The Iron Age 1936-12-17: Vol 138 Iss 25

¥ J ADVANTAGES Have you ever wished for sheet that would resist and corrosion, that could worked easily and without damage its rust-resisting surface, that, because the heat-resistance its surface, could used for stove and oven linings, that could inexpensively painted last? EPUBLIC you have need for such sheet, let ask another question: Have you ever considered the advantages STEEL Republic Galvannealed? Here true galvannealed sheet coated with molten zinc and heat-treated before the zinc Republic produces sheet for every has time cool, thus producing series iron-zinc alloys degree bon steel, copper-bearing steel, copper- integral with the base metal—a corrosion-resisting surface bearing iron, Toncan Copper Molyb- that will not flake crack even under severe bending. and Baduro Stsialess Republic Galvannealed easy work and weld—with- out material effect its resistance corrosion. Oven lin- —is ideal for stove and oven linings, illustrated the oil burner bake oven above. And takes and holds paint, enamel and lacquer without expensive preparation. purposes—a more economical, more satisfactory material— consider Republic Galvannealed. Write for full CLEVE! 2—THE IRON AGE, December 1936 THE IRON AGE, published every Thursday the CHILTON CO., (INC.), Chestnut 56th Sts., Philadelphia, Pa. Entered second November 1932, the Post Office Philadelphia under Act March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 138, No, » : EV ? R C O N S CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET Owned and Published CHILTON COMPANY NEW YORK, (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. A. MUSSELMAN, President FRITZ Executive Vice-President STEVENS, Vice-President JOSEPH EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer matte! FRITZ FRANK President VAN DEVENTER Editor Managing Editor 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 SANDERSON ASA JR. ALLISON Toronto, Ontario Birmingham St. Louis Buffalo Conten December 17, 1936 Power Transmission Relation Production.......... Concealed Corrosion Insulated Metal Rate Activity Capital Goods Copyright 1936 Chilton Company BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau of Circulations ADVERTISING STAFF Member Associated Business Papers Emerson Findley, 621 Union Bldg., B. L. Herman, Chilton Bidg., Chestnut & 56th Indexed the Industrial Arts Index. Sts., Philadelphia, Pa. Published every Hottenstein, 802 Otis Chicago tion Price: United States and Pos- Peirce Lewis, 7310 Woodward Ave., Detroit ada, $8.50, including duty; Foreign Ober, 239 39th New York $12.00 year. Single copy, cents. Robinson, 428 Park Bidg., Cable Address. ‘‘Ironage. N. Y."* D. C. Warren, P. O. Box $1, Hartford, Conn. + J | | 4 hy N No. toughest, most abusive service faze Bethlehem Omega Tool Steel. stands under heavy battering fully withstands frequently repeated, drastic impacts. This ability take punishment used hard find. That explains why users tool steel who try Omega for the rough-and-tumble jobs become enthusiastic about it. This steel the logical solution the problem what tool steel use when the going hard and the battering relentless. Omega was developed and perfected the laboratories and shops Bethlehem Steel Company. has truly outstanding physicals which make ideally suited wide variety applications where formidable combination high strength and great toughness required meet the conditions. Oil-quenching and suitable drawing give Bethlehem Omega Tool Steel these able physical properties: tensile strength 340, 000 Ibs. per sq. yield point 310,000 per sq. in; Rockwell—58 scale); Izod value—7 per sq. in. Drawing slightly higher temperature produces even greater toughness Izod value Ibs. per sq. in.— without materially affecting the tensile strength the steel. There are many jobs where Omega will speed work and save money. especially recommended for use pneumatic chisels, rivet sets and busters, beading tools, punches —for every type tool used heavy bat- tering service. \ | iat THE IRON AGE... DECEMBER 1936 ESTABLISHED 1855 Vol. 138, No. Observe the Oyster! the troubled ages, people faced with perplexing problems have been advised take council with Nature. Thus the admonition the great Teacher those his hearers who were worrying too much about material things: the lilies the field. They toil not, neither they spin, yet Solomon all his glory was not arrayed like one Surely the interpretation this not, some believe, that people should stop toiling and spinning, join nudist colonies and become grass eaters de- pend for food and clothing upon from higher quarters. Rather, the thought that should the best can from day day and then stop worrying about what may happen tomorrow. Then, too, there was the injunction Solomon the lazy man. said: the ant, thou sluggard; consider her ways and Very good advice, this, sluggards, for ants spite being completely organized not insist upon six-hour day. What comfort can find Nature for the perplexed shop executive, big boss straw boss who harassed and hampered the irritation labor troubles and whose sleep disturbed visions sit-down strikes, stand-up strikes, walkouts, picket lines and other unpleasant happenings? such men, Solomon might have said, the oyster! complacent, peaceful and untroubled oyster ever produced requires the stimulus irritation induce oyster make pearl. grain sand piece shell some other foreign substance gets into his whereupon proceeds coat it, self-defense, with those iridescent and diaphan- ous concentric layers shell which form pearl. Let hope that the present-day irritations which industry experiencing will eventually result producing pearls wisdom great price. Certainly there are enough foreign substances getting into the works. There another thought about oysters that may value management. this: oyster ever produced pearl keeping his mouth shut time when should have opened it. : 4 RANDOM EEL MAN STEEL making and the industry are now passing through most important phase development. Because the form manner this evolution, the significance the trend not usually appreciated first glance. The period 1890 1929 was production units large capacity, coupled with