The Iron Age 1937-06-24: Vol 139 Iss 25

Owned and Published by CHILTON COMPANY (Incorporated) Chestnut and 56th Sts., Philadelphia, Pa. 239 West 39th Street, New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS L. KANE CHARLES BAUR G. CARROLL BUZBY FAHRENDORF FRITZ FRANK President VAN DEVENTER Editor Managing Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Washington Editor MOFFETT Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cincinnati FRAZAR Boston Hamburg, Germany MEYER LOREN IRWIN Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham LERoy ALLISON Roy EDMONDS Newark, N. J. St. Louis TURNER Buffalo Editorial and Executive Offices WEST 39TH STREET, NEW YORK, BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed in 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 a year. Single copy. 25 cents. Cable Address, **Ironage, N. Y.’’ ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleve'and B. L. Herman, Chilton Bldg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bldg., Chicago H. E. Leonard, 239 W. 39th St., New York eiree 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. O. Box 81, Hartford, Conn 24, 1937 Getting Back Normal Morgan Supplants Garrett Joliet Plastic Molding Requires Sound Engineering Industrial Railways Provide Unusual Services Welded Steel Railroad Service New Equipment Automotive Industry Statistics Metal-Working Activity Rate Activity Capital Goods Washington News NEWS CONTENTS Plant Expansion and Equipment Buying New Industrial Literature Just Between Two Products Advertise Index Advertisers (Copyright 1937 by Chilton Company (Inc.) Ryerson Stock List. Use your guide all steel products, including ide Cold Ang ivets, Bolts, Babbitt etal ‘Sc atc, Alloy steels all major S.A.E. tool steels, stainless and heat resisting steels are immediately available from the ten Ryerson Steel-Service plants. All other steel and allied products are also carried stock. Experienced crews—unequalled facilities—and special dispatching methods assure quick, accurate handling your orders. The Ryerson Stock List your guide these large stocks. you are sure find the kind, shape and size you re- quire. you not have the current issue, will glad send it. JOSEPH RYERSON SON, INC., Chicago, Milwaukee. St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City 28—THE IRON AGE, June 24, 1937 Special all other Steels Stock for Immediate Shipment. . | | | THE IRON AGE ... JUNE 24, 1937 ESTABLISHED 1855 Vol. 139, No. Getting Back Normal COMPETENT and well informed Englishman has been visiting the United States. has quite naturally and fact unavoidably been impressed the volume and the violence the labor troubles that are experiencing. Labor trouble not unknown England. fact that country has had its share such disturbances. Unionization further advanced the little than here, and England has even experienced Labor Government. the visitor was not impressed much with our epidemic strikes might have been expected. was, however, greatly impressed one thing that accompany- our strikes America and which has not been allowed accompany them England. said, serious consequences for your country. England, every one respects the courts. group has ever been permitted flout them. Englishmen believe our courts the bulwarks our freedom. Our nation would rise wrath against any attempt replace court authority mob rule. And that what your federal, state and local governments are permitting not encouraging. Unfortunately, what says true and obvious undeniable. And the example was set this matter for our state and local political authorities the President the United States his unprecedented attempt make rubber stamp the Supreme Court our country. But fortunately the courageous members the Senate Judiciary Com- mittee have effectively closed the door the possibility success this proposal. the most scathing indictment administrative act that any President has yet received from members his own party, this report sounds the death knell Constitutional nullification. This report the Senate Judiciary Committee upon the President's court packing bill should read from beginning end every liberty loving American. our second Declaration Independence. The fact that Democratic Senators were courageous enough write the ringing words this indictment proof that our country getting back normal. — : | « A | | \ ‘ gin A J 7 ve | : : PERHAPS George Bed- son, Manchester, England, was ama- teur historian well adept engineer. Or, perhaps, only hazily recalled his youthful studies Cortez’ conquest Mexico, and how that impetuous Spaniard expedited burning his ships and making re- treat impossible. Or, perhaps, was ignorant the whole affair. any case, Bedson consciously unconsciously subscribed the same policy forceful action liquidate crisis. superintendent Richard Johnson Nephew Wire Works, Mr. Bedson had devoted years repeated experiment and persistent endeavor set stands rolls straight line, with speeds and reductions adjusted that iron billet could fed one end and continuously reduced wire Overcoming almost insur- mountable difficulties, Mr. Bedson 1867, succeeded one morning getting his 17-stand group rolls regularly turning out iron rods. Returning the afternoon, found the workmen had closed down the continuous installation and were making rod usual the old-style hand mill. Thereupon, Mr. Bedson whistled for the crane, had the housings the old mill carried the drop and broken into Wire rod circular cross-section and generally long commercial operation permits. the finished product the hot rolling mill, but con- stitutes the raw material used the wire mill; for it’s the first step the making wire. Wire rod varies from 0.734 in. diameter down 0.207 in. (No. 5). Anything larger classified bars, anything smaller wire. 16-point tolerance commercially acceptable today, and most rod mills prefer work the heavy side, sell- ing No. rod with diameter near 0.218 in. Rod can rolled down No. 0.162 in., but the trade con- siders more economical draw No. rod down this size rather than attempt accurately roll such small diameter. 