The Iron Age 1937-05-27: Vol 139 Iss 21

FRITZ FRANK President VAN DEVENTER Editor FINDLEY Editor Emeritus Art Editor Metallurgical Editor WRIGHT Managing Editor MILLER Machinery Editor Associate Editors Consulting Editor Washington Editors Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany MEYER Milwaukee SANDERSON Toronto, Ontario ALLISON Newark. N. J. LOREN IRWIN San Francisco ASA JR. Birmingham Roy EDMONDS St. Louis TURNER Buffalo Editorial ond Executive Offices 239 WEST 39TH STREET, NEW YORK, Owned and Published by CHILTON COMPANY (Incorporated) Chestnut and 56th Sts., Philadelphia, Pa. West 39th Street, New York, OFFICERS AND DIRECTORS ©. A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC C. STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS KANE CHARLES BAUR CARROLL BUZBY P. M. FAHRENDORFE BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign $12.00 year. Single copy, 25 cents. Cable Address, “*Ironage, N. Y."’ ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bldg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bldg., Chicago H. E. Leenard, 239 W. 39th St., New York Peirce Lewis, 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St., New York W. B. Robinson, 428 Park Bldg., Pittsburgh D. C. Warren, P. 0. Box 81, Hartford, Conn. MAY 27, 1937 Crutches Versus Footwork Real Facts Industrial Employment The Consumer King—So What? Developments Metallurgy and Stee! Planning Overhead Handling for Economy Hardening Machine for Double Gears New Equipment Statistics Metal-Working Activity Rate Activity Capital Goods Automotive Industry Washington News NEWS CONTENTS Plant Expansion and Equipment Buying w w New Industria! Literature Just Between Two. Products Advertised Index Advertisers Copyright 1937 Chilton Company (Inc.) 119 138 166 : . — | Ryerson brings you the largest stocks—widest range products—and most complete service steel and allied products. There are always thousands tons steel—all shapes, sizes and kinds—in stock ready for Immediate Ship- ment. Years experience have taught how quickly and accurately meet the hurry demands industry. You can draw any the ten Ryerson plants with full assurance that your steel will the way you the shortest possible time. you not have the current Ryerson Stock List write, will glad send it. Address the nearest Ryerson plant. JOSEPH RYERSON SON, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City Ryerson Stocks Include: Beams and Heavy Structurals Channels, Angles, Tees and Zees Rails, Splices, Spikes, Bolts, Etc. Plates—Sheets Strip Steel, Flat Wire, Etc. Stainless Steel Hot Rolled Hoops and Bands Cold Finished Shafting and Screw Stock Extra Wide Cold Finished Flats Alloy Steels—Tool Steels Heat Treated Alloy Steel Bars Boiler Tubes and Fittings Welding Rod—Mechanical Tubing Rivets, Bolts, Nuts, Washers, Reinforcing Bars Babbitt Metal and Solder , : THE IRON AGE ... MAY 27, 1937 ESTABLISHED 1855 Vol. 139, No. Crutches Versus Footwork DEPRESSION develops complexes. Sometimes they are good ones, some- times bad. And they give people Going against brings out the best qualities some men and women. They tighten their belts, throw out their chests and redouble their efforts. These are the people whom depressions cannot lick. they are forced accept assistance, public private, during some period the emergency, they cannot rest until they are back their own feet again. the other hand, there are people whom the depression has seemed de- velop permanent inferiority complex. They have become accustomed the use crutches and not seem able abide the thought ever discarding them. This just true the case some who have been employed throughout the depression some who have been unemployed and who are still Gov- ernment relief. The difference that there excuse for the people the latter class, but none all for those the former. The industrial executive who finds sales department depression hangover indeed out luck. Perhaps you have observed cases this kind. salesman, perhaps sales manager, becomes obsessed with the idea that his competitor has better and more salable product because that competitor mak- ing relatively greater sales gains than is. may using pre-depression even mid-Victorian sales methods, but never enters his mind that these are blame. always the product. the designers would only change the position the levers and handles and the production department paint the product differ- ent color, sure that could beat out competition. The inferiority complex victim the sales department becomes passed the production department. and large there have been very few in- stances inferiority complexes the production departments our industry dur- ing the depression. They have tightened their belts, improved their products and given the salesmen vastly improved values sell. als But even the finest values the world and the lowest price will not-solve the com- petitive problem where there inferiority complex the sales manager's office. Sometimes you find instances superior selling product with less excellence and higher price than its competition. The reason for this that, not having all the advantages superior product, the more aggressive sales organization com- pensates superior headwork and more footwork. jars Tubing Wi J 5 : = i 4 = x t Zees Etc. s and Screw REAL FACTS Industrial PHILIP BLISS President, The Warner Swasey Company, Cleveland, Ohio. THE Warner Swasey Company has just received what feel particularly significant comments the em- ployment situation, from 229 rep- resentative industrial concerns the United States, employing total almost 800,000 people. The facts thus gathered, believe, nesses—particularly those engaged manufacturing enterprises. For many months we, like other business men, had read great deal the magazines and news- papers about the unemployment situation. Yet the same time were also told that businesses all over the country were suffering from acute shortage skilled workmen. seemed somewhat paradox see one page story that thousands men couldn’t find work, and the next page that employers couldn’t find men. was particularly important for our own business that try ascertain the actual