many mechanical de- vices designed reduce labor re- quirements offer relief from drudgery. the earlier stages this policy resulted displacing labor, both skilled and unskilled. Obviously such system causes shifts and readjustments em- ployment. the latter phase, be- cause labor saving machines rather than labor displacing ma- chines, the tendency the reverse the first phase, inasmuch new positions are created entirely new lines productivity. the operation such machinery labor found employment where employ- ment previously did not exist, 32—THE IRON AGE, December 1936 FRANK CROCKARD the same time services were per- formed that otherwise could not have been accomplished. change this development the steel any other industry since has been vitally important fac- tor contributing the expansion industry, the creation new forms goods and services, at- tended with decreasing costs which are later reflected decreased prices consumer interests. properly functioning industry must gate. The blind lame cannot expect remain the line through their participation the only effect that dragging down the general industrial level the operation obsolete ma- chines the retention outmod- policies involving substandard wage levels and the attendant de- creased purchasing power. History not gorged with recitals the brilliant accomplishments armies organized such disin- genuous basis. Speed progress those upon the clear highway industrial mass tonnage pro- duction, when directed those familiar with controllable ma- chine need not characterized “reckless driving.” and through more equitable adjustment these controls, speed not optional but mandatory. Having through mechanization sampled and enjoyed the benefits time savings, with relative extension useful life, with the amelioration and, the same token, increased money savings, with truly ample life, the urge for greater mechanization now ir- return any reces- sion less effective methods former periods sporadic resistance may retard, but cannot prevent forces progress. Indeed, greater emphasis essential reasonable prices are obtain, view the trend toward higher wages, shorter hours, and social provisions im- posing additional tax charges ac- a : | | | ] | : ] | ; ° ° ° | i ] | | | j : Lehigh University and Michigan College Mines, Mr. Crockard found first employment with the National Tube Co. Wheeling, Va. After serving five years superintendent blast furnaces, was appointed manager the Riverside Department. Upon the acquisition the Tennessee Coal, lron Railroad Co. the Moore Schley Syndicate, was elected vice-president and general manager that company with headquarters Birmingham. During his administration the Ensley plant was rebuilt, including blast furnaces, open hearth, and blooming and rail mill departments. number patented features were developed him which contributed greatly increased production decreased cost. The Ensley furnaces equipped with Crockard mechanical tops for the first time southern iron history produced over tons with their linings, while the fuel consumption was greatly reduced. The installation new duplex plant greatly decreased previous metallurgical losses occurring the former plant, while the time required for open-hearth heats was cut half. His experiments converting open-hearth mill scrap into bessemer iron for recarburiz- ing purposes was important metallurgical contribution the production southern open-hearth rails. Mr. Crockard organized department social science, activity accomplish- ing important results relating better housing, sanitation, and the general health and recreation provisions throughout the company communities. The well known Tennessee Coal, Railroad Co. hospital, through its excellent equipment and technical staff, provided most unusual medical and surgical service. The accomplishments this department received most favorable comment sociolo- gists. Later, after serving short engagement president, the Nova Scotia Steel Co., returned Alabama president the Woodward Iron whose extensive holdings high quality raw materials the district rank magnitude next those the United States Steel Corp. During his administra- tion the work rebuilding remodeling included coal and ore mines, blast furnaces and the by-product plant. result decreased fuel consumption following blast furnace remodeling, beehive ovens which supplemented the by-product coke plant were permanently retired from service. The development mechanical system ore mining enabled the company reduce its active Red Mountain ore operations from four two mines, both which are located company rails. FRANK CROCKARD companying the present methods social readjustment. Laying aside any consideration the great progress made power development represented boilers, turbines, generators, motors, their accessories, etc., one impressed the important changes occurring the manufac- turing methods. For example, the tube and pipe industry during the life the present generation has swung through three methods manufacture. For years lap and butt held sway, followed the seamless method and more recently the electric welding process, each requiring plant changes most radical char- acter, while the several methods for very different skills the part the mill operators. The electric furnace has virtually dis- placed the crucible, while the con- tinuous mills represent the most revolutionary and dramatic transi- tion from hand methods that the machine the rolling mill practice century. result decreased costs, improved quality and surface finish this increased tonnage will carry sheet production incredible heights through American ingenu- ity offering responding the demands occasioned greater uses the steel house, air condi- tioning equipment, additional trucks, automobiles, streamlined trains, household and office equip- ment and many other uses now laboratory development. The stag- gering charges obsolescence, replacement and commercial devel- opment incident this rapid transition need not elaborated. Rail Preeminence Unlikely The prospects continuing heavy production the rail mill group not especially encourag- ing. These mills with their very large investments and their heavy production formerly constituted