2Cobble, rolling mill parlance, means that rod fails hit roll aperture. continuous unit, with speeds 1000 ft. per min. (today, about 3500 ft. per min.), failure enter the next roll means that the workmen dive for the exits and the rod takes possession the building, generally ending knot around the rafters. Belgian looping system devel- oped during the same period the continuous system, both which killed off the single-stand hand mill. Users Belgian mills either could not get did not want continuous mill, although Belgian rod failed match continuous mill rod. The Belgian set- stands side side, all running the Same speed. The rod was reduced one set rolls, then hand looped around for further reduction the next set. Finishing speeds were faster than roughing speeds, and rods were necessarily short oxidized. 30—THE IRON AGE, June 24, 1937 scrap. The workmen suddenly de- veloped extraordinary enthusiasm for the continuous mill, and shortly thereafter the company proudly exhibited continuous iron rod 0.244 in. diameter (No. and 1600 ft. long the Paris Exhibi- tion, the open-mouthed awe contemporary producers. Such was the birth continu- Bedson’s continuous ous rolling. rod mill, the prototype the sleek modern continuous sheet-strip mill, despite its supremacy over the single-stand hand mill had haz- ardous history. For decade the superior and longer rod produced England recognized equal, and there was immediate need for such machine this country. For the few hand mills the United States proved totally inade- cope with the demands for longer and stronger wire string Samuel Morse’s telegraph along the railroads springing over night all over the country. the same time the wire nail was ridiculed idea and barbed wire fence the West, inventor’s dream, both held abeyance until better and cheaper wire became available. Fortunately for this country (and also for the idea continu- ous rolling) Bedson’s good friend. Ichabod Washburn, Washburn Moen Mfg. Co., Worcester, Mass., had sufficient foresight and cour- age personally contract for continuous mill, which was success- fully placed operation 1869. But still the process would prob- ably have languished Washburn had not had clever superinten- dent, Charles Morgan, and iron (which tended pull apart the continuous unit) during this time had not been rapidly subvert- cheap bessemer and open- hearth steel which quickly demon- strated adequate homogeneity and tensile strength the heated con- dition permit commercial pro- duction continuous unit without constant danger and serious breakdowns. available and Morgan’s ingenuity developing power reel, re- vamping the roll arrangement and developing finer coordination draft, roll diameters and roll speeds, resulted comparatively modern unit 1880, which con- sistently turned out No. rod, lengths 1000 ft. more and speeds nearly 1500 ft. per min. Nonetheless, the continuous mill was still expensive and tem- peramental piece equipment, re- quiring constant care and highly skilled operators. The different quality metal this stage the game, still another mill superintendent, Mr. William Garrett, Cleveland Roll- ing Mill Co., revamped the old-type Belgian looping mill’, made par- tially automatic (see page 35), and approximated many the ad- vantages the continuous system keeping the front end the billet constantly moving forward Garrett’s setup required little high- skilled labor, production was higher, was more fool-proof and flexible, and, withal, just accu- rate. Licenses were easy obtain, and the industry flocked this process. 1892 Garrett had built and | | was operating mill the Joliet Steel Co., Joliet, Ill., and was during this period and through the turn the century that tasted real success. His consistent production No. rod the rate tons per hr. bundles 150 (1300 ft.) was the admira- tion the rolling fraternity, al- though must admitted that modern standards his diameter tolerances were most liberal—Mr. Garrett guaranteed nothing better than No. one direction and No. the other. During this time continuous roll- ing dropped its nadir, simism became rife that one Morgan’s engineers, Mr. Daniels, publicly advised least one com- pany purchase Garrett mill Nonetheless, Morgan persisted. Roll speeds were increased, more efficient twist guides were devised, controls simplified, more depend- able relations between reduction and rolling speeds developed, and thousand and one other problems solved, Slowly, favor again swung the continuous method, this time permanently, and prior the World War Morgan’s method was dominant. Although Garrett did not live witness the reversed trend, Charles Morgan did. number Garrett mills still are turning out rods, many being retained because their flexibility, which permits rapid production rod should not considered specialty item produced only small quantities. The total production all makers quite sizable, amount- ing well over 2,000,000 tons last year, which considerably excess the tonnage heavy and light struc- tural shapes produced Same period. special sections small lots. Joliet’s Garrett mills went the scrap pile 1931, and for six years rods have been rolled the scene triumph. But this week, Joliet dedicates new plant, which contains two Morgan’s most modern continuous rod rolling units and numerous special devices designed en- gineers the American Steel Wire Co. The entire plant has been devised turn out standard No. rod with maximum efficiency, and American Steel Wire Co. claims record for speed, length rod, accuracy gage, and efficiency the handling and inspection bundles. The new mill contains two iden- tical 19-stand continuous rod mills, paralleling each other. One will turn out No. rod all times and the other will take care gages from No. 0.5 in. diameter. This construction part American Steel Wire Co., which includes improvements the South Chicago and Gary billet mills, well the wire mills Illinois. None the rod made Joliet for sale; all the tons produced annually scheduled process material supply the wire mills American Steel Wire Co. Kalb, and the Rock- dale and Scotts Street works Joliet. Each mill finishes two rods sim- ultaneously, and delivery speed exceeds 3400 ft. per min., miles per hr. Thus, possible