used the brick has been calcined tem- perature only sufficient elimi- nate shrinkage the firing tem- perature. exceeding this tem- perature under actual service con- ditions, further shrinkage the grog occurs and pulls away from APPING electric furnace. The best steel the spout can ruined ill- advised application refractories. the clay. This produces zone weakness and allows the turbulent metal currents carry away the grains, thus creating potential in- clusions. Good ladle lining practice calls for uniform sized brick, medium thin, tight joints and proper use such shapes wedges and arches. Some operators have noted that the use high temperature ce- ment place ordinary fireclay for laying the brick has resulted crease ladle lining life. This has also been efficacious reducing the amounts fireclay-type inclu- sions the steel. Nozzles may range from cone (2714 deg. F.) cone (3002 deg. F.), cone nozzle having softening point around 2400 deg. Most nozzles appear consist clay and rather small percentage medium THE IRON AGE, July 16, 1936—47 3 Bay | fine grog. They have water absorption about per cent. Cursory miscroscopic examination does not show evidence high vitrification but disclose rather considerable amounts free quartz well distributed the clay substance. Hard-burned noz- functions: (1) act seat for the stopper head shutting off the flow metal from the ladle, and (2) outlet for and con- trol the character and velocity the stream metal. clay-graphite stopper head used, examination after teem- floor Timken's plant Canton, Ohio. the extreme right there string ingot molds equipped with the latest type permanent metal hot tops. zles and sleeves are rejected most steel plants since they show greater tendency crack and spall service. Care must exercised during the drying and firing treat- ments that warpage deforma- tion occurs, since imperfectly shaped nozzle may directly affect the quality the which passes through it. The successful teeming heat steel depends greatly the nozzle, which has two main 48—THE IRON AGE, July 16, 1936 ing will show that has closely retained its original shape, while the nozzle will disclose that the stopper head has been pushing into washed out the steel. The noz- zle pyro-plastic condition and long does not deform flow too much result the temperature the fluxing action taking place, this plastic condition good shut-off. rather delicate balance must maintained tween temperature, fluxing action, stopper and nozzle. the steel either too hot too cold, sticking may result. This would espe- cially true the stopper head were clay. Best results are obtained when the two pieces not have the same softening point. Sometimes only partial shut- off obtained and the steel slowly dribbles through the nozzle. This may due faulty design nozzle, stopper, well, cracking the nozzle, excessive erosion, insufficient plastic defor- mation the nozzle allow the head reform the seat, forma- tion skull the nozzle well. essential that there good initial contact between the head and nozzle. Both pieces must closely inspected before and after being set the ladle. some cases faulty nozzles may ground specially shaped cutting wheel area. the interior softer than the surface skin the grinding may expose this softer interior and produce teeming difficulties, mak- ing essential that the nozzle fired correctly. The nozzle must set the ladle that the hole will abso- lutely vertical. not, the stream will hit the side the mold be- fore reaches the bottom. The bottom surface the nozzle tip must exactly perpendicular the nozzle hole for otherwise the stream will thrown one side may spray. Such conditions will decrease mold life and result faulty ingot surface; for steel hitting spraying the mold sides and freezing before the metal the mold can reach will tend produce scabs the ingot surface, thereby increasing chip- ping costs and sometimes causing rolling difficulties. The original diameter the nozzle hole and its the steel considerable im- portance for the same reasons. Graphite nozzles with clay stopper heads and magnesite noz- zles have not been used any large extent. Magnesite, due its higher heat conductivity, may de- velop skull the nozzle well. also exhibits tendency build and decrease the size the open- ing. Sleeves vary from cone (2894 deg. F.) (CONTINUED PAGE 114) J | i ADIUM made its debut the field medicine but its beneficial properties have extended the field metals. Here its properties are not applied cure in- terior defects but reveal them. Mr. Woods gives very readable exposition this subject which one that will receive more and more at- tention our industry time and science march on. looked like derby hat, made steel, standing about four feet tall and three feet across, with six-inch and was used cauldron con- tainer some sort. The point interest that the buyer said leaked, and refused pay for it, and the maker said didn’t leak, Photographs courtesy Rodion Co. and Worthington Pump Machinery Hadium metal ructures ROBERT WOODS Consulting Engineer and demanded his money. What would decide? radium test was made, flaw was found, and the bill was paid. taken front rank position metal manufacturing and the last decade has played impor- tant part scientific advance. the intent this article pre- sent briefly the principles which make radium commercial inter- est, and discuss some its various industrial applications. The average X-ray machine finds fronted with objects four inches more solid steel. From here the engineer must consider use “see” cracks and other defects such heavy metal structures. passing might mention that X-ray companies are developing high voltage tubes produce what might ‘well called “gamma X-rays” economical basis, but although they will ultimately suc- ceed, indeed doubtful radium industry will ever entirely supplanted. From the standpoints cost and efficiency find that the high in- tensity