The Iron Age 1936-09-03: Vol 138 Iss 10

SEP 1936 SEPTEMBER 1936 sively prove? i REPUBLIC DOUBLE ENGTH STEEL save weight without sacrifice strength—to reduce dead load—to increase pay load—to cut corrosion losses —to all these things economically the job every designer transportation equipment faces today. Republic Double Strength Steel formed sections will play increasingly important role its properties become better known and its possibilities from design standpoint are appreciated. Already, thousands tons these sections are being built into railway cars all types for bolster posts, sides and bottoms, sheet stiffeners, REPUBLIC STEEL CORPORATION Strength Formed Sections. NAME POSITION 2—THE IRON AGE, September 1936 THE IRON AGE, published every Thursday the CHILTON CO., (INC.), Chestnut 56th Sts., Philadelphia, November 1932, the Post Philadelphia under Act March 1879. $6.00 year Canada $8.50, Foreign $12.00. Uperating Economies GENERAL OFFICES CLEVELAND, OHIO Please send complete data Double We floor supports, intermediate sills, side sills, door headers, and similar parts. Here material with yield point more than twice that ordinary carbon steel—high weldability—ductility that makes for easy fabrication and the corrosion resistance that only finely made nickel- copper-molybdenum alloy can possess. Let assist you the correct utilization these Republic Double Strength Steel formed sections. Your inquiry may open world possibilities for the design more economical transportation units. Use the coupon, write detail. Republic CORPORATION GENERAL OHIO ALLOY STEEL -MASSILLON, OHIO 4 Entered second Vol. 138. No. 10. > © 7 & 4 THIS 0 FRITZ FRANK President VAN DEVENTER Editor Cc. E. WRIGHT A. I. FINDLEY Managing Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors Resident District Editors Washington Chicago Cleveland Detroit Pittsburgh Editorial Correspondents London, England Cincinnati Boston CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Hamburg, Germany Milwaukee San Francisco Sales Offices SANDERSON ASA ROUNDTREE, JR. ALLISON Toronto, Ontario Birmingham, Ala. Newark, WEST 39TH STREET NEW YORK, Roy TURNER St. Louis Buffalo Con 1936 How Times Have Changed.... Kelvinator Adopts All-Welded Construction........... Bonneville Sets Stage for West Coast Owned and Published CHILTON COMPANY Copyright 1936 Chilton Company (Inc.) (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. BAUR, General Advertising Manager MUSSELMAN, President DIX, Manager Reader Service FRITZ FRANK, Executive Vice-President Member, Audit Bureau Circulations ADVERTISING STAFF Emerson Findley, 621 Union Cleveland FREDERIC STEVENS. Vice-Pesident Member, Associated Business Papers HILDRETH Indexed the Industrial Arts Index. and Chilton Bldg., Chestnut 56th Peirce Lewis, Woodward Ave., Detroit EVERIT sessions, Mexico, Cuba, $6.00; Can- Ober, 239 39th St., New York ada, $8.50, including duty; Robinson, 428 Park Pittsburgh ERNEST HASTINGS, $12.00 year. Single copy, cents. Sweetser, 239 West 39th St., New York WILLIAM BARBER, Treasurer Cable Address, ‘‘Ironage, Warren, Box 81, Hartford, Conn. JOHN BLAIR MOFFETT, Secretary 4 b Aw Ky Ba | | i 7 | | | | matter fo, 10. “RYERSON SAVED LIFE THAT had plenty sheets ordered but they didn't arrive. Stock hand would only last through the day—then Division Four would have shut down, and the production line would thrown out. had have tons for the next day's production. phoned Ryerson P.M. and they promised deliver all tons the morning. 8:10 next morning, the sheets were coming in. Ryerson had taken them out stock, loaded them trucks, and travelled all night—but the sheets arrived and full day's production was saved." hope that you will not often need such fast service, but emergency you can definitely count Ryerson everything possible deliver the material you need the time you require it. And remember—this service can secured not only sheets, but structurals, plates, shafting, alloys, stainless—practically everything the steel line. 28—THE IRON AGE, September 1936 = ‘ q d THE IRON SEPTEMBER 1936 ESTABLISHED 1855 Vol. 138, No. How Have Changed matic machinery have put and kept many people out work. Many his close advisers the New Deal, including Mrs. Roosevelt, are known regard improved. machinery job-destroying monster. Sometimes let our imaginations run away with such matters. there ever was potential job-eating monster, was that known Camco was the nickname the now Consolidated Automatic Merchan- dising Corporation, which was formed the consolidation number companies making automatic vending machines. This company was going clerks behind the counter with machines which would almost human. Some them were such skilled robots that they would make the sale, give the change the customer, say thanks him and deliver nice little sales talk. show how ambitious were the plans this company, the stock prospectus, is- sued Lisman Co., September, painted estimated net profits 1933 likely over $17,000,000. That, course, would mean gross volume busi- ness per year least $60,000,000, for conscionable corporation could think earning more than per cent. Elsewhere this same stock prospectus, the story told machine operation the Main Post Office New York, which makes average about 500 transac- tions day, thereby doing about one clerk's This, cost only one dollar per day. this basis can figure just how many white collar jobs this Frankenstein was expected eat up. For each dollar sales per day, automatic machinery would re- place one clerk. Sixty million dollars per year equals $200,000 per day for 300-day year, allowing for Sundays and holidays. Thus the expectation was that the new vend- ing machines would replace 200,000 clerks the fifth year the company's existence. the prospectus euphemistically put it, they released for more construc- tive course, the company continued progress the expected geometrical pro- portion disclosed the prospectus, there might not have been any jobs left for white collar people retail merchandising. Lest you get the idea that this mechanical Frankenstein brought the depression, let reassure you. The company went and every stockholder inveigled into parting with $55 per unit for the stock, lost every dollar