facts. Our company manufactures machine tools particularly, turret lathes. lathes sell depends small extent upon the capabilities the men who operate them. customers buying turret lathes were literally unable find enough men who knew how operate turret lathes efficiently, this would bring the fore serious prob- lem which would naturally vitally concerned. If, the other hand, the cur- rent talk shortage labor was largely talk arising from the fact that various companies who had not had occasion hire new men for long time were un- dergoing the routine difficulties reemployment program, there would less occasion for concern. short, wanted find the real answer the there shortage trained men industry? And so, what done about it? Method Gathering Facts The method which employed get the answers these ques- tions was the time-worn one sending out questionnaire; but this was questionnaire with difference. selected recipients only people whose answers would im- portant and representative. picked 410 firms covering wide range activities throughout the entire country, all whom were engaged impor- tant industrial enterprises. made our questionnaire brief possible, and set | j j | 5 Employment such way that could answered with minimum time and effort. asked merely for direct answers specific ques- tions. The questionnaire was lows: QUESTIONNAIRE Are you experiencing shortage skilled labor? What classifications workmen are you now most need of? Which the fellowing methods your experience proving the most practicable for renewing the supply trained men: (Check your preference) Employing unskilled men and teach- ing them your own plant Setting joint training school cooperatively run industries Relying trade and vocational schools now existing part your city's school system Have men taken into your employ dur- ing the last two years come largely from relief rolls and federal employ- ment? nN you secure your city any active Given 229 Companies Employing 791,820 People cooperation between federal relief public works agencies along the line transferring men from government relief pay rolls onto private em- ployment” How many men does your company employ? the 410 firms receiving the questionnaire, 229 answered. These 229 employ total 791,820 people. The businesses which they are engaged are too various attempt list this article. They include all leading manufacturing industries the country—and would difficult call name branch industry which not included the list. Most the questionnaires were returned with letter signed executive the company receiv- ing the questionnaire, indicating that the answers had been given consideration people properly qualified supply the in- formation requested. The simplest method sum- marizing the answers take each question consecutive order. Are You Experiencing Shortage Skilled Labor? the 229 firms answering, 195 said said “no.” significant that the firms who have shortage skilled la- bor answered this question with the one word whereas many the firms who reported the negative added such the following: “Expect prevailing shortage disappear shortly.” “Shortage more than normal for this stage “No shortage present but ex- pect big one expansion con- “No shortage, but would payroll were increased.” : x > A e s 2 “Shortage not yet acute.” “Shortage not enough curtail production but couldn’t get more skilled men from outside short, out the who re- ported shortage, comparative- large proportion qualified their answers the above fashion. the whole, therefore, there the present time serious shortage skilled labor. What Classifications Workmen Are You Now Most Need Of? Naturally answers this ques- tion were given only the firms who said they were experiencing shortage skilled labor. There were many duplications answers, because job classification terminology rather broad, and single general classification may include various specific classifica- tions. However, tabulation replies actually received rather in- teresting. Types workmen needed are listed the following order: Type Number Firms Workmen Mentioning Need for Machine Operators Lathe Operators ......... Boring Mill Operators...... Automatic Screw Machine Machine Assemblers Machine Grinders Hand Screw Machine Oper- Pattern Makers Planers ...... Welders ..... Draftsmen Electricians ...... Core Makers ..... Twenty-six other specific trade occupations were lesser degree. significant that firm re- labor. Although the question was phrased, “Are you experiencing shortage skilled labor?”, would seem probable thet company thus had experienced shortage unskilled labor, would have replied that effect. that such was the case. Preferable Method for Renewing Supply Trained Men asked companies indicate which method was, their ex- perience, proving the ticable for renewing the supply trained men—employing unskilled men and teaching them their own plants, setting joint school cooperatively run tries, relying upon trade and vocational schools. Naturally there was some over- cated. the whole, however, the answer favor employing unskilled men plant. One hundred three firms replied being flatly favor this method; while only said they preferred the method setting joint training schooi and only said they relied upon trade and vocational schools. Fifty- seven firms said that they both training their own men and utilizing men from trade and voca- tional schools; firms said that they were training their own men and also depending upon joint training schools cooperatively run industries; firms said they were using all three methods. teered connection with this sub- ject are particularly interesting. One company replied, “For ma- chinists have had rely upon other industries furnish ex- perienced men.” course action provides manent remedy. interesting that this same company adds, are considering setting edu- cational program within our fac- tory.” Many companies mentioned plans and progress with respect ap- prentice training schools, but were inclined question the time ele- ment, the difficulty being that men rapidly enough apprenticeship system meet present-day needs. number companies mentioned the advan- tages securing men had some vocational guidance seemed feel that education along these lines, although help, was not solution. Remarks this nature serve the majority conclusion that the best method renewing the supply trained men take them and train them. Relief Rolls and Government Employment answer the question, men taken into your employ dur- ing the last two years come largely from relief rolls federal em- ployment?” 