The Iron Age 1936-12-24: Vol 138 Iss 26

AND COMPANY HANNA BUILDING CLEVELAND, Pittsburgh Office, 1844 Oliver Building Chicago Office, 208 Street Eastern Representative: Rogers, Brown-Lavino Co. Boston New York EXCLUSIVE SALES SUPERIOR IRON ORE Washed Terminal Co DECEMBER 24, 1936 HINT DESIGNERS WHO WANT CUT WEIGHTS FORMED SECTIONS f With the development new high tensile steels resistance nickel-copper-molybdenum alloy steel— has come sudden and sensible trend the and the further reduction weight increase design transportation equipment toward strength made possible formed sections. Our lighter weights. Every pound that can eliminated engineering department will gladly assist you dead weight railroad car, locomotive, truck bus applying formed sections Republic Double Strength means extra pound pay load. also means reduced Steel your designs—or obtaining full value their fuel bills for empty partially loaded return trips— new designs. Write for full information. less wear equipment and tires. Designers have been quite successful reducing weight without sacrifice strength—but they seek means for further improving their designs. these men, suggest tee that they investigate formed sections Republic Double Strength Steel, few which are illustrated than twice that ordinary carbon steel; high weld- GENERAL OHIO ability; ductility and ease fabrication; the corrosion- ALLOY STEEL OHIO IRON AGE, December 24, 1936 THE IRON AGE, published every Thursday the CHILTON CO., (INC.), Chestnut 56th Philadelphia, Pa. second November 1932, the Post Office Philadelphia under Act March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 138, = At ay | ~ ‘ FRITZ FRANK President J. H. VAN DEVENTER Editor Cc. E. WRIGHT A. I. FINDLEY 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 CHESTNUT AND STREETS, PHILADELPHIA, PA. Hamburg, Germany Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. ALLISON WEST 39TH STREET NEW YORK, Roy TURNER St. Louis Buffalo Con December 24, 1936 Random Thoughts Idle Steel Man................ Washington News ................. Plant Expansion and Equipment Buying................. Owned and Published CHILTON COMPANY Copyright 1936 Chilton Company (Inc.) (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. BAUR, General Advertising Manager DIX, Manager Reader Service MUSSELMAN, President Member, Audit Bureau Circulations ADVERTISING STAFF FRITZ FRANK, Executive Vice-President Emerton Findley, 621 Union Cleveland Member Associated Business Papers FREDERIC Vice-President Herman, Chilton Chestnut 56th Sts.. Philadelphia, Pp, JOSEPH HILDRETH, Hottenstein, 802 Otis Chicago GEORGE GRIFFITHS, Published every Thursday. Leonard, 239 St., New York tion Price: United States and Peirce Lewis, Detroit ada, $8.50, including duty; Foreign 289 30th New York WILLIAM BARBER, Treasurer Cable Address, ‘‘Ironage, Warren, Box 81, Hartford, Conn. JOHN BLAIR MOFFETT, Secretary x | Ag fad * tter 9 26. FAR THE EYE STEEL ALL SHAPES, SIZES AND KINDS READY FOR IMMEDIATE SHIPMENT Here steel that you can depend maintain your production schedules —thousands and thousands tons ready use. You can draw these stocks with full assurance that the exact grade steel, the right size and finish will shipped once. There are ten Ryerson plants strategically located for quick delivery throughout the principal industrial areas. When you need steel, draw the one nearest you. you not have the current Ryerson Stock List, will glad send it. Joseph Ryerson Son, Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Buffalo, Boston, Philadelphia, Jersey City IRON AGE, December 24, 1936 Ryerson Stocks Include: Beams and Heavy Structurals Channels, Angles, Tees and Zees Rails, Splices, Spikes, Bolts, Etc. Plates—Sheets Strip Steel, Flat Wire, Etc. Stainless Steel Hot Rolled Bars—Bands and Hoops Cold Finished Shafting and Screw Stock Extra Wide Cold Finished Flats Alloy Steels Heat Treated Alloy Steel Bars Boiler Tubes and Fittings Welding Rod—Mechanical Tubing Rivets, Bolts, Nuts, Washers, Etc. Reinforcing Bars Babbitt Metal and Solder Gr | Me, ... THE IRON AGE... DECEMBER 24, 1936 ESTABLISHED 1855 Vol. 138, No. The Age Chivalry said that there nothing new under the sun, but some people doubt the truth that statement. While admitting that strikes are old the hills, they say that the "sit down certainly new development. The sit down strike first came into prominence during altercation, not many months ago, between the workers the vulcanizing department the Goodyear Tire Rubber Co. and its management. Instead going out the street and form- ing picket lines keep workers from getting into the plant, the strikers adopted the simpler expedient sitting down the mechines and staying there. Not long afterward, the French, who are great admirers American ingenuity, adopted this plan for their general strike. was found quite effective and the factor novelty furnished the which said in- valuable part military strategy. French industrial executives had had plenty expe- rience dealing with the more vociferous labor controversies which cobblestoned streets acted ammunition dumps for embattled workers. They did not know how pretty hard decide just what when people report for work and then just sit down and don't it. The German workers found that out some time ago. Ger- many strikes are illegal under Hitler, but the workers that country have gotten around through the practice Arbeit klebt they call it, motion" production. American management handling the sit down situation rather skillfully. one recent instance, steam was obligingly kept the management during sit down strike that the strikers would comfortable and not catch cold. several cases recently, matrons chaperons have been provided that breath scandal should attach the feminine element during more less prolonged absence from domestic fire- sides. must have strikes, perhaps the sit down method good any. does not result broken heads windows, nor does involve the recruiting flying squadrons, either pickets strike breakers. After all, workers have grievance against the boss, better take out sitting down than take him the nearest river and drown him, told the ancient Chinese the Hours Kai id re : Aw tie # get | e* a) ~ BLAST furnace such the one opposite, does excel- lent job transmutation—for comparatively useless red earth emerges molten stream marketable metal. Nevertheless, whether the furnace this older type casting into sand more modern unit with auxiliary strands molds, much improve- ment possible. Perhaps the shape could altered advan- tage, double bell should employed the efficiency might mount through the use sized material the charge. Photo Barrow Haematite Steel Co., Ltd. ° ° ° FRANK CROCKARD ° LAST week the author sketched the technolo- gical changes the making steel this country, and, also, the accompany- ing changes the types prod- ucts produced and the influence these products had consuming industries. The need more sults international research was mentioned, and number waste- ful procedures incident making steel today were listed. this, the second and last sec- tion Mr. Crockard’s paper, number practices are detailed and discussed, each which could ° ° conceivably cheapen and simplify operations the steel mill the future. Specific items which the opin- ion the writer would contribute further economies the cheaper production iron and steel fol- low. Some these could made effective once, while others will require considerable research. Coke: Utilization the heat now wasted coke discharged from ovens. Use superior coke se- cured lower ash and sul- phur content, result coal washing. The ammonia coke oven gas form other than ammonia sulphate. Oven insulation. Reduction the sulphur RANDOM THOUGHTS content coke during cok- ing post coking opera- tion. Blast Furnace: Adoption more satis- factory method stock dis- tribution the furnace after leaving the main bell. General application the isolated practice stock charges composed sized ore, stone, and coke. Reduction flue dust. Higher stove temperature. Dry blast. Adoption the largest type blast furnace plants which can profitably without loss flexibility. Blooming Mill: Partial displacement the blooming mill result THE IRON AGE, December 24, 4 : ; - Pe - Pa the development extru- sion process. Open Hearth: Development technique affording much more rapid reactions. Bessemer: Greater attention the in- creased production besse- mer alloy steels, and the further use the converter indicated hereafter. The underlying thought con- nection with these suggestions based upon the assumptions that existing tonnage capacity ex- cess requirements; that the era cost reduction through increased production longer offers the possibilities past decades; that quality phys- ical requirements increasingly exacting; vice represented delivery and helpful technical cooperation with the fabricator highly desirable; that greater attention directed the development more pre- cisely controlled operations, result- ing time, energy material savings offer attractive ities cost reduction which finished products increasingly superior character may prof- itably offered prices greater, less than those present standards. such approaches clear that considerations relating the attainment these objectives must also embrace interests prece- dent and subsequent that the immediate function. For example, improvements the blast furnace resulting the production pig iron more uniform quality either with reference chemical physical character may may not show saving the furnace, yet the advantages flowing from the use iron more uniform temperature and chemical composi- tion including very low sulphur content, could very easily result savings great importance the ingot rolling mill. While high sulphur can cooked out the open hearth, the process slow and costly because slag metal surface contact only. There specific item the cost sheet indicating the excessive cost due not only the use additional materials, wear bottoms, roofs and ports but also the longer shop time required and the disturbing 20—THE IRON AGE, December 24, 1936 effects such variable furnace practice. These basic facts are recognized those directly en- gaged with production problems, but their correction not always within their control. Within this field are many fascinating prob- lems which the pursuit and con- trol the molecule will prove profitable and glamorous were nage. One reads and hears much the establishment ultimate boundaries all kinds, the pass- ing pioneer days and the lack further opportunities, etc., that that the iron and steel industry are just “beginning com- mence.” Blast Furnace Dimensions For clarification purposes some the generalizations listed are de- serving further expansion. the case the blast furnace required about years move from 14-ft. hearth one ft. Another movement 1924 presented the 22-ft. hearth, which again expanded 28.5 ft. 1930. The ultimate diameter still un- determined. With this great hearth expansion there proportionate increase stock line, the disadvantages which were twofold: The stock volume the upper stack sections was decreased with relation greater hearth activity and did not give sufficient time for the most eco- nomical preparation the ore, while the greatly increased gas volumes passing through rela- tively constricted outlet, resulted higher gas velocities with the accompanying increased flue dust losses. There was hesitancy chang- ing the almost standardized clear- periphery and stock line inwalls. would greatly affect the distribution coarse and fine with reference the furnace walls and the center stock column. The dust losses reached 350 Ib. per ton iron and some instances were higher. This ejected material had handled and recovered. The sintering plant through negative action improved the economic phase. Sintering plants call capital expenditure, and continued costs operation. The facts the case are that the cone and hopper with smaller furnaces performed not only excellent gas seal, but toler- | i ts able stock distributor. Today the case large furnace with properly proportioned stock line functions gas seal only, and its continued use the present tolerable. interesting feature connection with this statement that every furnace man recog- nizes the condition and also knows modifications which mechan- ically worked satisfactorily the earlier furnaces the Lehigh Valley exemplified the Bau- man, Durham