have 600-lb. bundle No. rod (5200 ft. long), delivered the reels once every seconds. Even with this tremendous speed, the company fully expects diam- eter accuracy for No. rod within plus minus 0.005 in., tolerance which most conspicu- ous view the plus minus variation 0.016 in. commercially acceptable today. The great accuracy, the speed and the low power consumption (one 4500 hp. motor runs each unit, which represents saving about 1000 hp.) spring directly from the overall application tapered roller bearings. The first five roughing stands have four-row outside diameter; bearings the four intermediate stands are four-row assemblies having 8-in. straight bore with 12-in. diam- eter; and the last ten finishing stands have two-row bearings with tapered bore measuring in. All the roll neck bearings are grease lubricated. The close ad- justment necessary roll precision rods this type simplified specially designed bearing adjust- ments which permit close control over roll movement either ver- tical, horizontal longitudinal di- rections. Any roll weave has been effectively removed, and longer necessary adjust passes with sledge hammer. Notice the small levers beside the roll hous- ings pictures (2) and (3) the following page. movement any lever gives roll adjustment 0.001 in., and small- movements result correspond- ingly smaller adjustments. Power saving, extreme quiet- ness operation and precision adjustment and maintenance also result from the use universal spindles throughout, rather than the usual wabblers. All the pinions the roughing mill have herring- bone teeth. Pinions the finish- ing mill, together with their speed- gears, which are arranged the same case, have single helical teeth. The bevel gear drives are spiral and the gear reduction sets are All this precision power transmission has reduced mill vibration minimum. Details the rolls are fol- low: The five roughing mill rolls have 24-in. barrels, are in. diam- eter, and are provided with six passes across the roll face. The passes the first two roughing mills are ovals, the third square, the fourth oval, and the fifth THE IRON AGE, June 24, > cone » | | } | | j | “8 J | | | | | | | e — | ‘ — moe are ” STORAGE BILLET Scrap (1) BILLETS SQUARE FEED FROM TABLE INTO REHEATING FURNACE. Furnace Billet (2) BILLETS 2000 DEG. REDUCED ROUGHING Bundle Conveyor 4500 Hp. Motor AMERICAN STEEL WIRE NEW ROD JOLIET, ILLINOIS CAPACITY, 220,000 TONS YEARLY. f 4 j ec Stack (4) BUNDLE RODS BEING PUSHED FROM THE REEL THE BELT CONVEYOR. (3) HIGH-SPEED TWO-STRAND FINISHING STANDS WITH COBBLE SCREEN ABOVE. COILS RODS ARE INSPECTED FOR SHAPE AND SURFACE. MACHINE BOTTOM TRANS- Facilities FERS BUNDLES HOOK CON- square. Since there are six dupli- cate passes each roll, and, since two billets are roughed simultan- eously, the strands may shifted three times before all passes are worn. The roughing probably require changing once month. change rolls (either roughing the housing, together with the rolls, will re- moved, and another assembly, pre- viously adjusted, will set place, the entire operation requir- ing not over min. The four intermediate stands rolls measure in. diameter and have 24-in. barrel. Since the speed this point consid- erably greater than the rough- ing group, the wear the passes more pronounced. The smaller size the rod permits the machin- ing passes across each roll face. the passes wear and get inaccurate, the rod strand shift- ed, usually twice the intermedi- ate group for every shift the roughing group. Intermediate rolls will also last about month before they need removed for machin- ing. The ten finishing stands measure in. diameter and have 16-in barrels. The first six sets have passes across the face and the last four have duplicate passes. all the preceding roll groups (except the first two) reduction al- ternates from square oval throughout the finishing group, although the last stand naturally has round pass. Rolling speeds vary from 8.38 the first roughing stand progressively higher 1126.45 the final finishing stand. single billet will pass through the entire group sec. Maxi- mum reduction area any pass per cent and minimum reduction per cent (in the last pass). Except for one twist the roughing mill, the rod leaving square pass not twisted through- out its travel. leaving oval pass, however, the rod always twisted deg. before entering the following square pass. The guides edge the ovals (between alternate stands) may shifted parallel with the roll face the strand shifted from one pass worn. The use alternate squares and ovals typical both rod and bar mills all types, and has been recognized efficient reduction 34—THE IRON AGE, June 24, 1937 cycle for least 100 years. Prac- tically maximum flow metal obtained without danger split- ting, and the square and oval passes may machined with ease and accuracy. Other types passes may theoretically give bet- ter metal flow, but machining and operating difficulties long ago sent them the discard. Between the intermediate group rolls and the finishing group, flying shear placed crop off burred ends which might give rise cobbles the high-speed finish- ing roll train. The flying shear somewhat different from usual types, having particularly smooth, quick cycle) and controllable action. was designed several years ago George Rose, chief engineer American Steel Wire Co. The billets received Joliet measure 5/16 in. square, are about ft. long, and weigh the neighborhood The billets are placed onto skid platform and rolled onto the furnace ap- proach tables, one one, shown picture (1) the following page. After each pushed into the furnace, long arms come from the side the furnace and push the whole row billets towards the hot end the furnace. this way gradual feed bil- lets from the cold and towards the discharge end maintained. Full automatic temperature control secured means pyrometers hung from the roof the furnace and connected temperature re- cording instruments and the fuel control apparatus. the reheating furnaces has approximately ft. long and ft. wide, and heated coke oven gas from the coke plant. the discharge end the furnace the billets reach temperature 