182 firms answered some made definite answer. the surface this might appear indicate—either that men relief government projects are chiefly, has often been said, the unemployable class—or that relief and government agencies had not made proper effort men from government projects relief onto industrial payrolls. However, the answers next question throw light the subject. answer yt | i | i the question, you secure your city any active cooperation between federal relief public works agencies along the line transferring men ment relief payrolls onto pri- vate employment?” firms out the 229 replying definitely said Among comments regarding such cooperation appeared many such the following: "Yes, very good "Yes, the state employment service has been "Yes, cooperation has been offered any federal employment "Yes, government agents follow this very closely.” "Yes, they are actively trying place "Yes, the county relief administration and labor co-ordinating bureau have been active placing The fact appears be, there- fore, that government and relief agencies have been more active trying transfer men from public dole private employment than some least had realized. Does this mean then that failure effect such transfer larger degree due the inferior char- acter the abilities the people relief federal projects? certain extent, yes. For instance, there are comments line: relief federal payrolls are these men are not worth damn." not have the kind men can use. shy trying get men off re- lief because relief wages have spoiled good many men." "Such men are generally unsatisfac- the other hand, one company makes very important tinent comment. This company says: "We have hired approximately 300 men The simple but unusual ques- tionnaire that was used gather the data. r Have Men taken into during the two COme t | from these sources, which about re- mained; balance released quit. Major- ity either lack skill have desire seems very significant that this company, which has been through the experience trying take men off public projects and relief, found that little better than per cent these men proved sufficiently adaptable re- main permanent employment. The point that this percentage almost high that which many companies experience among applicants answering newspaper ads for employment. Evidently fair share people relief public projects can trained and placed industry; and from further studying the com- ments the questionnaires, seems evident that one reason why such comparatively small num- ber men have thus been trans- ferred has been the attitude industry itself toward these men. may quite true that many them are not constitutionally fitted for industrial employment but certainly industry should endeavor take more active part the sorting-out process. Some the comments the questionnaire in- dicate that industry whole has not made determined effort along this line. With apparently practically all the skilled workers the country already working, industry might least make broader effort try out men relief federal payrolls—just today must necessity experi- ment with younger men now com- ing into the employment field. Conclusions The main import replies the questionnaire lies, course, the opinions expressed need for trained men and method training them. The great majority replying firms said, “We are experiencing shortage skilled labor.” The great majority said the best tion “to employ unskilled men and train them our own plants.” seems that these an- swers definitely point the way to- ward the course action which must now pursued industry. industry get the skilled men which industry needs, must take new men and train them its own shops. This involves inevitably program weeding out the incompetent and the unde- sirable—but this process men who have been relief gov- ernment projects should given least “an even break” with the younger generation now arriving factory employment age. unduly optimistic one that within the next few years industry will have need all the men which can possibly trained during that period. mind, one the most important steps which any industry can take today set within its own plant method whereby tries out new men, sorts out the competent from the incompetent, and gains process certain number new, skilled workmen who will stand good stead the period greater productivity which be- lieve today store for Ameri- can industry. Inventor Projects Himself Into the Future known American scientist and inventor, former vice-president the Leeds Northrup Co. and authority electrothermics, has written imaginative story the life, inventions, and reflections scientist living from 1920 the year 2000 A.D. Readers will see that Dr. North- rup has drawn his own life for the material this unique modern autobiography. The book origi- nal its conception—nothing like has ever come off the press—and technical matters vast impor- tance are disclosed. For instance, for the first time solution said presented for the escape humans from the earth’s gravita- tional attraction, and means for navigating projectile-ships outer space are described. The book also introduces many important applications the “elec- tric guns” with which Dr. Northrup has been experimenting—at the Ajax Electrothermic Corp. plant, government arsenal, and the research laboratory the General Electric Co. Schenectady. The writer Eighty,” now years old, has lived produc- tive life, that has lifted him place among the world’s scientists and brought him many awards the scientific field. feels that the technical matter dis- closed this book the most im- portant his life’s works. The book, containing illustra- tions, interesting narrative the first humans circumnavigate the moon, told lucid style, en- joyable and informative the lay reader well the