types and the sug- gested Witherbee modifications. Nevertheless, the writer knows case which anything be- ing done correct most defec- tive piece apparatus. the absence any other form charging mechanism the bell will have enlarged the size necessary restore the relation- ship previously followed, while smaller concentric bell, sealing within the larger one will dis- tribute stock within smaller anulus. The excessive weight such bell could minimized the use radially ribbed castings which plate inserts filled the segmental sections. Bells not made plant shops would have split for transportation. Such product coke oven not ment. dry quenching the plant could develop con- siderable power and the furnace operator could save heat use the improved coke. Furthermore, plants often could use more in- sulation siderable advan- tage, and the con- sistent use dryed and de-dusted coal might result able monetary sav- ings. bell will enable the operator re- store the older and preferable dis- tribution the walls and vastly improve the uniformity the mix- ture across the throat section re- sulting from decreased segrega- tion, which less channeled, slower and more uniform gas flow should, increased time action the gases, effect decreases fuel consumption. Since the lifting effect gas upon particles gas stream assumed vary the square the velocity the gases, the ef- fect the larger bell with refer- ence dust abatement flue dust cumulative, first result the permissible larger throat and second because decreased gas production following decreased fuel consumption. outer skirt section between the bell and fur- nace walls will assist reducing throat abrasion, and also reduce dust carry-over preventing the off-going gases blowing through the entire depth the falling curtain ore drops from the main bell. Not all dust composed iron ore; limestone and coke dust are also carried over, the latter frequently excess sintering requirements. These wastes could, course, greatly reduced more careful prepara- tion the stone the quarry, care being taken remove all clay and small particles stone. The fine coke wastes are largely self imposed, most which can re- moved the quenching station, subject which will given fuller attention under coke wastes. Final- ly, with the adoption the venturi top which gas velocities are further reduced and the gas re- moved through high outlets proper disposition and generous dimensions, shall have the nec- essary elements greatly decreased material wastes. Closely related these factors are the advantages obtained charging sized material including ores (which not readily de- crepitate break down), coke and stone. The comparatively few isolated cases where this practice has been adopted have reflected its advantages, more particularly with reference reduced fuel con- sumption coke waste, occasioned doubt the more uniform gas solid contact resulting from this practice. the redesign fur- nace made necessary the modifi- cations indicated, would desirable give consideration the mobility the furnace charg- ing aparatus above the floor the furnace top without dismembering it. The plan followed the Ensley furnaces greatly reduced the time and effort required changing bells. Other methods will sug- gested further study the subject. Because the largely in- creased investment temporarily rendered idle, time waste bell changes factor importance. Blast-Furnace Hearth Modifications the upper sec- tion the blast furnace have re- ceived much attention, hearth has been greatly expanded diameter, but the writer not aware any attempt greatly increase its depth. The hearth serves other important functions than that mere receiver per- mitting the separation iron and slag. Repeated oxidation and re- duction very intensive char- acter the part the alkali metals existing the gaseous state below the tuyere level and above the slag line probably play im- portant role transferring oxy- gen carried down the super- heated liquids their way the liquid pool. deeper hearth af- THE IRON AGE, December 24, 4 WN ° ° ° = covering these reactions may con- ceivably result further oxygen transfer from the slightly oxidized materials their way down. Since sulphur removal and its final reactions are also not definitely known equally conceivable that further desulphurization might result affording the slag increased reaction period while trickling down longer path. probable that the loss sensible heat molten iron could reduced the insulation the hot metal mixer, where sulating material could readily applied. addition the utilization slag, cement base, concrete aggregate and mineral wool, ex- periments the Alabama Poly- technic Institute Auburn, Ala., indicate the possibilities its use the manufacture glass. Furthermore, German experi- ments which finely ground limey slags were used was found “that slag not only effects the same in- crease some soils but often sur- passes the effect limestone manure. Like limestone the slag acts efficient neutralization agent combating the turning sour the soil, although its effects take somewhat slower course. The slag particularly suited for improving the physical properties the lighter soils. The specific effect the slag depends its high content highly assimilable silica which increases the resis- tance plants attacks para- sites.” many instances blast furnaces are located near centers dense population. The demand for concrete aggregate track bal- last such areas requires very large tonnages. much greater percentage these requirements could derived from blast fur- nace slag, maintaining suit- able magnesia content the slag, and pouring manner pro- moting greater density the solid- ified slag. Pits suitably arranged for such purposes offer additional advantages, because decreased costs track and maintenance. The continued operation many stoves now use results several forms waste readily preventable. Due the avail- ability washed gas, improvement checker design, insulation and automatically controlled regulation 22—THE IRON AGE, December 24, 1936 crease existing efficiencies and per cent and per cent, accompanied the devel- opment much higher blast tem- peratures. probable that even higher temperatures now regarded top