The Iron Age 1937-04-01: Vol 139 Iss 13

| og wet « ans REAL, ae » | Mi RING WORKS LTe 3 ENGINE Te a DAVY and FOUR STAND TANDEM PLATE ith lt We. lesigned and built by iy 2—THE IRON AGE, April 1937 AGE, published every Thursday the CHILTON CO., (INC.). Publication Office, Chestnut 56th Sts., Philadelphia, Pa. Editorial and Executive Offices, 39th St., New York, Entered second class matter November 1932, the Post Office Philadelphia under \ct March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 139, No. 13. FRITZ FRANK President VAN DEVENTER Editor c. E. WRIGHT A. I. FINDLEY Managing Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Washington Editors Resident District Editors Chicago Cleveland Detroit Pittsburgh Editorial and Executive Offices Editorial Correspondents STR NEW YORK, London, England Cincinnati Boston Hamburg, Germany Milwaukee San Francisco SANDERSON ROUNTREE, JR. ALLISON Toronto, Ontario Birmingham St. Louis Buffalo Contents April 1937 Time Change the Medicine ................ Welding Problems the Automobile Industry Playing Safe the Bethlehem Plant ... Rubber Lined Sewer Pipe for Acid Waste Why Railroads Should Buy Modern Machine Tools..... Modern Rolls for Modern Truck Builder Improves Finishing Operations ........... Statistics Metal-Working Activity ...... CHILTON COMPANY NEWS CONTENTS ....... and Sts., Philadelphia, Pa. 239 West 39th Street, New York, FRITZ FRANK, Executive Vice-President Index Advertisers .......... FREDERIC STEVENS. Vice-President JOSEPH HILDRETH. Copyright 1937 Chilton Company (Inc.) EVERIT TERHUNE, BAUR, General Advertising Manager ERNEST HASTINGS, DIX, Manager Reader Service Member, Audit Bureau Circulations ADVERTISING STAFF Sts., Philadelphia, Pa. Hottenstein, 802 Otis Chicage JULIAN CHASE Leonard, 239 39th St., New York tion Price: United States THOMAS KANE Mexico, Cuba, Peirce Lewis, 7310 Woodward Ave., Detroit CHARLES BAUR ada, $8.50; Foreign $12.00 year. Ober, 239 39th St., New York Single copy, cents. Robinson, 428 Park Cable Address, ‘‘Ironage, Warren, Box 81, Hartford, Conn. FAHRENDORF JOHN VAN DEVENTER Indexed the Industrial Arts Index. CARROLL BUZBY Editorial under — ; es op Let’s figure out Ryerson Stocks Include: Beams and Heavy Structurals steel from Ryerson and have tomorrow. Channels, Angles, and Quick production—rapid turnover. depreciation— obsolete stocks. Steel, Flat Wire, save time and trouble. Time placing orders—time interviewing salesmen—time following orders—time Finished waiting for shipment—time receivi Screw Stock receiving, checking and Extra Wide Finished Flats paying tor the material. Alloy Heat Treated Alloy Steel Bars —And, better still, worry over meeting production schedules elim- Boiler Tubes and Fittings inated. Ryerson has all steels well stocked ready for immediate ship- ment. experienced organization, with special cutting, handling Rivets, Bolts and shipping facilities, gives added assurance against delay. When Bars you need steel—call Ryerson—it pays. Babbitt Metal and Solder you not have the current Ryerson Stock List, will glad send it. JOSEPH RYERSON SON, Chicago, St. Louis, Detroit, Buffalo, Philadelphia, Boston, Jersey City. 36—THE IRON AGE, April f @ ee é i THE IRON AGE APRIL 1937 ESTABLISHED Vol. 139, No. Time Change the Medicine American public getting this time intensive and rather costly object lesson theory versus practicality. have been spoon fed, for five years, the theories concocted professorial minds human conduct and relationships. The collegians have mixed the dose and the politicians have manipulated the spoon. large part the public has swallowed the mixture willingly, because has been liberally mixed with sugar the form cash and promises. Those who thought was emetic, rather than tonic, have been subjected forcible feeding. What has gone down now beginning come the form the most violent eruption discord and disregard for law and order that this country has experienced since the Civil War. When and where will end and what cost, one can foretell. Certainly will not end long those power con- tinue give the same medicine that has caused the trouble. have quarrel with the New diagnosis our economic ills, have with its treatment them. All may agree with the belief that labor should have more purchasing power; but dose medicine the form wage rises resulting price inflation not the way achieve it. Many will unite the belief that labor should permitted raise its voice collective bargaining through such agencies chooses, but when labor's voice becomes that dictator which renders State Federal laws and courts im- potent, the medicine causing inflammation. Inflation disease that uncomfortable but not often fatal. Inflammation class hatred, unless promptly checked, will bring the body politic its death bed. The time stop the fever inflammation when starts. And can not successfully treated political would have our country today the Governor Michi- gan had enforced the law Flint. shall have more them than ever, now that, the Detroit emergency, law and law enforcement have virtually been de- clared incompetent the Governor his passing the job John Lewis removing trespassers from private property. time change the medicine. - { i Mpc 5 } > Metallurgical Problems THE very wide appli- cation welding the automotive indus- try has been dictated sound engineering principles. First all, welding joins parts into one whole, strength and eliminating rattle and wear. Second, duces unnecessary weight. Third, the use automatic welding ma- chines has reduced eliminated the human factor, and consistently good welds obtained. Fourth, welding has materially re- duced the cost production. The extensive use welding the Ford V-8 may shown the following figures: Tudor sedan, there are approxi- mately 3800 welds the body and chassis exclusive the welds component parts such horns, generator and lamps. all these welds per cent are spot weld- ings, per cent arc weldings, per cent oxyacetylene weldings, and the remaining per cent made resistance butt-weld- ings and seam weldings. These figures, however, not actually give true comparison between the various welding processes be- cause they are based number welds and not inches surface welded. The various welding processes may two classes: metals are heated well above their melting point, and their union brought about the liquid state; and those processes which the metals are heated the plastic state and which the application *Condensed from paper presented Dr. Giulio Feb. before the Detroit Section the American Weld- ing Society and the Detroit Chapter the American Society for Metals. 