invested. just goes show that you cannot believe all that you hear read about the automatic machine job eater. Among the names the officers and directors Camco, this stock prospec- tus September, 1928, appears the name Franklin Roosevelt New York. How times have changed! a” ee “pad > | » “ 4 4 ° ° HERBERT SIMONDS and YOUNG ° ZINC one the for- tunate metals now en- joying increasing ac- ceptance American industry. Because the widening scope application die castings and the facility with which zinc alloys are adapted this form metal fabrication, the coloring zine generally and die castings specifically assumes added impor- tance. Commercially, relatively little being done the field coloring zinc, but the laboratory many interesting processes have 30—THE IRON AGE, September 1936 been developed and the few appli- cations which have reached the commercial stage seem have im- portant features. The Cronak process controlled the New Jersey Zinc Co. now being used increase the life serve the surface alloy products. Demands for longer and longer life galvanized wire and galvanized fittings, especially railroad electrification and tele- phone work, have lead the de- velopment new coating processes, which the electrogal- vanizing processes the Bethle- hem Steel Co. and Langbein- Pfanhauser (of Germany) are out- standing. these and other re- cent processes now possible apply heavier coatings zine wire than previously was the case, and thus the Chronak method new hydraulic jack, made the Blackhawk Mfg. Co., illustrates the use die castings reduce the number parts minimum. The cylinder, reservoir and pump chamber are all single cast- ing shown the sectional view. chemical treatment indicated for the interior surfaces. XCEPTING iron, zinc the metal. Therefore, the lem properly finishing zinc and zinc alloys im- portant one. Strangely, little has been done the field chemical coloring. This ar- ticle, which the fourth series the coloring metal, describes the few commercial methods coloring zinc and also out- lines the chief research now progress. Other features covered include electroplat- ing die castings and gal- vanized iron and the alloying zinc for finish effect. ° : FOR kitchen appliances, zinc parts are electroplated where they come contact with food and are lacquered elsewhere. Previous articles this series have covered iron and steel, copper and other non- ferrous metals and aluminum. The next article will discuss metal coloring processes and some commercial considera- tions. Mr. Simonds vice-pres- ident Products Exhibits, Rockefeller Center, New York. Dr. Young, associated with Dr. Colin Fink Columbia chemical engineering, technical director the United Corp., Long Island City, surface protection added these new heavy coats the life gal- vanized wire may extended be- yond anything some years ago. With the exception iron, the least expensive metal for in- dustrial use, and, therefore, with the new surface consciousness to- ward all metal products, the finish- ing zinc, whether enamel metal coloring, bound be- come systematized and extended the near future. previous articles this series “Coloring Metals” various processes have other than chemical coloring. These processes have included alloying, heat treating, plating, and electro- chemical treatment. Heat treating has little place the sur- face effect produced zinc zine alloys. Alloying has more important role coloring zinc base products and will consid- ered briefly here. The chief proc- esses described this article, how- ever, are chemical, electrochemical, and electroplating. Zine loses weight under exposure the formation films composed oxides, carbonates, chlorides, combinations two more these. The exact nature depends condition the base metal. the laboratory, and commer- cially some extent Europe, brown, black, blue, and even pur- ple colors are produced zinc. The black colors seem have par- ticular promise and several meth- ods warrant attention. There one known the Schulein process which makes use low voltage alternating current passed through solution containing chromic acid THE IRON AGE, September ° ° ° 4 a 3 - if and sulphuric acid. Usually the parts thus coated constitute the electrodes. The coating black and under certain conditions has good corrosion resistance. This process has been experimentally used for continuous treatment galvanized wire give added cor- rosion resistance. Another process the anodic process which similar that described previous article for aluminum. When zinc parts are made the anodes electric cir- cuit with electrolyte composed chiefly dilute sulphuric acid, porous film produced which lacks the hardness and bond the oxide film aluminum but which never- theless sufficiently interesting encourage experimenters con- tinue with its development. modifying some the variables seems possible that good base for dyes eventually may cured. Some success reported through the use barium hydrox- ide the electrolyte with in- creasing potential bath. This particular method being used England with some practical applications Some Specific Formulas ebony black produced cleaning coated products the usual zine alloy die castings and then immersing them the following solutions: trate, oz.; ammonium chloride, oz.; cupric chloride, hy- drochloric acid, fluid oz.; and water, gal. This solution should used 100 deg. After dry- ing, the parts are brush finished and then heated 160 deg. for min., after which time the black color will set. Parts can then dry scratch brushed and pro- tected transparent lacquer. the parts are sand blasted before lacquering dead black finish can produced. Another method producing black zine immerse the Copper sulphate, per cent; po- tassium chlorate, per cent; and water, liter. The color becomes deeper with greater length time immersion, but min. usually sufficient produce satisfactory black. Combinations electrolysis and chemical action may used United States patents the New Jersey Zinc Co., Nos. 1,953,997, 1,953,998, 1,953,999 and 1,954,000. 