2000 2100 deg. F., and are mechanically pushed from the furnace directly into the first roll the continuous mill. the old Belgian Garrett mills, temperature drop during rolling was the direct cause most the operator’s headaches. The billets had heated exces- sively, which resulted scaling, but none the less the front end the rod generally finished hot and the last end finished cold, the result being tapered end; diameter inaccuracies were com- mon throughout the entire length the rod because the changing malleability the steel and the tendency overfill (fin) under- fill the passes. this new Joliet unit, however, the passage through the roll train very rapid and temperature drop almost negli- gible—not more than about 350 deg., from about 2100 deg. down about 1750 1800 deg. The ob- vious results this quick passage are less scrap loss and uniform malleability the steel, the latter resulting minimum roll ad- justment keep diameter ances within plus minus 0.005 in. the rods leave the final finish- ing pass speed 3400 ft. per min., they pass through water- cooled guide pipes and scaling device, thence coiling reels set below the floor level. These reels are the conventional pouring type, i.e., the rod directed into receptacle revolving synchro- nized speed. Examination the drawing the preceding page will show that each mill supplied with six reels. semi-automatic switch- ing device can throw the rods from one reel another with only few inches spare between the ends the rods, and this arrangement per- mits coiling fast the mills can turn out the rod. When one entire length rod (5000 5200 ft.) has been coiled one reel, hydraulic spider dis- engages the coil and lifts flush with the floor level. the preced- ing page, photo (4) shows coil this position. The sketch the same page indicates that the reels are arranged groups three that bundles rods (after ris- ing floor level) may pushed onto central drag conveyor. After moving slowly forward for about min. this conveyor, the bun- dles reach transfer machine. Each the four drag conveyors for part its length surrounded muffle, top which kept pool water. This arrangement permits partial control over cooling speed. transfer the bundles from the drag conveyor overhead hook conveyor, the engineers Amer- ican Steel Wire Co. have de- vised unique machine, view which shown the preceding page. Normally, bundles are merely flopped over onto hook conveyor, which system results some abuse the bundle and also places the rear end the rod (which requires the more detailed inspection) the back where access difficult. The transfer machines used ; | Joliet (four them—one for each drag conveyor) handles the bundles entirely different manner. Note photo how the machine straddles the drag conveyor. 45-deg. angle. The machine moves forward, the ram nose the machine drops deg., engages the bundle and lifts hori- zontal position. The hinged section Bottom Roll Cross Section Rolls MR. WILLIAM GARRETT, superintendent the Cleveland Rolling Mil Co. 1880, was the same time clever engineer and canny Scot, which probably accounts for his exasperation every time passed the clattering Bel- gian looping mill slowly grinding out 300- ft. lengths wire rods less than ton per hr., withal more often than not oval cross-section rather than round and Stand Finishing Stands all times coated with generous layer scale most difficult remove prior drawing into wire. Mr. Garrett recog- nized need for greater speed, longer rods and closer tolerances. Thereupon journeyed Worcester, Mass., see what luck those old masters rod roll- ing, Washburn and Charles Mor- gan Washburn Moen Mfg. Roughing Stands were having with their revamped Bedson continuous Their rods were half again long and the hourly output tons most spectacular; but the tandem setup was temperamental the extreme, expensive build and maintain, bad scaling still was problem and diameter tolerances were unimpressive. Anyhow, Washburn and Morgan were reluctant license competitors. Later, Mr. Garrett was Columbus check rumors automatic return loops Belgian mill means repeaters devised Mr. McCallip. Then the idea was conceived speed the Belgian process breaking down the mill into three independent sections, each driven progressively increasing rate, rough low speeds and finish rates 1200 ft. per min., thereby keeping the loops from lying all over the floor for long time intervals. The system became per cent automatic using repeater, hourly outputs went then more tons, lengths increased over 1000 ft., the process became compara- tively fool-proof, flexible, accurate and low cost. Garrett mills far overshadowed all other processes for several decades after 1885, and number mills still are turning out rods. much improved Morgan continuous mill, however, has since before the War outclassed Garrett's mill many ways. The stands the original Belgian mill were side side, all driven the same speed from the same shaft. Garrett's mill, sketched above, was essentially Belgian, although was broken into three independent roll groups arranged echelon. Billets first were reduced, square then oval, hand passing back and forth one roughing stand, until they were long and flexible enough loop the Belgian manner. The intermediate and finishing stands then took the reduction increasingly rapid speed, frequently handling two bars one time, above. Instead having man each roll catch the rod, twist and feed into the next pass, repeaters (horizontal, trough-shaped, semi-circular, open-top guides) are used. That is, the rod, issues from one roll stand, runs around this trough and into the following pass. Roll speeds are not adjusted take all the increased length due reduction; consequently the loops grow longer, and doing free themselves rising bodily out the repeater and spreading out over sloping floor. Note, however, that repeater only fool-proof the square side the mill, taking this bar, twisting deg. and returning the next oval pass the neighboring stand. It's not dependable twisting oval deg. and returning the next square pass. Because repeaters failed edge ovals properly, catchers were most always retained the oval side. took