38—THE IRON AGE, April 1937 DR. ARMAND GIULIO Metallurgist, Ford Motor Co. pressure causes the union take place. The first class weld- ing includes the following esses: (1) gas welding, (2) elec- tric welding, (3) brazing, and (4) thermit welding, the differ- ence between the processes being the source heat. Underlying Metallurgical Factors Without entering into tailed description each these processes, may consider the metallurgical factors upon which depend the quality the weld. The heating the metals above their melting points, quent cooling, results sequence conditions which the chem- ical and physical properties the metals undergo marked changes. the automobile industry, are concerned mostly with the welding steel, and, order understand what takes place when two pieces steel are welded, must refer briefly consider steel containing 0.4 per cent carbon, the cycle changes during welding may summar- ized follows: the annealed condition, this steel consists ferrite and pearlite about equal proportions. The carbon present the steel only slightly solu- ble ferrite, and, room tem- perature, present the cemen- tite the When this steel heated the eutectoid temperature about 1335 deg. F., the pearlite becomes unstable and transforms into austenite. this phase, carbon goes into solution the extent represented point corresponding 1.7 per cent. Ferrite also begins transform into the non-magnetic phase, and upon reaching the line, changes into austenite. Further increase temperature within the region austenite re- sults increase the grain size until the line reached, Within the area and BC, melt- ing continues until point line reached (about 2700 deg. F.) where the austenite decom- poses into delta iron, plus liquid. Above line ABC, the alloy to- tally molten. Reactions between the metal and the slag, and be- tween the metal and the gases present, take place primarily when the metal the molten state. These reactions are very similar those which take place the open-hearth furnace and are re- sponsible for the changes which occur both the electrode and the metal welded. When cooling begins, reverse process the one described takes place. Oxidation Held Minimum Numerous researches have es- tablished the fact that all the pos- sible sources heat fusion welding cause oxidation. Therefore, care must taken order minimize this effect. For instance, carbon may oxidized the extent per cent the original amount steels con- taining from 0.25 0.48 per cent carbon. The amount carbon “burned” depends primarily upon the type electrode used and the nature the atmosphere sur- rounding the weld. the other elements present steel, silicon 7 t 7 : — | j { easily oxidized; next man- ganese. The gas content the deposited metal also affected the nature the electrode. bare electrode, for example, de- posits about 0.3 per cent oxygen and about 0.12 per cent nitrogen, whereas shielded arc electrode will deposit material containing about 0.06 per cent oxygen and 0.018 per cent nitrogen. course, gas welding, the type flame used will greatly determine the amount gas left the weld. general may said that stronger and weldings are produced with shielded elec- trodes. any fusion welding process, heating accomplished very rapid rate and relatively small area. Consequently, due the thermal conductivity the metal, there present tempera- ture gradient which covers zone extending from the melting point steel the weld point un- affected the heating. cool- ing, heat dissipated from the central part the weld faster rate than from the outer portions. within this uneven temperature zone that changes illustrated the iron- carbon diagram take place very rapid rate. Equilibrium con- ditions are not reached. There- fore, the structure the weld and the metal adjacent show practically all the stages transformation for the steel in- volved. see what takes place, let examine under the microscope typical weld. sample was taken from the weld Ford front radius rod made from flat steel composition similar S.A.E. 1040 rolled into tube. The tubes were next placed continuous are welding machine which the seam was welded the rate about in. per sec., using electrode the follow- ing composition: 0.10 maxi- mum; Mn, 0.20 maximum; 0.02 maximum; 0.03 maximum. The photomicrographs, Fig. show the structure section the weld. can seen from the structure the high-carbon steel, that the cooling was very fast because the trans- the Automobile Industry* formation from austenite fer- rite and pearlite has produced very fine pearlite surrounded ferrite. the cooling had been slower, the temperature trans- formation would not have de- pressed and the resulting pearlite would have had more the ap- pearance the conventional plate- like structure, easily recognized even low magnification. Gas welding finds only ited number applications the production the 1937 Ford. These Fic. diagram. THE IRON AGE, April 1937—39 x F | i are found mostly joints between the body proper and the floor panel, and places where would impossible use other welding machines. Resistance Welding Important Auto Industry Pressure-resistance type weld- ing the one which finds its greatest application the auto- mobile industry. The resistance type welding far the most important for the automobile in- dustry because its extensive application and the large capital invested. Its greatest advantages IRON AGE, April 1937 >, £ d* 0.40 carbon steel tube. (A) Typical structure hot-rolled steel unaffected zone. (B) Zone which was heated not much above the point where recrystallization takes place. (C) Zone heated high within the austenitic range, where large grains were produced upon cooling. (D) The weld itself, are: (1) smoother finish, and (2) quicker and more flexible method fabrication assem- blies. this class weld, the parts united are brought the plastic stage the passage electric