very important item list total rolled products. Without substantial increase exports requirements based upon exten- sive national replacements calling for heavier sections, seems im- probable that rails will again re- gain their importance former years. The substitution the bus for the street car will also un- favorably affect the production the special type rails used this service. Obviously railroad extensions the United States have virtually ceased; thus future rail orders will made re- placement requirements almost ex- clusively. The higher quality rails now available result in- creased ingot discard, heavier sec- tions, modified chemistry including alloy additions and recently devel- oped heat treating procedures, all are factors contributing longer service period. result these improvements the old fail- ure “transverse fissure” now threatened with extinction. Expanding this general observa- tion, may noted that consumer demands call for more highly finished products. Finishing toler- ances are more restricted, requir- THE IRON AGE, December 1936—33 Distribution Production Finished Steel (Expressed Percentage Total Domestic Steel Production) Year 1922-1926 Rails Shapes Plates Pipe av. ... 9.0 11.0 12.0 10.5 6.5 17.0 12.5 11.5 eee 6.5 12.0 12.5 13.0 6.0 11.0 10.5 11.5 4.0 9.0 8.0 9.5 ee ee 2.5 6.5 7.0 9.5 5.5 8.0 7.5 10.0 3.0 6.5 7.0 8.0 Tin All Strip Wire Plate Bars Sheets Other 2.5 9.0 5.0 17.5 8.0 7.5 4.0 18.0 14.0 6.0 12.5 8.0 6.0 17.0 12.5 5.5 9.0 9.5 7.5 16.0 14.0 5.0 12.0 11.5 9.5 16.0 15.5 5.0 11.5 12.0 12.0 16.0 18.5 4.5 12.0 9.0 9.0 17.0 17.0 5.0 14.0 10.0 8.5 18.5 21.0 3.5 Particularly noticeable the very marked decrease the proportion rails and heavy shapes manufactured and the rather remarkable increase shown lighter such sheets, tin plate and strip. This transformation has occurred less than decade. thus very strikingly illustrating the very rapid swing market This shift has required very costly and extensive readjustments plant facilities. ing more accurate temperature control not only the heating furnaces, but also the progress the steel through the mill. highly encouraging and sig- nificant change the attitude the steel maker that which util- izes more fully the development methods based upon scientific approach. Not many years ago the making steel was more less secret art based trained eye and the practical ex- perience the operator. Today realized that slight variability operations cannot disregard- determining influence affect- ing the quality the finished product. The very complex re- actions steel making are affected many variables not all occult, but which when understood and chemical processes result more uniform product. During the early years the century the steel maker used ferro- manganese spiegeleisen his chief furnace ladle addition. Today the list includes, either metal alloys, two grades manganese, three grades spie- geleisen, three grades manganese and silicon alloys, aluminum and silicon least three forms, cobalt, copper, chromium, molyb- denum, nickel, titanium, tungsten, vanadium, zirconium, along with large group special deoxidizers with their several combinations. Freedom from formity character chemistry, physical properties, surface finish and size, and the meeting the diverse requirements modern shop processes which permits the realization split-second pro- duction schedules, are all desiderata which are increasingly mand. The greater appreciation the importance slag control with reference the composition and viscosity has led the systematic regulation furnace interchange closely adjusted basicity and FeO slag content within determined pattern. These controls together with proper alloy addi- Changes Processes and Production the United States (Data Gathered the American and Steel Institute) Basic Open Acid Open Total Alioy Year Hearth Hearth Bessemer Crucible Electric Other Gross 1880 100,851 1,074,262 7,558 1900 3,398,135 6,684,77 4,862 1910 14,858,353 608,153 9,854,437 107,671 50,821 25,154,087 1,013,913 1916 29,616,858 1,788,769 11,059,039 168,918 604 42,773,680 1,362,615 1920 31,375,323 72,265 3,535 42,132,934 1,660,292 1929 6,645 951,431 56,433,473 3,957,207 1930 34,268,316 780,856 5,035,459 2,253 612,599 40,699,483 2,317,183 1935 30,361,237 354,192 2,835,031 642 441,492 34,092,594 2,119,658 IRON AGE, December 1936 tions permit the retention defi- nite amounts iron oxide and iron nitride the steel. The grain size established permits within economic limits much more uni- form control hardenability, toughness and iron aging. Progress the arts based not only upon the development ideas, but also upon the dependable availability suitable materials cost permitting their commer- cial use. The discovery the Bessemer process 1855 was one the most significant events that century. superior material lower cost was made available for use the great physical de- velopment America the world large. Following this discovery came that the acid and basic open hearth. each instance product cheaper and superior iron was made avail- able for the uses man. The character these steels was de- termined largely their carbon content, ranging from the softest welding steel the high-carbon tool steels. With their low cost and great adaptability the world moved forward Gargantuan strides steel production and consumption, which movement the United States rapidly attained tion. The ever-pressing demand for steels possessing superior qualities, particularly under the stimuli World War requirements led the development many alloy steels now available. The term alloy steel just mentioned refers simple, binary, ternary, quater- nary, complex alloys which one more alloying elements other than carbon are present sufficient proportions modify substantially and prove its properties. This defini- tion would therefore include the pearlitic and stainless steels, the commercial importance which very great. does not include steels which the alloy alloys prevent minimize ills which the steel might possess were the alloy- ing element elements not pres- ent. the case the higher alloy steels which the strength may double triple that simple steels the matter heat treatment most important, since the