figures will available the development more suitable top checker refrac- tories capable resisting the at- tack the fine dry dust composed alkaline salts accumulating and softening the top course. far these objectives are real- ized additional surplus gas will available for other than stove use and higher blast temperatures will increase hearth Following the train which will found reductions fuel and flux requirements, decreased sul- phur and phosphorous the pig iron, lower blast volume, which decreasing off-going gas velocities will further decrease flue dust losses. Higher stove temperatures would permit the use more basic slags, which while tending increase fuel consumption, would also greatly increase the total potash volatilized car- bonates from the charge thus mak- ing more attractive the recovery potash blast furnace by- product. Use Dry Blast the case the easily visual- ized materials entering the blast furnace effort made main- tain uniform composition the ore, coke and stone. the case air which constitutes far the greatest tonnage charged, variations ranging from per cent 100 per cent are not unusual. fur- nace producing 600 tons iron daily with blast consumption 40,000 cu. ft. deg. and lb. absolute requires about 2400 tons air daily. For each grain moisture content per cu. ft. the furnace hearth would receive about gal. water each hr. While true that the water vapor enters stove temperature, the breaking down the water H,O gram calories. The hydrogen and oxygen again reunite another and cooler part the furnace re- turning the same amount heat, but unfortunately this does not compensate for the heat removed from the smelting zone where most needed. limiting these variations within narrow ranges great uniformity, Gayley his classic demonstration Isabella eliminated lb. water per ton iron produced 23,192 lb. for hr. Pig iron production creased about per cent, flue dust decreased from per cent. Fuel dropped from 2147 lb. 1726 saving 421 lb. coke per ton iron. The fuel reduction was excess the theoretical saving which could expected from moisture elimination; this was accounted for the development heat the tuyeres where heat was needed, cent all the heat required smelt the iron and slag. The extra heat represented only per cent the total energy coke charged, yet represented per cent the heat available the tuyeres, since only per cent the fuel any case available for smelting the tuyere region. Be- cause the margin safety thus secured the burden ratio could reduced constant factor, which not only resulted lowered fuel consumption with phur content the iron, but also much smoother working furnace, since the incipient development continuous sloughing was prevented the stabilization the zone fusion. The increased thermal efficiency the furnace was reflected de- crease per cent and increase per cent CO, content the top gases. Almost concurrently with this development came also that the gas engine for driving blowing engines and generators. Because fuel sav- ing possibilities this direction, the blast furnace has been run gas producer, rather than strict- heat engine for reduction purposes only. this shift practice the furnace manager was deprived the use tool which gave that precision fur- nace operation resulting su- perior product great uniformity, permitting the development practices subsequent metallurgi- cal operations which would inestimable value. Oxygen Enriched Blast Much discussion the suggested use oxygen, oxygen-enriched blast. The gen above the normal content would again greatly increase heat potential the hearth, resulting 4 | | | | | | | ‘ | | | | decreased fuel consumption, de- creased blast and stove require- ments. While the cost gaseous oxygen has been steadily decreas- ing, the current cost production remains prohibitive. possible that occasional and limited use tance preventing impending furnace dyspepsia from de- into one acute indiges- tion. The regular use enriched blast result increase carbon dioxide and decrease carbon monoxide the top gases, seriously affecting the heat value this very impor- tant fuel, which terms coal HIS mill ing continuous steel strip from molten metal. The problem such vast economical im- portance seems worth rating major project re- search. plete solution would greatly reduce the production costs light plates, skelp, sheets which themselves represent very im- portant percentage total rolled prod- ucts. equivalent, depending upon the fur- nace, may range from 250 tons 450 tons coal per day. For this and other reasons would seem that the place for the greatest economic advantages following the use enriched blast would the Bessemer converter and not the blast furnace. Coke Oven Wastes outstanding coke oven waste that the sensible heat the coke, uselessly dissipated water quenching. the use dry practice generate about 1000 steam per net ton coke cooled. With output 1000 tons coke per day there would sufficient steam continuously generated produce about 3400 kw. per hr., assuming condens- ing turbine consumption lb. per kw. That energy now most- used producing free steam and dust which effectively pollute the atmosphere and corrode plant structures. dry quenching the coke being free water shock stronger, producing less fracturing coke and reducing the breeze production. The latter recovered the dry state has thermal value about per cent greater than the usual wet breeze. The Witkowitzer plant using dry quenched coke showed furnace fuel reduction over per cent, while that Homécourt showed slightly over per cent. Reduced fuel consumption carries with the probability further sulphur reduction the pig iron well flux savings. Screening the coke effected the dry state affording more complete removal coke dust and breeze, which later reflected decreased flue dust losses the furnace, while the recovered breeze effectively used fuel. The use dry quenched coke affords more accu- rate production yield records the coke plant, permits uni- form (weight) charges carbon the furnace, and, because its freedom from moisture, requires less water for the condensation steam the gas washers. These are factors affecting greater pre- creased water requirements, the latter being form