The Iron Age 1936-12-03: Vol 138 Iss 23

Zip! success and even life itself depend per- fect coordination and muscle the last split second... From bobsledding steel far cry, but steel making too, skillful coordination vital. many complex metallurgical factors essential Important among these factors the addition the correct amount right ferro-alloys the proper time during the melting heat. For over thirty years Electromet has made the right Metallurgists, with years practical melting, will gladly work with you—right your own plant your own operating conditions—to help you use these ferro-alloys make better steel. For further information, write for the booklet, Products and Service,” which offered without obligation. ELECTRO METALLURGICAL COMPANY Unit Union Carbide and Carbon Corporation Carbide and Carbon Building, 42nd St., New York, YOU BETTER THAN SPECIFY— ELEPHANT BRAND PHOSPHOR CASTINGS TUBING ROPE INGOTS Corrosion thief, deadly and implacable sapping vital parts your product their strength and efficiency destroying the Quality you have built destroying hard-won confidence, creating dissatisfaction the part your customers. This menace your profits can stopped! Easily, too. Materials that resist corrosion are readily available and, foremost among them point pure merit and widespread use, ELEPHANT BRAND PHOSPHOR BRONZE. ELEPHANT BRAND, standard for over years, con- tains nothing but Virgin metals, carefully selected for the and strong and tough, yet elastic. But, above all, resists the corrosive action both salt and fresh water moisture. its many grades, there one perfectly suited your purpose. And, the first producers Phosphor Bronze America, are fully equipped supply authoritative information and close cooperation determining the proper grade for your needs and furnish this uniformly dependable material, with prompt, efficient service. For complete information any product, for quota- tions, write— THE PHOSPHOR BRONZE SMELTING CO. 2210 Washington Avenue, Philadelphia, Pa. 7 2 CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET NEW YORK, Owned and Published CHILTON COMPANY Executive and Publication Offices, Chestnut and Sts., Philadelphia, Pa. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS. EVERIT TERHUNE, HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ FRANK President VAN DEVENTER Editor WRIGHT Managing Editor FINDLEY Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Resident District Editors Washington Chicago Cleveland Detroit Pittsburgh Editorial Correspondents London, England Cincinnati Boston Hamburg, Germany Milwaukee San Francisco Toronto, Ontario Birmingham Newark, St. Buffalo Conten December 1936 Lest There Forgotten Reclamation and Handling Foundry Sands........... These New Soviet Open-Hearth Inland Expands Indiana Harbor Plant................. Controlled Gear Washington News BAUR, General Advertising Manager DIX, Manager Reader Service ADVERTISING STAFF Member Associated Business Papers Emerson Findley, 621 Union Cleveland Herman, Chilton Chestnut 56th Indexed the Industrial Arts Index. Philadelphia, Pa. Published every Thursday. Subscrip- Hottenstein, 802 Otis Bldg., Chicago tion Price: United States and Pos- Pei ada, $8.50, including duty ; Foreign C. H. Ober, 239 W. 39th St.. New York $12.00 year. Single cents. Robinson, 428 Park Pittsburgh Cable Address, ‘‘Ironage. Warren, Box 81, Hartford, Conn. Member, Audit Bureau Circulations N Copyright 1936 Chilton Company (Inc.) | half century experience fifty years, longer than any other company America, Bethlehem has been making alloy steels. this time great fund knowledge has been collected, bearing the manufacture alloy steels and their application various fields industry. This information, boiled down toa con- centrated form and organized for the convenient 32—THE IRON AGE, December 1936 reference alloy-steel users, has been published book, “Bethlehem Alloy Steels.” Here technical publication packed with data right from furnace and rolling mill well from the processes alloy-steel-consum- ing industries. gives close-up alloy steels through the eyes men who live with them. 4 DECEMBER 1936 ESTABLISHED 1855 Vol. 138, Ne. Lest There Forgotten Men this happy post-election atmosphere peace earth and good will toward men, with wage increases industrial workers daily occupying our headlines—and price increases following their heels—we must careful that magnanimity tempered with justice. Where the accelerating upward spiral wages and prices going land nobody really knows. hope sincerely that may the promised land prosperity for all and better living for those the foot the ladder. There are skeptics, how- ever, who say that may lead the desert inflation where the mirage prosperity never nearer than the horizon. not take that stand this time. little inflation not bad thing when the business activity curve turning constantly upward. not bad the deflation which takes place the downward spiral depression. The thing that are chiefly afraid of, connection with the present upward spiral that being built industry, that may leave forgotten men and women behind. Some them have not yet caught the elevator. Currency inflation spreads itself evenly over rich and poor alike. But wage and price inflation discriminatory. Those who not catch the elevator are out luck. thinking especially the lower salaried white collar employees industry. quite true that these clerical and other white collar workers have certain ad- vantages over the hourly wage earner with respect regularity income and work. Many, not most them, receive vacations with pay. the majority cases, they are not for occasional absence because illness. Granting all this, must admit that these advantages have already been establishing white collar salaries. Admitting, however, that our industrial concerns have exercised spirit fairness establishing pay differentials between various classes workers the past, there danger unfairness ascending wage-price spiral. are wise, will take this into account. there general increase for those who wear overalls, there should proportionate adjustments for those who not, among the lower salaried workers. not have worry about the higher salaried people. They are better able take care themselves under the law supply and demand rising market for special ability. Our consideration should for those the broad base the pyramid, matter what sort working uniform they wear. a a rer x re COND RECLAMATION. ONING HANDLING FOUNDRY author's thesis that even small find profitable install equipment for: controlling permeability, bond strength, moisture and inert fines the sands used molding. Detailed descriptions are given modern equipment designed for this type control, and mention made THE subject sand reclamation and recon- ditioning closely al- lied the subject sand control. fact the writer’s experience that without sand control most comprehensive programs sand reclamation will *Submitted the exchange paper the A.F.A. for presentation the 1936 meeting the French Foundry Technical Association. 