The Iron Age 1937-02-04: Vol 139 Iss 5

CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET Owned and Published CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and Sts., Philadelphia, Pa. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary NEW YORK, FRITZ FRANK President J. H. VAN DEVENTER Editor Managing Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Resident District Editors MACMILLAN Washington Chicago Cleveland Detroit Pittsburgh Editorial Correspondents London, England Cincinnati Boston Hamburg, Germany Milwaukee San Francisco SANDERSON ROUNTREE, JR. ALLISON Toronto, Ontario Birmingham Newark, St. Louis Buffalo Contents February 1937 Basic Elements Handling Die Forged Locomotive Rods lron Ores New Jersey... Automotive Industry ............ Statistics Metal-Working Activity Washington News ........ Plant Expansion and Equipment Buying................. 144 Products Advertised ...... 176 Copyright 1937 Chilton Company (Inc.) BAUR, General Advertising Manager DIX, Manager Reader Service ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bidg., Chestnut & 56th Sts., Philadelphia, Pa. Published every Thursday. Leonard, 239 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit ada, $8.50, including duty; Foreign C. H. Ober, 239 W. 39th St.. New York $12.00 year. Single copy, cents. Robinson, 428 Park Pittsburgh Cable Address, ‘‘Ironage, Warren. Box 81, Hartford, Conn Member, Audit Bureau Circulations Member Associated Business Papers Indexed in the Industrial Arts Index. J Stainless sheets full range sizes “Ryerson steel stocks include Allegheny Iso more than other kinds are stock for immediate shipment Together with all general Steel Products, Angles, Channels, Bolts, Rivets, Welding Rod, Etc. The Ryerson Stock List your guide these large stocks steel and allied products. you not have the current copy, write and will send Joseph Ryerson Son, Chicago, Milwaukee, St. Louis, Detroit, Cleveland, Philadelphia, Buffalo, Boston, Jersey City ps: 54—THE IRON AGE, February 1937 ... THE IRON AGE... FEBRUARY 1937 ESTABLISHED 1855 Vol. 139, No. The Moral Challenge SECRETARY LABOR PERKINS, rebuking Alfred Sloan, last week for failing accept her invitation confer with John Lewis, stated follows: think there moral challenge involved this situation. one that the American people should face. large number employees agree meet with their employers. General Motors will not confer while they remain their plants. call this legalistic obstacle. This though parked his car property and said wouldn’t talk him until removed his car.” agree with Madam Perkins that there moral challenge involved the situa- tion, but not the one that she mentions. the moral challenge presented the refusal authorities, State and national, protect the right work 250,000 work- ers who want work and who cannot because insignificant minority has seized the plants and holds them for ransom. Dr. Leo Wolman, former head the Automobile Labor Board and labor authority, has recently stated that does not believe that the membership General Motors workers amounts more than about per cent most. Mr. Sloan doing more nor less than his plain duty American citizen refuse compromise this situation. Surely the great majority Americans have not yet become befuddled the new school thought share Madam doubt the moral and technical wrong involved plant seizures either majorities minorities. Justice Louis Brandeis has said: have said that essential that the employer should strive only for the right. equally important that should suffer wrong done him. The history American liberty. rests upon that struggle resist wrong—to resist any cost when first offered.” expecting one sit down with another table, there also the matter table manners considered. gentleman can hardly expected sit the same table with loud-mouthed and conceited braggart whose every other word con- sists threat, vituperation insult. Madam analogy the parked car not very convincing. some one parked car her driveway, preventing access her garage, and refused depart when re- quested, she would undoubtedly call policeman. And refused his duty, would hear from headquarters. Ses i 3 HANDL MATERIALS ° ° FRANCIS JURASCHEK Consulting Editor, The Age FACTOR ECONOM THE substitution human intelligence for human muscle the handling the ma- terials production cannot dated any more than the character Topsy “Uncle Tom’s Cabin.” one knows who first fitted pair wheels and two handles skid platform make the first hand truck. Someone should credited with the idea hanging block from roof beam and lift- ing casting more easily onto machine sling formed one end the rope. The roller con- veyor must have had some begin- ning—and certainly the whole family cranes and derricks trace their common ancestry back the Egyptian pyramid builders. makes difference today, ex- cept that clear understanding the functions all mechanical handling devices may best had through consideration the basic elements entering into their design and construction. Each de- vice can considered means 56—THE IRON AGE, February 1937 and shift load. But mechanical devices for lifting and shifting loads not themselves alone make systems materials han- dling. This the great fault still ican industrial plants; that scores and hundreds excellent mechani- cal devices are used handle parts and materials without any planned, logical conception how they may best tied together form economical system. Two basic principles underlie the design any comprehensive ma- terials handling system any in- dustrial plant: Continuous, progressive flow, from beginning end. The avoidance any re-han- dling. self-evident are these prin- ciples, that would seem foolish stress their importance. Yet literally thousands plants they are ignored, part even whole. Many plants, like Topsy, have just grown; from small be- ginnings through the addition ° ° The Basic Elements Materials Handling ystems machine after machine and de- partment after department, hap- hazardly, until they present pic- ture materials and parts being constantly shifted here, there and everywhere from process pro- cess, from operation operation, with thought given the miles useless travel, the tons wasted