32—THE IRON AGE, September 1936 produce interesting color effects zine. For instance, zinc made the cathode solution contain- ing from oz. ammonium molybdate per gal. water, with low voltage current from amp. per sq. ft., the zine will assume wide variety colors varying from golden yellow lavender blue and finally jet black. One the authors (Dr. Young) has produced attractive designs this method, using platinum anode. This same proc- ess will work aluminum, iron, and tin, although each case the actual surface condition the metal important determining the resultant color. general rule, rough coatings work best with the brighter colors, ished surfaces with the dark colors. the current ranges toward the amp. mark and electrolysis allowed continue for about min., the color will grow gradually darker until finally the deep black produced. Mere immersion solution ammonium molybdate for sufficient length time will also produce black. Four interesting methods pro- ducing brown colors are follow: Die castings after chemical cleaning are immersed bath containing 250 grams chromic acid per liter water. The castings are connected elec- trodes low voltage circuit using alternating current. dark brown color appears from min. Another means brown through the for- mation cuprous oxide which can obtained immersing zinc parts solution containing lb. copper nitrate and gal. water. The resultant color while pleasing not stable and must protected transparent lacquer. third method producing brown zinc paint over the surface well cleaned castings other zine alloy parts with the following solution: phate, sodium carbonate crystals, sucrose, oz.; and water, gal. The purpose the sucrose prevent the precipita- tion copper carbonate. After painting, the solution allowed dry and then washed and dried second time, after which usually protected with lacquer. attractive rich brown immersion the following solu- tion: 124 grams; lead acetate, grams; and water, liter. Brighter Colors combination cobalt and am- monium chloride solution produce steel blue zine die cast- ings. The instructions for produc- ing this color are merely im- OMBINATIONS metal and fixtures. Pleasing effects may the metal merse clean parts solution containing grams cobalt and grams ammonium chloride liter water. When nickel am- monium sulphate used with am- monium chloride, bright purple obtained much the same proc- ess. the latter case the solution should contain grams nickel ammonium sulphate and grams ammonium chloride, and should held 140 deg. during the immersion which takes from min. Nearly all the compounds are white, which the reason ERS, « * ‘wi j me that the metal not more readily eclored. Sulphide zine white which rare exception among metallic sulphides. For this rea- son the best way proceed tackling the problem coloring metals the zine surface. Zinc lends itself this action readily lacquer finish are popular for desk secured chemically coloring surfaces. series and therefore active. Some the typical reactions are: even from the cyanide, Zine will also displace gold, silver, lead, tin, and mercury from aque- ous solutions. Immersion solution cop- per tartrate and soda may used for producing some beau- tiful bright colors. for- mula is: Copper tartrate, caustic soda, and water, gal. this held 110 deg. yellow, light brown, crimson, blue, purple, and light green may produced with variation immer- sion time. The changes take place rapidly and are difficult control. the solution used lower temperature are slower and better control there- fore gained some sacrifice color brightness. Several solutions may used produce similar iridescent se- quences colors most zinc alloys. One solution consists of: Copper sulphate, cream carbonate, and water, gal. thin adherent coating ar- senic zine produced using the following solution: Arsenous acid, oz. per gal.; potassium cyanide, oz. per gal.; sodium phosphate, oz. per gal; and water, gal. The bath usually worked hot, but the coating form cold bath. When held about 110 deg. F., stable close- adhering gray coating produced from min. This particu- lar coating seems have good easily applied and gives pleasing stable finish. forms good for lacquers. The Cronak Process The Cronak process also rela- tively easy apply involves sodium di-chromate solution. The chemical reaction resulting from this immersion causes insoluble film deposited the surface the metal. The film de- posited contains small amount slightly soluble material which corrosion inhibiting and thus protects the surface when moisture comes contact with it. The color the film varies from yellow brown depending upon the nature the base metal and the time the immersion. The pres- ence copper, which included some commercial zine alloys, produces more definitely green- ish color. any case, however, the thickness the deposit, and therefore the degree protection, may determined after little experience the color produced, the color variation direct proportion the film thickness. Strictly speaking, the color the Cronak coating not particu- larly decorative. Nevertheless, the process being used some pro- ducers die castings improve the appearance much pro- tect the surface. Quoting from one engineer: “This new Cronak proc- ess gives visible protective coat- ing that materially reduces the corrosion rate. and prevents the formation white corrosion under many conditions where would otherwise form zine cad- mium. The film has appearance not unlike brass with greenish brown iridescence.” Because the commercial ac- ceptance already acquired the Cronak method and also because announcement the process has been made only within the past two months, report one the New Jersey Zine Co. engineers here reproduced detail. Tests Cronak Process “The inhibitor contained the coating formed the Cronak process definitely prevents for- mation loose bulky corrosion products and reduces the normal rate corrosion the metal. Since the inhibitor slightly soluble nature, will ultimately removed moisture coming contact with it. The slight solu- bility the inhibitor advanta- geous cases total immersion water, since permits protection areas from which the film may have been abraded rough han- dling and, the case galvanized iron, permits some degree protection exposed areas the iron itself. The Cronak process will normally find application for the protection zine two dis- tinct fields: (1) where moisture coming contact with the film either entrapped