34—THE IRON AGE, December 1936 ° ° LESTER KNIGHT, JR. National Engineering Co., Chicago the mechanical results ob- tained and the monetary savings effected through the use such equipment. emphasized, however, that equipment alone will not re- sult such savings, for there must rational use the dividual problems each foundry. prove unsatisfactory over period time. Much knowledge has been gained the past ten years this sub- ject and many improvements have been developed equipment for re- claiming, conditioning trolling foundry sands. The subject sand control large and important one and many papers have been written ° ° ° Much the subject beyond the scope this paper, which will deal largely with equipment operated the field for reclaiming and condi- tioning foundry sand. Foundrymen should realize the importance study the sand conditions their foundries, the effect upon the quality product they produce and the opportunity this phase their operations pre- sents for improvement quality and reduction cost manufac- ture their product. During the past few years the writer has had the opportunity conduct “sand surveys” many different classes foundries. most invariably where the causes scrap loss are classified, the per cent the daily foundry loss. the classification losses correct, well rounded sand con- ditioning and control program reduce losses attributable sand. Equipment for handling, ° ° tioning reclaiming sand should provide means for controlling the most important variables the sand. Assuming that the grain structure the sand used suitable for the class casting made, the variables con- trolled are (1) permeabil- ity, (2) bond strength, (3) moisture, and (4) inert fines. Each these vari- ables are inter-related and each has its effect the other properties given sand. The question arises how these variables should controlled and the limits which they should controlled. general the permea- bility the sand should sufficiently high allow for the free passage gases when the metal poured. Too open sand may cause rough castings metal penetration, both which are un- desirable. Too close sand may scabs, blows gas holes, which are also undesirable. The al- lowable limits permeability for given class castings must de- termined empirically and obser- sand prepared paddle type mixer. Note the smear unmixed clay. batch type muller used considerable extent for conditioning foundry sands. vation casting results after the castings are cleaned. The sand should controlled within that range these limits. Bond and Moisture: Many tests have proved that excess bond moisture, both, causes majority sand defects. The molding sand, natural synthetic, will > / have minimum bond and moisture required for workability. The sand must sufficiently work- able allow clean im- pression the pattern, al- low finishing and closing the mold and prevent cuts, washing, swells, etc. excess bond, mois- there usually results scabs, excessive burning on, rough castings, blow holes, all leading exces- sive losses and high clean- ing costs. extremely essential that the bond and moisture uniformly distributed the sand. The most desir- able condition have formly coated with film clay and tempered with minimum moisture required for workability. For this tempering and bonding the sand the batch type muller most widely used and the highest degree uniformity obtained. Importance Mulling Sand: Fig. shows one the larger size batch type mullers most widely used for proper conditioning 3—Photomicrograph mold surface sand prepared batch type muller. Note the film clay around each grain sand. THE IRON December 1936—35 4 Roe. foundry sands. The mulling ac- tion thoroughly coats each grain sand and develops the maximum plasticity the clay with mini- mum moisture. Hence mini- mum clay bond and moisture required for workability when the sand mulled. Tests have been made de- termine the importance form bond distribution and the ef- fect mulling the sand. Fig. shows photomicrograph part mold surface made from sand prepared paddle type mixer with six minutes mixing. Note the smear unmixed clay. When the metal was poured this mold the casting surface was very dirty due the burning the sand these points. Fig. shows photomicrograph part similar mold surface 36—THE IRON AGE, December 1936 made from the same sand mixed for four minutes muller type mixer. Note the film clay around each grain sand and that un- mixed clay present. When the metal was poured this mold the casting surface was smooth and peeled readily. Strength Affected Clay and Moisture: Ordinarily sand with given percentage clay content and optimum moisture content, when mixed muller, will show from per cent greater green strength and from 300 per cent greater dry strength than the same sand mixed paddle type mixer. This due the greater uniformity distribution the clay and moisture, the coating the sand grains with film bond and the development the maxi- mum plasticity the clay mulling. The test figures Table il- lustrate the difference strength developed the two dif- ferent methods mixing the same sand. The standard test procedure the American Foundrymen’s As- sociation was followed. The conclusion drawn from the data Table that, for given bond strength required for view used gray iron, malleable and steel foundries claiming, condition- ing and controlling sands. certain class casting, less bond and moisture are