superior properties are due not only the presence the alloy but also proper heat treatment, the means for which progressively ; q | \ | | : | | | ‘ | | | . i | | | improve, also methods working and welding. Alloys Open New Markets Fortunately the industry has re- cently learned the stances which astounding cor- rosion resistance, increased strength with decreased weight, may obtained the addition bessemer con- verter today may comparatively indifferent producer the steel. But its discovery 1855 was signally outstanding event that century. All credit the besse- mer process— turned out superior material more quickly and cheaply and thereby contributed greatly development world large. fractional percentages the al- loys reacting with oxygen and nitrogen. The adoption these alloy steels the many mill forms now available should reflected higher pay load ratio and in- creased life due corrosion re- when used for railroad, Street cars, trucks, water craft, roofing other purposes. Another important use alloy steels, nothing short revolution- ary, followed their adaptation tool steels. The more recent devel- opment the several types includ- ing the cemented tungsten carbide type, along with the growth con- sumer machine goods has required the redesigning machine tools with reference heavy duty fea- tures. The special service machines producing standard commodities decreased prices, permitting the development entirely new lines are now hastening greatly in- tensified “machine age,” which new era industrial activity through lowered costs existing commodities and the development new ones will contribute ever broadening social satisfactions. another example the coales- cence the requirements inven- tive genius made possible suitable commercially available material. well-known fact that surface hardness 1000 Brinell obtained nitriding certain steels. Such surface hard- ness coupled with ductile core will result growing use for any material possessing such qualities. has been found that some alloy steels also respond nitriding after their regular heat treatment. The importance this develop- Youngstown Sheet &€ Tube Co. ment tool and machine main- tenance apparent. Pearlitic alloy steels are in- teresting group due their typical characteristics and applications. These low-alloy steels offer certain qualities corrosion and oxida- tion resistance, high temperature, ity, varying with the chemical composition. The well known, are used applica- tions too severe for carbon steels THE IRON AGE, December 1936—35 1 | 7 » j but find favor for applications not sufficiently severe require the use the higher alloy stainless steels. The selection alloy steel course based upon considera- tion intended use; these factors may dynamic strength, corro- sion, abrasion, resistance rust, heat fatigue. These sev- eral requirements are encountered primary motors, oil refining and cracking. the chemical in- dustry they find use the manu- facture nitric acid, the manufacture pulp paper, where sodium sulphide dis- turbing factor, are acids the textile and dye industries. Again the chromium alloys serve most useful purpose furnace parts, rabble arms, glass molds, etc. their broadening development the artist will find new and growing field for the expression his talent, developing “eye appeal” not only the smaller products industry, but also larger fabrications and architectural work. The continuing improve- ment surface finish enamel- ing, etching, polishing coloring are further helpful aids meeting growing demands for beauty fabrication architecture. The transition from the ponderous and unattractive the light and streamlined, greater flexibility and portability one the dis- tinctive trends stylized period. Due their longer life the alloy steels will increasingly displace the carbon steels and also decrease the replacement tonnage characteriz- ing the use the latter steels. far this effective there will reduced demands for the basic raw materials—coal, coke, iron ore and carbon steel. against this trend there will uses found virtue their special qualities, and further ex- pansion the electro-metallurgi- cal industry occasioned addi- tional alloy requirements. these observations with reference alloy steels seem somewhat over amplified, the transgression per- missible because the profound social and economic influences re- sulting from their further develop- ment and application and their determinative influence upon the future trend the steel industry. For the convenience the read- the accompanying table lists data AGE, Vol. No. 52) which will assist show- 36—THE IRON AGE, December 1936 ing production trends the vari- ous steel products. From this table seen that the open hearth from its small tonnage 1900 led all other proc- cesses the record year 1929, which time produced 87.4 per cent the total output the country. Bessemer production reached its peak 1906 and has steadily declined tonnage and relative importance Electric steel, entering with normal production 1916, had 1935 not only continued its upward trend but relatively exceeded former rec- ords. Crucible melting, the meantime, had been virtually dis- placed, while the acid open hearth occupied further subordinate position. Regarding future tonnage trends, manifestly impossible main- tain such ratio increases those recorded the decades from 1880 1920. equally impossible extrapolate curve indicating future production, but that the rate amazing rate quite evident. Re- placement requirements have be- come more important compared with new uses. The expanding uses alloy steels will have further effect upon replacement. Self-containment policies other nations will result lowered ex- port opportunities. Modernization and the adoption American methods foreign nations without our high wage scales will re- flected the competition world markets. Japan, for example, formerly important outlet not only self-contained, but now seeks export commodities will further seek su- premacy their various competi- tive fields. These fundamental changes, gradually, but none the less pregnantly, now affect our in- ternal and external economies, the serious consideration which should find stirring incitement the