and never per- mitted cease contact with the surface insufficient quan- tity run off, and (2) where vari- able volumes moisture contact the surface and run off carrying with them small amount dis- solved inhibitor. “It apparent the first case that where the prescribed condi- tions obtain, the inhibitor not lost but will continue present whenever moisture surface. Under these conditions, the life the film and the protec- tion which affords the surface will indefinitely long. The cases carburetor and auto- motive door lock assemblies and the white rusting galvanized sheets storage and during ship- THE IRON AGE, September 4 Lee AST ’ ment fall, general, this classi- fication. “It more difficult give even approximate estimate the duration the protection expected from the film under con- ditions where the water runs off the surface. apparent that since definite amount inhibitor present, the duration its pro- tection will depend upon the fre- quency and duration water present the coating, which still highly colored prevent the appearance corrosion products. Weight change measurements ob- tained over period years under these same exposure condi- tions show per cent de- crease the weight normally lost zine the result corrosion. The trend the data shows clearly that the degree protection was constant throughout the entire ANY automobile hood ornaments are now die cast. They are usually chromium plated but designers are now experimenting with different color effects through chemical treatment. contact. Test data which are avail- able from number experi- mental exposures will give some idea the scope and duration the protection afforded the film. Outdoor exposure tests have been under way for the past years Eastern semi-industrial loca- tion. the end this period, there sufficient inhibitor 2In neither the above cases has the soluble portion the film been removed under the exposure condi- tions encountered. expected from other tests that the insoluble portion the film will continue protect the zinc surface some extent even after the soluble inhibitor longer pres- ent. untreated specimen exposed under these same extreme conditions was covered with white corrosion prod- ucts few days. 34—THE IRON AGE, 1936 year period’. Just how long the film will maintain its protection can ascertained only from tests considerably longer duration. “Exposures climates which the rainfall greater, less, than that obtaining the above tests will naturally decrease, increase, respectively, the life expected from the film. ap- parent, however, that far the general type atmosphere encountered this country concerned there every reason believe that the film will afford its number years. some in- terest this connection note that the film substantially re- sistant the salt spray test, from which may implied that may offer special advantages sea-coast locations. “Some tests carried out study the Cronak process, under extreme conditions exposure, have dem- onstrated that while the major pro- tection afforded the soluble inhibitor, there every evidence that the insoluble portion the film can, itself, greatly hinder the spreading corrosion after the soluble material has been re- moved. For instance, test was made atmosphere saturated with moisture 104 deg. Ina chamber operated under these con- ditions, moisture constantly con- densing the objects contained therein and dripping away. The test is, therefore, somewhat com- parable slow stream run- ning water 104 deg. Under these conditions, exposure peri- one year was required be- fore white corrosion products became evident few scattered areas the specimen surfaces. The brownish color the soluble material was largely removed this treatment, leaving only the greenish soluble film. the ex- posure was continued, was found that the spots which corrosion had initiated did not spread rapidly would anticipated the absence the soluble inhib- “An even more striking demon- stration the ability the film prevent the corrosion over long periods time under especially adverse conditions was obtained test which un- treated specimens galvanized iron and specimens subjected the Cronak process were totally immersed separate small vol- umes boiled distilled water which was changed every two weeks. The corrosion zinc boiled distilled water tends relatively rapid with the produc- tion voluminous white corrosion products. Under these conditions immersion, the untreated speci- mens showed rusting the basis metal after weeks. Those speci- mens which had been subjected the Cronak process showed first signs basis rust after 130 weeks. Certain difficulties encountered zine alloy die cast carburetors end automobile locks were attrib- uted the presence white cor- rosion products. The Cronak ess has been used generally “3 4 ‘wal / 4 SAN these parts for over year now and has successfully removed the factor white corrosion products and the possible causes this difficulty. have heard absolute- complaint concerning the sticking locks since this process has been use, and the appear- ance white corrosion products carburetor bowls has removed BELOW ROPER operation requires clean surfaces which not clog. Die castings are ex- cellently suited carbureter con- struction except for the surface formation white films. This diffi- culty said completely eliminated the Cronak chemical treatment. this from the possible causes choking the orifices.” Plating Zinc may plated and there- fore all the possibilities previously coatings other metals are open for zinc and zine alloys, being understood, however, that some spe- cial adaptation procedure required. Zine die castings present pleasing appear- ance just they come from the method has now been largely Superseded the use very thick under-deposits. molds and, they the surface effect with some the alloys used not unlike chromium. However, such surface stable unless protected, and electro- plating well lacquering frequently employed for this pur- pose. Among the electroplates desired for zine nickel which gives pleasing finish itself and also furnishes good base for chro- mium plating. However, order plate nickel zinc, several fac- tors must taken into account. Zine more reactive than nickel and thus has tendency dis- place nickel