required the sand mulled than pre- pared paddle type mixer. This lower bond and moisture con- tent not only results lower sand costs but also better surfaced castings, lower cleaning costs and scrap losses due sand defects. Many other laboratory and shop tests have been made over period Sin ay | Screen Enclosure Adjustable Air Diagrammatic sketch the sand re- claiming, conditioning and control unit shown Fig. Magnetic Magnetic Rejections years demonstrate that preparing sand the batch type muller possible obtain the highest degree control the sand, minimum use new sand bond and moisture for workability, and thus obtain clean smooth-sur- faced casting with low scrap loss due sand defects and low clean- ing costs. Before going further, per- tinent state that proper sand conditioning and control will not correct inherent defects casting design, methods molding, pour- Cooling Hood -Refuse Chute Simpson Mixers Aerator Line ing, gating the metal itself. But the sand into which the metal poured one the most important variables which daily affects the production high quality castings. That is, after design, pattern equip- ment, etc., have been developed properly. Inert Fines: The fourth variable listed fines.” Each time metal cast sand certain amount clay bond dehydrated par- tially dehydrated, some the sea- Storage Measuring Exhaust --Dust Mixers Totally Enclosed coal, burned ash, and some the silica grains fractured. This fine material inert, has bond- ing quality and decreases perme- ability and causes rough, dirty cast- ings with excessive burning the sand. some cases these fines actually show false strength for the sand which, when metal poured, cause washes and scabs the casting. typical check for this condition shown Table II. Sand No. Table had the fines partially removed before con- ditioning, and, when the casting Moving Power Power Mold Conveyor. Platform Mold Discharge Castings Cleaning y Screened Sand Hoppers Mixer Pulley Intensive Aerator Fic. and elevation sketches continuous sand handling system using batch type mullers for sand preparation. Shakeout and Sand Screen PLAN Distributing Conveyor ELEVATION Flask repared Sand Hoppers / Spill Sand Conveyor THE IRON AGE, December 1936—37 4 3 TABLE Comparative Bond Strength Sand Mixed Paddle Unit and Muller TEST NO. test sand used, having per cent clay and 5.0 5.2 per cent moisture Mixing time Green compression strength ............... Dry compression strength ................. 5.6 per sq. in. 79.0 lb. per sq. in. Muller Four Minutes Paddle Mixer Seven Minutes 3.7 per sq. in. 42.0 per sq. in. TEST NO. Burned foundry heap sand used, having 5.0 5.2 per cent moisture Mixing time Green compression strength .............. Dry compression strength ................ 6.5 Ib. per sq. in. 55.0 per sq. in. Muller Four Minutes Paddle Mixer Seven Minutes 3.5 per sq. in. 35.0 Ib. per sq. in. was poured, was sound and clean. Sand No. had fines removed, and, when the castings were poured, scabs and “washes” were found. The removal and control the amount fines will aid greatly controlling permeability. Tests have proved that the removal given sand will result much larger increase than the addition per cent new coarse silica sand. recent test illustrated that per cent ad- dition coarse silica sand caused increase permeability. Functions Sand Reclamation The up-to-date modern sand re- clamation, reconditioning and con- OUST HOOD SIMPSON MIXER NATIONAL FLOOR trol unit provides for the four fol- lowing factors: TABLE Difference Between Sands With All Fines Present and With Fines Partially Removed Sand Sand No.1 No.2 Green bond strength (comp.) Dry bond strength (comp.) Moisture content per cent 5.4 5.8 Cleaning and screening the sand remove metallic and other refuse. Reconditioning re-bonding the used sand the batch type muller that minimum new sand bond and moisture re- quired for workability. Properly aerating the sand after has been conditioned the muller. The aeration after proper conditioning increases the flowability the sand and thus helps obtaining smooth surfaced castings with sharp edges and maintained closely tolerances and weight allowances. Complete housing and air ex- haust the equipment handling the shakeout sand with damper con- trol the exhaust outlets or- der control closely the amount inert fines the sand. This not only allows simple control permeability without excess addi- tions new sand but also elimi- nates the dust hazard surrounding the equipment. Figs. and illustrate typi- sand reclamation, recondition- ing and control unit used many steel, malleable and gray iron foundries for the preparation facing sands, rebonding additions heap sands and reclaiming sand formerly discarded refuse. will noted that the unit consists shakeout grate floor level into which the used sand charged. means belt conveyor the sand carried over magnetic pulley remove metallic refuse EXHAUST OUTSIDE DUST COLLECTOR VIBRATING SCREEN MAGNETIC BELT CONVEYOR REJECTIONS sketch simple sand reclaiming, conditioning and control unit used small shops producing gray iron, malleable, steel and non-ferrous castings. IRON AGE, December 1936 7 Y Y SKIP HOIST Y BUCKET LOADER 2 ‘ — hs view the sand reclaiming, condi- tioning and control unit shown diagram- matically Fig. and the sand charged into the elevator and thence revolving hexagonal screen where core butts and other refuse removed. The charged into the storage bin lo- cated over batch measuring hop- pers located above batch type mul- lers. Aerators are mounted the discharge ends the mixers aerate the sand automatically discharges from the mixers into boxes for transportation the molders floors. The unit hooded, housed and exhausted with dampers each the exhaust outlets control the amount fines removed. All additions new sand, bond, moisture, seacoal, cereal binder, etc., are made the mixer that each batch sand may, within limits, desired. minimum amount new sand bond re- quired and maximum uniformity and control obtained. analysis savings effected malleable foundry pouring approxi- mately 100 tons per day shown Table III. The unit was installed Decem- ber, 1934, and put into operation Jan. 1935. The tabulation dis- closes that the saving sand costs paid for the unit eight months operation. The improvement quality product, reduction cleaning costs and scrap losses were additional profits available. Steel foundries which are not equipped reclaim their used sand report that they require from 1800 lb. 2500 lb. new silica sand per ton good castings produced. Several steel foundries using equip- ment similar that shown Fig. report that their new silica sand consumption approximately 450 lb. 800 per ton good cast- ings produced. addition, reported that they require per cent less clay bentonite, have lower cleaning costs (from per cent and obtain better sur- face their castings with virtual elimination pin holes and pene- tration the metal into the sur- face the mold. They are able maintain permeability within (CONTINUED PAGE 119) TABLE III Cost Savings When Sand Reclaiming, Conditioning and Control Unit Used January, 1934 through June, 1934 Clay bond consumption... 