nimble and strong man nab and twist these rods without getting lassoed, particularly the last stand where speeds exceeded ft. per min. Early the game, some forgotten Irishman named Mickey was notorious for his able last oval. name has been slurred mucky, and this day Garrett men refer the last oval return the mucky pass. the drag conveyor drops back horizontal position take an- other bundle, and during this time interval the transfer machine moves forward and places its bundle onto the hook conveyor. Throughout this procedure, the rod encounters abuse, and, when the transfer completed, the rear end the outside, photo (5), where readily accessible inspectors. The speed the hook conveyor varies from ft. per min., and the bundles are slowly carried around the building (see sketch) they drop sufficiently tempera- handling inspectors. The in- spectors watch for slivers, cracks pipe the rods (which can traced back the ingot), and keep their eyes and micrometers busy for immediate detection rolling defects, such flat, finned lap- ped rods due improper setting rolls, bad ends due lash the rod end passes through the rolls because insufficient crop- ping, and rough surface, arising from excessive wear grooves. THE IRON AGE, June 24, 1937—35 | much has been said about the ease with which molded plastic parts are produced, the misconceived notion often prevails that little planning engineering skill required this constantly growing industry. Contrarily, the opposite true. day spent the plant any numerable examples planned production molding where finished parts must meet exacting require- ments; where molding tempera- tures and pressures must main- tained definite specifications; and where molding operations must carried out with extreme accu- racy that the parts produced will within tolerances close plus minus 0.005 in. Take, for instance, the plant the Chicago Molded Products Corp. where production molded prod- ucts not only well planned, but consistent with good quality. This plant equipped with molding presses vary size from small hand presses for moderate low production quirements 500-ton presses for either large multiple-cavity molds single-cavity molds for unusually large molded parts. Production includes not only con- 36—THE IRON AGE, June 24, 1937 ventional compression molding, but also injection extrusion molding which gaining importance. also includes the building and ser- vicing molds well equipped tool room. Even before production molds are made, the design molded parts checked the plant’s engineering department. Often models parts and sample molds are made before any work started production molds. This practice eliminates many costly er- rors which are difficult rectify once production molds have been made. This department works close cooperation with the customer and frequently recommends changes design which will mini- mize mold and production costs, and still give the desired results. Bakelite molding materials are stored racks covered contain- ers kept the original drums until required. separate storage room, away from the dust, used store colored molding materials that they will not become con- taminated. Material Mostly Preformed About per cent the molding material employed Each preforming machine room itself confine the dust incident its use the immediate location the machine. Preform- ing machines employed for colored astic Mold ing Requires molding materials are carefully cleaned whenever the changed. Materials that are not preformed are usually weighed into cups and delivered covered tote boxes the molding presses. some jobs, where the molding cycle com- paratively long, the press operator measures weighs the material the press. Loading frames are employed for quantity production small pieces and these are filled the operator during the molding cycle the preceding charge. Beside behind each operator bench where the charge prepared and where molded pieces are usually placed until cool, un- less necessary cool pieces the mold. Here, also, the operator gives the molded pieces prelimi- nary inspection see that they are free from defects. Flat pieces and others which may have tendency warp and which not require cooling the mold are sometimes placed under pressure special cooling fixtures; they are care- fully placed covered tote boxes for slow cooling. Automatic Molding Predominates Most high-production molds are automatic and kept the press. Light-weight hand molds are used for many small medium sized parts, especially when the produc- tion run short, when the molding cycle comparatively long, where considerable time required place metal inserts the mold, where split mold parts are re- quired. Sometimes, handling the mold facilitated attaching the lower platen the press steel shelf made from wide channel iron. The top this shelf level with the platen. the shelf moves with the platen, easy handle the mold and slide from the press. speed opening molds and ejecting parts, hand arbor presses are em- e | | ployed. When there are several small parts ejected once, they drop into tray ready for quick transfer into tote boxes the fin- ishing department. When light colored molding ma- terials are used, presses are well screened and tote boxes are kept covered exclude dust from ad- jacent presses. Operators wear clean white gloves which not only protect the hands, but quickly indi- cate the presence dirt. Each press equipped with time clock which the press oper- ator sets every time his press closes new charge. This insures uni- formity the molded parts. When unusually close limits are required, the operator may use checking gages. Generally, inspectors watch the molded parts coming from sev- eral presses and check them fre- quently minimize rejects and make sure that the parts meet cus- tomer requirements. Method Used for Clock Part Fairly typical medium size molding produced this plant the housing for one model the Western Clock Co. This part produced two-cavity mold the rate about pieces hour. Four inserts, one near each corner, and four preforms, one placed ad- jacent each insert, comprise the charge. When removed from the mold, each piece cooled under