scientist. The author was the inventor the Ajax-Northrup high frequency induction furnace. © | | | | | i | The Consumer What? OLLOWING the full text address made John Van Deventer, editor, The Age, the dinner meeting the National Association Purchasing Agents Pittsburgh, May 24. presenting review some the important present-day changes that are being forced upon the steel industry from without, Mr. Van Deventer pictured the effect upon the buyers and consumers the world's greatest basic material. remarks the men who are primarily responsible for build- ing the steel industry. speak- ing the people who have the principal interest its future; and who more than any others, have vested interest its welfare. not refer the stockholders the industry, nor its manage- ment its labor. refer you gentlemen who buy steel and who represent the vast army steel consumers. You all remember the definition island that were obliged body land entirely surrounded water.” Without the water, there could island. like that business. successful busi- ness ene that surrounded customers. Without the consum- ers, there could and would business. these changing times the con- sumer beginning pushed into unfavorable through the action new and strange economic philosophies. was left out the cold for exam- ple the theory enunciated the legality and morality the sit- down strike. were told this connection that labor obtains property interest the company for which works because what has contributed that company. Strangely enough, and inconsistent- ly, those who preach this doctrine not extend include the buy- ers the company’s products—the consumers whose purchases finance both profits and payrolls. would think that the people who support industry, and who keep going, deserve considera- tion and the protection their in- terests any scheme social modernization that may pro- posed new philosophy for America. Not only the con- sumers pay all industry’s bills and all its wages but they also pay for all its mistakes and misfortunes. The economic change- JOHN VAN DEVENTER lings all land, eventually, the consumer’s doorsteps, matter who fathers mothers them! tonight, let look this steel industry which you have built and which you support and with- out which you could not possibly get along any more than could get along without you. Let look from the standpoint the changes that are now taking place this industry and what these changes mean your inter- ests buyers and consumers our greatest basic product. You should interested this, for the welfare and proper conduct the steel industry mean much you, consumers, they mean capital, management, and labor the industry itself. Great changes are taking place the industry today. Unusual changes. these changes are for the good the industry, the buy- ers and consumers steel will ben- efit far more than will the pro- ducers. the changes damage THE IRON AGE, May 27, — injure the steel industry thou- sand buyers and ten thousand con- sumers will suffer for each pro- ducer who damaged. Changes have always taken place our industry. There have been plenty changes both the mak- ing and the marketing steel since those days, little more than 150 years ago, when the making iron America was bootleg in- dustry, forbidden British law. But today’s changes are vastly dif- ferent from those which have gone before. the past, changes the steel business, all American business, have been brought about the natural evolution experi- ence, discovery, and steady im- provement. Evolution means change. But not all change evolution. Reversing Evolution Today, influential government circles, and with certain econo- mists, the theory improvement industry evolution seems unpopular was the teach- ing the Darwinian theory which occasioned the famous Scopes trial.. Then, you will remember, William Jennings Bryan, the silver voiced fundamentalist, held that was impossible make men out monkeys through the operation natural laws. Today some are beginning believe that the reverse process, least, prac- ticable and that monkeys are now being made out men through the operation unnatural laws! Evolution too slow suit the American taste today. want the order the day, but orders come from Washington, through executive mandate and legislation. there had been introduced this present Congress, total 8090 pieces proposed legislation. Most these bills—and the average apiece for each lawmaker—have with some change, modifica- tion regulation ways doing business. Many them would af- fect the steel industry, carried through into law. Fortunately for Congress not efficient our Supreme Court keeping with its docket. For date, but these mea- sures have been enacted into law. Eight thousand and eighty them are still behind the bars, but clam- oring released roam the fields American business. 42—THE IRON AGE, May 27, 1937 When industrial changes are brought about man- date and legislation, instead of, formerly, the natural prog- ress evolution, the buyer and the consumer are the ones most likely suffer. For they are los- ing their rightful former positions the promoters industrial change and improvement and sur- rendering them the dictatorship the politician and the dema- gogue. The consumer the logical and the rightful boss American in- dustry. the man who pays the has demanded recog- nition and the past has gotten it. His desire for continuous improve- ment quality products and for American industry unparalleled peaks accomplishment. the man who has dictated the policies great and small corporations; who has commanded the erection new plants the modernization and relocation existing ones. The steel industry has been one our many progressive American indus- tries which have long recognized the consumer’s natural and pre- dominant right the head seat their tables. Consumer Has Been Boss The consumer has earned that seat industry’s table because in- dustrial evolution, operating through the natural laws com- petition and initiative, has put him there. has been the man who both the literal and the meta- sense has given the orders. Because this, has been able protect his interests. His voice has been heard and heeded. Today, the consumer