300 tons $3.50 per ton $1050 Disposal cost (used sand) .2500 tons $0.40 perton 250 tons 900 Reported decrease (approx.) per cent. Cleaning costs .......... Reported decrease (approx.) per cent. January, 1935 through January, 1935 June, 1935 through Approx. June, 1935 Saving perton THE IRON AGE, December : he PRENTISS Cleveland Editor, The Iron Age PRODUCTION meth- ods the manufacture welding wire have progressed with the greater output that has resulted from the increased demands the welding industry. Not only have economies been effected making the electrodes, but the 40—THE IRON AGE, December 1936 quality the product has been materially improved. Specializing this field, Mau- rath, Inc., Cleveland, makes only alloy welding wire, producing analyses for joining corrosion and heat resisting and stainless steel products. These electrodes are made sizes from 5/64 in. 3/16 in. diameter. With much its equipment spe- cially designed and automatic operation, both the plant arrange- steel welding rod reduced welding wire .sizes the automatically controlled drawing block shown the foreground. After liming between passes, the coils wire are hung the drying rack the rear and subse- quently pass reels from which the wire again fed into the drawing block. Cleveland Maker Draws Wire Specially Designed Blocks and Anneals Electrical Re- sistance, While Workers Are Beguiled With Radio Music ments and the methods followed the Maurath plant for processing welding wire produce high quality product are highly inter- esting. the quality the elec- trodes improved processing the wire controlled atmosphere, both the coating room and the dry- ing room are air-conditioned maintain uniformity both tem- perature and humidity. equipment any condition both temperature and humidity may obtained and kept uniform. Work- ing conditions for the men also are made more comfortable, particu- larly extremely hot weather. unique feature the plant that radio entertainment pro- vided for the employees while work. There master receiving set which connected six loud speakers located along the walls Music, sports, political ballyhoo and news the day add the contentment the workers, and the radio en- tertainment said promote rather than interfere with their ef- ficiency. The employees have their own dining room which also served the radio during the noon hour. Hot-rolled alloy steel welding rods, all in. diameter, reach the plant coils ranging weight from lb. 250 lb. These are increased 700 coils weld- ing the ends separate coils to- gether. The use larger coils saves in. rod pointing for successive drawing operations. Not only there saving scrap the use large coils, but labor q Wi? IRE annealed being heated direct resistance, both a.c. and d.c. cur- rent being used, the former for preheating and the latter for the final high temperature. This picture shows the wire passing through the roller type electrodes and entering the continuous pickling tank red heat. take-up reel the end the unit draws the wire through the electrodes and pickling tank. applied the wire machine that fully automatic. The coating material after being mixed placed the loading cylinder the left and from this transferred screw-operated extruding cylinder that located horizontal position above the machine. Wires are fed from the hopper the right, and, after coating, are discharged onto belt conveyor through the housing shown the rear into the adjoining drying room. THE IRON AGE, December i conserved the pointing, starting and handling operations have been considerably reduced number. The rod drawn into wire double drawing block, the reels being instead the usual vertical position. The wire reduced 0.50 in. the first pass through the drawing dies, from approxi- mately 0.220 0.170 in. diam- eter. The number passes ranges from one seven, depending the analysis and size the fin- ished electrode. The drawing block special design that was built the Mau- rath electrically con- trolled and automatically stops the wire breaks, the coil becomes snarled and when the coil fin- ished. using the large coils, the machine practically self at- tended. Annealing the alloy wire necessary after each pass through the drawing block re- duce the hardness produced cold working. unique method been adopted for annealing the wire electrically. The wire heated during its continuous movement through the annealing unit passing electric current through it, both a.c. and d.c. being used the annealing process. Wire first pre- heated 1300 deg. passing between rollers that are electrodes for high-amperage alternating cur- rent, and then passes between another set supplied with direct current, which heats the wire 2000 deg. From the latter rollers the wire bright red 42—THE IRON AGE, December 1936 moves into the pickling tank. The d.c. current also serves the pickling tank. With duplicate equipment for annealing, two strands wire may annealed one time. The speed anneal- ing ft. per min., de- pending the size the wire. The pickling tank ft. long. non-acid solution used the tank for removing the scale and also ects quenching medium for softening the austenitic steel cooling. The wire fed from reel drawn through annealing equipment and pickling tank variable speed collapsible takeup reels. leaving the pickling tank passes