current, and the ex- ertion mechanical pressure helps cause the union the parts. has been stated that the heavy lo- calized heat and pressure cause recrystallization the metal fol- lowed grain growth which per- mits the grains grow together. Heavy localized pressure small area will provide the strain necessary for recrystallization. with the higher carbon tube material left and low-carbon steel the electrode the right. Electrode material the as-cast condition, with large columnar crystals. (Magnification, 500x) Resistance-butt welding consists gripping the pieces between two electrodes “jaws” and press- ing the parts together while the electric current causes heating the surface contact. The heat generated high enough bring the metal plastic state and with the proper good welds are obtained. some applications, the pressure regulated produce arcing effect which results welding. welding finds only limited number ap- plications the making the Ford V-8, but used im- portant parts such welding the front radius rod feet, and welding the left and right mem- bers the radius rod. The so-called right and left foot are forgings made steel similar These forgings are given quench and draw treatment before being welded. Both static and fatigue tests are performed daily ascer- tain that the weldings not any way impair the desired physi- properties the assembly. such the hood hinge bracket base the retainer, the head- light unit retainer the front fender, and the rear reinforcing assembly the hood top. Seam welding may consid- ered series overlapping spot welds. typical application seam welding the con- struction the gas tank which consists terne plate welded series stationary machines. spot welding, the pieces welded are placed between two 4 electrodes whose tips are relative- small and large current Heavy pressure applied the electrodes and, immediately after, the current passed for short interval time, the pressure be- ing maintained momentarily after the current has been shut off. modern automatic welding ma- chines, elaborate timing devices permit close regulation pres- sure and current which assure welds uniform quality. would 3—(A) Structure 0.40 carbon forging after quench and draw. (B) Structure resistance butt weld between forging and tube similar material. The structure weld this type seen the photomicro- graphs, Fig. seen the structure the forging, while seen the structure the weld proper. Referring structure the are weld Fig. one can notice that there considerable difference bet ween the structures the two welds. Fig. the grains are well defined and much larger. evident that although the tempera- ture this weld was never high the previous one, the mass metal heated that cooling took place much slower rate. Hence, formation austenite ferrite approached more nearly equilibrium conditions. Spot Welding Most Used Projection welding finds its ap- plication where small parts are piece. can used successfully for thicknesses in. the Ford passenger car, applications projection welding are found various assemblies the body, 4—Surface spot welds made with electrodes. IG. Unetched section rough spot weld made with mushroomed tip. ° (500x) 5—Uneven surface spot welds made with roomed" electrode. THE IRON AGE, April | | 4 almost impossible enumerate all the parts the 1937 Ford which are joined means spot welding, but constitutes far the most used process welding and its use increasing contin- uously. Proper Electrode Important Spot Welding The chief metallurgical prob- lem arising connection with spot 4 4 - & wr Fic. 7—Structure good spot welding the choice the proper electrode material having the fol- lowing properties: High electrical conductiv- ity required order decrease the resistance and prevent over-heating the point contact. High thermal conductivity nec- essary keep the electrode tips cold possible. most spot welding machines, water cooling either the use hollow electrodes circulating water around them. combination hardness, impact and wear resistance and retention these prop- erties are necessary, because with resistance welding general, and primarily spot welding, the electrode must able withstand high pressure applied suddenly. necessary, therefore, that the area contact between the electrodes and the pieces constant. the tip area becomes larger and uneven, the unit pressure becomes lower and poor weld obtained. 42—THE IRON AGE, April 1937 One can hardly overemphasize the fact that the electrode tip must smooth and uniform area assure good welds. This point Fig. shows the smooth surface obtained when the electrode tips are kept the proper condition, while Fig. shows the surface spots produced points. Not only the surface but the weld itself affected can the weld illustrated Fig. unetched show what seems tear the metal, pro- duced the electrode tip sticking the surface the steel. Fig. shows the appearance good spot weld. There appears the coarse structure produced the heat and the pressure. The line the weld visible and both sides one may see the extent the zone which the highest temperature was reached. For the average spherical pointed electrode, this zone shape elongated ellipse whose major axis parallel the sur- face the steel. Fig. shows the structure the weld one the spots Fig. Heat and pressure were not uniformly dis- tributed. Consequently, crystallized zone extends unevenly across both pieces sheet steel. Such structure indication poor weld, fact which further proved physical tests. The requirements electrode material are such that are limited our choice non-ferrous metals and alloys. The operating temperatures almost all resis- tance welding processes are such that copper electrodes are softened and become useless after tively short time. For this reason, and also because the increased tendency toward higher working pressures, became necessary develop other alloys which could substituted for the pure copper electrode. result, several alloys are now avail- able whose electrical and thermal properties are not high those ~ 8—Structure poor weld, showing the recrystallized zone extending unevenly across both pieces sheet steel. pure copper but the other physi- cal properties, especially hardness, are much better. Although their cost per pound considerably higher, they have replaced copper electrodes almost completely cause actual service they are more economical due their longer life. These alloys possess age hardening properties, that is, they can hardened heat treatment. However, even for these alloys there exists tem- perature which they become soft and care must taken that, service, this temperature never approached. Cast Electrodes Save Machining this connection, oppor- tune mention that the Ford Mo- tor Co. has very successfully pio- neered the use cast elec- trodes. These cast electrodes have made from bar stock, and the casting process has resulted considerable saving due the re- duced amount machining. the present, small plant en- tirely engaged the preparation resistance welding electrodes. © +. 