ejected from the head seat indus- try’s table. not through any desire action the part in- dustry that this taking place, for industry values its consumers. the inevitable result the dis- natural law industrial evolution and the substitution its place, control business mandate, legislation and conversation. For industry that started America with single product, charcoal iron, the steel business has grown remarkably complex one. industry has more variety product. The American Iron and Steel Institute during code days, for example, listed prices more than 100,000 shapes, sizes and com- positions steel, and this the standard, portion the industry. When comes special alloy steels, the number be- comes almost infinite. ducer alloy steels, for example, prepared furnish over 1800 composition varieties. Equally complex, necessity, are the merchandising methods. These, like the technical branching out the industry, have been the result evolution. And evolution, both making and marketing methods, has been inspired, through good sound business sense, the desire render better fairer service the American steel con- sumer. Experience Has Built Slowly Many these marketing meth- ods, built slowly and through long experience and for the mutual ben- efit consumers and producers, are now threatened with destruc- tion serious modification Gov- ernment mandate. The request for change does not come from the con- sumers, except isolated cases which change would result preferential position for the few and damage the many. And these changes should brought about, out every 100 steel buyers and will penalized for every one that will benefit. Take, for example, the basing point system. This system equal- izes the price competition for steel among widely distributed buyers and consumers. primary benefit that great majority steel consuming units which are not cannot located near steel pro- ducing centers, and the smaller producing units which cannot af- ford widely distributed chain producing plants. If, threatened, steel forced merchandise its product f.o.b. mill basis, steel consumers and fabricators who not happen situated close mills who cannot move there would penalized, competitively, from per ton. That unless all the manufacturers steel products moved their plants Pittsburgh, Chicago other steel producing centers. And that surely would result extremely uncomfortable and unhealthy con- gestion. Certainly would the reverse the modern idea de- centralization. (CONTINUED PAGE 121) | ; | J | i | | | | WATERHOUSE THIS paper plans cover briefly some the recent developments iron and steel metal- One the best ways keep touch with developments any kind study the literature the subject. The present topic exception, and attention may drawn the annual review issues the technical magazines such AGE, Steel, and Jron and Coal Trades Review, usually appearing early January each year. Such magazines give wealth statis- tical and other information. One article, however, deserves special the recent joint meeting the Iron and Steel Institute and the Verein Deutsche Dus- seldorf, Germany, Fritz Spring- orum, President the Verein. printed Stahl und Eisen both German and English and *Presented before the general meet- ing the American Iron and Steel Institute, New York, May 27. evelopments Production etal urgy and GEORGE WATERHOUSE Professor Metallurgy, Massachu- setts Institute Technology, Cam- bridge, Mass. also published the last volume the Journal the Iron and Steel manner technical developments German practice during the last years. regard raw materials increasing amount attention being paid proper preparation, notably iron ore. This not par- ticularly new because for some years has been realized that proper sizing and preparation ore, limestone and coke necessary for the best blast furnace practice. There have been many papers pub- lished this important subject, es- pecially the workers the Iron and Steel section the United States Bureau Mines. recent tioned, which tested the re- ducibility many kinds iron ore, and drew some very interest- ing conclusions based practice. “Tf large lumps hard dense ore are charged into the blast furnace they will reach the top the bosh and the fusion zone with unreduced centers. The size such ores should reduced according the porosity, which has been shown bear direct relation the time required for reduction. Finer crush- ing has improved furnace practice Alabama ores and Utah ores.” This true also the dense Wabana ore Newfoundland. recognized, too, that fines should sintered for good prac- tice and careful attention being given this modern plants, both here and abroad. The whole mat- ter proper preparation raw materials for blast furnace prac- tice, and proper methods charg- ing, appears well founded that would seem axiomatic, but while considerable progress being made there are many plants paying little attention the subject, and some can still found where the ore varies from fines pieces over one hundred pounds weight. Recent developments blast furnace design have been along conservative lines. The size the THE IRON AGE, May 27, 1937—43 > | ; \ x 4 j ~ : ‘ > ° ° ° : x ‘ ram lurgy. | ‘ . 4 i . TABLE Blast Furnace Practice Corby, England, Showing Comparative Production Data Manufacture Low-Silicon Iron from Ores High Alumina/Silica Ratio Carbonate, per cent............ 7.55 6.00 13.6 0.37 0.6 31.4 Brown-weathered, per cent.... 10.5 7.9 3.5 0.05 0.65 33.2 100 per cent crushed and 100 per cent crushed and graded local and manga- nese, Slag analysis (calculated total 100 per cent) Iron analysis, per cent: Basicity slag: (CaO Iron made per day; tons........ Limestone additions; Coke consumption; Blast temperature; deg. F........ nese and basic slag. 30.9 33.6 22.1 26.0 40.0 35.7 7.0 4.7 (1.42) (1.80) 0.55 0.6 0.05 0.13 1.85 2.00 1.42 1.4 1.51 1.20 1.29 1.06 238 288 1120 2875 2425 17.3 14.4 1210 1120 hearth and the throat diameter con- tinue increase. More attention being paid proper reduction the charge the shaft that when enters the fusion zone can melted thoroughly and com- pletely. The importance plen- tiful supply air blast more fully recognized and with the mod- ern furnaces large outputs uni- form, good iron are being obtained because plentiful blast volume, high blast temperatures, coke that persists down the tuyeres where TABLE Four High Continuous Strip Mills Operation, Under Construction and Authorized the United States Started Annual Oper- Capacity Company Location Mill ating Size (G.T.) Allegheny Brackenridge, Pa. ... 