formulation policies vast- different from those characteriz- ing the adolescence the industry. The forces motivating the indus- try have been the struggle for earnings, the pressure consumer requirements for materials meeting more stringent specifications and the contributions research work. addition these pressures are those intensely social nature. Social progress and the mechanisms economics have not kept pace with technological prog- eet ress, fact which maintains toric consistency. Today there every evidence that social progress will actively continue until part this lag has been taken up, Necessarily evolutional acter the general pattern will con- tain designs embracing higher wages, shorter hours, severance compensation, old age and unem- ployment insurance and other fea- tures entailing higher production costs. List Wasteful Processes axiomatic that any business enterprise which does not operate profit cannot indefinitely con- tinue operations, and its decline will prove most unprofitable field for capital and labor. The inter- ests both are dependent upon the value which added during the process conversion. Un- necessary costs any character are drag tending retard pre- vent consumption. Because these inescapable facts industry faced with the necessity intensifying efforts developing and installing labor saving equipment, improving processes and the reduction elimination waste any char- acter. such limited assess- ment, any consideration the problems power, engineering materials, personnel, sales and dis- tribution, while subjects great moment, are beyond the scope this theme. the steel industry these wastes may roughly grouped under the following headings, and since they are generic character their weighting will vary dif- ferent plants: (1) Waste Energy: Fuel and power. Stack temperatures. Sunday gas and power waste. Loss heat. Bessemer converter. Sensible heat slag. Sensible heat hot coke. Sensible heat molten iron. (2) Waste Material: Failure secure the greatest commercial value waste products, entirely neglect- ing the utilization those now lost. Failure utilize the most suit- able engineering materials operation, repair and main- tenance. Unsuitable refractories, which because character imperfec- tion unfitness require ‘ | | | | | | re | | | | wy | | | | | | 4 = frequent replacement, thus imposing heavy costs not only material and labor but also idle plant charges. Metallurgical progress now hindered refractory limita- tions. Waste abuse materials and tools through careless handling and failure make partial reclamation when possible. Wastes occasioned the use ENERAL search monopolistic function. not end within itself— for findings should promptly and ef- fectively publicized. palling inadequacy procedure regard- ing the international dissemination the results laboratory investigations. raw materials lacking proper beneficiation. Waste losses furnaces and (3) Waste Time: Due inefficient improperly maintained tools and shop equipment. Inadequate plan- ning. Due inaccurate unreliable information connection with operations involving tempera- ture and atmosphere control. metallurgical operations, such failure develop adopt more rapid and cheaper meth- ods. Finally, there the appalling inadequacy procedure regarding research and the dissemination its findings. Research its broad sense includes not only fundamen- tal scientific problems upon which the industry based, but also the closely related subjects comprising new uses, consumer problems, and sociological problems affecting those associated with the industry and the effects their impingement upon society general. Correlation Research Since research the only means which enlightened progress may made seems appropriate give first, only brief considera- tion. Research conducted number agencies the yearly ex- penditures which aggregate millions dollars. These several agencies are educational institu- tions, engineering societies, re- search foundations, State and Federal bureaus, which have been added, recent years, the laboratories many corporations. addition these organizations there are many older and highly important foreign groups, especial- England, France and Ger- many. Thus the subject broadens one international importance. While the publications these in- stitutions are available the orig- inal texts linguists who enjoy access specialized libraries, the iron and steel industry such has failed set instrumen- tality which continuous colloca- tion the various scientific pub- lications, either transactions technical press publications, could quickly and economically dissemi- nate through technical monthly other means the most recent information relating the various interested subdivisions industry. While true that much help- Lindberg Steel Treating Co. ful information, especially for those engaged research, now tions the Engineering Index Service, the American Institute Mining and Metallurgical En- gineers, Metals and Alloys, Chem- ical Abstracts, and others, the fact remains that the industry has not developed organ directly and specifically serving the require- ments those responsible for the technical progress such im- portant basic industry. The American Iron and Steel In- stitute the most representative organization the industry has since its inception published annual volume containing all the technical papers presented dur- ing the year. These papers are (CONCLUDED PAGE 45) THE IRON AGE, December 17, 1936—37 Ww 3 it- ENERAL objectives and method research were outlined the first article. this second part, Dr. Theisinger discusses the heat effect welding five plain carbon steels. For each steel gives the hardness values for the affected zones, the weld and the plate metal and, addition, describes and illustrates the microstruc- ture the affected plate metal adjacent the weld. Commercial interest the heat effect problem centers about the hardening the metal adjacent the weld. limiting hardness variation HAVING described the manner making the IRON AGE, Oct. 15, page 81], the results the hardness surveys and microscopic examina- tions the following steels will considered S.A.E. 1015 (0.17 per cent carbon) S.A.E. 1025 (0.25 per cent