water waste prevention. the South most coking coals are dirty that beneficiation necessary before coking. the northern fields this requirement not rigidly mandatory. Ap- preciating the fuel and flux wastes incident the use unprepared coal, there has been increased tendency wash those coals which were previously coked the raw state. The results derived from washing coal for coking purposes, ical and Metallurgical Engineer, 1933, 470) are: (1) Ash and sulphur reduc- tion the coke produced. (2) per cent im- provement physical qual- ities determined tum- bler tests. (3) Decreased yield small sizes coke with corre- sponding increase metal- lurgical coke. (4) per cent reduction hydrogen sulphide coke oven gas. (5) yields by- products the increased percentage volatile matter the coal. (CONTINUED PAGE 60) THE IRON AGE, December 24, 1936—23 3 % q 4 4 : this the first two- section article, the author introduces his review all known aluminum alloys. together, the alloys are grouped into classifica- tions, covering all analyses used here and abroad. This first section the article covers these alloys, in- cluding binary alloys such the more common aluminum- properly present the metallurgical situ- ation the field aluminum alloys, advisable first give brief pic- ture the general requirements which any alloy must satisfy prove high value, and, second, give the fundamental structural features that form prerequisite for meeting such re- quirements. The most important characteris- tics required make alloy highly useful are: considerably higher strength than possessed the basic metal. 24—THE IRON AGE, December 24, 1936 ALLOYS zinc, aluminum-copper, alum- inum-magnesium, aluminum- manganese and aluminum-sil- icon alloys, all which are plain non-heat-treated. Next week the author will de- scribe the other alloy classifications, and, con- clusion, will point out that only foundry and wrought alloys are really required. high elasticity limit and yield point sufficiently dis- tant from the ultimate ten- sile strength. considerable ductility insure good workability the alloy during pressing and drawing—at least within certain conveniently main- tainable range tempera- tures. good resistance cor- rosion, especially atmos- pheric, fresh water and sea water corrosion. number other conditions might mentioned, but they all are secondary nature and ° ° CORSON Consulting Metallurgist, New York ° must considered in_ specific cases only. All these requirements can expected met one struc- tural case only, namely: The alloy composition should type that represents nearly uniform solid solution the added ele- ments the basic one, least within some range temperature. This rule most universal nature. applies all steels, all high-strength bronzes and brasses, etc. True enough, there are excep- tions and these are sometimes great industrial importance. ever, the fact that such excep- tional compositions never represent approximation solid solu- tion plays strictly negative part. These exceptional alloys are ac- cepted not because they are in- capable ever forming solid solu- tions but spite this fact. Cast iron, both chilled, one such instance alloy that never does form solid solution. For this reason pos- sesses comparatively low strength and ductility whatso- ever. used merely because easy make and very, very inexpensive. Another instance excep- tion from the rule may pre- sented the case copper-high lead and copper-tin high-lead al- loys. These two can never form even approximation solid solution. Consequently, their ten- sile strength lower than that copper, their elastic tremely low and their ductility most inferior. And, due these negative characteristics, copper- lead alloys are used only few particular applications. tain types bearings their high plasticity (due the high lead content) highly useful that the low strength and low ductility inherent them must left out consideration. With this first rule structural fitness expounded, one more ques- tion might asked: Shall the alloy represent permanent solid decomposition two more con- stituents? Unfortunately, one- way answer possible. From the view easy manu- facturing the first situation the first clamshell dredge utilize aluminum boom construction. most desirable. make hard product mere cold working and anneal represents the ultimate low cost. However, the hardness and strength obtainable are limited, while other characteris- tics, particularly conductivity for heat and electricity, are quite low both the cold-worked and the soft-annealed state. The capacity change from solid solution mixture two three phases, one more these being dispersed through the matrix the major phase (com- posed mostly the basic metal) cases. permits the obtaining strengths nesses and elastic limits consider- ably above the values obtainable cold work alone, and allows raising considerably the alloy’s specific electrical and thermal con- ductivities. the other hand, requires careful work, special ap- paratus and most certainly entails loss time. Hence the aver- age manufacturer prefers not use such alloys, unless their use absolutely necessary. Coming now the subject aluminum alloys, necessary face the question how prolific aluminum may its form solid solutions, and, further, which them are the permanent and which the alterable type. And this point the first dis- appointment met. Aluminum The outer ft. this boom built strong aluminum alloy structural shapes and plates which permitted the operator, Sternberg Dredging Co., use dipper per cent larger capacity than would have been possible with conventional boom the same length. Aluminum Co. America photo. THE IRON AGE, December 24, 1936—25 4 does not form many solid solu- tions iron, nickel, copper, gold and even silver are able form. Aluminum somewhat more ver- satile this direction than mag- nesium, considerably more than but still this versatility aluminum rather limited. There are only few elements which are taken into solid solution aluminum any larger extent. For copper, magnesium, zinc and lithium the solubilities high and low temperatures have been estab- lished with great deal pre- cision. Then again, consider manga- nese, chromium and silicon for which the