from its compounds. When zine metal placed solution nickel sulphate will precipitate metallic nickel and into solution zine sulphate. The nickel thus produced non-adhering, spongy, and unstable for finished coating. Thus this particular reaction must avoided Several methods have been devised. One increase the current density and another use separate nickel bath strike the products and then plate ordinary baths over the ABOVE modern jump clock has die cast case with scratch brush metal appearance known Butler finish. Photo courtesy New Jersey Co. good nickel bath for such special strike purposes follows: Nickel sulphate, 14.5 nickel am- monium sulphate, 6.7 and water, 1.0 gal. With this bath current amp. per sq. ft. should used for sec. cer- tain organic compounds are added the nickel baths they have the effect suppressing the ionization the nickel salts and thus afford another way overcome the diffi- culty referred above. or- ganic compound which may used advantage sodium citrate. also possible decrease the ionization nickel salts add- ing common ion such potas- sium, sodium, magnesium sul- phate. Two typical formulae are follows: Formula No. Nickel sulphate, oz. per gal.; ammonium chloride, oz. per gal.; sodium sulphate oz. per gal.; boric acid, oz. per gal.; the 5.6 and the solution (CONTINUED PAGE 110) THE IRON AGE, September 1936—35 > 4 3 Es system handling total 750,000 cu. ft. air per min. has been put work the foundry the Dodge Division Chrysler Corp., Detroit. withdrawing the air for washing, and supplying fresh air, powerful suction fans are used, handling over 800,000 cu. ft. air per min. and requiring total 1174 hp. for their opera- \\ 4 tion. Improvement working conditions has been obtained great expense. Altogether, the in- stallation, which was recently com- pleted, cost over quarter mil- lion dollars. UTSIDE view the east bank dust collectors, show- ing the double deck arrangement dry collectors. The new air-cleaning system divided into four sections, battery east side dust collectors, west side dust collectors, smoke exhaust, and fresh air supply. Fresh air supplied four shakeouts, and the total volume handled 76,180 cu. ft. per min., total hp. being required. The smoke exhaust sys- tem removes smoke the shake- outs and also from the tunnels the cooling sections the mold hoods over the pouring zones. For this system alone, 458,880 cu. ft. air handled through fans driven motors ranging size from hp. and requiring total 289 hp. From the dust collecting systems, both east and west, approximately collected per day through arrestors which involve both wet and dry units. The output each system ultimately collected water and pumped central point where the solids are removed and later dumped into railroad cars for re- moval from the premises. For the east system there are two cloth screen dry dust collectors connected hoods over two cylinder sand blast machines and five dry dust collectors handling the exhaust from swing tumbling mills, core grinders, waste sand conveyor and group cylinder blow-off booths. There are also six wet dust collectors handling the exhaust from hoods over the cooling conveyor trans- fers, the sand blast conveyor trans- fers, two shakeouts and cylinder blow-off booth. The equipment supported off the ground struc- tural work running four levels. Altogether, the east side system handles total volume air 191,680 cu. ft. per minute and uses total 540 hp. motor sizes ranging from 100 hp. The largest size motor handles the ex- haust for the tumbling mills. general principle, the dry dust collectors act which simply strain the dust-laden air passing through cloth. These cloth bag dust collectors are nothing more than vacuum cleaners large industrial scale. The exhaust fans suck the air through the bags that the impellers come con- tact only with cleaned air. The bags are spread over steel frames wire separators which can shaken intervals knock free the dust which collects the out- side the bag. The dust sand collects the outside the bags and when shaken off deposited trough through which cir- culated stream water. From sump, dirty water pumped the central settling system. Between the two batteries dry collectors are the six wet dust col- lectors. These collectors are the form towers through which the wash water pumped. The air introduced into the tower the bottom. The bottom cone the collector acts wet cyclone, collecting that point all the heavy dust and sand particles. Dirty water from these towers collected central trough which enters the main system. ATTERY nine wet dust collec- tors showing the valves the bottom the cyclone cones. These collectors are made in. steel electrically welded. ° ° Se, series nine wet dust col- lectors also used the west side system. These collectors receive dirty air from various points the sand preparation equipment and from both the motor block and small parts shakeouts. This sys- tem handles total volume 91,- 330 cu. ft. per min., with total 255 hp. divided between nine hp. motors. Liquid settling the collecting | > Electrically Clarity ing Valves Sewer plan the Dodge foundry air-cleaning installation, showing the east and west dust collecting systems and the de-watering apparatus. equipment for covering sand and dirt from cleaning system. The refuse from both wet and dry dust collec- tors pumped from various points the system. IRON AGE, September 1936 4 H KW Z 10 { M hopper passes out through el- bow connection into the central drain trough under the battery washers. valve provided the bottom for flushing. The dirty water contains ap- proximately per cent age from the cyclone through water seal, while the reservoir under tubes can drained use These wet collectors are that the drainage the first group pumped into the second group and thence into the third group. The third pump sends the dirty water the central separating system. Dewatering equipment has been installed for recovering the sand and dust from the dirty water. The wet refuse from this equipment dumped belt conveyor. This conveyor discharges its load into paddle mixer into which dry waste sand also dumped bringing down the over-all moisture content that the refuse can handled freight car. Clean water from