plate steel prevent warpage. another press bumper blocks for automobile door dovetails are being molded the rate 1000 per hr. These blocks measure in. Each has two cored holes for springs hold con- tact with the metal dovetail. service, the blocks shock and frictional action, and should not squeak when contact with the door frame. For this rea- son, graphite-filled type Bake- ound Engineering Practice lite molding material used form the surface the block. insure adequate strength, however, the body the block made from preform special impact-resis- tant molding material. This pre- form keeps the impact-resistant material separate from the self- lubricating material until they fuse the molding operation. producing these blocks, 84- cavity mold employed and double-deck loading frame used with it. fill the frame, the lower deck first charged level flush with the graphite-filled molding material. The upper deck then fitted over the lower and preforms impact material are placed OLDING phenolic dove- tail bumper blocks, showing the 84-cav- ity mold and the two-deck fixture for loading the two types compound, the other shock re- sistant. the recesses the upper deck. Then the loading frame fitted over the lower half the mold and the molding material and pre- forms are discharged into it. This results the graphite material be- ing next each cavity surface and brings the preforms near the cen- ter where strength required. When the mold opened, the molded pieces come away with the upper half. Upon withdrawal the pins which form the cored holes, the bumper blocks drop into tray. Frequent tests the bumper blocks are made check their strength. For each test, five sam- ple blocks, molded the same cav- 4 i we THE IRON AGE, June 24, 1937—37 ~ ity, are placed one time specially designed impact tester, equipped with 5-lb. weight. This weight dropped bumper block from height in. Blows are repeated until each block broken. the average number blows required break the five sample blocks less than given standard, steps are taken immedi- ately determine, first whether the material use has the correct plasticity; second, whether the op- erator adhering the correct curing cycle; and third, whether the correct amount material being charged into the mold. These tests assure uniformity the part and minimize the chance rejec- tion because inadequate strength. Among the molded parts pro- duced this plant are those form- ing the segments bowl urea plastic for overhead lighting fixture. Production the segments carried out four-cavity mold yielding about pieces hour. Molded gas-cock handles, some which have die-cast inserts, are produced molds having cav- ities. Another form handle that produced from black Bakelite 38—THE IRON AGE, June 24, 1937 several large molds production radio cases. These are produced both phenolic and urea plastics, depending the color de- sired. ~ } at : ‘ 4 4 4 ARGE mold which hair-steam- ing helmets for beauty parlor use are produced. split cavity made from tapered blocks heavy chase required clear cores forming the smaller openings the helmet. LEFT mold which solid handles are produced for the Eureka vacuum cleaner. Preheated preforms are em- ployed, but the thick sections require long cure. FACING PAGE holes five gas range special quick ing fixture ployed. for the Eureka vacuum cleaner six-cavity mold. Preform used this case are preheated shorten the cycle, but the section thick- ness averages about in., rather long cure required. Six seven charges are molded per hour. Several different designs radio cabinets, including the recent prize- winning cabinet molded for Sears- Roebuck, are among the rather large moldings produced. Cabinets are produced single two- cavity mold, usually operating gives the operator time weigh out the charge. Other large moldings include 16-in. Rand-McNally globe made single-cavity mold from special high impact-resis- tant grade Bakelite. These globes are built cementing together both hemispheres, which are produced the same mold. In- terchangeable split rings are used form offsets for the stepped lap joint between the hemispheres, yielding smooth surface the joint. (CONTINUED PAGE 119) THE IRON AGE, June 24, 1937—39 + $ GRAY CAST ° RON ° SAM TOUR Vice-President, Lucius Pitkin, Inc. ° IMPROVEMENTS through the years gray cast iron are indi- cated Table where- may seen that 1918 iron castings were divided into three types, light, medium and heavy, and carried specification for ten- sile strength 18,000, 21,000 and 24,000 per sq. in. respectively. 1936, the gray iron industry had advanced sufficiently, however, that the American Society for Testing Materials’ new tentative specifications list seven different grades cast iron running from 20,000 lb. per sq. in. tensile strength all the way 60,000 lb. per sq. in. Along with this great advance tensile strength, there have been corresponding advances carrying ability indicated the transverse tests with the standard transverse test bars. Figures for these were not included this table was desired keep the data simple possible. further improvements over these specified seven classes the Ameri- can Society for Testing Materials, the industry now has available the high test cast iron also Table has always been considered the past that cast iron mate- rial with practically ductility, 40—THE IRON AGE, June 24, 1937 ° but evident that the recent developments the industry make possible produce high test cast iron which after heat-treat- ment yields not only high strength, indicated here, but also con- siderable amount elongation. These figures were taken from paper prepared MacPher- ran the Allis-Chalmers Co. addition the regular grades non-heat treated cast iron fications, there available the market now numerous other types gray iron containing various alloy additions such the nickel- chromium cast iron, the molyb- denum cast irons, the special treat- cast irons such Meehanite. would impossible attempt give the trade names all the different cast irons the mar- ket. Suffice say that most them are cast irons made pro- cesses where endeavored accurately control the graphitiza- tion which takes place cast iron