under spray water for cleaning before being wound the reels. The power plant for the anneal- ing and pickling equipment con- sists two 600-amp., General Electric d.c. welding motor generator sets and one 300-amp. Wilson motor generator welding set. Two transformers are pro- vided for supplying coating room conveyor de- livers the wire conveyor that serves the drying oven shown this picture. The drying room makes two through the drying oven, the oven conveyor permitting eight reduc- tions speed from the time the wire enters until leaves the oven. a.c. current for heating the wires. There also 5-kw., 250-volt mo- tor generator set that supplies di- rect current for operating contac- tors that control the high-amper- age current and the motor driven take-up reels. removal from the take-up reels, the coils are hung crane and dipped into tank the floor level containing cleaning solution remove all smudge and then dipped into lime solution make ready for the next pass through the drawing machine. After liming, the coil lifted from the crane onto drying rack consisting vertical shaft and six arms. After being hung one the arms the rack revolved short distance its axis bring the coil close proximity the wire drawing block. Wire straightened and cut length after drawing size two high-speed straightening machines special design. These machines have eight-die rotary straighten- ing arbors instead the usual five-die arbors. The arbors have variable speed drive, advantages which are said close adjust- ment and more accurate straight- ening. The arbor has speed 5000 r.p.m The straightening ma- chines were built the Lewis Machine Co. The wire cut standard 18- in. lengths, and then ground specially designed machine order remove the drawing com- pound, foreign matter and fins left the ends after cutting length. (CONTINUED PAGE 120) : NEW SOVIET DEPARTMENTS Planned Work and Discipline RALPH VAILL Azov Steel, Mariupol, Ukrainia, Americans, the term “planned economy” political abstraction. vague, nebulous ideal. But, the Soviet Union, can bear witness, after four years ser- vice open-hearth operator, this business “planning” laughing matter. the daily concern not only the director the plant and the superintendent department, but governs the first helper his furnace, the ladleman with his ladles, and the brick mason who repairs the fur- naces. The for steelmak- ers comes down direct from G.U.M.P or, you, from the head office the metallurgical industry, section the People’s Commis- sariat Heavy Industry. The planning bureau our plant, receipt the from G.U.- M.P. then prepares local plan for each department. receipt these rectified plans, which are monthly occurrence, the director the plant generally calls meet- ing (Sobranya) heads all operating departments, supply, fi- nace, personnel, etc., and after the usual review successes fail- ures regards last month’s plan goes into this question meeting the new plan that “before the house.” And the way, these, well most the many (Sob- ranyas) that are held, are night affairs, lasting often until eleven twelve o’clock. The accepted plan, and they are always accepted, then becomes the operating law the plant. Materials, men, and transportation are given accord- ance with this plan. Delays, re- pairs, shutdowns and schedules are arranged that this plan can realized. And realized must be. For the “big boss” Ordjonikidze, will accept excuses for costs, for labor turnover, for accidents and casualties. But you peruse Rus- sian papers, Industrialization particular, you will see that removes men, big and little for one reason—failure “meet the plan.” thread, “the plan” both the warp and woof, and the color and texture the cloth this man’s land. the steam the boiler that has raised the speed daily production from rate 13,000 tons day inthe dark win- ter 1932-33 the present 45,- 000-ton days. Not only does the plant have this monthly plan, but THE IRON AGE, December 1936—43 e met a ° ° ° x each department has its daily plan, and each turn its shift plan. forms the psychology the actual worker. first helper, for ex- ample, does not worry about make, whether his “buddy” left him weak bottom. no! has plan for his work during the shift. certain hour must have the heat melted, certain hour must have the heat tapped. And those “planned” times are the forefront his consciousness. The very operation changing shifts principally one getting all gears into that one mesh called for the “plan.” roof falls and the “plan shot” for that day. The the Guard" The change shift almost serious performance Soviet open-hearth shop mounting guard Buckingham. True, don’t have the music. But other ways it’s pretty good show. And serious one all concerned. Does the shift foreman come into the “charging floor shanty” plunk his feet down the nearest desk and talk his relief about the baseball scores the news board passed through the city? Not here. Rather comes the shop one good full hour ahead time. Goes over every section the plant. Notes condition all current work. How many ladles ready. How many sets molds. How many charges prepared. Gets accurate knowledge condition every furnace. Then goes office and prepares “the plans” for all his people. They the meanwhile have inspected their own particular jobs. And min. before time “take over” the whole shift assembles groups, various places, for the min. “pep” meeting that precedes each shift. Some the “get out and die for Siwash” talks that are given these meetings would make foot- ball coach out and study oratory. From this they forth “ac- cept” their furnaces, ladles, etc., and begin the shift work. The late, and the new shifts inspect com- pany. And minutely too. And what arise! Frequently, high authority must called arbitrate. For, one says heat “melted,” and the other says “T’isn’t” then how else can the question decided? vital. According plan, Ivan should have melted the heat. For success- fully completing that process would get, say, per cent the total pay for the heat. Pavel 44—THE IRON AGE, December 1936 allows that the heat melted, then time thereafter. This shouting and tumult dies away, only grow again when the shift that has been relieved goes make the report. All the work the