human effort, and the dollars potential profit swallowed daily these wild and uncorrelated jour- neyings. The first step the designing any materials handling system should careful charting production flow. Starting the point where the raw materials are received the plant, this study should consider detail every es- sential operation that must per- formed the material until leaves the plant finished prod- uct. What the relation process process? How can each located relation the pre- ceding and succeeding process cut down the time and dis- tance and effort moving from one another? What are the limi- tations the building buildings which the orderly flow proc- esses must housed? How does the cost making changes neces- sary achieve orderly progression compare with the savings made from the elimination ef- fort? The second step design the adaptation available mechanical handling equipment this orderly, progressive production such way cut the cost handling much possible, and the same time keep the sys- tem flexible. Since handling itself never for moment static, any system designed utilize the cost- saving advantages mechanical handling devices should not ir- revocably fixed its nature. should capable change, ex- pansion. should lend itself read- ily variations production capacity and methods, and the addition new equipment without destroying the value usefulness that which installed for im- mediate use. This applies more particularly, course, equip- ment with fixed installation fea- tures, such conveyors and over- head trackage. Mobile equipment, such trucks, inherently cap- able adaptation changes the system, and therefore may considered flexible this sense. consideration the various types equipment available for incorporation into system ma- terials handling should include discussion limitations well advantages. Further analysis such equipment shows that the functions lifting and shifting may more clearly understood reference the fundamental functions the devices from which the equipment has been developed. the same time, should noted that hard and fast line can drawn between lifting and shifting equipment, because the combination and adapta- tion mechanical devices both functions that the system han- dling may designed. For example, whether hand power operated, pri- marily lifting device. But when crane running overhead track- age, swinging arm pivoted the load. the other hand, truck, whether hand power op- erated, primarily shifting de- vice, but when equipped with LEFT revolving drum affords purchase and multiplies ing effort. LEFT block-and- tackle multiplies pull proportion the turns rope. RIGHT THe mission concen- trates power the hoist head. elevating mechanism permits lifting well shifting the load. And, although conveyors are primarily shifting mechanisms, they can designed lift loads well. The following outline reduces all mechanical handling devices their basic elements. These ele- ments are but twelve number. Out them have been developed all the materials handling systems use today. The Revolving Drum. The capstan one the earliest forms which this principle was made available for the service man. When anchors became heavy that direct lifting became arduous, vertical revolving drum was mounted the bow ship, the anchor rope was passed several times around secure pur- chase, and leverage was applied means bars inserted radially the frame the drum. Power was multiplied the expense speed. Later muscular effort was replaced steam electricity drive the capstan. The same prin- ciple governs the winch all its varied developments. should noted that the capstan and the winch the hoisting cable not fixed the drum and does not wind it. few turns the cable around the drum are taken solely for the purpose obtaining grip. the loaded end the cable winds the drum, cor- responding amount the free end unwinds. When the revolving drum made act like reel which the hoisting cable fixed and which winds, have the de- velopment widely used mine hoists and high-speed commercial elevators. Movement down can closely controlled that loads may spotted accurately any point the vertical plane. the case mine hoists and eleva- tors, movement the horizontal plane restricted the guides which the car runs. the derrick, the other hand, certain amount horizontal movement afforded the swing the mov- able boom, but accurate spotting the loads becomes matter the exercise manual skill op- eration. special adaptation the principle found the skip hoist. Here the hoisting cable draws car inclined plane point where tripping mech- THE IRON AGE, February 1937—57 Es Saul - ay r~ +. — LEFT heavy loads. ° RIGHT pneumatic hoist. anism dumps the car, whereupon the cable unreeled permit the car return the loading point again. The grab-bucket merely special loading device attached the end the hoisting cable derrick crane, and the drag- line utilizes and fro movement cable which buckets are attached, and which controlled its movements pivots fixed each end the area covered the buckets. All these devices are basically founded the re- volving drum, and their major ap- plications are found either the construction fields, cargo handling and other marine work. The Block-and-Tackle. This usually made use only temporary expedient. Power multiplied the expense speed proportion the number turns the hoisting cable around the blocks. From this principle has been developed chain hoist, usually hand-operated, and also used principally for tem- porary work occasional jobs. Action slow even with light loads, and becomes slower still the loads increase weight. Fields usefulness are therefore severely restricted from materials han- dling viewpoint. The Planetary Transmission. substituting the block-and- tackle device planetary gear transmission place the ordi- nary head block, power, speed and accuracy movement are gained. the spur-geared chain hoist find great improvement over the differential hoist. When elec- tric motor was substituted for the 58—THE IRON AGE, February 1937 worm and gear developed the power hoist handle the hydraulic elevator and the . ‘ hand-pull chain the way was paved for the varied development the electric hoist, capacities ranging many