4 E > - 4 | “Playing Bethlehem Plants ‘ plants the Bethlehem Steel Co. that are adjacent tracks roadways are equipped with “cat remind possible danger from ap- proaching yard engines other equipment. land plant the Bethlehem Steel Co., Sparrows Point, Md., wear “heat constructed fine-mesh wire screening. The fine screening checks the heat absorbing it, making their work more comfortable and also safer. a HERE'S vigilance that’s automatic. Note the wrist- lets and attached wire cords worn the operator this punch press machine, the @rop forge shop the Bethlehem Steel Co.'s Bethlehem plant. Should this operator negligently leave his hand the path descending punch the cord would become taut, jerking the hand away from the danger zone. ERE non-skid wheel barrow, the type now em- ployed many services the Bethlehem Steel Co. The rubber tire takes the jolts and prevents the wheel slipping sideways when passing over tracks other obstructions. THE IRON AGE, April 1937—43 4 ‘ § 3 | 4 q q FIG. 3—A portion the com- pleted line. THOSE who have close- followed the develop- ment modern continu- strip pickling meth- ods during the past five years are well acquainted with the contribu- tions which the rubber industry has made toward increasing the effi- ciency this operation. First, the process which permits the bonding rubber steel with practically integral adhesion. Then Triflex—a three-ply acid-proof rub- ber lining combining the advan- tages both hard and soft rubber 44—THE IRON AGE, April 1937 Rubber Lined Steel and equipped with built-in expan- sion joints. Five years ago the use rubber the pickling room was consid- ered daring experiment. Today, check outstanding strip mill installations will show practically one hundred per cent acceptance this material lining for tank and ventilating equipment. Although the problems leak- ing tanks, acid loss and fume dis- posal have been successfully solved, there still remains the important one acid disposal. Many pickling operations, particularly continuous strip, present problem han- dling spent pickling liquor hur- riedly and large quantities. most instances not practical allow the acid cool prior emptying into the sewer. Since the uncooled acid ranges tem- perature from 160 200 deg. F., cannot satisfactorily conveyed through ceramic pipe due dan- ger cracking thermal shock. Such condition naturally objectionable because high main- tenance costs and possibility acid leakage points where apt cause undermining build- ing structures. pioneers the use rubber- lined tanks for strip pickling, engineers the Inland Steel were the opinion that rubber might well used for acid dis- posal service. conjunction with engineers The Goodrich Co., they set about find ways and means further utilizing this material. They were successful efforts and result the Inland Steel Co. has installed its In- diana Harbor plant during the past year acid sewer line embodying entirely new design. The sewer consists approximately 650 ft. standard 18-in. steel pipe with plain ends. Pipe lined with Triflex rubber which extends out over either end and carried back for short distance the outside. The lengths pipe are coupled with Flexlock rubber gaskets and rubber-lined split steel ARGE quantities spent liquor must handled rather high temperatures connection with continu- ous pickling operations such accompany continuous strip production. Disposal this liquor has been satisfac- torily accomplished means rubber lined steel sewer pipe lines. This gasket, which recent Goodrich development, consists rubber ring having internal and external circumferential ribs which grip both the pipe and the sleeve. Each end the pipe has Flex- lock gasket snapped over and the gaskets are compressed make seal with the split sleeves. Side rubbers are inserted furnish the necessary compression the point where the two halves the sleeves join. The pipe supported both front and back each joint the Flexlock gasket not designed take load but merely act seal. After the iine was installed was tested with 20-lb. water pres- sure and showed absolutely leak- addition resisting the se- vere thermal conditions this ser- vice and thereby preventing failure due cracking the line, this construction offers number outstanding advantages. The pipe easily only necessary snap the Flex- lock gaskets over the ends, place the lengths their respective po- sitions and bolt the split sleeve over the two pipe ends. Inland, after the pipe was strung along the ditch, approximately 300 ft. the 18-in. sewer line was laid less than four hours. The use Flexlock gaskets per- mits joint flexibility its construc- tion such that slight angularities line can installed with- out fabricating special angle pieces. The joint will allow also for rea- — 4 ? bs 4 ol > . ti 4 sonable amount settling the line after installation. made for expansion. When the pipe installed space approximate- in. allowed between pipe ends. The Flexlock gaskets con- tinue seal, regardless the ex- pansion contraction the line. The Triflex construction used the pipe proper offers the desirable properties both hard and soft rubber. has the sistance hard rubber plus the desirable expan- sion and contrac- tion properties soft rubber. The sion vent buckling cracking the lining any one length pipe. With the use there was always the danger its cracked due The rugged con- struction offered steel pipe elim- Sewer Pipe Handling KLEIN Chemical Sales Division