shift here reviewed the superintendent the shop, one his assistants. Why was the plan not fulfilled this, that? Fines and reprimands, and premiums are awarded with gusto. Lengthy reports are entered into journals. course, one ever reads them. There are confounded many. New orders (prekazes) are made out. This takes hour, never less. Hence shift really hr. Mountains Mute Evidence Believe me, difficult for American reconcile himself this way working, even though its tremendous value such new enterprise, this, evident. Much damage does result. The backyard any new, big, Soviet plant has mountain mute evi- dence this effect. Evidence that graphically tells the story heat and toil, hardship, feverish work and fierce despair that has been the portion these beginners. But know other system whereby they could have progressed greatly they have these past four years. And furthermore not fair mention these back- yards without some comment the front yards. For interest- ing duality exists. The contrast startling. these front yards have, alongside blast furnaces and open hearths, intensively cultivated parks, with fountains, statues, trees, flowers, benches and all. Here Azov Steel, have “bureau which tends these parks, cleans streets, sidewalks, floor spaces and building exteriors. staffed mostly with peasant girls wearing gay uniform beret, blue coat and grey skirt. Match that! Back the glamorous days when the full import this new Soviet industrialization began dawn us, those engaged here used have great arguments how people’s noses could kept the industrial grindstone without the “money incentive”—the “accumulation private property” capitalistic fellows custom- arily regarded it. Generally agreed that “It couldn’t done.” But the discipline obtaining these plants today completely re- futes us. There very little ab- senteeism. Practically none the higher categories. The director the plant, the superintendent department are respected leaders just they are America. Direct willful disobedience order unheard of. Even though vodka the most plentiful thing the land, and obtainable everywhere every store, yet good “whiskey breath” very rare thing the plant. Weighty books tion are given all workers. one dreams flouting these in- structions. Fines and reprimands are dealt out with startling harsh- ness. But against this premiums are awarded just prodigally. For complete fulfillment plan high pay possible. For overfulfill- ment, much five times base pay possible. All cyclical oper- DR. EDWARD BAUSCH Dec. Dr. Edward Bausch, who trayed the opposite page, will receive the medal the American Society Mechan- ical Engineers for distin- guished public service. Dr. Bausch has been active the optical industry since 1874. addition his great accomplishment reducing the cost the public microscopes and other high- grade precision struments through improve- ments manufacturing meth- ods, has been one the world's leading pioneers the advancement optical science. Today, the age 83, still the job every day, working with his asso- ciates the solution diffi- cult problems. ations, for example, are divided in- logical periods. charging, fettling, melting, and refining heat steel the first helper and his helpers are paid much for each operation. True, this requires bookkeeping. Stalinsk, for 1500 workers had 200 “pencil push- ers.” For special occasions the superintendent the shop has fund play with. roof falls in, can summon the bricklayers and offer them bonus for comple- (CONTINUED PAGE 121) ws, | Waa! t - q ~ 4) | | Pittsburgh steel producer has installed and now using new type soaking pit made the Amsler-Morton Co. This de- scription the furnace shows that has number desirable characteristics, namely, simplicity, adapta- bility any type fuel, low fuel consumption WITH the development ingot steel and the subsequent rolling the im- portance equalizing the tempera- ture the entire ingot body before rolling was realized. then be- came necessary develop fur- nace pit which the steel in- gots could literally “soak” heat which would impart HERINGTON ° ° means re-circulating gas flow, recuperator design, automatic firing and highly efficient cover. Two tables are included which show fuel consumption hot and cold heats and com- parative data the mak- ing bottom the Amco soaker. form temperature and softness for rolling. The first devices employed were actually simple soaking pits, which extra fuel was applied and true soak obtained. How- ever, production conditions were variable; the ingots generally ar- rived the soaking pits too long after pouring contain sufficient sensible heat yield true and SOA NEW satisfactory soak. The form the soaking pit changed that became heat- ing furnace well soaking pit. Fuel saving features such regenerators and recuperators be- came essential parts. can seen once that such operation opens the way for various methods and experiments, operating and with different fuels, the correct use preheated air, regulation furnace atmos- phere, etc. result, there found the steel in- dustry today definite trend for the improvement, use and opera- tion soaking pits. Too fre- quently mill has failed solve certain rolling problems because the effect the soaking pit steel quality was ignored. Experience has taught that the ideal soaking pit should have impart the steel the following characteristics: THE IRON AGE, December 1936—47 § . va ~ a T | 4 4 Extreme simplicity. Adaptibility any fuel fuel mixture and minimum con- sumption thereof. effective, durable and inex- pensive recuperator. Elimination the destruction the original scale (washing). Automatic control opera- tion and temperature with positive uniform heating. Continuous firing with fur- nace atmosphere control. Uniform grain structure. Such soaking pit would in- evitably result important econ- omies, superior finished prod- uct and increased production. Seeking solution for the ideal pit, engineers the Amsler-Morton Co., Pittsburgh, have placed operation and patented both dis- tinctly new type soaking pit and new type recuperator. The char- acteristics the ideal pit described above are said achieved actual practice, to- gether with economies assuring quick rate amortization. The pit and