tons. mounting crane, the end movable boom secured building column the wall, horizontal movement gained addition the vertical movements the hoist itself. The Worm-and-Gear. For the handling loads heavier than may safely picked the plane- tary transmission hoist, the worm- and-gear transmission paved the way for the development the electric hoist capacities ranging many hundreds tons. Thus three principles may traced the development power hoisting equipment; the revolving drum, the planetary gear transmis- sion and the worm-and-gear trans- mission. Except the case the mine-hoist, the elevator and the skip-hoist, such hoisting mechan- isms are capable movements plane suspending them from trolleys, cranes movable booms. The Plunger. Movement tightly fitting plunger hollow cylinder responsible for the de- velopment three devices wide- spread use the field materials handling. The hydraulic plunger elevator not popular today once was, because slow rack-and-pinion slow-speed but accurate lifting device. wheeled frame the most common materials handling device known. action, although very steady and safe. The pneumatic hoist widely used where compressed air tion. And the ram has become pop- ular two forms; feed loose material regular quantities in- termittently, such coal furnace fire, and turn shift parts regular intervals set them proper position for the next process step. adaptation the hydraulic plunger movement found the lift-truck; hand operated device whereby the pumping action handle lifts the platform the truck pick skid-load material from the floor that may moved bodily another the truck. The Rack-and- Pinion. De- velopments this principle are found mostly industrial truck operation. certain power op- erated trucks lifting section may rack-and-pinion moved lift load from the floor for transfer the truck another location. Or, hand truck similar de- vice, including pawl and ratchet may serve the same purpose just described for the hydraulic lift truck. Lifting speeds tively slow all these mechan- isms, although should noted that the lifting operations are only secondary the shifting opera- tions the trucks which they are built. this point well note that the reverse lifting move- ment may carried out any these mechanisms, but that 4 SS ai! SS ut “ H Wu le ‘he . ‘ie of NH an as addition have the force grav- ity alone our disposal. Goods may lowered gravity down smooth-faced chutes, either straight spiral, slid down over roller conveyors. Control direction simple; control accurate spotting material difficult, spite various bumper and brak- ing devices. The Wheeled Frame. From the two-wheeled, two-handled hand truck, through the platform box three four wheels, swivel- mounted rigid, and the indus- Flat surfaced material, such plates, rods, tubes, coils, ma- terial boxes, bales coils can slid over these rollers grav- ity, certain rollers may driven power draw the ma- terial along. conveyor simply endless belt running over sets rollers, making pos- sible the movement loose ma- terials small parts. Since belt conveyors give positive forward motion, however, their use not limited the transfer small parts loose materials. They are used many places where the rol- LEFT ONVEYORS are adaptable prac- tically every materials handling problem. screw primarily device for delivering certain rate speed. power truck and tractor train, the development this principle has been progressive and logical. Means must provided, for loading and unloading ma- terials any these mechanisms, although later types trucks, special devices have been added these things also. There are almost infinite possibilities among the hundreds types isms this class equipment now available. All require, obvi- ously, clear floor platform space for operation. are extremely flexible. Conveyors. general there are three types conveyors; rol- ler, belt and bucket. roller con- veyor simply series paralle! rollers set longitudinal frame. BELOW fan the basis for most suction and blowing systems delivery. ler conveyor does not give sufficient positive movement. bucket con- veyor endless belt chain running over rollers, with pockets receptacles attached pick and move quantities loose ma- terial, principally grade, even vertical direction. Com- binations conveyor sections may direction travel the materials handled. Recent developments design and construction convey- ors make these systems very flex- ible and adaptable almost every handling operation the indus- trial plant warehouse. The Vibratory Conveyor. Spe- cial note should taken the fact that certain materials must handled such high tempera- tures, the materials may abrasive nature, that ordinary conveyors cannot used handle them successfully. For such ma- terials vibratory conveyor sys- tem now available, which somewhat flexible metal trough slowly advances few inches, then quickly pulls back, the same time flexing and down. The vibratory movement, gether with the inertia the material, jerks ahead, even slight incline. Naturally, attempt made use such con- veyor where ordinary mech- (CONTINUED PAGE 112) RIGHT VERHEAD age puts mater- ials handling prob- lems off the working floor. THE IRON AGE, February 1937—59 : x \ / \ x HIS the fifth article extensive series Mr. Jennings. The first install- ment appeared The Age Dec. 24, the second Dec. 31, the third Jan. 14, and the fourth Jan. 21. Subsequent chap- ters will appear ensuing issues. Welding Processes ods welding cast iron the metallic are process. The more important these processes will discussed separately order outline their essential differences. Preheating not when welding cast iron many the approved metallic arc processes, but general will are number meth- 60—THE IRON AGE, February 1937 ° ° CHARLES JENNINGS Engineer Charge Welding Research, Westinghouse Electric found advantageous. Preheat- ing prevents the formation stresses resulting form heating, tion, and reduces the hard areas adjacent the weld, all which tend improve the quality the weld and prevent cracks. Proper preparation the joint necessary all cases. Cracks should properly prepared and cut out insure suitable weld- ing surface. The wider the joint preparation, the greater fusion zone and the