carbon) 38—THE IRON AGE, December 1936 part two between weld, hard zone and plate 100 points Vickers- Brinell suggested. this basis, table maximum welding speeds has been drawn up. formula for translating the latter into the minimum heat energy for each steel given and with this formula table mini- mum allowable heat energy has been calculated, per- mit the operator adjust the amperage, voltage and weld- ing speed reasonably as- sure holding the hardness variation carbon steels within the specified value 100 points. S.A.E. 1035 (0.33 per cent carbon) S.A.E. 1045 (0.44 per cent carbon) S.A.E. 1050 (0.53 per cent carbon) Five hot-rolled plates, in. in. in., were selected from each grade and “welded” depositing bead the top surfaces the plates. One specimen from each grade was welded each the following welding speeds inches Carbon Steels ° ° Welding and Metallurgical Engineer Lukens Steel Co., Coatesville, Pa. The specimens were X-rayed and section cut from each specimen point from in. from the center the crater. The section measured in. along the line the bead with cross-sectional di- mensions in. One face the cross-section was polished for microscopic examination the usual laboratory method and etched lightly with 1.0 per cent Nital reagent. The etchant was em- ployed reveal the heat-affected zones that the hardness survey would not fail pick out the sig- nificant points lying extreme- narrow area, since the greatest hardness occurs zone confined seldom more than 0.10 in. depth. Hardness Recorded Graphic Form The Vickers machine was used this research permits the locating im- pressions close 0.02 in. apart and even close together 0.01 in. very hard material. The hardness surveys were made ac- cordance with the plan illustrated 7 | | | | { | | | | | | | | 33 = | | | | | J | 3 ° ° | | 0.17 Hardness +——— + + Welding Speed, inches per minute Letts. « 4 8—S.A.E. 1015 (0.17 per cent Carbon) per cent Four, welding speed. Pearlite sorbite with decreasing grain size. the previous article. aver- age impressions and readings were made the cross-sections each specimen. The usual method reporting these figures was plot them the form graph and superimpose these curves the macrograph the welded specimen, as, for example, Fig. Such record supplies useful information for individual speci- mens, but when more than hun- dred specimens representing hun- dred different conditions welding plate composition are re- ported, the material becomes too bulky. Furthermore, fails present comparative can readily assimilated. or- der fulfill this need, the Vickers- Brinell hardness values are record- graphic form illustrated Fig. All hardness results are plotted against welding speed inches minute. The solid straight line in- dicates the hardness the unaf- fected plate material. The solid sloping line illustrates the changes hardness the hard zones re- sulting from variations welding speeds, and the broken line shows the representative hardness the weld metal. The method adopted arriving the figures used these curves will become clear referring the preceding macrographs Figs. graph, Fig. 11. For the welding speed in. minute, the hard- ness value which representative the major portion the weld, lines and 160 Vickers-Brin- ell. The five readings the hard- ened zone show average 176 and the unaffected plate metal IG. 7—S.A.E. 1015 (0.17 per cent Car- able welding speed based 100 points in. per min. WELD PLATE in. per min. 140. These figures are given below Vickers-Brinell hardness values: Weld 160 Zone 176 Plate 140 They may found referring Fig. for the welding speed in. minute. All the values for the remainder the specimens plotted this chart well the other illustrations given are ob- tained this manner. Plate Composition Powerful Variable the curves are studied, soon becomes evident that plate compo- sition, especially carbon content, powerful variable affecting the responsiveness the parent plate the welding conditions. When comparing the hardness the de- posited welds, must kept THE IRON AGE, December 1936—39 Sorte | | | | | } | | | | numa } } | Weld | x 7 300 Carbon Amperes Hardness | IG. 9—S.A.E. 1025 (0.25 per cent Car- bon). able welding speed based 100 points Brinell, in. per 1025 (0.25 per cent Carbon) per cent Nital. Four, 12, in. per min. welding Pearlite sorbite with decreasing grain size. mind that these beads were depos- ited bare arc and were thus subject the influence the ef- fects nitrogen and oxygen re- tained the molten metal its passage through the stream. The effect increasing welding speeds manifests itself increas- ing hardness both the weld and the hard zone for all steels report- herein. This statement con- fined general terms, since there are only slight differences hard- ness between specimens welded in. minute and those in. minute. the speed welding increased, amperage and voltage being constant, the cross-sectional area the deposited bead de- creases proportionately. This may Further, since the heat energy per length weld decreases with in- creasing welding speed, the heat 40—THE IRON AGE, December 17, 1936 gradient becomes steeper more localized and the cooling action the heated metal more intense, Plate Metal Acts Quenching Medium The plate metal acts quenching medium the weld and adjacent base metal dissipating the welding heat. Thus those steels which possess great hardening power should dealt with welding manner consistent with good heat-treating practices for that particular grade steel. For such steels, drastic quench- ing from temperatures excess the critical range produces high hardness values the treated plate. welding, the melt tempera- tures attained are far beyond those employed ordinary heat treat- ment and the rate cooling this deposited metal from liquid solid state and below the transformation points likewise surpasses the usual quenching rates. This may ob- served simply striking arc without any attempt laying bead. The globule, less than second, has passed from solid melt and returned solid state again. hand may placed before any heat the surrounding plate perceptible the touch. This might term the maxi- mum cooling rate or, for our pur- pose, our most rapid welding speed. Here the welding