X-rays makes them superior where the metal not too heavy, but the material thick- ness increases, artifically produced rays must give way gamma radi- ation. X-rays from the ordinary outfit will good job two- inch sample steel with ex- posure one two minutes, while even large radium source, say 500 milligrams, half gram, would take least hour for the same work. If, the other hand, our steel six inches thick, then the inferior penetration would run the X-ray time five days while the high piercing ability radi- um’s gamma ray would the trick one day. For engineer play nursemaid X-ray ma- chine for five days and nights would carry testing ex- tremes—and would probably fall into coma about the third day anyway. THE IRON AGE, July 16, 1936—49 | | { { 4 | ° ° ° : 1 “ ot =< small radium capsule, when placed the cartridge, sup- ported the string, front the specimen examined. Films for the radiographs are fastened the back the castings examined. exposure even one day for the radium picture, however, may seem long until remember that radium, once placed, does all the work its own accord without any tending operating. Radium Has Advantages Then, too, radium requires ex- pensively equipped permanent lab- oratory, does not get out order “under foot,” and can used places far too small accom- modate any X-ray machine. practice, silver capsule radium salt enclosed duralumin “cartridge” suspended supported the proper relation object and film. this case, the radiation “machine,” cartridge, measures not more than two three cubic inches—which takes consider- ably less room than the sq. ft. X-ray apparatus. After the ex- posure, the cartridge merely put away safe returned the renting company. Radium has another very real attribute which helps compen- sate for the low quantity, intens- ity, its rays. The beam from X-ray tube, for instance, limited its scope and makes imprac- tical take more than one radio- graph time, whereas radium 50—THE IRON AGE, July 16, 1936 ’ “sprays” its blessings out equally all directions and number objects grouped circle about the source can thus all one sitting. not denied that where X-rays are feasible, one radium ex- posure for one single object will prove the more costly. Let il- lustrate this the example plant, without X-ray equipment their own, which wishes have number three-inch-thick steel castings radiographed for suspect- flaws. this thickness either gamma rays X-rays could used—which would cheaper? examine one these castings radium, reasonable time, say overnight, would require 300 milli- grams radium, rental fee $30. But X-ray this work casting and ra- diograph same showing cracks dis- covered gamma ray picture. could done minutes for $20. There can argument about the superiority X-rays here. Suppose there are six cast- ings tested, however. Then the X-ray would have treat each casting separate job and the result would charge $120, while all six could done the same $30 worth radium over- night and make the cost each casting only $5. addition, the time taken cart the work and from the X-ray laboratory and set each one for exposure would prob- ably use the better part day. This “group picture” trick special value when used for inspec- tion pump housings, pistons, en- gine heads, rotor shafts, railway wheels, etc. Some other articles tested radium are pro- pellers, welded ship plates, high pressure boilers, tur- bine castings, oil crack- ing parts, and heavy metal objects, separately assembled, which must withstand strain and safe- guard life. Friendly Rivals convey that radium and X-rays are rivals, for they work, rather, hand glove, each one sup- | | | ! 3 3 q q a | q | | 4 og Me Bee 5 x 4 A * = * ‘ , ps plementing the other until they almost spread-eagle field jndustrial testing. find this close association X-rays and radium beginning practically the cradle—in fact they were nearly twins. Roentgen’s discovery physicists search for similar radiations from natural sources. 1896 Prof. Becquerel Paris found such rays emitted urani- salts pitchblende. Later, Prof. and Mme. Curie proved that pitchblende itself was many times more radioactive than pure urani- metal and 1898 they succeed- isolating the element radium, thousandfold more active than the parent element uranium. Discovery that radium rays were valuable tumor treatment imme- diately created demand which led expeditions, mostly unsuccessful. Although has been estimated that ordinary rock anywhere has radium con- tent one gram million tons, concentrated deposits are few and far between. There has been radium-rush comparable the early “forty-niners,” for prospect- ing, detecting, mining, and extract- ing radium from the ground are long, complicated processes that re- quire much hard cash and higher usually needed the old “sour- dough.” These factors all combine make radium worth today about $40,000 gram—better than $1,- 000,000 ounce, compared with gold $35 ounce. The high price radium and its specialized applications make impractical have any large stock hand. Some institutions have much two three* grams and one New York hospital has over eight grams for treatment purposes, but general the amount the element used gram) the gram. Sources Radium For many years the world radi- supply came from carnotite ores Colorado and Utah, but discov- ery rich pitchblende deposits the Belgian Congo made working American ores unprofitable. Our carnotite mines now have turned the recovery vana- dium. Radium-earth also exists other parts, although not such rich amounts the Congo, yet the world might still said the one who has the time and money seeking. Radium, white metallic ele- ment, never occurs the pure state, but always associated with uranium which known the parent element, for undergoes spontaneous changes, ultimately transforming itself into radium. The nature these changes was first explained early 1902 Sir Ernest Rutherford “transformation theory.” grasp