stronger the joint. Drilling the end crack prevent its extension generally not necessary because the heat gradient the casting should never great enough expand and extend it. The first successful method welding cast iron the metallic process consisted using bare electrodes and studs. The joint drilled, and steel studs inserted. The size, location, and number the studs depended upon the joint Mfg. Co. ° being repaired and the thickness the material. The total area the studs should about that the casting and they should long enough extend through the first layer deposited metal. The diameter the studs should studding makes mechanical joint the casting. Good fusion be- tween the steel studs deposited metal possible and the bond the casting required only make the joint pressure tight. Joints this type are not neat appearance, but they have proved entirely service. The next development the use steel metallic electrodes weld cast iron consists steel electrode with suitable flux coat- ing. These electrodes have proved very satisfactory produce joints stronger than the casting without preheating studding. When using electrodes this type, they should not larger than Fe | | = in. diameter. The welding currents should held low possible and only about in. weld deposited time. After depositing about in. weld, should peened lightly and the joint allowed cool. Welds this type are satisfactory except cases where machining re- quired. The fusion zone hard and the first layer. more than layer deposited, the top layers may easily machined. Another method welding cast iron use copper electrode. These electrodes are many varied types and general con- tain coatings which used primarily the are. Good fusion obtained and joints having strength equal that the parent metal possible. Peening generally found help- Welds made with copper electrodes are not machinable the fusion zone and are different color than the parent metal. Electrodes larger than in. are often used process which means greater welding speeds. es- sential that the casting kept cool, however, other proc- esses. order make machinable welds cast iron, electrodes con- taining high percentages nickel are generally used. mentioned before, nickel promotes graphitiza- tion. That why electrodes this type will prevent the forma- tion chilled cast iron adjacent the weld. These types elec- trodes will produce good fusion and deposit similar appearance the parent metal. The strength such welds generally lower than that welds made with steel electrodes, but entirely ade- quate. The disadvantage this type electrode its high cost. Because this fact, not used unless machinability essential. Monel metal electrodes are this type and are often used make machinable welds cast iron. addition the previously mentioned electrodes, there has also been developed coated cast- iron electrode which has certain special applications. trode deposits cast iron deposit which machinable when properly made. The proper technique this electrode requires preheating and puddling long enough during welding insure that the de- posited metal does not cool below red heat less than seconds. suited when building large sections where preheating pos- sible, and where downhand weld- ing can used. Aluminum Aluminum silvery metal having low specific gravity, high thermal conductivity, and relatively low melting tempera- ture. being heated, aluminum does not change color ap- pearance until approaches the melting point and then suddenly collapses. When heated and ex- posed the air, film oxide forms the surface. This film has melting point much higher than aluminum and does not form fusible slag. The physical properties com- mercially pure aluminum and its alloys may varied over wide range cold working, chemical composition, and heat treatment. Tensile properties ranging from 13,000 68,000 sq. in. and ductility values ranging from nil per cent in. are ob- tained. The lowest ductility, how- ever, not necessarily obtained from the alloys with the highest tensile strength. The fusion welding aluminum readily accomplished the arc welding the proper electrode and welding pro- cedure are used. properties the resultant welds will function the alloy welded, the composition the elec- trode, and the subsequent heat treatment after welding. The use flux coated electrodes essential for the satisfactory metallic are welding aluminum and its alloys. Electrodes es- sentially pure aluminum can used, but general the most sat- isfactory results are obtained with electrode containing about per cent silicon. The per cent silicon alloy has lower melting temperature, range, and smaller solidification contraction than other aluminum alloys. These features, combined with its high strength, make adaptable for parts held rigidly clamps, joints that are apt de- velop high contraction strains, and strong alloys that are more hot- short than pure aluminum. One point that must con- sidered when welding aluminum and aluminum alloys with per cent silicon welding electrode that the finished joint should not heated above 940°F. This alloy weak this temperature and failure the joint possible. edges required for butt joints plates in. less thickness. Materials thicker than should beveled with in. lip the bottom the joint and included angle deg. For thin plates, in. and less, lap welding generally preferred butt welding. Reverse polarity used the metallic are welding aluminum and the current values should equal to, greater than, those used plain carbon steels. short arc should used and the welding speed approximately three times that used steel welding. Recommended electrode diame- ters for different plate thicknesses are shown Table XL. TABLE Recommended Electrode Diameter for Different Plate Thicknesses Electrode Diameter (Inches) Plate Thickness above in. Preheating not required thin parts, but will found helpful obtaining good fusion heavy plates. high currents are used effort obtain fusion, excessive spatter may encountered. permits the use lower welding currents thereby reducing the amount spatter and subsequent cleaning. The slag should thoroughly cleaned from all beads deposited metal before restriking the and before depositing second