1932 in. 275,000 American Rolling Mill Co.......... Middletown, Ohio ... 1928 in. 372,000 1926 in. 312,500 Bethlehem Steel Co................ Lackawanna, Y.... 1936 in. 600,000 *Sparrows Point, Md... in. 600,000 Carnegie-Illinois Steel Corp........ 1927 in. 360,000 So. Chicago, 1931 in. 720,000 McDonald, Ohio ..... 1935 in. 300,000 Homestead, Pa. ...... 1937 100 729,000 Great Lakes Steel Corp........... Ecorse, Mich. ........ 1980 in. 400,000 Ecorse, Mich. ........ 1936 in. 720,000 Granite City Steel Co... Granite City, in. 275,000 Indiana Harbor, Ind... 1932 600,000 Jones Laughlin Steel Corp....... Pittsburgh, Pa. ..... 1937 in. 720,000 Otis Steel Co...... Cleveland, Ohio ...... 1932 in. 375,000 Republic Steel Corp............ Warren, Ohio ..... 1927 in. 302,000 *Cleveland, Ohio ...... in. 800,000 Tennessee Coal, Iron Ala. in. 300,000 Weirton, Va...... 1927 in. 550,000 Wheeling Steel Corp... ...... Steubenville, Ohio ... 1929 in. 540,000 Youngstown Sheet Tube Co... Campbell, Ohio ...... 1935 in. 600,000 *Under construction. (estimated capacity given). 44—THE IRON AGE, May 27, graded local and manga- promptly burned, and careful preparation and burdening the charge. notable development blast furnace practice has taken place England during the last few years, Corby Northamptonshire. Corby roughly half way between Sheffield and London the middle England. Three modern furnaces are smelting local ore and fourth furnace will soon operation. The ore mainly carbonate iron with part weathered and changed limonite. Formerly most the carbonate was calcined be- fore being charged but now the whole the ore charged raw into the furnaces. However, the ore crushed and graded, cer- tain amount the fines are sin- tered, and very careful system charging followed. Calcina- tion carried out wholly within the shaft the furnace. Turbo- blowers are used and considerable degree automatic control blast volumes and temperatures exer- cised. The ore low iron content, and the gangue has high propor- tion alumina silica. new system burdening the furnace has been worked out, based the formation low melting point slag with good viscosity, other words free running slag rela- tively low melting point. The de- sirable limits the slag were chosen after careful study the ternary diagram the system, and the viscosity determinations Prof. McCaffery and his students the University Wisconsin. The reasoning fol- lowed and some the results ob- tained are given recent paper few extracts may given they give clear picture what be- ing done and the principles fol- lowed are applicable blast furnace practice many places. “To give the optimum conditions for the smooth working and eco- nomical operation blast fur- nace, the burden should arranged that the slag formed has melting point not exceeding 1400 deg. (2250 deg. and preferably practical operating maximum 1375 deg. (2500 deg. F). The difficulties which have been experi- enced the manufacture basic iron low silicon content from ores having high ratio alumina silica have arisen from charging the furnace with mixture ore | | | | | | : { j | \ ‘ | and limestone which formed slags melting points which exceed this practical working limit. order form slags which shall have free- running properties and melt suitable distance above the com- bustion zone the furnace, the lime content the slag must varied progressively the alumina rises above falls below mean value about per cent. attain this object the basicity factor ratio lime silica must decreased progressively from the value 1.15 for slag per cent approximately 1.0 for slags per cent per cent these percentages being based the calculated values with the CaO and MgO con- tents totalling 100 per cent. The deductions just outlined have been applied practice. ough examination was made the ore deposits, determine the pos- sibility assembling mixture the local ores available which would yield slags within the normal work- ing range alumina content. Ex- periments were also made the lines commonly adopted diluting the alumina content increasing the slag volume the addition siliceous materials the burden. None these attempts yielded the desired economic results. was decided base the manu- facture pig iron the local ores alone and according the prin- ciples outlined above. the old practice, from one-third the whole the ore was calcined prior charging, and this was applied specially the carbonate type ore, only the weathered hydrated ore being charged the raw state. The calcination the ore has been discontinued, and the whole the ore charged raw into the furnace. ensure complete reduction and preheating the ore the stack, soaking pit with cover removed. the ore was crushed and graded, the screened sizes being charged separately from the fines. Finally, opposition the usual practice seeking improve the fluidity the slag and the smoothness operation raising the hearth temperature additions lime and increasing the coke ratio, the slag was made more siliceous re- ducing the lime additions, and the coke ratio was decreased creasing the ratio ore coke. The operating results fully con- firmed the theoretical deductions. With the furnace engaged the manufacture foundry iron, the lime content the slag was re- duced from per cent and the alumina content rose from per cent. The rate produc- tion showed increase per cent while the coke consumption decreased per cent. the manufacture steel mak- ing low silicon iron the results are even more striking. With furnace specifically designed for operation this class ore, and with the ore crushed and graded the sizes necessary for its com- plete preheating and reduction be- fore reaching the melting zone, Table shows the change prac- tice effected the application the new principle burdening the furnace. change was made the class preparation