solubilities are small and none too precisely established. This statement made view the fact that the ranges solu- bility were determined for these series one method only (micro- examination sections) and they should corroborated other, well accessible means. And further again, consider silver and tin, both which are definitely soluble solid alumi- num but are incapable produc- ing strong alloys, and, further- more, are decidedly deleterious corrosion resistance. Apart from the elements just mentioned, others form solid solutions aluminum beyond 0.05 per cent, though the present au- thor would persist his suspi- cion that larger extent solubility must exist From the solubility sented the accompanying table, evident that, with the excep- tion magnesium and zinc, all other elements just mentioned are soluble aluminum rather moderate degree. the solubility dissolved atoms per 100 atoms solution solubility figures would have become considerably smaller. Copper which has maxi- mum solubility near per cent weight actually soluble 2.7 atomic per cent only. com- parison it, the maximum solu- bility beryllium copper (2.7 per cent weight) amounts fully atomic per cent. would quite logical, therefore, the alloyed atoms, when fully dis- persed among aluminum atoms the latter’s grains, were pro- duce comparatively slight im- provement its mechanical char- acteristics. And this actually the case. 26—THE IRON AGE, December 24, 1936 far binary aluminum alloys can kept the state per- fect solid solutions, the effect re- mains comparatively small. being the second most soluble element, whether weight atomic percentage, naturally exerts the largest hardening in- fluence even while the fully dispersed state. Also, because num-zine alloys—mostly ing not over per cent zine per cent was the standard many)—were widely used and probably are still used small extent, with the exception France. However, number material defects accompanied the advantages mentioned. rule, aluminum does not exert strong the right aluminum alloy piston with abrasion-resisting surface formed the Alumilite process. This type piston was adopted many leading automobile manufacturers for 1936 models. the left untreated aluminum alloy piston. can kept solid solution with- out much difficulty (by quenching even air cooling from the proper temperature) does not too strongly affect the ductility aluminum with zine with not over per cent the latter (by weight) form the strongest and most ductile alloys the basis nearly permanent solid solu- tion. There are other reasons why alloys might have represented one the most im- portant structural the field aluminum alloys. They are most easy obtain sound, that is, sufficiently gas- free state. They take good pol- ish. They are most easy make merely dissolving melting zinc molten aluminum. Alloys These were the reasons why the continent Europe, alumi- corrosion protective action upon elements alloyed it. For this reason alloys containing large amounts zinc are not immune even tap water, say nothing about sea-water spray. Further- more, alloys have their atoms mobile such extent that cold-worked articles are apt self anneal room temperatures; heating deg. robs them large extent the strength and hardness induced cold work. French manufac- turers found out these defects expense after small coins this alloy used the colonies deteri- orated thoroughly. the light the result just mentioned, aluminum-zinc alloys must considered have little importance the field indus- trial metallic materials. However, they can and should used for castings wherever conditions service permit. These alloys will | 4 designated No. the list article. They deserve this position least from the historical view- point. There belief that the sec- ond historically used alloy aluminum was binary aluminum- nickel alloy carrying per cent the latter and used mainly for castings. Perhaps this belief cor- responds historical facts, al- though authentic data regarding the use such alloys and their characteristics are sadly lacking. But, may, such alloys were quite early aluminum-copper alloys—one which, with per cent copper, from the use alloys which are not and could not represent solid solutions. While they contain only about per cent more copper they may into solid solution, and while they may not contain more than per cent weight per cent volume the hard and brittle compound their characteristics are very much lower than might expected. should quite warranted look for some 30,000 lb. per sq. in. ultimate strength and elongation 10, perhaps per cent. Instead this, rarely possible get 21,000 per sq. in. strength and not over per cent elongation. The cast alloy contains far too SS i the Toledo Plaskon scale, some aluminum parts the form sand cast- ings, die castings and sheet help keep the weight the scale minimum. The price chart, made from sheet aluminum, contains over 95,000 figures. Since will not wrinkle swell, the price indicator can placed close the chart, thereby eliminating inaccuracies caused parallax. Aluminum Co. America photo. remained the standard aluminum foundry composition for many years and known alloy No. the United States and the “American” alloy Europe. this article, will listed alloy No. This aluminum-copper alloy striking example forthe rule that particular improvement may come much the compound along the boundaries its grains (as cast) possess any substantial amount ductility. addition, rarely, ever, quite sound because gas inclusions. Never- theless, was and still one the most common alloys the aluminum foundry. Doubtless there must reasons why this per cent Cu-Al alloy used preference alloys lower higher copper. Per- haps alloys the first type might too soft and deformable, but this subject has not yet been thor- oughly investigated. Higher copper aluminum alloys are also used, namely, those with and per cent copper. These two analyses will designated alloys Nos. and herein. They may carry fancy names—like “pis- ton alloy”, but this does not mean all that one another particularly suitable for pistons the like. Comparative tests were evidently never made least never reported. Lower alloys (as copper con- tent) were used extent the rolled state. Made