layer. After welding, the slag should removed completely. Most the slag may easily knocked off. What slag does not come off this manner may completely removed dipping the sulphuric acid nitric acid for several minutes. The posited from some electrodes may washed off with warm water. THE IRON AGE, February i : - 5 » = = j ae ~ The high coefficient expansion aluminum and its alloys makes the use fixtures and bracing essential prevent distortion and buckling. Also, the aluminum and without warning when heated the melting temperature makes the use back-up bars very de- sirable whenever possible. Cop- per generally used for this purpose. The tensile strength alumi- num and its alloys determined primarily the cold working and the heat treatment the parts have obtained. The heat welding an- neals the base metal adjacent the joint. result, the parent metal adjacent the weld will the weakest part the joint and the tensile strength will only equal that the annealed base material. al- loy castings can often treated after welding the resultant welds will have proper- ties comparable that the base material. According the Aluminum carbon can successfully adapted certain types joints aluminum. This method, how- ever, not flexible its ap- plication metallic welding. The use the carbon for weld- ing aluminum present con- fined butt joints, either straight corner, and the similar types lap joints. this type weld- ing flux-coated filler rod in- serted between the joint welded and the carbon electrode. The welding heat then trans- mitted through the rod the edges the joint, and the becoming molten, will remove the oxide film with which comes contact, allowing the parent and filler material gether. “This method are welding particularly well adapted butt joints light gage metal (from Copper Commercial copper prepared two grades: electrolytic and deoxidized copper. difference between them deoxidized copper free oxy- gen while electrolytic copper con- tains from 0.3 0.7 per cent oxy- gen. The strength commercially pure copper will vary depending upon the cold working, 62—THE IRON AGE, February 1937 and will range from 20,000 sq. in. for annealed copper 60,000 sq. in. for cold-drawn copper. The strength welded joint will seldom equal that the original base metal because some annealing action will take place during welding. Copper has high thermal expan- sion, high heat conductivity, and low electrical resistance. addi- tion, when molten heated above 1680°F. for more than few seconds, there will formed ac- cumulations cuprous oxide the grain boundaries which great- weaken the metal. successful procedure for welding copper must take into consideration all these factors. The carbon are process employ- ing phosphorus-bronze filler rod produces the most sults for welding copper. coat- ing the rod flux required. The success this process de- pendent upon high welding speeds prevent the formation cuprous oxide, the use long are pre- vent the filler metal and molten copper from dissolving gas and be- coming porous from exposure the oxygen the air and carbon monoxide, and the low melting point the filler metal. Several types phosphorus bronze may used, but ELDING section the prime focus cage for 200 in. telescope. This section ft. high and ft. diameter. Coated electrode welding used throughout. the most satisfactory results are obtained from one containing about per cent tin, about 0.3 per cent phosphorus, and the remainder cop- per. Welds made with the filler rod will have tensile strength 30,000 sq. in. and sufficient duc- tility withstand flatback bend test. Plates butt-welded should beveled they are over 3/16 in. thick angle sufficient width allow complete penetra- tion. Recommended angles bevel are deg. for %-in. plates, deg. for plates, and deg. for plates. (These bevels correspond included angles deg., 104 deg., and 120 deg. respectively). Even when making lap joints desirable bevel the plate edge increase the or- dinary 90-deg. angle about 135 deg. the joints should backed with steel heavy copper backing bars pre- vent the molten metal the bot- tom the joint from falling away. The diameter the filler rod used should sufficient fill and reinforce the joint single pass. The welding process carried out follows: (1) The end the rod should laid the groove and the are be struck the rod and not the plate. Striking the are this man- ner causes the end the rod melt and deposit pool bronze the copper thereby protecting from the deposit carbon that results when striking are with carbon electrode cold plate. After the are has been maintained this pool for short time pre- heat the copper the required temperature, the bronze will spread out and tin the copper and the welding can continued along the seam. high enough welding cur- rent should used obtain tin- ning the copper the initial pool bronze about five seconds. (2) long are corresponding should held. (3) Recommended welding cur- rents and filler rod diameters for welding copper are given Table XLI. (4) The welding speed should fast. Speeds slower than in. per minute will produce porous welds and oxide inclusions the fusion when trolytic copper. (5) The filler rod should held slight angle above the surface the plates with the end down the bottom the groove. This prevents the molten metal from running ahead the cold plate. (6) Plates over in. thick should preheated dull red heat. zone (7) Vertical and overhead weld- ing are not possible this process. Physical properties welds made electrolytic copper having tensile strength 33,000 Ib. | TABLE Filler Rod Diameters and Current Values for the “Carbon Welding Copper Copper Thickness Size (Inches) Gage (Inches) 1/20 6/160 3/16 1/16 3/16 9/128 3/16 5/64 3/32 7/64 in. will develop tensile strengths 30,000 sq. in. Welds made deoxidized copper will develop tensile strength 30,000 32,000 lb. sq. in. The ductility both cases will good. Within recent years, shielded- arc phosphorus bronze electrodes have been developed that will pro- duce satisfactory welds copper. The fact that the welding current used metallic are welding de- pendent upon the diameter elec- trodes makes this type welding unsatisfactory for welding heavy plates because sufficient heat