the ore used, the only variation being the amount lime additions. will seen that production was raised per cent and coke consumption was reduced 450 pounds, per cent. second, slightly larger fur- nace working with additions scrap bring the iron content the burden per cent, and again operating with true slag 33.5 per cent SiO., 25.9 per cent 36.0 per cent CaO and 4.6 per cent MgO; ratio CaO 1.08 1.0, the produc- tion low silicon iron 376 tons per day coke con- sumption 2130 pounds per ton iron. The most important feature the practice based this principle the regularity operation, with its lower blast pressure, freedom THE IRON AGE, May 27, 1937—45 | > pe | TABLE Tabulation Mill and Drive Data—Continuous Strip Mill, Lackawanna, Work Roll Diam- eter, Mill Characteristics In. Hot Mills Seale breaker ....2 high stand Broadside mill ...4 high stand Seale breaker ....2 high stand Finishing stand ..4 high stand Finishing stand ..4 high stand Finishing stand ..4 high 1 stand 24% Finishing stand high stand Finishing stand high stand Finishing stand ..4 high stand Cold Mill Tandem mill ..... high stand Tandem mill ..... high stand Skin pass high stand Skin pass mill....4 high stand Skin pass mill....4 high stand Skin pass mill....2 high stand Backing Roll Diam- Roll Mo- eter, In, In. Hp. Volts R.p.m. 76 1000 6600 375 3000 6600 150 49 79 3000 6600 500 49 79 3000 6600 500 49 79 3000 6600 500 500 600 150 to 600 3500 600 175 300 49 79 3500 600 175 to 300 49 79 4500 600 125 to 250 49 79 4500 600 125 to 250 2500 600 175 350 49 54 (3)1250 600 300 to 600 1250 600 300 600 49 75 1250 600 300 to 600 49 93 1250 600 300 to 600 250 250 500 1000 from scaffolding and uniformity composition the iron. study Table very in- structive. The improved results are given the second column and are striking. visit the plant observe the operating results confirmed the table. The furnaces are working smoothly, giving good tonnage and with low fuel con- sumption. The managers the plant are congratulated the results being obtained, and for the courage they have shown applying theoretical research work practical problems: Incidentally they are producing cheapest pig iron the world. The sulphur the pig iron Corby often runs higher than shown the table. This high sul- phur taken care largely additions sodium carbonate the iron the ladle. This treat- ment iron reduce sulphur fairly recent development. being used great deal foundries offset the sulphur pick-up cupola melting, but few steel plants abroad are using reduce the sulphur steel-making iron. All open hearth operators know the trouble and delay caused trying remove sulphur and this develop- ment worth watching. Open Hearth Developments The developments regard the open hearth have been along three main directions: design, heat economy and operation. number new open hearth furnaces have 46—THE IRON AGE, May 27, 1937 been constructed recently and the features design are worth care- ful study. Among the new furnaces may mentioned those the Great Lakes Steel Corp. Detroit, the Bethlehem Co. Lacka- wanna, and the Inland Steel Co. near Chicago. All are marked the careful use insulating brick material around the furnaces, flues and checkers, whereby the heat effici- ency considerably increased over older furnaces. The Bethlehem plant has many other features interest. exceedingly spacious with very wide working floor. Coke oven gas the main fuel and each furnace equipped with auto- matic control devices for the fuels and for air. Everything the ground floor readily accessible, and new system division the checkers has been worked out that there are eight checker cham- bers instead four. Also there are waste heat boilers. One mat- ter interest, which now com- mon many open hearth plants, the use the carbometer deter- mine the carbon the test samples. None the foregoing features are revolutionary particularly new, but are logical developments open hearth practice over the last few years. Another development which con- tinues attract attention slag control. This reaches back careful study the charge and effort produce the proper slag early the history the heat possible. Slag control being watched and followed all over the world and very good results are be- ing obtained improved quality steel and uniformity product. The most notable recent develop- ment methods steel production the rebirth renaissance the basic Bessemer process England. Many improvements been made this process Germany recent years. The size the vessel has been increased until now some vessels are operated with charges this figure could safely in- creased. Some details the im- provements along these lines are given the paper However, England this process had completely disappeared and was only revived recently the plant Corby mentioned before. Three converters were installed about tons maximum capacity each, and fourth has just been added. will noticed that the composition the iron given Table particularly suited this process, and the supplies ore are very large. The steel being made going mostly into pipe but suitable for many other pur- poses. Progress Refractories Before leaving the steel making processes mention should made the good work being done ToTAL HEAT CONSUMPTION PER TON RAW STEEL 2—Decrease the heat consump- tion per ton raw steel planned heat economy German practice. | J @ I 1927 HEAT HEAT re] the field refractories, especially with basic and neutral refractories, one phase which well covered and the accompanying discussion. certain class bricks dried and not burned. The bricks are formed adding special inorganic refractory binding agents the mix, using very high hydraulic pressures mold the bricks, and then drying. Great care used selecting the particle sizes and then combining these sizes proper proportions. These bricks, chrome and magnesite, have given very good results service, and particularly resistance spalling. Another recent develop- ment the new magnesite refrac- tory developed Professor Caughey, and made from the min- eral brucite found Nevada. This mineral when calcined gives nearly pure magnesium oxide. With proper additions and firing, cal- cium ferrite-bonded high magnesia