Goodrich inates all such worries. However, individual pipe length should the arise. Due to.the fact that space left between the pipe ends time installa- damaged length and cid Waste placement without disrupting any other portion the line. This sewer line has been service for several without any signs leakage. result this highly satisfactory performance, the owners feel con- fident that with this installation they have eliminated all problems acid disposal for years come. Two other large strip mills haye recently adopted this method handling acid waste and the lines, one 1600 ft. length and the other 610 and are now process installation. Both lines are 16-in. pipe. ment rubber- lined steel prpe for this service should prove ‘of double interest members the Not only does clear away one the final obstacles efficient, low- cost pickling op- erations, but _opens en- tirely FIG. 2—Rubber sleeves and gaskets prior THE IRON: April 1937—45 c ° Be FIG. steel sewer rubber lining installed Why the Railroads Shou effecting economies increasing output, either industrial shop, modern equipment neces- sary. Labor’s effort and manage- ment’s most perfect supervision can accomplish little without the proper tools with which work. the case railroad shops, with equipment averaging more than years age, the much faster modern tools would ob- viously considerably shorten the machining time involved making necessary motive power repairs. The less time required for the locomotives the more time these revenue-producing units are available for profit-making ser- vice. With fewer locomotives fines today than were service during the early months 1930 and with traffic nearing the level that year, there increasing demand for faster repairing. Un- repairs are speeded short- ages motive power may develop. That railroad management con- scious the possibility such shortage seems definitely reflected from the heavy purchasing loco- motives during the last few months 1936. Many railroads not only need this new and more efficient motive power, but also need modern ma- chine tools adequately handle the repairing it. Some roads that invested heavier locomotives the late ’20’s found, for example, that the new locomotives could not repaired satisfactorily with the shop facilities their disposal. During the depression few these roads had spend consider- able money for shop improvements HIS driving box borer and facer machines boxes the rate min. per piece, floor-to-floor time. 46—THE IRON AGE, April 1937 —money that could have been used for operating during those slack years. With the replac- ing more and more the old light power with heavier locomo- tives, logical expect that other railroads will similarly find shops service the new power sat- isfactorily. This pressure replacement in- capacitated machine tools, either speed repairing adequately service the new power, will result reducing costs. the repairing motive power accounts for per cent railroad operating costs, Buy HORTAGE locomo- tives indicated not only statistics, such those included with Mr. previous article, THE IRON AGE Feb. 34, but the recent eavy purchasing new motive power. The situation many dollars can added earn- ings through more efficient meth- ods. Furthermore, with competition — | Modern Machine Tools definitely calls for speed- ing repairing. The role modern ma- chine tools this, and the servicing the newer locomoti es, well effecting economies the cost repairing, discussed this article. the handling traffic increas- ing with both labor and material prices the rise and with more less rigid rate structure con- tend with, important that the greatest possible efficiency at- tained the maintaining well the operating locomotives. Thus, the replacement inefficient machine tools will not only benefit profits keeping revenue-produc- ing units more actively engaged, but will increase profits reduc- ing the actual cost repairing these units. Only the repairing steam pow- has been considered here be- cause the present has been mainly steam power with which the railroads have had deal. There ° ° ° LEE STERRY The Bullard Co., Bridgeport, Conn. ° ° ° are relatively few electric and Diesel locomotives service today that their repairing problem small relation the problem repairing steam power. Although modern machine tools can definitely assist the railroads the various ways outlined above, should understood that the machine division locomotive shop only one factor the main- taining power. Actually, the man hours labor the machine department locomotive repair shop are only about per cent the total man hours in- volved classified repairs. this time from per cent di- rectly machine time, the balance being bench work. Thus, far machine tools are concerned, only about per cent the labor involved locomotive repairing directly affected them—a fact that would seem indicate less need for installing modern ma- chine tools than generally sup- posed. But far have considered only the direct savings, which are probably the smallest part the benefits possible, since the speed work done the machine depart- ment railroad shop has direct bearing the speed repairing nearly all other divisions the shop. Actually the total time repairing locomotive governed considerable extent the time the longest individual job. The speed repairing departments other than the machine shop con- trolled large extent man power, but the machine shop the machine the controlling factor. Thus when the machine shop op- erating capacity, additional 24-in. vertical turret lathe tooled for rapid machining brasses. THE IRON AGE, April 1937—47 ity Te 4 rey 4 4 i. : . are better men are little help speeding repairs. Modern ma- chines must purchased replace the 20, and 40-yr. old tools ac- tive service cut the time this work and keep this department bal- anced with the effective output the others. Quality work turned out the machine department also defi- nitely affects other shop operations. With the old machines and pressure for fast repairing quite possible satisfactorily accurate work; but with time element and only old machine tools available, the work less accurate, and considerably more time re- quired for fitting other depart- ments, hence slowing all