recuperator are marketed under the name Amco. describing the construction and operation these new units, the relation the ideal character- istics already listed will pointed gas flow the Amco soaking pit such produce turbulent, fountain-like rounding the ingots. out, omitting (3) for detailed de- scription later. The soaking pit will use any common industrial fuel includ- ing blast furnace gas mixed gas. This soaking pit does not deviate from the correct basic principle heat applied parallel the long axis the stock. The flame enters the combustion chamber natural convection current through port the hearth, and the in- gots which surround the port are not directly the path the flame. The velocity the gas applied extremely low pressure increases rapidly after release 48—THE IRON AGE, December 1936 the pit and (see Fig. produces turbulent, fountain-like envelope completely surrounding the ingots, Induction re-circulates part the comparatively cooler gases the furnace and true soaking condition attained. Waste gases are removed through spaced out- lets located near the corners the side walls slightly above the coke braize. The gases from each out- let pass into the recuperator thence tioned here that producer gas used the port provided with dual controlled supply system that fuel may supplied con- tinuously from one the two lines while the other being burned out. The actual fuel consumption per ton steel heated exceedingly low, the writers’ knowledge the lowest that has ever been attained soaking pit operation. Known fuel rates in. in. Bes- semer ingots averaging min. the mold are 200,000 B.t.u. per gross ton 12-ingot (37 gross tons) charges. full charges cold ingots, the rate 1,400,000 B.t.u. per gross ton. Features contributing this low the incorporation every known means obtaining economy fur- nace design. The walls the pit ° ° ° type cover and traverses from closed full open- ing either direc- tion. 4 — > . if are cambered provide stability particularly the cover seal which rides the walls. important fac- tor fuel economy and even maintaining lasting effectiveness the furnace and the automatic fuel controls specially designed Amco seal type cover. This flat, refractory arch, moving ver- tically relation carriage which turn moves level notchless track. ganister seal engages the edge the cover. single master switch controls the movements the carriage and cover, synchronizes fuel, air supply, and draft, succession, avoid heavy heat losses during charging and discharging, thereby saving fuel. photo this seal- type cover shown Fig. Elimination Washing Complete retention the origi- nal scale formed upon the ingots during heating has always been the objective soaking pit opera- tion. However, overheating and melting has too frequently resulted “wash- ing” the destruction this scale some degree. regenerative pits this wash- ing was minimized means al- ternating the periods heating and soaking. This system though, often not conducive economi- good heating results and generally skillful manipulation the damp- ers experienced heater. spite this, due the impinge- ment flame, the ingots front the firing ports are usually washed. Washing results the WasTe GaAs / Section through Amco air flow recupera- tor. This design said increase the face per cent the same space ator and requires about per cent the weight. BELOW Cross-section Amco air flow re- cuperator showing flow gases down- ward through tubes, and air hor- ve izontally and up- ward around tubes, inside the recuperator structure There wasted space sides. (Right) Obsolete design usual re- cuperator wherein the waste gas en- ters ator through the side tively localize heat, and reverses direc- tion outside recu- perator proper. Parenra Penoing metallurgical reaction cipient fusion due the loss the protective scale coat. Incipient fusion best described the leaching intergranular deposits metallic compounds, metalloids, and alloying elements from the crystal aggregates com- posing the true surface the in- got. Because these elements have low fusion point, they are at- tacked the high temperature the flame when unprotected the iron-oxide scale. Now the results effected controlling the heating the ingot proving highly important. Washed points spots vary the structure and surface PREHEATEO Fk THE IRON AGE, December the ingot and result defects the finished product. Even small washed corner ingot will cover considerable area after final elongation the finishing mills. Another serious difficulty brought about washing the resultant high iron-bearing scale which de- posited upon the hearth. This de- posit fluxed the coke braize and exceedingly difficult keep out the checker chambers. reacts with the refractories the pit and shortens the life the lining. also forms slag which adheres the brick work. or- der remove this necessary take the pit out production and this results the loss great part the heat the brick- work together with effective heat- ing time. TABLE Fuel Requirements Soaking Pit Coal Equiva- Gas Used Steel B.t.u. Re- lent per per Gross Charged, Temperature quired per Gross Ton, Ton, Gross Tons Deg. Gross Ton Pounds Feet 185 Cold 1,555,000 140.5 1,495 1700 223,400 20.1 214 5,402 Hot and Cold 269,000 24.3 258 Natural gas figured 1040 B.t.u. per cu. ft. Coal 13,500 0.82 11,100 per lb. * The data given below were obtained from one full week continuous operation the pit, from May May inclusive. Temperature Steel Charged, B.t.u. Required Gas Used per Gross Ton, Coal Equivalent per Gross Ton, Deg. per Gross Ton Pounds Cubic Feet 1700 202,000 18.2 194 Cold Heats) 1,460,000 132.0 1,400 Control temperature 220 deg. (in waste gas estimated temperature pit 2450 deg.; preheated air temperature 1200 deg.; waste gas temperature bottom recuperator 700 deg.; and average time ingots pits hr. 50—THE IRON AGE, December 1936 ° ° ° 5—Placing the twelfth ingot into pit. Note the heat. condition the previously placed ° ° actual opera- tion the pit has proved that when firing continu- the entire cycle there washing the steel. Con- sequently all the dif- ficulties scribed inated. smal] amount slag forms the hearth, but this deposit, comparatively, very mild. week operation 37-ton pit produces only some 