heat localized and confined very small area the plate metal adjacent the “weld.” If, the other hand, the electrode movement only down- ward maintain the are and feed the bath, the surrounding plate metal becomes heated the | | | | | | | | | | | | | i Plate j | ar ‘ Welding per minute | 4 w oS =) Carbon Amperes Hardness ¢ hy d > ~ i. a” « pe Welding per minute a 1035 (0.33 per cent Car- able welding speed based points Brinell, in. per min. PLATE 2 > 12—S.A.E. 1035 (0.33 per cent Carbon) per cent Nital. Four, 12, in. per min. welding speed. welding heat conducted farther and farther into the plate. When this large globule solidifies, and its adjacent plate metal “preheated” mold plate metal and the cooling rate less drastic than that described above. This puddled crater may call our slowest speed welding. Between these two conditions lies the range normal welding practice. Welding Speed Selection Influ- enced Carbon Content doubt there are many reasons for the selection particular speed welding, important one being the commercial objective; yet from metallurgical viewpoint the major factor influencing the selec- tion welding speeds would the hardening power the steel welded. The most common alloying Pearlite fine grained sorbite. element which contributes the hardening iron carbon. The result varying amounts car- bon steels shown the ac- companying charts and photomicro- graphs. The effect increasing carbon content the plate metal adjacent the weld and the weld metal it- self establishes this element the most influential variable dealt with welding. The hard- ness both the affected plate and the weld increases under all condi- tions the carbon content the base metal increased. This should and strictly ac- cordance with the principles metallurgical practices and heat treating. summarizing the data appear- ing these hardness charts, the content the plate in- creases, the welding speed should decreased the amperage in- creased. This suggestion concerned with the variations between the af- fected hardened zone and the as- rolled plate metal. the lower welding speeds, the hardness the weld drops below the plate hard- ness because low carbon base electrode was employed. However, safe assume that with the use suitable high-strength rod, the weld hardness would usually keep pace with the hardness the affected plate. While stress relieving will reduce the hardness the metal adjacent the weld, this beneficial treat- ment not and often cannot given many the welded struc- tures present. Being aware that such hardness values shown herein are present the welding these steels, seems reasonable THE IRON AGE, December | | | | | | | - | | | | WELD ag f fey > 0.44 Carbon 375 Amperes Vickers- Brinell Hardness 1045 (0.44 per cent bon). Maximum able welding speed based Brinell, in. per min. WELD PLATE 14—S.A.E. 1045 (0.44 per cent Carbon) per cent Nital. Four, 12, in. per min. welding speed. Pearlite through sorbite troostite with troostite containing patches martensite that some effort should expended keeping this effect minimum. Limiting Hardness Between Hard Zone and Plate The point which this study hopes bring light the suggestion some limiting hardness between weld, hard zone and plate, especial- between the latter two, that will have influence fixing the welding conditions for various car- bon and alloy steels. Certainly some line must drawn restrict- ing the variations hardness be- tween these areas beyond which considered unsafe practice trespass. 42—THE IRON AGE, December 1936 (see opinion what range hard- ness values should permitted. This choice must left the judgment the engineer until such time further research will produce the defining terms. For the sake comparison let select arbitrary figure 100 points Brin- ell, more explicit, where higher hardnesses are found, 100 points Vickers-Brinell the limit permissible variation. This vari- ation the difference the maxi- mum welding speed which shows greater differences than 100 points Vickers-Brinell between the unaf- fected plate, weld and hard zone. With the exception the high- speed welds the 0.17 per cent and 0.25 per cent carbon where the hardness the weld metal greater than that the hard zone and the lower speeds the higher carbons where the hardness the weld falls below that the unaffected plate, the real differ- ence hardness confined values lying between the hard zone and the unaffected plate metal. This fortunate for the compari- son made below because can discuss the variations hardness between the hard zone and the plate and, general, apply the data the field metallic arc welding je | | | | | ° Welding inches per minute | 4 500 Vickers- Brinell Hardness Oo 200 100 Welding Speed, inches per minute « xi + Fas a A 3 » 1050 (0.53 per cent Carbon) per cent Nital. Four, 12, in. per min. welding speed. Sorbite troostite and troostite with patches martensite (see long normal grade electrode employed for each type steel. Examples will included later show the result obtained with the use covered electrodes welded with bare wire electrodes. Maximum Welding Speeds 100 points Vickers-Brinell between hard zone, weld and plate, the max- imum welding speed for each grade steel given the following. welding speeds greater than the allowable welding speeds listed, the differences are more points. Maximum Allowable Grade Steel Speed S.A.E. 1015 per min. 1025 per min. S.A.E. 1035 in. per min. S.A.E. 1045 per min. S.A.E. 1050 per min. These welds were made 375 amperes and volts. Here have excellent example the superiority heat energy units (Joules) are welding speed, am- perage and voltage expressions welding conditions which pro- duce the hardness values shown the chart. Heat energy data Joules per inch may obtained the use the formula: Amperage Welding Speed Joules/in. this equation the above maxi- mum allowable welding speeds for each type plain carbon steel translated into the minimum heat energy for each steel. For values THE IRON AGE, December 1936—43 1050 (0.53 per cent Car- Maximum allow- able welding speed based 100 points Brinell, in. per min. | | | 7, T t + } + + + + t - - t + —— —+— -— rig | | | ce less than these listed, the difference hardness between hard zone, weld and plate will greater than 100 points Vickers-Brinell. Minimum Allowable Grade Steel Heat Energy 1015 28,750 Joule/in. S.A.E. 1025 28,750 Joule/in. S.A.E. 1035 31,360 Joule/in. S.A.E. 1045 39,800 Joule/in. S.A.E. 1050 57,500 Joule/in. With these figures, the operator may now adjust the amperage, voltage and welding speed keep within the requirements and reasonably sure holding the hardness variation carbon steels between hard zone, weld and plate within the specified value 100 points Vickers-Brinell. 