can- not developed produce fusion. Very satisfactory results can obtained plates in. thick less, however. with Reverse polarity used freight car made with low-alloy, high-strength steel. Carbon Filler Rod Diameter Welding Current Inches (Amperes) 3/32 120-160 3/32 130-180 1/8 140-190 1/8 150-200 5/32 195-260 5/32 200-270 5/32 210-280 3/16 225-300 3/16 250-330 3/16 280-370 1/4 300-400 1/4 315-430 5/16 340-450 370-470 3/8 400-500 420-550 coated phosphorus trodes and short are recom- mended obtain good fusion and prevent excessive spatter. Sound welds high strength can obtained copper the metallic are process, but the duc- tility slightly less than that ob- tained with the carbon are process. Welding Copper Steel Copper can successfully weld- steel both the carbon arc and metallic are processes when using phosphorus-bronze electrodes. The metallic are process the most satisfactory for copper plates in. less thickness. For plates over in. thickness, the carbon are process should used. (TO CONCLUDED) HEN this series com- pleted, the articles will reprinted the Westing- house Electric Mfg. Co. and anyone desiring copies the booklet may obtain them from Westinghouse distrib- utors direct from the weld- ing sales section east Pittsburgh, Pa. THE IRON AGE, February 1937—63 - au 4 «5 13 1/4 3 1/4 / Ay 7/16 3/8 oe 7/16 ° ° RODRICK ° ° ° this age progres- sive management more thought should given the importance the work being performed cer- tain employees, and their rightful place the organization, maxi- mum results are obtained. upon anything too small de- serve study. consider job unskilled not warrant es- timate its worth managerial step backward rather than for- ward. The railroad walker who WATCH taps with hammer the wheels train when stops station, has responsibility comparable part that the engineer. And yet, the simplicity the work does not imply the seriousness his task. industrial plant the same true what was once considered the least important duty all— the night watchman. His job though not yet dignified clothed with the responsibility protect- ing property least per cent the day order that the entire LOG Neme Date Condition Lathe LA9 Assembly Shop Running Roof Corner Court Leaking (Shut off Water) Secure 4to Fire Doe's Mill Checked Out Water Pipe Tool Room 3rd Floor Leaking Shop Foreman Notified Repaired NOTE; submitted duplicate the Plant Office before out. Where action required one copy returned the watchman upon reporting for duty. 64—THE IRON AGE, February 1937 force may have place work and equipment work with when they return the morning. While the executives, office force, and skilled workers sleep awake, and his working hours are attended the fears always present night. The functions this employee should appear the organization chart safeguarding the empty factory against fire—that danger that nev- sleeps—and waste, and the posi- tion not one properly en- trusted old man with lantern unless physically and mentally qualified understand fully what will required him. should selected the same scientific basis other employees, and trained and instructed like manner. said that fire losses increase about per cent after the closing time industrial plants. alert watchman, therefore, making reg- ular rounds, can detect any condi- tion which, allowed remain, would probably result fire. Spontaneous Combustion Spontaneous combustion one the most frequent causes fires, and this condition just likely during the night the day. surprisingly large num- ber materials that are commonly present factories may take fire without the application flame heat from external source. Among them are: bituminous coal, and sawdust; oily rags, and cotton waste that have been used paint- ers for cleaning machines; lin- seed oil, turpentine, and varnish; and metallic powders various kinds. Combustible material any kind should not allowed lie about, especially when leaving the shops night. Rags used paint- ers should not exposed heat, and cotton waste moistened with linseed oil should not allowed stand contact with the air. Such q a Action Taken ae | > materials should always stored approved metal cans with self- closing covers. Workmen are apt leave oily overalls and jumpers their lockers, and for this reason steel lockers should provided they will confine fire case one starts. Since rubbish heaps are always fire hazards, all trash should removed from the plant once day, and men detailed should required see that re- fuse cans are put the designated places outside for trash trucks. smoking allowed should obvi- ously confined less dangerous places, and never permitted any- where after one hour before clos- ing time. This affords oppor- tunity discover any smoldering fire that may existence prior the time the buildings are vacat- ed, since such fire from this cause likely manifest itself within one hour. All persons smoking should required deposit the cigarette, cigar, pipe remains metal cuspidor receptacle filled with water. Sand filler for these receptacles should not used. fire preventive but with cigarettes particularly the stub continues burn, and the air soon becomes foul from the escaping smoke. water used both the fire and smoke are once extin- guished. the presence these and similar conditions that may cause fire after working hours, and the efficient watchman will the lookout for them patrols the buildings. How Fight Fire The watchman should, however, instructed further than merely detect fire hazards. must taught how fight fire, and how use properly first-aid fire equip- ment. bad fire almost in- variably the uncontrollable adult form what was once easily controllable infant,” and glass What The Night? water might sufficient the fire discovered early enough.” The importance fighting fire vigorously and intelligently its inception cannot over-empha- sized. fighting fire the fire itself should attacked rather than the flame, and the stream from extin- guishers and hose should direct- not the flame but the place from which the flame comes. Knowing the right type ex- tinguisher use emergency very important avoid disas- trous consequences. The soda-acid foam types, because their quenching and cooling effect, should used incipient