the dewater- ing recirculated through the system. About gal. per min. fresh water supplied order keep down the scum which would interfere with the action. dust collectors, showing the inlet ducts the bottom and the outlet ducts the top. uses are being found every day for sheet metal and now comes the Goodhart Memorial Co., Belleville, which has recently developed com- plete line headstones and grave markers made porcelain enameled gage Armco Ingot The exterior the marker given six coats porcelain enamel, while the interior receives two. After its being treated this manner, there exposed metal, mak- ing impossible for rust corrode. The enamel itself guaranteed not peel, discolor, rust tarnish. The markers may transported and handled easily because their relatively weight, and the price much lower than the conventional memorial. THE AGE, September i MANY techniques that have been developed for welding thin gage steel for automobile bodies are now being applied the elec- tric refrigeration industry. the Grand Rapids plant the Kelvina- tor Corp., where both Kelvinator and Leonard cabinets are made, there has recently been installed some high-speed welding equipment that comparable with the latest practice the automotive indus- try. adopting 100 per cent welded shell, possible con- struct cabinet with graceful, flowing curves and one that pro- vides maximum formance excluding air and its attendant moisture content from the interior the cabinet walls. The one-piece welded shell forms structural backbone for the cabinet and makes unnecessary any frame wood other composite struc- ture, permitting use maximum frame, giving much better in- 40—THE IRON AGE, September 1936 sulated cabinet. Formerly the cabi- nets were bolted together. There are number varied types welding operations join- ing the various panel stampings, which make the complete cab- inet. the line, for example, end panel stampings are welded the top panel, front center cross panel welded place, the bottom bulk head panel projection welded its four flanged edges the sides the shell, while automatic multiple spot welding machine at- taches the back panel the shell. The base panel assembly (of four separate stampings) gun welded the bottom flanges the upper- shell. Other types cabinets use projection welding place flash welding. general, because projection welds require but little metal fin- ish, they are used most the main junction points such bulk- heads and cross panels. Gun welds, single and progressive spot welds cause indentations the metal surface and their utility, therefore, limited the backs and bases the cabinets. fabricating Kelvinator’s cab- inet interior food chamber, the roller seam weld used obtain clean, smooth seams, free from burn marks, allowing better porce- laining the more uniformly flat surfaces obtainable. this method chamber seams are heated the exact line the weld, preventing any buckling which would occur the heat were not controlled. Nor are weld strains left the metal cause buckling and distortion when later subjected the high heat the porcelain enamel- ing furnaces. Throughout all the welding processes, accuracy holding ex- act dimensions practically auto- matic, each operation being con- predetermining the position one part with respect another. When completed, the cabinet compact, solid shell which readily lends itself the subsequent metal finishing process, painting and assembly operations. Initial cost install- ing necessary welding equipment produce the one-piece welded shell justified and offset the greatly increased strength and product uniformity, assuring maximum performance the lowest cost maintenance and operation the finished electric J | refrigerator. welding technique has made pos- sible more pleasing contours, sales asset that also offsets any in- crease cost production. fabricating food chambers the back and two sides are formed one U-shaped piece and the first operation the assembly weld top and bottom piece form open-ended chamber. This operation performed two steps. the first, top and bottom stampings are seam-welded the back side the chamber wall. the second step, the sides are welded the top and bottom. this two handlings are required the second set-up. unusual seam welding ma- chine, shown Fig. has been developed the Federal Machine Welder Co. cooperation with the Kelvinator Corp. Chief fea- tures are two movable carriages which the welding jigs are mounted. Each carriage has four wheels running track and longitudinal movement hy- draulic plungers. The work itself clamped pneumatically the fixture that the edges overlap 1/16 in. The seam welding equip- ment, which composed two rollers, itself travels over- head track through motor-driven pinion and rack. The capacity the machine 225 kva. and aver- age output chambers hour, with average length weld in. notable design feature this unit the fact that the secondary transformer terminals nected flexible brush copper busses each wheel and the cir- cuit completed through the work. The circuit formed between the work and the backing dies which are bridged flexible copper jumper. other words, the two welding wheels are series, rather than parallel. arrangement this kind permits adjustment FIG. seam welding food compartments 45- machine having moveable work- holding carriages that can with- drawn for loading and unloading. rollers and backing dies accom- modate various widths cham- bers. Three operators are required for the machine. both ends there operator load and unload the work and the side sits man who controls the hydraulic valves for carriage operation push button switch which controls the seam welder travel. opera- tion, one carriage first loaded and advanced the work position. The welding rollers then automat- ically descend and the seam weld- ing operation begins. the com- pletion travel, the roller raised and the work carriage re- turns the unloading position. the meantime, partially welded sheet metal assemblies have been placed the second carriage and clamped position and await only the action hydraulic valve advance the whole assembly the work position. roller conveyor carries the work from the first posi- tion the second and order facilitate loading the second position, the