carelessly they not represent solid solu- tion, but nondescript mixture solid solution with precipitated grainlets the aluminum-copper compound various states dis- persion. And while alloys with per cent copper, kept solution quenching previous hard rolling, are capable being quite strong and hard and the same time sufficiently resistant the carelessly made product not all corrosion re- sistant. Hence binar aluminum- copper alloys are practically un- known the trade the wrought state. Aluminum-Magnesium Alloys Binary aluminum-magnesium al- loys had very strange history. “Deoxidation” being the alpha and omega the foundryman’s desiderata, matter what metal alloy intends use, great hopes were placed upon the potent deoxidizing power magnesium metal. For this reason was used frequently small quantities time when little anything was known regarding aluminum-mag- nesium alloys. did not live the expectations. other aluminum base alloy managed possess such chalky dull coloring its fractures magnesium- treated aluminum did. Higher amounts magnesium seem have met with some suc- cess, commercial more than tech- nical. Some years ago alloy called “magnalium” was adver- tised kind miracle metal Europe. was offered spe- cifically for parts scientific in- THE IRON AGE, December 24, 1936—27 4 ay struments used hot and damp climates. Scientific expeditions for their photographic equipment. However, this fad proved quite ephemeral. makes bold state that the old “magnalium” probably had magnesium all. Otherwise, hardly might have happened that during that considerable pe- riod time that elapsed between the use the old magnalium and the new aluminum-magnesium al- loys actually containing from per cent magnesium, very little was being heard them. These new aluminum-magnesium alloys evidently require specific method for compounding. Once the form ingots, they seem easily tackled with the regular foundry equipment. They can used both as-cast the wrought state and certainly form the strongest aluminum alloys pro- ducible without any specific heat- treatment. Their corrosion resis- tance also quite high. The two alloys containing from per cent magnesium will desig- nated herein Nos. and Aluminum-Manganese Alloys Binary aluminum-manganese al- loys constitute class having con- siderable practical use, though very limited composition range. Not over per cent manganese added aluminum for castings and just about 1.2 per cent the making wrought products. The first one possesses the sand- cast state practically the same mechanical characteristics the Al-Cu alloy No. (author’s No. 2). The per cent and 1.2 per cent Al-Mn will designated herein alloys Nos. and Years ago, manganese was thought being nearly insoluble solid aluminum and crystal- lizing secondary constituent the formula This made the situation rather strange, for meant that some per cent brittle intermetallic compound located around the daries could produce hardening some per cent and more. the light recent investigations which show that manganese soluble solid aluminum the maximum extent 1.8 per cent, becomes clear that the consider- able hardening effect inherently present aluminum manganese alloys must due that solu- bility and number addi- tional effects based upon it. known also now that the first aluminide manganese formed has the formula Aluminum-Silicon Alloys Silicon also soluble alumi- num the extent nearly per cent. However, little improvement the characteristics aluminum obtainable when silicon added within that limit its solid solu- bility. The reasons for this are SOLID SOLUBILITY DIFFERENT ELEMENTS ALUMINUM AND THE FORMULA THE NEXT CONSTITUENT Solubility Near Solubility the Melting Point, Room Temperatures Next Element Per Cent Per Cent Constituent (I) Group Considerable Solubility 5.8 less than 0.5 Magnesium ......... about less than 0.5 about less than 0.3 (II) Group Slight Solubilities Manganese .......... about 1.8 less than 0.2 about 0.3 very slight than 0.2 very slight less than 0.1 very slight Group Quite Insoluble Elements (IV) Quite Insoluble Even Liquid Aluminum Bismuth, Cadmium, Carbon, Lead, Phosphorus, Potassium, Selenium, Sodium, Sulphur, Tellurium, Thallium. 28—THE IRON AGE, December 24, 1936 not clear. necessary re- member that the rule, that alloy extensive use must have its history range which forms nearly perfect solid solution, represents mum, not maximum, prerequisite. With the increase silicon con- tent, hardness and crease slowly until the maximum strength reached with about per cent silicon. the same time ductility decreases continuously. Beyond this limit strength drops well, though hardness continues increase. This quite logical because hardness sent continuous function the amounts the constituents present. Ordinary aluminum-silicon loys form good materials for the foundry. With precaution (They must melted carefully, avoiding gas contaminations. The ingot aluminum should not con- tain over 0.3 per cent iron), they yield sound, leakproof castings good wear resistance, and, re- gard corrosion, they are quite superior all aluminum-copper alloys. There quite gradual change higher strengths and hardness the lower range (up per cent), and, therefore, definite dis- tinction impossible. However, two alloys—one with per cent and one with per cent silicon may considered representing this class alloys. These alloys shall designated alloys Nos. and 10, while the higher silicon alloys (about per cent) shall called No. 11. All aluminum-silicon alloys can higher strength and much higher ductility, though their yield point and hardness remain unchanged. This done treating the molten alloys with small amounts dium sodium fluoride. The change expressed also the lowering the eutectic tempera- ture and increase the amount silicon the eutectic composi- tion from 10.5 per cent. The eutectic grainlets silicon are much smaller the modified than the ordinary alloy, the whole structure looking more refined. per cent silicon, the modi- fied alloy may had with strength 30,000 lb. per sq. in. and ductility per cent, which rarely met aluminum-base 4 | | | screw-machine products made from free foundry alloys. This alloy will called No. 12. The mechanism the modifying