fires occurring wood, paper, textiles, animal and vegetable fibers generally, coal, coke, starch, sugar, cereals, bitu- men, asphalts, waxes that not melt readily under heat, photo- graphic, X-ray, and motion picture film and proxylin products gen- erally. For oil fires, including gasoline, kerosene, alcohol, and turpentine, well those paints, varnish- es, and lacquers, the carbon-tetra- chloride type should cause its blanketing effect. electrical fires, including those insulation motors, PLANT PROTECTION CHART PLANT ENGINEER WATCHMAN General Extinguish Lights Combustible Materials Close Wind- ows, Fire Doors, and Automatic Sprinklers shers Machines Hose Turn off Radiator Valves Fire Fighting Leaks Thievry and ism Inspections Clock Poor keeping Electrical Hazards Report Fire Hazards Report Wastes Report ety ards Report Ele- Hazards Record usual occu- rrences Check vious re- ports THE IRON AGE, February 1937—65 4 te Exits Stop - f . 5 ~ if generators, transformers, switch- boards, and electrical wiring gen- erally, the carbon-dioxide type should used because its stream non-conductor. The electrical hazard fire ex- tinguishing not generally understood. Discharging streams from hand extinguishers elec- trically charged objects may pres- ent very serious hazard. When using hand extinguisher the fire must approached quite closely order direct the stream effec- tively. Because this the extin- the form continuous solid stream. were possible for the user stand considerable dis- tance from the fire, the stream would break sort spray, and the air spaces between the va- rious sections the stream would prevent the free passage the electric current. The proper extin- guishing solution use such fires therefore very important. Under ordinary conditions water more less effective conductor electricity, and the addition chloride other mineral substance does not reduce the con- ductivity, but usually increases it. Soda-and-acid solutions, well substances which produce foam, are electrical conductors. Carbon dioxide not only non-conductor but dissipates quickly and does damage the equipment. With fires this character all possible care should exercised regardless the potential voltage; the higher the potential, the greater the caution. The obvious thing cut off the current immedi- ately, there circuit breaker switch near by. always advisable disconnect all current night except such needed for lights, elevators, and fire pumps. addition, the watchman should instructed the use fire hose which, all well-managed plants, attached fire hydrants stand-pipes and neatly folded rack that can quickly pulled without tangling. each floor building there should be, each the four corners, hydrant which should attached hose sufficient length reach pos- sible fire any part that partic- ular floor. Instruction the use should include actual discharg- ing each some convenient place outside the building. facilitate quick location 66—THE IRON AGE, February 1937 well paint wide red band around the pillar the wall which one attached, and designate the kinds narrow strip different color should painted above it. For example, yellow for the soda-acid and foam types; blue like color, for the tetrachlo- ride; and green, for the carbon- dioxide. Sprinkler Systems automatic sprinkler sys- tem installed, the watchman should thoroughly understand the operation all the valves and know how shut off the water should valve open when there fire. fire breaks out which gets beyond his first-aid equipment must know how give the alarm the city fire department, understand the switches start the fire pumps, and then proceed protect the equipment and material much with tarpaulins other like ma- terial lessen the water damage. possible for incipient fire night gain such headway destroy plant before being dis- covered somebody not connected with the company. One such fire may cost many times the yearly pay watchman. The watchman also the plant protector against waste—that gradual wearing away capital investment which may occur night well during the day. should, therefore, make complete round and thorough inspection the entire plant immediately after closing time, observing then any waste that may exist. For exam- ple, all lights, except standing ones, should extinguished; windows, fire doors, and exits closed; radia- tor valves turned off, unless neces- sary stay prevent freez- ing; and dripping spigots shut off. should also note gas and oil leaks; leaking water steam pipes, and air hose; leaks roofs; gas fires left burning; and machines left running. obvious that should the lookout for the thief who would pilfer the van- dal who would destroy. The elim- ination these, well other, consequential wastes over period one year may more than pay his annual wage. The watchman also the night inspector safety. should cor- rect any poor-housekeeping condi- tion left the workers which con- stitutes hazard, might inter- fere with his free movement fighting incipient fire that the city fire department called into action. However, electrical, like, unsafe conditions found exist- ing should reported the man- ner described, but steps should taken the time rec- tify them because the potential danger. watchman, patroling his post during the night, came into contact with wire dangling from the corner building. grasped the wire push out the way, whereupon there occurred severe flash such intensity cause temporary blindness and injury his eyes, later diagnosed retinitis. Investigation devel- oped that the wire was connected unprotected switch installed the corner the building and used for power for large lifting magnet, and that several small wires about No. gage were hanging from loosely and care- lessly made connection the upper fuse-post clips this switch. The switch was closed. Apparently, moving the wire, the watchman had caused short circuit with the small loose wires dangling from the opposite fuse post. Watchman's Duties The watchman should make his rounds the entire plant stated and regular periods, punch clock, and the time slip should checked the plant engineer the next morning. should also keep log noting thereon anything irregu- lar observed occurring. fire hazard, like those described, has been left the workers should safe condition found, too, should entered. Should any un- usual event transpire, such disgruntled employee returning intoxicated condition and threat- ening supervisor, the appear- ance thievish suspects, should noted. Even fire close prox- imity the factory should mentioned order that study might given possible ex- terior fire hazard. the following morning, all log entries should investigated the plant engineer, and the necessary steps taken correct those conditions that need correcting. When the reports for duty that evening should furnished with copy the action ordered each his previous entries, and his first inspection the plant should check items, noting his findings. 