repair- ing. course, with number old machines and ade- quate man power, difficulties might not experienced. During the de- pression, however, the railroads re- tired many worn-out and obsolete machine tools abandoned shops, they did motive power, and hence have not the same facilities they had available few years ago. addition, skilled labor not plenti- ful today and therefore the maxi- 48—THE IRON AGE, April 1937 mum output per man definitely needed. With modern tools, better work can produced considerably fast- and less experienced help LEFT packing rings are machined this set-up the rate pieces per 8-hr. day. plain rings, the pro- duction pieces day. BELOW LAIN Hydromatic milling machine employed the Lehigh Valley Sayre shops for finishing four surfaces in. bronze crosshead shoes one opera- tion. Shoes are fin- each, giving 8-hr. production shoes—with per cent com- pared with machin- ing the previous method. than needed with machines that along. Hence with modern equip- ment not only can repairing speeded but accuracies can maintained and some cases im- proved, and the difficulties find- ing highly skilled workmen may great extent alleviated. These greater today the modern rail- road shop, both speeding repairs and effecting economies, than they would have been few years ago. The trend today toward centralized shops against the numerous small shops years ago; and this has been made neces- sary and possible through the use heavier and more efficient motive power that able more miles between shoppings. principle all work now flows through the shop production basis and any delay one department has much more serious effect the output subsequent departments. With the greater amount re- pairing done these centralized shops, there has been greater de- partmentalizing operations, and production scheduling systems have been installed. This modern locomotive more production plant, with all the benefits, and also all the disadvantages, derivable from this production principle. With each re- pair job worked schedule and —e = the activity the entire shop tied together this manner, much more serious condition exists when one department cannot keep up. Operating with 40-yr. old equipment the machine department extremely handicapped its in- ability increase output only adding men. The machine department today much more parts production department Through understanding draw-cut shaper ing steel driving duction the rate boxes per 8-hr. day. between the stores department and the shops and through greater standardization, new work being produced larger quantities the main shop, stored and then shipped outlying shops needed. Much this work can only roughed out, with sizing operations done when fitted, but even source time and money savings. Although these changes larger quantity repair make for faster and nomical repairing even with the 20-yr. old tools use today, still greater savings are possible through modern machine which are more adaptable this type production. Not all railroads have made these changes their shop operat- ing methods, but the trend this direction, and the changes take place the need modern ma- chine tools will become more ap- parent. With machine tools major fac- tor the speeding repairs and cutting costs, the direct sav- indirect benefits outlined above may now considered. impossible state definitely that with the new tools per cent more repairing could done that costs gen- eral could reduced definite amount, because the effect the new tools the whole depends upon too many conditions. How- ever, possible cite economies made individual parts through the use modern machine tools. modernizing the Oelwein shops the Chicago and Great Western, 135 old tools were replaced modern motor-driven machines and sufficient capacity maintained for all needs. this case, the old tools, picked random, averaged yr. age, which indicates some extent why few new ma- chines were needed. The equipment was installed the same time that other major changes were made operating methods and arrange- ment the shop, that the new tools had all the advantage sys- temized operating procedure. this case the rearranging the shop and the purchase modern machines was made necessary the need facilities repair the heavier power purchased 1930 must done other railroads the new power they are now pur- chasing put into service. Some the savings obtained individual jobs are quite outstand- ing. modern 24-in. lathe reduced the time turning piston rods and fittings from hr. min. hr. min. because the greater power the new machine and the ability machine the work higher speeds and with heavier cuts. Another lathe, the wheel shop, reduced the time turning hr. another case 30-in. slab grinder used variety parts per cent over previous methods. the Reading shops the Reading Railroad, where the major part this road’s locomotive re- pairing done, old machine tools averaging years age (CONTINUED PAGE 122 THE IRON AGE, April 1937—49 | THE rapidly increasing acceptance stainless and high-alloy steels wide range mar- kets has been responsible for sig- nificant changes certain producing equipment. the mechanical and chemical processes *All data and photographs used this article were furnished Pitts- burgh Rolls Corp., Blaw-Knox Co., Pittsburgh. OURING alloy iron into manufacture are the subjects continuous experiment search. New tools, new machinery, new chemical and alloy formulas are being introduced, which result improved methods and improved equipment meet the demands producing this steel. The introduction stainless sheets and plates has resulted certain definite changes the tech- OADING iron rolls into fired heat-treat- ing furnace. 