corners are either THE IRON AGE, September some hand finishing operations the piece, including hammering the corners and crowning the top and sides give good appear- ance after enameling. Any rough- ness cleaned hand ro- tary files before the work goes the pickling tanks prior receiy- ing the ground coat. forming the outside box case, the first operation flash weld the two end panels the top, one side time, two separate machine setups, Fig. The case inverted position and the stampings are clamped pneumatic- ally, automotive practice, pair Federal flash welders FIG. ABOVE panels being flash-welded the top panel inverted position. aluminum latches facilitate locking the clamp bars position. ° ° spot gas welded After final seam welding opera- tion, the work returned belt conveyor from which taken off for subsequent operations. This particular operation highly important one, since any defective welds will show the porcelain enameling operation. the welding pressure not right, there may gas in- clusions which later show keep the wheels properly dressed mushroomed edges have marked effect the welding cur- rent and heat. equally impor- tant gas weld the corners properly, since this job that the seam welder rollers obviously cannot do. Actually, rejections from this source are very low com- pared with those obtained when the entire box was gas welded. These seam welds must also strong enough withstand subse- quent forming beading opera- tions the four sides and corners horning press. There are also 42—THE IRON AGE, September 1936 ° ° FIG. BELOW vidual spot welds are made successively attaching the back panel the side and top panels this unit. The work-holding table raised air pressure, whereas the welding tips are depressed under hydraulic pressure. rated 200 kva. resistance flash welding the metal sheets are “putted” edge edge the weld- machine without overlapping. fact, using thin gage metal such Nos. and gage these cabinets, essential that the work accurately alined and hence substantial dies and work clamps are called for. this par- ticular set-up the center section top first placed the formed dies with the welding edge against gage, which later withdrawn. Clamping arms are first lowered, however, and large heat-treated aluminum latches are thrown into clamping position. The side mem- ber similarly placed position and clamped toggle action. Operation the welder entirely automatic including the flashing and upsetting the weld edge, cutting off the welding current and stopping the motor. Cycle time hour. For another model, projection welding Swift machine being employed. The largely questions ultimate cost versus quality. neater weld formed flashing the sheets together, since rounded corners are permissible, but great deal more time required clean the flash cup and disk grinding well hand filing. good pro- jection weld requires practically finishing, since the abutting piece the outside flat section copper alloy which leaves inden- tation the surface the metal. the other hand, only small percentage the metal actually compared with 100 per cent = FIG. Swift projection welders used progressively Kelvinator cases. Three the six Federal gun welders may seen the background. ° ° for flash weld, but full sheet strength developed. Another machine found application heretofore prin- cipally automotive plants that multiple spot welding the back panel the side panels and top. This operation performed “Hydromatic” welder, Fig. which reality progressive, mul- tiple spot-welding machine. this instance, indentations left the welding electrode tips are unimpor- tant. this particular unit ap- proximately individual welds are made successively period about sec. Output ap- proximately units an_ hour. The table which the fixture clamped advanced upward the welding position through air pres- sure. machine this kind each individual electrode advanced through plunger action, using oil under 500 per sq. in. pressure. multiple port valve employed which only one port uncovered time, which means that only one electrode can oper- ating any one moment with the full power the kva. trans- former going through it. Flexibil- ity control obtained means air driven motor which drives both the hydraulic valve mechanism and also the timer which governs the duration the welding current. other machines the line, flexibility paramount. Al- together, there are two welding lines and distinct models are run over them. Part the re- design the cabinet called for standardization with respect welded seams that maximum welds could handled over the same equipment. When production high, the aver- age length run 1500 1600 cases, but when production fall- THE IRON AGE, September 1936—43 4 § H ing off, the run must made much lower units; the change-over time extremely im- portant. the example the Hydromatic welder, possible vary the number welding tips use and change the width between the banks welds down each side. The timer must re- set and the air changed. rather simple fixture for holding the work employed and this need only shifted side- wise widths box. Just great flexibility re- quired the projection welders, Fig. which comprise the major- ity the group. Here largely matter changing electrode die plates usually fastened the ma- chine countersunk capscrews. Referring again the model cabinet, after the shell leaves the Hydromatic welder, goes kva. Swift projection welder where the center cross rail at- tached each side. The side panels are notched receive the cross 44—THE IRON AGE, September 1934 FIG. RIGHT HIS double-head projection welder attaches the front top panel the sides Leonard case. relay panel first one and then the other head operate. Air con- trolled collapsible dies permit with- drawal the work after welding. ° FIG. BELOW spot welds are made once this 400 kva. pro- jection welder shown joining the bottom bulkhead the cen- ter front cross panel. Low and high pres- sure air receivers top the machine are used connec- tion with automatic- ally controlled valves give the desired welding and subse- quent squeeze pres- rail which indented for four spots each side. Control the fully automatic, including timing the welding current and its light pressure followed much heavier