refractory was made approxi- mately the following composition: Silica, 2.5 per cent; ferric oxide, 7.0 per cent; alumina, per cent; lime, per cent, and magnesia, 79.5 per cent. carload this material has been tried out. said produce dense monolithic hearth high magnesia content, with very high resistance iron- rich slags. slag mixed with it, and frits into place the open hearth quickly and well. This development promises supply another domestic source basic refractory addition that found Washington. Considerable improvement has been made recently the field soaking pit and reheating furnaces. Indeed the whole field develop- ment the heating steel whether for rolling, forging heat treat- ing could made the subject long paper. interesting innova- 3—The finishing train six rolling mills and scale breaker action, with strip simultaneously engaged all six. tion the circular soaking pit now installed number steel plants. One these pits, with the cover removed, shown Fig. Modern control provided which gives exact ratios the fuel and air used the fur- nace. record made during given conditions possible. Heat furnished small burners, which, together with accurate values and premixers, give suit- able atmosphere all rates fir- ing. Usually small amount combustibles maintained the waste gases, and scale the ingots kept about half usual prac- tice. The combustion chamber formed sloping walls behind the ingots. The burners fire into this deg. that there vigorous re- circulation the hot gases within the furnace and around the ingots, and down through central flue. The temperatures desired are main- tained means pyrometer con- trol. Altogether this very promising development furnace without regenerators recupera- tors, using preference mixture coke oven and blast furnace and applying this impor- tant part steel plant operation the automatic controlled operation used for many years small heat- treating furnaces. all heating furnaces consider- able attention now being paid control the furnace atmosphere. This has required and still requires great deal research work re- garding the nature scaling, the various oxides that are formed, and methods limit prevent scale formation. The lead much this research work has been taken English and German workers. result constant effort along practical lines, workers country have arrived many fur- nace designs, for heating steel for forging and rolling, that deliver steel with very small amount scale, and, heat treatment work, bright annealing being carried out successfully many plants. Mention should made the continued careful study fuel re- quirements the iron and steel plants. More attention than ever being given the cleaning and storing blast furnace gas, and the proper use blast furnace gas (CONTINUED PAGE 124) THE IRON AGE, May 27, 1937—47 | A 3 Planning has been said re- peatedly various authorities that making,” and that “The biggest cost-savings today and tomorrow are likely come from planned moving, rather than from making.” these statements there may added the observation that the savings made mechanical handling methods for manual handling methods cannot gaged merely the extent payroll reductions. While may true that some low-priced labor rendered unnecessary when mechanical handling equipment installed, the big savings come the release high-priced machine operators for more work pro- ductive nature instead much manual effort, thus making for bet- ter quality and quantity goods manufactured, the closer coor- dination processes and the con- sequent speeding production, and the elimination the losses caused the time and effort re- quired for unnecessary rehandling. Some years ago the first argu- ment used any salesmen ma- terials handling equipment was, that his devices would replace the labor and many men. This was undoubtedly true the time, for little attention was paid using such equipment func- tional part system mate- rials handling. Then various items gether, such industrial trucks, conveyors, overhead tramrail sys- tems, hoists and cranes, and weld- into comprehensive and coor- dinated systems for moving mate- rials progressively throughout series manufacturing operations. The equipment used thus be- came tool production, much any machine piece process apparatus. this point the labor displaced became only minor ar- gument because, making the me- 48—THE IRON AGE, May 27, chanical handling equipment tool production, production processes had keyed into the moving materials. not reversing the proper order statement here. Formerly the moving materials was keyed best might the produc- tion processes. Now the major em- phasis was shifted (because mak- ing had attained high degree efficiency, but moving was still primitive state development) the idea continuous flow materials and parts from the be- ginning the end manufac- turing process; with the result that, for the first time, the process was keyed the exigencies the materials handling problem. Here was truly revolutionary Overhead Hand idea. the past few years, led largely the example the au- tomobile production line, has swept American industry from Maine California. And one the surprises which have come light its adoption has been, not technological production cost-cutting through more natural coordination man- ufacturing processes, the elimina- tion wasted time and effort, and striking increase the quantity and quality the goods produced. The far-reaching effect study- ing the processes manufacturing functions the movement materials from raw state fin- ished product has advantageously affected operating costs every department many the coun- try’s largest plants. HEPARD NILES shows typical scheme comprehensive overhead handling serve several departments metal working plant. | | ‘ for The new conception mechani- cal equipment system ma- terials handling has changed the basic idea the function such equipment from labor displacing apparatus production-aid appa- ratus. this new conception there are two vital principles in- volved. When planning any system materials handling these princi- ples should recognized and ac- corded consideration from every point view. Two Vital Principles Credit chee