treatment still quite obscure. physical measurement and X-ray search for possible change the internal structure the grainlets silicon have re- sulted far providing key the phenomenon. But, while out place discuss here all the possible theories offered, the author wishes state that his opinion the action sodium probably causes an_ increased amount atomic dispersion silicon while the alloy still liquid, and that this atomically dispersed silicon may far more soluble solid aluminum and far less capable forming large eu- atomically dispersed silicon the melt. The modified aluminum-silicon alloy otherwise known Alpax was enthusiastically received the time its discovery, for here was extremely convenient and inexpensive method obtaining strong aluminum castings. How- ever, was found also that the castings are likely porous and that this porosity not easy control. Hence the present field uses for Alpax quite re- machines. stricted and the non-modified alloy with per cent silicon plays far more important part. And end reached the list plain heat-treated) binary alloys aluminum that are being used now with some reason. number other binary aluminum alloys can made and used and sometimes even ad- vantage sort may claimed, which quite easy thing. But, whether manage add some iron, titanium, vanadium, molyb- denum, tungsten, cobalt, tantalum, zirconium—and this practically completes the list possibilities—the result will that the added element will form complicated nature (mostly more than less). This aluminide may located within the grains boundaries (most frequently); purely additive way will al- ways raise somewhat the alloy’s hardness and strength while low- ering its ductility way out proportion the slight hardening obtained. Due the softness and plas- ticity aluminum can hot sometimes cold worked after these foreign con- stituents have brought its elonga- THE IRON AGE December 24, 1936—29 cutting aluminum alloy developed primarily for use automatic screw tion (in the statical test) near zero. But way these for- eign constituents form im- provement whether the cast the wrought state. The same true for alloys which number elements in- soluble solid aluminum are added the molten metal small amounts the hope that each one will exert distinct and bene- ficial influence. There was for time upon the market alumi- num alloy containing, for instance, per cent nickel, 1/3 per cent chromium, 1/3 per cent molyb- denum and 1/3 per cent tungsten —all forming aluminides and only the first two slightly soluble solid aluminum. Lots advan- tages were claimed for this alloy, although its mechanical character- istics were not bit better than those the regular alloy con- taining 1.2 per cent manganese. This quinary alloy has been used for time even airplane con- structions, but discreetly eliminated the run time. Ed. Note: Next week the au- thor will this discus- sion aluminum alloys describing the heat hardened binary alloys and tural characteristics ternary alloys. rapid growth the use electric arc welding and the development modern alloys calls for highly knowledge arc welding and its appli- cation. gain this specialized knowledge, essential that continuous program re- search and development carried not only with re- the practical and eoretical aspects arc welding, but also with re- spect the design arc welded structures with view determining the best procedure, conditions and materials for the job. Ever since arc welding was first developed, Westing- house has carried such program. This has been re- sponsible for many advances metals dependent upon great many fac- tors, such chemical metallurgical char- acteristics, physical properties, type electrode and welding tech- nique employed, treatment prior 30—THE IRON AGE, December 24, 1936 WELD ° ° CHARLES JENNINGS Research, Westinghouse Electric Welding Manufacturing Co. the design welding equipment and the prac- tice arc welding. this and following ar- ticles comprehensive and unusually series, The Age will present the Westinghouse welding ex- metals. addition the text matter and tables this first installment, attention called the nine pages specific operating data con- clusive. These data will found great value criteria for comparing one's practice with best practice and also estimating time and cost with respect various forms welded joints. welding, and subsequent treatment after welding. Some metals, such low carbon steels, are relatively easy arc weld while others, such brass, are more less difficult weld. every case, however, there definite reason for the results obtained and knowledge these factors the utmost importance both the welding operator and designer welded products and structures. The success obtained when weld- ing any metal function the oxidation the chemical constitu- ents, the vaporization some the alloying elements, the pres- ence non-metallic inclusions, changes the metallurgical struc- ture, and the solubility gases the deposited metal. Certain elements metal, such carbon, may combine with oxygen form gaseous oxide and cause gas pockets the weld. Other elements, such silicon and aluminum will oxides which result slag inclu- sions. third type element, such iron, will form solid oxides which are soluble the molten weld metal and consequently pro- duce welds that are brittle and low strength. The presence some elements alloy, such zinc, have melting temperature lower than that the alloy metal. Conse- quently, they will vaporize result the welding operation and produce change the chemical composition the metal. This | | a i | i} a i | q | : | | | | ° | may result the presence gas holes the deposited metal. Some metals contain finely di- vided oxides which have melting point higher than that the parent metal. These oxides not coalesce result the refin- ing operation the metal. The extremely high temperatures ob- tained the welding opera- tion often causes these finely di- vided inclusions coalesce and form inclusions the fusion zone the weld. All metals changes result the are welding operation. These changes are function the chemical composition the material, the temperature obtained during the welding operation, and the rate cooling from the molten state. The effe