this theory best, perhaps, that recall for moment some the mechanistic ideas atomic struc- ture. For the sake contrast, let compare the most complex all atoms, uranium atomic number and atomic weight 238, with the simplest pos- sible atom, hydrogen atomic number and weight the hydro- gen atom have one single elec- THE IRON AGE, July 16, 3 + large casting and radiograph same showing internal structure. q EST radium film taken bronze block in. thick. Holes drilled in., 1/16 in., and 1/32 ture shows all thrée plainly. This proves that defects less than cent total tron wheeling orbit-wise about central core nucleus mass 1835 times that the electron. Re- cently the nucleus has disclosed it- self the host for several differ- ent types those entities, protons, electrons, neutrons, positrons, which writers delight call “build- ing blocks nature.” Neverthe- less, rather than entangle ourselves any complicated nuclear specula- tions, let take the line least confusion and say merely that these “atom hearts” contain two things, electrons and massive units posi- tive charge called protons. This means that find negative elec- trons both orbits swinging around the nucleus and the nucleus itself, but protons exist the nucleus only. Within normal nuclei protons and electrons are al- ways evenly balanced except for the presence one spare proton for each orbital electron—just keep the atom neutral. For example, the atomic number there one electron orbit and least one proton the nu- charge. But hydrogen’s atomic Minutes Seconds weight also and since atomic weight practically all rests atom’s protons, means that hy- drogen has only one each unit— the simplest possible atom. The element helium, however, has number indicating the pres-. ence but two electrons, and least two nuclear protons. Its atomic weight showing us. that there must two extra pro. tons the nucleus and, course, two extra electrons the nucleus Thickness Steel, inches exposure times for 200,000 volt X-rays and Gamma rays from 500 milligram radium milligrams would take five times 500, etc. Usual cost renting radium $10 per 100 milligrams for hours, any part thereof. showing gamma ray pictures thin specimens. This interest- ing since demonstrates possibility good gamma ray films thin objects despite contrary opinion some users the X-ray. 52—THE IRON AGE, July 16, 1936 keep the peace. The weight two electrons negligible. Returning now from the lightest the heaviest element, reach the uranium atom again, with its atomic number and atomic weight 238. From previous remarks will seen that uranium has orbital electrons balanced nu- clear protons and, addition, 238 146 extra proton-elec- tron pairs its nucleus. Uranium nuclei are complicated they can- not “take it” and they break down shedding protons and elec- trons. These tiny bullets are shot out from the nucleus great hurry accompanied penetrat- ing ether wave called gamma ray. The bullets leaving the atom are known alpha rays and beta rays, the latter being nothing more than high-speed electrons. Although the (CONTINUED PAGE 115) | | | | | | | : : | | 6 | 4 J i | | 34 | i i ° ° ° CAMPBELL Pittsburgh Editor, The Iron Age ° ° steel executives have always been the lookout for happy medium between quality and pro- duction—the best steel the low- est cost. Especially has this quest been pursued the blooming mill where unsatisfactory forming the steel often resulted high chipping costs. Such conditions were quite prevalent the days when the three-high mill was ex- tensively used. Drafts these mills were fixed and did not allow individual attention different grades and rolling temperatures. With stricter requirements from consumers and the desire pro- ducers make better steel, the trend toward steam driven two- mill quality high reversing mills occurred. While this mill sacrificed tonnage some extent, turned out much better product since the top roll, being adjustable, allowed proper drafts depending the grade being rolled and the tem- perature which the rolling took place. substantial amount power was lost the steam driven Transfer No.3 Blooming _—— requirements type overcoming friction; many cases only per cent being used actually deforming the steel. The next logical step the development the blooming mill led the electrically driven two- high reversing mill which retained the good features the steam driven machine but which was much more efficient that the bal- Delivery Track Bldg + y / — Plan No. 44-in. blooming mill, 28-in. billet mill and Morgan billet mill the Pittsburgh works the Jones Laughlin Steel Corp. THE IRON AGE, July 16, 1936—53 | B | { \\ Of oO. =) oO | } | ABOVE ENERAL view, from upper mo- tor room, Jones new 44- inch blooming mill recently installed the corporation's Pittsburgh Works. The housings the left protect the pin- ions for transmitting the power the 7000 hp. electric drive the rolls. The all-welded ton manipulator seen the right the rolls. RIGHT OOKING into the manipulator and rolls the new 44- in. blooming mill. ance between quality and tonnage became reality. Since this history has also been the experience Jones and Laugh- lin Steel Corp., was natural that they should decide the latest type mill with many modern improvements possible aux- 1936, electrically driven 44-in. two high reversing Mackintosh- Hemphill blooming mill went into production the company’s Pitts- burgh works. There was loss 54—THE IRON AGE. July 16, 1936 production during the construc- tion, the old three-high mill, which was being replaced the new one, continued operation until after the change-over. After test runs the new mill, the old one was demolished and normal practice inaugurated the two- high mill. While the mill proper many respects similar some built few years ago, there are several up-to-date improvements mill and the auxiliary equip- ment. For instance, the manipu- lator all welded and operated hydro-pneumatic p