200 lb. cinder containing about per cent iron. This very loose and may removed with diffi- culty delay. Although the importance and possible benefits absolute and automatic temperature control within the soaking pit have long been understood, their achievement complicated reversing furnaces has been slow and many cases imperfect. large number cases ingot rolling temperatures are judged only the practiced eye the pit operator. view the fact that there narrow range rolling temperatures for various chemical analyses such method unquestionably crude and undependable. The Amco pit han- dles this problem with tempera- ture control system consisting thermocouples the four waste gas outlets wired parallel potentiometer controller which turn operates valve the fuel lines. The initial firing rate set the heater accordance with schedule set for the time the ingots have been the molds be- fore stripping. throttling range setting the controller selected which starts reduce the fuel flow prior the recording the _ | | the second ingot. Note the arcuate stabilized wall. thermocouples the control temperature which the soaking period begin. The controller then continues reduce the fuel during the soaking period until the steel com- pletely soaked, the thermal coming constant supply stack and radiation loss. The fuel flow meter thus records the comple- tion the soaking period show- ing the leveling off the rate fuel flow which has become con- stant. Thus achieved the vital uni- formity controlled automatic heating which important for and perfect rolling. This method eliminates any necessity for skill. does away with un- equal elongation and curling the steel the mill and the ac- companying grain structure vari- ation. The rollers are much better able adjust the screw-downs for each pass, and with each ingot requiring approximately the same screw-downs, mill efficiency im- mediately increased. There also further danger roll breakage cold ingot butts cause ex- pensive mill shut-downs. order provide continuous firing and high efficiency the pit was necessary devise methods automatic combustion and inter- nal pressure control. With these, atmosphere and scale control can secured, giving the pit complete adaptability all types steel ingots. orifice, for imparting mea- sure fuel flow diaphragm regulator, operating butterfly the intake line low pressure fan, provide combustion control. The low pressure fan provides posi- tive but variable flow and insures air supply through the recu- reaches the soaking period. Ex- perience has proved this highly desirable improvement perator for fast starting when the tiles are cool the beginning operations. The air flow mea- the fan inlet ahead the butterfly valve and indicated upon flow meter. Hand knob adjustments may made the air ratio regulator. steel heating. means controlling pres- sure two sampling tubes are placed opposite each other in. below the curb blocks the side walls the pit. These furnish static pressure impulses the diaphragm regulator which operates The ratio equipment automatically changes the flame from luminous clear the heating cycle terfly damper the stack means piston. The pit can (CONTINUED PAGE 130) TABLE Comparative Data Making Bottom During the week, May inclusive, the following comparative data bottom making between the Amco pit hole, ingots) and three holes old-style pits ingots per hole) were observed: Amco Pit Old-Style Pit Number bottoms replaced per Amount coke per bottom, 5,850 1,125 Amount coke per addition, 4,050 None Total coke required for ingots, 9,900 27,000 Amount cinder and slag removed, 6,484 13,800 Amount metallic bearing slag recovered, pounds........ 184 2,700 Metallic content recovered slag, per 22.33 Amount coke returned pits, 4,950 11,100 Time required for making bottoms, Time required for making one addition, minutes.......... Labor for making bottoms,.in THE IRON AGE, December p 3 x Riek | gee be 7 e a iw furnaces, nine soaking pits, and mill are among Inland Steel Co.’s new construction devel- opments which amplify steel ser- vice from its Indiana plant. Each 125-ton furnace thoroughly insulated and each unit equipped with central instru- ment and control panel whereby operating conditions are under ob- servation all times. The combi- nation oil and gas-fired soaking pits are closely controiled auto- matic instruments, the result being that combination with effective top sand seals air the building unusually clear. The new bloomer, which equipped with 43-in. 100-in. rolls, designed with electrically driven and con- trolled manipulators located front and behind the roll hous- ing. Extension the No. open hearth building (which formerly housed units) provides for the four open hearth furnaces and mixing pit which served standard gage track and Pugh mixers from which hot metal poured into ladles for distribution overhead cranes the fur- naces. The new units are constructed line with the old furnaces, and 80-ft. centers, condition necessi- tated adherence the previous building design. Bath depth in. and each hearth measures ft. wide ft. long, providing area 623 sq. ft., which lent 4.15 sq. ft. per ton steel produced. Furnace bottom supports are placed that section ft. both sides the tap hole de- pressed in., thereby affording de- sired depth bath, extra brick below the tap hole, and economy depth magnesite the ends. Chill boxes are shallow and truss design has given way girders with webs consisting plates separated spacers with openings for air cooling. The bottom con- sists first insulating brick and then successive layers fire-brick, chrome brick, chrome plastic, and magnesite. Roofs are formed 16-in. silica bricks except above the tap hole, where 22% in. bricks Nine circular soaking pits serve the new 46-in. slabbing mill. IRON AGE, December Insulation consists in. thermo flake coating overlaying in. thermo flake granules. Slabs cut and welded form buckstays which support the sides, ends and sloping backwall. Fire-brick paneled doors, designed with water cooled frames and mullions, are operated push button controls. Oil burners, which may raised and lowered, are in- serted water-cooled, welded- steel plate housing which located the center wall between the