4 i FORGED LOCOMOTIVE for every revolution the driving wheels locomotive, the reciprocating parts—comprising the piston, piston rod, crosshead and front half the main rod—must move the length the piston stroke. This means that 100 miles per hr., mass almost equal weight ordinary automobile must started and stopped times every second. This mass course must counterbalanced for otherwise the hammer blows developed the higher speeds would destroy the track. recent development specially designed forged alloy rods equipped with roller bearings has greatly reduced this reciprocating weight thus making pos- sible increase train speeds much miles per hr. some instances before developing hammer equal those existing the lower speeds for the plain rods. This article not only describes the design these rods but also considers the forging practice and the metallurgical requirements solved during manufacture. ° DIE forged main and side rods chrome- nickel molybdenum steel, heat treated se- cure the best physical properties and operating tapered roller bearings, are giving new speeds modern steam locomotives. These rods, produced the Timken Roll- Bearing Co. and made from high dynamic steel, are being made the plant the Park Drop Forge Co., Cleveland. Perfecting the application heat-treated die-forged quired years research and ex- perimental work; for before they ° could used successfully, the ap- plication anti-friction bearings crank pins and crossheads had perfected. This complex prob- lem was finally solved and made possible saving weight over thousand pounds the recipro- cating parts compared with con- struction using the machined from carbon steel slabs. illustrates the rod ar- rangement split-up, which radically different from the conventional pattern. will noted that the knuckle pin elimi- nated, reducing the main crank pin loading 55.5 per cent compared Fig. RODS the standard plain bearing design with its wide bearing areas and large rods. the Timken design the piston thrust transmitted through the main rod the outside diameter the bearing cup which floats between the bearing and the hard bronze bushings the rods. Piston thrust split three ways, one-third going through the bear- ing the main wheel, one-third di- rect the rear wheel and one-third the front wheel the case standard locomotive driving axles. With full piston thrust 120,000 this new de- sign gives only 89,000 the main pin, while with the standard design the load- ing would 200,000 Rod eyes bear directly the main bearing cup, which the case the main pin serves the double function knuckle pin and crank pin distributing the piston thrust from the main rod the front and rear drivers. spacer provided between the front rod, which nearest the wheel, and the main rod, allowing No. driver dropped without disturbing the main rod bearing. Clearance provided between faces allow for lateral and THE IRON AGE, February 1937—67 . : te é x 4 2 ther Rear Driver Axle Front Driver Axle cup and cone Shown out position rod arrangement radically different for the alloy rod with roller bearings, compared with the angular movement the rods the pin, which further facilitated the taper the width the rod. the case both front and rear pins, the bearings consist two sets tapered rollers running separate cones, with single cup. Bearing and mounting parts for the front and rear crank pins are identical and interchangeable. The rear crank pin essentially second main pin, its extended po- sition relieves the main pin bend- ing loads due piston thrust. reduce weight and the same time provide reservoir for lubricating oil for the bearings the rods, all crank pins are hollow bored. Localized Stress Two years research, over 6000 laboratory tests rod eye design T-in. Round Upset Spheres Ends Upsetters Pancake End and Forge Round Into Flat Hydraulic Press 68—THE IRON AGE, February 1937 conventional pattern for plain rod. and almost many more col- umn sections were required before the first die forged set locomo- tive rods went into service. These tests were necessary determine the most effective distribution metal avoid high stress concen- trations. The final approved design was based I-section column with round ends modified some extent flat column design. The ends the column section are tapered according Dinnik’s for- mula that the tapered section the moment inertia varies from the body section the eye section the ratio the cube. Full piston thrust applied column load was used designing the main rod and approximately half much for the side rods. Particular care was exercised designing the eye section all rods avoid the possibility localized stresses either around the eye the section where the eye blends into the column section. Formerly the severe lateral bending due the high eccentric loading encoun- tered plain bearing design caused rod failures where the eye merges into the body section. the forged rods the design such that the lateral width decreases the vertical depth increases throughout the critical section, uniform stress- ing being maintained throughout. Length between centers varies according locomotive design, but the column section all main rods in. deep in. wide, the flanges being 13/16 in. thick and the web in. the bearings the width only in., but section area and stressing maintained con- stantly increasing the depth and Trim Flash Finish Drop Forge Trim Flash Rough Drop Forge 2—The four major steps the forging allo rod. t - ‘es q >. \_ \ - } : = ye =