100 points variation considered ex- cessive, then the allowable welding speeds must decreased the heat energy per unit weld in- creased. limit the hardness varia- tions over area less than the figure suggested above, the range welding variables restricted. This fact becomes more pronounced the alloy steels are studied where, for example, S.A.E. 4130 definitely superior S.A.E. 4150 allowing greater latitude welding conditions. mat- ter fact, points Brinell the permissible variation, the for- mer may welded in. min- ute, whereas the higher carbon grade practically eliminated re- gardless speed welding. Hardness Values and Microstructure Metal Adjacent Weld Returning the subject matter this part the research, take the hardness curves each the plain carbon steels this series. addition the hardness values for the affected zones, weld and plate metal, each the five welding speeds there also pho- tomicrograph opposite showing the microstructure the affected met- adjacent the weld. The photo- micrographs were taken over length 0.05 in. the specimen from within the weld, through fu- sion line and the hardened zone. The magnification 150 times the actual distance measured the specimen. All the illustrations were obtained the bottom the weld along line (Figs. 5). For example, Fig. the ex- treme top the photomicrograph for each the five specimens re- 44—THE IRON AGE, December 1936 veals portion the weld near the fusion line, the fusion line area appears just below this the up- per half each illustration, and the affected hardened plate met- adjacent the weld seen the lower half the views. may expected, the struc- ture the metal both the weld and plate takes the transition constituents type and nature depending upon the speed weld- The Several 1015—Hardness curves Fig. Photomicrographs Fig. per cent Nital This 0.17 per cent carbon steel falls the range structural steels 55,000 lb. per sq. in. tensile strength thickness under in. Heat treatment has little effect hardening this grade steel due its initially low hardening power. Thus would expect find little change hardness, regardless the cooling rate speed weld- ing. Such the case shown the hardness curves. The greatest difference between weld, hard zone and plate points Brinell in. minute. The photomicrographs reveal the lower portion the weld the top the illustrations, the fusion area just below the base the weld and the affected plate metal the lower half the views. The slow welding speed in. min- ute 375 amp. and volts results slow cooling the weld and af- fected plate. Here the large grains are indicative the cooling condi- tions well the high tempera- tures attained. The microstruc- ture any the welding speeds higher order than sorbite, and apparent that this con- stituent visible only the 18-in. specimen. the other specimens, the difference noted the decreasing grain size the weld- ing speed increased. 1025—Hardness curves Fig. Photomicrographs Fig. per cent Nital etch Although 0.25 per cent carbon steel slightly higher than the structural range carbon steels, ing; other words, conforming the rapidity the quenching ac- tion. Where large-grained pearlite appears, find low hardness the metal adjacent the weld. Likewise, will described un- der Certain Alloy Steels later, Vickers-Brinell hardness 642 indicative martensitic struc- ture and such was found, will shown the photomicrograph that specimen. Carbon Steels ing welded for many the higher tensile strength requirements. The cooling rate from above the critical range or, for our use, the speed welding, has more effect this than had the previous type steel. The greatest difference Brinell. interesting note that the variation hardness be- tween the three areas in. minute less than points Brin- ell. Some idea the grain size that can obtained from the slow ute. The tendency toward the for- mation sorbite more pro- nounced and much evidence the 18-in. specimen. S.A.E. 1035—Hardness Curves Fig. 11, Photomicro- graphs Fig. (150x—1.0 per cent Nital Etch) 0.33 per cent carbon ap- proach the upper limit the safe welding steels insofar harden- ing power concerned. When the several types steels are studied, will noticed that beyond 0.33 per cent carbon the hardness curves mount rapidly away from the base metal values (may seen Fig. 6). The photomicrographs not re- veal hardening constituent higher order than fine-grained Sor- bite shown the 18-in./min. speci- men. Certainly this grade steel can classified weldable type, least from metallurgical view- point. Practically, the welding charac- teristics this steel were the best any the plain carbon steels. This experience has with steadiness the arc, regardless | 7 | the welding speeds. Some steels required very careful adjustment electrode feed and are voltage control, and often each speed had tried again and again or- der obtain steady run through- out. But this 0.33 per cent carbon steel responded nicely any set- ting the welding speeds. There was much less trouble from this standpoint below 0.33 per cent car- bon than there was found the increased beyond this fig- ure. S.A.E. 1045—Hardness Curves Fig. 13, Photomicro- graphs Fig. (150x—1.0 Per Cent Nital etch) this steel found the first evidence the higher hardeniny constituents. Sorbite, troostite and troostite with patches marten- site are visible. Such structures are indicated the hardness values obtained, especially the faster welding speeds. Lowering Random Thoughts Steel Man (CONCLUDED FROM PAGE 37) presented leading experts the industry, frequently the expense much time and research the part the authors. date not single volume these proceed- ings goes further than listing the title and name the author. No