during cooling and thereby im- prove the mechanical properties the metal well make more uniform the properties and thin sections individual castings. The Alloys Iron Research Committee doing commendable work this field, such review, correlate, and condense all avail- able knowledge alloys iron, including carbon and alloy steels and plain and alloy cast irons, published the literature the world and secured from co- operators the form unpub- lished data, and publish the re- sults series monographs. These monographs also call atten- tion the gaps the knowledge that research may done fill these gaps. The monographs save time and effort attendant upon laborious survey previous work each individual researcher, and prevent the waste time doing research work which has already been done but published some journal not readily available most investigators. For the foundry industry, the following has been accomplished: Constitution and Structure The scientific foundation for the constitution cast iron has been laid completely four chapters (50,000 words) Epstein’s “The Alloys Iron and Carbon, Consti- tution,” Vol. and two chapters (25,000 words) Greiner, Marsh and Stoughton’s “The Alloys Iron and Silicon.” these discus- sions are reviewed, correlated and presented, form capable being used any trained metal- he | | 4 | ° | a s 4 ‘ | | | ‘ ‘ | lurgist, all the data necessary for understanding the essen- tials underlying the constitution commercial cast iron. Epstein’s book there also adequate dis- cussion metallographic structure and heredity-effects commer- cial cast iron. comprehensive summary the properties cast and malleable iron, including data all the variables which affect the proper- ties, given Sisco’s “The Alloys Iron and Carbon, Vol. II, now being released. There are three chapters (35,000 words) the ordinary properties and the variables affecting these proper- ties. other chapters are sum- marized data fatigue, elevated- temperature properties, corrosion, physical constants, electric and magnetic properties, impact, damp- ing, machineability, ance and other miscellaneous prop- erties. All the data available the world (up the date publica- tion) the effect alloying metals the constitution and prop- erties cast iron are reviewed the various monographs published and preparation, follows: (a) Greiner, Marsh and Stoughton: “The Alloys Iron Silicon” “High-Silicon Cast Iron,” 5,000 words. (b) Gregg: “The Alloys and Iron and Molybdenum”; “Molybdenum Cast Iron,” 20,000 words. (c) Gregg: “The Alloys Iron and Cast Iron,” 3,000 words. (d) Gregg and Daniloff: “The Al- loys Iron and Cast Iron,” 15,000 words. (e) preparation: “The Alloys Iron and Chromium”; ium Vol. “Chromium Cast 10,000 words. Iron and Nickel:” complete dis- cussion nickel and nickel alloy cast irons. (g) preparation: “The Alloys discussion the role manganese iron. Planned for the near future the preparation comprehensive monograph cast iron. This will Kenzie. Included the monograph will discussion the constitu- tion ordinary and alloy cast iron more elementary form than was used the other monographs the series order that thorough knowledge the principles equilibrium diagrams will not necessary use it. The proper- ties plain and alloy cast iron will discussed more detail than was attempted the mono- graphs mentioned above. Further- more, all the data published made available subsequent pub- lication the other monographs will included. Report important activity the the project being carried out special committee summarize the gray cast iron has evolved rom uncertain status become recognized, de- pendable and inexpensive en- gineering material. This transformation sketched the author herein, and, also included, list sources which contain all the known information about cast iron. The author also traces the improvement malleable iron, steel castings and some the more important non- ferrous alloys. the past two decades available information alloy cast iron and publish its findings special report. The committee, under the chairmanship Born- stein, Deere Co., Moline, and composed some the best known foundry metallurgists and research workers. review work sub-divided into sections which cover: (a) “Metallurgical Theory Under- lying Alloying.” (b) “Effects the Various Alloy- ing Elements.” (c) “Properties Alloy Cast Irons.” (d) “White and Chilled Alloyed Cast Irons.” (e) “Heat Treatment.” (f) “Specific Applications.” “Foundry Practice.” Preliminary reports the sec- tions heat treatment, foundry practices and specific applications were made the 1936 Convention meeting the editorial committee held Nov. 13, Chicago, the re- maining sections were reviewed and final plans for publishing the com- plete report the Spring 1937 were made. Another worthwhile development the cast iron field that the permanent molding cast iron. This work was largely pioneered the Holley Carburetor Co. Michigan where for quite number years they have been casting carburetor parts permanent molds. This process produces gray iron castings very uniform prop- erties production scale some- what beyond that which could obtained sand casting practice. would not quite proper leave the subject cast iron even for the moment without first some remarks with regard machine- ability. Machineability not neces- sarily directly proportional soft- ness gray iron, nor its graph- itic carbon content. The most im- portant thing the condition which the combined carbon pres- ent. Fig. shows the structure 500 magnification cast iron containing 3.55 per cent total car- bon, 0.51 combined carbon, 2.35 silicon, 0.62 manganese and 0.42 phosphorus. will seen here that the structure made network phosphide eutectics embedded matrix pearlite and shot through the whole are numerous flakes graphite. Pearl- ite made alternate layers soft iron known ferrite and hard iron carbon compound known cementite. This structure pearlite makes possible for the cutting edge the tool travel through without the soft pure iron balling the point the tool ruining the cutting edge. also makes possible for the cutting tool travel through the network hard phosphide eutectics and break without damage the tool. If, instead having this ground-mass matrix the form pearlite, were present the form soft iron ferrite, there would entirely different prop- osition. There would then soft iron the binding material for very hard and brittle material known the phosphide eutectic. The structure would then the same grinding wheel where the hard particles are available wear off the tool and held posi- tion the bonding matrix. Fig. there such struc- ture cast iron which analyzes 3.42 per cent total carbon, 0.04 com- bined carbon, 2.17 silicon, 0.61 manganese and 0.30 phosphorus. will noted here that the phos- rhorus somewhat lower than was THE IRON AGE, June 24, iy i | | | | has 4 ay x: | | ee 6GC—v— TABLE CHANGES SPECIFICATIONS FOR CAST IRON Tensile Lb. Year Type Class per Sq. In. Light castings, %-in. sections....... 