follow-up squeeze pressure. very nice adjustment required the work pressure get proper weld. Too light pressure burns the work; too heavy causes defective weld since the projections are flattened and the current distributed over too wide area. Similar automatic cycle control applied the next two Swift projection welders, machines rated 400 kva., one the first set-up the head attached the back and front the case and the second the side panels. From spots are welded time, depend- ing upon the size the cabinet. Welding and squeeze pressure | | + hed applied through air ram con- junction with toggle mechanism having 20:1 ratio. top the machine are two air receivers, one low pressure, the other high, and solenoid actuated air valves control their output the ram. Welding time ranges between cycles and automatically controlled vacuum tube relay. another welder used for Leonard cases, which the unit the top, the front top panel spotted the sides double-headed machine which first one side and then the other welded, Fig. relay panel controls this operation that the full electric load con- centrated one set welder dies, and the transformer capacity held down 150 kva. Because the nature the work, air con- trolled collapsible welding dies are employed order permit the assembly withdrawn after the welds are completed. These die air valves are treadle operated. Welding and squeezing pressure also applied pneumatically, with the control entirely automatic push button and relay panel. Projection welding also em- ployed for assembling the four stampings that make the base for the “K” series. Spot welders are used attach small stamping known float panel the back panel and special spot welder with deep horn die supple- ments the Hydromatic welder peak load. Altogether there are six Federal gun welders, three each line, used attach the base assembly the shell. These operations formed inside flanged edges that the question appearance does not enter, and weld indenta- can seen Fig. the cabinet inverted and held hand simple supporting fixture locating the work. About spot welds are made each assembly and the output jobs hour. Gun welder practice follows that the automotive industry. Trans- formers kva. capacity are suspended overhead monorails and both the cables and the weld- ing tips are water cooled. The gun spring-loaded reel and cable. Com- bination air and electric control employed, timed automatically produce 120-150 spots minute. good consistent weld strength the main consideration. These particular welds are called upon severer duty than any other welds the case, not when the refrigerator service, but the assembly plant Detroit, where the units are installed and only, necessary ding up, disk grind, hand file and buff. the flash welded cases, trimming the flash with vitrified cup wheel first necessary, and the disk grinding, hand filing and buf- fing are obviously more time con- suming. All power tools are the portable high-frequency type and FIG. welding bases inverted cabinets the rate hour. Automatic timers and water-cooled cables and electrodes permit 150 spot welds minute made. subsequent shipment dealers, the cabinet bolted skid base which the crate built. Inertia effects freight cars are sufficient occasionally pull out the feet bolts, but the gun welds have never failed. Metal operations vary according the type weld used. cabinets assembled visible portions projection welding are counter-balanced cable and spring-loaded reel. Work pushed hand between the various finish- ing operations until reaches the final inspection and touch-up. From here the cabinets are hung overhead monorail conveyor which takes them through steam cleaner, spray bonderizing chambers, rinse and dry, then the paint shop for the synthetic enamel finish. THE IRON AGE, September 1936—45 | | | EDWIN HODGE Consulting Geologist—North Pacific Division, Engineers BONNEVILLE Dam, Oregon, will com- pleted sometime 1937. that time there will made available from two units 640,356,000 kw-hr. year per cent load factor. The foundation laid for four addi- tional units, providing ultimately the same load factor 1,578,552,- 000 kw-hr. year. the present time prospec- tive purchasers for this new power are definitely known. Three dif- ferent methods disposing the Paci power are being agitated: (1) cheap power farmers and similar consumers, (2) wide distribution tie-in with Boulder and Grand Coulee dams and (3) sale large electro chemical and metallurgical industries located near Bonneville. the belief that the latter course would give the greatest benefits the largest number citizens, study was made and report issued titled “Available Raw Materials for Pacific Coast Iron Industry,” un- der the direction the Engi- neers. published four vol- umes, contains over 1000 pages and may purchased for $5.00 from the Engineers, 523 Pittock Block, Portland, Oregon. This pa- per review the salient fea- tures the report. The report deals with the quality, quantity and delivered cost the fic Coast Market OMPLETION Bonneville between Oregon and Washing will immediately made avai kw.-hr. per year and later date tric power. The prospective availability Boulder Dam and Grand Coulee prospective power demands are more than fraction the total, complete elaborate survey territory. This survey, made under points the feasibility Pacific employing electric smelting, which Coast ores. For the benefit our readers, articles abstracting the 1000 page first article deals with the market Coast area. Subsequent articles raw materials. { - * ¥ ton, able clos this and raw the Coa repo for deal | the Stage for Dam, the Columbia River ton, scheduled for 1937. There able that time, some 650 million 900 million more elec- this power, together with that and the fact that present and entirely inadequate consume has caused the Engineers material resources this supervision the author, Coast iron producing industry particularly suited Pacific Mr. Hodge has prepared series report the Engineers. The for iron and steel products the deal with availability and cost raw mineral materials Bonne- ville for use iron smelting. For- eign and domestic sources are con- sidered and much attention given well advertised deposits and large number a