15-ton heat nique roll making. Roll manu- facturers have not been slow realizing the needs and problems which concerned their product. the roll tool for specific use stainless alloy steels has been evolved. There are, course, vari- ous types for various problems, but definite improvements have been made available the modern roll. There are three important steps which have been taken roll pro- ducers meeting the new condi- tions imposed stainless and high-alloy steel rolling. They have introduced into the rolls alloys provide greater strength for heat and stress resistance. They have increased resistance firecracking and wear. They have provided “mirror finish” the roll surface facilitate the production superior, flawless surface upon the finished product. These three fac- tors each have brought direct benefit the producer. Upon analyzing the three steps, the re- sultant advantages will made clear. The first fact importance present problem, that the in- troduction nickel, chrome, and other alloys necessary for the pro- duction the alloy steels, in- creases the melting point the metal. Consequently, the rolling temperature the ingot bloom delivered the mill from the soak- ing pit high. This, course, subjects the rolls greater heat stress. the other hand, often not possible deliver the mate- rial the rolls temperature high enough prevent decided increase stress during reduction. then, such alloy steels, the old time carbon even the semi-steel roll used, mill operators are faced with new possibilities breakage and wear. Reduction drafts and increase the num- ber passes become necessary, and loss efficiency results. The roll manufacturer has solved this problem the first step; the in- ¥ for Modern troduction new alloys into the rolls. Although this step was necessarily accompanied longer and more expensive heat treat- ments the rolls order reap the full benefit the alloys, this way the roll maker has kept with the introduction new alloys the production field and im- proved his product. The second step, the increasing resistance firecracking and wear, direct result the fact that alloy and stainless steels re- quire smooth finish, free from all blemish. For semi-finished steels, slightly firecracked roll could used with ill effects the fin- ished product, since perfect sur- face finish not necessary. Great wearing quality also will contribute good surface finish. But does more than that. permits in- creased drafts and fewer passes the attainment the duction. Greater efficiency and increased tonnage result. great many high-alloy and stainless steels require “mirror finish,” flawless perfectly smooth, the name implies. Since any roll surface mark defect would necessarily conveyed and enlarged upon the rolled sur- face, roll bearing mirror finish has been developed. Because the perfection this finish, impor- tant economy time saving also realized, since such rolls require far fewer dressings. from the three important im- provements roll manufacture the production field may derive three distinct benefits which will apply their rolling stainless alloy HERINGTON steels. The modern roll will give them greater strength for heat and stress tension. will give great- resistance firecracking and wear. will give superior surface and reduction roll dressing needed. With quality definitely becom- ing the key word the steel indus- try, there can real economy using roll improper chemi- treatment the rolling high al- loy and stainless steels. The roll maker stands prepared provide superior tool aid the mak- ing superior product. LEFT rough- ing grinder be- ing shaped near final finishing size. BELOW type ishing parting within in. mean diameter. | a Truck Builder Modernizes Finishing Operations MOTOR truck manu- facturers are following the recent design and better finish, shown the later models trucks, both the heavy and commercial delivery types. Streamlining has been extended the truck building industry and considerably more sheet metal used the fabrication fenders and other body parts than few years ago. Fenders are larger than formerly and now have skirted fenders. Dull gray for long time was Now truck builders are getting away from the somber gray and are finishing trucks bright colors. Operators trucks for many purposes, particularly store delivery trucks, there advertising value the use trucks that are finished attractive colors that are pleas- ing the eye. Attention also has been given recently the rela- tion color safety. Trucks 52—THE IRON AGE, April 1937 finished bright colors more readily seen night and, stated, are less frequently in- volved collisions other acci- dents than trucks painted dull gray. The White Motor Co., Cleveland, some time ago streamlined all its models trucks and supplying these almost any color com- bination colors the buyer de- sires. The increased importance the metal finishing department motor truck plant together with its desire reduce finishing costs and provide better and more durable finishes led the White company discard its previous finishing methods and install new conveying and other equip- booth which the primer coat applied sheet metal truck parts while moving overhead conveyor. Back the booth the left the picture the baking oven. ment for coating truck parts. Formerly the parts were trucked and from spray booths which they were given lacquer finish. This was slow process that required great deal labor for handling. With the new layout, parts after being cleaned are hung end- less chain conveyor which they move while being three spray coatings, two bakings and sanding. When they leave the con- veyor they are ready assembly the chassis. Synthetic tuted for lacquer coating ma- terial. The use enamel instead lacquer necessitated the installa- tion baking ovens. Installation the modernized painting system has resulted much speedier pro- duction, sharp savings finishing costs and conservation space. the White plant used for enameling fenders, cowls, running boards, shields and miscellaneous sheet metal parts. Another paint- ° ° chassis, while moving the as- sembly line, passes through spray booth which the frame and various assembled parts are painted. ° ° somewhat smaller has been vided for finishing lamps, hoods, radiators and cabs. The painting equipment fenders located along one side the final chassis assembly room. Sheet metal parts, trucked from the material control room, are stacked storage space con- venient the conveyor line. The first operation cleaning formed the side the parts storage space. The work first washed hot alkali solution and then rinsed hot water, after which hung the plant con- veyor. Here the pieces are wiped with cloth dipped lacquer thinner and then tack ragged. The conveyor the overhead endless chain type 750 ft. long. parts for trucks are