18,000 1918 Medium castings, 2-in. sections..... 21,000 Heavy castings, 2-in. sections...... 24,000 1936 High test heat treated............. 75,000 elongation High test heat treated............. 107,000 per cent elongation TABLE PROGRESS SPECIFICATIONS FOR MALLEABLE IRON 1936 1915 1930 High Strength A.S.T.M. for Railroads 32,500 36,000 Tensile strength ....... 38,000 50,000 54,000 Elongation in....... per cent per cent per cent Charpy impact ........ 7.75 TABLE PROGRESS SPECIFICATIONS FOR STEEL CASTINGS Tensile Yield Elonga- Reduc- Strength, Point, tion tion Lb. per Lb. per Area, Year Type Sq. In. Sq. In. Per Cent Per Cent 1915 Class soft ...... 60,000 27,000 1915 Class B medium .......... oe 70,000 31,500 18 25 1924 Class soft ..... 60,000 45% T.S. 1924 Class medium 70,000 45% T.S. Pearlitic carbon steels: Low carbon annealed...... 83,000 39,000 carbon steels: Medium carbon ........... 84,000 47,000 carbon steels: 105,000 56,000 16 28 1936 Low alloy steels, heat treated: Cr, Ni-Cr, Mo, Cr-Mo.. 183,000 173,000 TABLE the case the previous illustra- tion, but due the fact that the ground work all ferrite and not pearlite, have material which rapidly wears away the cutting tool and is, therefore, not good machineable material. The main difference between these two mate- rials the amount combined carbon present and its disposition within the iron. Were the com- bined carbon present large par- ticles hard iron carbide, would still difficult machine, but with present pearlite be- comes readily machineable mate- Malleable The progress the foundry in- dustry the production malle- able iron indicated somewhat Table II, wherein the properties malleable iron called for 1915 and 1930, and the properties some the newer higher strength malleable irons for the railroads being produced 1936 are shown. Here quite evident that malleable iron has progressed from material which did not have very great strength and but little elongation material very considerable strength and very con- siderable elongation. These figures for the higher strength malleables are the result thousands tests made production and reported the symposium for malleable iron castings held jointly between 1931. Special malleable with pearlitic and sorbitic bases subject heat-treatment have been devel- oped addition these higher strength irons for railroad work. Numerous examples this type malleable iron are the market CHANGES SPECIFICATIONS FOR NON-FERROUS ALLOYS Tensile Elastic Strength, Limit, Year Material Lb. per Sq. In. Lb. per Sa. In. 1910 Government bronze 88-10-2 ............... 18,000 24,590 10,000 13,000 1915 Government bronze 30,000 15,000 1936 Aluminum copper alloy 1936 Aluminum copper alloy, heat treated...... 42—THE IRON AGE, June 24, 1937 Elongation Reduction In., Area, Brinell Per Cent Per Cent Hardness 2.5 to 5.8 4.7to10.89 = ...... 20 to 30 14 to 23 65 to 75 10 9 120 5 4 50 to 70 network phosphide eutectics embedded matrix pearlite and shot through the whole are eutectic. numerous flakes graphite. This material machines well. 500 diameters. under various trade names and would impossible discuss all them this time. Steel Castings Some more years ago, the American Society for Testing Ma- terials divided steel castings into two classes and For Class tensile strength requirements were specified. For Class there were three sub-classes, soft, med- ium and hard, for which the spe- cifications were indicated Table III. These somewhat 1924 and the require- ments yield point changed slightly and the requirements elongation in. and reduction area increased again indi- cated. These specifications, how- ever, are notably lower than obtain- able 1936 and now available different types steel castings. For example, pearlite carbon steel castings low carbon content and annealed are available today with tensile strengths 83,000 lb. per sq. in., yield point 39,500, elonga- tion per cent in., and reduction area per cent. Medium carbon pearlitic available today the annealed and normalized condition show about the same tensile strength, higher yield point, and, course, slightly lower elongation indicated. High carbon pearlitic steels normal- ized and annealed today show ten- sile strength 105,000 lb. per sq. in., yield point 56,000 and elongation in. per cent. Non-Ferrous Alloys Non-ferrous castings are made from many different alloys that would practically imposible for anyone one evening dis- cuss them all. Only few them can considered, and means these few possible point out some the advances which have been made during the years. have selected for this purpose standard Government bronze per cent copper, per cent tin and per cent zinc; manganese bronze the per cent copper variety with additions various agents for increasing strength; and the aluminum-copper alloys. The progress these particular metals shown Table IV. 1910 Government bronze was re- ported have tensile strength 18,000 24,590 lb. per sq. in., elastic limit 10,000 13,000 lb. per sq. in., elongation 2.5 5.8 per cent and reduction area 4.7 10.8 per cent. 1915, the specifications for this grade material were increased call for minimum tensile strength 30,- 000 per sq. in., elastic limit 15,000, and elongation per cent. However, 1936, the specifications recommended prac- tices the industry call for tensile 2—The structure here soft iron matrix