given two finish coats syn- thetic baking enamel they move along conveyor this double spray booth. From the booth the pieces move the baking oven the background. follows somewhat rectangular course around the painting depart- ment, but also makes several loops within the rectangular space, with- which the spraying and baking equipment located. The pieces are suspended from the conveyor chain work holders various shapes fit the different pieces. These work holders are hung 40-in. centers hooks that form part the conveyor chain that the holders are interchange- able. Sheet metal parts enter THE IRON AGE, April 1937—53 single spray booth and are given coat primer surfacer, oil oxide base primer being used. This has filling qualities that cause the coating fill slight scratches and weld marks. After priming, the work passes through oven. emerging from the oven and while moving along the line, the pieces are sandpapered smooth Beyond the point sanding the conveyor loops back through double spray booth ft. long, which the parts are given two finish coats synthetic bak- ing enamel. The speed the con- veyor permits 5-min. interval between the two sprayings this booth. From the enamel spraying booth the conveyor moves straight line back into the baking oven. Both the prime and finish coats are baked one hour tempera- ture 200 deg. The oven built the White plant, gas-fired Surface Combustion Corp. heater with capacity 1,000,000 B.t.u.’s. The conveyor makes two loops through the prime coat side the oven, bringing the work out the end opposite which enters, but the finish bake side makes but one loop, coming out the side which enters. The oven ft. long the prime baking side and ft. long the finish coat bak- Offers New Leak Proof Roofing NEW form galvanized cor- rugated roofing for roofing and siding, which claimed leak proof, has been brought out the Kor-Lok Co., Union Trust Building, Cleveland. apply- ing this roofing nails are driven into the sheets, nail holes and the leaks caused them are obviated. 54—THE IRON AGE, April 1937 ing side, but with the arrangement the loops the length travel through the two sides identical that the baking time the same both sides. After emerging from the oven the conveyor with the finish baked parts loops around the end the painting department and moves along straight line the start- ing point the other end the room. While moving along this sec- tion the conveyor, the enameled parts are taken from the conveyor and subassemblies are made dur- ing their short travel the chas- sis assembly line, which extends down the center the room par- allel with the overhead painting conveyor. Production the paint- ing department with the chassis erection schedule. The conveyor serves bank for parts and thus space that otherwise would necessary. The finish coat spray booth well ventilated, fumes being car- ried away two large stacks the indirect exhaust method. The spraying enamel handled gal. tanks and the material, which mixed the plant, checked every day make sure that the established standard viscosity maintained. The tanks are filled twice day noon and night that they are always Leaks resulting from capillary at- traction are also said entirely avoided minimized, and siphon- age eliminated. Designated the Kor-Lok, this forming machine the sides the ordinary corrugated sheets form interlocking joint. The formed sheets have concentric curved sur- faces and flanges along the sides that there close contact be- tween two sheets when their flanged edges are joined and kept least half filled with enamel. The time cycle for handling the pieces the paint line until they are removed with their finish coat enamel, ready assembled the chassis, approximately hr. The conveyor operated variable speeds, but usually moves about in. per minute. The production capacity the paint- ing system parts for trucks 8-hr. day. Only seven men are required for its operation, two for cleaning the pieces, one for spraying the prime coat, two for sanding and two for spraying the finish coating. Work taken off the conveyor the men employed the chassis assembly line. Be- fore the painting system was in- stalled, was necessery during normal production have eight painters work night keep the assembly line supplied with parts. After the chassis has undergone partial assembly with the motor and its auxiliary parts, axles and wheels mounted the frame, spray painted booth while moving along the assembly line conveyor with two coats air- drying synthetic enamel. The mov- ing chassis washed with naphtha the conveyor and the motor covered protect from the spray before the chassis enters the booth. seam provided that said practically water tight. The sheets are fastened the roof side wall small clips stamped from 18-gage steel corre- sponding shape the formed flanges. The clip fits snugly over the curvature along the side the bottom sheet and when place nailed the roof deck. The top sheet then slid over into posi- tion. When applied steel framing the clip welded strap, one roofing formed ma- chine left applied shown above. — ‘ | 7. — ° ° ° spindle this turret lathe mounted tapered roller bearings and has bore. The machine for boring, turning, fac- ing, and tapping op- erations large steel forgings. end which bent around channel, or, instead being weld- ed, the strap may put through slot the clip. sheet metal clip easily made the roofer may also used fastening device the sheets are fastened wood. The Kor-Lok Co. was organized Harry Ansel, mechanical and structural engineer, who its pres- ident. The sheets and fasteners are covered patents and license arrangements will made with distributers, whom machines for forming will furnished. New Line Fluid Motors first unit new line fluid motors multiple-piston type has been introduced the Sundstrand Machine Tool Co., Rockford, Ill. This unit, shown the illustration, has rating hp. 900 r.p.m. small and compact and although designed q ULTIPLE-PISTON fluid motor designed for high-speed ap- plications. primarily for high-speed applica- tions said suitable for speeds low r.p.m. can reversed instantly while running 3000 r.p.m. The unit well the larger sizes will built with constant speed. The company also bringing out line mu